WO2024183111A1 - 用于搅拌摩擦焊的纤维丝材制备方法、设备及其焊接方法 - Google Patents

用于搅拌摩擦焊的纤维丝材制备方法、设备及其焊接方法 Download PDF

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WO2024183111A1
WO2024183111A1 PCT/CN2023/084343 CN2023084343W WO2024183111A1 WO 2024183111 A1 WO2024183111 A1 WO 2024183111A1 CN 2023084343 W CN2023084343 W CN 2023084343W WO 2024183111 A1 WO2024183111 A1 WO 2024183111A1
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Prior art keywords
fiber
wire
welding
unidirectional
tape
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English (en)
French (fr)
Inventor
周应国
蒋振国
杨金强
陈书锦
邹俊
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Jiangsu University of Science and Technology
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Jiangsu University of Science and Technology
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/06—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using friction, e.g. spin welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00—Subject matter not provided for in other groups of this subclass

Definitions

  • the invention relates to the technical field of welding, in particular to a method and equipment for preparing fiber wires used for friction stir welding and a welding method.
  • FSW friction stir welding
  • This process is mainly used for the connection of light alloys and low-carbon steel, and is also used in a small amount for the welding of polymers.
  • the friction stir welding of polymers has the advantages of low temperature, intense plastic deformation and high joint quality, but it also has many limitations and shortcomings.
  • the welding quality is greatly affected by the process, so the welding process window is narrow, and the optimal welding process is not easy to stabilize in practical applications.
  • the substantial reason is that the strength of the weld is still far lower than that of the parent material, resulting in the failure of the weld during application mainly occurring in the welding area.
  • the purpose of the present invention is to provide a method and equipment for preparing fiber wires for stir friction welding and a welding method, which can significantly improve the mechanical properties of the weldment.
  • the present invention provides a method for preparing a fiber wire for friction stir welding, comprising the following steps:
  • Step S1 after the bundled fiber material is widened and pre-impregnated with a shaping glue to form a unidirectional thin fiber tape, a thermoplastic polymer is melted and plasticized and then coated on the unidirectional thin fiber tape to form a fiber coated tape;
  • Step S2 the fiber coated tape is axially wound to form a unidirectional multi-layer fiber/polymer prepreg wire material with a circular cross-section;
  • Step S3 the unidirectional multi-layer fiber/polymer prepreg wire material is cut and kept in a semi-connected state, and then hot-melt treated and cooled to obtain a fiber wire material that is cut and then fused.
  • thermoplastic polymer is the same as the base material to be welded.
  • step S1 the fiber content of the fiber coating tape is 40% to 60%.
  • the cross-sectional layering lines of the unidirectional multi-layer fiber/polymer prepreg wire material are Archimedean spiral lines.
  • step S3 the cutting ratio accounts for 70-90% of the entire circular cross section, and the cutting length is 1.5-2.5 times the diameter of the friction stir welding head.
  • step S3 the slit unidirectional multi-layer fiber/polymer prepreg wire material is subjected to axial force extrusion and remelting during the hot melt treatment.
  • the fiber filament prepared by the above method is applied to a thermoplastic polymer friction stir welding process.
  • the welding method comprises the following steps:
  • Step 1 Repair and level the welded part of the connecting piece and remove the material from the middle of the welded part;
  • Step 2 embedding or melting the prepared fiber filament into the part to be welded where the material has been removed, and then flattening the part to be welded;
  • Step 3 After the welding parts of the two parts to be connected are butt-jointed, a lateral force is applied and they are pressed and fixed. After the stirring head rotates at a high speed, the two parts are connected.
  • the material removed from the middle of the part to be welded in step 1 is consistent with the volume of the fiber wire to be embedded or melted in step 2.
  • the downward pressure is controlled so that the end face of the stirring head shoulder exceeds the upper surface of the welding wire by 0.05 to 0.15 mm after the welding wire is pressed in, and the downward pressure is less than or equal to the difference between the thickness of the weldment and the length of the stirring needle.
  • the present invention provides a fiber wire preparation device for friction stir welding, comprising:
  • the extruder is used to extrude the thermoplastic polymer after melting and plasticizing; the yarn spreading roller is used to widen the bundled fiber material to form a unidirectional thin-layer fiber dry tape; the fiber tape bonding roller is used to pre-impregnate the unidirectional thin-layer fiber dry tape with a shaping glue to form a whole piece of unidirectional thin-layer fiber tape; the impregnation head is used to coat the unidirectional thin-layer fiber tape with the melted and plasticized thermoplastic polymer to form a fiber coated tape; the axial winder is used to axially wind the fiber coated tape to form a unidirectional multi-layer fiber/polymer prepreg wire material; the traction roller pair is used to pull the unidirectional multi-layer fiber/polymer prepreg wire material onto the crawler traction machine; the longitudinal cutter is used to longitudinally cut the unidirectional multi-layer fiber/polymer prepreg wire material; the hot melt oven is used to re-melt the fracture of the unidirectional multi-
  • it also includes a speed-adjustable pair of rollers, whose speed is the same as the speed of the traction pair of rollers and is less than the speed of the crawler traction machine.
  • the present invention can significantly improve the strength of the weld; the present invention avoids the anisotropy of the mechanical properties at the weld due to fiber reinforcement; the present invention can effectively avoid the probability of weld pores or gaps that are easily generated by ordinary polymer stir friction welding; the present invention is easy to use, and the re-fusion of the wire after slitting can significantly improve the convenience of use, and welding is easy to implement; the wire preparation and welding process are both green and pollution-free.
