CN116713597B - Composite welding method for die-casting aluminum alloy parts with complex structures - Google Patents
Composite welding method for die-casting aluminum alloy parts with complex structures Download PDFInfo
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- CN116713597B CN116713597B CN202311003233.2A CN202311003233A CN116713597B CN 116713597 B CN116713597 B CN 116713597B CN 202311003233 A CN202311003233 A CN 202311003233A CN 116713597 B CN116713597 B CN 116713597B
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- 229910010038 TiAl Inorganic materials 0.000 description 1
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Classifications
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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
- B23K26/346—Working by laser beam, e.g. welding, cutting or boring in combination with welding or cutting covered by groups B23K5/00 - B23K25/00, e.g. in combination with resistance welding
- B23K26/348—Working by laser beam, e.g. welding, cutting or boring in combination with welding or cutting covered by groups B23K5/00 - B23K25/00, e.g. in combination with resistance welding in combination with arc heating, e.g. TIG [tungsten inert gas], MIG [metal inert gas] or plasma welding
-
- 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
- B23K26/60—Preliminary treatment
-
- 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
- B23K26/70—Auxiliary operations or equipment
- B23K26/702—Auxiliary equipment
-
- 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
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/02—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
- B23K35/0255—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape for use in welding
- B23K35/0261—Rods, electrodes, wires
- B23K35/0266—Rods, electrodes, wires flux-cored
-
- 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
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
- B23K35/24—Selection of soldering or welding materials proper
- B23K35/28—Selection of soldering or welding materials proper with the principal constituent melting at less than 950 degrees C
- B23K35/286—Al as the principal constituent
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/10—Greenhouse gas [GHG] capture, material saving, heat recovery or other energy efficient measures, e.g. motor control, characterised by manufacturing processes, e.g. for rolling metal or metal working
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Plasma & Fusion (AREA)
- Arc Welding In General (AREA)
- Laser Beam Processing (AREA)
Abstract
The invention relates to the technical field of automobile part manufacturing, in particular to a composite welding method of a die-casting aluminum alloy part with a complex structure, namely, based on the characteristics of a casting structure of the die-casting part, the composite welding is performed in a composite welding mode, and the composite welding is laser-MIG composite welding or laser-CMT composite welding and is assisted by a special welding wire which is independently researched and developed, so that the strength and the plasticity of a welding joint can be obviously improved, and meanwhile, the porosity of a welding seam is reduced. And the strength of the welded joint reaches more than 90% of the strength of a base metal, the plasticity of the joint is close to that of the base metal, and the porosity in a welding line is kept below 1% through optimization and improvement of the welding process. The invention can solve the problems of poor strength and high porosity of the welded joint when the die-casting aluminum alloy is welded by a single welding method, and improve the welding quality of the die-casting aluminum alloy.
Description
Technical Field
The invention relates to the technical field of automobile part manufacturing, in particular to a composite welding method for a die-casting aluminum alloy part with a complex structure.
Background
The traditional die-casting aluminum alloy parts with complex structures adopt an extrusion profile welding process, and have the main problems that on one hand, the welding procedures are more, the product precision is difficult to control, the manufacturing procedures are complicated, the quality control of the tray is more difficult, and the production period is longer; on the other hand, it is difficult to further optimize the weight due to the existing process limitations.
Unlike aluminum alloys produced by other processes (e.g., extrusion), die-cast aluminum alloys form low-melting eutectic structures due to the high content of reinforcing alloy elements, and have a wide crystallization temperature range and high shrinkage, and are prone to crystallization cracks and liquefaction cracks in weld joints and heat affected zones during welding, thereby reducing the strength of welded joints. In addition, the die casting process can generate a gas rolling phenomenon in the process of filling the aluminum liquid due to the inherent high-speed filling characteristic, so that the die casting aluminum alloy has high gas content, especially high hydrogen content. During welding, the high temperature of fusion welding can cause the phenomenon of surface bubbling in a welding heat affected zone, and the welding seam and the fusion zone can also cause serious air hole defects due to gas release and expansion. These factors have hindered the improvement of the welding performance of die-cast aluminum alloys.
At present, the aluminum alloy welding method is commonly MIG welding, however, the traditional single pulse MIG welding joint has a plurality of air holes and thick weld grains, so that the quality and performance of the joint cannot be ensured, and a new welding method needs to be developed. One of the welding techniques is laser welding, which adopts high-energy density laser as a heat source, has the advantages of small splashing, narrow heat affected zone, attractive weld formation and the like, and gradually becomes one of important welding methods. Compared with the traditional MIG welding, the laser welding has the outstanding advantage that the welding speed can be more than several times of that of the traditional arc welding, so that the welding speed is one of high-efficiency welding methods. Although the efficiency of laser welding is very high, aluminum alloy has very strong reflectivity to laser, so that the utilization rate of laser welding power is low, and the high thermal conductivity of the aluminum alloy causes high porosity and large crack tendency of laser welding, which limit the wide application of the aluminum alloy in aluminum alloy welding to a certain extent.
Therefore, aiming at the technical defects and technical problems existing in the processing and manufacturing process of the die-casting aluminum alloy parts with the complex structures in the prior art, a new technical method is required to be provided for realizing the processing and manufacturing of the die-casting aluminum alloy parts with the complex structures.
Disclosure of Invention
The invention provides a composite welding method for die-casting aluminum alloy parts with complex structures, which at least can solve part of problems in the prior art.
