CN112872528A - Dissimilar metal ultrasonic-assisted eutectic reaction brazing method - Google Patents
Dissimilar metal ultrasonic-assisted eutectic reaction brazing method Download PDFInfo
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- CN112872528A CN112872528A CN202110321924.1A CN202110321924A CN112872528A CN 112872528 A CN112872528 A CN 112872528A CN 202110321924 A CN202110321924 A CN 202110321924A CN 112872528 A CN112872528 A CN 112872528A
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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
- B23K1/00—Soldering, e.g. brazing, or unsoldering
- B23K1/20—Preliminary treatment of work or areas to be soldered, e.g. in respect of a galvanic coating
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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
- B23K1/00—Soldering, e.g. brazing, or unsoldering
- B23K1/06—Soldering, e.g. brazing, or unsoldering making use of vibrations, e.g. supersonic 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
- B23K1/00—Soldering, e.g. brazing, or unsoldering
- B23K1/20—Preliminary treatment of work or areas to be soldered, e.g. in respect of a galvanic coating
- B23K1/206—Cleaning
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Abstract
The invention relates to a dissimilar metal ultrasonic-assisted eutectic reaction brazing method, and belongs to the technical field of dissimilar material welding. The ultrasonic welding of the magnesium alloy and the aluminum alloy is carried out by adding the zinc intermediate layer, so that the generation of Mg-Al series intermetallic compounds is successfully avoided, and the welding quality and the welding strength of the joint are improved. And adjusting proper welding process parameters to weld the workpiece, and researching the influence of different process parameters on the shearing strength of the joint. The adjusted process parameters are as follows: the welding energy is 0-9999J, the welding amplitude is 60-100%, and the welding static pressure is 0-0.65 MPa. By adjusting the parameters, the dissimilar materials of the 0.1mm magnesium alloy sheet and the 0.1mm aluminum alloy sheet can be connected, and the welding joint is ensured to have small deformation, good forming and no welding defects such as cracks, air holes and the like. When the welding energy is 1700J, the welding amplitude is 95 percent, and the static welding pressure is 0.4MPa, the joint shear strength reaches the maximum value of 57.62MPa, and compared with the Mg/Al ultrasonic welding process without the intermediate layer, the joint strength is improved by 89.66 percent.
Description
Technical Field
The invention relates to the technical field of dissimilar material connection/welding, in particular to a dissimilar metal ultrasonic-assisted eutectic reaction brazing method.
Background
With the rapid development of scientific technology and industrial technology, the requirements for light weight, environmental protection and energy conservation are increasing under the promotion of the automobile industry, aluminum alloy and magnesium alloy are adopted to replace the welding of steel plate materials, and the structural weight can be reduced by more than 50%, so that the magnesium alloy/aluminum alloy composite component is an important way for realizing the weight reduction of parts, the welding of magnesium alloy/aluminum alloy dissimilar metals is realized, firm and reliable welding joints are obtained, and the high importance of people is also increased.
Because the physical and chemical properties of the magnesium alloy and the aluminum alloy are greatly different and are very easy to oxidize, a large amount of brittle intermetallic compounds are easily formed in the welding process, and welding defects such as holes, cracks, inclusions, lack of welding and the like are easily generated, the weldability of the magnesium alloy/the aluminum alloy is poor, and a joint with excellent performance is difficult to obtain by adopting a traditional fusion welding method. At present, the common methods for connecting Mg/Al dissimilar metals are laser welding, resistance welding, friction stir welding and ultrasonic welding. However, in any of these methods, it is inevitable that the direct contact of aluminum and magnesium causes a hard and brittle Mg — Al intermetallic compound, which increases the tendency of brittle fracture of the joint, and the quality of the joint is greatly deteriorated. Therefore, the related researchers pointed out that the generation of brittle intermetallic compounds is reduced by preventing the direct contact of Mg, Al parent materials by adding an intermediate layer. Meanwhile, under the action of welding heat, the intermediate layer is melted and spread between the Mg interface and the Al interface, and the fusion area of the welding joint is increased, so that the aim of improving the mechanical property of the welding joint is fulfilled.
