CN111958979B - Friction lap welding method for metal and thermoplastic resin material - Google Patents
Friction lap welding method for metal and thermoplastic resin material Download PDFInfo
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- CN111958979B CN111958979B CN202010638471.0A CN202010638471A CN111958979B CN 111958979 B CN111958979 B CN 111958979B CN 202010638471 A CN202010638471 A CN 202010638471A CN 111958979 B CN111958979 B CN 111958979B
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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
- B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
- B29C65/64—Joining a non-plastics element to a plastics element, e.g. by force
- B29C65/645—Joining a non-plastics element to a plastics element, e.g. by force using friction or ultrasonic vibrations
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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
- B23K26/36—Removing material
- B23K26/38—Removing material by boring or cutting
- B23K26/382—Removing material by boring or cutting by boring
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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
- B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
- B29C65/7841—Holding or clamping means for handling purposes
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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
- B29C65/82—Testing the joint
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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
- B29C65/82—Testing the joint
- B29C65/8207—Testing the joint by mechanical methods
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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
- B29C66/022—Mechanical pre-treatments, e.g. reshaping
- B29C66/0222—Mechanical pre-treatments, e.g. reshaping without removal of material, e.g. cleaning by air blowing or using brushes
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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
- B29C66/022—Mechanical pre-treatments, e.g. reshaping
- B29C66/0224—Mechanical pre-treatments, e.g. reshaping with removal of material
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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
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/74—Joining plastics material to non-plastics material
- B29C66/742—Joining plastics material to non-plastics material to metals or their alloys
Abstract
The invention provides a friction lap welding method of metal and thermoplastic resin materials, which comprises a pretreatment process, a laser processing process, a clamping process before friction lap welding and a friction lap welding process; wherein, the laser processing procedure is as follows: carrying out laser processing treatment on the surface of the metal plate to generate periodic micropores on the surface of the metal plate; the friction lap welding process is as follows: starting the friction stir welding equipment, adjusting a welding tool main shaft of the friction stir welding equipment to enable the needleless welding stirring head to be perpendicular to the metal plate, controlling the needleless welding stirring head to be rotationally pressed into the metal plate, stopping pressing and keeping after the bottommost end of the shaft shoulder is pressed into the surface of the metal plate to set the pressing depth, and then keeping the set pressing depth and welding at a constant feeding speed. The method can ensure that the metal plate and the resin plate are not easy to separate after welding, and a high-strength welding joint is formed, and has low welding cost and high welding efficiency.
Description
Technical Field
The invention relates to the technical field of welding, in particular to a friction lap welding method for metal and thermoplastic resin materials.
Background
Friction lap welding is a new method of directly joining materials including thermoplastic resin materials and metal materials. The friction lap welding may be performed by a friction stir welding apparatus which generates heat energy by friction of a stirring head with a metal surface, presses the stirring head, which can be reused, into the metal plate surface and moves along an area where the metal plate and the thermoplastic resin plate overlap, and applies pressure to a connection interface while heating a connection material. Friction lap welding is similar in appearance to friction stir welding, but the friction stir welding tool has a stir probe in the stir head to assist in material flow and does not include this structure. The heat is transferred from the heated metal to the thermoplastic resin sheet to form a narrow molten region in the resin material near the faying interface, and the molten thermoplastic resin is solidified under the pressure generated by the contact with the metal matrix, thus achieving the metal-to-thermoplastic resin connection. Therefore, the friction lap welding has the advantages of producing a high-strength joint and causing no damage to basic materials, welding equipment or the design of the geometric shape of the joint, and also has the advantages of less setting parameters, no pollution to the environment and wide application prospect.