  • FIG1 is a schematic diagram of the structure of a fiber filament preparation device of the present invention.
  • FIG2 is a physical picture of the fiber filaments of the present invention after cutting and then fusing
  • FIG3 is a welding physical diagram of the present invention.
  • FIG4 is a SEM characterization image of the fiber wire material at the weld of the workpiece according to Example 1 of the present invention.
  • FIG5 is a SEM characterization image of the fiber-free material after welding using polycarbonate as raw material according to Example 2 of the present invention.
  • FIG6 is a sample appearance diagram of welding test pieces of Example 1 and Example 2 of the present invention before and after the test;
  • FIG. 7 is a SEM characterization image of the weld of the workpieces connected in Example 3 of the present invention.
  • the device for preparing fiber filaments used for stir friction welding of the present invention is shown.
  • Figure 1 also shows the preparation process of the fiber filaments.
  • the device mainly includes an extruder 1, a yarn frame 2, a yarn spreading roller 4, a fiber tape bonding roller 5, an impregnation head 7, an axial winder 8, a traction roller pair 9, a crawler traction machine 10, a longitudinal cutter 11, a hot melt oven 12 and a speed-adjustable roller pair 13.
  • the extruder 1 is connected to the impregnation head 7.
  • a yarn frame 2, a yarn spreading roller 4, and a fiber tape bonding roller 5 are arranged on one side of the extruder 1 in sequence.
  • An axial winder 8, a traction roller pair 9, a hot melt oven 12, and a speed regulating roller pair 13 are arranged on the other side of the extruder 1 in sequence.
  • a crawler traction machine 10 and a longitudinal cutter 11 are arranged between the traction roller pair 9 and the hot melt oven 12. The longitudinal cutter 11 is arranged directly above the crawler traction machine 10.
  • Step (1) the thermoplastic polymer is melted and plasticized through an extruder 1 and then enters an impregnation head 7;
  • Step (2) placing a specific fiber material in a creel 2, at which time the fiber material is in a bundle shape, and the fiber bundle 3 is formed into a unidirectional thin fiber dry belt after being widened by a yarn spreading roller 4;
  • the number of creels 2 can be one or more, and the number of yarn spreading rollers 4 should be consistent with that of creels 2;
  • Step (3) when a plurality of flattened dry fiber tapes pass through a fiber tape bonding roller 5, they are pre-impregnated with a trace amount of shaping glue to form a whole piece of unidirectional thin layer fiber tape 6, and the fiber tape 6 also enters an impregnation head 7, where the fiber tape 6 is evenly coated with a polymer high-temperature melt to form a fiber coated tape; controlling the coating amount of the fiber coated tape can control the fiber content and ensure uniform distribution of the fibers in the coated tape.
  • the fiber content is maintained between 40% and 60%;
  • Step (4) the fiber coating tape is subsequently wound axially by an axial winder 8 to form a unidirectional multi-layer fiber/polymer prepreg wire material with a circular cross section;
  • Step (5) the wire material enters the crawler traction machine 10 under the action of the traction roller 9, and is cut by the longitudinal cutter 11 and maintained in a semi-connected state;
  • Step (6) when the semi-connected wire passes through the hot melt oven 12, a small amount of polymer at the fracture is melted. At the same time, it is slightly blocked by the speed-adjustable roller 13 behind it, so that the molten polymer is compressed and adheres to each other, thereby forming a fiber wire 14 that is cut and then fused. The wire is subsequently wound or coiled for standby use.
  • the speed of the speed-adjustable roller 13 can be consistent with the speed of the traction roller 9, and their speeds are 2 to 5% lower than the speed of the crawler traction.
  • thermoplastic polymer stir friction welding which specifically comprises the following steps:
  • step 1) The material removed from the middle of each part to be welded in step 1) is consistent with the volume of the wire to be embedded or melted in step 2).
  • the welding process conditions in step 3) mainly include the downward pressure and the welding speed.
  • the downward pressure is controlled so that the end face of the stirring head shoulder exceeds the upper surface of the welding wire by 0.05 to 0.15 mm after the welding wire is pressed in, and the downward pressure is less than or equal to the difference between the thickness of the weldment and the length of the stirring needle.
  • this embodiment carries out friction stir welding on a transparent polycarbonate weldment.
  • the main raw materials used include polycarbonate (PC, melting volume rate of 24 cm 3 /10min, (300°C/1.2kg)) and carbon fiber (12K, T700), both of which are commercially available.
  • the whole process mainly includes two steps: wire preparation and welding.
  • the wire preparation process is as follows:
  • the polycarbonate is melted and plasticized by the extruder 1 and then enters the impregnation head 7.
  • a bundle of carbon fibers is placed in the creel 2.
  • a unidirectional thin fiber dry tape is formed.
  • the fiber tape 6 also enters the impregnation head 7, and the fiber tape 6 is evenly coated with the polycarbonate high-temperature melt to form a fiber coating tape;
  • the fiber coating tape is axially wound by the subsequent axial winder 8, and the cross section gradually forms an Archimedean spiral, forming a unidirectional multi-layer fiber/polymer prepreg wire material with a circular cross section.
  • the wire material enters the crawler traction machine 10 under the action of the traction roller 9, and is cut by the longitudinal cutter 11 and kept in a semi-connected state; the cutting ratio accounts for 80% of the entire circular fiber/polymer prepreg cross section, and the cutting length is 12mm (the diameter of the friction stir welding head is 6mm).
  • the semi-connected wire material passes through the hot melt oven 12, a small amount of polymer at the fracture is melted.
