CN111037143B - Method for regulating and controlling weld joint structure performance based on welding thermal cycle - Google Patents
Method for regulating and controlling weld joint structure performance based on welding thermal cycle Download PDFInfo
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- CN111037143B CN111037143B CN201911187476.XA CN201911187476A CN111037143B CN 111037143 B CN111037143 B CN 111037143B CN 201911187476 A CN201911187476 A CN 201911187476A CN 111037143 B CN111037143 B CN 111037143B
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Abstract
The invention relates to a method for regulating and controlling the structure performance of a welding seam based on welding thermal cycle, which comprises the following steps: based on an Al-Zn-Mg-Cu aluminum alloy narrow-gap MIG welding heat source model and a material constitutive model, obtaining a welding heat cycle rule and a weld joint residual force evolution process by adopting a numerical simulation method, and further obtaining a welding process parameter adjusting weld joint residual stress mechanism; based on weld crystalline structure characteristics and microstructure characteristics after subsequent welding thermal cycle, a welding thermal cycle regulation weld structure performance mechanism is obtained; and regulating the residual stress mechanism of the welding seam based on the obtained welding process parameters, and regulating the microstructure performance and the welding residual stress distribution of the welding seam based on the welding heat cycle regulation and control welding seam structure performance mechanism. The invention can ensure the effect of regulating and controlling the structure performance of the welding seam.
Description
Technical Field
The invention belongs to the technical field of high-strength aluminum alloy welding, and particularly relates to a method for regulating and controlling the structural performance of a welding seam based on welding thermal cycle.
Background
Al-Zn-Mg-Cu aluminum alloy is an aluminum alloy structural material with highest strength at room temperature, and is widely applied to various fields of ship manufacturing, military equipment, traffic and transportation engineering and the like which concern China and civilian life. Along with the improvement of the light weight level and the technological content of equipment, the demand of the series of aluminum alloy materials is increased day by day, and the number of retired structural members of the series of alloy is increased day by day, so that the manufacturing and remanufacturing technology of the series of alloy has wide application prospect and must generate huge social and economic benefits. The technologies of connecting, preventing abrasion, preventing corrosion covering or repairing mechanical parts by using a welding method are collectively called as maintenance welding technologies. The thick plate high-strength aluminum alloy repair welding requires high energy utilization rate, high efficiency, portable equipment, low cost, good welding accessibility and simple control. The narrow-gap consumable electrode gas shielded welding is particularly suitable for assembly welding, maintenance welding and rapid welding forming manufacturing of thick plate aluminum alloy structural parts, and when the thick plate welding working condition is limited to single-side welding, single-side narrow-gap MIG multi-layer multi-pass welding is often preferred.
The performance regulation and control of the thick plate multi-layer multi-pass welding joint must be based on the welding thermal cycle process research, the welding material design, the joint mechanical property evaluation and the joint tissue evolution theory.
The complex welding thermal cycle law is the basic attribute of a multilayer multi-pass welded joint, and the attribute necessarily causes the difference of organization characteristics among different thermal cycle characteristic areas in the joint. Even if the same thermal cycle characteristic region, such as a weld zone, subsequent welding passes carry out uneven repeated heating on the finished weld, so that the dilution rate, the grain size, the distribution characteristics of the strengthening phase and the like of the weld zone all show unevenness along the plate thickness direction, and the difference of the mechanical property of the weld along the plate thickness direction is caused. The nonuniformity of the mechanical property of the welding seam metal increases the difficulty of judging weak links of the joint and regulating and controlling the mechanical property.
Therefore, a reliable method for regulating and controlling the properties of the weld structure based on the welding thermal cycle is needed to ensure the regulating and controlling effects of the properties of the weld structure.
Disclosure of Invention
The invention aims to provide a method for regulating and controlling the structure performance of a welding seam based on welding thermal cycle, so as to solve the technical problem.