Thermoplastic resin-lightweight metal composite structures are increasingly being used in the automotive, aerospace and electronics industries, where they have high strength to weight ratios, excellent corrosion resistance, thermal and electrical insulation properties and design flexibility, and are therefore highly attractive. Bonding and mechanical fastening are conventional processes for joining thermoplastic resin materials to metals, however, these techniques suffer from drawbacks such as environmental pollution, long processing time, insufficient joint strength, stress concentration, and the like. Other methods of joining thermoplastic resin materials to metals, such as laser welding, ultrasonic welding, friction spot welding, etc., have been studied in recent years. However, laser welding is costly and complicated in welding parameters, and ultrasonic and friction spot welded joints are limited in size and shape. In recent years, a method of directly connecting a metal and a thermoplastic resin by friction lap welding has been developed and made a great breakthrough, but among them, thermoplastic resin materials all have a polar molecular structure (for example, aluminum alloy/ABS resin, aluminum alloy/polyamide resin, etc.). In the welding process, polar groups on the surface of the polar thermoplastic resin material and oxides on the surface of the metal form hydrogen bonding action, so that a welding joint with higher strength is formed. Friction lap welding of metals with some nonpolar thermoplastic resins with excellent properties is only mentioned at present.
By non-polar thermoplastic resin is meant that the functional groups of the organic chemical constituents of the resin do not produce a significant electric dipole moment and thus exhibit non-polar character. Polyetheretherketone (PEEK) type resins are typical non-polar thermoplastic resin materials. As a semi-crystalline, non-polar thermoplastic resin and a special engineering material with excellent performance, PEEK has excellent heat resistance and thermal stability and can be used for a long time in steam at the temperature of 200-250 ℃. At the same time, it is a very strong material with excellent long-term creep and fatigue resistance. In addition, compared with other special engineering materials, PEEK has the characteristics of excellent mechanical properties, good self-lubricating property, chemical corrosion resistance, flame retardance, peeling resistance, wear resistance, radiation resistance, good compatibility with human bodies and the like. As a novel special engineering resin, PEEK has very wide prospects in the fields of aerospace, automobile manufacturing, electronic and electric products, medical treatment, food processing and the like. The carbon fiber reinforced PEEK composite material further remarkably improves the mechanical property on the basis of PEEK, wherein the tensile strength of the carbon fiber reinforced PEEK composite material filled by 30 percent is doubled compared with that of common PEEK at room temperature, and in addition, the material formed by filling carbon fibers is greatly improved in the aspects of impact strength, bending strength and modulus, the wear rate and the like are also obviously lower than those of common PEEK resin, and the carbon fiber reinforced PEEK composite material also has wide application space. However, when the metal and the PEEK material are directly connected by friction lap welding, a welding joint with strength cannot be obtained, and due to the large difference of the properties of the two materials and the chemical properties of the nonpolar resin functional groups, in the welding process, the resin generally hardly reacts with the metal to form effective chemical bonds, so that the two materials cannot be effectively connected, and the excellent resin materials such as PEEK and the like and the light metal such as aluminum alloy and the like cannot form an effective composite structure, and thus cannot be effectively put into application.
Disclosure of Invention
In order to overcome the defects in the prior art, the invention aims to provide a friction lap welding method for metal and thermoplastic resin materials; the method can ensure that the metal plate and the resin plate are not easy to separate after welding, form a high-strength welding joint, improve the quality and the performance of the welding joint, and has low welding cost and high welding efficiency.