In order to solve the technical problems, according to one aspect of the present invention, the following technical solutions are provided:
the composite welding method for the die-casting aluminum alloy parts with the complex structures comprises a plurality of aluminum alloy die-casting units, wherein the aluminum alloy die-casting units are welded in a composite welding mode, the composite welding is laser-MIG composite welding or laser-CMT composite welding, and the composite welding is a side-axis composite welding mode in which a laser heat source is in front and a MIG or CMT heat source is in back;
the composite welding of the aluminum alloy parts comprises the following steps:
(1) Preparing a workpiece to be welded, and cleaning and preprocessing a sample to be welded;
(2) Performing laser cleaning treatment on the pretreated sample by adopting a laser cleaning head;
(3) Fixing the cleaned workpiece on a welding fixture, and performing welding treatment by using the composite welding process, wherein a welding wire adopted in the welding treatment is of a core-shell structure and comprises a surface skin and a core material, the surface skin is AlMgMnTiSi high-entropy alloy, and the core material is a mixture of borax, potassium fluorozirconate and yttrium oxide;
(4) And detecting the quality of the workpiece after welding treatment.
As a preferable technical scheme of the composite welding method for the die-casting aluminum alloy parts with the complex structures, the aluminum alloy die-casting unit is made of Al-Si die-casting aluminum alloy, and the characteristic thickness of the parts is 1.5mm-6.0mm.
As a preferable technical scheme of the composite welding method of the die-casting aluminum alloy part with the complex structure, the method comprises the following specific steps of: when the characteristic thickness of the part is more than or equal to 4mm, the workpiece to be welded is provided with a groove, and the workpiece to be welded is cleaned and pretreated by adopting an acetone solution.
As a preferable technical scheme of the composite welding method of the die-casting aluminum alloy part with the complex structure, the method comprises the following specific steps of: and installing the workpiece to be welded on a workbench, adjusting the relative positions of a laser cleaning head and a dust collection port, setting laser cleaning process parameters through a controller, and sequentially starting a dust collector or a smoke purifier and a laser to perform laser cleaning treatment on the workpiece to be welded.
As a preferable technical scheme of the composite welding method of the die-casting aluminum alloy parts with the complex structures, the method comprises the following technological parameters of laser cleaning treatment in the step (2): the laser is in a pulse mode, the laser wavelength is 1.064 microns, the average power of the laser is 85W-95W, the scanning line width is 60mm-70mm, the pulse frequency is 80KHz-100KHz, and the cleaning rate is 0.6m/min-1.0m/min.
As a preferable technical scheme of the composite welding method of the die-casting aluminum alloy part with the complex structure, the method comprises the following specific steps of: and fixing the workpiece to be welded after the laser cleaning treatment is finished on a welding fixture, adjusting the gap between the group and the offset of two sides of the welding line, and adjusting the posture of a welding gun according to the assembly state of the workpiece to be welded to weld.
As the preferable technical scheme of the composite welding method for the die-casting aluminum alloy parts with the complex structures, the assembly gap in the step (3) is 0mm-0.6mm, the welding groove angle is 60-70 degrees, and the misalignment amount of two sides of a welding line is less than 0.1mm.
As the preferable technical scheme of the composite welding method of the die-casting aluminum alloy parts with the complex structure, the composite welding laser fiber in the step (3) has the core diameter of 200 mu m, the laser defocusing amount of 0mm-5mm, the scanning frequency of 20Hz-40Hz, the arc length correction coefficient of-10% to +10%, the vertical inclination angle of the laser beam of 5 DEG-10 DEG and the laser power of 1500W-4000W;
the included angle between the axis of the CMT welding or MIG welding gun and a base metal is 60-70 degrees, the distance between optical wires is 1-3 mm, the extension amount of a welding wire between a welding gun conducting nozzle and the surface of a workpiece is 3-8 mm, the included angle between a shielding gas nozzle and the vertical direction is 45-60 degrees, the shielding gas is mixed gas of argon and helium (the proportion of helium is 1-5 vol%), the flow rate of the shielding gas is 15-25L/min, the CMT welding or MIG welding is adaptively regulated according to the laser power, the welding speed is 1-7 m/min, and the wire feeding speed is 5-20 m/min.
As the preferable technical scheme of the composite welding method for the die-casting aluminum alloy parts with the complex structures, the diameter of the welding wire is 0.8-1.6 mm, the mass percentage of the surface skin in the welding wire is 70-90%, and the mass percentage of the core material is 10-30%; the surface AlMgMnTiSi high-entropy alloy consists of the following elements in atomic percent: 40-60% of Al, 10-15% of Mg, 10-15% of Mn, 10-15% of Ti, 10-15% of Si and the mass percentages of the components in the core material are as follows: 40-70% of borax, 20-30% of potassium fluozirconate and 5-10% of yttrium oxide.
As a preferable technical scheme of the composite welding method of the die-casting aluminum alloy part with the complex structure, the method comprises the following specific steps of: and (3) performing quality inspection on the welded finished product by using an ultrasonic detector, and detecting weld defects by using a transverse wave method.
The beneficial effects of the invention are as follows:
1. in the prior art, a single welding mode, such as CMT, MIG, variable polarity plasma welding, laser welding and the like, is used for welding the die-casting aluminum alloy, the welding seam strength ratio breaks through 80 percent, but the welding joint strength is extremely unstable, and a large number of air holes still exist on the section of the welding seam. Based on the characteristics of casting structures of die-cast parts, the invention obviously improves the strength and plasticity of welded joints and reduces the porosity by adopting special welding wires which are independently researched and developed through compound welding, namely laser-MIG compound welding or laser-CMT compound welding. And the strength of the welded joint reaches more than 90% of the strength of a base metal, the plasticity of the joint is close to that of the base metal, and the porosity in a welding line is kept below 1% through optimization and improvement of the welding process.
