CN110893690A - Method for enhancing strength of alloy and composite material resistance welding mixed joint - Google Patents
Method for enhancing strength of alloy and composite material resistance welding mixed joint Download PDFInfo
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- CN110893690A CN110893690A CN202010002502.3A CN202010002502A CN110893690A CN 110893690 A CN110893690 A CN 110893690A CN 202010002502 A CN202010002502 A CN 202010002502A CN 110893690 A CN110893690 A CN 110893690A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/40—Applying molten plastics, e.g. hot melt
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/02—Preparation of the material, in the area to be joined, prior to joining or welding
- B29C66/028—Non-mechanical surface pre-treatments, i.e. by flame treatment, electric discharge treatment, plasma treatment, wave energy or particle radiation
Abstract
The invention provides a method for enhancing the strength of a resistance welding mixed joint of an alloy and a composite material. Because the special structure of candle carbon dust coating, after attaching to the alloy surface, provide abundant space structure for the alloy surface simultaneously to utilize the lipophilic characteristics of candle carbon dust originally, use can be more firm laminating on the alloy surface for welded thermoplastic film, thereby effectual improvement alloy and the welding strength between the combined material.
Description
Technical Field
The invention relates to the technical field of connection of metal and composite materials, in particular to a method for enhancing the strength of a resistance welding mixed joint of an alloy and a composite material.
Background
Alloys and advanced composite materials are two important materials with high specific strength and high rigidity, and are widely applied to the manufacturing of space shuttles as lightweight structural members. Therefore, the connection and assembly of titanium alloy and advanced composite material parts is one of the indispensable technologies in the aviation industry. Researchers in the aerospace field have developed a variety of connection techniques for the connection and damage repair of metal and composite parts. Mechanical joining and bonding are conventional methods of joining and repairing metal and composite parts. However, mechanical connections also have their drawbacks, such as high stress concentrations caused by drilling, additional metal fasteners that increase the overall mass of the structure, etc. The operation period of the cementing process is long, the connecting strength is low, and the cementing process is difficult to become a mainstream connecting mode of metal and composite materials in the future. At present, emerging welding technologies, especially resistance welding, provide a perfect solution for efficient connection between titanium alloy and composite material parts.
Resistance welding is the use of joule heat to melt the polymer film in the joining area to achieve the joining of the titanium alloy and the composite material. The welding efficiency is high, the required materials are few, the equipment is simple, and the welding device can be applied to large-scale structures through a continuous welding process. It is therefore considered to be a promising aerospace connection technology. The titanium alloy component is connected to the composite material part through resistance welding, and the titanium alloy component has a very wide application prospect in assembly and manufacture of various airplanes. Metal-thermoplastic composite interfacial strength is a key factor affecting the performance of composite joints. In particular, the wettability of molten polymers on metal surfaces is a difficulty in resistance welding processes. A number of methods, including etching, anodizing, grit blasting, laser texturing, plasma spraying and silane primers have been used to modify the surface of metal attachments. After these surface treatments, higher metal-thermoplastic interfacial strength can be achieved by increasing mechanical interlocking, physical attraction, and/or chemical bonding. However, the above surface treatment of titanium alloy requires expensive equipment and complicated preparation process, and some of them cause environmental pollution.
Disclosure of Invention
Aiming at the problems in the prior art, the invention provides a method for enhancing the strength of a resistance welding mixed joint of an alloy and a composite material, and the method is mainly used for solving the technical problems by growing a coating with a porous candle carbon ash structure on the surface of the alloy by a candle burning method, further using a wire mesh as a heating element for mixed resistance welding of the alloy and the composite material, using a thermoplastic resin film as a melting adhesive, and obtaining the high-strength alloy and composite material resistance welding joint after welding. Because the special structure of candle carbon dust coating, after attaching to the alloy surface, provide abundant space structure for the alloy surface simultaneously to utilize the lipophilic characteristics of candle carbon dust originally, use can be more firm laminating on the alloy surface for welded thermoplastic film, thereby effectual improvement titanium alloy and the welding strength between the combined material.