  • Fusion means in the present invention that the polymer of the fiber filament at the fracture is melted, the molten polymer is compressed and adheres to each other, and after cooling, the polymer at the fracture is connected in an adhesive manner, wherein at the fracture, the cut fiber remains in a cut state after bonding.
  • the prepared wire is then used for friction stir welding, mainly including:
  • the downward pressure of the welding head is controlled to be 0.30mm
  • the thickness of the weldment is 2mm
  • the selected stirring needle length is 1.5mm.
  • the weld of the connected workpieces was characterized by SEM, and the results are shown in Figure 4.
  • fibers of almost equal length are evenly distributed in an arc shape, and the reinforcing effect of the fibers can be foreseen from its structure.
  • the cut fibers can be distributed 360 degrees in all directions under the drive of the high-speed rotating stirring head.
  • all angles of the weld can be reinforced by fibers, avoiding the anisotropy of the mechanical properties of the weld due to fiber reinforcement.
  • the use of wire can also effectively avoid the probability of weld pores or gaps that are easily generated by ordinary polymer stir friction welding.
  • the wire-reinforced weldment of the present invention has a fiber distribution structure of a specific form, exhibits excellent mechanical properties, and has excellent application prospects.
  • Example 2 For comparison with Example 1, similar to Example 1, this comparative example also uses commercially available polycarbonate (melting volume rate of 24 cm 3 /10min) as the base material, but Example 2 does not use fiber filaments.
  • the welding process is mainly as follows: obtain the parts to be connected using polycarbonate as the raw material through hot pressing or other processes, then butt the parts to be welded of the two parts to be connected, apply a proper lateral force, and then press and fix them on the workbench. Under certain welding process conditions, the two parts are connected as one after the high-speed rotation of the stirring head.
  • the welds of the connected workpieces were characterized by SEM, and the results are shown in FIG5 . As can be seen in FIG5 , there are many voids and gaps at the joint of the welds, so it is foreseeable that the strength of the welds will not be very good.
  • FIG6 A rectangular test specimen was cut out of the connected workpiece and subjected to a tensile mechanical property test. The appearance results are also shown in FIG6 , wherein FIG6c and FIG6d respectively show the appearance of the sample before and after the test. As can be seen from FIG6d , the tensile fracture occurred at the weld without any suspense at this time, which is sufficient to indicate that the mechanical properties at the weld need to be improved.
  • this comparative example also carried out friction stir welding on a transparent polycarbonate weldment, and the main raw materials used included polycarbonate (melting volume rate of 24 cm 3 /10 min) and carbon fiber (12K, T700), both of which are commercially available.
  • the whole process mainly includes two steps: wire preparation and welding.
  • the wire preparation process is similar to the existing conventional long fiber reinforced polymer granular materials except that no cutting is performed: the polycarbonate is melted and plasticized through an extruder and then enters the impregnation head. At the same time, the carbon fiber tow placed in the creel is also introduced into the impregnation head. The fiber is impregnated with the high-temperature melt of polycarbonate in the impregnation head to form a fiber/polymer prepreg wire with an irregular cross-section. The wire is subsequently pulled, wound or coiled for use to form a continuous wire.
  • the prepared wire was then used for friction stir welding as follows:
  • the weld of the connected workpieces was characterized by SEM, and the result is shown in FIG7 .
  • the fiber distribution at the weld is very disordered, the fiber length difference is also large, and the distribution of the fibers in all directions is also relatively disordered.
  • friction stir welding is performed on nylon weldments.
  • the main raw materials used include nylon (PA66, melting volume rate is 23 cm 3 /10min) and glass fiber (12K, T700), both of which are commercially available.
  • the whole process mainly includes two steps: wire preparation and welding.
  • the wire preparation process is as follows:
  • the PA66 is melted and plasticized by the extruder 1 and then enters the impregnation head 7.
  • two bundles of carbon fibers are placed in two creels 2 respectively, and are respectively spread by two yarn spreading rollers 4 to form unidirectional thin-layer fiber dry tapes.
  • the two unidirectional thin-layer fiber dry tapes are then pre-impregnated with a trace amount of shaping glue when passing through the fiber tape bonding roller 5 to form a whole piece of unidirectional thin-layer fiber tape 6, and the fiber content is maintained at 60%.
  • the fiber tape 6 also enters the impregnation head 7, and the fiber tape 6 is evenly coated with the PA66 high-temperature melt to form a fiber coating tape;
  • the fiber coated tape is axially wound by the subsequent axial winder 8, and the cross section gradually forms an Archimedean spiral to form a unidirectional multi-layer fiber/polymer prepreg wire with a circular cross section.
  • the wire enters the crawler traction machine 10 under the action of the traction roller 9, and is cut by the longitudinal cutter 11 and kept in a semi-connected state; the cutting ratio accounts for 1.3% of the entire circular fiber.
  • the slitting length is 9cm (the diameter of the friction stir welding head is 6mm)
  • the speed of the speed regulating roller 13 is consistent with the speed of the traction roller 9, their speeds are 5% lower than the speed of the crawler traction, so the semi-connected wire will be slightly blocked by the speed regulating roller 13 behind, and the molten polymers are pressed and bonded to each other, thereby forming a fiber wire 14 that is cut and then fused, and the wire is subsequently wound or coiled for standby use.
  • the appearance of the fiber wire that is cut and then fused is also similar to Figure 2.
  • the prepared wire was then used for friction stir welding as follows:
  • the downward pressure of the welding head is controlled to be 0.35mm
  • the thickness of the weldment is 2mm
  • the selected stirring needle length is 1.5mm.