2. The composite welding process of the die-casting aluminum alloy part with the complex structure provided by the invention adopts a welding wire structure of the surface skin and the core material, the surface skin adopts the AlMgMnTiSi high-entropy alloy, and the high-entropy alloy has the mechanical properties of high yield strength and high breaking strength. According to the invention, aiming at the die-casting aluminum alloy sample, the aluminum-based high-entropy alloy is used as the surface skin of the welding wire, and all elements and the die-casting aluminum alloy have good infiltration and intersolubility, so that the connection strength of a welding line can be improved. Compared with the AlSi-based alloy welding wires commonly used in the prior art and other types of welding wires, the aluminum-based high-entropy alloy can strengthen the welding seam of the die casting on one hand, and can also strengthen the welding seam with the die casting aluminum alloy in a mutual melting manner in the welding process, so that the phenomenon that the welding seam between other metal welding wires and the die casting aluminum alloy has larger stress and the mechanical strength of the welding seam is influenced is avoided.
3. The AlMgMnTiSi high-entropy alloy in the welding wire surface skin contains Si with higher content, which is equivalent to the content of silicon element in C37, so that the welding wire surface skin can be better subjected to mutual fusion welding with a die-casting aluminum alloy workpiece, and the welding strength of a welding line and the workpiece is improved. The silicon element can also improve the strength and hardness of the aluminum alloy, has low solid solubility to aluminum and can improve the mechanical property of the welding seam. The magnesium element can strengthen the aluminum alloy and greatly improve the strength and hardness of the aluminum alloy. The manganese element can improve the strength and toughness of the aluminum alloy, so that the weld joint has higher yield strength and ductility. The titanium element can form TiAl intermetallic compound with aluminum to become crystal nucleus for refining the weld seam structure of the crystal structure.
4. According to the invention, borax and potassium fluozirconate added into the core material of the welding wire play a role in activating infiltration in a welding pool in the welding process, so that the viscosity of molten metal in the pool can be reduced, the fluidity of the pool is improved, the mechanical strength of each part of a welding line is more uniform, and the welding quality of die-casting aluminum alloy is improved. In addition, borax and potassium fluozirconate can not generate hydrogen chloride toxic gas in the welding and heating process, and the welding and heating process has certain safety and environmental protection.
5. The yttrium oxide is added into the core material of the welding wire, and has the effect of refining crystallization on molten metal in an aluminum alloy molten pool, so that the crystallization fineness can be improved, and the tensile strength and yield strength between the die-casting aluminum alloy and a welding line can be improved. Meanwhile, the yttrium oxide can also reduce the contact angle of molten metal in a molten pool and improve the infiltration effect of the molten metal and die-casting aluminum alloy in the molten pool.
Detailed Description
The following description will be made clearly and fully with reference to the technical solutions in the embodiments, and it is apparent that the described embodiments are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
It should be noted that, if a directional indication (such as up, down, left, right, front, and rear … …) is involved in the embodiment of the present invention, the directional indication is merely used to explain the relative positional relationship, movement condition, etc. between the components in a specific posture, and if the specific posture is changed, the directional indication is correspondingly changed.
In addition, if there is a description of "first", "second", etc. in the embodiments of the present invention, the description of "first", "second", etc. is for descriptive purposes only and is not to be construed as indicating or implying a relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defining "a first" or "a second" may explicitly or implicitly include at least one such feature. In addition, the technical solutions of the embodiments may be combined with each other, but it is necessary to base that the technical solutions can be realized by those skilled in the art, and when the technical solutions are contradictory or cannot be realized, the combination of the technical solutions should be considered to be absent and not within the scope of protection claimed in the present invention.
The invention provides a composite welding method for die-casting aluminum alloy parts with complex structures, and can solve the problems of poor welding joint strength, low porosity and the like when die-casting aluminum alloy is welded by a single welding method through optimizing and improving a welding process, thereby improving the welding quality of the die-casting aluminum alloy.
The composite welding method for the die-casting aluminum alloy parts with the complex structures comprises a plurality of aluminum alloy die-casting units, wherein the aluminum alloy die-casting units are welded in a composite welding mode, the composite welding is laser-MIG composite welding or laser-CMT composite welding, and the composite welding is a side-axis composite welding mode in which a laser heat source is in front and a MIG or CMT heat source is in back;
the composite welding of the die-casting aluminum alloy part with the complex structure comprises the following steps of:
(1) Preparing a workpiece to be welded, and cleaning and preprocessing a sample to be welded;
(2) Performing laser cleaning treatment on the pretreated sample by adopting a laser cleaning head;
(3) Fixing the cleaned workpiece on a welding fixture, and performing welding treatment by using the composite welding process, wherein a welding wire adopted in the welding treatment is of a core-shell structure and comprises a surface skin and a core material, the surface skin is AlMgMnTiSi high-entropy alloy, and the core material is a mixture of borax, potassium fluorozirconate and yttrium oxide;
(4) And detecting the quality of the workpiece after welding treatment.
Preferably, the aluminum alloy die casting unit is made of an Al-Si die casting aluminum alloy, and more preferably Castasil-37 (C37).
