WO2023005188A1 - 一种铝合金药芯焊丝及其制备方法 - Google Patents

一种铝合金药芯焊丝及其制备方法 Download PDF

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WO2023005188A1
WO2023005188A1 PCT/CN2022/075863 CN2022075863W WO2023005188A1 WO 2023005188 A1 WO2023005188 A1 WO 2023005188A1 CN 2022075863 W CN2022075863 W CN 2022075863W WO 2023005188 A1 WO2023005188 A1 WO 2023005188A1
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powder
content
aluminum alloy
welding wire
metal
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French (fr)
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赵玉涛
苗畅
怯喜周
杜成超
曹睿
徐壮壮
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Jiangsu University
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Jiangsu University
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Priority to US18/008,455 priority patent/US12042885B1/en
Priority to GB2218345.3A priority patent/GB2609380B/en
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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
    • 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°C
    • B23K35/286—Al as the principal constituent
    • B23K35/288—Al as the principal constituent with Sn or Zn
    • 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
    • B23K35/40—Making wire or rods for soldering or welding

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  • the invention belongs to the technical field of aluminum alloy flux-cored welding wire, and relates to an aluminum alloy flux-cored welding wire and a preparation method thereof, in particular to a flux-cored welding wire filled with mixed salt and rare earth for welding 7XXX aluminum alloys and a preparation method thereof.
  • Aluminum is the most abundant metal element in the earth's crust. With the continuous improvement of productivity, aluminum alloy has become the most widely used material after steel. In recent years, due to its advantages such as low density, low melting temperature, good thermal conductivity and plasticity, and low cost, it has been widely used in aerospace, military industry, rail vehicles, pressure vessels and other fields. 7XXX series aluminum alloy, as an ultra-high-strength, heat-treatable and strengthened aluminum alloy, has been widely used in the aerospace field, for example: 7085 aluminum alloy has been applied to the wing spar and wing rib of A380, Boeing, Airbus and other large aircraft; 7N01 has been widely used in the field of high-speed rail tracks.
  • Chinese patent CN11015013A discloses a flux-cored wire reinforced with micro-nano particles for welding 2A12 high-strength aluminum alloys, which suppresses the weld zone and fusion zone by adding micro-nano particles such as TiC, TiN, SiC, and ZrC to the flux-cored wire Grain growth and pinning of dislocations to increase the strength of welded joints; by refining the second phase and dendrites to compensate for the strain caused by the solidification process and reduce the tendency of hot cracking.
  • micro-nano particles such as TiC, TiN, SiC, and ZrC
  • the present invention organically combines the flux-cored welding wire technology and the in-situ nano-particle reinforcement mechanism, and designs and prepares a flux-cored welding wire filled with mixed salt and rare earth for welding 7XXX aluminum alloys.
  • There are serious problems such as serious crack tendency, burning loss of alloying elements, coarse structure and grain, and serious decline in joint performance.
  • the aluminum alloy flux-cored welding wire designed and prepared by the present invention can increase the adjustment range of the aluminum alloy weld composition by adjusting the mixed salt ratio in the flux core formula, realize the optimization of the microstructure and performance of the 7XXX aluminum alloy weld, and improve the Weld joint strength.
  • Using the welding wire of the invention can significantly reduce the thermal cracking tendency of the weld metal while ensuring that the chemical composition, mechanical properties and corrosion resistance of the weld metal meet the relevant requirements, and obtain a welded joint with beautiful shape, high strength and excellent performance.
  • the present invention uses mixed salt as the flux-cored wire filler, and directly induces the mixed salt and the welding base metal to form in-situ nanoparticles through welding heat.
  • This method not only reduces the production cost of the welding wire, but also enhances the good wettability of the particles and the base metal in situ It better solves the problem of combining the added particles with the base metal.
  • the addition of rare earth elements has a significant grain refinement effect, which provides a new idea for the selection of flux-cored wires for 7XXX aluminum alloy welding.