  • this comparative example also carried out friction stir welding of fiber wires without cutting for nylon weldment, and the main raw materials used included nylon (melting volume rate of 23 cm 3 /10min) and carbon fiber (12K, T700), both of which are commercially available.
  • the whole process mainly includes two steps: wire preparation and welding.
  • the wire preparation process is similar to the existing conventional long fiber reinforced polymer granular materials except that no cutting is performed: the nylon is melted and plasticized through an extruder and then enters the impregnation head. At the same time, the carbon fiber bundle placed in the creel is also introduced into the impregnation head. The fiber is impregnated with the high-temperature melt of nylon in the impregnation head to form a fiber/polymer prepreg wire with an irregular cross-section. The wire is subsequently pulled, wound or coiled for use to form a continuous wire.
  • the prepared wire was then used for friction stir welding as follows:
  • the welds of the connected workpieces were characterized by SEM, and the results were similar to those in Example 3.
  • the fiber distribution at the welds was very chaotic, the fiber lengths varied greatly, and the distribution of the fibers in all directions was also relatively chaotic.
  • the fiber content of the fiber-coated tape is 40%; the cutting ratio accounts for 70% of the entire circular cross-section, the cutting length is 15 mm, and the downward pressure of the welding head is controlled to be 0.25 mm.
  • the fiber content of the fiber-coated tape is 60%; the cutting ratio accounts for 90% of the entire circular cross-section, the cutting length is 15 mm, and the downward pressure of the welding head is controlled to be 0.32 mm.

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Abstract

本发明公开了用于搅拌摩擦焊的纤维丝材制备方法和设备及焊接方法，制备方法包括以下步骤：S1、束状纤维材料经过宽展后并预浸定型胶形成单向薄层纤维带，将热塑性聚合物熔融塑化后涂覆在单向薄层纤维带上形成纤维涂覆带；S2、将纤维涂覆带轴向卷绕形成截面为圆形的单向多层纤维/聚合物预浸丝材；S3、将单向多层纤维/聚合物预浸丝材分切并保持半连状态后热熔处理并冷却得到切后再熔合的纤维丝材，本发明的纤维丝材焊接时能被均匀全方位分布在焊接部位，从而显著提高焊缝的强度，分切后的纤维可在高速旋转的搅拌头带动下呈现360度全方位的分布，焊缝处的各个角度均能得以纤维增强，避免了焊缝处力学性能因纤维增强所可能带来的各向异性。

Description

用于搅拌摩擦焊的纤维丝材制备方法、设备及其焊接方法 技术领域
