CN117962318A - Connection method of thermoplastic plastic substrate and metal substrate - Google Patents
Connection method of thermoplastic plastic substrate and metal substrate Download PDFInfo
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- CN117962318A CN117962318A CN202410218453.5A CN202410218453A CN117962318A CN 117962318 A CN117962318 A CN 117962318A CN 202410218453 A CN202410218453 A CN 202410218453A CN 117962318 A CN117962318 A CN 117962318A
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- 239000000758 substrate Substances 0.000 title claims abstract description 189
- 229920001169 thermoplastic Polymers 0.000 title claims abstract description 125
- 229910052751 metal Inorganic materials 0.000 title claims abstract description 94
- 239000002184 metal Substances 0.000 title claims abstract description 94
- 238000000034 method Methods 0.000 title claims abstract description 33
- 238000003466 welding Methods 0.000 claims abstract description 74
- 239000000463 material Substances 0.000 claims abstract description 21
- 230000002787 reinforcement Effects 0.000 claims abstract description 17
- 230000008569 process Effects 0.000 claims abstract description 12
- 238000005253 cladding Methods 0.000 claims abstract description 4
- 239000000843 powder Substances 0.000 claims description 54
- 239000004416 thermosoftening plastic Substances 0.000 claims description 33
- 238000003892 spreading Methods 0.000 claims description 26
- 230000007480 spreading Effects 0.000 claims description 26
- 229910000838 Al alloy Inorganic materials 0.000 claims description 17
- 238000010438 heat treatment Methods 0.000 claims description 7
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 6
- 229920001652 poly(etherketoneketone) Polymers 0.000 claims description 6
- -1 polyethylene Polymers 0.000 claims description 6
- 229920000049 Carbon (fiber) Polymers 0.000 claims description 4
- 239000004917 carbon fiber Substances 0.000 claims description 4
- 238000001816 cooling Methods 0.000 claims description 4
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims description 4
- 238000003825 pressing Methods 0.000 claims description 4
- 229910000861 Mg alloy Inorganic materials 0.000 claims description 3
- 239000004677 Nylon Substances 0.000 claims description 3
- 239000004696 Poly ether ether ketone Substances 0.000 claims description 3
- 239000004952 Polyamide Substances 0.000 claims description 3
- 239000004697 Polyetherimide Substances 0.000 claims description 3
- 239000004698 Polyethylene Substances 0.000 claims description 3
- 239000004734 Polyphenylene sulfide Substances 0.000 claims description 3
- 239000004743 Polypropylene Substances 0.000 claims description 3
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 3
- 229910001069 Ti alloy Inorganic materials 0.000 claims description 3
- 229920001778 nylon Polymers 0.000 claims description 3
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims description 3
- 239000002245 particle Substances 0.000 claims description 3
- 229920002647 polyamide Polymers 0.000 claims description 3
- 229920000515 polycarbonate Polymers 0.000 claims description 3
- 239000004417 polycarbonate Substances 0.000 claims description 3
- 229920002530 polyetherether ketone Polymers 0.000 claims description 3
- 229920001601 polyetherimide Polymers 0.000 claims description 3
- 229920000573 polyethylene Polymers 0.000 claims description 3
- 229920000069 polyphenylene sulfide Polymers 0.000 claims description 3
- 229920001155 polypropylene Polymers 0.000 claims description 3
- 229920000915 polyvinyl chloride Polymers 0.000 claims description 3
- 239000004800 polyvinyl chloride Substances 0.000 claims description 3
- 238000007790 scraping Methods 0.000 claims description 3
- 239000011863 silicon-based powder Substances 0.000 claims description 3
- 229920006259 thermoplastic polyimide Polymers 0.000 claims description 3
- 229910000831 Steel Inorganic materials 0.000 claims description 2
- 238000009740 moulding (composite fabrication) Methods 0.000 claims description 2
- 239000010959 steel Substances 0.000 claims description 2
- 238000005304 joining Methods 0.000 claims 6
- 239000004721 Polyphenylene oxide Substances 0.000 claims 1
- 229920006380 polyphenylene oxide Polymers 0.000 claims 1
- 230000007547 defect Effects 0.000 abstract description 8
- 229920001643 poly(ether ketone) Polymers 0.000 description 15
- 230000002708 enhancing effect Effects 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 239000000155 melt Substances 0.000 description 3
- 150000002739 metals Chemical class 0.000 description 3
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 229920013636 polyphenyl ether polymer Polymers 0.000 description 2
- 238000003672 processing method Methods 0.000 description 2
- 239000012779 reinforcing material Substances 0.000 description 2
- 229910000853 7075 T6 aluminium alloy Inorganic materials 0.000 description 1
