CN110773860A - Forming ring for aluminum alloy drawing type friction plug welding and welding method thereof - Google Patents
Forming ring for aluminum alloy drawing type friction plug welding and welding method thereof Download PDFInfo
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- CN110773860A CN110773860A CN201910984812.7A CN201910984812A CN110773860A CN 110773860 A CN110773860 A CN 110773860A CN 201910984812 A CN201910984812 A CN 201910984812A CN 110773860 A CN110773860 A CN 110773860A
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- stopper rod
- forming ring
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
- B23K20/122—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
- B23K20/122—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
- B23K20/1245—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding characterised by the apparatus
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- Shafts, Cranks, Connecting Bars, And Related Bearings (AREA)
Abstract
The invention discloses a forming ring for aluminum alloy drawing type friction plug welding, wherein a central through hole of the forming ring is a two-section step-shaped hole which is divided into a first step part close to a workpiece to be welded and a second step part far away from the workpiece to be welded, the taper of the first step part is greater than that of the second step part, and the length of the first step part is less than that of the second step part; the welding method includes the selection of the diameter of the stopper rod, the use of the forming ring of the present invention and the determination of the welding feed. The invention provides a method for selecting the diameter of a stopper rod for friction plug welding, which is used for ensuring that the stopper rod is not broken or deformed during welding; the structure of the forming ring can effectively eliminate the defect that the upper part and the lower part of the joint are not welded, thereby improving the production efficiency and the quality; the method for determining the welding feed amount can help a user to determine the welding process parameters, so that high-quality welding is realized.
Description
Technical Field
The invention relates to a friction stir welding technology, in particular to a welding method for aluminum alloy drawing type friction plug welding and a forming ring designed in a matching way.
Background
Friction stir welding was invented by the british institute of welding in 1991, as a solid phase joining technique, has the characteristics of low heat input, small residual stress, small residual strain and the like, and is widely applied to the fields of aerospace, automobiles, ocean engineering and the like. The friction plug welding is used as the further development of friction stir welding and can play an important role in repairing welding defects. With the development of aerospace industry in China, China puts higher requirements on the transport capacity of rockets. The propellant storage tank is a main bearing part of the carrier rocket, and welding defects are difficult to avoid in the welding process due to the large size, thin wall thickness and poor rigidity of the propellant storage tank. In the traditional TIG welding repairing method, the mechanical property of a welding area is reduced, and the integrity of a welding structure is further reduced. The friction plug welding has the characteristics of small residual deformation, small residual stress and the like, so that the friction plug welding can be widely applied to repair work of welding defects.
Friction plug welding can be classified into upset type friction plug welding and draw type friction plug welding according to the direction of applied load. The draw forging type friction plug welding does not need a back supporting device during welding, has low cost and high efficiency, and has outstanding advantages in the aspects of spot defect repair welding and stirring friction welding keyhole repair of closed welding structures such as storage tanks and the like. Whereas forge-and-forge friction plug welding is prone to unwelded defects at the interface which are difficult to eliminate by adjusting the welding process parameters.
The present invention has been made in view of the above problems, and it is an object of the present invention to provide a welding method for controlling the flow of material, which can eliminate the welding defect of friction plug welding by extruding the portion with defects out of the effective thickness of the joint by controlling the flow of material mainly by a specially designed forming ring.
Disclosure of Invention
The invention aims to overcome the defects in the prior art, and provides a forming ring for aluminum alloy drawing type friction plug welding and a welding method thereof according to the welding principle and process of the drawing type friction plug welding.
The technical scheme adopted by the invention is as follows: the utility model provides a shaping ring for aluminum alloy draws formula friction plug welding, the central through hole of shaping ring is two segmentation ladder type holes, two segmentation ladder type holes divide into and are close to the first ladder portion of waiting to weld the work piece and keep away from the second ladder portion of waiting to weld the work piece, the tapering of first ladder portion is greater than the tapering of second ladder portion, the length of first ladder portion is less than the length of second ladder portion.
Further, the taper angle of the first step part is 60 degrees, and the length of the first step part is 1.8 mm.
Further, the taper angle of the second step part is 30 degrees, and the length of the second step part is 8.2 mm.
Furthermore, the forming ring is positioned and connected with the supporting seat through a bolt.