本发明涉及焊接技术领域，尤其是用于搅拌摩擦焊的纤维丝材制备方法和设备及焊接方法。
背景技术
材料焊接可以显著提高制品生产的可连续性，对于较多复杂金属制品来说，合理的焊接工艺可以明显缩短制造周期，减轻制品重量，提高制品外形及结构设计的灵活性，因而，焊接成为了一种重要的制品成型的工艺方法而广为关注，应用极其广泛。其中，搅拌摩擦焊(FSW)作为一种固态焊接过程，靠旋转工具和工件材料之间的摩擦产生热量，进而导致搅拌摩擦焊工具附近区域变软、混合并最终实现工件的结合。工件经过搅拌摩擦焊后往往具有较好的力学性能。目前，该工艺主要用于轻合金及低碳钢等的连接，也少量用于聚合物的焊接。
相对其它焊接方法来说，聚合物的搅拌摩擦焊具有温度低、塑性变形剧烈、接头质量高等优点，但也具有较多的限制及不足，比如，焊接质量受工艺的影响很大，因而施焊工艺窗口窄，在实际应用中施焊最优工艺不易稳定等，其实质性的原因则在于焊缝处的强度仍然远远低于母材，导致焊件在应用过程中的失效主要发生在焊接区域。
发明内容
发明目的：本发明的目的在于提供一种用于搅拌摩擦焊的纤维丝材制备方法和设备及焊接方法，能够显著提升焊件的力学性能。
技术方案：在第一方面，本发明提供的用于搅拌摩擦焊的纤维丝材制备方法，包括以下步骤：
步骤S1、束状纤维材料经过宽展后并预浸定型胶形成单向薄层纤维带，将热塑性聚合物熔融塑化后涂覆在单向薄层纤维带上形成纤维涂覆带；步骤S2、将纤维涂覆带轴向卷绕形成截面为圆形的单向多层纤维/聚合物预浸丝材；步骤S3、将单向多层纤维/聚合物预浸丝材分切并保持半连状态后热熔处理并冷却得到切后再熔合的纤维丝材。
进一步的，所述步骤S1中，所述热塑性聚合物与待焊接的母材材料相同。
进一步的，所述步骤S1中，纤维涂覆带纤维含量为40％～60％。
进一步的，所述步骤S2中，单向多层纤维/聚合物预浸丝材的截面分层线为阿基米德螺旋线。
进一步的，所述步骤S3中，切断比例占整个圆形截面的70～90％，分切长度为搅拌摩擦焊头直径的1.5～2.5倍。
进一步的，所述步骤S3中，分切后的单向多层纤维/聚合物预浸丝材在热熔处理时轴向受力挤压再熔。
在另一方面，上述方法制备得到的纤维丝材，其应用于热塑性聚合物搅拌摩擦焊焊接工艺，具体的，焊接方法包括如下步骤：
步骤1、将欲连接件的待焊部位修理平整后并将待焊部位中部去除材料；
步骤2、将所制备的纤维丝材嵌入或熔入已去除材料的待焊部位后将待焊部位压平；
步骤3、将两欲连接件的待焊部位对接后施以横向作用力，并压紧固定，经过搅拌头的高速旋转后，两件被连接。
进一步的，步骤1中待焊部位中部去除的材料与步骤2欲嵌入或熔入纤维丝材的体积量保持一致，步骤3的焊接过程中，下压量控制为压入焊丝后搅拌头轴肩端面超出焊丝上表面0.05～0.15mm，且下压量小于或等于焊件厚度与搅拌针长度之间的差值。
在另一方面，本发明提供一种用于搅拌摩擦焊的纤维丝材制备设备，包括：
挤出机，用于将热塑性聚合物熔融塑化后挤出；展纱辊，用于将束状纤维材料宽展后形成单向薄层纤维干带；纤维带黏合辊，用于将单向薄层纤维干带预浸定型胶形成整片的单向薄层纤维带；浸渍机头，用于将熔融塑化后的热塑性聚合物涂覆单向薄层纤维带形成纤维涂覆带；轴向卷绕器，用于对纤维涂覆带沿轴向卷绕形成单向多层纤维/聚合物预浸丝材；牵引对辊，用于将单向多层纤维/聚合物预浸丝材牵引至履带牵引机上；纵向切割器，用于对单向多层纤维/聚合物预浸丝材进行纵向分切；热熔烘箱，用于对单向多层纤维/聚合物预浸丝纵向切割后的断口再熔，再熔后冷却即得到纤维丝材。
进一步的，还包括调速对辊，其速度与牵引对辊的速度相同，且小于履带牵引机的速度。
有益效果：本发明能够显著提高焊缝的强度；本发明避免了焊缝处力学性能因纤维增强所可能带来的各向异性；本发明可以有效避免普通聚合物搅拌摩擦焊容易产生的焊缝孔隙或间隙存在的机率；本发明使用方便，丝材分切后的再熔合可显著提高使用的便利性，焊接易实施；丝材制备及焊接过程均绿色无污染。
附图说明
图1为本发明的纤维丝材的制备设备结构示意图；
图2为本发明的纤维丝材切后再熔合实物图；
图3为本发明的焊接实物图；
图4为本发明实施例1的纤维丝材在工件焊缝处的SEM表征图；
图5为本发明实施例2的以聚碳酸酯为原料无纤维材料焊接后的SEM表征图；
图6为本发明实施例1和实施例2焊接测试样片的测试前后的样品外形图；
图7为本发明实施例3中所连接的工件焊缝处SEM表征图。
具体实施方式
下面结合附图和具体实施例对本发明技术方案作进一步说明。
如图1所示的是本发明的用于制备搅拌摩擦焊所使用的纤维丝材的设备，该图1也同样显示了纤维丝材的制备工艺，设备主要包括挤出机1，纱架2，展纱辊4，纤维带黏合辊5，浸渍机头7，轴向卷绕器8、牵引对辊9、履带牵引机10、纵向切割器11、热熔烘箱12和调速对辊13。
挤出机1连接浸渍机头7，挤出机1一侧设置依次纱架2，展纱辊4，纤维带黏合辊5，挤出机1的另一侧依次设置有轴向卷绕器8、牵引对辊9、热熔烘箱12和调速对辊13，此外在牵引对辊9和热熔烘箱12之间设置有履带牵引机10和纵向切割器11，纵向切割器11设置在履带牵引机10的正上方。
通过上述的设备制备纤维丝材的步骤如下：
步骤(1)，将热塑性聚合物通过挤出机1熔融塑化后进入到浸渍机头7中；