- 229910000851 Alloy steel Inorganic materials 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
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- 230000004048 modification Effects 0.000 description 1
- 239000002861 polymer material Substances 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000013585 weight reducing agent Substances 0.000 description 1
Landscapes
- Pressure Welding/Diffusion-Bonding (AREA)
- Lining Or Joining Of Plastics Or The Like (AREA)
Abstract
The invention discloses a connection method of a thermoplastic plastic substrate and a metal substrate, which belongs to the technical field of dissimilar material connection and comprises the following steps: s1: processing a plurality of necking grooves in a region to be welded of the metal substrate; s2: cladding thermoplastic plastics mixed with reinforcements in the necking grooves, wherein the thermoplastic plastics are consistent with the thermoplastic plastic substrate in material quality, and the thermoplastic plastics are cooled and then protrude out of the metal substrate to form convex textures; s3: processing concave textures matched with the relief textures in a region to be welded of the thermoplastic plastic substrate through an ultrasonic vibration head with the convex tooth textures; s4: inserting the convex pattern into the concave pattern, and performing ultrasonic welding on the thermoplastic plastic substrate and the metal substrate. The invention can greatly enhance the weldability between the thermoplastic plastic substrate and the metal substrate, and reduce the power and the process difficulty required by ultrasonic welding; and the welding defects such as local stress concentration, air holes, microcracks and the like caused by ultrasonic welding of the dissimilar materials can be avoided.
Description
Technical Field
The invention relates to the technical field of dissimilar material connection, in particular to a connection method of a thermoplastic plastic substrate and a metal substrate.
Background
With the development of polymer material technology, thermoplastic plastics are widely applied to the industrial fields of aerospace, marine vessels, automobile traffic biomedical treatment, power electronics and the like due to the advantages of good strength, easy processing, corrosion resistance, weldability and the like. Due to the restrictions of processing cost, manufacturing process, production conditions and other factors, the connection technology is unavoidable when manufacturing complex structures or large parts, in particular the connection of metals and thermoplastics.
The metals and thermoplastics are dissimilar materials, and the thermodynamic and physicochemical properties of the materials are greatly different, so that the connection structure of the materials is difficult to obtain enough strength. The connection modes currently suitable for thermoplastic plastics and metals are mechanical connection (screw connection and riveting), bonding and welding. Mechanical connections have the disadvantages of stress concentration and non-weight reduction, and are less suitable for connection of thicker materials. Although the bonding can overcome the defects of mechanical connection, the bonding surface is strictly pretreated due to the severe dependence of the adhesive performance and curing conditions, and the process requirement is strict and the efficiency is low. Although the welding efficiency is high, the weldability to dissimilar materials is poor, and defects such as air holes, microcracks and the like are easily generated in a welding area, so that the connection strength is insufficient.
Disclosure of Invention
The invention aims to provide a method for connecting a thermoplastic plastic substrate and a metal substrate, which aims to solve the problems that the prior metal and thermoplastic plastic are poor in weldability, and air holes, microcracks and the like are easy to generate in a welding area, so that the connection strength is insufficient.
The technical scheme for solving the technical problems is as follows:
a method of connecting a thermoplastic substrate to a metal substrate, comprising the steps of:
S1: processing a plurality of necking grooves in a region to be welded of the metal substrate;
S2: cladding thermoplastic plastics mixed with reinforcements in the necking grooves, wherein the thermoplastic plastics are consistent with the thermoplastic plastic substrate in material quality, and the thermoplastic plastics are cooled and then protrude out of the metal substrate to form convex textures;
S3: processing concave textures matched with the relief textures in a region to be welded of the thermoplastic plastic substrate through an ultrasonic vibration head with the convex tooth textures;
S4: inserting the convex pattern into the concave pattern, and performing ultrasonic welding on the thermoplastic plastic substrate and the metal substrate.
