CN112705833B - Friction stir welding process for thick aluminum alloy plate - Google Patents
Friction stir welding process for thick aluminum alloy plate Download PDFInfo
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- CN112705833B CN112705833B CN202011350980.XA CN202011350980A CN112705833B CN 112705833 B CN112705833 B CN 112705833B CN 202011350980 A CN202011350980 A CN 202011350980A CN 112705833 B CN112705833 B CN 112705833B
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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
- B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
- B23K20/122—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
- B23K20/1245—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding characterised by the 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
- B23K20/26—Auxiliary equipment
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Abstract
The invention provides a friction stir welding process for an aluminum alloy thick plate, which is used for solving the technical problems of large welding deformation and large welding furrow tendency caused by overlarge welding heat input, low welding efficiency caused by undersize early-stage heat input, easy breakage of a stirring pin and the like in the conventional friction stir welding process for a medium-thickness plate aluminum alloy. The method comprises the key steps of assembling and positioning welding test plates, cleaning a welding area, punching points by a sample, positioning and welding a small-size stirring head, walking and welding a large-size stirring head and the like, wherein the two welding test plates are pre-compacted, the welding test plates are punched together by the sample punching, then the small-size stirring head is used for positioning and welding to form rigid connection between the two welding test plates, then the large-size stirring head is used for walking and welding, the heat accumulation in the initial welding stage is realized by adjusting the welding speed and the welding speed of the large-size stirring head, and the risks of welding furrows and collapse caused by broken pins of the large-size stirring head and welding overheating in the welding process are reduced.
Description
Technical Field
The invention relates to the technical field of aluminum alloy friction stir welding, in particular to a friction stir welding process for an aluminum alloy thick plate.
Background
Friction stir welding is a novel high-efficiency thermal solid state plasticizing welding technology, has the advantages of high efficiency, low consumption, environmental protection and the like compared with the traditional fusion welding method, can realize the effective welding of nonferrous metals such as aluminum, magnesium, copper and alloys thereof, and is widely applied to various industries such as aerospace, rail transit and the like. The heat required by friction stir welding mainly comes from friction heat production between the surface of a weldment and a stirring head, a funnel-shaped temperature field with high height and low height is formed in a welding fishing zone, and when an aluminum alloy thick plate is welded, the difference of the structure performance of the thickness of a welding seam is large, the structure of a welding bottom layer is loose, and the defects of holes and the like are easy to occur. The existing aluminum alloy thick plate has the disadvantages of small welding heat input and slow heat accumulation in the initial welding stage, so that the heat accumulation time in the welding pressing process is long, the welding efficiency is low, and a stirring pin of a stirring head is easy to break in the welding process; the problems of large welding deformation, large welding furrow tendency and the like are caused by overlarge welding heat input in the normal welding stage. The welding quality mainly depends on the rotating speed of the stirring head and the welding speed, and the existing adjustable process parameters are less, so the welding technology of the aluminum alloy thick plate is more difficult.
Disclosure of Invention
The invention provides an aluminum alloy thick plate friction stir welding process, which aims to solve the technical problems of large welding deformation and welding furrow tendency caused by overlarge welding heat input, low welding efficiency caused by too small early heat input, easy breakage of a stirring pin and the like in the conventional friction stir welding technology of aluminum alloy thick plates, effectively realizes heat accumulation in the initial welding stage, and greatly reduces the risks of welding furrows and collapse caused by broken pins of large-size stirring heads and overheating welding in the welding process of the aluminum alloy thick plates.