  • the invention innovation point of this patent is a significant grain refinement effect.
  • a flux-cored welding wire filled with mixed salt and rare earth for welding 7XXX aluminum alloys which is characterized in that 1070 semi-hard pure aluminum strip is used as the outer skin, and the filling rate of the welding wire is 20%- 30%, that is, the mass of the powder accounts for 20-30% of the mass of the flux-cored wire.
  • the medicinal powder is prepared according to the mass percentage of the following components, the total mass percentage is 100%, and the mass percentage of each component in the medicinal powder is: the content of metal Zn powder is 4.5% to 8.0%, the content of metal Mg powder is 1.2% to 3.5%, and the content of metal Cu The powder content is 0.5%-2.5%, the metal Mn powder content is 0.04%-0.5%, the mixed salt powder content is 5%-30%, the rare earth powder content is 0.1%-1.0%, and the balance is pure aluminum powder.
  • the above mixed salt powder includes two kinds of K 2 ZrF 6 and KBF 4 , both of which are white powder. Before use, the powder needs to be ground to 200 mesh. There is a certain proportional relationship between the amount of K 2 ZrF 6 and KBF 4 , and the mass ratio is 0.86 ⁇ 1.12:1.
  • the above-mentioned rare earth powder is a composite additive of Sc, Er, Sc and Zr or a composite additive of Er and Zr.
  • the addition method is: add Sc and Er elements alone or mix them in the following mass ratio: compound addition of Sc and Zr, wherein the mass ratio of Sc and Zr is 2:1; compound addition of Er and Zr, wherein the mass ratio of Er and Zr is 2 :1.
  • Rare earth powder is added in the form of high-purity powder, which is spherical or nearly spherical, with a particle size of 150-250 ⁇ m, a mass purity of Sc and Er of 99.9% to 99.99%, a mass purity of Zr of 99.5% to 99.8%, and an average oxygen content. less than 50ppm.
  • the amount of Zn powder, Mg powder, Cu powder, and Mn powder added above matches the composition of the welding base metal, and different content is added according to the base metal.
  • Cu and Mn are in accordance with the standard Add 1.1 to 1.3 times the content of Cu and Mn; add 1.3 to 1.5 times the standard Zn and Mg content in the base metal grade for Zn and Mg.
  • the weight percentage of mixed salt powder is 14%-17%, and the mass ratio of K 2 ZrF 6 and KBF 4 is preferably 0.94:1.
  • the preferred addition weight percentage is 0.4% to 0.7%, and when the rare earth Er powder is added alone, the preferred addition weight percentage is 0.3% to 0.6%; Sc and Zr composite rare earth powder or Er and Zr composite When the rare earth powder is mixed and added, the optimal weight percentage of Sc or Er is 0.3%, and the optimal weight percentage of Zr is 0.2%.
  • the Zn powder, Mg powder, Cu powder, Mn powder and other metal powders are added in the form of high-purity metal powder with a mass purity greater than 99.9%; the metal powder is spherical or nearly spherical, the powder particle size is 150-250 ⁇ m, and the oxygen content is lower than 50ppm.
  • the flux-cored filler wire of the present invention is produced by conventional flux-cored wire forming technology.
  • the preparation method of the flux-cored welding wire filled with mixed salt and rare earth for 7XXX aluminum alloy welding as above is characterized in that:
  • the 1070 semi-hard pure aluminum strip with a width of 10-16mm and a thickness of 0.6-1.0mm is used as the outer skin of the filler wire.
  • the pure aluminum strip is cleaned of the oxide film on the upper surface with a scraper, and then rolled into a U-shaped groove for filling.
  • the weight of the powder is 20-30% of the weight of the welding wire, after closing the U-shaped groove, pass through the wire drawing dies with different diameters one by one, draw and reduce the diameter one by one, and clean the surface of the welding wire to obtain the welding wire
  • the finished product has a diameter of 0.8 to 3.0mm.