Preferably, the C37 (AlSi 9 MnMoZr) material comprises the following elements in percentage by mass: si:8.5% -10.5%, fe:0.15%, cu 0.05%, mn:0.35% -0.6%, mg:0.06%, zn 0.07%, sr:0.01% -0.015%, other impurities are less than or equal to 0.05% singly, and the balance is Al.
Preferably, the specific steps of the step (1) are as follows: when the characteristic thickness of the part is more than or equal to 4mm, the workpiece to be welded is provided with a groove, and the workpiece to be welded is cleaned and pretreated by adopting an acetone solution.
Preferably, the specific steps of the step (2) are as follows: and installing the workpiece to be welded on a workbench, adjusting the relative positions of a laser cleaning head and a dust collection port, setting laser cleaning process parameters through a controller, and sequentially starting a dust collector or a smoke purifier and a laser to perform laser cleaning treatment on the workpiece to be welded so as to remove an oxide film on the surface of the workpiece.
Preferably, the process parameters of the laser cleaning treatment in the step (2) are as follows: the laser is in a pulse mode, the laser wavelength is 1.064 microns, the average power of the laser is 85W-95W, the scanning line width is 60mm-70mm, the pulse frequency is 80KHz-100KHz, and the cleaning rate is 0.6m/min-1.0m/min.
Preferably, the specific steps of the step (3) are as follows: and fixing the workpiece to be welded after the laser cleaning treatment is finished on a welding fixture, adjusting the gap between the group and the offset of two sides of the welding line, and adjusting the posture of a welding gun according to the assembly state of the workpiece to be welded to weld.
Preferably, in the step (3), the pairing gap is 0mm-0.6mm, the welding groove angle is 60-70 degrees, and the misalignment amount of the two sides of the welding line is less than 0.1mm.
Preferably, the laser fiber core diameter of the compound welding in the step (3) is 200 mu m, the laser defocusing amount is 0mm, the scanning frequency is 20Hz-40Hz, the arc length correction coefficient is-10% to +10%, the vertical inclination angle of the laser beam is 5 DEG-10 DEG, and the laser power is 1500W-4000W.
Preferably, the included angle between the axis of the CMT welding gun or the MIG welding gun and the base metal is 60-70 degrees, the distance between optical wires is 1-3 mm, the elongation of a welding wire between a welding gun conducting nozzle and the surface of a workpiece is 3-8 mm, the included angle between a shielding gas nozzle and the vertical direction is 45-60 degrees, the shielding gas is a mixed gas of 95-99 vol% of argon and 1-5 vol% of helium, the flow rate of the shielding gas is 15-25L/min, the CMT welding or the MIG welding is adaptively adjusted according to the laser power, the welding speed is 1-7 m/min, and the wire feeding speed is 5-20 m/min.
Preferably, the diameter of the welding wire is 0.8-1.6 mm, the mass percentage of the surface skin in the welding wire is 70-90%, and the mass percentage of the core material is 10-30%; the surface AlMgMnTiSi high-entropy alloy consists of the following elements in atomic percent: 40-60% of Al, 10-15% of Mg, 10-15% of Mn, 10-15% of Ti, 10-15% of Si and the mass percentages of the components in the core material are as follows: 40-70% of borax, 20-30% of potassium fluozirconate and 5-10% of yttrium oxide.
Preferably, the specific steps of the step (4) are as follows: and (3) performing quality inspection on the welded finished product by using an ultrasonic detector, and detecting weld defects by using a transverse wave method.
The following describes in detail an example of butt welding of C37 die-cast aluminum alloy sheets.
Example 1
According to the process flow, a laser-arc welding composite welding process is adopted, and equipment adopted by welding comprises an IPGYLS-6000 multimode fiber laser, a front TPS500i welding machine and a KUKAKRC2 welding robot.
The element composition of the C37 die-casting aluminum alloy plate is as follows (mass percent): 10% of Si, 0.15% of Fe, 0.05% of Cu, 0.5% of Mn, 0.06% of Mg, 0.07% of Zn, 0.01% of Sr, less than or equal to 0.05% of other impurities and the balance of Al.
(1) Pre-weld preparation
Selecting a plate with the thickness of 4mm, uniformly preparing workpieces to be machined and welded for later use, arranging grooves at the positions of welding seams of the workpieces to be welded, forming Y-shaped grooves at the positions of the welding seams, ultrasonically cleaning the machined and formed workpieces to be welded by adopting an acetone solution for 20min, and removing greasy dirt attachments on the surfaces of the workpieces.
(2) Laser cleaning
Installing a die-casting aluminum alloy test piece to be welded on a workbench, adjusting the relative positions of a laser cleaning head and a dust collection port, setting technological parameters, starting a dust collector or a smoke purifier, starting a laser, starting to clean an oxide film on the surface of a workpiece to be welded, and carrying out laser cleaning on the welding parts of all the welded workpieces until metallic luster is exposed.
The technological parameters of the laser cleaning treatment are as follows: the laser is in a pulse mode, the laser wavelength is 1.064 microns, the average power of the laser is 90W, the scanning line width is 70mm, the pulse frequency is 90kHz, and the cleaning rate is 0.8m/min.
(3) Composite welding
And fixing the die-casting aluminum alloy test piece after cleaning on a welding fixture, pressing the test pieces on two sides of the welding line by using a clamping fixture, and adopting a laser-MIG composite welding process. And (3) rigidly fixing the laser head and the MIG welding gun by using a clamp, and adjusting the posture of the welding gun according to the assembly state of the workpiece to be welded to weld.
