CN111299881A - Double-ultrasonic-assisted laser-CMT (constant current machine) hybrid welding system and welding method - Google Patents
Double-ultrasonic-assisted laser-CMT (constant current machine) hybrid welding system and welding method Download PDFInfo
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- CN111299881A CN111299881A CN202010223671.XA CN202010223671A CN111299881A CN 111299881 A CN111299881 A CN 111299881A CN 202010223671 A CN202010223671 A CN 202010223671A CN 111299881 A CN111299881 A CN 111299881A
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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
- B23K28/00—Welding or cutting not covered by any of the preceding groups, e.g. electrolytic welding
- B23K28/02—Combined welding or cutting procedures or apparatus
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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
- B23K20/10—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic 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
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/20—Bonding
- B23K26/21—Bonding by 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
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/08—Non-ferrous metals or alloys
- B23K2103/10—Aluminium or alloys thereof
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Abstract
The invention relates to a double-ultrasonic-assisted laser-CMT composite welding system and a welding method, wherein the system consists of a workbench, an ultrasonic mechanical vibration mechanism and a laser-CMT composite welding part; the workpiece clamping and welding speed is finished by a PLC control system, the ultrasonic vibration structure comprises an upper ultrasonic part and a lower ultrasonic part, and the upper ultrasonic part is provided with a waist hole with an adjustable angle, so that the application of ultrasonic waves with different angles is facilitated; the laser-CMT composite welding realizes the welding with low heat input and low welding deformation; the aluminum-based composite material is cleaned before welding such as polishing and cleaning, and is clamped on a workbench, and a self-made flux-cored wire is selected as a welding wire. By adjusting the ultrasonic position and angle (distance d)1、d2And theta), the invention meets the welding of the aluminum matrix composite material with low stress and low heat input, the fluidity of the molten pool is improved, and the tensile strength of the welding joint reaches the parent metalMore than 70 percent of the material, obviously reduced number of pores in the joint, and brittle intermetallic compound Al in weld metal4C3The amount is reduced and the dispersion is distributed, and the product TiC plays the role of a reinforcing phase.
Description
Technical Field
The invention relates to the field of welding of aluminum-based composite materials, in particular to a double-ultrasonic-assisted laser-CMT composite welding system and a welding method.
Background
The aluminum-based composite material has the advantages of small density, high specific strength/specific stiffness, high shear strength, low thermal expansion coefficient, high temperature resistance, wear resistance and the like, and has more applications in the fields of ships, aerospace and the like, but the fusion welding difficulty of the aluminum-based composite material is higher, and when an aluminum alloy matrix is heated to be above a melting point, reinforcing phases such as silicon carbide and the like are still solid, so that high molten pool viscosity, poor fluidity and poor weld forming are easily caused, the defects of welding joints are increased, the joint strength is lower, the reinforcing phases are easy to burn, and brittle intermetallic compounds, air holes, cracks and the like are easily generated. At present, the research on fusion welding of the aluminum matrix composite material is less, and a welding material matched with the aluminum matrix composite material is lacked; meanwhile, because the joint has more defects, the mechanical property of the joint cannot be ensured, and the joint needs to be considered from the novel welding process and the welding material.
The related documents have reports of ultrasonic mechanical vibration assisted welding process, but on the welding method, the main focus is on a single welding method, and few reports are reported on the laser-arc composite method. In the laser-CMT composite welding process, the research on ultrasonic mechanical vibration auxiliary welding is not seen. In addition, in the problems to be solved, the ultrasonic is mainly used for refining grains and reducing the number of air holes in the connection process of the aluminum alloy and the magnesium alloy, and the welding of the composite material is not involved. In the aspect of application, in the prior art, single ultrasound is mostly used, the action on an ultrasound action plane is large, and when the plate thickness is large, the other side of the ultrasound action cannot be affected by the ultrasound action, so that the utilization rate of ultrasound is reduced. In the early research process, the joint performance is found to be poor when the aluminum-based composite material is welded by laser. In order to reduce the number of defects of the joint and improve the fluidity of a molten pool, a laser-arc composite process is adopted, and a novel filling material is designed.