In order to solve the technical problem, the invention adopts the following technical scheme: a friction stir welding process for an aluminum alloy thick plate comprises the following specific steps:
step S1: placing two aluminum alloy welding test plates on a tool backing plate and carrying out butt joint, wherein grooves are not machined on the two welding test plates, then adjusting butt joint seams of the two welding test plates, and pre-fixing the welding directions and the welding parallel directions of the two welding test plates so as to finish preliminary clamping and fixing of the two welding test plates;
step S2: cleaning the welding areas of the two welding test plates;
step S3: punching point positioning is carried out on the butt-joint welding seam of the two welding test plates, and after punching is finished, the two welding test plates are clamped and fixed by an upper portion pressing tool and a side portion jacking tool;
step S4: the small-size stirring head is used for welding in a positioning mode along the butt-joint welding line of the two welding test plates, the small-size stirring head is rotationally pressed into the welding test plates and then is welded at a certain welding speed, and the shaft shoulder of the small-size stirring head can stir and form enough welding flux and form a compact and stable welding line so as to finish rigid fixation between the two welding test plates;
step S5: the method comprises the following steps of carrying out walking welding along a butt welding seam of two welding test plates by using a large-size stirring head, wherein the large-size stirring head is pressed into the welding test plates in a rotating mode at a normal welding rotating speed which is 2 times that of the large-size stirring head, so that the welding test plates are subjected to high welding heat input, the large-size stirring head is stagnated for a certain time after the large-size stirring head is pressed into the welding test plates until burrs are generated around a shaft shoulder, then the large-size stirring head is adjusted to the normal welding rotating speed, welding is started at 28% -32% of the normal walking welding speed of the large-size stirring head, the walking welding speed of the large-size stirring head is gradually increased to the normal walking welding speed after welding is stable, and meanwhile, air cooling and water cooling are carried out on a welding area in the normal walking welding process;
step S6: after the welding is finished, the welding speed of the large-size stirring head is reduced to zero, meanwhile, the large-size stirring head keeps the normal welding speed for drawing back, and after the stirring pin of the large-size stirring head is completely drawn out of the welding test plate, the large-size stirring head stops rotating, and the welding is finished.
The gap of the butt welding seam between the two welding test plates is 0-1 mm.
The diameter of each punching point is 1mm, and the distance between every two adjacent punching points is 20-30 mm.
The length of a stirring needle of the small-size stirring head is 3mm, and the diameter of a shaft shoulder is 10 mm; the length of a stirring needle of the large-size stirring head is 8.5mm, and the diameter of a shaft shoulder is 17 mm.
The included angles between the axial directions of the small-size stirring head and the large-size stirring head and the normal direction of the plane where the butt welding line is located are both 2-4 degrees.
In the positioning welding process, the shaft shoulder pressing-in amount of the small-size stirring head is 0.1-0.3 mm, the welding speed of the small-size stirring head is 1200r/min, and the welding speed is 300 mm/min.
In the walking welding, the normal welding speed of the large-size stirring head is 300r/min, and the normal walking welding speed of the large-size stirring head is 80 mm/min.
In the walking welding process, the press-in amount of the shaft shoulder of the large-size stirring head is 0.2-0.5 mm, and the dead time of the large-size stirring head is 5-7 s.
The upper portion compresses tightly frock and the tight frock in lateral part top all include clamp plate and clamp bolt, and the clamp plate cooperatees with the welding test panel, and the clamp plate passes through clamp bolt to be fixed on the workstation.
After the two welding test plates are pre-compacted, the welding test plates are point punched together through sample punching so as to ensure the stability of the position relation in the assembling process of the welding test plates; then, the small-size stirring head is used for positioning welding to enable the two welding test plates to form rigid connection, so that the butt welding test plates cannot be extruded and separated and the position relation cannot be changed in the rotating pressing and welding processes of the large-size stirring head; and finally, the large-size stirring head is used for walking welding, in the welding process, the welding rotating speed and the welding speed of the large-size stirring head are adjusted, so that a welding test plate is enabled to obtain higher welding heat input, the time of heat accumulation in the welding pressing process is shortened, the welding efficiency is improved, the risk of needle breakage in the welding process of the large-size stirring head is reduced, and furrows, collapse and the like caused by overheating in the welding process are avoided.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the drawings without creative efforts.
FIG. 1 is a schematic view of a butt joint assembly and a sample punching point of a welding test plate according to the present invention;
FIG. 2 is a schematic view of a welding process of the large-sized stirring head according to the present invention;
FIG. 3 is a schematic view of the welding of a small-sized stirring head according to the present invention;
FIG. 4 is a schematic diagram of the welding process of the large-size stirring head or the small-size stirring head of the invention.
In the figure, 1 is a tool backing plate, 2 is an upper portion pressing tool, 3 is a side portion jacking tool, 4 is a welding test plate, 5 is a pressing plate, and 6 is a pressing bolt.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be obtained by a person skilled in the art without inventive effort based on the embodiments of the present invention, are within the scope of the present invention.