The misalignment amount of two sides of a welding line in the composite welding process is less than 0.1mm, the welding groove angle is 60 degrees, the diameter of a welding wire is 1.0mm, a welding material is a welding wire with a core-shell structure, the mass percentage of a surface skin in the welding wire is 80%, the mass percentage of a core material is 20%, the surface skin is AlMgMnTiSi high-entropy alloy, and the high entropy consists of the following elements in atomic percentage: 60% of Al, 10% of Mg, 10% of Mn, 10% of Ti and 10% of Si, wherein the core material comprises the following components in percentage by mass: 70% of borax, 25% of potassium fluozirconate and 5% of yttrium oxide.
The core diameter of the laser fiber for composite welding is 200 mu m, the defocusing amount of the laser is 0mm, the scanning frequency is 30Hz, and the vertical inclination angle of the laser beam is 10 degrees.
The included angle between the axis of the CMT welding or MIG welding gun and the base metal is 70 degrees, the distance between optical wires is 2mm, the elongation of the welding wire between the welding gun conducting nozzle and the surface of a workpiece is 5mm, the included angle between the shielding gas nozzle and the vertical direction is 60 degrees, and the shielding gas is mixed gas of 97vol% argon and 3vol% helium, and the gas flow is 20L/min.
Other specific process parameters of the composite welding process are shown in table 1.
(4) Welding quality detection
And (3) carrying out quality inspection on the welded finished product by using an ultrasonic detector, detecting weld defects by using a transverse wave method, and if the sound waves encounter the defects in the process of transmission, reflecting part of the sound waves back and displaying defect echoes on the fluorescent screen.
The welding of the C37 die-cast aluminum alloy sheet and the 6061 aluminum alloy sheet will be described in detail below as an example.
Example 2
The laser-MIG composite welding process was used and the welding process parameters different from those of example 1 are shown in table 1.
Example 3
The laser-MIG composite welding process was used and the welding process parameters different from those of example 1 are shown in table 1.
Example 4
The laser-CMT hybrid welding process was used and specific welding process parameters different from example 1 are shown in table 1.
Example 5
The laser-CMT hybrid welding process was used and specific welding process parameters different from example 1 are shown in table 1.
Example 6
According to the process flow, a laser-arc welding composite welding process is adopted to weld the C37 die-cast aluminum alloy plate and the 6061 series aluminum alloy plate, and equipment adopted by welding comprises an IPGYS-6000 multimode fiber laser, a front TPS500i welding machine and a KUKAKRC2 welding robot.
The elements of the C37 die-cast aluminum alloy plate are as follows: 10% of Si, 0.15% of Fe, 0.05% of Cu, 0.5% of Mn, 0.06% of Mg, 0.07% of Zn, 0.01% of Sr, less than or equal to 0.05% of other impurities and the balance of Al.
(1) Pre-weld preparation
Selecting a plate with the thickness of 4mm, uniformly preparing workpieces to be machined and welded for later use, arranging grooves at the positions of welding seams of the workpieces to be welded, forming Y-shaped grooves at the positions of the welding seams, ultrasonically cleaning the machined and formed workpieces to be welded by adopting an acetone solution for 20min, and removing greasy dirt attachments on the surfaces of the workpieces.
(2) And (3) mounting the die-casting aluminum alloy test piece to be welded on a workbench by laser cleaning, adjusting the relative positions of a laser cleaning head and a dust collection port, setting technological parameters, starting a dust collector or a smoke purifier, starting the laser, starting to clean an oxide film on the surface of the workpiece to be welded, and performing laser cleaning on the welding parts of all the welded workpieces until the metallic luster is exposed.
The technological parameters of the laser cleaning treatment are as follows: the laser is in a pulse mode, the laser wavelength is 1.064 microns, the average power of the laser is 90W, the scanning line width is 70mm, the pulse frequency is 90KHz, and the cleaning rate is 0.8m/min.
(3) Composite welding
And fixing the die-casting aluminum alloy test piece after cleaning on a welding fixture, pressing the test pieces on two sides of the welding line by using a clamping fixture, rigidly fixing a laser head and an MIG welding gun by using the fixture by using a laser-MIG composite welding process, and adjusting the posture of the welding gun according to the assembly state of a workpiece to be welded to weld.
The misalignment amount of two sides of a welding line in the composite welding process is less than 0.1mm, the welding groove angle is 70-degree, the diameter of the welding wire is 1.0mm, the welding material is a welding wire with a core-shell structure, the mass percentage of a surface skin in the welding wire is 85%, the mass percentage of a core material is 15%, the surface skin is AlMgMnTiSi high-entropy alloy, and the high entropy consists of the following elements in atomic percentage: 52% of Al, 12% of Mg, 12% of Mn, 12% of Ti and 12% of Si, wherein the core material comprises the following components in percentage by mass: 60% of borax, 30% of potassium fluozirconate and 10% of yttrium oxide.
The core diameter of the laser fiber for composite welding is 200 mu m, the defocusing amount of the laser is 0mm, the scanning frequency is 30Hz, and the vertical inclination angle of the laser beam is 10 degrees.
The included angle between the axis of the CMT welding or MIG welding gun and the base metal is 70 degrees, the distance between optical wires is 2mm, the elongation of the welding wire between the welding gun conducting nozzle and the surface of a workpiece is 5mm, the included angle between the shielding gas nozzle and the vertical direction is 60 degrees, and the shielding gas is mixed gas of 97vol% argon and 3vol% helium, and the gas flow is 25L/min.
