WO2024093247A1 - Near-non-weld-thinning friction stir welding method for aluminum alloy sheet - Google Patents
Near-non-weld-thinning friction stir welding method for aluminum alloy sheet Download PDFInfo
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- WO2024093247A1 WO2024093247A1 PCT/CN2023/100562 CN2023100562W WO2024093247A1 WO 2024093247 A1 WO2024093247 A1 WO 2024093247A1 CN 2023100562 W CN2023100562 W CN 2023100562W WO 2024093247 A1 WO2024093247 A1 WO 2024093247A1
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- thinning
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- 238000003756 stirring Methods 0.000 title claims abstract description 129
- 238000003466 welding Methods 0.000 title claims abstract description 84
- 238000000034 method Methods 0.000 title claims abstract description 44
- 229910000838 Al alloy Inorganic materials 0.000 title claims abstract description 24
- 230000008569 process Effects 0.000 claims description 20
- 229910052751 metal Inorganic materials 0.000 claims description 16
- 239000002184 metal Substances 0.000 claims description 16
- 230000009471 action Effects 0.000 claims description 8
- 238000009826 distribution Methods 0.000 claims description 6
- 230000007704 transition Effects 0.000 claims description 4
- 239000007769 metal material Substances 0.000 claims description 3
- 230000009286 beneficial effect Effects 0.000 abstract 1
- 230000007547 defect Effects 0.000 description 14
- 238000010586 diagram Methods 0.000 description 11
- 238000005516 engineering process Methods 0.000 description 9
- 238000013461 design Methods 0.000 description 6
- 238000000227 grinding Methods 0.000 description 5
- 239000000463 material Substances 0.000 description 5
- 238000005242 forging Methods 0.000 description 4
- 230000000694 effects Effects 0.000 description 2
- 210000001503 joint Anatomy 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 230000008439 repair process Effects 0.000 description 2
- 238000012795 verification Methods 0.000 description 2
- 229910001148 Al-Li alloy Inorganic materials 0.000 description 1
- 241000219112 Cucumis Species 0.000 description 1
- 235000015510 Cucumis melo subsp melo Nutrition 0.000 description 1
- 101001121408 Homo sapiens L-amino-acid oxidase Proteins 0.000 description 1
- 101000827703 Homo sapiens Polyphosphoinositide phosphatase Proteins 0.000 description 1
- 102100026388 L-amino-acid oxidase Human genes 0.000 description 1
- 102100023591 Polyphosphoinositide phosphatase Human genes 0.000 description 1
- 101100012902 Saccharomyces cerevisiae (strain ATCC 204508 / S288c) FIG2 gene Proteins 0.000 description 1
- 101100233916 Saccharomyces cerevisiae (strain ATCC 204508 / S288c) KAR5 gene Proteins 0.000 description 1
- FJJCIZWZNKZHII-UHFFFAOYSA-N [4,6-bis(cyanoamino)-1,3,5-triazin-2-yl]cyanamide Chemical compound N#CNC1=NC(NC#N)=NC(NC#N)=N1 FJJCIZWZNKZHII-UHFFFAOYSA-N 0.000 description 1
- JFBZPFYRPYOZCQ-UHFFFAOYSA-N [Li].[Al] Chemical compound [Li].[Al] JFBZPFYRPYOZCQ-UHFFFAOYSA-N 0.000 description 1
- 238000004220 aggregation Methods 0.000 description 1
- 230000002776 aggregation Effects 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
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- 239000001989 lithium alloy Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/24—Preliminary treatment
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/26—Auxiliary equipment
Definitions
- the invention belongs to the technical field of rocket equipment, and in particular relates to a friction stir welding method for aluminum alloy thin plates with near-zero thinning.
- friction stir welding technology As an advanced solid-phase joining technology, friction stir welding technology has been widely used in shipbuilding, aerospace, rail transportation and other fields.
- single-shoulder friction stir welding technology has the largest application scale, which is mainly divided into single-shoulder conventional friction stir welding technology and single-shoulder retractable friction stir welding technology.
- the conventional single-shoulder friction stir welding technology uses a shoulder and a stirring needle integrated stirring head for welding open welds, such as the longitudinal seams of the barrel section of the launch vehicle tank and the longitudinal seams of the melon slices at the bottom of the tank.
- the single-shoulder retractable friction stir welding technology uses a shoulder and a stirring needle separated stirring head. During the welding process, the shoulder and the stirring needle are controlled separately, and the welding and retraction actions are carried out simultaneously, thereby filling the keyhole defects after the stirring needle welding and realizing the welding of closed annular seams, such as the annular seams at the bottom of the launch vehicle tank and the annular seams of the box assembly.
- A1 and A2 together cause the overall thinning of the weld, especially in the friction stir of thin aluminum alloy.
- the product is extremely sensitive to weld thinning. A large amount of thinning will seriously affect the weld forging force.
- the repair welding will further aggravate the weld thinning, causing a vicious cycle of weld quality. Therefore, strictly controlling the thinning amount of A1 and A2 can greatly reduce the overall weld thinning and improve the weld quality.
- the present invention aims to provide a friction stir welding method for aluminum alloy thin plates with near-zero thinning to address the deficiencies of the prior art.
- a friction stir welding method for aluminum alloy thin plates with near-zero thinning comprises the following steps:
- the nearly non-thinning stirring head comprises a shaft shoulder and a stirring needle, and the shaft shoulder and the stirring needle are an integrally formed structure.
- step S2 Furthermore, the method for controlling the amount of thinning of the back side of the weld in step S2 comprises the following steps:
- the plasticized metal material of the product flows circumferentially from the forward side to the backward side and then to the forward side under the rotating stirring action of the stirring needle and the shoulder.
- the plastic metal on the forward side flows out to form a cavity, and the metal on the backward side fills the cavity on the forward side under the action of the stirring head.
- the process parameters of the nearly non-thinning stirring head in step S3 are: the stirring head inclination angle 1° ⁇ 2°, stirring head rotation speed 300 ⁇ 600r/min, welding travel speed 100 ⁇ 250mm/min.
- the structural curve of the shoulder is an Archimedean double helix structure, and the distribution angle of each spiral line of the Archimedean double helix structure is 180°.
- the structural curve of the shoulder is an Archimedean triple helix structure, and the distribution angle of each spiral line of the Archimedean triple helix structure is 120°.