As shown in FIG. 1, the invention provides a friction stir welding process of an aluminum alloy thick plate, which comprises the following specific steps: step S1: arrange two welding test panels 4 of aluminum alloy in on the frock backing plate 1 and dock, two welding test panels 4 do not all process the groove, then adjust two butt weld of welding test panel 4, in this embodiment, the preferred clearance of butt weld between two welding test panels 4 is 0~1mm, reuse upper portion after the adjustment compress tightly frock 2 and lateral part top tight frock 3 weld direction and the welding parallel direction of two welding test panels 4 and fix in advance to accomplish that two welding test panels 4's preliminary clamping is fixed. Step S2: after the step S1 is completed, the welding areas of the two welding test plates 4 are cleaned, that is, the butt weld between the two welding test plates 4 and the area within 20mm of the periphery of the butt weld are cleaned, the oxide film on the welding test plates 4 is removed by mechanical polishing, and the welding areas are cleaned by using absolute ethyl alcohol or acetone after polishing, so as to ensure that the welding areas are clean and pollution-free before welding, and further ensure the welding effect.
Step S3: the use appearance is dashed and is carried out towards some location to the butt weld of two welding test panels 4, namely after two welding test panels accomplish the butt joint and the clean butt weld, dash some along the butt weld with the appearance, dash some can make two welding test panels realize adhesion each other through small deformation, thereby realize welding test panel precompression back, dash along the butt weld with welding test panel point together through appearance, the high efficiency realizes the preliminary location of two welding test panels, can effectively avoid welding test panel position relation in the assembling process to change, and then guaranteed the stability of position relation in the welding test panel assembling process. In this embodiment, dash a little diameter and be 1mm, and two adjacent dashes the distance between the point and be 20 ~ 30mm to guarantee that dislocation or wrong limit of assembling relation can not take place for two welding test panels. After the punching point is completed, the upper portion pressing tool 2 and the lateral portion jacking tool 3 are reused for further clamping and fixing two welding test plates, after the tools are pressed, the limiting tools around the welding test plates can effectively clamp the welding test plates, and therefore the welding test plates are prevented from changing positions along with the movement of the stirring head in the welding process.
Step S4: as shown in FIG. 3, the small-sized pin tool is used for welding along the butt weld of two welded test plates 4, and the pin tool length of the small-sized pin tool is 3mm and the shoulder diameter is 10 mm. As shown in fig. 4, an included angle between the axial direction of the small-sized stirring head and the normal direction of the plane of the butt-welding seam is 2-4 degrees, preferably 3 degrees, namely the inclination angle of the small-sized stirring head is 3 degrees, then the small-sized stirring head is rotationally pressed into the welding test plate 4 and then welding is carried out at a certain welding speed and welding speed, specifically, the shaft shoulder pressing-in amount of the small-sized stirring head is 0.1-0.3 mm, in the pressing-in process, the welding speed of the small-sized stirring head is gradually increased to 1200r/min, forward welding is started at the certain welding speed, and the welding speed is 300 mm/min. The shaft shoulder of the small-size stirring head can stir and form enough welding flux and form a compact and stable welding line by using the small-size stirring head for one-step positioning welding so as to finish the rigid fixation between the two welding test plates 4. In the embodiment, as the stirring pin and the shaft shoulder of the small-size stirring head are smaller in size, the flash of a formed welding line is also smaller, the stirring pin of the large-size stirring head is larger in diameter and longer in shaft shoulder diameter, the assembled welding test plate is probably extruded in the process of rotationally pressing the stirring pin into the welding test plate, the assembly gap is enlarged, the material under the shaft shoulder is reduced in the stirring friction welding process, the stirring pin key hole part of the large-size stirring head cannot be backfilled, and the tendency of generating furrow defects in the welding process is increased. Therefore, the welding test plates are rigidly connected by the small-size stirring head positioning welding seam, the position relation of the two welding test plates can be effectively prevented from being changed due to extrusion of the large-size stirring head in the welding process, namely, the butt welding test plates can not be extruded and separated and the position relation can not be changed in the rotating pressing and welding processes of the large-size stirring head.