The other technical scheme adopted by the invention is as follows: an aluminum alloy drawing type friction plug welding method comprises the following steps:
selecting the diameter of the stopper rod;
installing the forming ring for the aluminum alloy drawing type friction plug welding on the back of a plug hole of a workpiece to be welded;
and determining the total welding feed amount.
Further, the method for determining the diameter of the stopper rod comprises the following steps:
the stopper rod is simultaneously subjected to tensile stress and torque during welding, and the theoretical strength [ sigma ] of a fourth strength theory with a safety coefficient of the stopper rod is calculated according to a formula (2):
wherein tau is the maximum shear stress,
wherein M is
eIs maximum torque, W
PIs the torsional section coefficient; sigma is the maximum tensile stress of the steel sheet,
wherein F is the maximum pulling force, and A is the sectional area of the stopper rod; n is a safety coefficient;
after selecting the stopper rod material and the welding process parameters, the maximum tensile stress sigma and the maximum torque M which can be borne by the stopper rod material are ensured
eAnd substituting the maximum tension F and the safety factor n into a formula (2), and obtaining the diameter of the stopper rod according to the formula (2).
Further, the total welding feed comprises a preloading feed, a welding feed and an upsetting feed;
the preload feed is determined by the plug repair welder itself;
the method for determining the upsetting feed amount comprises the following steps: when the upsetting force is changed between 20kN and 50kN, the upsetting feed amount corresponding to the upsetting force is linearly changed between 2mm and 7 mm;
the method for determining the total welding feed comprises the following steps: the maximum value of the welding feed amount can not enable the stopper rod to contact the forming ring, the minimum value needs to ensure that the intersection point of the stopper rod and the forming ring and the intersection point of the stopper rod and the plug hole are on the same straight line, and the welding feed amount is adjusted between the maximum value and the minimum value.
The invention has the beneficial effects that:
the invention can provide a diameter selection method of a stopper rod for friction plug welding, so as to ensure that the stopper rod is not broken or deformed during welding; the invention can effectively eliminate the defect of non-welding of the upper part and the lower part of the joint by designing the structure of the forming ring, thereby improving the production efficiency and the quality; the method for determining the welding feed amount can help a user to determine the welding process parameters, so that high-quality welding is realized.
Drawings
FIG. 1: the defects of the upper part and the lower part in the existing friction plug welding are schematically shown;
FIG. 2: using the stress condition of a traditional forming ring;
FIG. 3: material flow using conventional forming rings;
FIG. 4: the forming ring structure of the invention is a front view schematic diagram;
FIG. 5: FIG. 4 is a sectional view taken along line A-A;
FIG. 6: the invention discloses an assembly schematic diagram of a forming ring and a supporting seat;
FIG. 7: the stress condition of the forming ring is used;
FIG. 8: the invention relates to the determination of the total welding feed in the welding process.
The attached drawings are marked as follows: 1. forming a ring; 11. a first stepped portion; 12. a second stepped portion; 2. a workpiece to be welded; 3. a supporting seat; 4. a stopper rod; 5. the conventional forming ring.
Detailed Description
In order to further understand the contents, features and effects of the present invention, the following embodiments are illustrated and described in detail with reference to the accompanying drawings:
the invention designs a joint form capable of eliminating the defects of a friction plug welding head according to the welding principle and the welding process of the drawing type friction plug welding. The specific welding principle of the pull-type friction plug welding is that firstly, the plug rod 4 is driven by a driving device to axially feed while rotating at a high speed, and in the process, the plug rod 4 is subjected to a certain axial load. Then after the stopper 4 contacts with the plug hole of the workpiece 2 to be welded, a large amount of welding heat input is generated due to friction, the workpiece 2 to be welded is changed into a thermoplastic state, the stopper 4 stops rotating after the material flows fully, and then axial force is applied immediately, so that the stopper 4 and the workpiece 2 to be welded are in metallurgical connection. During this welding process, the axial force applied acts primarily between the stopper rod 4 and the tap hole. Most of the materials of the plug hole are aluminum alloy, and the plug hole is easy to soften under the action of a large amount of friction heat and then enters a plastic state, so that sufficient rigid contact between the plug hole and the plug rod 4 cannot be generated. It is therefore necessary to place a shaped ring 1 on the back of the tap hole, with the rigid shaped ring 1 holding the flowing material against it, so that it interacts sufficiently with the stopper rod 4 under the action of the axial force to form the joint.