In order to achieve the purpose, the invention is realized by the following technical scheme: a friction lap welding method of metal and thermoplastic resin material is characterized in that: the method comprises a pre-treatment process, a laser processing process, a clamping process before friction lap welding and a friction lap welding process which are sequentially executed; wherein, the first and the second end of the pipe are connected with each other,
the pretreatment process comprises the following steps: respectively carrying out pretreatment on the metal plate and the thermoplastic resin plate to ensure that the specification and the shape of the metal plate are matched with those of the thermoplastic resin plate; removing an oxide layer on the welding surface of the metal plate, and cleaning and drying the metal plate and the thermoplastic resin plate;
the laser processing procedure is as follows: carrying out laser processing treatment on the surface of the metal plate by using a laser to generate periodic micropores on the surface of the metal plate; cleaning and drying the metal plate subjected to laser processing;
the clamping procedure before friction lap welding is as follows: overlapping and clamping a metal plate and a thermoplastic resin plate on a welding tool workbench clamp; wherein the metal plate is positioned above the thermoplastic resin plate, the thermoplastic resin plate is positioned below the metal plate, and the surface of the metal plate subjected to laser processing faces the thermoplastic resin plate; the welding tool is friction stir welding equipment with a needleless welding stirring head;
the friction lap welding process is as follows: starting a welding tool, adjusting a main shaft of the welding tool to enable a needleless welding stirring head to be perpendicular to a metal plate, and controlling the needleless welding stirring head to be rotationally pressed into the metal plate until the bottommost end of a shaft shoulder of the needleless welding stirring head is pressed into the surface of the metal plate to reach a set pressing depth; then the needleless welding stirring head keeps the set pressing depth and moves on the welding area on the surface of the metal sheet at a constant feeding speed in a rotating state to weld.
Preferably, in the laser processing procedure, the laser is an Nd-YAG laser; performing laser processing treatment on the surface of the metal plate by a YAG laser in an atmospheric environment; the periodic micropores are generated on the surface of the metal plate, the aperture D ranges from 20 to 600 microns, the depth ranges from 20 to 600 microns, and the center distance of the pores ranges from 1 to 3 times of the aperture D.
Preferably, the laser power range of the Nd-YAG laser is 1-100W, the wavelength range is 1055-1070 nm, the pulse duration range is 80-120 ns, the frequency range is 22-80 kHz, and the maximum pulse energy is 0.5 mJ.
Preferably, in the laser processing procedure, the step of cleaning the metal plate after laser processing is to adopt ultrasonic cleaning, and the cleaning time is more than or equal to 10 min; so as to remove the scraps left by laser processing and ensure the laser processing effect of the metal plate.
Preferably, in the clamping step before friction lap welding, the lap width of the metal plate and the thermoplastic resin plate ranges from 5mm to 100 mm.
Preferably, in the friction lap welding procedure, the rotating speed range of the pin-free welding stirring head is set to be 800-5000 rpm, the value range of the pressing depth is set to be 0.1-1 mm, and the value range of the constant feeding speed is set to be 50-600 mm/min. The pressing depth of a needleless welding stirring head of the friction stir welding equipment is set to be 0.1-1 mm, so that the welding stability in the welding process is ensured, the heat conduction is enhanced, the rapid melting of a resin material is facilitated, and the welding quality is improved.
Preferably, the environmental conditions of the friction lap welding are: the environmental temperature is kept at 25-35 ℃, and the humidity is kept at 35-45%; the needle-free welding stirring head is made of H13 steel, and the diameter range of a shaft shoulder is 5-30 mm.
Preferably, the friction lap welding process is followed by a welding effect evaluation process; the welding effect evaluation procedure is as follows: the quality of the welded joint formed by friction lap welding was evaluated.
Preferably, in the welding effect evaluation process, the quality evaluation method includes: intercepting part of welding joint samples to prepare samples, and performing a mechanical tension-shear test; and cutting out a welding joint sample, carrying out cold inlaying on the sample, then grinding and polishing, and carrying out microstructure evaluation on the welding joint.