At present, the ultrasonic welding research of Mg-Al dissimilar metals added with an intermediate layer mainly focuses on the influence of a plating layer and tin foil on the performance of a joint, and the research has been reported on the addition of a zinc intermediate layer. Based on the similarity of crystal structures of Mg and Zn, mutual diffusion is easy to occur, and the residual stress after welding is small; al and Zn can be dissolved in any proportion without limit, and a brittle intermetallic compound cannot be formed, so that the technical idea of improving the mechanical property of the joint by adding the zinc intermediate layer and optimizing the welding process parameters to promote the metallurgical reaction of Mg, Zn and Al is feasible. The connection technology of magnesium alloy and aluminum alloy dissimilar metal materials has important practical value and wide application prospect in the fields of aerospace, automobile industry and the like.
Disclosure of Invention
The invention aims to provide a dissimilar metal ultrasonic-assisted eutectic reaction brazing method, which solves the problems in the prior art. According to the invention, the zinc foil is used as the middle layer, and the high-quality and high-efficiency welding of the magnesium alloy and the aluminum alloy is realized under the combined action of static welding pressure and ultrasonic high-frequency vibration by an ultrasonic welding process. Based on the Mg/Zn foil/Al interface reaction mechanism, the influence rule of the interface temperature on the reaction kinetics and the properties of interface reaction products, the interface metallurgical reaction is promoted by optimizing the welding process parameters, the formation of brittle intermetallic compounds between magnesium and aluminum is inhibited, the problems and the defects existing in the prior art are solved, and the industrial blank is filled.
The above object of the present invention is achieved by the following technical solutions:
the dissimilar metal ultrasonic-assisted eutectic reaction brazing method comprises the following steps:
(1) pre-welding pretreatment:
intermediate layer pretreatment: polishing the surface of the zinc intermediate layer to be bright by using No. 1000 abrasive paper, placing the bright zinc intermediate layer in acetone, cleaning in an ultrasonic cleaning instrument with the ultrasonic power of 100-120W for 5-10 min at the temperature of 20-25 ℃, taking out a blower and drying, and ensuring that no metal oxide film, oil stain and water exist in a region to be welded, so as to obtain a treated intermediate layer;
base metal pretreatment: sequentially using No. 240 abrasive paper, No. 600 abrasive paper, No. 800 abrasive paper and No. 1000 abrasive paper to polish the surfaces of the magnesium alloy and the aluminum alloy to be bright, then placing the magnesium alloy and the aluminum alloy with the bright surfaces in acetone, cleaning in an ultrasonic cleaning instrument with the ultrasonic power of 100W-120W for 10 min-15 min at the temperature of 20-25 ℃, taking out a blower for drying, and ensuring that no metal oxide film, oil stain and moisture exist in a region to be welded, so as to obtain the treated magnesium alloy and the treated aluminum alloy;
(2) the joint form is as follows:
the test adopts a mode of 'aluminum on magnesium' for assembly welding, the lap joint amount is 20mm, a zinc intermediate layer is arranged between two pieces to be connected in the welding process, the pieces are sequentially stacked and assembled from bottom to top according to the sequence of aluminum alloy, zinc foil and magnesium alloy, no gap is left on the interface, and an assembly piece is obtained;
(3) the welding process comprises the following steps:
placing the assembly part on a lower sound level of an ultrasonic welding machine, keeping the workpiece completely attached to the lower sound level, adjusting a welding station, and pressing an upper sound level to the workpiece from top to bottom under the action of an ultrasonic transducer so as to realize the connection of the magnesium-aluminum dissimilar alloy; by adopting a single variable method, the metallurgical reaction of an Mg/Zn foil/Al interface is promoted by optimizing welding process parameters and welding heat input, the thickness of an intermetallic compound layer is limited, welding defects such as air holes, cracks and the like are prevented, the mechanical property and the welding quality of a joint are improved, and the process parameters are as follows: welding energy is 0-9999J, welding amplitude is 60-100%, and static welding pressure is 0-0.65 MPa;
through the steps, the ultrasonic welding of the magnesium alloy and the aluminum alloy is realized, and a Mg/Zn foil/Al welding piece is obtained.
The magnesium alloy is AZ31B magnesium alloy, the thickness is 1mm, the size of a workpiece is 25mm multiplied by 25mm, and the chemical composition is Mn: 0.2 to 0.5; zn: 0.5 to 1.5; al: 2.5 to 3.5; si: less than or equal to 0.1; cu: less than or equal to 0.05; fe: less than or equal to 0.005; ni: less than or equal to 0.005; mg: and (4) the balance.