FIG. 1 is a schematic diagram of the defects of conventional friction plug welding, and it can be seen that there are non-welded weld defects in both the upper and lower portions of the joint that are difficult to eliminate by a single adjustment of the process parameters.
Fig. 2 shows a conventional forming ring 5 without a stepped bore. During the rotation and axial feeding of the stopper rod 4, the plug holes are quickly softened by a large amount of frictional heat, so that the plug holes cannot play a rigid supporting role for the stopper rod 4. The conventional forming ring 5 at the bottom of the plug hole can still keep rigidity at the welding temperature due to the characteristics of the material (45 steel), so the supporting function of the existing forming ring 1 on the plug rod 4 is the most important way to realize the axial force of welding during welding. The point a in figure 2 is the position where it actually acts as a rigid support, at which point the material that would otherwise follow the downward movement of the stopper 4 is compressed and undergoes a change in flow direction, i.e. partly upwards and partly downwards. The upward flowing material will effectively fill the upper joint at the non-welded location while forcing the remaining weld defects out of the effective thickness of the tap hole. The arrows in fig. 3 indicate the different flow directions of the material. Furthermore, by means of the extension of point a in fig. 2 (dashed line), it can be seen that the area of the stopper rod 4 actually subjected to the welding axial force F is only segment BC in the figure. In this case, the portion actually subjected to the force occupies a small proportion of the whole stopper 4, which results in uneven stress on the stopper 4 and a defect that the joint is not welded easily at the lower portion of the joint. In addition, the conventional forming ring 5 has no stepped hole at the lower part, which causes insufficient space when the material flows downwards, is difficult to flow fully, and is easy to form unwelded defects at the lower part.
Fig. 4 and 5 show a forming ring 1 for aluminum alloy pull-type friction plug welding, wherein a central through hole of the forming ring 1 is a two-section stepped hole, the two-section stepped hole is divided into a first stepped portion 11 close to a workpiece 2 to be welded and a second stepped portion 12 far away from the workpiece 2 to be welded, the taper of the first stepped portion 11 is greater than that of the second stepped portion 12, and the length of the first stepped portion 11 is less than that of the second stepped portion 12. In this embodiment, the taper and the length of the first step portion 11 are 60 ° and 1.8mm, respectively; the taper of the second step part 12 is 30 degrees and the length is 8.2 mm. The taper and the depth of the central through hole of the forming ring 1 can be adjusted to adapt to different materials and welding process parameters.
Fig. 6 shows the installation position of the forming ring 1, and the forming ring 1 is positioned and connected with the supporting seat 3 through four bolts.
Fig. 7 shows a forming ring 1 with a stepped bore according to the invention. Firstly, due to the existence of the stepped hole, the supporting point A of the forming ring 1 for plugging the hole is closer to the center than the original supporting point, so that the stressed part BC section of the stopper rod 4 is prolonged, obviously, the stressed area of the stopper rod 4 is enlarged under the action of the forming ring 1, the whole stress of the stopper rod 4 is more uniform, and the defect that the upper part is not welded can be effectively eliminated. In addition, due to the stepped hole, when the stopper rod 4 moves downwards under the action of the axial force, the flowing space for the plastic material is enlarged, the flowability of the material can be greatly improved, and the welding quality of the lower part is ensured.
In the invention, the design of the joint is mainly divided into four parts, namely the diameter selection of the stopper rod 4, the elimination of the non-welding defect at the upper part of the joint, the elimination of the non-welding defect at the lower part of the joint and the calculation of the total welding feed during welding.
In the first part, the diameter of the stopper 4 is chosen and a theoretical way of calculating the diameter of the stopper 4 is given.
According to the force analysis of the stopper rod 4 during welding, the stopper rod 4 is subjected to both tensile stress and torque during welding, and therefore, the fourth strength theory should be used for calculation.
In the formula, σ
r4Which is the theoretical strength of the fourth strength theory, tau is the maximum shear stress,
wherein M is
eIs maximum torque, W
PFor torsional section modulus, for a solid cylinder,
sigma is the maximum tensile stress force of the steel,
wherein F is the maximum pulling force and A is the sectional area of the stopper 4.