Patent CN 107570872B proposes a method for laser welding of heterogeneous materials assisted by ultrasonic vibration, which aims to improve the performance of the joint through the action of ultrasonic waves, but for the laser-arc hybrid welding process, the assembly of an ultrasonic generating mechanism can reduce the applicability of the laser-arc hybrid welding process. Patent CN 102581473B proposes an ultrasonic-assisted semi-solid friction stir welding method suitable for connection of particle-reinforced aluminum matrix composite, wherein ultrasonic is applied to a stirring pin, and the ultrasonic action is mainly used for refining grains in a solid phase and reducing the abrasion of the stirring pin, and the action effect of ultrasonic in a liquid molten pool is not involved. Patent CN 105364326B proposes a method of laser-ultrasonic double-sided welding of magnesium alloy, in which ultrasonic is applied to the back of the weld in a non-contact manner, and the application of ultrasonic effect is limited. Patent CN 105728930B proposes an ultrasonic vibration assisted welding method, in which ultrasound is placed on the back of a weld joint, and an ultrasonic welding head is pressed against the weld joint by spring pressure. Patent CN 105880852B discloses a welding method of ultrasonic auxiliary pulse laser-MIG composite heat source welding device, which is used for solving the problems of large crystal grains and high porosity of an aluminum alloy welding seam.
In conclusion, the main problems of the existing aluminum matrix composite material fusion welding are as follows:
(1) the heat input of fusion welding is large, the loss of reinforced phase is large, and a high-quality welding joint is difficult to obtain.
(2) The aluminum-based composite material has poor molten pool fluidity, poor wettability between high-melting-point reinforcing phase particles and Al aggregates, and easy occurrence of viscous phenomenon and impurities in the molten pool, and influences the quality of welding seams.
(3) A large amount of Al4C3 intermetallic compounds are formed in weld metal, so that the brittleness of the weld is increased, and the performance of the joint is reduced.
(4) The reinforcing phase and the matrix have obvious difference in physical properties, and cavity and air hole defects are easily formed at a high cooling speed of fusion welding, so that the performance of the joint is reduced.
Disclosure of Invention
The applicant provides a double-ultrasonic-assisted laser-CMT composite welding system and a welding method aiming at the defects in the prior art, so that high-quality welding of the aluminum-based composite material is realized.
The technical scheme adopted by the invention is as follows:
a double-ultrasonic-assisted laser-CMT composite welding system comprises a frame, wherein a numerical control workbench which moves horizontally and can be used for loading workpieces is arranged at the upper part of the frame, an upper ultrasonic mechanism is arranged above the workbench, and a lower ultrasonic mechanism is arranged in the frame below the workbench; the upper ultrasonic mechanism adjusts the angle and the distance from the edge of the welding seam through the driving mechanism, and the lower ultrasonic mechanism adjusts the distance from the edge of the welding seam through the driving mechanism; the laser-CMT composite heat source is composed of a CMT welding machine and a fiber laser.
As a further improvement of the above technical solution:
an upright post is arranged on one side of the rack, a horizontal support is arranged at the top of the upright post, the upper ultrasonic mechanism which horizontally moves along the horizontal support is arranged on the horizontal support through a clamping mechanism, and the distance d1 between an ultrasonic welding head of the upper ultrasonic mechanism and the edge of a welding seam is 5-30 mm; the structure of the clamping mechanism comprises a clamping frame, a clamping installation sleeve is arranged outside the upper ultrasonic mechanism, a waist hole is formed in the clamping frame, the waist hole is matched with a pin on the clamping frame, an included angle theta formed between the upper ultrasonic mechanism and an ultrasonic welding head of the upper ultrasonic mechanism and a horizontal support is adjusted, and the theta can be adjusted at will within the range of 0-30 degrees.
A first horizontal guide rail is arranged at the bottom in the rack, a vertical guide rail sliding along the first horizontal guide rail is arranged on the first horizontal guide rail, a lower ultrasonic mechanism sliding along the vertical guide rail is arranged on the vertical guide rail, the structure of the lower ultrasonic mechanism is the same as that of the upper ultrasonic mechanism, and an ultrasonic generator and an ultrasonic cylinder are arranged in the lower ultrasonic mechanism; the distance d2 between the ultrasonic welding head of the lower ultrasonic mechanism and the edge of the welding seam is 3-15 mm; the vertical guide rail and the lower ultrasonic mechanism are driven by driving a first motor and a second motor respectively.