Compared with the prior art, the invention has the following advantages and beneficial effects:
1. according to the invention, the metal surface is processed by using laser, on one hand, a microporous structure is formed, so that in the welding process, molten resin enters micropores under the action of pressure to form a large number of micro mechanical interlocking structures, and thus, a metal plate and a resin plate are not easy to separate after being welded, and a high-strength welding joint is formed; on the other hand, the surface characteristics of the metal plate, particularly the hydrophilicity and hydrophobicity of the surface of the metal plate, are changed by laser processing, and the hydrophobicity of the metal plate after laser processing is greatly improved compared with that of the metal plate before, so that a hydrophobic surface or even a super-hydrophobic surface is formed, the free energy of resin on the surface of the metal plate is greatly improved, the connection effect is enhanced during welding, and the strength of a welding joint is improved; therefore, the welding method can realize the welding between the metal material and the thermoplastic resin material with greatly different physical and chemical properties such as melting point, hardness, thermal conductivity, chemical components and the like; the welding method is suitable for welding between the nonpolar thermoplastic resin material and the metal material, and is also suitable for welding between other thermoplastic resin materials and the metal material;
2. YAG laser processed metal surface not only can be outputted continuously and in pulse, but also can realize the super pulse output with high peak power by Q-switching technology, thus providing various metal surface processing schemes and providing possibility for realizing and improving more subsequent welding methods;
3. the invention utilizes the prior friction stir welding equipment and the Nd-YAG laser which is popularized in a large scale, has lower cost and mature technology to weld, thereby greatly saving the equipment investment; meanwhile, the method has the advantages of few set parameters, simple operation and low requirement on environmental conditions, and improves the welding processing efficiency of the metal and the resin material;
4. the friction lap welding belongs to a low-temperature welding technology, and a large amount of bubbles can not be generated at a welding seam due to overhigh temperature under reasonable parameters, so that the strength of a welding joint is not influenced; meanwhile, the welding temperature is low, and welding materials cannot be damaged; the welded joint with beautiful appearance can be obtained, and meanwhile, no pollution is caused to the environment.
Drawings
FIG. 1 is a schematic flow diagram of the present invention;
FIG. 2 is a schematic diagram of the present invention for preparing a mechanical tension-shear test sample;
FIG. 3 is a scanning electron microscope image of laser-processed micro-holes on the surface of a metal plate according to an embodiment of the present invention and a contact angle test result image;
FIG. 4 is a scanning electron microscope image of a cross section of a weld joint of a weldment according to the second embodiment of the present invention;
FIG. 5 is a scanning electron micrograph of laser-processed micro-holes on a surface of a trimetal plate according to an embodiment of the present invention and a contact angle test result chart;
FIGS. 6(a) and 6(b) are graphs showing the results of mechanical tension-shear tests performed on the welded joints of three welded articles according to the embodiment of the present invention;
FIG. 7 is a scanning electron microscope image of a cross section of a welded joint of a third weldment of the embodiment of the invention.
Detailed Description
The present invention will be described in further detail with reference to the accompanying drawings and specific embodiments.
Example one
As shown in fig. 1, a friction lap welding method of a metal and a thermoplastic resin material includes a pre-treatment process, a laser processing process, a clamping process before friction lap welding and a friction lap welding process which are sequentially performed.
Wherein the content of the first and second substances,
the pretreatment process comprises the following steps: respectively carrying out pretreatment on the metal plate and the thermoplastic resin plate to ensure that the specification and the shape of the metal plate are matched with those of the thermoplastic resin plate; and removing an oxide layer on the welding surface of the metal plate, and cleaning and drying the metal plate and the thermoplastic resin plate.
The step of removing the oxide layer on the welding surface of the metal plate refers to: the surface of the metal plate is polished by using 2000 or more mesh abrasive paper so as to eliminate the interference of other factors on the surface in the subsequent laser processing and ensure the laser processing effect.
The laser processing procedure is as follows: carrying out laser processing treatment on the surface of the metal plate by using a laser to generate periodic micropores on the surface of the metal plate; and cleaning and drying the metal plate subjected to the laser processing treatment.
The laser is Nd, YAG laser; performing laser processing treatment on the surface of the metal plate by a YAG laser in an atmospheric environment; the periodic micropores are generated on the surface of the metal plate, the aperture D ranges from 20 to 600 microns, the depth ranges from 20 to 600 microns, and the center distance of the pores ranges from 1 to 3 times of the aperture D.