The aluminum alloy is 6082-T6 aluminum alloy, the thickness is 1mm, the size of the workpiece is 25mm multiplied by 25mm, and the chemical composition is Si: 0.7 to 1.3; mn: 0.4 to 1.0; cu: 0.1; fe: 0.5; zn: 0.2; ti: 0.1; cr: 0.25; mg: 0.6 to 1.2; al: and (4) the balance.
The purity of the middle layer zinc foil is 99.9%, the thickness of the middle layer zinc foil is 30 micrometers, and the size of the zinc foil is 20mm multiplied by 25 mm.
The method is characterized in that Viper-20 ultrasonic metal welding equipment is adopted for welding, the rated power is 3000W, the working frequency is 20.11KHz, the power supply voltage is 200-240V, the ultrasonic amplitude is 10 mu m, the maximum pressure of compressed gas is 90psi, the welding time is 0.005-9.999 s, the welding head and the bottom die of the welding machine are in the shape of sharp teeth, the height of the welding head is 1.2mm, the area of the welding head is 5.2 mm multiplied by 7.8 mm, and the maximum stroke of the welding head is 15 mm.
The welding energy is respectively 200J, 500J, 800J, 1100J, 1400J, 1700J, 2000J and 2500J; the welding amplitudes are respectively selected from 65%, 75%, 85% and 95%; the static welding pressure is 0.2MPa, 0.3MPa, 0.4MPa and 0.5MPa respectively.
The welding joint reaction layer comprises a Mg-Zn reaction layer, a Zn-Al reaction layer and a residual Zn intermediate layer; the presence of the residual Zn interlayer prevents the mixing and interdiffusion of the Mg, Al elements, thereby avoiding the formation of brittle Mg-Al intermetallic compounds.
The invention has the beneficial effects that:
(1) by adopting the ultrasonic welding technology, the joint is free from high-temperature pollution and damage in the welding process, the deformation and residual stress of the welded workpiece are less than those of the traditional fusion welding method, the low-stress deformation-free welding can be realized, the welding speed is high, and the efficiency is high;
(2) the welding process is simple and easy to implement, is beneficial to popularization, does not need gas protection in the welding process, does not need to add solder or scaling powder, does not need to carry out other treatments on the welded workpiece, is beneficial to improving the production efficiency and realizing the automation of welding production, and is environment-friendly and pollution-free;
(3) by adopting the ultrasonic welding technology, no or a small amount of intermetallic compounds are generated in the welding process, so that the welding seam forming quality is high, the welding seam is low in temperature and pressure, the energy consumption is low, the range of weldable materials is wide, the connection of the same material can be realized, and the connection of different materials can also be realized;
(4) zn is adopted as an intermediate layer, the Zn and Al are infinitely mutually soluble, the Zn and Mg are limitedly mutually soluble, the connection of the magnesium alloy and the aluminum alloy is realized by utilizing contact reaction, the direct mutual diffusion of magnesium and aluminum atoms is hindered, the generation of brittle and hard Mg-Al series intermetallic compounds is successfully avoided, the practical significance is great for expanding the application field of the magnesium alloy and aluminum alloy composite member, and the design idea of the intermediate layer can be provided for the connection of other dissimilar metals;
(5) the addition of the zinc intermediate layer can improve the oxidation resistance of the to-be-welded surface of the magnesium alloy and the aluminum alloy, and the zinc intermediate layer is less in dosage and easy to obtain, thereby being beneficial to reducing the welding production cost.
Drawings
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the invention without limiting the invention.
FIG. 1 is a schematic view of the ultrasonic welding of a magnesium alloy-aluminum alloy and the assembly of a workpiece according to the present invention;
FIG. 2 is a schematic view of a shear test fixture of the present invention;
FIG. 3 is a general view of the formation of the Mg/Zn foil/Al ultrasonic welded joint of the present invention;
FIG. 4 is a microstructure view of the joint interface of the Mg/Zn foil/Al ultrasonic weld joint of the present invention.
In the figure: 1. a through hole; 2. pressing a plate; 3. a workpiece accommodating groove; 4. a circular sleeve; 5. a gasket; 6. pressing a plate; 7. a gasket; a. a Mg-Zn reaction layer; b. a residual Zn intermediate layer; c. a Zn-Al reaction layer.
Detailed Description
The details of the present invention and its embodiments are further described below with reference to the accompanying drawings.