步骤(2)，将特定的纤维材料置于纱架2中，此时纤维材料为束状，纤维束3经过展纱辊4的宽展作用后形成单向薄层纤维干带；纱架2的数量可以为一个或一个之上，展纱辊4的数量与纱架2应保持一致；
步骤(3)，若干展平后的纤维干带经过纤维带黏合辊5时被预浸微量定型胶形成整片的单向薄层纤维带6，该纤维带6也进入到浸渍机头7中，纤维带6被均匀的涂上聚合物高温熔体，形成纤维涂覆带；控制纤维涂覆带的涂覆量可控制纤维含量并保证纤维在该涂覆带中的均匀分布，本实施例中，纤维含量保持在40％～60％之间；
步骤(4)，纤维涂覆带被随后的轴向卷绕器8沿轴向卷绕，形成截面为圆形的单向多层纤维/聚合物预浸丝材；
步骤(5)，丝材在牵引对辊9的作用下进入到履带牵引机10上，并被纵向切割器11分切并保持半连状态；
步骤(6)，半连状态的丝材在通过热熔烘箱12时，断口处的聚合物少量熔融，同时，受到后面的调速对辊13的轻微阻滞力量，使熔融的聚合物受压并相互黏结，从而形成了切后再熔合的纤维丝材14，该丝材后续被缠绕或卷取后备用，调速对辊13的速度可与牵引对辊9的速度保持一致，它们的速度均比履带牵引的速度低2～5％。
上述方法制备得到的纤维丝材，其应用于热塑性聚合物搅拌摩擦焊的焊接工艺，具体的，包括如下步骤：
1)将欲连接件的待焊部位修理平整后并将待焊部位中部去除适量材料；
2)将所制备的丝材嵌入或熔入待焊部位后将待焊部位压平；
3)将两欲连接件的待焊部位对接后施以适量横向作用力，并随后压紧固定在工作台上，在确定的焊接工艺条件下，经过搅拌头的高速旋转后，两件被连接。
其中，在步骤1)中每一个待焊部位中部去除的材料与步骤2)欲嵌入或熔入丝材的体积量保持一致。
在步骤3)中的焊接工艺条件主要包括下压量及焊接速度，一般的，下压量控制为压入焊丝后搅拌头轴肩端面超出焊丝上表面0.05～0.15mm为宜，且下压量小于或等于焊件厚度与搅拌针长度之间的差值。
实施例1
为更容易展示实施效果，本实施例针对透明聚碳酸酯焊件开展搅拌摩擦焊，使用的主要原料包括聚碳酸酯(PC，熔融体积速率为24cm3/10min，(300℃/1.2kg))及碳纤维(12K，T700)，均为市售。
整个过程主要包括丝材制备及施焊两步，其中丝材制备过程如下：
首先，将聚碳酸酯通过挤出机1熔融塑化后进入到浸渍机头7中，同时，将1束碳纤维置于纱架2中，经过展纱辊4的宽展作用后形成单向薄层纤维干带，再经过纤维带黏合辊5时被预浸微量定型胶形成整片的单向薄层纤维带6，纤维含量保持在50％，该纤维带6也进入到浸渍机头7中，纤维带6被均匀的涂上聚碳酸酯高温熔体，形成纤维涂覆带；
其次，纤维涂覆带被随后的轴向卷绕器8沿轴向卷绕，截面逐渐形成阿基米德螺旋线，形成截面为圆形的单向多层纤维/聚合物预浸丝材，丝材在牵引对辊9的作用下进入到履带牵引机10上，并被纵向切割器11分切并保持半连状态；切断比例占整个圆形纤维/聚合物预浸物截面的80％，分切长度为12mm(搅拌摩擦焊头直径为6mm)，半连状态的丝材在通过热熔烘箱12时，断口处的聚合物少量熔融，同时，由于调速对辊13的速度与牵引对辊9的速度一致，它们的速度均比履带牵引的速度低3％，因而，半连状态的丝材会受到后面调速对辊13的轻微阻滞作用，熔融的聚合物受压并相互黏结，从而形成了切后再熔合的纤维丝材14，该丝材后续被缠绕或卷取后备用。切后再熔合的纤维丝材的外形如图2所示。熔合指的是本发明中，断口处的纤维丝材的聚合物熔融，熔融的聚合物受压并相互黏结，冷却后断口处的聚合物以粘合的方式连接，其中，在断口处，粘合后受到切割的纤维仍然保持切断状态。
制备的丝材继而被用于搅拌摩擦焊，主要包括：
1)通过热压或其它工艺获得以聚碳酸酯为原料的将欲连接件，将其待焊部位修理平整后并将待焊部位中部去除与丝材截面相当的材料；
2)将所制备的丝材嵌入到待焊部位后将待焊部位再次压平；
3)将两欲连接件的待焊部位对接后施以适量横向作用力，并随后压紧固定在工作台上，在确定的焊接工艺条件下，经过搅拌头的高速旋转后，两件被连接为一体。
上述过程及焊接制品形状效果如图3所示。
其中，由于丝材在嵌入待焊部位后，丝材距离焊件外上壁有0.2mm，则焊接头的下压量控制为0.30mm，焊件厚度为2mm，选择的搅拌针长度为1.5mm。
对所连接的工件焊缝处用SEM表征，其结果如图4所示，在图4中可以看出，几乎同等长度的纤维呈圆弧状均匀分布，从其结构可以预见纤维的增强作用。分切后的纤维可在高速旋转的搅拌头带动下呈现360度全方位的分布，此时焊缝处的各个角度均能得以纤维增强，避免了焊缝处力学性能因纤维增强所可能带来的各向异性，丝材的应用也可以有效避免普通聚合物搅拌摩擦焊容易产生的焊缝孔隙或间隙存在的机率。
对所连接工件截取出矩形测试样片，进行拉伸力学性能测试，其外形结果如图6所示，其中图6a与6b分别显示的是测试前后的样品外形，从图6b可知，此时拉伸断裂并不发生在焊缝处，而是离焊接稍近的影响区域，这足以表明焊缝处的力学性能较好，已经超过母材的影响区域。测试结果列于表1之中。
从表1结果可知，该实施例所得焊缝的拉伸强度接近母材，因而，本发明的丝材增强焊件具有特定形态的纤维分布结构，表现出力学性能优异的特点，具有优异的应用前景。
实施例2