The technical scheme adopted by the invention for solving the technical problems is as follows: a method for enhancing the strength of a resistance welding mixed joint of alloy and composite materials comprises the following steps:
(1) adopting a candle burning method to deposit a candle carbon ash coating on the surface of the area to be welded of the alloy;
(2) taking a metal wire mesh as a heating element for resistance welding of a mixture of alloy and thermoplastic composite material, taking a thermoplastic resin film as a fusion bonding agent, respectively coating a thermoplastic resin film on the upper surface and the lower surface of the metal wire mesh, and then implanting an overlapped area to be welded of the alloy and the thermoplastic composite material;
(3) and applying initial pressure of 0.1-0.5 MPa, electrifying and heating, adjusting power to enable the highest temperature of a welding area to be 160-400 ℃, welding time to be 30-180 s, enabling a thermoplastic resin film to be melted and filled in gaps of the welding area and bonding the alloy and the thermoplastic composite material by Joule heat generated in the welding process, and cooling at room temperature for 3-5 min to obtain the high-strength alloy and composite material resistance welding head.
Furthermore, the candle carbon ash coating is of a multi-gap array structure, and the diameter of each gap is 0.5-2 μm.
Further, the specific operation of the step (1) is as follows:
1.1 cleaning of alloy surfaces
Cleaning the surface of the alloy with an organic solvent for 30-60 min to remove dirt and organic pollutants deposited on the surface;
1.2 burning candles to prepare carbon soot coatings
And (3) lighting the candle, after the flame of the candle is kept stable, placing the area to be welded of the alloy on the flame, keeping the area at the flame temperature of 800-1100 ℃ for 2-20 min, and gradually depositing candle soot on the surface of the alloy.
Further, the distance between the area to be welded of the alloy and the wax core is controlled to obtain the proper flame temperature.
Further, the candle is one of cylinder wax, pointed bamboo wax, torch wax, floating wax, round-head wax, flat-head wax and sliced paraffin wax.
Further, the metal wire mesh is one of a stainless steel mesh, a nickel-chromium alloy wire mesh, an iron-chromium-aluminum alloy wire mesh and a nickel-copper alloy wire mesh.
Furthermore, the wire diameter of the wire mesh is 0.03-0.25 mm, and the pore diameter is 0.03-0.7 mm.
Preferably, the wire mesh has a wire diameter of 0.1mm and a hole diameter of 0.16 mm.
Further, the alloy is one of a titanium alloy, an aluminum alloy, and a magnesium alloy.
Further, the alloy is a Glare (Glare) laminate which is prepared by alternately laying up aluminum alloy sheets and glass fiber prepregs and then molding the aluminum alloy sheets and the glass fiber prepregs in an autoclave.
Furthermore, the aluminum alloy sheet is one or more of 1060, 2A12, 2024, 3003, 3A21, 5A02, 5052, 5754, 6061, 6063 and 7075, and has a thickness of 0.3-0.5 mm, a length of 100-300 mm and a width of 100-300 mm.
Further, the glass fiber prepreg is one of a glass fiber/polyphenylene sulfide (GF/PPS) prepreg, a glass fiber/polyetherimide (GF/PEI) prepreg, a glass fiber/polyether ketone (GF/PEK) prepreg, a glass fiber/polyether ketone (GF/PEKK) prepreg, and a glass fiber/polyether ether ketone (GF/PEEK) prepreg.
Further, the thermoplastic composite material is a thermoplastic resin-based composite material or a thermosetting composite material subjected to surface plasticizing treatment, and the surface plasticizing treatment is to perform surface plasticizing treatment by adopting a layer of thermoplastic resin film or a layer of thermoplastic prepreg.