Referring to fig. 1 to 4, the dissimilar metal ultrasonic-assisted eutectic reaction brazing method of the present invention has advantages of short welding time, high production efficiency, good stability, convenient operation, low requirement for the surface of a workpiece, etc. based on ultrasonic waves; by utilizing the characteristics that the crystal structures of Mg and Zn are similar, mutual diffusion is easy to occur, the residual stress after welding is small, Al and Zn can be dissolved in any proportion without limit, brittle intermetallic compounds cannot be formed and the like, the ultrasonic welding of the magnesium alloy and the aluminum alloy is carried out by adding the zinc intermediate layer, the generation of the Mg-Al intermetallic compounds is successfully avoided, and the welding quality and the welding strength of the joint are improved. And adjusting proper welding process parameters to weld the workpiece, and researching the influence of different process parameters on the shearing strength of the joint. The adjusted process parameters are as follows: the welding energy is 0-9999J, the welding amplitude is 60-100%, and the welding static pressure is 0-0.65 MPa. By adjusting the parameters, the dissimilar materials of the 0.1mm magnesium alloy sheet and the 0.1mm aluminum alloy sheet can be connected, and the welding joint is ensured to have small deformation, good forming and no welding defects such as cracks, air holes and the like. When the welding energy is 1700J, the welding amplitude is 95 percent, and the static welding pressure is 0.4MPa, the joint shear strength reaches the maximum value of 57.62MPa, and compared with the Mg/Al ultrasonic welding process without the intermediate layer, the joint strength is improved by 89.66 percent.
The invention discloses a dissimilar metal ultrasonic-assisted eutectic reaction brazing method, which is an ultrasonic welding method of magnesium alloy and aluminum alloy containing an intermediate layer, wherein zinc foil is added as the intermediate layer, and the ultrasonic welding technology is utilized to realize high-strength welding of dissimilar metal materials of the magnesium alloy and the aluminum alloy, and the method is specifically carried out according to the following process steps:
(1) pre-welding pretreatment:
intermediate layer pretreatment: polishing the surface of the zinc intermediate layer to be bright by using No. 1000 abrasive paper, placing the bright zinc intermediate layer in acetone, cleaning in an ultrasonic cleaning instrument with the ultrasonic power of 100-120W for 5-10 min at the temperature of 20-25 ℃, taking out a blower and drying, and ensuring that no metal oxide film, oil stain and water exist in a region to be welded, so as to obtain a treated intermediate layer;
base metal pretreatment: sequentially using No. 240 abrasive paper, No. 600 abrasive paper, No. 800 abrasive paper and No. 1000 abrasive paper to polish the surfaces of the magnesium alloy and the aluminum alloy to be bright, then placing the magnesium alloy and the aluminum alloy with the bright surfaces in acetone, cleaning in an ultrasonic cleaning instrument with the ultrasonic power of 100W-120W for 10 min-15 min at the temperature of 20-25 ℃, taking out a blower for drying, and ensuring that no metal oxide film, oil stain and moisture exist in a region to be welded, so as to obtain the treated magnesium alloy and the treated aluminum alloy;
(2) the joint form is as follows:
the test adopts a mode of 'aluminum on magnesium' for assembly welding, the lap joint amount is 20mm, a zinc intermediate layer is arranged between two pieces to be connected in the welding process, the pieces are sequentially stacked and assembled from bottom to top according to the sequence of aluminum alloy, zinc foil and magnesium alloy, no gap is left on the interface, and an assembly piece is obtained;
(3) the welding process comprises the following steps:
placing the assembly part on a lower sound level of an ultrasonic welding machine, keeping the workpiece completely attached to the lower sound level, adjusting a welding station, and pressing an upper sound level to the workpiece from top to bottom under the action of an ultrasonic transducer so as to realize the connection of the magnesium-aluminum dissimilar alloy; by adopting a single variable method, the metallurgical reaction of an Mg/Zn foil/Al interface is promoted by optimizing welding process parameters and welding heat input, the thickness of an intermetallic compound layer is limited, welding defects such as air holes, cracks and the like are prevented, the mechanical property and the welding quality of a joint are improved, and the process parameters are as follows: the welding energy is 0-9999J, the welding amplitude is 60-100%, and the welding static pressure is 0-0.65 MPa.
Through the steps, the ultrasonic welding of the magnesium alloy and the aluminum alloy is realized, and a Mg/Zn foil/Al welding piece is obtained.
