WO2018176628A1 - 一种超声波无钎剂铝管钎焊方法及装置 - Google Patents

一种超声波无钎剂铝管钎焊方法及装置 Download PDF

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Publication number
WO2018176628A1
WO2018176628A1 PCT/CN2017/086537 CN2017086537W WO2018176628A1 WO 2018176628 A1 WO2018176628 A1 WO 2018176628A1 CN 2017086537 W CN2017086537 W CN 2017086537W WO 2018176628 A1 WO2018176628 A1 WO 2018176628A1
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welded
solder
ultrasonic
tube
pipe
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PCT/CN2017/086537
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English (en)
French (fr)
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陈海燕
赖振民
高攀
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广东工业大学
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Publication of WO2018176628A1 publication Critical patent/WO2018176628A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K1/00—Soldering, e.g. brazing, or unsoldering
    • B23K1/06—Soldering, e.g. brazing, or unsoldering making use of vibrations, e.g. supersonic vibrations

Definitions

  • the invention relates to the field of brazing technology, in particular to an ultrasonic fluxless aluminum tube brazing method.
  • the invention also relates to an ultrasonic fluxless aluminum tube brazing device.
  • aluminum as a material with small specific gravity and good electrical conductivity, is an important way to reduce weight and reduce cost in profile processing.
  • the hardness of aluminum is low and the material is soft.
  • aluminum is generally mixed with other metal materials, or aluminum alloy is directly used. The mixing between different metal materials is generally achieved by welding.
  • aluminum it can generally be completed by friction welding, explosion welding or brazing, and the brazing process is most widely used.
  • Brazing is to use a metal material with a lower melting point than the base material as a brazing material, heating the weldment and the brazing material to a temperature higher than the melting point of the brazing filler metal and lower than the melting temperature of the base metal, and moisturizing the base material with the liquid brazing material to fill the joint gap and A method of interconnecting a base material to achieve a joint weldment.
  • the brazing deformation is small, the joint is smooth and beautiful, and it is suitable for welding precision, complex and components composed of different materials, such as honeycomb structural plates, turbine blades, carbide tools and printed circuit boards.
  • the main problem of aluminum brazing is that a hard and insoluble oxide film is formed on the surface of the aluminum during welding.
  • a mass ratio of solder: flux of 7:1 especially aluminum-zinc alloy and aluminum-magnesium alloy.
  • medium-temperature brazing which is commonly used strong acid.
  • Alkali brazing fluxes such as strontium fluoroaluminate (AlF3-CsF) flux, are expensive, while CsF is very expensive, must be cleaned after welding, and the flux can also pollute the environment. Causes health damage.
  • the present invention provides an ultrasonic fluxless aluminum tube brazing method, comprising:
  • the welding end of the large pipe to be welded and the welded end of the small pipe to be welded are assembled according to a preset gap, and a solder ring is sleeved on the small pipe to be welded;
  • the outer surface of the welded end of the large tube to be welded is pressed by ultrasonic impact while the solder ring is heated and melted.
  • the method further includes:
  • the molten solder is immersed on the outer surface of the soldering end of the small tube to be welded, and specifically includes:
  • the outer surface of the welded end of the tube to be welded is pressed by ultrasonic impact, and the tube to be welded is uniformly rotated circumferentially.
  • the inner surface of the tapered hole of the large pipe to be welded and the tapered surface of the small pipe to be welded are assembled according to a preset gap, the inner surface of the tapered hole of the large pipe to be welded and the tapered surface of the small pipe to be welded
  • the vertical distance between the outer surfaces is in the range of 40 to 400 ⁇ m.
  • the large pipe to be welded and the small pipe to be welded are synchronously rotated at a preset angular velocity.
  • an ultrasonic shock is generated by the ultrasonic vibrating head, and when the outer surface of the welded end of the large pipe to be welded and the small pipe to be welded is impact-impacted, the ultrasonic vibrating head is perpendicular to the large pipe to be welded and to be welded The outer surface of the welded end of the small tube.
  • the invention also provides an ultrasonic fluxless aluminum tube brazing device, comprising:
  • solder bath for holding solder and heating it to melt
  • solder ring for arranging on the small tube to be welded to fill the welded end of the large tube to be welded after melting a gap between the inner surface and the outer surface of the welded end of the tube to be welded;
  • An ultrasonic vibrating head for extruding the outer surface of the welded end of the tube to be welded and the small tube to be welded by ultrasonic impact to break the metal oxide film formed on the welded end of the large tube to be welded and the small tube to be welded;
  • a heater for heating the ultrasonic vibration head to a preset temperature such that the ultrasonic vibration head melts the solder ring when impact-extruding the outer surface of the welded end of the large pipe to be welded.
  • a generator coupled to said ultrasonic vibrating head for generating ultrasonic waves
  • a transducer coupled to said generator for regulating the power and frequency of ultrasonic waves generated thereby, and for said The cooler for cooling and cooling.