Further, the thermoplastic resin matrix composite material, the thermoplastic resin film on the wire mesh, the thermoplastic resin film adopted for plasticizing treatment and the thermoplastic prepreg adopted for plasticizing treatment are prepared by selecting the thermoplastic resins with the same or similar polarities;
the thermoplastic resin base material with similar polarity is any one of Polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), Polystyrene (PS), Polyamide (PA), Polyformaldehyde (POM), Polycarbonate (PC), polyphenylene sulfide (PPS), Polyetherimide (PEI), polyether ketone (PEK), polyether ketone (PEKK), polyether ether ketone (PEEK) and polyarylether nitrile (PEN).
Further, the thickness of the thermoplastic resin film on the wire mesh and the thickness of the thermoplastic resin film adopted in the plasticizing treatment are 0.1-0.5 mm.
According to the alloy and composite material mixed welding joint based on the enhancement of the candle carbon ash coating interface, the tensile shear strength (LSS) of a single lap welding joint of various composite materials reaches 5-30 MPa according to the difference of thermoplastic resin matrixes.
The principle of the invention is as follows:
the carbon micro-nano material, such as carbon nano tube, graphene and carbon ash, has the unique properties of ultrahigh aspect ratio, good super-hydrophobicity and lipophilicity, and particularly, the candle carbon ash as a unique hydrophobic and lipophilicity material can be used for surface modification of a template or an auxiliary material to adjust the wettability of the surface of the material. Generally, flame synthesis is a low cost, low cost process that does not require large and expensive equipment, while the candle flame volume provides both a carbon rich chemical reaction environment and heat requirements to grow candle soot on metal surfaces, which can synthesize candle soot in a short residence time, and is an efficient process for continuously producing candle soot coatings. For metal to polymer bonding, the surface treatment of the flame grown candle soot coating to the metal plate facilitates improved wetting of the polymer to the metal, resulting in a significant increase in the strength of the overall hybrid joint. According to the invention, a candle carbon ash coating is firstly grown on the surface of the titanium alloy by a candle burning method, and then the wettability of the resin sheet on the surface of the titanium alloy in the application of resistance welding is improved by utilizing the lipophilicity of the carbon ash and the pore structure of the candle carbon ash, so that the mechanical property between joints of the titanium alloy composite material is improved.
Compared with the prior art, the invention has the beneficial effects that:
1) the candle burning method is adopted to deposit a candle carbon ash coating on the alloy surface, and the candle carbon ash coating can improve the wettability of the alloy surface, improve the binding force between the alloy and the resin, improve the uniformity of the temperature of a welding area and the molten state of the resin, and improve the welding efficiency; meanwhile, the interface bonding strength between the metal wire mesh and the resin is improved due to the nano-structure reinforcing effect of the carbon dust; the mechanical property of the composite material welding head is obviously improved by the two beneficial effects;
2) the upper surface and the lower surface of the metal wire mesh are coated with the thermoplastic resin films, so that the content of resin in a welding area is improved, and the dense filling of the gaps of the metal wire mesh and the rapid melting and bonding of the resin on the surface of the thermoplastic composite material are facilitated; meanwhile, the resin film is quickly melted under the action of joule heat, and the candle carbon ash coating on the alloy surface is also ensured not to be oxidized and decomposed at high temperature;
3) the candle carbon ash coating grows on the surface of the alloy by adopting a candle burning method, so that the alloy and thermoplastic composite material mixed welding joint is prepared, the preparation process has the advantages of simplicity, rapidness, low cost, high efficiency, high flexibility, strong adaptability, easiness in industrial popularization and the like, and the candle carbon ash coating has a wide application prospect in the connection field of composite materials such as aviation, aerospace, automobiles and the like;
4) the invention can be applied to the connection of thermoplastic composite materials and can also be used for the connection of thermosetting composite materials with surface plasticizing modification; meanwhile, the method can be applied to the connection and assembly of large composite material structures with complex curved surfaces.