- the structural parameters of the shoulder are:
- the radius of the convex spherical surface is R50 ⁇ R65mm
- the shoulder diameter is ⁇ 13 ⁇ 16mm
- the angle of the stirring head body on the shoulder side is 90°
- the fillet of the transition zone between the shoulder and the stirring head body is R0.5 ⁇ R1mm
- the radius of the Archimedean spiral arc groove is R0.25 ⁇ R0.4mm
- the radius of the spiral end point is 0.8 ⁇ 1mm smaller than the shoulder radius.
- the structural parameters of the stirring needle are:
- the stirring needle has a taper angle of 18 to 20°, a root diameter of ⁇ 4 to ⁇ 6mm, a root fillet of R0.8 to R1, three inclined surfaces are arranged on the stirring needle, and the three inclined surfaces are distributed at 120°.
- the height of the inclined surfaces is 2.5 to 3.5mm
- the thread is a trapezoidal structure
- the height of the trapezoidal thread is 0.25 to 0.35mm
- the width of the thread root is 0.2 to 0.25mm
- the taper angle is 60°
- the end point is 0 to 0.3mm higher than the inclined surface.
- the friction stir welding method for aluminum alloy thin plates with near-zero thinning described in the present invention has the following advantages:
- the present invention discloses a method for stir friction welding of aluminum alloy thin plates with near-zero thinning.
- the present invention realizes stir friction welding of aluminum alloy thin plates with near-zero thinning and near-defects, makes high-quality welding of thin-plate aerospace products possible, greatly improves the welding quality of products, and reduces welding deformation of products. It has important practical significance and huge economic value for the engineering application of aerospace model products.
- FIG1 is a schematic diagram of a friction stir weld thinning state in the prior art according to an embodiment of the present invention
- FIG2 is a schematic diagram of a double helix structure of a stirring head with near-zero thinning according to an embodiment of the present invention
- FIG3 is a schematic diagram of a triple-helix structure of a stirring head with near-zero thinning according to an embodiment of the present invention
- FIG4 is a schematic cross-sectional view of a shaft shoulder of a stirring head with near-zero thinning according to an embodiment of the present invention
- FIG5 is a schematic diagram of a double helix structure of a shaft shoulder of a stirring head with near-zero thinning according to an embodiment of the present invention
- FIG6 is a schematic diagram of a triple-helix structure of a shaft shoulder of a stirring head with near-zero thinning according to an embodiment of the present invention
- FIG7 is a schematic diagram of the structure of a stirring pin according to an embodiment of the present invention.
- FIG8 is a schematic diagram of a cross-sectional structure of a stirring needle according to an embodiment of the present invention.
- FIG9 is a schematic diagram of filling the forward side cavity during the friction stir welding process according to an embodiment of the present invention.
- FIG. 10 is a schematic diagram of the plastic metal flow state in the cross-sectional direction during the friction stir welding process according to an embodiment of the present invention.
- FIG11 is a schematic diagram of the back chamfering of the butt joint edge before welding according to an embodiment of the present invention.
- FIG. 12 is a schematic diagram of the overall method flow described in an embodiment of the present invention.
- the terms “installed”, “connected”, and “connected” should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two components.
- installed should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two components.
- a friction stir welding method for aluminum alloy thin plates with near-zero thinning comprises the following steps:
- the nearly non-thinning stirring head comprises a shaft shoulder structure and a stirring needle structure, wherein the shaft shoulder structure and the stirring needle structure are an integrally formed structure, and both the shaft shoulder structure and the stirring needle structure are used for welding welds.
- the present invention greatly reduces the thinning amount in the current single-shaft shoulder stir friction welding.
- the overall thinning amount of the weld is reduced by The thickness of the weld was reduced from 0.25 to 0.4 mm to 0.1 to 0.15 mm, and the weld qualification rate was increased to more than 95%, achieving near-zero-thinning and near-defective friction stir welding, improving the quality of the weld, and achieving the goal of qualified welding in one go.
- the shoulder of the nearly non-thinning stirring head adopts the Archimedean spiral as the basic structural curve.
- an Archimedean double spiral or triple spiral structure is adopted.
- the distribution angle of each spiral line of the Archimedean double spiral is 180°
- the distribution angle of each spiral line of the Archimedean triple spiral is 120°, as shown in Figures 2 and 3.
- the end face of the shaft shoulder of the nearly non-thinning stirring head adopts a convex spherical structure, which can increase the forging pressure of the stirring head during welding, ensuring that the weld has sufficient weld density while reducing the amount of thinning, thereby improving the mechanical properties of the weld.
- the shaft shoulder structure follows the following design:
- the radius of the convex spherical surface is R50 ⁇ R65mm
- the diameter of the shaft shoulder is ⁇ 13 ⁇ 16mm
- the main stirring head on the shaft shoulder side is The body angle is 90°
- the fillet of the transition zone between the shaft shoulder and the main body of the stirring head is R0.5-R1mm
- the radius of the Archimedean spiral arc groove is R0.25-R0.4mm, as shown in Figure 4.
- the radius of the spiral end point is 0.8-1mm smaller than the shoulder radius, which can improve the edge morphology on both sides of the weld and make the transition between the weld and the base material smooth, as shown in Figures 5 and 6.
- the stirring needle structure follows the following design:
- the stirring needle has a taper angle of 18-20°, a root diameter of ⁇ 4- ⁇ 6mm, a root fillet of R0.8-R1, three inclined planes are machined on the stirring needle, distributed at 120°, and the height of the inclined plane is 2.5-3.5mm.
- the thread adopts a trapezoidal structure, which can effectively enhance the structural strength of the stirring needle compared with the current triangular thread.
- the height of the trapezoidal thread is 0.25-0.35mm
- the root width of the thread is 0.2-0.25mm
- the taper angle is 60°.
- the tool gradually withdraws within 1/4 of a circle, and the end point is 0-0.3mm higher than the inclined plane, as shown in Figures 7 and 8.
- This structure can greatly improve the structural strength and reliability of the stirring head, and can meet the continuous and uninterrupted welding of at least 16m long ring welds.
- the plasticized metal material flows from the forward side to the backward side and then to the forward side in an annular direction under the rotating stirring action of the stirring needle and the shaft shoulder.
- the plastic metal on the forward side flows out to form a cavity.
- the metal on the backward side fills the forward side cavity under the action of the stirring head to maintain the consistency of the tissue density in the weld.
- the entire welding process is a dynamic balance process of tissue flow. The unreasonable structure of the stirring head and the process parameters will break the dynamic balance of the welding process and lead to the generation of internal defects in the weld.
- the process range is: stirring head inclination angle 1° ⁇ 2°, stirring head rotation speed 300 ⁇ 600r/min, welding travel speed 100 ⁇ 250mm/min, which can obtain weld joints with beautiful shape, dense structure, excellent mechanical properties and weld front thinning less than 0.1mm.