YAG laser, the laser power range is 1-100W, the wavelength range is 1055-1070 nm, the pulse duration range is 80-120 ns, the frequency range is 22-80 kHz, and the maximum pulse energy is 0.5 mJ. YAG laser has the advantages of high gain, low threshold, high quantum efficiency, small heat effect, good mechanical property, simple operation, convenient carrying, stable performance, low cost and the like, and is suitable for being applied to various fields such as industrial production and the like.
Cleaning the metal plate after laser processing refers to ultrasonic cleaning, and the cleaning time is more than or equal to 10 min; so as to remove the scraps left by laser processing and ensure the laser processing effect of the metal plate.
The clamping procedure before friction lap welding is as follows: overlapping and clamping a metal plate and a thermoplastic resin plate on a welding tool workbench clamp; wherein the metal plate is positioned above the thermoplastic resin plate, the thermoplastic resin plate is positioned below the metal plate, and the surface of the metal plate which is processed by laser processing faces the thermoplastic resin plate. The welding tool is a friction stir welding device with a needleless welding stirring head. The overlapping width range of the metal plate and the thermoplastic resin plate is 5-100 mm.
The friction lap welding process comprises the following steps: starting a welding tool, adjusting a main shaft of the welding tool to enable a needleless welding stirring head to be vertical to a metal plate, and controlling the needleless welding stirring head to be rotationally pressed into the metal plate until the bottommost end of a shaft shoulder of the needleless welding stirring head is pressed into the surface of the metal plate to reach a set pressing depth; then the needleless welding stirring head keeps the set pressing depth and moves on the welding area of the surface of the metal plate at a constant feeding speed in a rotating state to weld.
The rotating speed range of the needleless welding stirring head is set to be 800-5000 rpm, the value range of the pressing depth is set to be 0.1-1 mm, and the value range of the constant feeding speed is set to be 50-600 mm/min. The pressing depth of a needleless welding stirring head of the friction stir welding equipment is set to be 0.1-1 mm, so that the welding stability in the welding process is ensured, the heat conduction is enhanced, the rapid melting of a resin material is facilitated, and the welding quality is improved.
The environmental conditions of the friction lap welding are as follows: the environmental temperature is kept at 25-35 ℃, and the humidity is kept at 35-45%; the needle-free welding stirring head is made of H13 steel, and the diameter range of a shaft shoulder is 5-30 mm.
After the friction lap welding process, preferably, a welding effect evaluation process is further included; the welding effect evaluation procedure is as follows: the quality of the welded joint formed by friction lap welding was evaluated.
In the welding effect evaluation procedure, the quality evaluation method comprises the following steps: intercepting part of welding joint samples to prepare samples, and performing a mechanical tension-shear test; and cutting a welding joint sample, carrying out cold inlaying on the sample, then grinding and polishing, and carrying out microstructure evaluation on the welding joint by using an optical microscope, a scanning electron microscope, a 3D profile scanner and the like.
According to the invention, the metal surface is processed by using laser, on one hand, a microporous structure is formed, so that in the welding process, molten resin enters micropores under the action of pressure to form a large number of micro mechanical interlocking structures, and thus, a metal plate and a resin plate are not easy to separate after being welded, and a high-strength welding joint is formed; on the other hand, the surface characteristics of the metal plate are changed by laser processing, particularly the hydrophilicity and hydrophobicity of the surface of the metal plate are changed, the hydrophobicity of the metal plate after laser processing is greatly improved compared with that before, and a hydrophobic surface or even a super-hydrophobic surface is formed, so that the surface free energy of the resin on the metal plate is greatly improved, the connection effect is enhanced during welding, and the strength of a welding joint is improved.
Example two
In this example, a 6061-T6 type aluminum alloy sheet was used as a metal sheet, and a PEEK sheet was used as a thermoplastic resin sheet.