The whole workbench is driven by a third motor and a screw nut transmission mechanism and slides along second horizontal guide rails arranged on two sides of the upper surface of the rack; and a PLC control system of a driving mechanism and an ultrasonic power supply electrically connected with the upper ultrasonic mechanism and the lower ultrasonic mechanism are also arranged in the frame.
A welding method of a double-ultrasonic-assisted laser-CMT composite welding system comprises the following steps:
the first step is as follows: grinding a workpiece, namely an aluminum-based composite material to remove a surface oxide film, cleaning the surface of the composite material by using acetone, wherein an aluminum-based flux-cored wire is adopted as a welding wire, and 600-mesh abrasive paper is used for grinding the outer skin of the flux-cored wire to remove the surface oxide film and stains; before welding, a single-side 30-degree V-shaped groove is formed, a truncated edge with the thickness of 0-1mm is reserved in the groove, and the aluminum-based composite material is placed on a workbench and clamped firmly;
the second step is that: parameter selection during welding: the laser power of the fiber laser is 1.6kW-2.6kW, the welding speed is 0.01m/s-0.05m/s, 99.99% Ar gas is selected as the protective gas, the power supply welding current of the CMT welding machine is 50-200A, the arc voltage is 15-25V, the front side and the back side of a workpiece need to be protected, and the flow rate of the protective gas is 10-20L/min;
the third step: before formal welding, the positions of a laser beam of the fiber laser, a CMT welding machine, an upper ultrasonic mechanism and a lower ultrasonic mechanism are adjusted, namely the numerical values of d1, d2 and theta are adjusted;
the fourth step: in the welding process, the laser-CMT composite heat source keeps static, the work piece moves by the workbench, and the running speed of the work piece can reach 4 m/min; selecting one of the upper ultrasonic mechanism and the lower ultrasonic mechanism or simultaneously implementing the upper ultrasonic mechanism and the lower ultrasonic mechanism according to the actual size of the workpiece;
the fifth step: and after the welding is finished, stopping laser output, and simultaneously closing a power supply of the CMT welding machine.
As a further improvement of the above technical solution:
the sheath of the flux-cored wire is 6067 aluminum alloy, and the flux core is composed of Al-Mg-Si-Ti powder in the following proportion: mg 2-5%, Ti 5-15%, Si 1-5%, and the balance of Al, the filling rate of the welding wire is 20%, and the diameter of the welding wire is 1.2 mm.
The overall length of the upper ultrasonic mechanism and the lower ultrasonic mechanism is 850mm, the diameter of the ultrasonic welding head is 25mm, the length is two, one is 100mm, and the other is 50 mm; the power of ultrasonic generators arranged in the upper ultrasonic mechanism and the lower ultrasonic mechanism is 3kW, the frequency is 20kHz, and the pressure of an ultrasonic cylinder arranged in the upper ultrasonic mechanism and the lower ultrasonic mechanism is 0.3 MPa; the optical fiber laser adopts a 6kW optical fiber laser, and the angle between a laser beam and a welding wire is 30-60 degrees.
The invention has the following beneficial effects:
the double-ultrasonic-assisted laser-CMT composite welding system and the welding method can realize high-quality welding of the aluminum-based composite material, the welding process is simple, the molten pool viscosity phenomenon is obviously improved, the number of defects in a welding seam is obviously reduced, and the performance of a welding joint can be improved by 50%.
The welding system consists of a workbench, an ultrasonic mechanical vibration mechanism and laser-CMT composite welding;
the workpiece clamping and welding speed is completed by a PLC control system, the ultrasonic vibration structure comprises an upper ultrasonic mechanism and a lower ultrasonic mechanism, and the upper ultrasonic mechanism is provided with a waist hole with an adjustable angle, so that the application of ultrasonic waves at different angles is facilitated;
the laser-CMT composite heat source realizes the welding with low heat input and low welding deformation;
cleaning the aluminum-based composite material before welding, clamping the aluminum-based composite material on a workbench, selecting a self-made flux-cored wire as a welding wire, and adjusting the ultrasonic position and angle (distance d)1、d2And theta) can satisfy the welding of low stress and low heat input of the aluminum-based composite material, the fluidity of a molten pool is improved, the tensile strength of a welding joint reaches more than 70 percent of a parent metal, the number of pores in the joint is obviously reduced, and a brittle intermetallic compound Al in weld metal4C3The quantity is reduced and the dispersion distribution is realized,the product TiC acts as a reinforcing phase.