- the thinning of the back of the weld is mainly caused by the grinding and cleaning of weak bonding defects. Controlling the weak bonding defects can control the amount of grinding on the back of the weld, and controlling the amount of grinding can control the amount of thinning on the back of the weld.
- the flow direction of the plastic metal on the weld cross section during the stir friction welding process is shown in Figure 10. Under the action of the stirring needle thread, the plastic metal tends to flow to the back of the weld. Therefore, increasing the mixing degree of the plastic metal in the gap range of 0.15 to 0.25 mm between the end face of the stirring needle and the back pad can effectively control the generation of weak bonding defects.
- the control method is: before welding the product, open a chamfer of C0.2 to C0.5 on the back of the two butt edges, as shown in Figure 11.
- the plastic metal in the weld will be fully filled and mixed in the chamfer, which can effectively control the generation of weak bonding defects.
- the number of weak bonding defects on the back of the weld is reduced to 10 to 20% before optimization.
- the back of the weld only needs to be polished and smooth, and the thinning amount can be controlled within 0.05mm.
- the present invention develops a thin plate aluminum alloy near-zero thinning stirring head, designs the stirring head shaft shoulder and stirring needle structure, and adopts the stirring head to effectively control the thinning amount of the weld front side;
- the present invention adopts a method of chamfering the back side of the product to be welded, which effectively controls the generation of weak bonding defects in the weld, and further controls the amount of grinding on the back side of the weld and the amount of thinning of the weld.
- the present invention realizes nearly zero-thinning and nearly zero-defect stir friction welding of thin-plate aluminum alloy, makes high-quality welding of thin-plate aerospace products possible, greatly improves the welding quality of products, and reduces the welding deformation of products. It has important practical significance and huge economic value for the engineering application of aerospace model products.
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Abstract
Provided in the present invention is a near-non-weld-thinning friction stir welding method for an aluminum alloy sheet. The method comprises the following steps: controlling a thinning amount of a front side of a weld by means of a near-non-weld-thinning stir welding head; controlling a thinning amount of a back side of the weld by means of the near-non-weld-thinning stir welding head; and welding the weld by means of the near-non-weld-thinning stir welding head. The present invention has the beneficial effects that the present invention achieves the near-non-weld-thinning and near-zero-defect friction stir welding of an aluminum alloy sheet, thereby achieving the possibility of high-quality welding of sheet aerospace products, greatly improving the welding quality of products and reducing the welding deformation of the products, and the present invention has an important practical significance and great economic value for an engineering application of aerospace model products.
Description
本发明属于火箭设备技术领域,尤其是涉及一种铝合金薄板近无减薄搅拌摩擦焊接方法。The invention belongs to the technical field of rocket equipment, and in particular relates to a friction stir welding method for aluminum alloy thin plates with near-zero thinning.
搅拌摩擦焊接技术作为一种先进的固相连接技术,已经在造船、航空航天、轨道交通等领域获得了广泛的应用。在已实现工程化应用的搅拌摩擦焊接技术类型中,单轴肩搅拌摩擦焊接技术的应用规模最大,主要分为单轴肩常规搅拌摩擦焊接技术和单轴肩可回抽搅拌摩擦焊接技术两种。As an advanced solid-phase joining technology, friction stir welding technology has been widely used in shipbuilding, aerospace, rail transportation and other fields. Among the types of friction stir welding technologies that have been applied in engineering, single-shoulder friction stir welding technology has the largest application scale, which is mainly divided into single-shoulder conventional friction stir welding technology and single-shoulder retractable friction stir welding technology.
在航天器制造领域,单轴肩常规搅拌摩擦焊接技术采用轴肩和搅拌针一体式搅拌头,用于开敞类焊缝的焊接,例如运载火箭贮箱的筒段纵缝、箱底瓜瓣纵缝等。单轴肩可回抽搅拌摩擦焊接技术采用轴肩和搅拌针分体式搅拌头,焊接过程中轴肩和搅拌针分别控制,焊接与回抽动作同步进行,从而填补搅拌针焊后的匙孔缺陷,实现封闭类环缝的焊接,例如运载火箭贮箱箱底环缝及箱体总装类环缝等。In the field of spacecraft manufacturing, the conventional single-shoulder friction stir welding technology uses a shoulder and a stirring needle integrated stirring head for welding open welds, such as the longitudinal seams of the barrel section of the launch vehicle tank and the longitudinal seams of the melon slices at the bottom of the tank. The single-shoulder retractable friction stir welding technology uses a shoulder and a stirring needle separated stirring head. During the welding process, the shoulder and the stirring needle are controlled separately, and the welding and retraction actions are carried out simultaneously, thereby filling the keyhole defects after the stirring needle welding and realizing the welding of closed annular seams, such as the annular seams at the bottom of the launch vehicle tank and the annular seams of the box assembly.
现有技术的缺点:目前搅拌摩擦焊接过程中,受搅拌头轴肩锻压力影响,焊缝正面受挤压的塑态金属会形成飞边挤出焊缝区域,使得焊缝区会有一定程度的材料损失,造成焊缝的正面减薄,如图1中A1。搅拌摩擦焊接过程中,为防止搅拌针过长扎伤垫板,使垫板材料进入焊缝造成异种金属夹杂缺陷,搅拌针长会小于实际产品焊接区厚度0.15~0.25mm,但会在焊缝背面形成浅薄的弱结合缺陷,为保证焊缝质量,需对焊缝背面进行打磨去除弱结合缺陷,使得焊缝背面产生一定程度的厚度损失,如图1中A2。Disadvantages of the existing technology: During the current friction stir welding process, affected by the forging pressure of the stirring head shoulder, the plastic metal squeezed on the front of the weld will form flash and squeeze out of the weld area, resulting in a certain degree of material loss in the weld area, causing the front of the weld to be thinned, as shown in A1 in Figure 1. During the friction stir welding process, in order to prevent the stirring needle from being too long and piercing the pad, so that the pad material enters the weld and causes a dissimilar metal inclusion defect, the stirring needle length will be 0.15-0.25mm less than the actual product welding area thickness, but will form a shallow weak bonding defect on the back of the weld. In order to ensure the quality of the weld, the back of the weld needs to be polished to remove the weak bonding defect, resulting in a certain degree of thickness loss on the back of the weld, as shown in A2 in Figure 1.