  • the mixed salt and rare earth-filled flux-cored wire used for welding 7XXX aluminum alloys of the present invention is used for welding 7XXX aluminum alloys.
  • the welding methods include but are not limited to argon tungsten arc welding and gas metal arc welding. Placed in the gap or groove of two plates to be connected, the shielding gas is high-purity argon with a purity greater than 99.9%, and the welding slag on the surface is removed with a steel wire brush or copper wire brush after welding.
  • the components and functions of the flux-cored wire used are as follows:
  • Mg It is beneficial to increase the hardness of the weld without significantly reducing the plasticity
  • Zn Form MgZn 2 phase with Mg element, play a role of dispersion strengthening, and produce obvious strengthening effect on the alloy;
  • Mn plays the role of microalloying and strengthening and toughening, reduces the corrosion sensitivity of welds, especially improves the resistance to stress corrosion cracking;
  • Rare earth metals promote heterogeneous nucleation, refine grains, easily promote hydrogen to form stable compounds and inhibit the generation of hydrogen pores;
  • Zr reacts with rare earth to form a secondary phase of double-layer structure, which plays a role of dispersion strengthening and improves the strength of the weld;
  • the action mode and mechanism of mixed salt powder are as follows:
  • the reaction can proceed spontaneously from 718.1K (445°C) to 1318K (1045°C), that is, the reaction proceeds spontaneously in the molten state of the welded aluminum alloy ( ⁇ 660°C).
  • the ZrB 2 ceramic particles of the reaction product are nanoscale and fine grained; they have a good semi-coherent relationship with Al and the interface between the two phases is clean and pollution-free.
  • the generation of in - situ ZrB2 particles in the weld can effectively inhibit the growth of dendrites and refine the grains, thereby improving the performance of the joint ; in addition, ZrB2 particles can play the role of pinning dislocations and preventing dislocation movement , improve joint strength.
  • the filler wire for high-strength aluminum alloy of the present invention adopts 99.99% high-purity Ar gas as the shielding gas, has good welding shape, no defects such as protrusions and undercuts, and various properties of the weld metal meet engineering requirements.
  • the aluminum alloy flux-cored wire filled with mixed salt and rare earth is easy to process and form, low in cost, simple, convenient, efficient, good in adaptability and easy to popularize in operation process, and solves the problem of coarse grain structure and thermal crack sensitivity during welding of 7XXX aluminum alloys.
  • the problem of joint softening has very good market application value.
  • Fig. 1 represents and utilizes flux-cored wire welding aluminum alloy schematic diagram of the present invention
  • Fig. 2 shows the XRD pattern of ZrB 2 particles generated under the action of the flux-cored welding wire of the present invention.
  • Fig. 3 shows the SEM image of ZrB 2 particles generated under the action of the flux-cored welding wire of the present invention.
  • the filling rate of the welding wire in the following examples is 20-30%.
  • the metal powder includes metal Mg powder, metal Zn powder, metal Mn powder, metal Cu powder, rare earth (Sc or Er) powder or (Sc, Zr), (Er, Zr) mixed powder, pure Al powder, and the particle size of the powder is 150-250 ⁇ m; mixed salt powder includes K 2 ZrF 6 and KBF 4 , both of which are white powder. After the above powders are uniformly mixed by machinery, they are dried by heating at 200°C for 2 hours in a vacuum electric furnace.
  • Table 1 indicates that the filler core wire with a suitable diameter is selected according to the thickness of the base metal.
  • the composition of the sheath and drug core is as follows:
  • the filling rate of welding wire is 20%. 99.99% pure argon is used as shielding gas during welding.