The invention firstly prepares a plurality of necking grooves on a metal substrate, then melts and coats thermoplastic plastics mixed with reinforcing substances in the necking grooves, and bulges the metal substrate to form convex textures, the existence of the necking grooves ensures that the thermoplastic plastics and the metal substrate have good connectivity, and finally the convex textures and the concave textures on the thermoplastic plastics substrate are connected together through ultrasonic welding after being matched, so the ultrasonic welding of the metal substrate and the thermoplastic plastics substrate is essentially the ultrasonic welding between the thermoplastic plastics and the thermoplastic plastics substrate, namely the ultrasonic welding of dissimilar materials between the metal substrate and the thermoplastic plastics substrate is converted into the ultrasonic welding of the same materials between the thermoplastic plastics and the thermoplastic plastics substrate, thereby greatly enhancing the weldability between the thermoplastic plastics substrate and the metal substrate, and reducing the power and the process difficulty required by the ultrasonic welding; and the welding defects of local stress concentration, air holes, microcracks and the like caused by unmatched thermodynamic parameters such as specific heat capacity, thermal expansion coefficient and the like during ultrasonic welding of the dissimilar materials can be avoided.
Further, in the step S1, a multiple processing method of changing the laser incident angle and multiple scanning is adopted to process a necking groove in the to-be-welded area of the metal substrate, wherein the necking groove meets the following geometric conditions:
Wherein, Is the maximum incident angle of the laser, and/>M is the width of the opening of the groove, W is the interval of the groove, H is the depth of the groove, and the scanning times are more than or equal to 3.
Further, the region to be welded of the metal substrate is cleaned before the necking groove is processed.
Further, the step S2 includes the following substeps:
s21: horizontally placing a powder spreading die provided with through grooves above a region to be welded of the metal substrate with the necking grooves, and keeping the through grooves aligned with the necking grooves one by one;
S22: filling thermoplastic plastic powder mixed with the reinforcement into the through groove of the powder spreading die until the through groove is fully spread and the upper surface of the powder spreading die is higher than the upper surface of the powder spreading die;
S23: scraping powder higher than the upper surface of the powder spreading die, and vertically taking out the powder spreading die upwards;
s24: and heating the area to be welded of the metal substrate until the thermoplastic plastic powder mixed with the reinforcement is melted, stopping heating and cooling, and forming the relief pattern of the protruding metal substrate.
Further, the cross section of the through groove of the powder paving die is trapezoid with narrow upper part and wide lower part, and the geometric conditions of the trapezoid are as follows:
250μm≤G≤700μm；
B<A＝M；
K＝W；
wherein G is the depth of the through groove, B is the upper opening width of the through groove, A is the lower opening width of the through groove, and K is the spacing of the through grooves.
Further, the thermoplastic powder has a particle size of 500 mesh to 2000 mesh; the reinforcement is one or more of silicon powder, aluminum oxide powder, silicon dioxide powder and carbon fiber powder with the granularity of 500-2000 meshes, and the volume ratio of the reinforcement to the thermoplastic plastic powder is 1:100-10:100.
Further, the step S3 includes the following substeps:
S31: placing an ultrasonic vibration head with convex tooth textures on the end face vertically above a region to be welded of a thermoplastic plastic substrate;
S32: and starting ultrasonic vibration, so that the convex teeth of the ultrasonic vibration head are vertically pressed into the to-be-welded area of the thermoplastic plastic substrate, quickly and vertically lifting the ultrasonic vibration head until the pressing depth Z reaches the required depth, and stopping ultrasonic vibration, thereby preparing concave textures in the to-be-welded area of the thermoplastic plastic substrate.
Further, the geometric parameters of the convex teeth of the ultrasonic vibration head satisfy the following conditions:
L＝K＝W；
N≥G；
P≥B；
G≤Z≤N；
Wherein: l is the spacing of the convex teeth, N is the height of the convex teeth, beta is the tooth-shaped oblique angle, and P is the tooth top width of the convex teeth.
Further, the step S4 includes the following substeps:
s41: overlapping the to-be-welded area of the metal substrate and the to-be-welded area of the thermoplastic plastic substrate, horizontally placing the overlapped to-be-welded area on a base of the ultrasonic welding device, and ensuring that the metal substrate is positioned above the thermoplastic plastic substrate;
s42: inserting the relief pattern of the region to be welded of the metal substrate into the concave pattern of the region to be welded of the thermoplastic plastic substrate;
S43: and moving the ultrasonic welding head to the upper part of the area to be welded, and performing ultrasonic welding on the metal substrate and the thermoplastic plastic substrate until the welding is completed.