Step S5: after the step S4 is completed, the large-sized probe is used to weld along the butt weld of the two welding test plates 4, the probe of the large-sized probe has a length of 8.5mm and a diameter of the shoulder of 17mm, and the included angle between the axial direction of the large-sized probe and the normal direction of the plane of the butt weld is 3 °. In the initial stage of walking welding, as shown in fig. 2, the welding heat is completely derived from the heat generated by stirring the stirring pin and the welding test plate before the stirring pin of the large-size stirring head is not completely immersed into the welding test plate, which is far from meeting the heat required by solid-state welding of material friction stir welding heat, so that the welding heat input needs to be increased in the process, namely, in the initial stage of walking welding, the large-size stirring head is rotationally pressed into the welding test plate 4 at 2 times of normal welding speed, so that the welding test plate 4 obtains higher welding heat input, the time for the aluminum alloy to enter a thermoplastic state is shortened, and the welding quality in the initial stage of welding is ensured; after the large-size stirring head is pressed into the welding test plate 4 until the flange 10 is generated around the shaft shoulder of the large-size stirring head, the large-size stirring head stagnates for a certain time, in the embodiment, the pressing amount of the shaft shoulder of the large-size stirring head is 0.2-0.5 mm, the stagnation time of the large-size stirring head is 5-7 s, and the welding heat in the stagnation process comes from the stirring action of the stirring pin and the heat generated by the stirring friction between the shaft shoulder and the welding test plate. And then adjusting the large-size stirring head to a normal welding speed, starting welding at 28% -32% of the normal walking welding speed of the large-size stirring head, preferably starting welding at 30% of the normal walking welding speed, gradually increasing the walking welding speed of the large-size stirring head to the normal walking welding speed after the welding is stable, effectively finishing heat accumulation in the initial welding stage, and reducing the risk of needle breakage of the stirring head. In the embodiment, in normal walking welding, the normal welding speed of the large-size stirring head is 300r/min, and the normal walking welding speed of the large-size stirring head is 80mm/min, namely in the initial stage of walking welding, the large-size stirring head is rotationally pressed into the welding test plate 4 at the welding speed of 600r/min, the pressing of the stirring head into the welding test plate is stopped and lagged, the welding speed of the large-size stirring head is gradually reduced to 300r/min, then the welding is started at the walking welding speed of 24mm/min, and after the welding seam is continuously and stably formed, the welding speed is gradually increased to the normal walking welding speed of 80mm/min, so that the problem that the welding efficiency is reduced due to insufficient welding heat input in the initial welding stage can be effectively avoided, and meanwhile, the occurrence of broken pins of the stirring head caused by directly starting high-speed welding is also prevented. Further, the welding area is continuously subjected to air cooling and water cooling in the normal walking welding process, so that the phenomena of furrowing, collapse and the like caused by overheating in the welding process are effectively avoided.
Step S6: after the welding is finished, the welding speed of the large-size stirring head is reduced to zero, meanwhile, the large-size stirring head keeps the normal welding speed for drawing back, and after the stirring pin of the large-size stirring head is completely drawn out of the welding test plate 4, the large-size stirring head stops rotating, and the welding is finished.
In this embodiment, the tight frock in lateral part top 3 is including vertical tight frock in top and the tight frock in horizontal top, and vertical tight frock in top and the tight frock in horizontal top all are equipped with two sets ofly at least, and wherein two sets of vertical tight frock in top set up the upper and lower both sides at the welding test panel respectively, and two sets of horizontal tight frock in top set up the left and right sides at the welding test panel respectively, then cooperate upper portion to compress tightly the frock to it is fixed to realize that the omnidirectional clamping of welding test panel. The upper portion compresses tightly frock 2 and the tight frock 3 in lateral part top all include clamp plate 5 and clamp bolt 6, and clamp plate 5 cooperatees with welding test panel 4, and clamp plate 5 passes through clamp bolt 6 to be fixed on the workstation, and the clamp plate is used for fixed welding test panel 4 promptly, adjusts the elasticity of clamp plate 5 fixed welding test panel 4 through twisting clamp bolt 6, whole easy operation, convenient to use.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents, improvements and the like that fall within the spirit and principle of the present invention are intended to be included therein.