A1与A2共同造成了焊缝的整体减薄,特别是在薄板铝合金的搅拌摩擦
焊接中,产品对焊缝减薄极为敏感,减薄量大会严重影响焊缝拉锻力,同时,如果焊缝存在超标缺陷涉及补焊时,补焊焊接会进一步加剧焊缝的减薄,造成焊缝质量的恶性循环,因此,严格控制A1及A2的减薄量,可大幅降低焊缝整体减薄量,提高焊缝质量。A1 and A2 together cause the overall thinning of the weld, especially in the friction stir of thin aluminum alloy. During welding, the product is extremely sensitive to weld thinning. A large amount of thinning will seriously affect the weld forging force. At the same time, if the weld has defects exceeding the standard and requires repair welding, the repair welding will further aggravate the weld thinning, causing a vicious cycle of weld quality. Therefore, strictly controlling the thinning amount of A1 and A2 can greatly reduce the overall weld thinning and improve the weld quality.
发明内容Summary of the invention
有鉴于此,本发明旨在提出一种铝合金薄板近无减薄搅拌摩擦焊接方法,以解决现有技术的不足。In view of this, the present invention aims to provide a friction stir welding method for aluminum alloy thin plates with near-zero thinning to address the deficiencies of the prior art.
为达到上述目的,本发明的技术方案是这样实现的:To achieve the above object, the technical solution of the present invention is achieved as follows:
一种铝合金薄板近无减薄搅拌摩擦焊接方法,包括以下步骤:A friction stir welding method for aluminum alloy thin plates with near-zero thinning comprises the following steps:
S1、采用近无减薄搅拌头控制焊缝正面减薄量;S1. Use a nearly non-thinning stirring head to control the thinning amount of the weld front;
S2、采用近无减薄搅拌头控制焊缝背面减薄量;S2. Use a nearly non-thinning stirring head to control the thinning amount on the back of the weld;
S3、采用近无减薄搅拌头焊接焊缝;S3, use a nearly non-thinning stirring head to weld the weld;
所述近无减薄搅拌头包括轴肩和搅拌针,所述轴肩与搅拌针为一体成型结构。The nearly non-thinning stirring head comprises a shaft shoulder and a stirring needle, and the shaft shoulder and the stirring needle are an integrally formed structure.
进一步的,在步骤S2中的焊缝背面减薄量的控制方法包括以下步骤:Furthermore, the method for controlling the amount of thinning of the back side of the weld in step S2 comprises the following steps:
A1、产品焊缝背面打磨圆滑;A1. The back of the product weld is polished and smooth;
A2、在两对产品接边背面开C0.2~C0.5的倒角。A2. Open a chamfer of C0.2~C0.5 on the back of the two pairs of product edges.
进一步的,在步骤S3中的近无减薄搅拌头在焊接焊缝过程中,产品塑态化的金属材料在搅拌针和轴肩旋转搅动作用下由前进侧向后退侧、再到前进侧环向流动,前进侧塑态金属流出后形成空腔,后退侧的金属在搅拌头的作用下填补前进侧空腔。Furthermore, in the process of welding the weld with the nearly non-thinning stirring head in step S3, the plasticized metal material of the product flows circumferentially from the forward side to the backward side and then to the forward side under the rotating stirring action of the stirring needle and the shoulder. The plastic metal on the forward side flows out to form a cavity, and the metal on the backward side fills the cavity on the forward side under the action of the stirring head.
进一步的,在步骤S3中的近无减薄搅拌头的工艺参数为:搅拌头倾角
1°~2°,搅拌头旋转速度300~600r/min,焊接行走速度100~250mm/min。Furthermore, the process parameters of the nearly non-thinning stirring head in step S3 are: the stirring head inclination angle 1°~2°, stirring head rotation speed 300~600r/min, welding travel speed 100~250mm/min.
进一步的,所述轴肩的结构曲线为阿基米德双螺旋结构,所述阿基米德双螺旋结构的各螺旋线分布角度为180°。Furthermore, the structural curve of the shoulder is an Archimedean double helix structure, and the distribution angle of each spiral line of the Archimedean double helix structure is 180°.
进一步的,所述轴肩的结构曲线为阿基米德三螺旋结构,阿基米德三螺旋结构的各螺旋线分布角度为120°。Furthermore, the structural curve of the shoulder is an Archimedean triple helix structure, and the distribution angle of each spiral line of the Archimedean triple helix structure is 120°.
进一步的,针对焊接区厚度2~4mm的产品,所述轴肩的结构参数为:Furthermore, for products with a welding zone thickness of 2 to 4 mm, the structural parameters of the shoulder are:
凸球面半径为R50~R65mm,轴肩直径为Φ13~Φ16mm,轴肩侧搅拌头主体夹角90°,轴肩与搅拌头主体过渡区圆角R0.5~R1mm,阿基米德螺旋线圆弧凹槽半径R0.25~R0.4mm,螺旋线收尾点半径小于轴肩半径0.8~1mm。The radius of the convex spherical surface is R50~R65mm, the shoulder diameter is Φ13~Φ16mm, the angle of the stirring head body on the shoulder side is 90°, the fillet of the transition zone between the shoulder and the stirring head body is R0.5~R1mm, the radius of the Archimedean spiral arc groove is R0.25~R0.4mm, and the radius of the spiral end point is 0.8~1mm smaller than the shoulder radius.
进一步的,针对焊接区厚度2~4mm的产品,所述搅拌针的结构参数为:Furthermore, for products with a welding zone thickness of 2 to 4 mm, the structural parameters of the stirring needle are:
搅拌针锥角18~20°,搅拌针根部直径Φ4~Φ6mm,根部圆角R0.8~R1,搅拌针上设有三个斜面,三个斜面呈120°分布,斜面高度2.5~3.5mm,螺纹为梯形结构,梯形螺纹高度0.25~0.35mm,螺纹根部宽度0.2~0.25mm,锥角60°,收尾点高于斜面0~0.3mm。The stirring needle has a taper angle of 18 to 20°, a root diameter of Φ4 to Φ6mm, a root fillet of R0.8 to R1, three inclined surfaces are arranged on the stirring needle, and the three inclined surfaces are distributed at 120°. The height of the inclined surfaces is 2.5 to 3.5mm, the thread is a trapezoidal structure, the height of the trapezoidal thread is 0.25 to 0.35mm, the width of the thread root is 0.2 to 0.25mm, the taper angle is 60°, and the end point is 0 to 0.3mm higher than the inclined surface.