Drawings
FIG. 1 is a microscopic topography of the surface of a Glare laminate modified with a coating of candle soot prepared in example 1 of the present invention;
FIG. 2 is a schematic view of an apparatus for manufacturing a composite material resistance weld joint according to example 1 of the present invention: 1-a pressure sensor; 2-a power supply; 3-Glare (R) laminate; 4-a first PEI film; 5-stainless steel mesh; 6-a second PEI film; 7-GF/PEI composite.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
Example 1
A method of enhancing the strength of a Glare (r) laminate and GF/PEI composite resistance weld hybrid joint, comprising the steps of:
(1) cleaning Glare laminate surface
The Glare laminated plate is an alloy composite material formed by alternately laying an aluminum alloy sheet and glass fiber prepregs, wherein the aluminum alloy sheet is 2024 aluminum, the thickness is 0.4mm, the length is 200mm, the width is 200mm, and the prepregs are GF/PEI prepregs; cleaning the surface of the Glare laminated plate with acetone for 30min to remove dirt and organic pollutants deposited on the Glare laminated plate;
(2) preparation of carbon ash coating by burning candle
Igniting a flat-head candle and burning for a period of time until the candle flame is kept stable, placing the to-be-welded area of the cleaned Glare laminate on the flame at a distance of 2cm from the wax core, the flame temperature of 800 ℃ for 3min, gradually depositing candle soot on the surface of the Glare laminate to obtain a Glare laminate welding part with a candle soot coating deposited on the surface, scanning by an SEM to obtain the micro-morphology of the surface as shown in figure 1, wherein the pore diameter of the candle soot coating deposited on the surface of the Glare laminate is about 1 μm;
(3) as shown in fig. 2, the device for preparing the composite material resistance welding joint is characterized in that the upper surface and the lower surface of a stainless steel net 5 with the wire diameter of 0.2mm and the hole diameter of 0.25mm are respectively coated with a first PEI film 4 and a second PEI film 6, wherein the film thickness is 0.3mm, and the films are embedded into the lap joint area of the resistance welding mixed joint of a Glare laminated plate 3 and a GF/PEI composite material 7 to be welded, so as to obtain a lap joint;
(4) the lap joint is placed in a resistance welding device, 0.4MPa of pressure is applied to the surface of the lap joint through a pressure sensor 1, the power is adjusted through a power supply 2 to enable the maximum temperature of a welding area to reach 380 ℃, the welding time is 120s, the room temperature is cooled for 5min, a Glare laminated plate and GF/PEI composite material resistance welding mixed joint is obtained, and the LSS of the resistance welding joint prepared by the method reaches 18.3 MPa.
Example 2
A method for enhancing the strength of a resistance welding mixed joint of a titanium alloy and a GF/PEK composite material comprises the following steps:
(1) cleaning titanium alloy surface
Cleaning the surface of the titanium alloy with acetone for 60min to remove dirt and organic pollutants deposited on the titanium alloy;
(2) preparation of carbon ash coating by burning candle
Igniting the round-head candle and burning for a period of time until the candle flame is kept stable, placing the cleaned titanium alloy region to be welded on the flame, keeping the distance between the titanium alloy region to be welded and the candle core at 2cm, keeping the flame temperature at 900 ℃ for 10min, and gradually depositing candle soot on the surface of the titanium alloy to obtain a titanium alloy welding part with a candle soot coating deposited on the surface;
(3) cutting a stainless steel mesh with the wire diameter of 0.1mm and the pore diameter of 0.16mm into a sample piece with the size of 50mm x 7mm as a heating element, respectively coating the upper surface and the lower surface of the stainless steel mesh with a layer of PEK film with the thickness of 0.3mm, and embedding the film into a lap joint area of a resistance welding mixed joint of titanium alloy to be welded and a GF/PEK composite material to obtain a lap joint;
(4) the lap joint is placed in a resistance welding device, 0.2MPa of pressure is applied to the surface of the lap joint through a pressure sensor, the power is adjusted through a power supply to enable the highest temperature of a welding area to reach 360 ℃, the welding time is 180s, the room temperature is cooled for 3min, and a GF/PEK composite material resistance welding joint is obtained, wherein the LSS of the titanium alloy and GF/PEK composite material resistance welding mixed joint prepared by the method reaches 16.2 MPa.