  • the heater is disposed around the stem of the ultrasonic vibrating head and is heated by an oxyhydrogen flame.
  • the solder bath includes a solder crucible for holding solder and a heating base for heating the solder, and the solder crucible is specifically in the shape of a triangular prism having an isosceles right triangle in cross section.
  • the ultrasonic flux-free aluminum tube brazing method provided by the invention mainly comprises four steps: immersing the welded end of the small tube to be welded into a solder bath containing molten solder; welding the small tube to be welded The outer surface of the end is immersed with molten solder and forms a solder layer; the soldered end of the large tube to be welded and the soldered end of the small tube to be welded are assembled according to a preset gap, and a solder ring is sleeved on the small tube to be welded; Ultrasonic impact presses the outer surface of the welded end of the large tube to be welded while heating and melting the solder ring.
  • the solder is contained in the solder bath and heated to melt, and then the soldered end of the small tube to be welded is immersed in the solder bath, where the small tube to be welded and the large tube to be soldered are according to Two welded workpieces distinguished by diameter.
  • the second step after the soldered end of the small tube to be welded is immersed in the molten solder, it is surrounded by the molten solder and is isolated from the air, and at this time, a molten solder is plated on the outer surface of the welded end of the small tube to be welded, and A solder layer is formed on the vial to be soldered.
  • the welding is started, and the welded end of the large pipe to be welded and the welded end of the small pipe to be welded are connected and fixed as required, and the gap between the two is ensured to be a clearance fit corresponding to the preset gap, and then A solder ring is then placed over the solder layer of the vial to be soldered.
  • the fourth step through ultrasonic shock Squeezing the outer surface of the welded end of the large pipe to be welded while heating and melting the solder ring.
  • a metal oxide film may appear on the inner surface of the welded end of the large pipe to be welded, and under the impact of ultrasonic waves
  • the metal oxide film is impact-broken to avoid the formation of the metal oxide film, and the impact pressing action of the ultrasonic wave causes the solder ring to melt and then wets rapidly by the capillary wetness of the weld, and rapidly fills the welding of the large pipe to be welded and the small pipe to be welded.
  • the gap at the end is finally completed for high-strength welding.
  • FIG. 2 is a structural view of a specific embodiment of the present invention.
  • FIG. 3 is a schematic view showing a specific welding process of a large pipe to be welded and a small pipe to be welded according to a specific embodiment of the present invention.
  • FIG. 1 is a flowchart of a specific implementation manner provided by the present invention.
  • the ultrasonic fluxless aluminum tube brazing method mainly comprises four steps, namely: immersing the welded end of the small tube 2 to be welded into the solder pool 3 containing molten solder. Soaking molten solder on the outer surface of the welded end of the small tube 2 to be welded and forming a solder layer 10; assembling the welded end of the large tube 1 to be welded and the welded end of the small tube 2 to be welded according to a preset gap, and A solder ring 4 is sleeved on the small tube 2 to be welded; the outer surface of the soldering end of the large tube 1 to be welded is pressed by ultrasonic impact while the solder ring 4 is heated and melted.
  • a sufficient amount of solder may first be loaded into the solder bath 3, and then the solder is heated by the solder pool 3, so that the solder gradually melts and finally forms a molten solder, at which time the solder is sticky. Thick liquid.
  • the tube 2 to be welded can then be compared with the tube 1 to be welded, the difference being the difference in diameter, both of which are metal tubes, and at least one of which is made of aluminum or aluminum alloy, and the other
  • the soldered end of copper, steel, etc. can be immersed in the solder bath 3.
  • the molten solder in the solder pool 3 needs to have a certain depth to ensure that the welded end of the small tube 2 to be welded is completely immersed in the molten solder.
  • a molten solder is immersed on the outer surface thereof to form a solder layer 10, that is, a part of the molten solder is tightly bonded to the welded end of the small tube 2 to be welded. on.
  • This step is mainly used to provide a prerequisite for wettability and caulking ability in the melt flow of the solder ring 4 in the subsequent soldering process. Since the formation of the solder layer 10 is formed in the molten solder, the entire process of isolating the air can effectively prevent the formation of the metal oxide film during the immersion plating.
  • the immersion plating of the solder layer 10 can be completed by ultrasonic shock.
  • the ultrasonic vibrating head 5 can be aligned with the welding end of the small tube 2 to be welded, and the outer surface of the welded end of the small tube 2 to be welded can be pressed by the ultrasonic wave generated by the ultrasonic vibrating head 5 so that the welded end of the small tube 2 to be welded is peripherally
  • the molten solder is polymerized under the impact compression of the ultrasonic wave and adheres to the surface of the small tube 2 to be welded, and the fixed connection of the molten solder to the small tube 2 to be welded is completed on the metallographic structure, and finally the solder layer 10 is formed.
  • the small tube 2 to be soldered can be uniformly rotated in the circumferential direction at a constant angular speed, so that the thickness of the solder layer 10 is uniform and dense.