为了与实施例1对比，与实施例1类似的，本对比实施例也使用市售聚碳酸酯(熔融体积速率为24cm3/10min)作为母材原料，不同的是实施例2没有使用纤维丝材，其焊接工艺主要为：通过热压或其它工艺获得以聚碳酸酯为原料的将欲连接件，然后将两欲连接件的待焊部位对接后施以适量横向作用力，并随后压紧固定在工作台上，在确定的焊接工艺条件下，经过搅拌头的高速旋转后，两件被连接为一体。
对所连接的工件焊缝处用SEM表征，其结果如图5所示，在图5中可以看出，焊缝的结合处有较多的空隙及间隙，因而该焊缝强度可以预见不会太好。
对所连接工件截取出矩形测试样片，进行拉伸力学性能测试，其外形结果也如图6所示，其中图6c与6d分别显示的是测试前后的样品外形，从图6d可知，此时拉伸断裂毫无悬念的出现在焊缝处，这足以表明焊缝处的力学性能有待提高。
拉伸力学性能测试，其结果也列于表1之中，此时拉伸断裂均发生在焊缝处，表明焊缝处的力学性能仍然较低。从表1结果可知，该对比例所得焊缝的拉伸强度与实施例1差距很大，表明使用纤维丝材与否对焊接质量的影响较大。
实施例3
为了和实施例1对比，本对比例也针对透明聚碳酸酯焊件开展搅拌摩擦焊，使用的主要原料包括聚碳酸酯(熔融体积速率为24cm3/10min)及碳纤维(12K，T700)，均为市售。
整个过程主要包括丝材制备及施焊两步，其中丝材制备过程中除不进行切割以外，和现有常规长纤维增强聚合物颗粒料类似：将聚碳酸酯通过挤出机熔融塑化后进入到浸渍机头中，同时，将置于纱架中的碳纤维丝束也引入到浸渍机头中，纤维在浸渍机头中被浸上聚碳酸酯高温熔体，形成截面不太规则的纤维/聚合物预浸丝材，该丝材后续被牵引、缠绕或卷取后备用，形成连续的丝材。
制备的丝材继而被用于搅拌摩擦焊，步骤如下：
1)通过热压或其它工艺获得以聚碳酸酯为原料的将欲连接件，将其待焊部位修理平整后并将待焊部位中部去除与丝材截面相当的材料；
2)将所制备的丝材嵌入到待焊部位后，按需切断，再将待焊部位再次压平；
3)将两欲连接件的待焊部位对接后施以适量横向作用力，并随后压紧固定在工作台上，在确定的焊接工艺条件下，经过搅拌头的高速旋转后，两件被连接为一体。
对所连接的工件焊缝处用SEM表征，其结果如图7所示，在图7中可以看出，焊缝处的纤维分布很乱，纤维长度差距也较大，纤维在各方向的分布也比较混乱。
对所连接工件截取出矩形测试样片，进行拉伸力学性能测试，其结果也列于表1之中，此时拉伸断裂均发生在焊缝处，表明焊缝处的力学性能仍然较低。从表1结果可知，该对比例所得焊缝的拉伸强度与实施例差距较大，表明纤维丝材的制备方法对焊接质量的影响较大。
实施例4
本实施例针对尼龙焊件开展搅拌摩擦焊，使用的主要原料包括尼龙(PA66，熔融体积速率为23cm3/10min)及玻璃纤维(12K，T700)，均为市售。
整个过程主要包括丝材制备及施焊两步，其中丝材制备过程如下：
首先，将PA66通过挤出机1熔融塑化后进入到浸渍机头7中，同时，将2束碳纤维分别置于两个纱架2中，分别经过两个展纱辊4的宽展作用后形成单向薄层纤维干带，两条单向薄层纤维干带再经过纤维带黏合辊5时被预浸微量定型胶形成整片的单向薄层纤维带6，纤维含量保持在60％，该纤维带6也进入到浸渍机头7中，纤维带6被均匀的涂上PA66高温熔体，形成纤维涂覆带；
其次，纤维涂覆带被随后的轴向卷绕器8沿轴向卷绕，截面逐渐形成阿基米德螺旋线，形成截面为圆形的单向多层纤维/聚合物预浸丝材，丝材在牵引对辊9的作用下进入到履带牵引机10上，并被纵向切割器11分切并保持半连状态；切断比例占整个圆形纤 维/聚合物预浸物截面的90％，分切长度为9cm(搅拌摩擦焊头直径为6mm)，半连状态的丝材在通过热熔烘箱12时，断口处的聚合物少量熔融，同时，由于调速对辊13的速度与牵引对辊9的速度一致，它们的速度均比履带牵引的速度低5％，因而，半连状态的丝材会受到后面调速对辊13的轻微阻滞作用，熔融的聚合物受压并相互黏结，从而形成了切后再熔合的纤维丝材14，该丝材后续被缠绕或卷取后备用。切后再熔合的纤维丝材的外形也与图2类似。
制备的丝材继而被用于搅拌摩擦焊，步骤如下：
1)通过热压或其它工艺获得以聚碳酸酯为原料的将欲连接件，将其待焊部位修理平整后并将待焊部位中部去除与丝材截面相当的材料；
2)将所制备的丝材嵌入到待焊部位后将待焊部位再次压平；
3)将两欲连接件的待焊部位对接后施以适量横向作用力，并随后压紧固定在工作台上，在确定的焊接工艺条件下，经过搅拌头的高速旋转后，两件被连接为一体。
其中，由于丝材在嵌入待焊部位后，丝材距离焊件外上壁有0.2mm，则焊接头的下压量控制为0.35mm，焊件厚度为2mm，选择的搅拌针长度为1.5mm。
对所连接工件截取出矩形测试样片，进行拉伸力学性能测试，其测试结果列于表1。从表1结果可知，该实施例所得焊缝的拉伸强度接近母材，因而，本发明的丝材增强焊件具有特定形态的纤维分布结构，表现出力学性能优异的特点，具有优异的应用前景。
实施例5
为了和实施例4对比，本对比例也针对尼龙焊件开展无切割处理的纤维丝材搅拌摩擦焊，使用的主要原料包括尼龙(熔融体积速率为23cm3/10min)及碳纤维(12K，T700)，均为市售。