Example 3
A method of enhancing the strength of a resistance welded hybrid joint of an aluminum alloy and a carbon fiber/epoxy (CF/EP) composite, comprising the steps of:
(1) plasticizing the surface of the CF/EP composite material in a co-curing mode, and curing a layer of GF/PEI prepreg on the outer layer when preparing the CF/EP composite material laminated plate to ensure that the thermosetting composite material has thermoplasticity so as to prepare the CF/EP composite material with the surface plasticized;
(2) cleaning of aluminium alloy surfaces
Cleaning the surface of the aluminum alloy with ethanol for 40min to remove dirt and organic pollutants deposited on the surface;
(3) preparation of carbon ash coating by burning candle
Igniting the candle and burning for a period of time, wherein the candle adopts sliced paraffin until candle flame is kept stable, placing a clean aluminum alloy region to be welded on the flame, keeping the distance between the clean aluminum alloy region and a wax core at 2cm and the flame temperature at 1100 ℃ for 8min, and gradually depositing candle soot on the surface of aluminum alloy to obtain an aluminum alloy welding part with a candle soot coating deposited on the surface;
(4) cutting a stainless steel net with the wire diameter of 0.1mm and the pore diameter of 0.3mm into sample pieces with the sizes of 50mm x 7mm as heating elements, respectively coating the upper surface and the lower surface of the stainless steel net with a layer of PEI (polyetherimide) film with the thickness of 0.2mm, and embedding the PEI films into lap joint areas of aluminum alloy and CF/EP (compact flash)/EP (EP) composite materials to obtain lap joint joints;
(5) and placing the lap joint in a resistance welding device, applying a pressure of 0.4MPa to the surface of the lap joint through a pressure sensor, adjusting the power through a power supply to enable the maximum temperature of a welding area to reach 350 ℃, setting the welding time to be 150s, and cooling at room temperature for 4min to obtain the resistance welding mixed joint of the aluminum alloy and the CF/EP composite material, wherein the LSS of the resistance welding mixed joint of the aluminum alloy and the CF/EP composite material prepared by the method reaches 9.2 MPa.
The technical idea of the present invention is described in the above technical solutions, and the protection scope of the present invention is not limited thereto, and any changes and modifications made to the above technical solutions according to the technical essence of the present invention belong to the protection scope of the technical solutions of the present invention.
Claims (10)
1. A method for enhancing the strength of a resistance welding mixed joint of alloy and composite material is characterized by comprising the following steps:
(1) adopting a candle burning method to deposit a candle carbon ash coating on the surface of the area to be welded of the alloy;
(2) taking a metal wire mesh as a heating element for resistance welding of a mixture of alloy and thermoplastic composite material, taking a thermoplastic resin film as a fusion bonding agent, respectively coating a thermoplastic resin film on the upper surface and the lower surface of the metal wire mesh, and then implanting an overlapped area to be welded of the alloy and the thermoplastic composite material;
(3) and applying initial pressure of 0.1-0.5 MPa, electrifying and heating, adjusting power to enable the highest temperature of a welding area to be 160-400 ℃, welding time to be 30-180 s, enabling a thermoplastic resin film to be melted and filled in gaps of the welding area and bonding the alloy and the thermoplastic composite material by Joule heat generated in the welding process, and cooling at room temperature for 3-5 min to obtain the high-strength alloy and composite material resistance welding head.
2. The method for enhancing the strength of a mixed alloy and composite resistance welding joint as recited in claim 1, wherein said candle soot coating is in a multi-void array structure, and the diameter of the voids is 0.5-2 μm.