  • the welding end of the large pipe 1 to be welded is clamped and fixed to the welding end of the small pipe 2 to be welded, and the assembly is carried out according to the preset gap requirements of the two to form a clearance fit that meets the gap requirement.
  • the vertical distance between the inner surface of the tapered hole of the large pipe 1 to be welded and the outer surface of the tapered surface of the small pipe 2 to be welded is generally in the range of 40 to 400 ⁇ m, and the tighter the clearance fit requirement, the smaller the value, and vice versa. Will be waiting After the welding large pipe 1 and the small pipe to be welded 2 are connected, the solder ring 4 is continuously placed on the small pipe 2 to be welded.
  • the solder ring 4 is mainly used for melting into a liquid state in a welding process, flowing and filling a weld bead between the small pipe 2 to be welded and the large pipe 1 to be welded.
  • the inner diameter of the solder ring 4 can be equivalent to the outer diameter of the small tube 2 to be welded, and generally close to the end of the solder layer 10, and also close to the inlet of the weld, and the height thereof is generally to be welded.
  • the outer diameter of the large pipe 1 is equivalent, and its volume is generally set to completely fill the weld between the large pipe 1 to be welded and the small pipe 2 to be welded when it is melted.
  • the welding can be officially started.
  • the outer surface of the welded end of the large pipe 1 to be welded is mainly pressed by ultrasonic impact, and the solder ring 4 is heated and melted.
  • the solder ring 4 is rapidly melted to form a liquid, and is rapidly flowed by the capillary wetting and ultrasonic vibration of the weld, flows into the weld and is quickly filled; and under the impact of the ultrasonic wave,
  • the inner surface of the welded end of the large pipe 1 to be welded is gradually compacted to the outer surface of the welded end of the small pipe 2 to be welded, and the gap between the two is filled with the liquid and the solder layer 10 melted by the solder ring 4, and the large pipe to be welded is to be welded.
  • the metal oxide film formed on the inner surface of the welded end due to high temperature is broken down and peeled off under the impact of ultrasonic waves, and finally incorporated into the molten solder to form a high-strength welded structure after cooling and solidification.
  • the large pipe 1 to be welded and the small pipe to be welded 2 can be synchronously rotated at a predetermined angular velocity, so that the large pipe to be welded is 1 and the small tube 2 to be welded will rotate synchronously during welding, so that the circumferential force of the welded end is uniform, the parameters such as the strength density are dense and uniform, and the welding quality is further enhanced.
  • FIG. 3 is a schematic view showing a specific welding process of the large pipe 1 to be welded and the small pipe to be welded 2 according to a specific embodiment of the present invention.
  • the metal oxide film is impact-broken by the impact of the ultrasonic wave to avoid the formation of the metal oxide film, and the solder ring 4 is melted by the impact pressing of the ultrasonic wave.
  • the capillary wetted by the weld is quickly flowed, and the gap between the welded end of the large pipe 1 to be welded and the small pipe to be welded 2 is quickly filled, and finally high-strength welding is completed.
  • the shape of the large pipe 1 to be welded and the small pipe to be welded 2 can be optimized before the welded end of the small pipe 2 to be welded is immersed in the solder pool 3.
  • the welded end of the large pipe 1 to be welded is flared to form a cone
  • the hole is simultaneously polished to form a tapered surface of the welded end of the small tube 2 to be welded, and the apex angle of the tapered hole and the tapered surface is equal.
  • the ultrasonic vibrating head 5 can be perpendicular to the large tube 1 to be welded and the small tube 2 to be welded. Weld the outer surface of the end.
  • the tube 2 to be soldered can be obliquely inserted into the solder bath 3 at an oblique angle of 45°, and the ultrasonic vibrating head 5 is obliquely inserted into the solder melting direction at an oblique angle of 135°.
  • the ultrasonic vibrating head 5 is made perpendicular to the small tube 2 to be welded.
  • FIG. 2 is a structural diagram of a specific embodiment of the present invention.
  • the embodiment further provides an ultrasonic fluxless aluminum tube brazing device, which mainly comprises a solder bath 3, a solder ring 4, an ultrasonic vibrating head 5 and a heater 6.
  • the solder pool 3 is mainly used for holding solder, and the solder can be heated to melt to form molten solder.
  • the solder bath 3 may include a solder crucible 301 and a heating base 302.
  • the solder crucible 301 is mainly used to hold the solder, and the solder crucible 301 is disposed on the heating base 302.
  • the heating base 302 can heat the solder crucible 301 to heat the solder.
  • the manner in which the small tube 2 to be welded and the ultrasonic vibrating head 5 are obliquely inserted may be employed, and for this purpose, the solder bump 301 may be provided in a triangular prism shape, and the cross section of the triangular prism For isosceles direct triangles.
  • the tube 2 to be soldered may first be inserted into the molten solder along one oblique side of the solder bump 301 and inserted all the way to the bottom end, while the ultrasonic vibrating head 5 may be placed along the solder bump 301.