  • the composition of the sheath and drug core is as follows:
  • the chemical composition (weight %) of medicine core is metal Zn powder content 5.5%, metal Mg powder content 2.3%, metal Cu powder content 1.4% , metal Mn powder content 0.3%, mixed salt powder content 15%, wherein the mass ratio of K 2 ZrF 6 and KBF 4 in the mixed salt is 0.94, (Sc, Zr) rare earth mixed powder content 0.4%, using Sc powder and Zr powder
  • the mass ratio is 2:1, the balance is pure aluminum powder, and the filling rate of welding wire is 24%. 99.99% pure argon is used as shielding gas during welding.
  • the composition of the sheath and drug core is as follows:

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  • Mechanical Engineering (AREA)
  • Nonmetallic Welding Materials (AREA)

Abstract

一种铝合金药芯焊丝，采用1070半硬态纯铝带作为外皮，焊丝的填充率为20％～30％，药粉由以下组分按质量百分比配制，总的质量百分比是100％，其中药粉中各成分的质量百分比为：金属Zn粉含量4.5％～8.0％，金属Mg粉含量1.2％～3.5％，金属Cu粉含量0.5％～2.5％，金属Mn粉含量0.04％～0.5％，混合盐粉含量5％～30％，稀土粉含量0.1％～1.0％，余量为纯铝粉；混合盐粉包括K 2ZrF 6和KBF 4两种，K 2ZrF 6和KBF 4质量比为0.86～1.12：1。还涉及一种铝合金药芯焊丝的制备方法。本焊丝采用混合盐作为药芯焊丝填充物，通过焊接热量直接诱发混合盐与焊接母材生成原位纳米颗粒，不仅使焊丝生产成本降低，而且原位增强颗粒与母材良好的润湿性更良好的解决了外加颗粒与母材的结合问题。

Description

一种铝合金药芯焊丝及其制备方法 技术领域
本发明属于铝合金药芯焊丝技术领域，涉及一种铝合金药芯焊丝及其制备方法，尤其涉及一种用于7XXX铝合金焊接的混合盐与稀土填充的药芯焊丝及其制备方法。
技术背景
铝是地壳中含量最多的金属元素，随着生产力的不断提高，铝合金已成为继钢铁外应用最广泛的材料。近年来，因其密度小、熔化温度低、导热性和可塑性好、成本低等优势，已广泛应用于航空航天、军工、轨道车辆、压力容器等领域。7XXX系铝合金作为一种超高强、可热处理强化铝合金，在航空航天领域有着广泛的应用，例如：7085铝合金已应用于A380、波音、空客等大飞机翼梁和翼肋；7N01已广泛应用于高铁轨道领域。
