CN1557628A - 热塑性树脂基复合材料超声波振动辅助电阻植入焊接方法 - Google Patents

热塑性树脂基复合材料超声波振动辅助电阻植入焊接方法 Download PDF

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CN1557628A
CN1557628A CNA2004100135490A CN200410013549A CN1557628A CN 1557628 A CN1557628 A CN 1557628A CN A2004100135490 A CNA2004100135490 A CN A2004100135490A CN 200410013549 A CN200410013549 A CN 200410013549A CN 1557628 A CN1557628 A CN 1557628A
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welding
composite material
thermoplastic resin
ultrasonic vibration
resin based
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CN1285460C (zh
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闫久春
王晓林
杨士勤
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Harbin Institute of Technology
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Harbin Institute of Technology
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
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    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
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Abstract

热塑性树脂基复合材料超声波振动辅助电阻植入焊接方法，它涉及热塑性树脂基复合材料焊接方法的改进。本发明首先将热塑性树脂基复合材料的搭接接头(3)放置到夹具(1)中，再将加热体(2)放置到被焊热塑性树脂基复合材料的搭接接头(3)中间，将超声波焊头(4)以0.05～0.15MPa的压力压在搭接接头(3)上，将加热体(2)的两端连接到电极(5)上，待焊接界面温度为200～220℃时启动超声波发生控制器(7)使超声波焊头(4)进行振动。本发明综合了电阻焊接加热面积大和超声波焊接加热速率快的优点，不仅缩短了单纯电阻焊接时的焊接时间，降低了焊接界面的残余内应力，而且，减小了“边缘热效应”，提高了焊接接头的力学性能，接头强度大于80％复合材料基体材料强度。