  • the other oblique side is inserted into the molten solder and is also inserted into the bottom end, so that the vertical relationship between the ultrasonic vibrating head 5 and the small tube 2 to be welded can be conveniently ensured to ensure the ultrasonic impact effect is optimized.
  • the solder ring 4 is mainly used to be placed on the small tube 2 to be welded so as to be melted during welding and flow into the weld to fill it.
  • the material of the solder ring 4 is the same as the material of the molten solder in the solder bath 3, and may be, for example, Sn-20Zn-2Cu-Al or WE53.
  • the ultrasonic vibrating head 5 is mainly used for pressing the outer surface of the welded end of the large pipe 1 to be welded and the small pipe 2 to be welded by ultrasonic impact to break the metal oxide film formed on the surface thereof, and to peel off and fall off.
  • the ultrasonic vibrating head 5 and the molten pool can both be made of titanium alloy or silicon nitride ceramic material, not only heat resistant rot Corrosion, and can avoid the corrosion of the material caused by the corrosion material, and strengthen the solder.
  • the heater 6 is mainly used to heat the ultrasonic vibrating head 5, and after heating it to a preset temperature, the solder ring 4 can be melted and welded.
  • the heater 6 can be disposed around the rod portion of the ultrasonic vibrating head 5, and mainly uses a water-fueled oxyhydrogen flame as a combustion medium, and the heating efficiency is high, overcoming the prior art using the resistance wire heating only It can weld tin solder below 300 °C, heat needs to contact ultrasonic vibrating head, affects ultrasonic propagation, and uses high frequency induction to adhere the coil to the horn, causing some ultrasonic vibration energy to be absorbed.
  • the ultrasonic vibrating head 5 can generally use a non-magnetic titanium alloy or a silicon nitride ceramic material, it is particularly suitable for heating by an oxyhydrogen flame. At the same time, the temperature of the hydrogen-oxygen flame is adjustable, and there are no pollution products such as flue gas and carbon black, and no high-pressure gas cylinder is needed for storage.