The invention provides a method for regulating and controlling the structure performance of a welding seam based on welding thermal cycle, which comprises the following steps:
step 1, obtaining a welding heat cycle rule and a weld joint residual force evolution process by adopting a numerical simulation method based on an Al-Zn-Mg-Cu series aluminum alloy narrow-gap MIG welding heat source model and a material constitutive model;
step 2, based on the obtained welding heat cycle law and the evolution process of the residual force of the welding seam, obtaining an influence law of welding process parameters on welding heat cycle characteristics, an influence law of welding heat cycle on residual stress evolution, subsequent welding heat cycle characteristics and crystallization welding heat cycle characteristics;
step 3, obtaining a welding process parameter adjusting weld joint residual stress mechanism based on an influence rule of welding process parameters on welding heat cycle characteristics and an influence rule of welding heat cycles on residual stress evolution;
step 4, obtaining the heterogeneity characteristic of the microstructure of the welding seam based on the crystalline structure characteristic of the welding seam and the microstructure characteristic after subsequent welding heat circulation, and judging and evaluating a metal strengthening mechanism of the welding seam;
step 5, obtaining a welding heat cycle regulation and control weld structure performance mechanism by combining the judgment and evaluation results of a weld metal strengthening mechanism based on the subsequent welding heat cycle characteristics, the crystallization welding heat cycle characteristics and the weld microstructure heterogeneity characteristics;
step 6, based on the mechanical property characteristics of the multilayer multi-channel welding seam, obtaining the mechanical property nonuniformity characteristics of the welding seam and weak links of the welding seam and the mechanical property, and optimizing welding process parameters;
and 7, regulating the residual stress mechanism of the welding seam, regulating the structural performance mechanism of the welding seam through welding heat circulation, regulating the structural performance mechanism of the welding seam through mechanical vibration and regulating the structural performance mechanism of the welding seam through the mechanical vibration based on the obtained welding process parameters, and regulating the microstructure performance and the welding residual stress distribution of the welding seam.
Further, the step 1 comprises:
constructing a single-side narrow-gap MIG multi-layer multi-pass welded columnar Gaussian heat source model, optimizing the heat source model by referring to the measured value of the shape characteristic parameter of the molten pool, and obtaining the error of the calculation result of the shape characteristic parameter of the molten pool;
establishing constitutive equations of welding filling materials and welding base materials, wherein in the setting of the constitutive equations of welding seams and base materials, the relationship among stress, strain rate and temperature is represented by adopting a modified constitutive equation, and each parameter in the equations is determined according to the test result of high-temperature tensile mechanical properties;
establishing a three-dimensional finite element model for numerically simulating welding thermal cycle and welding residual stress evolution in the forming process of the multilayer multi-channel welding seam;
simulating the thermal cycle process and the residual stress evolution process of each welding bead under the condition of different process parameters of multilayer multi-pass welding by adopting a numerical simulation method, and establishing mapping from welding process parameters to the peak temperature and the average cooling rate of a welding thermal cycle curve in the crystallization process, and the peak temperature and the distribution of the welding residual stress in the subsequent welding thermal cycle process;
and analyzing the influence rule of the subsequent welding heat circulation on the welding residual stress of the finished weld according to the welding heat circulation process of the bottom, the middle and the upper parts of the weld and the evolution process of the welding stress and the strain.
Further, the step 1 further comprises:
adjusting process parameters, and extracting welding thermal cycle curves of different characteristic areas and residual stress evolution curves of different characteristic areas in the welding joint;
and detecting the accuracy of the simulation result by adopting an infrared high-temperature camera, an X-ray method and a pinhole method.
Further, in step 4, the weld crystalline structure characteristics and the microstructure characteristics after the subsequent welding thermal cycle include grain size, second phase grain size and density, solid solution matrix phase solute concentration, dislocation configuration and density, and element distribution characteristics.
Further, in step 4, the weld microstructure inhomogeneity characteristics include differences of microstructures between the bottom, middle and upper portions of the weld, between the middle and near-fusion regions of the weld, and interlayer differences.