由于铝合金零部件已向着大型化、复杂化方向发展，因此解决铝合金的连接问题迫在眉睫。焊接，作为一种高效的连接手段，具有成行方便、适应性强、成本低等优势，但其应用在工业生产中，还存在很大的难题，例如焊接热裂纹倾向严重、焊缝晶粒粗大、焊缝力学性能软化等难题。例如，对7N01进行激光焊接，接头抗拉强度下降约110MPa；对7075进行TIG焊，焊缝表面存在严重的热裂纹。因此，铝合金焊缝作为构件的薄弱环节，严重制约着铝合金的应用。目前，已有研究表明，当向焊材中加入颗粒，焊缝宏观裂纹小时，焊缝中枝晶等轴晶化而有效细化晶粒，强度衰减也明显改善。
中国专利CN11015013A公开了一种用于2A12高强铝合金焊接的微纳米颗粒增强的药芯焊丝，其通过在药芯焊丝中添加TiC、TiN、SiC、ZrC等微纳米颗粒抑制焊缝区、熔合区晶粒生长并钉扎位错以提高焊接接头强度；通过细化第二相和枝晶弥补凝固过程引起的应变，减小热裂纹倾向。
但以上焊材在制备过程中，微纳米增强颗粒成本过高，并且外加增强颗粒与基体的润湿性不好，导致结合基体与界面的结合强度降低，限制其的生产应用。
发明内容
本发明将药芯焊丝技术和原位纳米颗粒增强机制有机的结合，设计制备了用于7XXX铝合金焊接的混合盐与稀土填充的药芯焊丝，目的是解决实心焊丝用 于7XXX铝合金时，裂纹倾向严重、合金元素烧损、组织晶粒粗大、接头性能下降严重等问题。利用本发明设计制备的铝合金药芯焊丝，可以通过在药芯配方中调整混合盐比例，增大对铝合金焊缝成分的调节范围，实现对7XXX铝合金焊缝组织、性能的优化，提升焊接接头强度。使用本发明焊丝可以在保证焊缝金属化学成分、力学性能、耐腐蚀性能满足相关要求的情况下，显著降低焊缝金属热裂纹倾向，获得成型美观，强度较高，性能优良的焊接接头。
本发明采用混合盐作为药芯焊丝填充物，通过焊接热量直接诱发混合盐与焊接母材生成原位纳米颗粒，此方式不仅使焊丝生产成本降低，原位增强颗粒与母材良好的润湿性更良好的解决了外加颗粒与母材的结合问题，除此之外，稀土元素的加入具有显著的晶粒细化作用，这为7XXX铝合金焊接用药芯焊丝的选取提供了新的思路，也是本专利的发明创新点。
本发明通过以下技术方案实现：一种用于7XXX铝合金焊接的混合盐与稀土填充的药芯焊丝，其特征在于，采用1070半硬态纯铝带作为外皮，焊丝的填充率为20％～30％，即药粉质量占药芯焊丝质量的20-30％。药粉由以下组分按质量百分比配制，总的质量百分比是100％，其中药粉中各成分的质量百分比为：金属Zn粉含量4.5％～8.0％，金属Mg粉含量1.2％～3.5％，金属Cu粉含量0.5％～2.5％，金属Mn粉含量0.04％～0.5％，混合盐粉含量5％～30％，稀土粉含量0.1％～1.0％，余量为纯铝粉。
上述混合盐粉包括K 2ZrF 6和KBF 4两种，均为白色粉末，使用前需将粉末研磨至200目，K 2ZrF 6和KBF 4添加量存在一定的比例关系，质量比为0.86～1.12：1。
上述稀土粉为Sc、Er、Sc和Zr的复合添加物或Er和Zr复合添加物。添加方式为：单独添加Sc、Er元素或者按以下质量比混合添加：Sc和Zr复合添加，其中Sc、Zr质量比为2:1；Er和Zr复合添加，其中Er、Zr的质量比为2:1。稀土粉以高纯粉的形式添加，为球形或近球形，粉末粒度为150-250μm，Sc和Er的质量纯度为99.9％～99.99％，Zr的质量纯度为99.5％～99.8％，氧含量均低于50ppm。
上述Zn粉、Mg粉、Cu粉、Mn粉的添加量与焊接母材成分相匹配，根据母材不同进行不同含量的添加，考虑到元素的烧损问题，Cu和Mn按照母材牌 号中标准Cu和Mn含量的1.1～1.3倍添加；Zn和Mg按照母材牌号中标准Zn和Mg含量的1.3～1.5倍添加。
优选的，混合盐粉较佳添加重量百分比为14％～17％，其中K 2ZrF 6和KBF 4的质量比优选为:0.94：1。