Other specific process parameters of the composite welding process are shown in table 1.
(4) Welding quality detection
And (3) carrying out quality inspection on the welded finished product by using an ultrasonic detector, detecting weld defects by using a transverse wave method, and if the sound waves encounter the defects in the process of transmission, reflecting part of the sound waves back and displaying defect echoes on the fluorescent screen.
Example 7
The laser-MIG composite welding process was used and the welding process parameters different from those of example 6 are shown in table 1.
Example 8
The laser-CMT composite welding process was used and the welding process parameters different from those of example 6 are shown in table 1.
Comparative example 1
Based on example 1, the operation method of pre-weld preparation, laser cleaning, and weld quality detection in example 1 was employed.
The welding adopts an MIG single welding mode for welding, and the specific operation is as follows:
and fixing the die-casting aluminum alloy test piece after cleaning on a welding fixture, and compacting the test pieces on two sides of the welding line by using a clamping fixture. And (3) rigidly fixing the MIG welding gun by using a clamp, and adjusting the posture of the welding gun according to the assembly state of the welding test piece to carry out welding.
The misalignment amount of two sides of a welding line in the welding process is less than 0.1mm, the diameter of a welding wire is 1.0mm, a welding material is a welding wire with a core-shell structure, the mass percentage of a surface skin in the welding wire is 80%, the mass percentage of a core material is 20%, the surface skin is AlMgMnTiSi high-entropy alloy, and the high-entropy consists of the following elements in atomic percentage: 60% of Al, 10% of Mg, 10% of Mn, 10% of Ti and 10% of Si, wherein the core material comprises the following components in percentage by mass: 70% of borax, 25% of potassium fluozirconate and 5% of yttrium oxide.
The included angle between the axis of the MIG welding gun and the base metal is 70 degrees, the distance between optical wires is 2mm, the elongation of a welding wire between a welding gun conducting nozzle and the surface of a workpiece is 5mm, the included angle between a shielding gas nozzle and the vertical direction is 60 degrees, and the shielding gas is mixed gas of 97vol% of argon and 3vol% of helium, and the gas flow is 20L/min.
Other specific process parameters of the welding process are shown in table 1.
Comparative example 2
Based on example 1, the operation method of pre-weld preparation, laser cleaning, and weld quality detection in example 1 was employed.
The welding is carried out by adopting a laser single welding mode, and the specific operation is as follows:
and fixing the die-casting aluminum alloy test piece after cleaning on a welding fixture, and compacting the test pieces on two sides of the welding line by using a clamping fixture. And (3) rigidly fixing the laser head by using a clamp, and adjusting the posture of the welding gun according to the assembly state of the welding test piece to carry out welding.
The misalignment amount of two sides of a welding line in the welding process is less than 0.1mm, a welding material is a welding wire with a core-shell structure, the diameter of the welding wire is 1.0mm, the mass percentage of a surface skin in the welding wire is 80%, the mass percentage of a core material is 20%, the surface skin is AlMgMnTiSi high-entropy alloy, and the high-entropy consists of the following elements in atomic percentage: 60% of Al, 10% of Mg, 10% of Mn, 10% of Ti and 10% of Si, wherein the core material comprises the following components in percentage by mass: 70% of borax, 25% of potassium fluozirconate and 5% of yttrium oxide.
In the laser welding process, the core diameter of the laser fiber is 200 mu m, the laser defocusing amount is 0mm, the scanning frequency is 30Hz, and the vertical inclination angle of the laser beam is 10 degrees.
Other specific process parameters of the welding process are shown in table 1.
Comparative example 3
Based on example 1, the operation method of pre-weld preparation, laser cleaning, and weld quality detection in example 1 was employed.
The specific operation of the compound welding is as follows:
and fixing the die-casting aluminum alloy test piece after cleaning on a welding fixture, and compacting the test pieces on two sides of the welding line by using a clamping fixture. And (3) rigidly fixing the laser head and the MIG welding gun by using a clamp, and adjusting the posture of the welding gun according to the assembly state of the welding test piece to carry out welding.
The misalignment amount of two sides of a welding line in the composite welding process is less than 0.1mm, a welding material is a single aluminum alloy material welding wire, the diameter of the welding wire is 1.0mm, and the mass percentages of elements in the welding wire are as follows: 89.0% of Al, 3.0% of Mg, 3.0% of Mn, 1.0% of Ti and 4.0% of Si.
The core diameter of the laser fiber for composite welding is 200 mu m, the defocusing amount of the laser is 0mm, the scanning frequency is 30Hz, and the vertical inclination angle of the laser beam is 10 degrees.
The included angle between the axis of the MIG welding gun and the base metal is 70 degrees, the distance between optical wires is 2mm, the elongation of a welding wire between a welding gun conducting nozzle and the surface of a workpiece is 5mm, the included angle between a shielding gas nozzle and the vertical direction is 60 degrees, and the shielding gas is mixed gas of 97vol% of argon and 3vol% of helium, and the gas flow is 20L/min.
Other specific process parameters of the composite welding process are shown in table 1.
Comparative example 4
Based on example 1, the operation method of pre-weld preparation, laser cleaning, and weld quality detection in example 1 was employed.
And fixing the die-casting aluminum alloy test piece after cleaning on a welding fixture, and compacting the test pieces on two sides of the welding line by using a clamping fixture. And (3) rigidly fixing the laser head and the MIG welding gun by using a clamp, and adjusting the posture of the welding gun according to the assembly state of the actual welding test piece to carry out welding.