Further, in step 6, the weld mechanical property nonuniformity characteristics include a weld cross section microhardness distribution rule, static tensile mechanical properties of upper, middle and bottom laminate slice samples of the weld, tensile fracture morphology characteristics and an element distribution rule.
Further, the step 6 comprises:
analyzing the composition and distribution characteristics of the weld metal phase by adopting a metallographic test, a scanning electron microscope test, an X-ray energy spectrum analysis, an X-ray diffraction test and a high-resolution transmission electron microscope test;
detecting microhardness distribution by using a microhardness meter, and detecting mechanical properties by using a static tensile test;
and obtaining the multi-layer multi-channel welding seam weak link in mechanical property by adopting a fracture analysis method.
Further, in step 5, the method for judging and evaluating the weld metal strengthening mechanism includes:
measuring the grain sizes of different characteristic areas by adopting a line intercept method;
under a transmission electron microscope, selecting more than 10 fields at random in the selected weld joint characteristic region, and analyzing the average size and distribution characteristics of second phase particles;
detecting a phase analysis spectrum and a lattice constant of a region to be detected based on an X-ray diffraction test, calculating dislocation density of the region to be detected, and analyzing the contribution of dislocation reinforcement to the weld strength;
observing dislocation distribution characteristics by adopting a high-resolution transmission electron microscope test;
and calculating the matrix phase solute atomic concentration according to the lattice constant, and evaluating the solid solution strengthening effect.
By means of the scheme, the method for regulating and controlling the structural performance of the welding seam based on welding thermal cycle can ensure the regulating and controlling effect of the structural performance of the welding seam.
The foregoing description is only an overview of the technical solutions of the present invention, and in order to make the technical solutions of the present invention more clearly understood and to make the technical solutions of the present invention practical in accordance with the contents of the specification, the following detailed description is given of preferred embodiments of the present invention with reference to the accompanying drawings.
Drawings
FIG. 1 is a flow chart of an embodiment of a method for regulating weld joint structure properties based on welding thermal cycling according to the present invention.
Detailed Description
The following detailed description of embodiments of the present invention is provided in connection with the accompanying drawings and examples. The following examples are intended to illustrate the invention but are not intended to limit the scope of the invention.
Referring to fig. 1, the present embodiment provides a method for regulating weld joint structure performance based on welding thermal cycle, including the following steps:
s1, obtaining a welding heat cycle rule and a weld joint residual force evolution process by adopting a numerical simulation method based on an Al-Zn-Mg-Cu series aluminum alloy narrow-gap MIG welding heat source model and a material constitutive model;
step S2, obtaining an influence rule of welding process parameters on welding heat cycle characteristics, an influence rule of welding heat cycles on residual stress evolution, subsequent welding heat cycle characteristics and crystallization welding heat cycle characteristics based on the obtained welding heat cycle rules and the weld seam residual force evolution process;
step S3, obtaining a welding process parameter adjusting welding seam residual stress mechanism based on the influence rule of the welding process parameter on the welding heat cycle characteristic and the influence rule of the welding heat cycle on the residual stress evolution;
step S4, based on the weld crystalline structure characteristics and the microstructure characteristics after the subsequent welding heat cycle, obtaining the weld microstructure non-uniformity characteristics, and judging and evaluating the weld metal strengthening mechanism;
step S5, based on the subsequent welding heat cycle characteristics, the crystallization welding heat cycle characteristics and the welding seam microstructure nonuniformity characteristics, the welding heat cycle regulation welding seam structure performance mechanism is obtained by combining the judgment and evaluation results of the welding seam metal strengthening mechanism;
step S6, based on the multilayer multi-channel welding seam mechanical property characteristics, obtaining welding seam mechanical property nonuniformity characteristics and welding seam mechanical property weak links, and optimizing welding process parameters;
and step S7, adjusting the residual stress mechanism of the welding seam, adjusting the structural performance mechanism of the welding seam by welding thermal cycle, adjusting the structural performance mechanism of the welding seam by mechanical vibration, and adjusting the residual stress mechanism of the welding seam by mechanical vibration.