优选的，稀土Sc粉末单独添加时较佳添加重量百分比为0.4％～0.7％，稀土Er粉末单独添加时较佳添加重量百分比为0.3％～0.6％；Sc和Zr复合稀土粉或者Er和Zr复合稀土粉混合添加时，Sc或Er较优添加重量百分比为0.3％，Zr较优添加重量百分比为0.2％。
所述Zn粉、Mg粉、Cu粉、Mn粉等金属粉以质量纯度大于99.9％的高纯金属粉的形式加入；金属粉末为球形或近球形，粉末粒度为150-250μm，氧含量低于50ppm。
所述的用于7XXX铝合金焊接的混合盐与稀土填充药芯焊丝，其中外皮为质量纯度大于99.5％的1070半硬态纯铝带。本发明药芯填充丝采用常规药芯焊丝成型技术制得。
如上述的用于7XXX铝合金焊接的混合盐与稀土填充的药芯焊丝的制备方法，其特征在于：
选用宽度为10～16mm，厚度为0.6～1.0mm的1070半硬态纯铝带为填充丝的外皮，首先将纯铝带用刮刀清除上表面氧化膜，然后将其轧制成U型槽填入上述混合均匀的药粉，药粉重量是焊丝重量的20～30％，将U型槽合口后，逐次通过不同直径的拉丝模，逐道拉拔、减径，并对焊丝的表面进行清理得到焊丝成品，其直径在0.8～3.0mm。
本发明所述的用于7XXX铝合金焊接的混合盐与稀土填充的药芯焊丝用于7XXX铝合金焊接，焊接方式包括但不限于钨极氩弧焊和熔化极气体保护焊，焊接时将焊丝置于两个待连接板件的缝隙或坡口中，保护气体为纯度大于99.9％的高纯氩气，焊后用钢丝刷或铜丝刷去除表面的焊渣。
所用药芯焊丝的组分及作用如下：
Mg：有利于提高焊缝硬度，同时又不会使塑性明显降低；
Zn：与Mg元素形成MgZn 2相，起弥散强化作用，对合金产生明显强化作用；
Mn：起微合金化、强韧化作用，降低焊缝腐蚀敏感性，特别是抗应力腐蚀开裂能力得到提高；
Cu：固溶强化作用，提高合金机械性能；
稀土金属：促进异质形核，细化晶粒，易于促进氢形成稳定化合物而抑制氢气孔的产生；
Zr：与稀土作用生成双层结构的二次相，起弥散强化的作用，提高焊缝强度；
混合盐粉末作用方式及机理为：
Al-Zr-B三元体系中会发生以下冶金化学反应：
[Zr]+3Al→Al 3Zr    (1)
2[B]+Al→AlB 2     (2)
Al 3Zr+AlB 2→ZrB 2+4Al    (3)
总反应方程式为：
3K 2ZrF 6+6KBF 4+10Al＝3ZrB 2+9KAlF 4+K 3AlF 6     (4)
标准生成自由能的计算公式为：
Figure PCTCN2022075863-appb-000001
当
Figure PCTCN2022075863-appb-000002
时，反应能自发进行，以上方程式涉及到的参加反应物质的标准自由能为：
物质 ΔG Θ
Al -5609.9-11.35T
Zr -8308.6-11.23T
B 7754.1-6.487T
Al 3Zr -370858.3+123.02T
AlB 2 -237812.8+1162.9T
ZrB 2 -242568.7-38.617T
进而计算可知：
Figure PCTCN2022075863-appb-000003
即：当T＜2053.3K时，
Figure PCTCN2022075863-appb-000004
Figure PCTCN2022075863-appb-000005
即：当T＜1318K时，
Figure PCTCN2022075863-appb-000006
Figure PCTCN2022075863-appb-000007
即：当T＞718.1K时，
Figure PCTCN2022075863-appb-000008