The misalignment amount of two sides of a welding line in the composite welding process is less than 0.1mm, the welding material is a welding wire with a core-shell structure, the diameter of the welding wire is 1.0mm, the mass percentage of a surface skin in the welding wire is 80%, the mass percentage of a core material is 20%, the surface skin is a conventional aluminum alloy material, and the mass percentages of elements in the surface skin are as follows: 89.0% of Al, 3.0% of Mg, 3.0% of Mn, 1.0% of Ti, 4.0% of Si and the mass percentage of each component in the core material is as follows: 70% of borax, 25% of potassium fluozirconate and 5% of yttrium oxide.
The core diameter of the laser fiber for composite welding is 200 mu m, the defocusing amount of the laser is 0mm, the scanning frequency is 30Hz, and the vertical inclination angle of the laser beam is 10 degrees.
The included angle between the axis of the MIG welding gun and the base metal is 70 degrees, the distance between optical wires is 2mm, the elongation of a welding wire between a welding gun conducting nozzle and the surface of a workpiece is 5mm, the included angle between a shielding gas nozzle and the vertical direction is 60 degrees, and the shielding gas is mixed gas of 97vol% of argon and 3vol% of helium, and the gas flow is 20L/min.
Other specific process parameters of the composite welding process are shown in table 1.
Comparative example 5
Based on example 1, the operation method of pre-weld preparation, laser cleaning, and weld quality detection in example 1 was employed.
And fixing the die-casting aluminum alloy test piece after cleaning on a welding fixture, and compacting the test pieces on two sides of the welding line by using a clamping fixture. And (3) rigidly fixing the laser head and the MIG welding gun by using a clamp, and adjusting the posture of the welding gun according to the assembly state of the actual welding test piece to carry out welding.
The misalignment amount of two sides of a welding line in the composite welding process is less than 0.1mm, the welding material is a single AlMgMnTiSi high-entropy alloy material, the material is a coreless material, the diameter of a welding wire is 1.0mm, and the mass percentages of elements in the welding wire are as follows: 89.0% of Al, 3.0% of Mg, 3.0% of Mn, 1.0% of Ti and 4.0% of Si.
The core diameter of the laser fiber for composite welding is 200 mu m, the defocusing amount of the laser is 0mm, the scanning frequency is 30Hz, and the vertical inclination angle of the laser beam is 10 degrees.
The included angle between the axis of the MIG welding gun and the base metal is 70 degrees, the distance between optical wires is 2mm, the elongation of a welding wire between a welding gun conducting nozzle and the surface of a workpiece is 5mm, the included angle between a shielding gas nozzle and the vertical direction is 60 degrees, and the shielding gas is mixed gas of 97vol% of argon and 3vol% of helium, and the gas flow is 20L/min.
Other process parameters of the composite welding process are shown in table 1.
The welding performance of each of the examples and comparative examples was tested as shown in table 1.
Table 1 other process parameters and welding performance of the welding process of examples and comparative examples
The appearance of the butt welds obtained in examples 1-8 of the present invention was analyzed, with good front and back welds, no obvious undercut, and no fusion defects.
The tensile test detection is carried out on the workpieces obtained in the examples and the comparative examples by adopting a metal material mechanical property method, and the related detection is carried out on the porosity in the welding seam by adopting a ray detection analysis method.
The butt welding is carried out on C37 materials and C37-6061 aluminum alloy materials, and the detection results show that the tensile strength and the elongation of the welding seam are obviously improved by adopting the composite welding process provided by the invention, and compared with the tensile strength of a base metal, the tensile strength of the welding seam is more than 90%, and the porosity is maintained below 1.0%.
Comparative example test results compared with example test results, comparative example 1 and comparative example 2 were conducted to weld C37 material by MIG welding and laser welding, respectively; comparative example 3 also used a composite welding process, but the welding wire used a non-high entropy alloy aluminum alloy material in the prior art, and no core material was added; comparative example 4 uses a composite welding process, the welding wire uses a non-high entropy alloy aluminum alloy material in the prior art as a skin material, and the core material is the same as the invention; comparative example 5 adopts a composite welding process, the welding wire does not adopt a core-shell structure, does not contain the core material of the invention, and only adopts the AlMgMnTiSi high-entropy alloy material of the invention as the welding wire for welding.
As can be seen from the test results, the tensile strength and yield strength of the welding seam in the comparative example are greatly reduced compared with the embodiment of the invention, the tensile strength is less than 90%, the elongation of the welding seam is higher compared with the embodiment of the invention, and the porosity is more than 1.0%. The result proves that the composite welding process adopted by the invention has remarkable effect on improving the welding performance of the die-casting aluminum alloy workpiece, improves the mechanical strength of the welding seam, reduces the porosity of the welding seam, and overcomes a plurality of defects and technical problems existing in a single welding method. In addition, the core-shell structure of the welding wire is improved in mechanical property of the welding seam due to the addition of the interfacial active substance and the rare earth element compared with a pure metal welding wire, the molten metal in a molten pool flows and disperses more uniformly, and the obtained welding seam has finer structure and lower porosity. Compared with the common aluminum alloy welding wire in the prior art, the high-entropy alloy welding wire has obvious effect on improving the mechanical property of the welding seam.
The foregoing description is only of the preferred embodiments of the present invention and is not intended to limit the scope of the invention, and all equivalent structural changes made by the content of the present invention or direct/indirect application in other related technical fields are included in the scope of the present invention.