In the present embodiment, step S1 includes:
constructing a single-side narrow-gap MIG multi-layer multi-pass welded columnar Gaussian heat source model, optimizing the heat source model by referring to the measured value of the shape characteristic parameter of the molten pool, and obtaining the error of the calculation result of the shape characteristic parameter of the molten pool;
establishing constitutive equations of welding filling materials and welding base materials, representing the relationship among stress, strain rate and temperature by adopting a modified constitutive equation in the setting of welding seams and base material constitutive equations, and determining each parameter in the equations according to the test result of high-temperature tensile mechanical properties;
establishing a three-dimensional finite element model for numerically simulating welding thermal cycle and welding residual stress evolution in the forming process of the multilayer multi-channel welding seam;
simulating the thermal cycle process and the residual stress evolution process of each welding bead under the condition of different process parameters of multilayer and multi-pass welding by adopting a numerical simulation method, and establishing mapping from the welding process parameters to the peak temperature and the average cooling rate of a welding thermal cycle curve in the crystallization process, and the peak temperature and the distribution of the welding residual stress in the subsequent welding thermal cycle process;
and analyzing the influence rule of the subsequent welding thermal cycle on the welding residual stress of the finished welding seam according to the welding thermal cycle process of the bottom, the middle and the upper parts of the welding seam and the evolution process of the welding stress and the strain.
In this embodiment, step S1 further includes:
adjusting process parameters, and extracting welding thermal cycle curves of different characteristic regions and residual stress evolution curves of different characteristic regions in the welding joint;
and (3) detecting the accuracy of the simulation result by adopting an infrared high-temperature camera (the highest temperature can be accurately detected to be 1500 ℃), an X-ray method and a pinhole method.
In this embodiment, in step S4, the weld crystalline structure characteristics and the microstructure characteristics after the subsequent welding thermal cycle include grain size, second phase grain size and density, solid solution matrix phase solute concentration, dislocation configuration and density, and element distribution characteristics.
In the present embodiment, in step S4, the weld microstructure non-uniformity characteristics include a difference in microstructure between the bottom, middle and upper portions of the weld, a difference between the middle and near-fusion regions of the weld, and an interlayer difference.
In this embodiment, in step S6, the weld mechanical property nonuniformity characteristics include a weld cross-section microhardness distribution rule, static tensile mechanical properties of upper, middle and bottom laminate slice samples of the weld, a tensile fracture morphology characteristic, and an element distribution rule.
In this embodiment, the step S6 includes:
analyzing the composition and distribution characteristics of the weld metal phase by adopting a metallographic test, a scanning electron microscope test (SEM), an X-ray energy spectrum analysis (EDS), an X-ray diffraction test (XRD) and a high-resolution transmission electron microscope test (HR-TEM);
detecting microhardness distribution by using a microhardness meter, and detecting mechanical properties by using a static tensile test;
and obtaining a multi-layer multi-channel welding seam weak link in mechanical property by adopting a fracture analysis method.
In this embodiment, in step S5, the method for determining and evaluating the weld metal strengthening mechanism includes:
measuring the grain sizes of different characteristic areas by adopting a line intercept method;
under a transmission electron microscope, selecting more than 10 fields at random in the selected weld joint characteristic region, and analyzing the average size and distribution characteristics of second phase particles;
detecting a phase analysis spectrum and a lattice constant of a region to be detected based on an X-ray diffraction test, calculating dislocation density of the region to be detected, and analyzing the contribution of dislocation reinforcement to the weld strength;
observing dislocation distribution characteristics by adopting a high-resolution transmission electron microscope test;
and calculating the matrix phase solute atomic concentration according to the lattice constant, and evaluating the solid solution strengthening effect.
In this embodiment, the step 9 includes:
based on the nonuniformity characteristics of narrow-gap MIG multi-layer multi-channel welding seams, a welding seam metal strengthening mechanism and a multi-layer multi-channel welding seam residual stress forming mechanism, the invention realizes the structure and performance regulation of the narrow-gap MIG multi-layer multi-channel welding seams of the thick plate Al-Zn-Mg-Cu alloy by a method for regulating welding thermal cycle.