Description

热塑性树脂基复合材料超声波振动辅助电阻植入焊接方法
技术领域：本发明涉及热塑性树脂基复合材料焊接方法的改进。
背景技术：高性能热塑性复合材料具有高强度、高损伤容限、低吸湿和优异的耐环境性能等特点，其应用于航空、航天承力和非承力结构件，对提高减重效率，改善飞行器性能有深远的意义。英国ICI公司、德国BASF公司、美国杜邦公司、氰胺公司等开发的聚醚醚酮(PEEK)、聚酰亚胺(PI)、聚醚酰亚胺(PEI)等高性能热塑性树脂基体，已经被应用于制备先进战斗机及民用机零件。然而，较差的焊接性成为该种材料应用的严重障碍。热塑性树脂基复合材料的公认较为实用的焊接方法，包括体加热(共凝固、热熔化的粘结剂、双树脂结合)，摩擦加热(旋转焊、振动焊、超声波焊)，电磁加热(感应焊、微波焊、电介焊、电阻焊)和双步骤技术(热板焊、热气焊、辐射焊)。研究发现，以上各种焊接方法仍然存在着一定的问题。共凝固是一种理想的连接方法，因为最终的结构没有增加多余的重量，融合线也没有引入异种物质，基本上不需要表面预处理，而且接头强度理论上和母材板的强度一样。并且可以在焊接融合区插入热熔化的热塑性粘结薄膜，用以改善不匹配件间的填充性。经证明，插入非晶态中间层可以减少强度的分散，从而增加了工艺窗口。双树脂粘接或非晶态粘接，需要在热粘接之前将非晶态的热塑性薄膜模铸到以半晶态的热塑性为基体母材板上比如将PEI薄膜涂敷到APC-2板材上。在焊接的过程中，温度应该在PEI的玻璃转换温度(Tg＝215℃)以上以使PEI熔化，但要低于半晶态的PEEK的熔化温度(Tm＝334℃)，以防止连接构件的高温老化。然而，整个件都要加热到熔化温度，这样通常就意味着要设计使用复杂的工装夹具以便在整个工件保持一定的压力，防止熔化。这样，生产时间长，生产成本过高，灵活性很差。在两阶段技术中，加热工具需要在加热和压焊两个阶段间从衬底表面移出。由于焊接的加热过程是在一个单独的步骤内进行的，因而这种方法限制了焊接件的尺寸。加热的时间长度是标准的，因为这决定于聚合物的低热传导率。在加热步骤和压焊步骤中间，表面的温度开始下降，而经历温度峰值的区域位于板材表面的下面。用来使接头凝固的压力在更高温度的内层区域会引起翘曲和流变。旋转焊和振动焊已经广泛用于塑料工业，但是却不太适合于热塑性复合材料的焊接，因为焊接件的相对运动可能会引起微结构的恶化，例如纤维的断裂。微波焊和电介焊可以用于热塑性塑料的连接，但是由于是整体加热，以及多层复合材料能很好的屏蔽微波，使得该方法非常不适合于热塑性复合材料的焊接，尤其是当复合材料是用碳纤维增强的时候。目前公认的三种最适合的焊接方法是超声波焊接、感应焊接和电阻焊接。在这些技术中，只要求焊接面达到熔化温度，这样减小了对结构其他部分的影响。通过连续或扫描的方法可以焊接大尺寸的结构，而且也有在线监视焊接凝固过程的可能性。但是这三种方法在焊接热塑性复合材料时，仍然存在着各种问题。(1)超声波焊接：超声波焊接是热塑性塑料最为常用的焊接方法，其应用方面如软盘、医疗器械、电池外壳和许多汽车零件的焊接等。在超声波焊接过程中，被连接件在压力的作用下紧紧的贴在一起，然后超声波垂直地加到两连接件相互接触区。高频率变化的应力在材料内部产生热量，如果组件设计的正确，就可以使热量通过波的迟滞和摩擦有选择的产生在接触界面上。焊接过程可以在距离焊头小到几分之一毫米大到几厘米的范围内完成，距离越远控制过程越灵敏。在焊接过程中，振动能通常集中在表面的突起处耗散成热量。人为制作的三角形突起，设计在连接件上用以引导熔化。在设计组件的早期阶段应该考虑使其能满足超声波焊接的需要。使用连接层可以避免在超声波焊接过程中使用导能筋。连接层是一种由基体物质制作的中间层，通过降低熔化温度来促使择优熔化。通过采用顺序或扫描或两者同时使用的方法就可以进行大尺寸的焊接。不使用导能筋或也不使用连接层会使焊接过程变得困难重重。对于用连续纤维增强的复合材料，使用超声波进行焊接的主要障碍是难以在复合材料薄板件上制作导能筋，以及为了获得好的连接而需要的较大变形可能会使界面处的纤维破裂。(2)感应焊接：通常聚合物既不导电也没有很高的导磁率，射频场被加到用铁粒子、微米级的氧化铁粒子、不锈钢、陶瓷、铁素体或石墨等填充的热塑性材料的带条上。也可以使用特制的金属网，这种金属网有双重作用，一是产生热量，二是为两个相容的热塑性材料提供机械互锁的地方。针对不同的形状尺寸的接头，需对感应器进行优化。同时用于感应加热的线圈设计是一项重要的工艺。由一个感应线圈产生的磁场是不均匀的，因而会产生不均匀的加热。通过优化金属网感应器的形状重新导向电流的流动方向可以改善温度场的不匀性。通常，感应焊适于焊接细长形状的工件，这是因为线圈的几何形状导致了合理的感应场。(3)电阻植入焊接：电阻植入焊接技术设备简单，方便高效，灵活性大。但是将电阻植入焊应用于热塑性复合材料焊接时存在以下几个问题，一个问题是虽然电阻植入焊可以同时对焊接面进行加热，但是对表面内层树脂加热是通过热传导进行的，由于复合材料中的碳纤维良好的导热性，使热量很快的传到整个复合材料体上，从而导致复合材料发生基体结构的破坏。另一个问题是由于空气导热性差，会造成所谓的“边缘热效应”，即焊接界面边缘处的温度在较长的焊接时间时会大大高于焊接界面内部的温度，从而导致焊接界面熔化的不均匀，产生比较严重的内应力。尽管使用脉冲电阻植入焊缩短了加热时间，减小了由于热传导而导致的过热问题，然而当能量输入增加时，脉冲电阻植入焊会进一步增加焊接界面温度的不均匀性，使工艺窗口变得狭窄。
发明内容：本发明的目的在于提供一种热塑性树脂基复合材料超声波振动辅助电阻植入焊接方法，它具有缩短电阻植入焊接所需的时间，减小边缘热效应，改善半结晶性热塑性材料及其复合材料的焊接性能，超声振动促进扩散缠接，消除残余应力，提高焊接时温度场的集中程度的特点。本发明的方法是：首先将热塑性树脂基复合材料的搭接接头3放置到夹具1中，再将加热体2放置到被焊热塑性树脂基复合材料的搭接接头3中间，将超声波焊头4以0.05～0.15Mpa的压力压在搭接接头3上，将加热体2的两端连接到电极5上，接通电源6，待焊接界面温度为200～220℃时启动超声波发生控制器7，使超声波焊头4进行振动，电阻焊的通电时间为6～10秒，超声波振动时间为3～5秒，加热体2停止通电1～2秒钟后，停止超声波振动，保压3秒钟后，等被焊接头冷却到固态时即可。本发明的焊接过程在大气环境下进行，环境温度以室温为宜，对于吸湿性较大的材料相对湿度应控制在65±5％。本发明综合了电阻焊接加热面积大和超声波焊接加热速度快的优点，不仅缩短了单纯电阻焊接时的焊接时间，降低了焊接界面的残余内应力，而且，减小了“边缘热效应”，提高了焊接接头的力学性能，使接头强度大于80％复合材料基体材料强度。焊接界面接触均匀、一致，有效连接面积≥90％。
附图说明：图1是本发明的焊接原理示意图。
具体实施方式一：(见图1)本实施方式的方法是：首先将热塑性树脂基复合材料的搭接接头3放置到夹具1中，再将加热体2放置到被焊材料的搭接接头3中间，将超声波焊头4以0.05～0.15Mpa的压力压在搭接接头3上，将加热体2的两端连接到电极5上，接通电源6，待焊接界面温度为200～220℃时启动超声波发生控制器7，使超声波焊头4进行振动，电阻焊的通电时间为6～10秒，超声波振动时间为3～5秒，加热体2停止通电1～2秒钟后，停止超声波振动，保压3秒钟后，等被焊接头冷却到固态时即可。本实施方式中所述的加热体2是挂有树脂的不锈钢金属网或碳纤维预浸料。所述超声波振动的振幅为40～60μm。所述电阻焊的电流为10～15安培。所述热塑性树脂基复合材料的搭接接头3是由碳纤维增强制成的，此时搭接接头3内采用碳纤维预浸料的加热体2。
具体实施方式二：本实施方式与具体实施方式一的不同点在于，加热体2采用不挂树脂的不锈钢金属网，焊接时，在不锈钢金属网的上下表面各加入一层母材基体材料制成的薄膜，薄膜的厚度为20～50μm。其它工艺过程及工艺条件与具体实施方式一相同。
具体实施方式三：本实施方式与具体实施方式一、二的不同点在于，在焊接前将焊件的待焊接表面用细砂纸打磨，并用丙酮清洗，细砂纸的粒度为400～600目。其它工艺过程及工艺条件与具体实施方式一、二相同。