The early stage treatment process comprises the following steps: the aluminum alloy plate is 200mm multiplied by 75mm multiplied by 2mm in specification, the aluminum alloy plate is polished by 400-2000-mesh sand paper to remove surface oxide layers and impurities, the surface of the aluminum alloy plate is cleaned by alcohol, and the aluminum alloy plate is dried after oil stains on the surface are removed. The PEEK plate adopts the specification of 150mm multiplied by 75mm multiplied by 5mm, the surface of the PEEK plate is cleaned by alcohol, and the PEEK plate is dried after oil stains on the surface are removed.
A laser processing procedure: and performing laser processing treatment on the surface of the aluminum alloy plate by using an Nd-YAG laser to generate periodic micropores, wherein the depth of the micropores is 400-500 mu m, the diameter of the pores is 200 mu m, and the center distance of the pores is 200 mu m. After the processing is finished, cleaning the aluminum alloy plate by using an ultrasonic cleaner for 15min, and drying after cleaning; the surface of the aluminum alloy plate is observed by using a scanning electron microscope and subjected to a contact angle test, and the result is shown in fig. 3, the periodic micropore profile is obvious, the effect is good, the contact angle of the surface to water reaches 140.5 degrees, the contact angle to oil is 0 degree, and the surface has hydrophobicity.
A clamping procedure before friction lap welding: overlapping and clamping an aluminum alloy plate and a PEEK plate on a welding tool workbench clamp of friction stir welding equipment; wherein aluminum alloy plate is located the top, and the PEEK board is located the below, and laser beam machining processes aluminum alloy plate surface towards the PEEK board, and the width in overlap joint region is 30 mm.
A friction lap welding procedure: the welding method comprises the steps of carrying out friction lap welding by using a welding tool, keeping the ambient temperature at 25-35 ℃ and the humidity at 35% -45%, wherein a needle-free welding stirring head used for welding is made of H13 steel, and the diameter of a shaft shoulder is 13 mm. Adjusting a main shaft of the welding tool to be vertical to the workbench, starting the main shaft to enable the needle-free welding stirring head to rotate at the rotating speed of 2000rpm, then controlling the stirring head to press in a workpiece to be welded while rotating, starting a feed switch of the main shaft after the pressing depth reaches 0.75mm, keeping the constant feed speed at 200mm/min, and keeping the pressing depth of the needle-free welding stirring head at 0.75mm all the time until the welding is finished.
A welding effect evaluation procedure: intercepting part of welding joint samples to prepare samples, and performing a mechanical tension-shear test; and additionally, cutting a part of a welding joint sample, carrying out cold sample inlaying, grinding and polishing by using an automatic sample grinder, and observing the microstructure of the cross section of the welding joint by using a scanning electron microscope.
The sample subjected to the mechanical test is processed into a strip with the width of 15mm and the direction perpendicular to the welding direction, and fig. 2 is a schematic diagram of sample preparation of the mechanical sample. An electronic universal testing machine is used for carrying out a tensile-shear test, the load of the universal testing machine is 50KN, the tensile speed of a chuck is 0.5mm/min, the result shows that the maximum load of the joint is 41.06MPa, and the effect is good. Scanning electron microscope observation is carried out on the cold-inlaid sample, images of the cross section of a welding joint are respectively a 6061-T6 aluminum alloy layer and a PEEK layer from top to bottom as shown in figure 4, the melted PEEK is filled into periodic micropores on the surface of the aluminum alloy to form an interface similar to a sawtooth shape, obvious defects such as air bubbles and holes are not observed on the connecting interface, the PEEK is filled compactly, and the welding effect is good.
EXAMPLE III
This example will be described by taking a 6061-T6 type aluminum alloy plate as a metal plate material and a carbon fiber reinforced PEEK plate (CF30PEEK plate) filled at 30% as a thermoplastic resin plate material.
The early stage treatment process comprises the following steps: the aluminum alloy plate is 150mm multiplied by 100mm multiplied by 2mm in specification, the aluminum alloy plate is polished by 400-2000-mesh sand paper to remove surface oxide layers and impurities, the surface of the aluminum alloy plate is cleaned by alcohol, and the aluminum alloy plate is dried after oil stains on the surface are removed. The CF30PEEK plate adopts the specification of 150mm multiplied by 100mm multiplied by 2.5mm, the CF30PEEK plate is cleaned by alcohol, and is dried after oil stains on the surface are removed.