The invention establishes a novel columnar Gaussian heat source model for numerically simulating a response field of a thick plate narrow gap welding process, calculates a temperature field of a multilayer and multichannel welding process to obtain a thermal cycle rule inside a joint, and verifies the accuracy of a numerical calculation result by adopting an infrared temperature measurement experimental method; based on the influence of the three-dimensional temperature field change rule of the thick plate Al-Zn-Mg-Cu alloy single-side welding process on the tissue characteristics and the mechanical property of a welding joint, a foundation is provided for regulating and controlling the tissue and the mechanical property of the thick plate joint; the non-uniformity of the mechanical properties of the multilayer multi-pass welding seam of the thick plate and the softening mechanism of the joint are disclosed, and a foundation is provided for predicting and preventing the joint from failing. The method comprises the following key technical contents:
1) establishing internal connection between multilayer multi-pass welding thermal cycle and weld microstructure evolution
By combining numerical simulation and experimental measurement, the heat cycle characteristic curve of any point in the welding seam can be obtained. The microstructure inside the welding seam adopts advanced detection and analysis means such as SEM, EDS, HR-TEM and the like to complete the accurate analysis of the weld seam structure; the intrinsic relationship between the thermal cycling law and the structure evolution can be established by means of the thermodynamics and kinetics of the weld crystallization.
2) Intrinsic connection of weld microstructure and mechanical properties
According to the L.Vigard law, the lattice constant of the solid solution and the concentration of solute atoms are in a linear relation, so that the lattice constant and the concentration of solute atoms can be obtained through a micro-area XRD detection result. Average grain size d of XRD coherent diffraction region XRD Lattice strain<e>Width of half height peak delta 2 theta, and peak position theta of each diffraction peak 0 The relationship between the X-ray wavelengths λ is as described in function (2):
linear regression analysis (delta 2 theta) 2 /tan 2 θ 0 And (δ 2 θ)/(tan θ) 0 sinθ 0 ) The relationship between them, can be obtainedGo out d XRD And<e>. Average grain size d of XRD coherent diffraction zone XRD And average lattice strain<e 2 > 1/2 Calculating the dislocation density, as shown in formula (3),
based on the results of the investigation of solute-derived concentration, dislocation density, weld grain size and second phase particle size and distribution, the mechanical property evaluation based on weld microstructure can be obtained by combining formula (1).
The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention, it should be noted that, for those skilled in the art, many modifications and variations can be made without departing from the technical principle of the present invention, and these modifications and variations should also be regarded as the protection scope of the present invention.
Claims (1)
1. A method for regulating and controlling the performance of a weld structure based on welding thermal cycle is characterized by comprising the following steps:
the method comprises the following steps of 1, obtaining a welding heat cycle rule and a weld joint residual force evolution process by adopting a numerical simulation method based on an Al-Zn-Mg-Cu series aluminum alloy narrow-gap MIG welding heat source model and a material constitutive model, and comprises the following steps:
constructing a single-side narrow-gap MIG multi-layer multi-pass welded columnar Gaussian heat source model, optimizing the heat source model by referring to the measured value of the shape characteristic parameter of the molten pool, and obtaining the error of the calculation result of the shape characteristic parameter of the molten pool;
establishing constitutive equations of welding filling materials and welding base materials, wherein in the setting of the constitutive equations of welding seams and base materials, the relationship among stress, strain rate and temperature is represented by adopting a modified constitutive equation, and each parameter in the equations is determined according to the test result of high-temperature tensile mechanical properties;
establishing a three-dimensional finite element model for numerically simulating welding thermal cycle and welding residual stress evolution in the forming process of the multilayer multi-channel welding seam;
simulating the thermal cycle process and the residual stress evolution process of each welding bead under the condition of different process parameters of multilayer and multi-pass welding by adopting a numerical simulation method, and establishing mapping from the welding process parameters to the peak temperature and the average cooling rate of a welding thermal cycle curve in the crystallization process, and the peak temperature and the distribution of the welding residual stress in the subsequent welding thermal cycle process;