Drawings
Fig. 1 is a perspective view of the upper ultrasonic mechanism of the present invention in the same view in several different rotational states.
FIG. 2 is a schematic view of another view of FIG. 1 with the CMT torch, fiber laser, and workpiece removed.
Wherein: 1. an upper ultrasonic mechanism; 2. a clamping mechanism; 3. a CMT welding gun; 4. a fiber laser; 5. a second motor; 6. a lower ultrasonic mechanism; 7. an ultrasonic power supply; 8. a third motor; 9. a first motor; 10. a workpiece; 11. a PLC control system; 12. a column; 13. a horizontal support; 14. a work table; 15. a frame; 16. a first horizontal guide rail; 18. a second horizontal guide rail; 101. an ultrasonic horn; 21. a clamping frame; 23. and (4) clamping the mounting sleeve.
Detailed Description
The following describes embodiments of the present invention with reference to the drawings.
As shown in fig. 1 and fig. 2, the dual ultrasonic-assisted laser-CMT hybrid welding system of the present embodiment includes a frame 15, a numerical control table 14 which moves horizontally and can be loaded with a workpiece 10 is installed on the upper portion of the frame 15, an upper ultrasonic mechanism 1 is installed above the table 14, and a lower ultrasonic mechanism 6 is installed in the frame 15 below the table 14; the upper ultrasonic mechanism 1 adjusts the angle and the distance from the edge of the welding seam through a driving mechanism, and the lower ultrasonic mechanism 6 adjusts the distance from the edge of the welding seam through the driving mechanism; the laser-CMT composite heat source is also composed of a CMT welding machine 3 and a fiber laser 4.
An upright post 12 is arranged on one side of the frame 15, a horizontal bracket 13 is arranged on the top of the upright post 12, an upper ultrasonic mechanism 1 which horizontally moves along the horizontal bracket 13 is arranged on the horizontal bracket 13 through a clamping mechanism 2, and the distance d1 between an ultrasonic welding head 101 of the upper ultrasonic mechanism 1 and the edge of a welding seam is 5-30 mm; the structure of the clamping mechanism 2 comprises a clamping frame 21, a clamping mounting sleeve 23 is arranged outside the upper ultrasonic mechanism 1, a waist hole is formed in the clamping mounting sleeve, the waist hole is matched with a pin on the clamping frame 21, an included angle theta formed between the upper ultrasonic mechanism 1 and an ultrasonic welding head 101 of the upper ultrasonic mechanism and the horizontal support 13 is adjusted, and the theta can be adjusted randomly within the range of 0-30 degrees.
A first horizontal guide rail 16 is arranged at the bottom in the rack 15, a vertical guide rail 17 sliding along the first horizontal guide rail 16 is arranged on the first horizontal guide rail 16, a lower ultrasonic mechanism 6 sliding along the vertical guide rail 17 is arranged on the vertical guide rail 17, the structure of the lower ultrasonic mechanism is the same as that of the upper ultrasonic mechanism 1, and an ultrasonic generator and an ultrasonic cylinder are arranged in the upper ultrasonic mechanism; the distance d2 between the ultrasonic welding head 101 of the lower ultrasonic mechanism 6 and the edge of the welding seam is 3-15 mm; the vertical guide rail 17 and the lower ultrasonic mechanism 6 are driven by driving the first motor 9 and the second motor 5 respectively.
The whole workbench 14 is driven by a third motor 8 and a screw nut transmission mechanism and slides along second horizontal guide rails 18 arranged on two sides of the upper surface of the rack 15; the frame 15 is also provided with a PLC control system 11 of the driving mechanism and an ultrasonic power supply 7 electrically connected with the upper ultrasonic mechanism 1 and the lower ultrasonic mechanism 6.