A laser processing procedure: and performing laser processing treatment on the surface of the aluminum alloy plate by using an Nd-YAG laser to generate periodic micropores, wherein the depth of the micropores is 400-500 mu m, the diameter of the pores is 200 mu m, and the center distance of the pores is 250 mu m. Cleaning the aluminum alloy plate by using an ultrasonic cleaner for 15min after the processing is finished, and drying after the processing is finished; the surface of the aluminum alloy plate is observed by using a scanning electron microscope and subjected to a contact angle test, and the result is shown in fig. 5, the periodic micropore profile is obvious, the effect is good, the contact angle of the surface to water reaches 159 degrees, the contact angle to oil reaches 8 degrees, and a super-hydrophobic surface is formed.
A clamping procedure before friction lap welding: overlapping and clamping an aluminum alloy plate and a CF30PEEK plate on a welding tool worktable clamp of friction stir welding equipment; wherein the aluminum alloy plate is located the top, and the CF30PEEK board is located the below, and the aluminum alloy plate surface that laser beam machining handled is towards the CF30PEEK board, and the width in overlap joint region is 30 mm.
A friction lap welding procedure: the welding method comprises the steps of carrying out friction lap welding by using a welding tool, keeping the ambient temperature at 25-35 ℃ and the humidity at 35% -45%, wherein a needle-free welding stirring head used for welding is made of H13 steel, and the diameter of a shaft shoulder is 13 mm. Adjusting a main shaft of the welding tool to be vertical to the workbench, starting the main shaft to enable the needle-free welding stirring head to rotate at the rotating speed of 2000rpm, then controlling the stirring head to press in a workpiece to be welded while rotating, starting a feed switch of the main shaft after the pressing depth reaches 0.75mm, setting the constant feed speed to be 200mm/min, and keeping the pressing depth of the needle-free welding stirring head to be 0.75mm all the time until the welding is finished.
A welding effect evaluation procedure: cutting out part of the welded joint sample, and performing a mechanical tension-shear test; and additionally, cutting a part of a welding joint sample, carrying out cold sample inlaying, grinding and polishing by using an automatic sample grinder, and observing the microstructure of the cross section of the welding joint by using a scanning electron microscope.
The sample subjected to the mechanical test is processed into a strip with the width of 15mm and the direction perpendicular to the welding direction, and fig. 2 is a sample preparation schematic diagram of the mechanical sample. The tensile shear test was carried out using an electronic universal tester with a universal load of 50KN and a chuck tensile speed of 0.5mm/min, and the results showed that the maximum joint load was 2.151KN, the results were good, and the tensile results of the test specimens were shown in fig. 6(a) and 6 (b). When the cold-setting sample is observed by a scanning electron microscope, the cross section of the welded joint is imaged as shown in fig. 7, which is a CF30PEEK layer and a 6061-T6 aluminum alloy layer from top to bottom, and a large amount of carbon fibers are observed in the CF30PEEK layer, but no carbon fibers are observed in the periodic micropores of the aluminum alloy surface, which means that the carbon fibers do not participate in the filling of the micropores. Meanwhile, obvious defects such as bubbles and holes are not observed on a connecting interface, CF30PEEK is densely filled, and the welding effect is good.
The above embodiments are preferred embodiments of the present invention, but the present invention is not limited to the above embodiments, and any other changes, modifications, substitutions, combinations, and simplifications which do not depart from the spirit and principle of the present invention should be construed as equivalents thereof, and all such changes, modifications, substitutions, combinations, and simplifications are intended to be included in the scope of the present invention.