相对于现有技术,本发明所述的一种铝合金薄板近无减薄搅拌摩擦焊接方法具有以下优势:Compared with the prior art, the friction stir welding method for aluminum alloy thin plates with near-zero thinning described in the present invention has the following advantages:
本发明所述的一种铝合金薄板近无减薄搅拌摩擦焊接方法,本发明实现了薄板铝合金的近无减薄近无缺陷搅拌摩擦焊接,使薄板航天产品的高质量焊接成为可能,大幅提高了产品焊接质量,并减小了产品焊接变形,对航天型号产品的工程化应用具有重要的现实意义和巨大的经济价值。The present invention discloses a method for stir friction welding of aluminum alloy thin plates with near-zero thinning. The present invention realizes stir friction welding of aluminum alloy thin plates with near-zero thinning and near-defects, makes high-quality welding of thin-plate aerospace products possible, greatly improves the welding quality of products, and reduces welding deformation of products. It has important practical significance and huge economic value for the engineering application of aerospace model products.
构成本发明的一部分的附图用来提供对本发明的进一步理解,本发明的示意性实施例及其说明用于解释本发明,并不构成对本发明的不当限定。在
附图中:The accompanying drawings constituting a part of the present invention are used to provide a further understanding of the present invention, and the exemplary embodiments of the present invention and their descriptions are used to explain the present invention, and do not constitute an improper limitation of the present invention. In the attached figure:
图1为本发明实施例所述的现有技术中的搅拌摩擦焊缝减薄状态示意图;FIG1 is a schematic diagram of a friction stir weld thinning state in the prior art according to an embodiment of the present invention;
图2为本发明实施例所述的近无减薄搅拌头结构双螺旋示意图;FIG2 is a schematic diagram of a double helix structure of a stirring head with near-zero thinning according to an embodiment of the present invention;
图3为本发明实施例所述的近无减薄搅拌头结构三螺旋示意图;FIG3 is a schematic diagram of a triple-helix structure of a stirring head with near-zero thinning according to an embodiment of the present invention;
图4为本发明实施例所述的近无减薄搅拌头轴肩剖面示意图;FIG4 is a schematic cross-sectional view of a shaft shoulder of a stirring head with near-zero thinning according to an embodiment of the present invention;
图5为本发明实施例所述的近无减薄搅拌头轴肩结构双螺旋示意图;FIG5 is a schematic diagram of a double helix structure of a shaft shoulder of a stirring head with near-zero thinning according to an embodiment of the present invention;
图6为本发明实施例所述的近无减薄搅拌头轴肩结构三螺旋示意图;FIG6 is a schematic diagram of a triple-helix structure of a shaft shoulder of a stirring head with near-zero thinning according to an embodiment of the present invention;
图7为本发明实施例所述的搅拌针结构示意图;FIG7 is a schematic diagram of the structure of a stirring pin according to an embodiment of the present invention;
图8为本发明实施例所述的搅拌针剖面结构示意图;FIG8 is a schematic diagram of a cross-sectional structure of a stirring needle according to an embodiment of the present invention;
图9为本发明实施例所述的搅拌摩擦焊接过程中前进侧空腔填补示意图;FIG9 is a schematic diagram of filling the forward side cavity during the friction stir welding process according to an embodiment of the present invention;
图10为本发明实施例所述的搅拌摩擦焊接过程中截面方向塑态金属流动状态示意图;10 is a schematic diagram of the plastic metal flow state in the cross-sectional direction during the friction stir welding process according to an embodiment of the present invention;
图11为本发明实施例所述的焊前对接边背面倒角示意图;FIG11 is a schematic diagram of the back chamfering of the butt joint edge before welding according to an embodiment of the present invention;
图12为本发明实施例所述的整体方法流程示意图。FIG. 12 is a schematic diagram of the overall method flow described in an embodiment of the present invention.
需要说明的是,在不冲突的情况下,本发明中的实施例及实施例中的特征可以相互组合。It should be noted that, in the absence of conflict, the embodiments of the present invention and the features in the embodiments may be combined with each other.
在本发明的描述中,需要理解的是,术语“中心”、“纵向”、“横向”、“上”、“下”、“前”、“后”、“左”、“右”、“竖直”、“水平”、“顶”、“底”、“内”、“外”等指示的方位或位置关系为基于附图所示
的方位或位置关系,仅是为了便于描述本发明和简化描述,而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作,因此不能理解为对本发明的限制。此外,术语“第一”、“第二”等仅用于描述目的,而不能理解为指示或暗示相对重要性或者隐含指明所指示的技术特征的数量。由此,限定有“第一”、“第二”等的特征可以明示或者隐含地包括一个或者更多个该特征。在本发明的描述中,除非另有说明,“多个”的含义是两个或两个以上。In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside" and the like indicate directions or positional relationships based on the figures. The orientation or positional relationship is only for the convenience of describing the present invention and simplifying the description, and does not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operate in a specific orientation, and therefore cannot be understood as a limitation of the present invention. In addition, the terms "first", "second", etc. are only used for descriptive purposes, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Therefore, features defined as "first", "second", etc. may explicitly or implicitly include one or more of the features. In the description of the present invention, unless otherwise specified, "multiple" means two or more.
在本发明的描述中,需要说明的是,除非另有明确的规定和限定,术语“安装”、“相连”、“连接”应做广义理解,例如,可以是固定连接,也可以是可拆卸连接,或一体地连接;可以是机械连接,也可以是电连接;可以是直接相连,也可以通过中间媒介间接相连,可以是两个元件内部的连通。对于本领域的普通技术人员而言,可以通过具体情况理解上述术语在本发明中的具体含义。In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood by specific circumstances.
下面将参考附图并结合实施例来详细说明本发明。The present invention will be described in detail below with reference to the accompanying drawings and in conjunction with embodiments.
如图1至图12所示,一种铝合金薄板近无减薄搅拌摩擦焊接方法,包括以下步骤:As shown in FIGS. 1 to 12 , a friction stir welding method for aluminum alloy thin plates with near-zero thinning comprises the following steps:
S1、采用近无减薄搅拌头控制焊缝正面减薄量;S1. Use a nearly non-thinning stirring head to control the thinning amount of the weld front;
S2、采用近无减薄搅拌头控制焊缝背面减薄量;S2. Use a nearly non-thinning stirring head to control the thinning amount on the back of the weld;
S3、采用近无减薄搅拌头焊接焊缝;S3, use a nearly non-thinning stirring head to weld the weld;
所述近无减薄搅拌头包括轴肩结构和搅拌针结构,所述轴肩结构与搅拌针结构为一体成型结构,所述轴肩结构与搅拌针结构均用于焊接焊缝。The nearly non-thinning stirring head comprises a shaft shoulder structure and a stirring needle structure, wherein the shaft shoulder structure and the stirring needle structure are an integrally formed structure, and both the shaft shoulder structure and the stirring needle structure are used for welding welds.