The welding method of the double ultrasonic auxiliary laser-CMT composite welding system comprises the following steps:
the first step is as follows: grinding a workpiece 10, namely an aluminum-based composite material to remove a surface oxide film, cleaning the surface of the composite material by using acetone, wherein an aluminum-based flux-cored wire is adopted as a welding wire, and 600-mesh abrasive paper is used for grinding the outer skin of the flux-cored wire to remove the surface oxide film and stains; before welding, a single-side 30-degree V-shaped groove is formed, a truncated edge with the thickness of 0-1mm is reserved on the groove, and the aluminum-based composite material is placed on a workbench 14 and clamped firmly;
the second step is that: parameter selection during welding: the laser power of the optical fiber laser 4 is 1.6kW-2.6kW, the welding speed is 0.01m/s-0.05m/s, 99.99% Ar gas is selected as protective gas, the power supply welding current of the CMT welding machine 3 is 50-200A, the arc voltage is 15-25V, the front side and the back side of the workpiece 10 need to be protected, and the flow of the protective gas is 10-20L/min;
the third step: before formal welding, the positions of a laser beam of the fiber laser 4, the CMT welding machine 3, the upper ultrasonic mechanism 1 and the lower ultrasonic mechanism 6 are adjusted, namely the numerical values of d1, d2 and theta are adjusted;
the fourth step: in the welding process, the laser-CMT composite heat source keeps static, the work piece 10 moves by the workbench 14, and the running speed of the work piece can reach 4 m/min; selecting one of the upper ultrasonic mechanism 1 and the lower ultrasonic mechanism 6 or performing the two mechanisms simultaneously according to the actual size of the workpiece 10;
the fifth step: after the welding is completed, the laser output is stopped, and the power supply of the CMT welding machine 3 is turned off.
The sheath of the flux-cored wire is 6067 aluminum alloy, and the flux core consists of Al-Mg-Si-Ti powder in the following proportion: mg 2-5%, Ti 5-15%, Si 1-5%, and the balance of Al, the welding wire filling rate is 20%, and the diameter of the welding wire is 1.2 mm.
The overall length of the upper ultrasonic mechanism 1 and the lower ultrasonic mechanism 6 is 850mm, the diameter of the ultrasonic welding head 101 is 25mm, the length is two, one is 100mm, and the other is 50 mm; the power of ultrasonic generators arranged in the upper ultrasonic mechanism 1 and the lower ultrasonic mechanism 6 is 3kW, the frequency is 20kHz, and the pressure of an ultrasonic cylinder arranged in the upper ultrasonic mechanism and the lower ultrasonic mechanism is 0.3 MPa; the optical fiber laser 4 adopts a 6kW optical fiber laser, and the angle between a laser beam and a welding wire is 30-60 degrees.
Two specific embodiments of the welding method of the double-ultrasonic-assisted laser-CMT hybrid welding system are as follows:
the first embodiment is as follows:
the method comprises the following specific steps:
the pre-welding treatment step of the aluminum matrix composite material comprises the following steps: before welding, a single-side 30-degree V-shaped groove is formed, a truncated edge of 0.5mm is reserved, the groove and the vicinity of the groove are polished by abrasive paper to remove oxide skin, and ultrasonic cleaning is carried out for 10min by acetone;
setting parameters: the workpiece 10 is a SiC reinforced aluminum-based composite material with 17% volume fraction and the size of 160 x 80 x 4mm and is arranged on a workbench 14, the running speed of the workbench 14 is set to be 1m/min, the optical fiber laser 4 adopts a continuous laser, the laser power and the defocusing amount are respectively 1000W and 15mm, and the welding current of a CMT welding machine 3 is set to be 80A; an upper ultrasonic mechanism 1 is used, the values of distances d1 and theta are adjusted to be 10mm and 20 degrees respectively, the ultrasonic power is 800W, and the pressure of an ultrasonic cylinder is 0.25 MPa;
the workpiece 10 is fixed by a special clamp, a 1mm gap is reserved on a groove, 99.999% pure Ar is used as shielding gas, the shielding gas is firstly introduced into 10s before welding, an ultrasonic power supply is connected to enable ultrasonic work, an ultrasonic welding head 101 is in close contact with the workpiece 10 under the pressure of an air cylinder, and a developed Al-Si-Mg-Ti flux-cored welding wire is selected as a welding wire.