Further, the thermoplastic plastic substrate is one or more of polyether-ether-ketone, polyether-ketone, polyethylene, polyvinyl chloride, polypropylene, polyphenyl ether, polyamide, polyphenylene sulfide, polyether imide, nylon, polycarbonate and thermoplastic polyimide with the thickness less than or equal to 5 mm;
The metal substrate is made of aluminum alloy, titanium alloy, magnesium alloy or steel with the thickness less than or equal to 5mm.
The invention has the following beneficial effects:
(1) The invention converts the ultrasonic welding of the dissimilar materials between the metal substrate and the thermoplastic plastic substrate into the ultrasonic welding of the same material between the thermoplastic plastic and the thermoplastic plastic substrate, thereby greatly enhancing the weldability between the thermoplastic plastic substrate and the metal substrate and reducing the power and the process difficulty required by the ultrasonic welding; and the welding defects of local stress concentration, air holes, microcracks and the like caused by unmatched thermodynamic parameters such as specific heat capacity, thermal expansion coefficient and the like during ultrasonic welding of the dissimilar materials can be avoided.
(2) The necking micro-groove processed in the to-be-welded area of the metal substrate can be anchored with thermoplastic plastics to form a dovetail joint, and the reinforcing materials mixed in the thermoplastic plastics can effectively improve the connection strength of the welding area, so that the welding structure of the thermoplastic plastics substrate and the metal substrate has good mechanical property and durability.
(3) In the invention, when ultrasonic welding is carried out, the metal substrate is positioned above the thermoplastic plastic substrate, so that the ultrasonic welding joint is directly contacted with the metal substrate, the attenuation of ultrasonic waves in the transmission process is reduced, and more energy can be obtained in a welding area.
(4) When the ultrasonic welding is carried out, the convex patterns of the to-be-welded area of the metal substrate are kept to be inserted into the concave patterns of the to-be-welded area of the thermoplastic plastic substrate, so that the welding area is fully contacted, the heat generated by friction is improved, the melt of the welding area is promoted to be fully diffused, the welding defects such as stress concentration, air holes and microcracks are reduced, and the welding structure strength is improved.
Drawings
FIG. 1 is a schematic view of the structure of a metal substrate processed with a necked trench of example 1;
FIG. 2 is a schematic structural diagram of a metal substrate with a relief pattern according to embodiment 1;
FIG. 3 is a schematic view of the structure of the thermoplastic substrate of example 1 when concave textures are processed;
FIG. 4 is a schematic view of the structure of a thermoplastic substrate with concave textures processed in example 1;
FIG. 5 is a schematic view of the structure of the metal substrate and thermoplastic substrate of example 1 in ultrasonic welding;
FIG. 6 is a microstructure of example 2 after ultrasonic welding of an aluminum alloy to PEKK (polyetherketoneketone).
In the figure: 10-a metal substrate; 11-necking the groove; 12-convex texture; 20-a thermoplastic substrate; 21-concave texture; 30-an ultrasonic vibration head; 40-ultrasonic welding head; 50-powder spreading mould.
Detailed Description
The principles and features of the present invention are described below with reference to the drawings, the examples are illustrated for the purpose of illustrating the invention and are not to be construed as limiting the scope of the invention.
Example 1:
the embodiment provides a connection method of a thermoplastic plastic substrate and a metal substrate, which comprises the following steps:
s1: processing a plurality of necking grooves 11 in a region to be welded of the metal substrate 10;
S2: cladding a thermoplastic mixed with a reinforcement in the necking groove 11, wherein the thermoplastic is consistent with the material of the thermoplastic substrate 20, and the thermoplastic is cooled to protrude out of the metal substrate 10 to form a convex texture 12;
S3: machining concave textures 21 matched with the relief textures 12 on the to-be-welded area of the thermoplastic plastic substrate 20 through an ultrasonic vibration head 30 with convex tooth textures;
S4: the relief texture 12 is inserted into the concave texture 21 and the thermoplastic substrate 20 is ultrasonically welded to the metal substrate 10.
Wherein the metal substrate 10 is made of alloy steel, titanium alloy, aluminum alloy or magnesium alloy, and the thermoplastic plastic substrate 20 is made of one or more of polyether ether ketone, polyether ketone, polyethylene, polyvinyl chloride, polypropylene, polyphenyl ether, polyamide, polyphenylene sulfide, polyether imide, nylon, polycarbonate and thermoplastic polyimide; the thickness of the metal substrate 10 and the carbon fiber thermoplastic composite substrate 70 is less than or equal to 5mm.