综合以上热力学数据说明反应在718.1K(445℃)至1318K(1045℃)均能自发进行，即在焊接铝合金熔化状态下(≥660℃)反应自发进行。反应产物ZrB 2陶瓷颗粒为纳米尺度，晶粒细小；与Al具有良好的半共格关系且两相界面间干 净无污染。原位ZrB 2颗粒在焊缝中生成能有效抑制枝晶生长使细化晶粒，从而提高接头的性能；除此之外，ZrB 2颗粒能起到钉扎位错的作用，阻止位错运动，提高接头强度。
本发明的高强铝合金用填充丝采用99.99％高纯Ar气作为保护气体，焊接成形良好，无凸起、咬边等缺陷，焊缝金属的各项性能符合工程需求。该混合盐与稀土填充的铝合金药芯焊丝加工成型简便、成本低廉，操作工艺简单、方便、高效、适应性好、易于推广，解决了7XXX铝合金焊接时晶粒组织粗大，热裂纹敏感，接头软化的问题，具有很好的市场应用价值。
附图说明
图1表示利用本发明药芯焊丝焊接铝合金示意图
图2表示本发明药芯焊丝作用下生成ZrB 2颗粒XRD图。
图3表示本发明药芯焊丝作用下生成ZrB 2颗粒SEM图。
图例说明：1-焊枪，2-药芯焊丝，3-保护气。
具体实施方式
为了使本发明的目的、技术方案等更加清楚明白，以下结合实施例对本发明进行进一步详细说明。应当理解，此处所描述的具体实施例仅用以解释本发明，并不用于限定本发明。以下实例中的焊丝的填充率为20～30％，金属粉包括金属Mg粉、金属Zn粉、金属Mn粉、金属Cu粉，稀土(Sc或Er)粉或者(Sc、Zr)、(Er、Zr)混合粉，纯Al粉，且粉末粒度为150～250μm；混合盐粉包括K 2ZrF 6和KBF 4两种，均为白色粉末。以上粉末通过机械均匀混合后，在真空电炉中200℃加热2h进行烘干。
表1 表示根据母材厚度选取合适直径的填充药芯丝。
表1 推荐使用的填充药芯直径表
板厚(mm) 2.0～4.5 4.5～7.0 ≥7.0
填丝直径(mm) 0.8～1.6 1.6～2.0 2.0～3.0
下面结合具体实施例对本发明做进一步说明。
实施例1
一种用于7085铝合金焊接的混合盐与稀土填充的药芯焊丝，其中生成ZrB 2颗粒含量为2％，稀土含量为0.5％。外皮和药芯成分如下：
采用1070纯铝带外皮10×1.0mm，药芯填充丝直径为1.0mm；药芯的化学组成(重量％)为金属Zn粉含量7.35％，金属Mg粉含量1.6％，金属Cu粉含量1.4％，金属Mn粉含量0.04％，混合盐粉含量10％，其中混合盐中K 2ZrF 6和KBF 4的质量比为0.93，稀土粉含量0.5％，为纯Sc粉，余量为纯铝粉，焊丝填充率为20％。焊接时采用99.99％纯氩气作为保护气。
实施例2
一种用于7075铝合金焊接的混合盐与稀土填充的药芯焊丝，其中生成ZrB 2颗粒含量为3％，稀土含量为0.4％。外皮和药芯成分如下：
采用1070纯铝带外皮12×1.0mm，药芯填充丝直径为1.2mm；药芯的化学组成(重量％)为金属Zn粉含量5.5％，金属Mg粉含量2.3％，金属Cu粉含量1.4％，金属Mn粉含量0.3％，混合盐粉含量15％，其中混合盐中K 2ZrF 6和KBF 4的质量比为0.94，(Sc、Zr)稀土混合粉含量0.4％，采用Sc粉与Zr粉质量比2:1的添加方式，余量为纯铝粉，焊丝填充率为24％。焊接时采用99.99％纯氩气作为保护气。
实施例3
一种用于7001铝合金焊接的混合盐与稀土填充的药芯焊丝，其中生成ZrB 2颗粒含量为5％，稀土含量为0.6％。外皮和药芯成分如下：