Claims (8)
1. The composite welding method for the die-casting aluminum alloy parts with the complex structures is characterized in that the die-casting aluminum alloy parts with the complex structures comprise a plurality of aluminum alloy die-casting units, the aluminum alloy die-casting units are welded in a composite welding mode, the composite welding is laser-MIG composite welding or laser-CMT composite welding, and the composite welding is a side-axis composite welding mode with a laser heat source in front and a MIG or CMT heat source in back;
the composite welding of the die-casting aluminum alloy part with the complex structure comprises the following steps of:
(1) Preparing a workpiece to be welded, and cleaning and preprocessing a sample to be welded;
(2) Performing laser cleaning treatment on the pretreated sample by adopting a laser cleaning head;
(3) Fixing the cleaned workpiece on a welding fixture, and performing welding treatment by using the composite welding process, wherein a welding wire adopted in the welding treatment is of a core-shell structure and comprises a surface skin and a core material, the surface skin is AlMgMnTiSi high-entropy alloy, and the core material is a mixture of borax, potassium fluorozirconate and yttrium oxide;
(4) Performing quality detection on the workpiece subjected to welding treatment;
the core diameter of the laser fiber welded by the compound welding in the step (3) is 200 mu m, the laser defocusing amount is 0mm-5mm, the scanning frequency is 20Hz-40Hz, the arc length correction coefficient is-10% to +10%, the vertical inclination angle of the laser beam is 5-10 degrees, and the laser power is 1500W-4000W; the included angle between the axis of a CMT welding or MIG welding gun and a base metal is 60-70 degrees, the distance between optical wires is 1-3 mm, the extending amount of a welding wire between a welding gun conducting nozzle and the surface of a workpiece is 3-8 mm, the CMT welding or MIG welding is adaptively adjusted according to laser power, the welding speed is 1-7 m/min, the wire feeding speed is 5-20 m/min, the included angle between a shielding gas nozzle and the vertical direction is 45-60 degrees, the shielding gas is mixed gas of argon and helium, and the flow is 15-25L/min; the diameter of the welding wire is 0.8-1.6 mm, the mass percentage of the surface skin in the welding wire is 70-90%, and the mass percentage of the core material is 10-30%; the surface AlMgMnTiSi high-entropy alloy consists of the following elements in atomic percent: 40-60% of Al, 10-15% of Mg, 10-15% of Mn, 10-15% of Ti, 10-15% of Si and the mass percentages of the components in the core material are as follows: 40-70% of borax, 20-30% of potassium fluozirconate and 5-10% of yttrium oxide.
2. The composite welding method for die-casting aluminum alloy parts with complex structures according to claim 1, wherein the composite welding method comprises the following steps: the aluminum alloy die casting unit is made of Al-Si die casting aluminum alloy, and the characteristic thickness of the part is 1.5mm-6.0mm.
3. The composite welding method for die-casting aluminum alloy parts with complex structures according to claim 2, wherein the composite welding method comprises the following steps: the specific steps of the step (1) are as follows: when the characteristic thickness of the part is more than or equal to 4mm, the workpiece to be welded is provided with a groove, and the workpiece to be welded is cleaned and pretreated by adopting an acetone solution.
4. A composite welding method for die-cast aluminum alloy parts with complex structures according to claim 3, which is characterized in that: the specific steps of the step (2) are as follows: fixing a workpiece to be welded on a workbench, adjusting the relative positions of a laser cleaning head and a dust collection port, setting laser cleaning process parameters through a controller, and sequentially starting a dust collector or a smoke purifier and a laser to perform laser cleaning treatment on the surface of the workpiece to be welded.
5. The composite welding method for the die-casting aluminum alloy parts with the complex structures, which is disclosed in claim 4, is characterized in that: in the step (2), the laser cleaning treatment is performed by adopting pulse laser, and the process parameters are as follows: the laser wavelength is 1.064 micrometers, the average power is 85W-95W, the scanning line width is 60mm-70mm, the pulse frequency is 80KHz-100KHz, and the cleaning rate is 0.6m/min-1.0m/min.
6. The composite welding method for the die-casting aluminum alloy parts with the complex structures, which is disclosed in claim 5, is characterized in that: the specific steps of the step (3) are as follows: and fixing the workpiece to be welded after the laser cleaning treatment is finished on a welding fixture, adjusting the gap between the group and the offset of two sides of the welding line, and adjusting the posture of a welding gun according to the assembly state of the workpiece to be welded to weld.
7. The composite welding method for the die-casting aluminum alloy parts with the complex structures, which is characterized in that: the pairing gap in the step (3) is 0mm-0.6mm, the welding groove angle is 60-70 degrees, and the misalignment amount of the two sides of the welding line is less than 0.1mm.
8. The composite welding method for die-casting aluminum alloy parts with complex structures according to claim 1, wherein the composite welding method comprises the following steps: the specific steps of the step (4) are as follows: and (3) performing quality inspection on the welded finished product by using an ultrasonic detector, and detecting weld defects by using a transverse wave method.
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| CN113996966A (en) * | 2021-11-02 | 2022-02-01 | 上海龙烁焊材有限公司 | Preparation method and application of aluminum-based light high-entropy alloy metal powder-cored welding wire |
| CN114289874A (en) * | 2022-01-19 | 2022-04-08 | 苏州大学 | Preparation method of high-strength weld joint |
| CN116275381A (en) * | 2023-04-14 | 2023-06-23 | 申为智能科技(江苏)有限公司 | Cold arc metal transition aluminum alloy welding method for laser-induced stable arc transition |
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