(4) And (3) shear testing:
and (3) carrying out a shearing test on the obtained Mg/Zn foil/Al welding piece by using a special shearing clamp through a universal testing machine. The fixture used to test the shear force is shown in figure 2. Before the shearing force is tested, the pressing plate 2 is firstly attached to the pressing plate 6, the Mg/Zn foil/Al welding piece is placed in the workpiece accommodating groove 3, the pressing plate 2 is fixed with the pressing plate 6 through the circular sleeve 4 with the through hole 1, and the position of the circular sleeve 4 is fixed through the gasket 5 and the gasket 7. The shear force test procedure was: the upper chuck and the lower chuck of the stretcher respectively clamp the pressing plate 2 and the pressing plate 6, and the chuck below the stretcher vertically moves downwards to ensure that the pressing plate 6 moves downwards, so that the shearing of a welding piece is realized, and the peak value of the shearing force is taken as the maximum shearing force.
The magnesium alloy is AZ31B magnesium alloy, the thickness is 1mm, the size of a workpiece is 25mm multiplied by 25mm, and the chemical components are Mn: 0.2 to 0.5; zn: 0.5 to 1.5; al: 2.5 to 3.5; si: less than or equal to 0.1; cu: less than or equal to 0.05; fe: less than or equal to 0.005; ni: less than or equal to 0.005; mg: and (4) the balance.
The aluminum alloy is 6082-T6 aluminum alloy, the thickness is 1mm, the size of a workpiece is 25mm multiplied by 25mm, and the chemical components are Si: 0.7 to 1.3; mn: 0.4 to 1.0; cu: 0.1; fe: 0.5; zn: 0.2; ti: 0.1; cr: 0.25; mg: 0.6 to 1.2; al: and (4) the balance.
The purity of the middle layer zinc foil is 99.9%, the thickness is 30 mu m, and the size of the zinc foil is 20mm multiplied by 25 mm.
The invention adopts a Viper-20 ultrasonic metal welding machine for welding, the rated power is 3000W, the working frequency is 20.11KHz, the power supply voltage is 200-240V, the ultrasonic amplitude is 10 mu m, the maximum pressure of compressed gas is 90psi, the welding time is 0.005-9.999 s, the welding head and the bottom die of the welding machine are in the shape of cusp, the height of the welding head is 1.2mm, the area of the welding head is 5.2 mm multiplied by 7.8 mm, and the maximum stroke of the welding head is 15 mm.
Preferably, the welding energy is respectively 200J, 500J, 800J, 1100J, 1400J, 1700J, 2000J and 2500J; the welding amplitudes are respectively selected from 65%, 75%, 85% and 95%; the static welding pressure is 0.2MPa, 0.3MPa, 0.4MPa and 0.5MPa respectively.
The reaction layer of the welding joint obtained by the invention comprises a Mg-Zn reaction layer, a Zn-Al reaction layer and a residual Zn intermediate layer; the presence of the residual Zn interlayer prevents the mixing and interdiffusion of the Mg, Al elements, thereby avoiding the formation of brittle Mg-Al intermetallic compounds.
The method of the invention is adopted to carry out the ultrasonic welding connection of the magnesium-aluminum dissimilar metals, and the performance indexes of the joint are as follows:
(1) the maximum shear strength of the Mg/Zn foil/Al ultrasonic welding joint is 57.62MPa, the joint shear fracture mainly occurs in a magnesium/zinc interface region, and compared with the Mg/Al ultrasonic welding process without the intermediate layer, the joint strength is improved by 89.66%;
(2) the metallurgical bonding of the Mg/Zn foil/Al ultrasonic welding joint interface is realized, and the Mg-Al intermetallic compound does not appear on the interface.
(3) The ultrasonic welding process is stable, the joint interface is well formed, and the joint has no welding defects such as cracks, air holes and the like.
Example 1:
effect of welding energy on joint shear Strength
Cutting 0.1mm thick aluminum alloy and magnesium alloy into squares with the specification of 25mm multiplied by 25mm, cutting 50 mu m thick zinc foil into rectangles with the specification of 20mm multiplied by 25mm, then performing pre-welding pretreatment and workpiece assembly on the partially cut aluminum alloy, magnesium alloy and zinc foil, wherein the rated power is 3000W, the working frequency is 20.11KHz, the power voltage is 200-240V, the welding energy is changed within the range of 200-2500J, and the welding energy is respectively 200J, 500J, 800J, 1100J, 1400J, 1700J, 2000J and 2500J, and performing ultrasonic welding on Mg/Zn foil/Al dissimilar alloys.