  • a generator 7, a transducer 8, and a cooler 9 are additionally provided in this embodiment.
  • the generator 7 is connected to the ultrasonic vibrating head 5, and is mainly used to generate ultrasonic waves, so that the ultrasonic vibrating head 5 generates shock vibration by ultrasonic waves.
  • the transducer 8 is connected to the generator 7 and is mainly used for adjusting the power and frequency of the ultrasonic waves generated by it.
  • the power adjustment range is 0 to 1.2 KW
  • the frequency adjustment range is 0 to 18 KHz.
  • the cooler 9 is mainly used for cooling and cooling the transducer 8 to ensure the normal function of the transducer 8 during high-power operation.
  • the cooler 9 can also be used for rapid cooling of the ultrasonic vibrating head 5 at the same time.

Abstract

一种超声波无钎剂铝管钎焊方法，包括：将待焊小管（2）的焊接端浸入盛装有熔融焊料的焊料熔池（3）中；在待焊小管（2）的焊接端外表面上浸镀熔融焊料并形成焊料层（10）；将待焊大管（1）的焊接端与待焊小管（2）的焊接端按照预设间隙装配，并在待焊小管（2）上套设焊料环（4）；通过超声波冲击挤压待焊大管（1）的焊接端外表面，同时加热焊料环（4）并使其融化。如此，在超声波的冲击作用下，将金属氧化膜冲击破碎，避免金属氧化膜的形成，同时使焊料环（4）融化后利用焊缝的毛细润湿快速流动，并迅速填充焊缝，整个工艺过程中无需使用钎剂，避免钎剂危害，解决了使用钎剂造成的焊接接头腐蚀问题，有利于环保。

Description

一种超声波无钎剂铝管钎焊方法及装置
本申请要求于2017年4月1日提交中国专利局、申请号为201710213731.8、发明名称为“一种超声波无钎剂铝管钎焊方法及装置”的中国专利申请的优先权，其全部内容通过引用结合在本申请中。
技术领域
本发明涉及钎焊技术领域，特别涉及一种超声波无钎剂铝管钎焊方法。本发明还涉及一种超声波无钎剂铝管钎焊装置。
背景技术
随着中国机械工业的发展，越来越多的金属加工制造工艺得到开发利用。
其中，铝作为一种比重小和导电性能良好的材料，是型材加工工艺中减轻重量和降低成本的重要途径。但是铝的硬度较低，材质偏软，为此一般将铝材与其余金属材质混合使用，或者直接使用铝合金。不同金属材质之间的混合使用一般通过焊接实现，对于铝材而言，一般可通过摩擦焊、爆炸焊或钎焊完成，其中钎焊工艺的应用最为广泛。
钎焊是采用比母材熔点低的金属材料作钎料，将焊件和钎料加热到高于钎料熔点且低于母材熔化温度，利用液态钎料润湿母材，填充接头间隙并与母材相互扩散实现连接焊件的方法。钎焊变形小，接头光滑美观，适合于焊接精密、复杂和由不同材料组成的构件，如蜂窝结构板、透平叶片、硬质合金刀具和印刷电路板等。
目前，铝钎焊的主要难题是在焊接时铝材表面会形成硬而难溶的氧化膜。传统的钎剂助焊技术中，一般需要以焊料∶钎剂为7∶1的质量配比使用，特别是铝锌合金和铝镁合金，由于其熔点较低，需要配合中温钎焊常用强酸强碱类钎焊剂，如氟铝酸铯(AlF3-CsF)钎剂等，其消耗巨大，而CsF成本价格非常高，焊后还要加以清洗，并且钎剂还会对环境造成污染，对人员造成健康伤害。
因此，如何在铝管钎焊过程中避免金属氧化物的形成和钎剂的危害，是本领域技术人员亟待解决的技术问题。
发明内容
本发明的目的是提供一种超声波无钎剂铝管钎焊方法，能够在铝管钎焊过程中避免金属氧化物的形成和钎剂的危害。本发明的另一目的是提供一种超声波无钎剂铝管钎焊装置。
为解决上述技术问题，本发明提供一种超声波无钎剂铝管钎焊方法，包括：
将待焊小管的焊接端浸入盛装有熔融焊料的焊料熔池中；
在所述待焊小管的焊接端外表面上浸镀熔融焊料并形成焊料层；
将待焊大管的焊接端与所述待焊小管的焊接端按照预设间隙装配，并在所述待焊小管上套设焊料环；
通过超声波冲击挤压所述待焊大管的焊接端外表面，同时加热所述焊料环并使其融化。
优选地，在将所述待焊小管的焊接端浸入所述焊料熔池之前，还包括：
将所述待焊大管的焊接端扩口形成锥孔，同时将所述待焊小管的焊接端外表面打磨形成锥面，并使所述锥孔的顶角与所述锥面的顶角相等。