3. The method for enhancing the strength of the alloy and composite material resistance welding hybrid joint according to the claim 1, characterized in that the specific operation of the step (1) is as follows:
1.1 cleaning of alloy surfaces
Cleaning the surface of the alloy with an organic solvent for 30-60 min to remove dirt and organic pollutants deposited on the surface;
1.2 burning candles to prepare carbon soot coatings
And (3) lighting the candle, after the flame of the candle is kept stable, placing the area to be welded of the alloy on the flame, keeping the area at the flame temperature of 800-1100 ℃ for 2-20 min, and gradually depositing candle soot on the surface of the alloy.
4. The method for enhancing the strength of a hybrid alloy and composite material resistance welding joint as recited in claim 1, wherein the wire mesh is one of a stainless steel mesh, a nickel-chromium alloy wire mesh, an iron-chromium-aluminum alloy wire mesh and a nickel-copper alloy wire mesh, the wire mesh has a wire diameter of 0.03-0.25 mm and a hole diameter of 0.03-0.7 mm.
5. The method of enhancing the strength of an alloy and composite resistance welding hybrid joint according to claim 1, wherein the alloy is one of a titanium alloy, an aluminum alloy, and a magnesium alloy.
6. The method for enhancing the strength of a resistance-welded hybrid joint of alloy and composite material according to claim 1, wherein the alloy is a Glare laminate, and the Glare laminate is prepared by alternately laying up aluminum alloy sheets and glass fiber prepreg and then forming the aluminum alloy sheets and the glass fiber prepreg in an autoclave.
7. The method for enhancing the strength of the alloy and composite material resistance welding hybrid joint according to claim 6, wherein the aluminum alloy thin plate is one or more of 1060, 2A12, 2024, 3003, 3A21, 5A02, 5052, 5754, 6061, 6063 and 7075, and the thickness of the aluminum alloy thin plate is 0.3-0.5 mm.
8. The method of enhancing alloy and composite resistance weld hybrid joint strength of claim 6, wherein the glass fiber prepreg is one of a glass fiber/polyphenylene sulfide (GF/PPS) prepreg, a glass fiber/polyetherimide (GF/PEI) prepreg, a glass fiber/polyether ketone (GF/PEK) prepreg, a glass fiber/polyether ketone (GF/PEKK) prepreg, a glass fiber/polyether ether ketone (GF/PEEK) prepreg.
9. The method for enhancing the strength of a resistance-welded hybrid joint of an alloy and a composite material according to claim 1, wherein the thermoplastic composite material is a thermoplastic resin-based composite material or a thermosetting composite material subjected to surface plasticizing treatment, and the surface plasticizing treatment is carried out by using a thermoplastic resin film or a thermoplastic prepreg.
10. The method of claim 9, wherein the thermoplastic resin-based composite material, the thermoplastic resin film on the wire mesh, the thermoplastic resin film used for the plasticizing process, the thermoplastic prepreg used for the plasticizing process, and the thermoplastic resins with the same or similar polarity are selected to be prepared.
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| CN112172179A (en) * | 2020-09-18 | 2021-01-05 | 沈阳航空航天大学 | Ultrasonic-resistance hybrid welding method for resin-based composite material |
| CN112475536A (en) * | 2020-10-13 | 2021-03-12 | 中车唐山机车车辆有限公司 | Method for welding weather-resistant steel strip paint for railway passenger car |
| CN113043604A (en) * | 2021-02-04 | 2021-06-29 | 东华大学 | Induction welding method for thermoplastic composite material with high welding strength and implanted layer |
| CN113561497A (en) * | 2021-06-28 | 2021-10-29 | 哈尔滨工业大学（威海） | Integrated connection method for metal material with woven surface and FRP composite material |
| CN114346616A (en) * | 2022-01-17 | 2022-04-15 | 哈焊国创(青岛)焊接工程创新中心有限公司 | Light alloy and fiber reinforced composite material heterojunction and preparation method thereof |
| CN114496433A (en) * | 2022-01-19 | 2022-05-13 | 大连理工大学 | Preparation method of thermoplastic composite material resistance welding element based on plasma treatment |
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