本发明大幅减少了目前单轴肩搅拌摩擦焊接中的减薄量,通过搅拌头结构的优化设计和焊前对工件背面待焊区的倒角处理,将焊缝整体减薄量由
0.25~0.4mm减小到了0.1~0.15mm,并将焊缝合格率提升至95%以上,实现了近无减薄近无缺陷搅拌摩擦焊接,提高了焊缝的质量,实现了一次焊接即合格的目标。The present invention greatly reduces the thinning amount in the current single-shaft shoulder stir friction welding. By optimizing the design of the stirring head structure and chamfering the back of the workpiece to be welded before welding, the overall thinning amount of the weld is reduced by The thickness of the weld was reduced from 0.25 to 0.4 mm to 0.1 to 0.15 mm, and the weld qualification rate was increased to more than 95%, achieving near-zero-thinning and near-defective friction stir welding, improving the quality of the weld, and achieving the goal of qualified welding in one go.
实施例1Example 1
本发明思路为:The idea of the present invention is:
1、减小甚至消除焊缝正面飞边,使焊缝正面存在较少的或不存在母材材料的损失,从而控制焊缝正面减薄量;1. Reduce or even eliminate the flash on the front of the weld, so that there is less or no loss of parent material on the front of the weld, thereby controlling the thinning amount on the front of the weld;
2、在减小焊缝正面减薄量的前提下,保证焊接过程中有足够的锻压力,保证焊缝的致密度,从而保证焊缝接头具有良好的力学性能;2. Under the premise of reducing the thinning amount of the weld front, ensure that there is sufficient forging pressure during welding to ensure the density of the weld, so as to ensure that the weld joint has good mechanical properties;
3、在减小焊缝正面减薄量及保证焊缝力学性能的前提下,提高焊接过程中塑态金属的流动性,加强搅拌头后退侧对前进侧空腔的回填作用,从机理上控制焊缝缺陷的产生,保证焊缝的一次焊接合格率;3. Under the premise of reducing the thinning amount of the weld front and ensuring the mechanical properties of the weld, improve the fluidity of the plastic metal during welding, strengthen the backfilling effect of the backward side of the stirring head on the forward side cavity, control the generation of weld defects from a mechanism point of view, and ensure the first-time welding pass rate of the weld;
4、充分利用塑态金属在竖直截面方向的流动性,控制背面弱结合缺陷的产生,从而减小焊缝背面的打磨量,控制焊缝背面的减薄量。4. Make full use of the fluidity of plastic metal in the vertical section direction to control the generation of weak bonding defects on the back side, thereby reducing the amount of grinding on the back side of the weld and controlling the amount of thinning on the back side of the weld.
近无减薄搅拌头轴肩结构设计:Nearly non-thinning mixing head shoulder structure design:
本发明中近无减薄搅拌头轴肩采用阿基米德螺旋线作为基本结构曲线,为提高轴肩结构对塑态金属的汇聚作用和焊接过程稳定性,采用阿基米德双螺旋或三螺旋结构,阿基米德双螺旋各螺旋线分布角度为180°,阿基米德三螺旋各螺旋线分布角度为120°,如图2和图3所示。In the present invention, the shoulder of the nearly non-thinning stirring head adopts the Archimedean spiral as the basic structural curve. In order to improve the convergence effect of the shoulder structure on the plastic metal and the stability of the welding process, an Archimedean double spiral or triple spiral structure is adopted. The distribution angle of each spiral line of the Archimedean double spiral is 180°, and the distribution angle of each spiral line of the Archimedean triple spiral is 120°, as shown in Figures 2 and 3.
近无减薄搅拌头轴肩端面采用凸球面结构,可提高焊接过程中搅拌头锻压力,保证焊缝在较小减薄量的同时具有足够的焊缝致密度,从而提高焊缝力学性能。针对焊接区厚度2~4mm薄板铝合金,轴肩结构遵循以下设计:The end face of the shaft shoulder of the nearly non-thinning stirring head adopts a convex spherical structure, which can increase the forging pressure of the stirring head during welding, ensuring that the weld has sufficient weld density while reducing the amount of thinning, thereby improving the mechanical properties of the weld. For aluminum alloy sheets with a thickness of 2 to 4 mm in the welding area, the shaft shoulder structure follows the following design:
凸球面半径为R50~R65mm,轴肩直径为Φ13~Φ16mm,轴肩侧搅拌头主
体夹角90°,轴肩与搅拌头主体过渡区圆角R0.5~R1mm,阿基米德螺旋线圆弧凹槽半径R0.25~R0.4mm,如图4所示。受阿基米德螺旋结构强聚料特点的影响,螺旋线收尾点半径小于轴肩半径0.8~1mm,可改善焊缝两侧边缘形貌,使焊缝与母材过渡圆滑,如图5和图6所示。The radius of the convex spherical surface is R50~R65mm, the diameter of the shaft shoulder is Φ13~Φ16mm, and the main stirring head on the shaft shoulder side is The body angle is 90°, the fillet of the transition zone between the shaft shoulder and the main body of the stirring head is R0.5-R1mm, and the radius of the Archimedean spiral arc groove is R0.25-R0.4mm, as shown in Figure 4. Influenced by the strong aggregation characteristics of the Archimedean spiral structure, the radius of the spiral end point is 0.8-1mm smaller than the shoulder radius, which can improve the edge morphology on both sides of the weld and make the transition between the weld and the base material smooth, as shown in Figures 5 and 6.
近无减薄搅拌头搅拌针结构设计:Nearly non-thinning stirring head stirring needle structure design:
针对焊接区厚度2~4mm薄板铝合金,搅拌针结构遵循以下设计:For aluminum alloy sheets with a thickness of 2 to 4 mm in the welding zone, the stirring needle structure follows the following design:
搅拌针锥角18~20°,搅拌针根部直径Φ4~Φ6mm,根部圆角R0.8~R1,搅拌针上加工三个斜面,呈120°分布,斜面高度2.5~3.5mm,螺纹采用梯形结构,相对于目前的三角螺纹可有效加强搅拌针的结构强度,梯形螺纹高度0.25~0.35mm,螺纹根部宽度0.2~0.25mm,锥角60°,螺纹加工结束时刀具在1/4圈内逐渐退出,收尾点高于斜面0~0.3mm,如图7和图8所示。该结构可大幅提高搅拌头结构强度和可靠性,能满足至少16m长环焊缝的连续不间断焊接。The stirring needle has a taper angle of 18-20°, a root diameter of Φ4-Φ6mm, a root fillet of R0.8-R1, three inclined planes are machined on the stirring needle, distributed at 120°, and the height of the inclined plane is 2.5-3.5mm. The thread adopts a trapezoidal structure, which can effectively enhance the structural strength of the stirring needle compared with the current triangular thread. The height of the trapezoidal thread is 0.25-0.35mm, the root width of the thread is 0.2-0.25mm, and the taper angle is 60°. At the end of the thread processing, the tool gradually withdraws within 1/4 of a circle, and the end point is 0-0.3mm higher than the inclined plane, as shown in Figures 7 and 8. This structure can greatly improve the structural strength and reliability of the stirring head, and can meet the continuous and uninterrupted welding of at least 16m long ring welds.