优选地，在所述待焊小管的焊接端外表面上浸镀熔融焊料，具体包括：
通过超声波冲击挤压所述待焊小管的焊接端外表面，并同时周向均匀转动所述待焊小管。
优选地，将所述待焊大管的焊接端与所述待焊小管的焊接端按照预设间隙装配时，使所述待焊大管的锥孔内表面与所述待焊小管的锥面外表面间的垂直距离处于40～400μm内。
优选地，通过超声波冲击挤压所述待焊大管的焊接端外表面时，以预设角速度同步旋转所述待焊大管和待焊小管。
优选地，通过超声振动头产生超声波冲击，且在冲击挤压所述待焊大管和待焊小管的焊接端外表面时，使所述超声振动头垂直于所述待焊大管和待焊小管的焊接端外表面。
本发明还提供一种超声波无钎剂铝管钎焊装置，包括：
焊料熔池，用于盛装焊料并将其加热至熔融；
焊料环，用于套设在待焊小管上，以在熔融后填补待焊大管的焊接端 内表面与所述待焊小管的焊接端外表面间的缝隙；
超声振动头，用于通过超声波冲击挤压所述待焊大管和待焊小管的焊接端外表面，以破碎所述待焊大管和待焊小管的焊接端上形成的金属氧化膜；
加热器，用于加热所述超声振动头至预设温度，以使所述超声振动头在冲击挤压所述待焊大管的焊接端外表面时使所述焊料环熔融。
优选地，还包括与所述超声振动头相连、用于产生超声波的发生器，与所述发生器相连、用于调节其产生的超声波的功率和频率的换能器，以及用于对所述换能器进行散热降温的冷却器。
优选地，所述加热器环绕设置在所述超声振动头的杆部，且通过氢氧焰对其进行加热。
优选地，所述焊料熔池包括用于盛装焊料的焊料坩埚和用于对其进行加热的加热底座，且所述焊料坩埚具体呈横截面为等腰直角三角形的三棱柱状。
本发明所提供的超声波无钎剂铝管钎焊方法，主要包括四个步骤，分别为：将待焊小管的焊接端浸入盛装有熔融焊料的焊料熔池中；在所述待焊小管的焊接端外表面上浸镀熔融焊料并形成焊料层；将待焊大管的焊接端与所述待焊小管的焊接端按照预设间隙装配，并在所述待焊小管上套设焊料环；通过超声波冲击挤压所述待焊大管的焊接端外表面，同时加热所述焊料环并使其融化。其中，在第一步中，在焊料熔池中盛装焊料，并将其加热至融化，然后将待焊小管的焊接端浸入焊料熔池中，此处待焊小管与待焊大管是根据其直径大小而区分的两个焊接工件。在第二步中，待焊小管的焊接端浸入熔融焊料中后，即被熔融焊料所包围，并且与空气隔绝，此时在待焊小管的焊接端的外表面上镀上一层熔融焊料，并在待焊小管上形成焊料层。在此过程中，由于待焊小管的焊接端沉浸在熔融焊料中，因此可以避免氧气与其外表面相接触，进而显著地避免金属氧化物的形成。在第三步中，开始焊接，将待焊大管的焊接端与待焊小管的焊接端按照要求接驳并固定，并保证两者之间的缝隙间距为符合预设间隙的间隙配合，然后再在待焊小管的焊料层上套设焊料环。在第四步中，通过超声波冲击 挤压待焊大管的焊接端外表面，同时加热焊料环并使其融化，其中，加热焊料环时，待焊大管的焊接端内表面可能出现金属氧化膜，而在超声波的冲击作用下，将金属氧化膜冲击破碎，避免金属氧化膜的形成，同时超声波的冲击挤压作用使焊料环融化后利用焊缝的毛细润湿快速流动，并迅速填充待焊大管和待焊小管的焊接端的缝隙，最终完成高强度焊接。并且整个工艺过程中无需使用钎剂，焊后无需清理，能够有效避免钎剂在生产环节和焊接过程产生的环境污染和人员伤害问题，解决了使用钎剂造成的焊接接头腐蚀问题，有环境保护和节约成本的重大意义。
附图说明
为了更清楚地说明本发明实施例或现有技术中的技术方案，下面将对实施例或现有技术描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅仅是本发明的实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据提供的附图获得其他的附图。
图1为本发明所提供的一种具体实施方式的流程图；
图2为本发明所提供的一种具体实施方式的结构图；
图3为本发明所提供的一种具体实施方式中待焊大管和待焊小管的具体焊接过程示意图。
其中，图2—图3中：
待焊大管—1，待焊小管—2，焊料熔池—3，焊料坩埚—301，加热底座—302，焊料环—4，超声振动头—5，加热器—6，发生器—7，换能器—8，冷却器—9，焊料层—10。
具体实施方式
下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
请参考图1，图1为本发明所提供的一种具体实施方式的流程图。
在本发明所提供的一种具体实施方式中，超声波无钎剂铝管钎焊方法主要包括四个步骤，分别为：将待焊小管2的焊接端浸入盛装有熔融焊料的焊料熔池3中；在所述待焊小管2的焊接端外表面上浸镀熔融焊料并形成焊料层10；将待焊大管1的焊接端与所述待焊小管2的焊接端按照预设间隙装配，并在所述待焊小管2上套设焊料环4；通过超声波冲击挤压所述待焊大管1的焊接端外表面，同时加热所述焊料环4并使其融化。
其中，在第一步中，首先可将足量的焊料盛装进焊料熔池3中，然后通过焊料熔池3对焊料进行加热，使得焊料逐渐融化，并最终形成熔融焊料，此时焊料为粘稠的液体状。之后即可将待焊小管2——与待焊大管1是相对概念，其区别为直径的不同，两者均为金属管，且其中至少一者为铝材或铝合金材质，而另一者可为铜、钢等——的焊接端浸入焊料熔池3中。为隔绝空气，避免氧气渗入出现氧化效果，焊料熔池3中的熔融焊料需具有一定深度，以保证待焊小管2的焊接端完全沉浸到熔融焊料中。