Claims (9)

1、热塑性树脂基复合材料超声波振动辅助电阻植入焊接方法，其特征在于首先将热塑性树脂基复合材料的搭接接头(3)放置到夹具(1)中，再将加热体(2)放置到被焊热塑性树脂基复合材料的搭接接头(3)中间，将超声波焊头(4)以0.05～0.15Mpa的压力压在搭接接头(3)上，将加热体(2)的两端连接到电极(5)上，接通电源(6)，待焊接界面温度为200～220℃时启动超声波发生控制器(7)，使超声波焊头(4)进行振动，电阻焊的通电时间为6～10秒，超声波振动时间为3～5秒，加热体(2)停止通电1～2秒钟后，停止超声波振动，保压3秒钟后，等被焊接头冷却到固态时即可。
2、根据权利要求1所述的热塑性树脂基复合材料超声波振动辅助电阻植入焊接方法，其特征在于所述的加热体(2)是挂有树脂的不锈钢金属网或碳纤维预浸料。
3、根据权利要求1所述的热塑性树脂基复合材料超声波振动辅助电阻植入焊接方法，其特征在于所述超声波振动的振幅为40～60μm。
4、根据权利要求1所述的热塑性树脂基复合材料超声波振动辅助电阻植入焊接方法，其特征在于所述电阻焊的电流为10～15安培。
5、根据权利要求1所述的热塑性树脂基复合材料超声波振动辅助电阻植入焊接方法，其特征在于热塑性树脂基复合材料的搭接接头(3)是由碳纤维增强制成的，此时搭接接头(3)内采用碳纤维预浸料的加热体(2)。
6、根据权利要求1所述的热塑性树脂基复合材料超声波振动辅助电阻植入焊接方法，其特征在于采用不挂树脂的不锈钢金属网，焊接时，在不锈钢金属网的上下表面各加入一层母材基体材料制成的薄膜。
7、根据权利要求6所述的热塑性树脂基复合材料超声波振动辅助电阻植入焊接方法，其特征在于薄膜的厚度为20～50μm。
8、根据权利要求1所述的热塑性树脂基复合材料超声波振动辅助电阻植入焊接方法，其特征在于在焊接前将焊件的待焊接表面用细砂纸打磨，并用丙酮清洗。
9、根据权利要求8所述的热塑性树脂基复合材料超声波振动辅助电阻植入焊接方法，其特征在于细砂纸的粒度为400～600目。
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