近无减薄搅拌摩擦焊工艺范畴:Nearly zero-thinning friction stir welding process scope:
如图9所示,搅拌摩擦焊接过程中,塑态化的金属材料在搅拌针和轴肩旋转搅动作用下由前进侧向后退侧、再到前进侧环向流动,前进侧塑态金属流出后形成空腔,后退侧的金属在搅拌头的作用下填补前进侧空腔,保持焊缝内组织密度的一致性,整个焊接过程是一个组织流动的动态平衡过程。搅拌头结构以及工艺参数的不合理均会打破焊接过程的动态平衡,导致焊缝内部缺陷的产生。As shown in Figure 9, during the friction stir welding process, the plasticized metal material flows from the forward side to the backward side and then to the forward side in an annular direction under the rotating stirring action of the stirring needle and the shaft shoulder. The plastic metal on the forward side flows out to form a cavity. The metal on the backward side fills the forward side cavity under the action of the stirring head to maintain the consistency of the tissue density in the weld. The entire welding process is a dynamic balance process of tissue flow. The unreasonable structure of the stirring head and the process parameters will break the dynamic balance of the welding process and lead to the generation of internal defects in the weld.
通过大量的工艺试验验证,针对铝锂合金材料,采用近无减薄搅拌头焊接,工艺范畴为:搅拌头倾角1°~2°,搅拌头旋转速度300~600r/min,焊接行走速度100~250mm/min,可获得成形美观、组织致密、力学性能优良、焊缝正面减薄量小于0.1mm的焊缝接头。
Through a large number of process tests and verifications, for aluminum-lithium alloy materials, near-zero thinning stirring head welding is adopted. The process range is: stirring head inclination angle 1°~2°, stirring head rotation speed 300~600r/min, welding travel speed 100~250mm/min, which can obtain weld joints with beautiful shape, dense structure, excellent mechanical properties and weld front thinning less than 0.1mm.
近无减薄搅拌摩擦焊背面减薄量的控制:Control of back thinning amount in friction stir welding with near-zero thinning:
焊缝背面的减薄主要是对弱结合缺陷的打磨清理造成的,控制弱结合缺陷就能控制焊缝背面打磨量,控制了打磨量就能控制焊缝背面的减薄量。搅拌摩擦焊接过程中塑性金属在焊缝截面上的流动方向如图10所示,在搅拌针螺纹作用下,塑性金属有向焊缝背面流动的趋势,因此提高搅拌针端面与背部垫板间0.15~0.25mm间隙范围内塑性金属的混合度,可有效控制弱结合缺陷的产生。The thinning of the back of the weld is mainly caused by the grinding and cleaning of weak bonding defects. Controlling the weak bonding defects can control the amount of grinding on the back of the weld, and controlling the amount of grinding can control the amount of thinning on the back of the weld. The flow direction of the plastic metal on the weld cross section during the stir friction welding process is shown in Figure 10. Under the action of the stirring needle thread, the plastic metal tends to flow to the back of the weld. Therefore, increasing the mixing degree of the plastic metal in the gap range of 0.15 to 0.25 mm between the end face of the stirring needle and the back pad can effectively control the generation of weak bonding defects.
控制方法为:产品焊接前,在两对接边背面开C0.2~C0.5的倒角,如图11所示,焊接过程中,焊缝内的塑性金属会在倒角内充分的填充混合,可有效控制弱结合缺陷的产生。通过试验验证,焊缝背面弱结合缺陷数量减少至优化前的10~20%,焊缝背面只需打磨圆滑,减薄量可控制在0.05mm内。The control method is: before welding the product, open a chamfer of C0.2 to C0.5 on the back of the two butt edges, as shown in Figure 11. During the welding process, the plastic metal in the weld will be fully filled and mixed in the chamfer, which can effectively control the generation of weak bonding defects. Through experimental verification, the number of weak bonding defects on the back of the weld is reduced to 10 to 20% before optimization. The back of the weld only needs to be polished and smooth, and the thinning amount can be controlled within 0.05mm.
本发明的目的:(1)本发明中研发了薄板铝合金近无减薄搅拌头,对搅拌头轴肩和搅拌针结构进行了设计,采用该搅拌头可有效控制焊缝正面减薄量;Purpose of the present invention: (1) The present invention develops a thin plate aluminum alloy near-zero thinning stirring head, designs the stirring head shaft shoulder and stirring needle structure, and adopts the stirring head to effectively control the thinning amount of the weld front side;
(2)本发明中采用了对产品待焊端背面开倒角的方法,有效控制了焊缝弱结合缺陷的产生,进而控制了焊缝背部打磨量和焊缝减薄量。(2) The present invention adopts a method of chamfering the back side of the product to be welded, which effectively controls the generation of weak bonding defects in the weld, and further controls the amount of grinding on the back side of the weld and the amount of thinning of the weld.
本发明的优势:本发明实现了薄板铝合金的近无减薄近无缺陷搅拌摩擦焊接,使薄板航天产品的高质量焊接成为可能,大幅提高了产品焊接质量,并减小了产品焊接变形,对航天型号产品的工程化应用具有重要的现实意义和巨大的经济价值。Advantages of the present invention: The present invention realizes nearly zero-thinning and nearly zero-defect stir friction welding of thin-plate aluminum alloy, makes high-quality welding of thin-plate aerospace products possible, greatly improves the welding quality of products, and reduces the welding deformation of products. It has important practical significance and huge economic value for the engineering application of aerospace model products.