After the welding is completed, the laser output is stopped, and the power supply of the CMT welding machine 3 is turned off.
Example two:
the method comprises the following specific steps:
the pre-welding treatment step of the aluminum matrix composite material comprises the following steps: before welding, a single-side 30-degree V-shaped groove is formed, a truncated edge of 0.5mm is reserved, the groove and the vicinity of the groove are polished by abrasive paper to remove oxide skin, and ultrasonic cleaning is carried out for 10min by acetone;
setting parameters: the SiC reinforced aluminum-based composite material with the volume fraction of 20% is placed on a workbench 14 with the size of 160 × 80 × 6mm, the running speed of the workbench is set to be 1m/min, the fiber laser 4 adopts a continuous laser, the laser power and the defocusing amount are respectively 1000W and 15mm, and the welding current of a CMT welding machine 3 is set to be 100A; adopting a lower ultrasonic mechanism 6, adjusting the distance d2 and the value theta to be 10mm and 0 degrees respectively, wherein the ultrasonic power is 800W, and the pressure of an ultrasonic cylinder is 0.3 MPa;
the workpiece 10 is fixed by a special clamp, a 1mm gap is reserved on a groove, 99.999% pure Ar is used as shielding gas, the shielding gas is introduced for 10s before welding, an ultrasonic power supply is connected to enable ultrasonic work, an ultrasonic welding head 101 is in close contact with the workpiece 10 under the pressure of an air cylinder, and a developed Al-Si-Mg-Ti flux-cored welding wire is selected as a welding wire.
After the welding is completed, the laser output is stopped, and the power supply of the CMT welding machine 3 is turned off.
The above steps are used to complete the weld of pass one, and for the weld of the cover, the same parameters can be used for welding, but in order to utilize the optimization effect of the ultrasound, the upper and lower ultrasonic mechanisms are used to apply mechanical vibration together, so as to reduce the generation of defects.
In actual operation, according to the size of the workpiece, for example, when the thickness of the workpiece is more than 4mm, the upper ultrasonic mechanism and the lower ultrasonic mechanism can be selected to apply mechanical vibration together so as to reduce the generation of defects.
The above description is intended to be illustrative and not restrictive, and the scope of the invention is defined by the appended claims, which may be modified in any manner within the scope of the invention.
Claims (7)
1. A double-ultrasonic-assisted laser-CMT hybrid welding system is characterized in that: the ultrasonic testing machine comprises a rack (15), wherein a numerical control workbench (14) which moves horizontally and can load a workpiece (10) is arranged at the upper part of the rack (15), an upper ultrasonic mechanism (1) is arranged above the workbench (14), and a lower ultrasonic mechanism (6) is arranged in the rack (15) below the workbench (14); the upper ultrasonic mechanism (1) adjusts the angle and the distance from the edge of the welding seam through a driving mechanism, and the lower ultrasonic mechanism (6) adjusts the distance from the edge of the welding seam through the driving mechanism; the laser-CMT composite heat source is characterized by also comprising a laser-CMT composite heat source formed by a CMT welding machine (3) and a fiber laser (4).
2. The dual ultrasonic-assisted laser-CMT hybrid welding system of claim 1, wherein: an upright post (12) is arranged on one side of the rack (15), a horizontal support (13) is arranged at the top of the upright post (12), the upper ultrasonic mechanism (1) which horizontally moves along the horizontal support (13) is installed on the horizontal support (13) through a clamping mechanism (2), and the distance d1 between an ultrasonic welding head (101) of the upper ultrasonic mechanism (1) and the edge of a welding seam is 5-30 mm;
the structure of fixture (2) includes holding frame (21), goes up ultrasonic mechanism (1) outside and is equipped with centre gripping installation cover (23) of being connected with holding frame (21), is equipped with the waist hole on it, through waist hole, with the pin fit on holding frame (21), adjust the contained angle theta that forms between ultrasonic mechanism (1) and ultrasonic horn (101) and horizontal stand (13) thereof, theta can adjust wantonly at 0-30 within range.