In practical applications, the theoretical strength of the fourth intensity theory should be given a safety factor n, and then the theoretical strength [ σ ] of the fourth intensity theory with the safety factor should be
After selecting the material of the stopper 4 and the welding process parameters, the maximum tensile stress sigma and the maximum torque M which can be borne by the material of the stopper 4
eAnd substituting the maximum tension F and the safety factor n into the formula (2), and estimating the diameter of the stopper rod 4 according to the formula (2).
The second and third portions are achieved by mounting the inventive forming ring 1 described above on the back of the tap hole of the workpiece 2 to be welded.
In the second part, in order to eliminate the defect of non-welding of the upper part of the connector, a forming ring 1 is added on the back of the plug hole. Since the plugging material is rapidly softened by the frictional heat during the welding process, it cannot sufficiently interact with the stopper rod 4 without rigid support, and most of the material flows downward with the movement of the stopper rod 4 when the stopper rod 4 is fed, and the upper part of the joint cannot be effectively filled, thereby causing the occurrence of the unwelded upper part of the joint. And the rigid support of the forming ring 1 strengthens the interaction between the plug hole and the stopper rod 4 on the one hand, and on the other hand, due to the rigid support point of the forming ring 1, when the material moves downwards along with the stopper rod 4, the material is shunted, namely, a part of the material flows upwards and a part of the material flows downwards, so that the defect that the upper part of the joint is not welded can be effectively filled.
In the third part, in order to eliminate the defect of non-welding of the lower part of the joint, the invention designs a step-shaped hole on the forming ring 1. Most of the traditional forming ring 5 is a tapered hole (the diameter of the hole on one side close to the stopper rod 4 is larger), so that the traditional forming ring 5 cannot effectively support the stopper hole in the welding process, and meanwhile, the plastic flowing range of the material is not large, and the defect of no welding is easy to occur. The forming ring 1 of the invention is improved more optimally on the basis of the original structure, and a stepped hole (as shown in figure 2) with larger taper and smaller depth is added at one side close to the stopper rod 4, so that the new forming ring 1 has a stepped shape. Therefore, due to the existence of the stepped hole, the area of the rigid support is greatly increased, and the axial force is effectively and uniformly acted on the contact surface of the stopper rod 4 and the stopper hole. Secondly, the forming ring 1 with the step hole type enlarges the plastic flowing range of the material, so that the stopper rod 4 is more fully contacted with the material of the stopper hole, and the defect can be extruded out of the effective thickness. Therefore, the defects of the lower part of the joint can be effectively eliminated. The depth of the stepped hole of the swage ring 1 can be changed for different materials and different geometries of the stopper rod 4 and the plug hole, thereby adjusting the molding effect.
In the fourth part, the invention provides a method for determining the total welding feed amount by combining the geometrical dimensions of the plug hole and the plug rod 4 and the welding parameters during welding.
FIG. 8 is a schematic illustration of the total weld feed during welding. The left half of fig. 8 is the relative position of the stopper 4 and the tap hole before welding, where the stopper 4 is just in contact with the edge of the tap hole. The right half of fig. 8 is the post-weld position, so the difference between the positions of the stopper rods 4 in the two figures is the total weld feed H during welding.
The total weld feed H includes a preload feed, a weld feed, and an upset feed. In general, the preload feed is given as a constant, determined by the nature of the plug welding machine itself, given by its own displacement sensor. The upsetting feed amount and the upsetting force have a direct proportional relationship, and when the upsetting force is changed between 20kN and 50kN, the corresponding upsetting feed amount is linearly changed between 2mm and 7 mm. Once the welding material and welding parameters are thus determined, the welding feed can be approximated. The maximum value of the total welding feed amount can not enable the stopper 4 to contact the forming ring 1, so that the stopper 4 is necked and further broken under the action of the forming ring 1; at a minimum, it is ensured that the point of intersection of the stopper rod 4 with the shaping ring 1 and the point of intersection of the stopper rod 4 with the nozzle are collinear (see the dashed line on the right half of fig. 8), so that it is ensured that the final rest position of the stopper rod 4 is sufficiently supported by the shaping ring 1. Therefore, by adjusting the welding feed amount within this range, a plug weld having a high quality can be obtained.
Although the preferred embodiments of the present invention have been described above with reference to the accompanying drawings, the present invention is not limited to the above-described embodiments, which are merely illustrative and not restrictive, and those skilled in the art can make many modifications without departing from the spirit and scope of the present invention as defined in the appended claims.