The results show that the shear strength of the joint shows a tendency to increase first and then decrease with increasing welding energy, and the shear strength of the joint reaches the maximum when the welding energy is 1700J.
Example 2:
effect of weld amplitude on joint shear Strength
Cutting 0.1mm thick aluminum alloy and magnesium alloy into squares with the specification of 25mm multiplied by 25mm, cutting 50 mu m thick zinc foil into rectangles with the specification of 20mm multiplied by 25mm, then performing pre-welding pretreatment and workpiece assembly on the partially cut aluminum alloy, magnesium alloy and zinc foil, wherein the rated power is 3000W, the working frequency is 20.11KHz, the power voltage is 200-240V, the welding amplitude is changed within the range of 60-100%, and the welding amplitude is respectively 65%, 75%, 85% and 95%, and performing ultrasonic welding on Mg/Zn foil/Al dissimilar alloy.
The results show that the shear strength of the joint shows a tendency to increase gradually with increasing welding amplitude, and reaches a maximum at 95% of welding amplitude.
Example 3:
effect of static welding pressure on joint shear strength
As a result of examination of examples 1 and 2, the shear strength of the ultrasonic welding of Mg/Zn foil/Al was found to be the maximum value at a welding energy of 1700J and a welding amplitude of 95%. The effect of static welding pressure on joint shear strength was investigated at a weld energy of 1700J and a weld amplitude of 95%. Cutting 0.1mm thick aluminum alloy and magnesium alloy into squares with the specification of 25mm multiplied by 25mm, cutting 50 mu m thick zinc foil into rectangles with the specification of 20mm multiplied by 25mm, then performing pre-welding pretreatment and workpiece assembly on the partially cut aluminum alloy, magnesium alloy and zinc foil, wherein the rated power is 3000W, the working frequency is 20.11KHz, the power voltage is 200-240V, the static welding pressure is changed within the range of 0-0.65 MPa, and the static welding pressure is respectively 0.2MPa, 0.3MPa, 0.4MPa and 0.5MPa, and performing ultrasonic welding on the Mg/Zn foil/Al dissimilar alloy.
The result shows that the shear strength of the joint shows a trend of increasing and then decreasing along with the increase of the static welding pressure, when the static welding pressure is 0.4MPa, the shear strength of the joint reaches the maximum of 57.62MPa, and compared with the Mg/Al ultrasonic welding process without the addition of the intermediate layer, the joint strength is improved by 89.66%.
Fig. 3 and 4 illustrate the interface formation and microstructure morphology for this process parameter. The result shows that the interface of the Mg/Zn foil/Al ultrasonic welding joint is well formed, and welding defects such as cracks, air holes and the like do not appear, the obtained welding joint reaction layer comprises a Mg-Zn reaction layer, a Zn-Al reaction layer and a residual Zn intermediate layer, and the mixing and mutual diffusion of Mg and Al elements are prevented by the residual Zn intermediate layer, so that the formation of brittle Mg-Al intermetallic compounds is avoided.
The above description is only a preferred example of the present invention and is not intended to limit the present invention, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, improvement and the like of the present invention shall be included in the protection scope of the present invention.