以上所述仅为本发明的较佳实施例而已,并不用以限制本发明,凡在本发明的精神和原则之内,所作的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。
The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (9)
- 一种铝合金薄板近无减薄搅拌摩擦焊接方法,其特征在于:包括以下步骤:A friction stir welding method for aluminum alloy thin plates with near-zero thinning, characterized in that it comprises the following steps:S1、采用近无减薄搅拌头控制焊缝正面减薄量;S1. Use a nearly non-thinning stirring head to control the thinning amount of the weld front;S2、采用近无减薄搅拌头控制焊缝背面减薄量;S2. Use a nearly non-thinning stirring head to control the thinning amount on the back of the weld;S3、采用近无减薄搅拌头焊接焊缝;S3, use a nearly non-thinning stirring head to weld the weld;所述近无减薄搅拌头包括轴肩和搅拌针,所述轴肩与搅拌针为一体成型结构。The nearly non-thinning stirring head comprises a shaft shoulder and a stirring needle, and the shaft shoulder and the stirring needle are an integrally formed structure.
- 根据权利要求1所述的一种铝合金薄板近无减薄搅拌摩擦焊接方法,其特征在于:在步骤S2中的焊缝背面减薄量的控制方法包括以下步骤:The friction stir welding method for aluminum alloy thin plate with near-zero thinning according to claim 1 is characterized in that the method for controlling the thinning amount of the back side of the weld in step S2 comprises the following steps:A1、产品焊缝背面打磨圆滑;A1. The back of the product weld is polished and smooth;A2、在两对产品接边背面开C0.2~C0.5的倒角。A2. Open a chamfer of C0.2~C0.5 on the back of the two pairs of product edges.
- 根据权利要求1所述的一种铝合金薄板近无减薄搅拌摩擦焊接方法,其特征在于:在步骤S3中的近无减薄搅拌头在焊接焊缝过程中,产品塑态化的金属材料在搅拌针和轴肩旋转搅动作用下由前进侧向后退侧、再到前进侧环向流动,前进侧塑态金属流出后形成空腔,后退侧的金属在搅拌头的作用下填补前进侧空腔。According to the near-zero-thinning friction stir welding method for aluminum alloy thin plates as described in claim 1, it is characterized in that: in the near-zero-thinning stirring head in step S3, during the welding process of the weld, the plasticized metal material of the product flows annularly from the forward side to the backward side and then to the forward side under the rotating stirring action of the stirring needle and the shaft shoulder, and the plasticized metal on the forward side flows out to form a cavity, and the metal on the backward side fills the cavity on the forward side under the action of the stirring head.
- 根据权利要求1所述的一种铝合金薄板近无减薄搅拌摩擦焊接方法,其特征在于:在步骤S3中的近无减薄搅拌头的工艺参数为:搅拌头倾角1°~2°,搅拌头旋转速度300~600r/min,焊接行走速度100~250mm/min。According to the near-zero-thinning stir friction welding method for aluminum alloy thin plates as described in claim 1, it is characterized in that the process parameters of the near-zero-thinning stirring head in step S3 are: stirring head inclination angle 1°~2°, stirring head rotation speed 300~600r/min, welding travel speed 100~250mm/min.
- 根据权利要求1所述的一种铝合金薄板近无减薄搅拌摩擦焊接方法,其特征在于:所述轴肩的结构曲线为阿基米德双螺旋结构,所述阿基米德双螺旋结构的各螺旋线分布角度为180°。 The friction stir welding method for aluminum alloy thin plate with near-zero thinning according to claim 1 is characterized in that the structural curve of the shoulder is an Archimedean double helix structure, and the distribution angle of each spiral line of the Archimedean double helix structure is 180°.
- 根据权利要求1所述的一种铝合金薄板近无减薄搅拌摩擦焊接方法,其特征在于:所述轴肩的结构曲线为阿基米德三螺旋结构,阿基米德三螺旋结构的各螺旋线分布角度为120°。According to the friction stir welding method for aluminum alloy thin plates with near-zero thinning as described in claim 1, it is characterized in that the structural curve of the shoulder is an Archimedean triple helix structure, and the distribution angle of each spiral line of the Archimedean triple helix structure is 120°.
- 根据权利要求5或6所述的一种铝合金薄板近无减薄搅拌摩擦焊接方法,其特征在于:所述轴肩的结构参数为:According to the friction stir welding method for aluminum alloy thin plate with near-zero thinning as claimed in claim 5 or 6, it is characterized in that the structural parameters of the shoulder are:凸球面半径为R50~R65mm,轴肩直径为Φ13~Φ16mm,轴肩侧搅拌头主体夹角90°,轴肩与搅拌头主体过渡区圆角R0.5~R1mm,阿基米德螺旋线圆弧凹槽半径R0.25~R0.4mm,螺旋线收尾点半径小于轴肩半径0.8~1mm。The radius of the convex spherical surface is R50~R65mm, the shoulder diameter is Φ13~Φ16mm, the angle of the stirring head body on the shoulder side is 90°, the fillet of the transition zone between the shoulder and the stirring head body is R0.5~R1mm, the radius of the Archimedean spiral arc groove is R0.25~R0.4mm, and the radius of the spiral end point is 0.8~1mm smaller than the shoulder radius.
- 根据权利要求7所述的一种铝合金薄板近无减薄搅拌摩擦焊接方法,其特征在于:所述搅拌针的结构参数为:The friction stir welding method for aluminum alloy thin plate with near-zero thinning according to claim 7 is characterized in that the structural parameters of the stirring needle are:搅拌针锥角18~20°,搅拌针根部直径Φ4~Φ6mm,根部圆角R0.8~R1,搅拌针上设有三个斜面,三个斜面呈120°分布,斜面高度2.5~3.5mm,螺纹为梯形结构,梯形螺纹高度0.25~0.35mm,螺纹根部宽度0.2~0.25mm,锥角60°,收尾点高于斜面0~0.3mm。The stirring needle has a taper angle of 18 to 20°, a root diameter of Φ4 to Φ6mm, a root fillet of R0.8 to R1, three inclined surfaces are arranged on the stirring needle, and the three inclined surfaces are distributed at 120°. The height of the inclined surfaces is 2.5 to 3.5mm, the thread is a trapezoidal structure, the height of the trapezoidal thread is 0.25 to 0.35mm, the width of the thread root is 0.2 to 0.25mm, the taper angle is 60°, and the end point is 0 to 0.3mm higher than the inclined surface.
- 根据权利要求8所述的一种铝合金薄板近无减薄搅拌摩擦焊接方法,其特征在于:所述轴肩的结构参数与所述搅拌针的结构参数设置均针对焊接区厚度2~4mm的产品。 According to the nearly non-thinning friction stir welding method for aluminum alloy thin plates as described in claim 8, it is characterized in that the structural parameters of the shoulder and the structural parameters of the stirring needle are both set for products with a welding zone thickness of 2 to 4 mm.
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