在第二步中，当待焊小管2的焊接端浸入熔融焊料后，在其外表面上浸镀一层熔融焊料并形成焊料层10，即将部分熔融焊料紧密结合到待焊小管2的焊接端上。此步骤主要用于为后续的焊接工序中焊料环4的熔融流动时的润湿性和填缝能力提供先决条件。由于焊料层10的形成是在熔融焊料中形成，因此全程隔绝空气，可有效避免在浸镀过程中形成金属氧化膜。
具体的，在本步骤中，可通过超声波冲击的方式完成焊料层10的浸镀。例如，可将超声振动头5对准待焊小管2的焊接端，并通过超声振动头5产生的超声波冲击挤压待焊小管2的焊接端外表面，使得待焊小管2的焊接端外围的熔融焊料在超声波的冲击挤压作用下聚合并紧贴在待焊小管2的表面上，在金相结构上完成熔融焊料与待焊小管2的固定连接，最终形成焊料层10。并且，在浸镀焊料层10的过程中，可同时周向均匀转动待焊小管2，使其按一定角速度匀速转动，如此可保证焊料层10的厚度均匀致密。
在第三步中，将待焊大管1的焊接端与待焊小管2的焊接端装夹固定，具体按照两者的预设间隙要求进行装配，形成符合间隙要求的间隙配合，此处，待焊大管1的锥孔内表面与待焊小管2的锥面外表面间的垂直距离一般处于40～400μm内，间隙配合要求越紧，该值越小，反之亦然。在将待 焊大管1和待焊小管2均接驳好后，继续在待焊小管2上套设焊料环4。该焊料环4主要用于在焊接工序中熔融成液态，流动并填充待焊小管2与待焊大管1之间的焊缝。具体的，该焊料环4的内径可与待焊小管2的外径相当，并且一般紧贴着焊料层10的端部，同时也紧贴着焊缝的入口，而其高度一般可与待焊大管1的外径相当，其体积一般设置为当其融化后完全填满待焊大管1与待焊小管2之间的焊缝。
在第四步中，可正式开始进行焊接，本步骤中主要通过超声波冲击挤压待焊大管1的焊接端外表面，同时对焊料环4进行加热，并使其融化。如此，在高温的作用下，焊料环4迅速融化形成液体，并利用焊缝的毛细润湿和超声振动作用进行快速流动，流入到焊缝中并迅速填满；同时在超声波的冲击作用下，待焊大管1的焊接端内表面逐渐压实待焊小管2的焊接端外表面，两者之间的缝隙被焊料环4熔化后的液体和焊料层10填满，而在待焊大管1的焊接端内表面上可能由于高温而形成的金属氧化膜，则在超声波的冲击作用下破碎分解并剥落，最终融入到熔融焊料中，在冷却凝固后形成高强度焊接结构。同时，优选地，在本步骤中，通过超声波冲击挤压待焊大管1的焊接端外表面时，可以预设的角速度同步旋转待焊大管1和待焊小管2，如此待焊大管1和待焊小管2在焊接时将同步旋转，可使焊接端的周向受力均匀，强度密度等参数致密均匀，焊接质量得到进一步增强。
如图3所示，图3为本发明所提供的一种具体实施方式中待焊大管1和待焊小管2的具体焊接过程示意图。
因此，本实施例所提供的超声波无钎剂铝管钎焊方法，通过超声波的冲击将金属氧化膜冲击破碎，避免金属氧化膜的形成，同时由于超声波的冲击挤压作用使焊料环4融化后利用焊缝的毛细润湿快速流动，并迅速填充待焊大管1和待焊小管2的焊接端的缝隙，最终完成高强度焊接。并且整个工艺过程中无需使用钎剂，焊后无需清理，能够有效避免钎剂在生产环节和焊接过程产生的环境污染和人员伤害问题，解决了使用钎剂造成的焊接接头腐蚀问题，有环境保护和节约成本的重大意义。
另外，在将待焊小管2的焊接端浸入焊料熔池3之前，还可对待焊大管1和待焊小管2的形状做优化。具体的，可将待焊大管1的焊接端扩口形成锥 孔，同时将待焊小管2的焊接端外表面打磨形成锥面，并使该锥孔和锥面的顶角相等。如此设置，当进行焊接工艺时，待焊大管1和待焊小管2之间所形成的焊缝将具有一定角度的倾斜，如此有利于焊料环4熔化后在焊缝中的迅速流动。
进一步的，在通过超声振动头5产生超声波冲击挤压待焊大管1和待焊小管2的焊接端外表面时，可使超声振动头5垂直于待焊大管1和待焊小管2的焊接端外表面。比如，在浸镀焊料层10时，可将待焊小管2以倾斜45°角的方式斜插入焊料熔池3中，同时将超声振动头5以倾斜135°角的方式反方向斜插入焊料熔池3中，使得超声振动头5垂直于待焊小管2。
如图2所示，图2为本发明所提供的一种具体实施方式的结构图。
本实施例还提供一种超声波无钎剂铝管钎焊装置，主要包括焊料熔池3、焊料环4、超声振动头5和加热器6。
其中，焊料熔池3主要用于盛装焊料，并且可对焊料进行加热，使其融化形成熔融焊料。具体的，该焊料熔池3可包括焊料坩埚301和加热底座302。其中焊料坩埚301主要用于盛装焊料，而焊料坩埚301设置在加热底座302上，加热底座302可对焊料坩埚301进行加热，从而加热焊料。此外，考虑到在浸镀焊料层10时，可采用斜插待焊小管2和超声振动头5的方式，为此，还可将焊料坩埚301设置为三棱柱状，并且该三棱柱的横截面为等腰直接三角形。如此，当浸镀焊料层10时，可首先将待焊小管2沿着焊料坩埚301的一条斜边插入到熔融焊料中，并且一直插入到底端，同时可将超声振动头5沿着焊料坩埚301的另一条斜边插入到熔融焊料中，同样一直插入到底端，如此即可方便地保证超声振动头5与待焊小管2的垂直关系，保证超声波的冲击效果最佳化。