整个过程主要包括丝材制备及施焊两步，其中丝材制备过程中除不进行切割以外，和现有常规长纤维增强聚合物颗粒料类似：将尼龙通过挤出机熔融塑化后进入到浸渍机头中，同时，将置于纱架中的碳纤维丝束也引入到浸渍机头中，纤维在浸渍机头中被浸上尼龙高温熔体，形成截面不太规则的纤维/聚合物预浸丝材，该丝材后续被牵引、缠绕或卷取后备用，形成连续的丝材。
制备的丝材继而被用于搅拌摩擦焊，步骤如下：
1)通过热压或其它工艺获得以尼龙为原料的将欲连接件，将其待焊部位修理平整后并将待焊部位中部去除与丝材截面相当的材料；
2)将所制备的丝材嵌入到待焊部位后，按需切断，再将待焊部位再次压平；
3)将两欲连接件的待焊部位对接后施以适量横向作用力，并随后压紧固定在工作台上，在确定的焊接工艺条件下，经过搅拌头的高速旋转后，两件被连接为一体。
对所连接的工件焊缝处用SEM表征，其结果也与实施例3类似，焊缝处的纤维分布很乱，纤维长度差距也较大，纤维在各方向的分布也比较混乱。
对所连接工件截取出矩形测试样片，进行拉伸力学性能测试，其结果也列于表1之中，此时拉伸断裂均发生在焊缝处，表明焊缝处的力学性能仍然较低。从表1结果可知，该对比例所得焊缝的拉伸强度与实施例差距较大，表明纤维丝材的制备方法对焊接质量的影响较大。
实施例6
与实施例1不同的是，本实施例中，纤维涂覆带纤维含量40％；切断比例占整个圆形截面的70％，分切长度为15mm，焊接头的下压量控制为0.25mm。
实施例7
与实施例1不同的是，本实施例中，纤维涂覆带纤维含量60％；切断比例占整个圆形截面的90％，分切长度为15mm，焊接头的下压量控制为0.32mm。
表1几种焊件的拉伸性能比较

Claims (10)

  1. 一种用于搅拌摩擦焊的纤维丝材制备方法，其特征在于，包括以下步骤：
    步骤S1、束状纤维材料经过宽展后并预浸定型胶形成单向薄层纤维带，将热塑性聚合物熔融塑化后涂覆在单向薄层纤维带上形成纤维涂覆带；
    步骤S2、将纤维涂覆带轴向卷绕形成截面为圆形的单向多层纤维/聚合物预浸丝材；
    步骤S3、将单向多层纤维/聚合物预浸丝材分切并保持半连状态后热熔处理并冷却得到切后再熔合的纤维丝材。
  2. 根据权利要求1所述的一种用于搅拌摩擦焊的纤维丝材制备方法，其特征在于：所述步骤S1中，所述热塑性聚合物与待焊接的母材材料相同。
  3. 根据权利要求1所述的一种用于搅拌摩擦焊的纤维丝材制备方法，其特征在于：所述步骤S1中，纤维涂覆带纤维含量为40％～60％。
  4. 根据权利要求1所述的一种用于搅拌摩擦焊的纤维丝材制备方法，其特征在于：所述步骤S2中，单向多层纤维/聚合物预浸丝材的截面分层线为阿基米德螺旋线。
  5. 根据权利要求1所述的一种用于搅拌摩擦焊的纤维丝材制备方法，其特征在于：所述步骤S3中，切断比例占整个圆形截面的70～90％，分切长度为搅拌摩擦焊头直径的1.5～2.5倍。
  6. 根据权利要求1所述的一种用于搅拌摩擦焊的纤维丝材制备方法，其特征在于：所述步骤S3中，分切后的单向多层纤维/聚合物预浸丝材在热熔处理时轴向受力挤压再熔。
  7. 根据权利要求1-6所述的任一种用于搅拌摩擦焊的纤维丝材制备方法制备的纤维丝材的焊接方法，其特征在于，包括如下步骤：
    步骤1、将欲连接件的待焊部位修理平整后并将待焊部位中部去除材料；
    步骤2、将所制备的纤维丝材嵌入或熔入已去除材料的待焊部位后将待焊部位压平；
    步骤3、将两欲连接件的待焊部位对接后施以横向作用力，并压紧固定，经过搅拌头的高速旋转后，两件被连接。
  8. 根据权利要求7所述的用于搅拌摩擦焊的纤维丝材的焊接方法，其特征在于，步骤1中待焊部位中部去除的材料与步骤2欲嵌入或熔入纤维丝材的体积量保持一致，步骤3的焊接过程中，下压量控制为压入焊丝后搅拌头轴肩端面超出焊丝上表面0.05～0.15mm，且下压量小于或等于焊件厚度与搅拌针长度之间的差值。
  9. 一种用于搅拌摩擦焊的纤维丝材制备设备，其特征在于，包括：
    挤出机(1)，用于将热塑性聚合物熔融塑化后挤出；
    展纱辊(4)，用于将束状纤维材料宽展后形成单向薄层纤维干带；
    纤维带黏合辊(5)，用于将单向薄层纤维干带预浸定型胶形成整片的单向薄层纤维 带(6)；
    浸渍机头(7)，用于将熔融塑化后的热塑性聚合物涂覆单向薄层纤维带(6)形成纤维涂覆带；
    轴向卷绕器(8)，用于对纤维涂覆带沿轴向卷绕形成单向多层纤维/聚合物预浸丝材；
    牵引对辊(9)，用于将单向多层纤维/聚合物预浸丝材牵引至履带牵引机(10)上；
    纵向切割器(11)，用于对单向多层纤维/聚合物预浸丝材进行纵向分切；
    热熔烘箱(12)，用于对单向多层纤维/聚合物预浸丝纵向切割后的断口再熔，再熔后冷却即得到纤维丝材。
  10. 根据权利要求9所述的一种用于搅拌摩擦焊的纤维丝材制备设备，其特征在于：还包括调速对辊(13)，其速度与牵引对辊(9)的速度相同，且小于履带牵引机(10)的速度。
PCT/CN2023/084343 2023-03-03 2023-03-28 用于搅拌摩擦焊的纤维丝材制备方法、设备及其焊接方法 Ceased WO2024183111A1 (zh)

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