The invention is characterized in that a plurality of necking grooves 11 are pre-processed on a metal substrate 10, thermoplastic plastics mixed with reinforcements are then clad in the necking grooves 11, the metal substrate is protruded to form convex textures 12, the existence of the necking grooves 11 enables the thermoplastic plastics to have good connectivity with the metal substrate 10, and finally, the convex textures 12 and concave textures 21 on the thermoplastic plastics substrate 20 are matched and then are connected together through ultrasonic welding, so that the ultrasonic welding of the metal substrate 10 and the thermoplastic plastics substrate 20 is essentially the ultrasonic welding between the thermoplastic plastics and the thermoplastic plastics substrate 20, namely, the ultrasonic welding of the dissimilar materials between the metal substrate 10 and the thermoplastic plastics substrate 20 is converted into the ultrasonic welding of the same materials between the thermoplastic plastics and the thermoplastic plastics substrate 20, thereby greatly enhancing the weldability between the thermoplastic plastics substrate 20 and the metal substrate 10, and reducing the power and the process difficulty required by the ultrasonic welding; and the welding defects of local stress concentration, air holes, microcracks and the like caused by unmatched thermodynamic parameters such as specific heat capacity, thermal expansion coefficient and the like during ultrasonic welding of the dissimilar materials can be avoided.
Referring to fig. 1, in step S1, firstly, a region to be welded of a metal substrate 10 is cleaned, and then a multi-time processing method of changing a laser incident angle and cooperating with a plurality of scans is adopted to process a necking groove 11 in the region to be welded of the metal substrate 10, wherein the necking groove 11 satisfies the following geometric conditions:
Wherein, Is the maximum incident angle of the laser, and/>M is the width of the opening of the groove, W is the interval of the groove, H is the depth of the groove, and the scanning times are more than or equal to 3.
In this embodiment, it is ensured that the focal point of the laser remains unchanged, and the laser transmitter is rotated to change the laser incident angle. Obviously, the necking groove 11 may be processed in such a manner that the positive defocus (the laser focus is on the outside of the region to be welded of the metal substrate 10), the negative defocus (the laser focus is on the inside of the region to be welded of the metal substrate 10), or the defocus is zero (the laser focus is on the outside of the region to be welded of the metal substrate 10).
The necking groove 11 processed in the to-be-welded area of the metal substrate 10 can be anchored with thermoplastic plastics to form a dovetail joint, and the reinforcing materials mixed in the thermoplastic plastics can effectively improve the connection strength of the welding area, so that the welding structure of the thermoplastic plastic substrate 20 and the metal substrate 10 has good mechanical property and durability.
In this embodiment, each of the lasers is a nanosecond or picosecond laser.
Referring to fig. 2, step S2 includes the following sub-steps:
S21: placing the powder spreading die 50 provided with the through grooves horizontally above the area to be welded of the metal substrate 10 processed with the necking grooves 11, and keeping the through grooves aligned with the necking grooves 11 one by one;
s22: filling thermoplastic plastic powder mixed with the reinforcement into the through groove of the powder spreading die 50 until the through groove is fully spread and the upper surface of the powder spreading die 50 is higher;
s23: scraping powder higher than the upper surface of the powder spreading die 50, and taking out the powder spreading die 50 vertically upwards;
s24: the region to be welded of the metal substrate 10 is heated until the thermoplastic powder mixed with the reinforcement is melted, and then the heating and cooling are stopped, forming the convex texture of the convex metal substrate 10.
Wherein, the cross section of the through groove of the powder spreading die 50 is trapezoid with narrow upper part and wide lower part, and the geometric conditions thereof are as follows:
250μm≤G≤700μm；
B<A＝M；
K＝W；
wherein G is the depth of the through groove, B is the upper opening width of the through groove, A is the lower opening width of the through groove, and K is the spacing of the through grooves.
The trapezoidal through grooves with narrow upper and wide lower can enable the formed embossment to be trapezoidal, and the connection stability between the thermoplastic plastic and the thermoplastic plastic substrate 20 is improved.
In this example, the particle size of the thermoplastic powder is 500 mesh to 2000 mesh; the reinforcement is one or more of silicon powder, aluminum oxide powder, silicon dioxide powder and carbon fiber powder with the granularity of 500-2000 meshes, and the volume ratio of the reinforcement to the thermoplastic plastic powder is 1:100-10:100.
