CN110948885B - 一种热塑性复合材料与铝合金搭接结构激光摆动焊接方法 - Google Patents
一种热塑性复合材料与铝合金搭接结构激光摆动焊接方法 Download PDFInfo
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Abstract
本发明涉及异种材料连接技术领域,公开一种热塑性复合材料与铝合金搭接结构激光摆动焊接方法,包括以下内容:S1:在铝合金激光焊接表面进行喷砂处理,在连接表面使用激光加工出钉钩结构;S2:在热塑性复合材料与铝合金搭接接头界面处填充一定厚度的树脂材料;S3:根据待焊件厚度选择线型或点阵型装夹方式,获得稳定搭接接头;S4:根据待焊件尺寸和要求确定光斑尺寸、形状及离焦量,设计激光摆动轨迹及扫描路径;S5:启动激光器对搭接接头进行焊接,每道焊缝焊接结束后利用冷却装置对焊缝进行冷却处理,再进行后续焊接。本发明可有效提高热塑性复合材料与铝合金连接接头力学性能,焊缝成型好、质量高,在航空航天领域中具有广泛的应用前景。
Description
技术领域:
本发明属于异种材料的连接领域,具体而言是涉及一种热塑性复合材料与铝合金搭接结构激光摆动焊接方法。
背景技术:
热塑性复合材料因其具有强度高、耐腐蚀、耐热等特点而被认为是一种有价值的复合材料,在航空航天制造领域有着广泛的应用。同时,铝合金材料因其既能满足轻量化设计理念,又能满足核心部件的机械性能,依然是航空飞行器的重要结构材料。因此,铝合金与热塑性复合材料的连接问题是不可避免的。传统的铝合金与热塑性复合材料的连接方法主要是机械连接和粘接技术。然而,由于热塑性复合材料的各向异性,在机械连接过程中产生的孔会影响接头的力学性能,采用紧固件也会使整体结构重量会增加,不符合轻量化要求。与机械连接相比较,虽然胶接技术对材料无损伤,连接无应力集中,抗疲劳性能优异,但是其工艺复杂,接头连接性能差,无法满足热塑性复合材料的实际应用。而利用激光作为热源连接铝合金和热塑性复合材料,可以在不损坏内部纤维的情况下获得良好的接头力学性能,而且焊缝成型美观,无裂纹、气孔、未焊透、未熔合等焊接缺陷,焊接工艺性能良好,从而可以取代传统异种材料连接技术。
发明内容:
为了获得较好的热塑性复合材料与铝合金接头连接质量,有效提高热塑性复合材料与铝合金连接接头力学性能,本发明提供一种热塑性复合材料与铝合金搭接结构激光摆动焊接方法,其能够在不损坏内部纤维的情况下获得良好的接头力学性能,且焊缝成型好、质量高。
本发明采用如下技术方案:一种热塑性复合材料与铝合金搭接结构激光摆动焊接方法,包括以下步骤:S1,在铝合金激光焊接表面进行喷砂处理,使用50目的二氧化硅颗粒,利用高速砂流的冲击作用清理和粗化铝合金焊接表面,然后利用激光在铝合金连接表面加工出钉钩结构;S2,在热塑性复合材料与铝合金搭接接头界面处填充一定厚度树脂材料;S3,根据待焊件厚度选择线型或点阵型夹具装夹,获得稳定搭接接头;S4,根据待焊件尺寸及要求确定光斑尺寸、形状及离焦量,设计激光头摆动轨迹及扫描路径;S5,启动激光器对搭接接头进行焊接,每道焊缝焊接结束后利用冷却装置对焊缝进行冷却处理,再进行后续焊接,直至焊接结束。
可选地,所述钉钩结构与合金材料表面之间角度为30°~60°,所述钉钩尺寸为0.5~1mm,面积密度为5%~20%。
可选地,所述树脂材料,包括环氧树脂、聚醚醚酮、聚苯硫醚、聚酰胺、聚甲醛等;树脂状态包括半固化胶黏状、粉末状和薄片状;树脂填充范围为整个连接界面。
可选地,所述树脂材料的填充厚度为0.3mm~0.5mm。
可选地,当待焊件厚度≤3mm时,所述焊接夹具采用线型夹具装夹;当待焊件厚度>3mm时,采用点阵型夹具装夹。
可选地,所述激光头摆动轨迹包括圆弧摆动轨迹和Z字型摆动轨迹,所述扫描路径优先选择直线路径。
可选地,扫描焊缝密度为20%~60%。
可选地,所述冷却装置对焊缝持续吹送高压低温冷却气体,并沿焊缝流向整个连接平面。所述冷却装置固定于激光焊接机械臂一侧,可随机械臂移动位置。
本发明具有如下有益效果:本发明提供了一种热塑性复合材料与铝合金搭接结构激光摆动焊接方法,针对热塑性复合材料与铝合金的搭接结构,利用激光摆动焊接,可以显著提高铝合金与热塑性复合材料之间异种连接强度,替代传统机械连接和胶接方式,避免了破坏复合材料中的增强纤维,保持了热塑性复合材料的完整性,获得焊缝完整、美观,无明显缺陷的搭接接头。
附图说明:
图1为一种热塑性复合材料与铝合金搭接结构激光摆动焊接示意图;
图2(a)为热塑性复合材料与铝合金搭接结构线型装夹示意图,(b)为热塑性复合材料与铝合金搭接结构点阵型装夹示意图;
图3为热塑性复合材料与铝合金搭接结构激光焊接扫描路径示意图;
图4为热塑性复合材料与铝合金搭接结构焊接激光头圆弧摆动轨迹示意图;
图5为热塑性复合材料与铝合金搭接结构焊接激光头Z字型摆动轨迹示意图。
图中标号如下:
1-热塑性复合材料板;2-铝合金板;3-铝合金垫板;4-热塑性复合材料垫板;5-夹具;7-夹具垫板;9-焊接激光头。
具体实施方式:
请参照图1所示,本发明一种热塑性复合材料与铝合金搭接结构激光摆动焊接方法,包括以下步骤:
首先,在铝合金2激光焊接表面进行喷砂处理,使用50目的二氧化硅颗粒,利用高速砂流的冲击作用清理和粗化铝合金2焊接表面,提高铝合金1焊接表面对激光的吸收率。在铝合金2连接表面利用激光加工出钉钩结构,钉钩与合金材料表面之间角度为30°~60°,钉钩尺寸为0.5~1mm,面积密度为5%~20%。在热塑性复合材料1与铝合金2搭接接头界面处填充一定厚度树脂材料,填充树脂材料可选择环氧树脂、聚醚醚酮、聚苯硫醚、聚酰胺、聚甲醛等,填充树脂状态可选择半固化胶黏状、粉末状和薄片状,树脂填充范围为整个连接界面,填充厚度为0.3mm~0.5mm。根据待焊件厚度选择线型或点阵型夹具装夹,焊件厚度≤3mm时采用线型夹具装夹(图2(a)),当待焊件厚度>3mm时采用点阵型夹具装夹(图2(b)),装夹过程中,在铝合金2下方放置一块与热塑性复合材料1厚度相同的热塑性复合材料垫板4,在热塑性复合材料1上方放置一块与铝合金2厚度相同的铝合金垫板3,在焊缝两侧各放置一块夹具垫板7,再利用夹具5夹紧,以获得稳定搭接接头。根据待焊件尺寸及要求确定光斑尺寸、形状及离焦量,设计激光头摆动轨迹及扫描路径,激光头摆动轨迹包括圆弧摆动轨迹(图4)和Z字型摆动轨迹(图5),扫描路径优先选择直线路径,扫描焊缝密度为20%~60%。
启动激光器对搭接接头进行焊接,每道焊缝焊接结束后利用冷却装置对焊缝进行冷却处理,冷却装置固定于激光焊接机械臂一侧,可随机械臂移动位置,使用气枪对焊缝持续吹高压低温冷却气体,并沿焊缝流向整个连接平面。焊缝冷却至室温后再进行后续焊接,直至焊接结束。
显然,本发明的上述实施例仅仅是为了清楚说明本发明所作的举例,而并非是对本发明的实施方式的限定,对于本领域的普通技术人员,依据本发明的思想,在具体实施方式及应用范围上均会有改变之处,本说明书内容不应理解为对本发明的限制。凡在本发明的精神和原则之内所作的任何修改、等同替换和改进等,均应包含在本发明权利要求的保护范围之内。
Claims (4)
1.一种热塑性复合材料与铝合金搭接结构激光摆动焊接方法,其特征在于包括如下步骤:
步骤一,在铝合金激光焊接表面进行喷砂处理,使用50目的二氧化硅颗粒,然后在铝合金连接表面利用激光加工出钉钩结构;
步骤二,在热塑性复合材料与铝合金搭接接头界面处填充一定厚度树脂材料;所述树脂材料状态包括半固化胶黏状、粉末状和薄片状;所述树脂材料填充范围为整个连接界面,填充厚度为0.3mm~0.5mm;
步骤三,根据待焊件厚度选择线型或点阵型装夹方式,当待焊件厚度≤3mm时,采用线型夹具装夹;当待焊件厚度>3mm时,采用点阵型夹具装夹;
步骤四,根据待焊件尺寸及要求确定光斑尺寸、形状及离焦量,设计激光头摆动轨迹及扫描路径,激光头摆动轨迹包括圆弧摆动轨迹和Z字型摆动轨迹,扫描路径优先选择直线路径;
步骤五,启动激光器对搭接接头进行焊接,每道焊缝焊接结束后利用固定于激光焊接机械臂一侧的冷却装置对焊缝持续吹送高压低温冷却气体,并沿焊缝流向整个连接平面,待冷却处理后再进行后续焊接,直至焊接结束。
2.根据权利要求1所述一种热塑性复合材料与铝合金搭接结构激光摆动焊接方法,其特征在于,所述钉钩结构与合金材料表面之间角度为30°~60°,钉钩尺寸为0.5~1mm,面积密度为5%~20%。
3.根据权利要求1所述一种热塑性复合材料与铝合金搭接结构激光摆动焊接方法,其特征在于,步骤二所述填充树脂包括环氧树脂、聚醚醚酮、聚苯硫醚、聚酰胺、聚甲醛。
4.根据权利要求1所述一种热塑性复合材料与铝合金搭接结构激光摆动焊接方法,其特征在于,所述圆弧摆动轨迹为多个连续单元呈螺旋状递进连接,所述扫描路径优先选择直线路径,扫描焊缝密度为20%~60%。
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