焊料环4主要用于套设在待焊小管2上，以便在焊接时融化并流入焊缝中将其填满。此处优选的，该焊料环4的材质与焊料熔池3中的熔融焊料的材质相同，比如可均为Sn-20Zn-2Cu-Al或WE53等。
超声振动头5主要用于通过超声波冲击挤压待焊大管1和待焊小管2的焊接端外表面，以破碎其表面形成的金属氧化膜，并使其剥离、脱落。并且超声振动头5和熔池坩埚可均采用钛合金或氮化硅陶瓷材料，不仅耐热腐 蚀，而且能够避免溶蚀材料对焊料造成污染，并对焊料起到强化作用。
加热器6主要用于对超声振动头5进行加热，而将其加热至预设温度后即可将焊料环4融化并进行焊接。具体的，该加热器6可环绕设置在超声振动头5的杆部位置，并且主要采用以水为燃料的氢氧焰作为燃烧介质，加热效率高，克服了现有技术中利用电阻丝加热只能焊接300℃以下锡焊料、加热需要接触超声震动头、影响超声传播、使用高频感应需要将线圈与变幅杆相粘连而导致部分超声振动能量被吸收等问题。而且由于超声振动头5一般可使用非磁性钛合金或氮化硅陶瓷材料，因此尤其适用于氢氧焰进行加热。同时氢氧火焰温度可调，没有烟气、炭黑等污染产物，无需高压气瓶储存。
另外，本实施例中还增设了发生器7、换能器8和冷却器9。其中，发生器7与超声振动头5相连，主要用于产生超声波，使得超声振动头5通过超声波产生冲击振动。换能器8与发生器7相连，主要用于调节其产生的超声波的功率和频率，比如功率调节范围为0～1.2KW，频率调节范围为0～18KHz。而冷却器9主要用于对换能器8进行散热降温，保证换能器8在大功率运行时的正常功能，当然，该冷却器9也可以同时用于为超声振动头5快速降温。
对所公开的实施例的上述说明，使本领域专业技术人员能够实现或使用本发明。对这些实施例的多种修改对本领域的专业技术人员来说将是显而易见的，本文中所定义的一般原理可以在不脱离本发明的精神或范围的情况下，在其它实施例中实现。因此，本发明将不会被限制于本文所示的这些实施例，而是要符合与本文所公开的原理和新颖特点相一致的最宽的范围。

Claims (10)

  1. 一种超声波无钎剂铝管钎焊方法，其特征在于，包括：
    将待焊小管的焊接端浸入盛装有熔融焊料的焊料熔池中；
    在所述待焊小管的焊接端外表面上浸镀熔融焊料并形成焊料层；
    将待焊大管的焊接端与所述待焊小管的焊接端按照预设间隙装配，并在所述待焊小管上套设焊料环；
    通过超声波冲击挤压所述待焊大管的焊接端外表面，同时加热所述焊料环并使其融化。
  2. 根据权利要求1所述的超声波无钎剂铝管钎焊方法，其特征在于，在将所述待焊小管的焊接端浸入所述焊料熔池之前，还包括：
    将所述待焊大管的焊接端扩口形成锥孔，同时将所述待焊小管的焊接端外表面打磨形成锥面，并使所述锥孔的顶角与所述锥面的顶角相等。
  3. 根据权利要求2所述的超声波无钎剂铝管钎焊方法，其特征在于，在所述待焊小管的焊接端外表面上浸镀熔融焊料，具体包括：
    通过超声波冲击挤压所述待焊小管的焊接端外表面，并同时周向均匀转动所述待焊小管。
  4. 根据权利要求3所述的超声波无钎剂铝管钎焊方法，其特征在于，将所述待焊大管的焊接端与所述待焊小管的焊接端按照预设间隙装配时，使所述待焊大管的锥孔内表面与所述待焊小管的锥面外表面间的垂直距离处于40～400μm内。
  5. 根据权利要求4所述的超声波无钎剂铝管钎焊方法，其特征在于，通过超声波冲击挤压所述待焊大管的焊接端外表面时，以预设角速度同步旋转所述待焊大管和待焊小管。
  6. 根据权利要求5所述的超声波无钎剂铝管钎焊方法，其特征在于，通过超声振动头产生超声波冲击，且在冲击挤压所述待焊大管和待焊小管的焊接端外表面时，使所述超声振动头垂直于所述待焊大管和待焊小管的焊接端外表面。
  7. 一种超声波无钎剂铝管钎焊装置，其特征在于，包括：
    焊料熔池，用于盛装焊料并将其加热至熔融；
    焊料环，用于套设在待焊小管上，以在熔融后填补待焊大管的焊接端内表面与所述待焊小管的焊接端外表面间的缝隙；
    超声振动头，用于通过超声波冲击挤压所述待焊大管和待焊小管的焊接端外表面，以破碎所述待焊大管和待焊小管的焊接端上形成的金属氧化膜；
    加热器，用于加热所述超声振动头至预设温度，以使所述超声振动头在冲击挤压所述待焊大管的焊接端外表面时使所述焊料环熔融。
  8. 根据权利要求7所述的超声波无钎剂铝管钎焊装置，其特征在于，还包括与所述超声振动头相连、用于产生超声波的发生器，与所述发生器相连、用于调节其产生的超声波的功率和频率的换能器，以及用于对所述换能器进行散热降温的冷却器。
  9. 根据权利要求8所述的超声波无钎剂铝管钎焊装置，其特征在于，所述加热器环绕设置在所述超声振动头的杆部，且通过氢氧焰对其进行加热。
  10. 根据权利要求9所述的超声波无钎剂铝管钎焊装置，其特征在于，所述焊料熔池包括用于盛装焊料的焊料坩埚和用于对其进行加热的加热底座，且所述焊料坩埚具体呈横截面为等腰直角三角形的三棱柱状。
PCT/CN2017/086537 2017-04-01 2017-05-31 一种超声波无钎剂铝管钎焊方法及装置 WO2018176628A1 (zh)

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