In this embodiment, the thermoplastic powder is melted to form the thermoplastic.
Referring to fig. 3 and 4, step S3 includes the following sub-steps:
S31: placing an ultrasonic vibration head 30 with a convex tooth texture on the end surface vertically above the area to be welded of the thermoplastic substrate 20, wherein the vibration direction of the ultrasonic vibration head 30 is vertical to the surface of the area to be welded of the thermoplastic substrate 20;
S32: the ultrasonic vibration is started, so that the convex teeth of the ultrasonic vibration head 30 are vertically pressed into the region to be welded of the thermoplastic substrate 20, the ultrasonic vibration head 30 is quickly and vertically lifted up until the pressing depth Z reaches the required depth, and the ultrasonic vibration is stopped, so that concave textures 21 are prepared in the region to be welded of the thermoplastic substrate 20.
Wherein, the geometric parameters of the convex teeth of the ultrasonic vibration head 30 satisfy:
L＝K＝W；
N≥G；
P≥B；
G≤Z≤N；
Wherein: l is the spacing of the convex teeth, N is the height of the convex teeth, beta is the tooth-shaped oblique angle, and P is the tooth top width of the convex teeth.
Referring to fig. 5, step S4 includes the following sub-steps:
s41: overlapping the to-be-welded area of the metal substrate 10 and the to-be-welded area of the thermoplastic plastic substrate 20, horizontally placing the overlapped to-be-welded area on a base of an ultrasonic welding device, and ensuring that the metal substrate 10 is positioned above the thermoplastic plastic substrate 20;
S42: the relief pattern 12 of the area to be welded of the metal substrate 10 is inserted into the concave texture 21 of the area to be welded of the thermoplastic plastic substrate 20, so that the welding area is fully contacted, the heat generated by friction is improved, the melt of the welding area is fully diffused, the welding defects such as stress concentration, air holes and microcracks are reduced, and the welding structure strength is improved;
S43: moving the ultrasonic welding head 40 to the upper part of the area to be welded, and performing ultrasonic welding on the metal substrate 10 and the thermoplastic plastic substrate 20 until the welding is completed; in ultrasonic welding, the metal substrate 10 is positioned above the thermoplastic substrate 20, so that the ultrasonic welding head 40 is directly contacted with the metal substrate 10 to reduce attenuation of ultrasonic waves in the process of propagation, and more energy can be obtained in the welding area.
Example 2:
the embodiment provides a specific example for describing the whole connection method, in the embodiment, 7075-T6 aluminum alloy and Polyetherketoneketone (PEKK) are used as welding substrates, the thicknesses are 2mm, the width of the area to be connected is 25mm, and the length is 25mm, and the method comprises the following steps:
S1: processing a plurality of necking grooves 11 in a region to be welded of an aluminum alloy substrate:
(1) And ultrasonically cleaning the to-be-welded area of the aluminum alloy substrate in acetone.
(2) Selecting laser processing parameters: nanosecond infrared laser is selected, the light spot energy is in Gaussian distribution, the diameter of a focusing light spot is=40 mu m, the pulse width is=200 ns, the frequency is=10 kHz, the average power is=8W, the scanning speed is=100 mm/s, and the scanning times are=3.
(3) The first, second and third processes are performed by adjusting the laser incidence angles to 0 °,10 ° and 20 °, respectively, and then the fourth and fifth processes are performed by adjusting the laser incidence angles to-10 ° and-20 °, the necking groove 11 is obtained by the five processes, at this time, the maximum incidence angle of the laser,The processed trench opening width M was 65 μm, the trench pitch W was 500 μm, and the trench depth H was 130 μm at 20 °.
(4) The region to be welded of the aluminum alloy substrate is processed multiple times to form a plurality of parallel necking grooves 11.
S2: forming convex textures 12 in the to-be-welded area of the aluminum alloy substrate:
(1) The powder spreading die 50 provided with the through groove is placed horizontally above the area to be welded of the aluminum alloy substrate where the necking groove 11 is processed, and the center of the through groove is kept aligned with the center of the necking groove 11.
In the embodiment, the powder spreading die is made of stainless steel, and has a width of 25mm, a length of 25mm and a height of 0.5mm. The geometric parameters of the through groove are as follows: the depth g=500 μm of the through grooves, the upper opening width b=120 μm of the through grooves, the lower opening width a=160 μm of the through grooves, and the pitch k=500 μm of the through grooves.