Claims (7)
1. A friction lap welding method of metal and thermoplastic resin material is characterized in that: the method comprises a pre-treatment process, a laser processing process, a clamping process before friction lap welding and a friction lap welding process which are sequentially executed; wherein the content of the first and second substances,
the pretreatment process comprises the following steps: respectively carrying out pretreatment on the metal plate and the thermoplastic resin plate to ensure that the specification and the shape of the metal plate are matched with those of the thermoplastic resin plate; polishing the metal plate to remove an oxide layer on the welding surface of the metal plate; cleaning and drying the metal plate and the thermoplastic resin plate;
the laser processing procedure is as follows: carrying out laser processing treatment on the surface of the metal plate by using a laser to generate periodic micropores on the surface of the metal plate to form a hydrophobic surface; the periodic micropores are generated on the surface of the metal plate, the aperture D ranges from 20 to 600 microns, the depth ranges from 20 to 600 microns, and the center distance of the pores ranges from 1 to 3 times of the aperture D; cleaning and drying the metal plate subjected to laser processing;
the clamping procedure before friction lap welding is as follows: overlapping and clamping a metal plate and a thermoplastic resin plate on a welding tool workbench clamp; wherein the metal plate is positioned above the thermoplastic resin plate, the thermoplastic resin plate is positioned below the metal plate, and the surface of the metal plate subjected to laser processing faces the thermoplastic resin plate; the welding tool is friction stir welding equipment with a needleless welding stirring head;
the friction lap welding process is as follows: starting a welding tool, adjusting a main shaft of the welding tool to enable a needleless welding stirring head to be perpendicular to a metal plate, and controlling the needleless welding stirring head to be rotationally pressed into the metal plate until the bottommost end of a shaft shoulder of the needleless welding stirring head is pressed into the surface of the metal plate to reach a set pressing depth; then the needleless welding stirring head keeps the set pressing depth and moves at a constant feeding speed in a welding area on the surface of the metal plate under the rotating state to weld;
in the laser processing procedure, the laser is Nd, YAG laser; performing laser processing treatment on the surface of the metal plate by a YAG laser in an atmospheric environment;
YAG laser, the laser power range is 1-100W, the wavelength range is 1055-1070 nm, the pulse duration range is 80-120 ns, the frequency range is 22-80 kHz, and the maximum pulse energy is 0.5 mJ.
2. The metal and thermoplastic resin material friction lap welding method according to claim 1, characterized in that: in the laser processing procedure, the cleaning of the metal plate after laser processing is ultrasonic cleaning, and the cleaning time is more than or equal to 10 min.
3. The metal and thermoplastic resin material friction lap welding method according to claim 1, characterized in that: in the clamping procedure before friction lap welding, the lap width range of the metal plate and the thermoplastic resin plate is 5-100 mm.
4. The metal and thermoplastic resin material friction lap welding method according to claim 1, characterized in that: in the friction lap welding procedure, the rotating speed range of the needleless welding stirring head is set to be 800-5000 rpm, the value range of the pressing depth is set to be 0.1-1 mm, and the value range of the constant feeding speed is set to be 50-600 mm/min.
5. The metal and thermoplastic resin material friction lap welding method according to claim 4, characterized in that: the environmental conditions of the friction lap welding are as follows: the environmental temperature is kept at 25-35 ℃, and the humidity is kept at 35-45%; the needle-free welding stirring head is made of H13 steel, and the diameter range of a shaft shoulder is 5-30 mm.
6. The metal and thermoplastic resin material friction lap welding method according to claim 1, characterized in that: the friction lap welding process also comprises a welding effect evaluation process; the welding effect evaluation procedure is as follows: the quality of the welded joint formed by friction lap welding was evaluated.
7. The metal and thermoplastic resin material friction lap welding method according to claim 6, characterized in that: in the welding effect evaluation procedure, the quality evaluation method comprises the following steps: intercepting part of a welding joint sample for sample preparation, and performing a mechanical tension-shear test; and additionally, cutting out a welding joint sample, carrying out cold inlaying on the sample, then grinding and polishing, and carrying out microstructure evaluation on the welding joint.
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