3. The dual ultrasonic-assisted laser-CMT hybrid welding system of claim 2, wherein: a first horizontal guide rail (16) is installed at the bottom in the rack (15), a vertical guide rail (17) which slides along the first horizontal guide rail (16) is installed on the first horizontal guide rail (16), the lower ultrasonic mechanism (6) which slides along the vertical guide rail (17) is installed on the vertical guide rail (17), the structure of the lower ultrasonic mechanism is the same as that of the upper ultrasonic mechanism (1), and an ultrasonic generator and an ultrasonic cylinder are arranged in the lower ultrasonic mechanism; the distance d2 between the ultrasonic welding head (101) of the lower ultrasonic mechanism (6) and the edge of the welding seam is 3-15 mm; the vertical guide rail (17) and the lower ultrasonic mechanism (6) are driven by driving the first motor (9) and the second motor (5) respectively.
4. The dual ultrasonic-assisted laser-CMT hybrid welding system of claim 1, wherein: the whole workbench (14) is driven by a third motor (8) and a screw nut transmission mechanism and slides along second horizontal guide rails (18) arranged on two sides of the upper surface of the rack (15); a PLC control system (11) of a driving mechanism and an ultrasonic power supply (7) electrically connected with the upper ultrasonic mechanism (1) and the lower ultrasonic mechanism (6) are also arranged in the frame (15).
5. A welding method of the dual ultrasonic assisted laser-CMT hybrid welding system of claims 1-4 to claim 1, wherein: the method comprises the following steps:
the first step is as follows: grinding a workpiece (10), namely an aluminum-based composite material to remove a surface oxide film, cleaning the surface of the composite material by using acetone, wherein an aluminum-based flux-cored wire is adopted as a welding wire, and 600-mesh abrasive paper is used for grinding the outer skin of the flux-cored wire to remove the surface oxide film and stains; before welding, a single-side 30-degree V-shaped groove is formed, a truncated edge with the thickness of 0-1mm is reserved on the groove, and the aluminum-based composite material is placed on a workbench (14) and firmly clamped;
the second step is that: parameter selection during welding: the laser power of the optical fiber laser (4) is 1.6kW-2.6kW, the welding speed is 0.01m/s-0.05m/s, 99.99% Ar gas is selected as shielding gas, the power supply welding current of the CMT welding machine (3) is 50-200A, the arc voltage is 15-25V, the front side and the back side of the workpiece (10) need to be protected, and the flow rate of the shielding gas is 10-20L/min;
the third step: before formal welding, the positions of a laser beam of the fiber laser (4), the CMT welding machine (3), the upper ultrasonic mechanism (1) and the lower ultrasonic mechanism (6) are adjusted, namely the values of d1, d2 and theta are adjusted;
the fourth step: in the welding process, the laser-CMT composite heat source keeps static, the work piece (10) moves by the workbench (14), and the running speed of the work piece can reach 4 m/min; selecting one of the upper ultrasonic mechanism (1) and the lower ultrasonic mechanism (6) or simultaneously implementing the two mechanisms according to the actual size of the workpiece (10);
the fifth step: and after welding is finished, stopping laser output, and simultaneously turning off a power supply of the CMT welding machine (3).
6. The welding method of the dual ultrasonic-assisted laser-CMT hybrid welding system of claim 5, wherein: the sheath of the flux-cored wire is 6067 aluminum alloy, and the flux core is composed of Al-Mg-Si-Ti powder in the following proportion: 2-5% of Mg, 5-15% of Ti, 78-5% of Si1 and the balance of Al, the filling rate of the welding wire is 20%, and the diameter of the welding wire is 1.2 mm.
7. The welding method of the dual ultrasonic-assisted laser-CMT hybrid welding system of claim 6, wherein: the overall length of the upper ultrasonic mechanism (1) and the lower ultrasonic mechanism (6) is 850mm, the diameter of the ultrasonic welding head (101) is 25mm, the length is two, one is 100mm, and the other is 50 mm; the power of ultrasonic generators arranged in the upper ultrasonic mechanism (1) and the lower ultrasonic mechanism (6) is 3kW, the frequency is 20kHz, and the pressure of an ultrasonic cylinder arranged in the upper ultrasonic mechanism and the lower ultrasonic mechanism is 0.3 MPa; the optical fiber laser (4) adopts a 6kW optical fiber laser, and the angle between a laser beam and a welding wire is 30-60 degrees.
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