analyzing the influence rule of the subsequent welding heat circulation on the welding residual stress of the finished weld according to the welding heat circulation process of the bottom, the middle and the upper parts of the weld and the evolution process of the welding stress and the strain;
adjusting process parameters, and extracting welding thermal cycle curves of different characteristic regions and residual stress evolution curves of different characteristic regions in the welding joint;
detecting the accuracy of the simulation result by adopting an infrared high-temperature camera, an X-ray method and a pinhole method;
step 2, obtaining an influence rule of welding process parameters on welding heat cycle characteristics, an influence rule of welding heat cycles on residual stress evolution, subsequent welding heat cycle characteristics and crystallization welding heat cycle characteristics based on the obtained welding heat cycle rules and the weld joint residual force evolution process;
step 3, obtaining a welding process parameter adjusting weld residual stress mechanism based on an influence rule of welding process parameters on welding heat cycle characteristics and an influence rule of welding heat cycles on residual stress evolution;
step 4, obtaining the heterogeneity characteristic of the microstructure of the welding seam based on the crystalline structure characteristic of the welding seam and the microstructure characteristic after subsequent welding heat circulation, and judging and evaluating a metal strengthening mechanism of the welding seam; the weld crystalline texture characteristics and the microstructure characteristics after subsequent welding thermal cycle comprise grain size, second phase grain size and density, solid solution matrix phase solute concentration, dislocation configuration and density, and element distribution characteristics; the weld joint microstructure heterogeneity characteristics include microstructure differences at the bottom, middle and upper portions of the weld joint, and microstructure differences between the middle and near-fusion zones of the weld joint and between layers;
step 5, obtaining a welding heat cycle regulation and control weld joint structure performance mechanism by combining the judgment and evaluation results of a weld joint metal strengthening mechanism based on the subsequent welding heat cycle characteristics, the crystallization welding heat cycle characteristics and the weld joint microstructure heterogeneity characteristics; the method for judging and evaluating the weld metal strengthening mechanism comprises the following steps:
measuring the grain sizes of different characteristic areas by adopting a line intercept method;
under a transmission electron microscope, selecting more than 10 fields at random in the selected weld joint characteristic region, and analyzing the average size and distribution characteristics of second phase particles;
detecting a phase analysis spectrum and a lattice constant of a region to be detected based on an X-ray diffraction test, calculating dislocation density of the region to be detected, and analyzing the contribution of dislocation reinforcement to the weld strength;
observing dislocation distribution characteristics by adopting a high-resolution transmission electron microscope test;
calculating the matrix phase solute atomic concentration according to the lattice constant, and evaluating the solid solution strengthening effect;
step 6, based on the mechanical property characteristics of the multilayer multi-channel welding seam, obtaining the mechanical property nonuniformity characteristics of the welding seam and the weak mechanical property links of the welding seam, and optimizing welding process parameters; the weld mechanical property nonuniformity characteristics comprise a weld cross section microhardness distribution rule, static tensile mechanical properties of slice samples at the upper part, the middle part and the bottom part of the weld, tensile fracture morphology characteristics and an element distribution rule;
the method comprises the following steps:
analyzing the composition and distribution characteristics of the weld metal phase by adopting a metallographic test, a scanning electron microscope test, an X-ray energy spectrum analysis, an X-ray diffraction test and a high-resolution transmission electron microscope test;
detecting microhardness distribution by using a microhardness meter, and detecting mechanical properties by using a static tensile test;
obtaining a multi-layer multi-channel welding line mechanical property weak link by adopting a fracture analysis method;
and 7, regulating the residual stress mechanism of the welding seam based on the obtained welding process parameters, and regulating the microstructure performance and the welding residual stress distribution of the welding seam based on the welding heat cycle regulation and control welding seam structure performance mechanism.
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