(2) The polyether ketone powder mixed with the silicon dioxide powder is scattered into the through groove of the powder spreading die 50 until the through groove is full and the upper surface of the powder spreading die 50 is higher. The granularity of the polyether ketone powder is 1000 meshes, the granularity of the silicon dioxide powder is 1000 meshes, and the volume ratio of the silicon dioxide powder to the polyether ketone powder is 5:100.
(3) The powder above the upper surface of the powder spreading die 50 is scraped off and the powder spreading die is taken out vertically.
(4) Heating the to-be-welded area of the aluminum alloy substrate to 450 ℃, stopping heating after the powder is completely melted, and forming convex textures 12 on the to-be-welded area of the aluminum alloy substrate after cooling.
S3: concave textures 21 are formed in the to-be-welded area of the polyether ketone base plate:
(1) The ultrasonic vibration head 30 with the convex tooth textures on the end surface is vertically arranged above the area to be welded of the polyether-ketone substrate, and the vibration direction of the ultrasonic vibration head 30 is vertical to the surface of the area to be welded of the polyether-ketone substrate.
(2) Setting ultrasonic vibration parameters: pressure f1=1 MPa, amplitude u1=90 μm, vibration frequency f1=20 kHz, vibration time t1=0.5 s; then, ultrasonic vibration is started, so that the convex teeth of the ultrasonic vibration head 30 are vertically pressed into the to-be-welded area of the polyether-ketone substrate, the ultrasonic vibration head 30 is quickly and vertically lifted up until the pressing depth Z is 500 mu m, and the ultrasonic vibration is stopped, so that concave textures 21 are prepared in the to-be-welded area of the polyether-ketone substrate.
In this example, the end face of the ultrasonic vibration head was a square 25mm×25mm, and the ultrasonic power was 2000W. The lobe geometry of the ultrasonic vibration head 30 is: the pitch l=500 μm of the teeth, the height n=600 μm of the teeth, the tooth pitch angle β=10°, and the tip width p=160 μm of the teeth.
S4: ultrasonic welding is carried out on the aluminum alloy substrate and the polyether ketone base plate:
(1) And overlapping the to-be-welded area of the aluminum alloy substrate and the to-be-welded area of the polyether ketone-based plate, horizontally placing the overlapping to-be-welded area on a base of an ultrasonic welding device, and ensuring that the aluminum alloy substrate is positioned above the polyether ketone-based plate.
(2) The relief pattern 12 of the area to be welded of the aluminum alloy substrate is inserted into the concave pattern 21 of the area to be welded of the polyetherketoneketone substrate.
(3) The ultrasonic welding head 40 is moved to the upper part of the area to be welded, and ultrasonic welding is carried out on the aluminum alloy substrate and the polyether ketone base plate until the welding is completed, and the microscopic profile of the section of the welding area of the polyether ketone base plate and the aluminum alloy substrate is shown in fig. 6.
In this embodiment, the end face of the ultrasonic welding head is a square with a length of 25mm×25mm, the ultrasonic power is 3000W, and the ultrasonic welding parameters are specifically as follows: pressure f2=1 MPa, amplitude u2=100 μm, vibration frequency f2=25 kHz, vibration time t2=1 s, dwell time t3=0.5 s.
The foregoing description of the preferred embodiments of the invention is not intended to limit the invention to the precise form disclosed, and any such modifications, equivalents, and alternatives falling within the spirit and scope of the invention are intended to be included within the scope of the invention.
Claims (10)
1. A method of connecting a thermoplastic substrate to a metal substrate, comprising the steps of:
S1: processing a plurality of necking grooves in a region to be welded of the metal substrate;
s2: cladding thermoplastic plastics mixed with reinforcements in the necking grooves, wherein the thermoplastic plastics are consistent with the thermoplastic plastic substrate in material, and the thermoplastic plastics are cooled and then protrude out of the metal substrate to form convex textures;
S3: processing concave textures matched with the relief textures in a region to be welded of the thermoplastic plastic substrate through an ultrasonic vibration head with the convex tooth textures;
S4: inserting the convex pattern into the concave pattern, and performing ultrasonic welding on the thermoplastic plastic substrate and the metal substrate.