Claims (7)
1. A dissimilar metal ultrasonic-assisted eutectic reaction brazing method is characterized by comprising the following steps: the method comprises the following steps:
(1) pre-welding pretreatment:
intermediate layer pretreatment: polishing the surface of the zinc intermediate layer to be bright by using No. 1000 abrasive paper, placing the bright zinc intermediate layer in acetone, cleaning in an ultrasonic cleaning instrument with the ultrasonic power of 100-120W for 5-10 min at the temperature of 20-25 ℃, taking out a blower and drying, and ensuring that no metal oxide film, oil stain and water exist in a region to be welded, so as to obtain a treated intermediate layer;
base metal pretreatment: sequentially using No. 240 abrasive paper, No. 600 abrasive paper, No. 800 abrasive paper and No. 1000 abrasive paper to polish the surfaces of the magnesium alloy and the aluminum alloy to be bright, then placing the magnesium alloy and the aluminum alloy with the bright surfaces in acetone, cleaning in an ultrasonic cleaning instrument with the ultrasonic power of 100W-120W for 10 min-15 min at the temperature of 20-25 ℃, taking out a blower for drying, and ensuring that no metal oxide film, oil stain and moisture exist in a region to be welded, so as to obtain the treated magnesium alloy and the treated aluminum alloy;
(2) the joint form is as follows:
the test adopts a mode of 'aluminum on magnesium' for assembly welding, the lap joint amount is 20mm, a zinc intermediate layer is arranged between two pieces to be connected in the welding process, the pieces are sequentially stacked and assembled from bottom to top according to the sequence of aluminum alloy, zinc foil and magnesium alloy, no gap is left on the interface, and an assembly piece is obtained;
(3) the welding process comprises the following steps:
placing the assembly part on a lower sound level of an ultrasonic welding machine, keeping the workpiece completely attached to the lower sound level, adjusting a welding station, and pressing an upper sound level to the workpiece from top to bottom under the action of an ultrasonic transducer so as to realize the connection of the magnesium-aluminum dissimilar alloy; by adopting a single variable method, the metallurgical reaction of an Mg/Zn foil/Al interface is promoted by optimizing welding process parameters and welding heat input, the thickness of an intermetallic compound layer is limited, welding defects such as air holes, cracks and the like are prevented, the mechanical property and the welding quality of a joint are improved, and the process parameters are as follows: welding energy is 0-9999J, welding amplitude is 60-100%, and static welding pressure is 0-0.65 MPa;
through the steps, the ultrasonic welding of the magnesium alloy and the aluminum alloy is realized, and a Mg/Zn foil/Al welding piece is obtained.
2. The dissimilar metal ultrasonic-assisted eutectic reaction brazing method according to claim 1, wherein: the magnesium alloy is AZ31B magnesium alloy, the thickness is 1mm, the size of a workpiece is 25mm multiplied by 25mm, and the chemical composition is Mn: 0.2 to 0.5; zn: 0.5 to 1.5; al: 2.5 to 3.5; si: less than or equal to 0.1; cu: less than or equal to 0.05; fe: less than or equal to 0.005; ni: less than or equal to 0.005; mg: and (4) the balance.
3. The dissimilar metal ultrasonic-assisted eutectic reaction brazing method according to claim 1, wherein: the aluminum alloy is 6082-T6 aluminum alloy, the thickness is 1mm, the size of the workpiece is 25mm multiplied by 25mm, and the chemical composition is Si: 0.7 to 1.3; mn: 0.4 to 1.0; cu: 0.1; fe: 0.5; zn: 0.2; ti: 0.1; cr: 0.25; mg: 0.6 to 1.2; al: and (4) the balance.
4. The dissimilar metal ultrasonic-assisted eutectic reaction brazing method according to claim 1, wherein: the purity of the middle layer zinc foil is 99.9%, the thickness of the middle layer zinc foil is 30 micrometers, and the size of the zinc foil is 20mm multiplied by 25 mm.
5. The dissimilar metal ultrasonic-assisted eutectic reaction brazing method according to claim 1, wherein: the method is characterized in that Viper-20 ultrasonic metal welding equipment is adopted for welding, the rated power is 3000W, the working frequency is 20.11KHz, the power supply voltage is 200-240V, the ultrasonic amplitude is 10 mu m, the maximum pressure of compressed gas is 90psi, the welding time is 0.005-9.999 s, the welding head and the bottom die of the welding machine are in the shape of sharp teeth, the height of the welding head is 1.2mm, the area of the welding head is 5.2 mm multiplied by 7.8 mm, and the maximum stroke of the welding head is 15 mm.
6. The dissimilar metal ultrasonic-assisted eutectic reaction brazing method according to claim 1, wherein: the welding energy is respectively 200J, 500J, 800J, 1100J, 1400J, 1700J, 2000J and 2500J; the welding amplitudes are respectively selected from 65%, 75%, 85% and 95%; the static welding pressure is 0.2MPa, 0.3MPa, 0.4MPa and 0.5MPa respectively.
7. The dissimilar metal ultrasonic-assisted eutectic reaction brazing method according to claim 1, wherein: the welding joint reaction layer comprises a Mg-Zn reaction layer, a Zn-Al reaction layer and a residual Zn intermediate layer; the presence of the residual Zn interlayer prevents the mixing and interdiffusion of the Mg, Al elements, thereby avoiding the formation of brittle Mg-Al intermetallic compounds.
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