Claims (5)
1. The friction stir welding process of the aluminum alloy thick plate is characterized by comprising the following specific steps of:
step S1: placing two aluminum alloy welding test plates (4) on a tool backing plate (1) and carrying out butt joint, wherein grooves are not machined on the two welding test plates (4), then adjusting butt joint welding seams of the two welding test plates (4), and pre-fixing the welding direction and the welding parallel direction of the two welding test plates (4) so as to finish preliminary clamping and fixing of the two welding test plates (4);
step S2: mechanically polishing the welding areas of the two welding test plates (4), and cleaning the polished welding areas by using absolute ethyl alcohol;
step S3: punching point positioning is carried out on butt welding seams of the two welding test plates (4), the diameter of each punching point is 1mm, the distance between every two adjacent punching points is 20-30 mm, and after punching points are finished, the two welding test plates are clamped and fixed by an upper portion pressing tool (2) and a side portion jacking tool (3);
step S4: the small-size stirring head is used for carrying out positioning welding along the butt welding seam of the two welding test plates (4), the small-size stirring head is rotationally pressed into the welding test plates (4) and then keeps a certain welding speed and welding speed for welding, and the shaft shoulder of the small-size stirring head can stir and form enough welding flux and form a compact and stable welding seam so as to finish rigid fixation between the two welding test plates (4); the length of a stirring needle of the small-size stirring head is 3mm, and the diameter of a shaft shoulder is 10 mm; in the positioning welding, the shaft shoulder pressing-in amount of the small-size stirring head is 0.1-0.3 mm, the welding speed of the small-size stirring head is 1200r/min, and the welding speed is 300 mm/min;
step S5: the method comprises the following steps of carrying out walking welding along a butt welding seam of two welding test plates (4) by using a large-size stirring head, wherein the large-size stirring head is pressed into the welding test plates (4) in a rotating mode at a normal welding speed which is 2 times that of the large-size stirring head, so that the welding test plates (4) are enabled to obtain higher welding heat input, the large-size stirring head is stopped for a certain time after the large-size stirring head is pressed into the welding test plates (4) until burrs are generated around a shaft shoulder of the large-size stirring head, then the large-size stirring head is adjusted to the normal welding speed, welding is started at 28% -32% of the normal walking welding speed of the large-size stirring head, after the welding is stabilized, the walking welding speed of the large-size stirring head is gradually increased to the normal walking welding speed, and meanwhile, air cooling and water cooling are carried out on a welding area in the normal walking welding process; the length of a stirring needle of the large-size stirring head is 8.5mm, and the diameter of a shaft shoulder is 17 mm; in walking welding, the normal welding speed of the large-size stirring head is 300r/min, and the normal walking welding speed of the large-size stirring head is 80 mm/min;
step S6: after welding is finished, the welding speed of the large-size stirring head is reduced to zero, meanwhile, the large-size stirring head keeps normal welding speed for drawing back, and after the stirring pin of the large-size stirring head is completely drawn out of the welding test plate (4), the large-size stirring head stops rotating, and welding is finished.
2. The friction stir welding process of an aluminum alloy thick plate according to claim 1, wherein: the gap of the butt welding seam between the two welding test plates (4) is 0-1 mm.
3. The friction stir welding process of an aluminum alloy thick plate according to claim 2, wherein: the included angles between the axial directions of the small-size stirring head and the large-size stirring head and the normal direction of the plane where the butt welding line is located are both 2-4 degrees.
4. The friction stir welding process of an aluminum alloy thick plate according to claim 3, wherein: in the walking welding process, the shaft shoulder pressing-in amount of the large-size stirring head is 0.2-0.5 mm, and the dead time of the large-size stirring head is 5-7 s.
5. The friction stir welding process of an aluminum alloy thick plate according to any one of claims 1 to 4, characterized in that: the upper portion compresses tightly frock (2) and tight frock (3) in lateral part top all include clamp plate (5) and clamp bolt (6), and clamp plate (5) cooperate with welding test panel (4), and clamp plate (5) are fixed on the workstation through clamp bolt (6).
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| CN104227226B (en) * | 2014-09-30 | 2017-02-01 | 湖北三江航天红阳机电有限公司 | Method for conducting preheating and friction stir welding on thick plate aluminum alloy |
| CN105127583B (en) * | 2015-09-09 | 2017-10-03 | 长春轨道客车股份有限公司 | A kind of aluminium alloy thick plate friction stir welding method |
| CN105772935A (en) * | 2016-04-01 | 2016-07-20 | 中国电子科技集团公司第三十八研究所 | Stirring head used for welding narrow-step water channel cover plate and welding technology for narrow-step water channel cover plate |
| CN105880826B (en) * | 2016-04-11 | 2017-12-15 | 江西理工大学 | A kind of slab friction stir welding method for avoiding bottom defect, improving joint performance |
| CN106862749B (en) * | 2017-01-23 | 2019-02-19 | 沈阳航空航天大学 | A kind of backfill formula friction stir spot welding method |
| DE102018111496B4 (en) * | 2018-05-14 | 2024-02-01 | Universität Stuttgart | Friction stir welding process |
| CN110091051B (en) * | 2019-03-29 | 2021-03-16 | 沈阳航空航天大学 | Method for eliminating surface peeling defect of magnesium-lithium alloy friction stir welding weld joint |
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