2. The method of joining a thermoplastic substrate to a metal substrate according to claim 1, wherein in step S1, a multi-process method of varying laser incidence angles in combination with a plurality of scans is used to process a necked-down groove in a region of the metal substrate to be welded, the necked-down groove satisfying the following geometric conditions:
Wherein, Is the maximum incident angle of the laser, and/>M is the width of the opening of the groove, W is the interval of the groove, H is the depth of the groove, and the scanning times are more than or equal to 3.
3. The method of joining a thermoplastic substrate to a metal substrate according to claim 2, wherein the area of the metal substrate to be welded is cleaned prior to processing the neck groove.
4. The method of joining a thermoplastic substrate to a metal substrate according to claim 1, wherein step S2 comprises the sub-steps of:
s21: horizontally placing a powder spreading die provided with through grooves above a region to be welded of the metal substrate with the necking grooves, and keeping the through grooves aligned with the necking grooves one by one;
S22: filling thermoplastic plastic powder mixed with the reinforcement into the through groove of the powder spreading die until the through groove is fully spread and the upper surface of the powder spreading die is higher than the upper surface of the powder spreading die;
S23: scraping powder higher than the upper surface of the powder spreading die, and vertically taking out the powder spreading die upwards;
s24: and heating the area to be welded of the metal substrate until the thermoplastic plastic powder mixed with the reinforcement is melted, stopping heating and cooling, and forming the relief pattern of the protruding metal substrate.
5. The method for connecting a thermoplastic plastic substrate and a metal substrate according to claim 4, wherein the cross section of the through groove of the powder spreading die is trapezoid with narrow upper part and wide lower part, and the geometric condition is as follows:
250μm≤G≤700μm；
B<A＝M；
K＝W；
wherein G is the depth of the through groove, B is the upper opening width of the through groove, A is the lower opening width of the through groove, and K is the spacing of the through grooves.
6. The method of joining a thermoplastic substrate to a metal substrate according to claim 4, wherein the thermoplastic powder has a particle size of 500 mesh to 2000 mesh; the reinforcement is one or more of silicon powder, aluminum oxide powder, silicon dioxide powder and carbon fiber powder with the granularity of 500-2000 meshes, and the volume ratio of the reinforcement to the thermoplastic plastic powder is 1:100-10:100.
7. The method of joining a thermoplastic substrate to a metal substrate according to claim 5, wherein step S3 comprises the sub-steps of:
S31: placing an ultrasonic vibration head with convex tooth textures on the end face vertically above a region to be welded of a thermoplastic plastic substrate;
S32: and starting ultrasonic vibration, so that the convex teeth of the ultrasonic vibration head are vertically pressed into the to-be-welded area of the thermoplastic plastic substrate, quickly and vertically lifting the ultrasonic vibration head until the pressing depth Z reaches the required depth, and stopping ultrasonic vibration, thereby preparing concave textures in the to-be-welded area of the thermoplastic plastic substrate.
8. The method of claim 7, wherein the geometric parameters of the ultrasonic vibration head teeth satisfy:
L＝K＝W；
N≥G；
P≥B；
G≤Z≤N；
Wherein: l is the spacing of the convex teeth, N is the height of the convex teeth, beta is the tooth-shaped oblique angle, and P is the tooth top width of the convex teeth.
9. The method of joining a thermoplastic substrate to a metal substrate according to claim 1, wherein step S4 comprises the sub-steps of:
s41: overlapping the to-be-welded area of the metal substrate and the to-be-welded area of the thermoplastic plastic substrate, horizontally placing the overlapped to-be-welded area on a base of the ultrasonic welding device, and ensuring that the metal substrate is positioned above the thermoplastic plastic substrate;
s42: inserting the relief pattern of the region to be welded of the metal substrate into the concave pattern of the region to be welded of the thermoplastic plastic substrate;
S43: and moving the ultrasonic welding head to the upper part of the area to be welded, and performing ultrasonic welding on the metal substrate and the thermoplastic plastic substrate until the welding is completed.
10. The method for connecting a thermoplastic substrate and a metal substrate according to any one of claims 1 to 9, wherein the thermoplastic substrate is one or more of polyetheretherketone, polyetherketoneketone, polyethylene, polyvinyl chloride, polypropylene, polyphenylene oxide, polyamide, polyphenylene sulfide, polyetherimide, nylon, polycarbonate, and thermoplastic polyimide having a thickness of 5mm or less;
The metal substrate is made of aluminum alloy, titanium alloy, magnesium alloy or steel with the thickness less than or equal to 5mm.
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