采用1070纯铝带外皮12×0.8mm，药芯填充丝直径为1.6mm；药芯的化学组成(重量％)为金属Zn粉含量7.5％，金属Mg粉含量3.0％，金属Cu粉含量1.8％，，金属Mn粉含量0.2％，混合盐粉含量28％，其中混合盐中K 2ZrF 6和KBF 4的质量比为0.89，(Er、Zr)稀土混合粉含量0.6％，采用Er粉与Zr粉质量比2:1的添加方式，余量为纯铝粉，焊丝填充率为26％。焊接时采用99.99％纯氩气作为保护气。

Claims (9)

  1. 一种铝合金药芯焊丝，采用1070半硬态纯铝带作为外皮，焊丝的填充率为20％～30％，即药粉质量占焊丝质量的20-30％，其特征在于，药粉由以下组分按质量百分比配制，总的质量百分比是100％，其中药粉中各成分的质量百分比为：金属Zn粉含量4.5％～8.0％，金属Mg粉含量1.2％～3.5％，金属Cu粉含量0.5％～2.5％，金属Mn粉含量0.04％～0.5％，混合盐粉含量5％～30％，稀土粉含量0.1％～1.0％，余量为纯铝粉；混合盐粉包括K 2ZrF 6和KBF 4两种，K 2ZrF 6和KBF 4质量比为0.86～1.12：1。
  2. 如权利要求1所述的一种铝合金药芯焊丝，其特征在于，混合盐粉使用前需将粉末研磨至200目。
  3. 如权利要求1所述的一种铝合金药芯焊丝，其特征在于，稀土粉为Sc、Er、Sc和Zr的复合添加物或Er和Zr复合添加物；Sc和Zr复合添加时，Sc、Zr质量比为2:1；Er和Zr复合添加时，Er、Zr的质量比为2:1；稀土粉以高纯粉的形式添加，为球形或近球形，粉末粒度为150-250μm，Sc和Er的质量纯度为99.9％～99.99％，Zr的质量纯度为99.5％～99.8％，氧含量均低于50ppm。
  4. 如权利要求1或3所述的一种铝合金药芯焊丝，其特征在于，稀土Sc粉末单独添加时含量为0.4％～0.7％，稀土Er粉末单独添加时含量为0.3％～0.6％；Sc和Zr复合添加时或者Er和Zr复合添加时，Sc或Er含量为0.3％，Zr含量为0.2％。
  5. 如权利要求1所述的一种铝合金药芯焊丝，其特征在于，Zn粉、Mg粉、Cu粉、Mn粉的添加量与焊接母材成分相匹配，根据母材不同进行不同含量的添加；考虑到元素的烧损问题，Cu和Mn按照母材牌号中标准Cu和Mn含量的1.1～1.3倍添加；Zn和Mg按照母材牌号中标准Zn和Mg含量的1.3～1.5倍添加。
  6. 如权利要求1所述的一种铝合金药芯焊丝，其特征在于，混合盐粉含量为14％～17％，其中K 2ZrF 6和KBF 4的质量比为0.94：1。
  7. 如权利要求1所述的一种铝合金药芯焊丝，其特征在于，所述Zn粉、Mg粉、Cu粉、Mn粉等金属粉以质量纯度大于99.9％的高纯金属粉的形式加入；金属粉末为球形或近球形，粉末粒度为150-250μm，氧含量低于50ppm；外皮为质量纯度大于99.5％的1070半硬态纯铝带。
  8. 如权利要求1所述的一种铝合金药芯焊丝，其特征在于，用于7XXX铝合金焊接，焊接方式包括但不限于钨极氩弧焊和熔化极气体保护焊，焊接时将焊丝置于两个待连接板件的缝隙或坡口中，保护气体为纯度大于99.9％的高纯氩气，焊后用钢丝刷或铜丝刷去除表面的焊渣。
  9. 如权利要求1所述的一种铝合金药芯焊丝的制备方法，其特征在于，选用宽度为10～16mm，厚度为0.6～1.0mm的1070半硬态纯铝带为填充丝的外皮，首先将纯铝带用刮刀清除上表面氧化膜，然后将其轧制成U型槽填入上述混合均匀的药粉，药粉重量是焊丝重量的20～30％，将U型槽合口后，逐次通过不同直径的拉丝模，逐道拉拔、减径，并对焊丝的表面进行清理得到焊丝成品，其直径在0.8～3.0mm。
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