Claims (7)
1. The utility model provides a shaping ring (1) for aluminum alloy drawing formula friction plug welding, its characterized in that, the central through hole of shaping ring (1) is two segmentation ladder type holes, two segmentation ladder type holes divide into and are close to wait first ladder portion (11) of welding work piece (2) and keep away from waiting second ladder portion (12) of welding work piece (2), the tapering of first ladder portion (11) is greater than the tapering of second ladder portion (12), the length of first ladder portion (11) is less than the length of second ladder portion (12).
2. A forming ring (1) for aluminium alloy drawn friction plug welding according to claim 1, characterized in that the first step portion (11) has a taper of 60 ° and a length of 1.8 mm.
3. A forming ring (1) for aluminium alloy drawn friction plug welding according to claim 1, characterized in that the second step portion (12) has a taper of 30 ° and a length of 8.2 mm.
4. A forming ring (1) for aluminium alloy drawn friction plug welding according to claim 1, characterized in that the forming ring (1) is positioned and connected with the support base (3) by means of bolts.
5. An aluminum alloy drawing type friction plug welding method is characterized by comprising the following steps:
selecting the diameter of the stopper rod (4);
mounting a forming ring (1) for aluminium alloy drawn friction plug welding according to any one of claims 1 to 4 on the back of the tap hole of the workpiece (2) to be welded;
and determining the total welding feed amount.
6. A method of drawn friction plug welding of aluminium alloys according to claim 5, characterized in that the diameter of the plug rod (4) is determined by:
the stopper rod (4) is simultaneously subjected to tensile stress and torque during welding, and the theoretical strength [ sigma ] of a fourth strength theory with a safety coefficient of the stopper rod (4) is calculated according to the formula (2):
wherein tau is the maximum shear stress,
wherein M is
eIs maximum torque, W
PIs the torsional section coefficient; sigma is the maximum tensile stress of the steel sheet,
wherein F is the maximum pulling force, and A is the sectional area of the stopper rod (4); n is a safety factor;
after selecting the material of the stopper rod (4) and welding process parameters, the maximum tensile stress sigma and the maximum torque M which can be borne by the material of the stopper rod (4)
eAnd substituting the maximum tension F and the safety factor n into the formula (2), and obtaining the diameter of the stopper rod (4) according to the formula (2).
7. The method of claim 5, wherein the total weld feed comprises a preload feed, a weld feed, and an upset feed;
the preload feed is determined by the plug repair welder itself;
the method for determining the upsetting feed amount comprises the following steps: when the upsetting force is changed between 20kN and 50kN, the upsetting feed amount corresponding to the upsetting force is linearly changed between 2mm and 7 mm;
the method for determining the total welding feed comprises the following steps: the maximum value of the welding feed amount can not enable the stopper rod (4) to contact the forming ring (1), the minimum value needs to ensure that the intersection point of the stopper rod (4) and the forming ring (1) and the intersection point of the stopper rod (4) and the plug hole are on the same straight line, and the welding feed amount is adjusted between the maximum value and the minimum value.
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| CN112658459A (en) * | 2020-12-03 | 2021-04-16 | 天津大学 | Aluminum alloy drawing type friction plug repair welding joint and machining method thereof |
| CN113042875A (en) * | 2021-03-22 | 2021-06-29 | 中国航空制造技术研究院 | Embedded linear friction welding joint defect control method and application thereof |
| CN114378422A (en) * | 2020-10-21 | 2022-04-22 | 天津大学 | Comprehensive adjusting method for assembling quality of friction stir welding joint |
| CN114523188A (en) * | 2022-02-18 | 2022-05-24 | 中国航空制造技术研究院 | Embedded linear friction welding joint quality control method |
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| CN114523188A (en) * | 2022-02-18 | 2022-05-24 | 中国航空制造技术研究院 | Embedded linear friction welding joint quality control method |
| CN114523188B (en) * | 2022-02-18 | 2022-12-16 | 中国航空制造技术研究院 | Embedded linear friction welding joint quality control method |
| CN114951957A (en) * | 2022-06-01 | 2022-08-30 | 中国航空制造技术研究院 | Dissimilar material embedded linear friction welding method |
| CN114951957B (en) * | 2022-06-01 | 2023-04-14 | 中国航空制造技术研究院 | Dissimilar material embedded linear friction welding method |
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