轻质异种材料搅拌摩擦点焊技术研究进展

doi:10.3901/JME.2020.06.147

摘要/Abstract

摘要： 由于汽车工业轻量化的要求，轻质材料复合结构取代单一材料结构的方法受到社会各界的广泛关注。对于异种材料复合结构的连接，传统焊接方法具有一定的局限性。搅拌摩擦点焊技术作为一种绿色、高效、固相连接技术，在异种材料连接方面具有很大潜力，国内外学者针对异种材料搅拌摩擦点焊开展了大量研究。从铝-碳纤维增强热塑性树脂基复合材料、铝-铜和铝-钢三种复合结构搅拌摩擦点焊的研究现状出发，阐述了国内外科研人员在焊接工艺、微观组织演变以及接头力学性能等方面的研究成果，并展望了搅拌摩擦点焊技术现阶段亟待解决的热点问题以及发展趋势。

关键词: 搅拌摩擦点焊技术, 轻质材料, 复合结构, 性能

Abstract: With the requirement of automotive industrial lightweight, lightweight composite structures replacing single material structure have attracted broad attentions. For dissimilar materials joining, conventional welding methods have limitations. However, friction stir spot welding, as a green and effective solid-state welding technology, is a promising process to join dissimilar materials. Extensive research on the friction stir spot welding of dissimilar materials is carried out. The research status about the progress of friction stir spot welding for Al-carbon fiber reinforced thermoplastics, Al-Cu and Al-steel composite structures is summarized. The welding process, the evolution of joint microstructure and mechanical properties are discussed in details. Moreover, present challenges and development direction in friction stir spot welding technology are expounded.

Key words: friction stir spot welding, lightweight materials, composite structure, properties

中图分类号:

TG453

汤祖阳, 王亚强, 董红刚. 轻质异种材料搅拌摩擦点焊技术研究进展[J]. 机械工程学报, 2020, 56(6): 147-158.

TANG Zuyang, WANG Yaqiang, DONG Honggang. Progress of the Friction Stir Spot Welding in Lightweight Dissimilar Materials[J]. Journal of Mechanical Engineering, 2020, 56(6): 147-158.

参考文献

[1] 李永兵,马运五,楼铭,等.轻量化多材料汽车车身连接技术进展[J].机械工程学报,2016,52(24):1-23. LI Yongbing,MA Yunwu,LOU Ming,et al. Advances in welding and joining processes of multi-material lightweight car body[J]. Journal of Mechanical Engineering,2016,52(24):1-23.
[2] HUANG Y X,MENG X C,XIE Y M,et al. Friction stir welding/processing of polymers and polymer matrix composites[J]. Composites Part A,2018,105:235-257.
[3] GULLINO A,MATTEIS P,D'AIUTO F. Review of aluminum-to-steel welding technologies for car-body applications[J]. Metals,2019,9(3):1-28.
[4] ZHANG Z H,YANG X Q,ZHANG J L,et al. Effect of welding parameters on microstructure and mechanical properties of friction stir spot welded 5052 aluminum alloy[J]. Materials & Design,2011,32(8-9):4461-4470.
[5] THOPPUL S D,FINEGAN J,GIBSON R F. Mechanics of mechanically fastened joints in polymer-matrix composite structures-a review[J]. Composites Science and Technology,2009,69(3-4):301-329.
[6] KWEON J H,JUNG J W,KIM T H,et al. Failure of carbon composite-to-aluminum joints with combined mechanical fastening and adhesive bonding[C]//13th International Conference on Composite Structures,2006,75(1-4):192-198.
[7] BERGMANN J P,PETZOLDT F,SCHURER R,et al. Solid-state welding of aluminum to copper-case studies[J]. Welding in the World,2013,57(4):541-550.
[8] BAKAVOS D,CHEN Y C,BABOUT L,et al. Material interactions in a novel pinless tool approach to friction stir spot welding thin aluminum sheet[J]. Metallurgical and Materials Transactions A,2011,42A (5):1266-1282.
[9] MA Z Y. Friction stir processing technology:a review[J]. Metallurgical and Materials Transactions A,2008,39A (3):642-658.
[10] ZHANG G F,ZHANG L J,KANG C W,et al. Development of friction stir spot brazing (FSSB)[J]. Materials & Design,2016,94:502-514.
[11] BOZZI S,HELBERT-ETTER A L,BAUDIN T,et al. Influence of FSSW parameters on fracture mechanisms of 5182 aluminium welds[J]. Journal of Materials Processing Technology,2010,210(11):1429-1435.
[12] VENUKUMAR S,YALAGI S G,MUTHUKUMARAN S,et al. Static shear strength and fatigue life of refill friction stir spot welded AA 6061-T6 sheets[J]. Science and Technology of Welding and Joining,201419(3):214-223.
[13] COX C D,GIBSON B T,DELAPP D R,et al. A method for double-sided friction stir spot welding[J]. Journal of Manufacturing Processes,2014,16(2):241-247.
[14] YAZDI S R,BEIDOKHTI B,HADDAD-SABZEVAR M. Pinless tool for FSSW of AA 6061-T6 aluminum alloy[J]. Journal of Materials Processing Technology,2019,267:44-51.
[15] LI W,LI J F,ZHANG Z H,et al. Improving mechanical properties of pinless friction stir spot welded joints by eliminating hook defect[J]. Materials & Design,2014,62:247-254.
[16] LIU X,WANG X J,WANG B S,et al. The role of mechanical connection during friction stir keyholeless spot welding joints of dissimilar materials[J]. Metals,2017,7(6):1-12.
[17] 相倩,吕念春,薛鹏,等.铝-钢异种金属搅拌摩擦焊研究现状及展望[J].机械工程学报,2017,53(20):28-37. XIANG Qian,LÜ Nianchun,XUE Peng,et al. Research status and prospect on friction stir welded dissimilar Al-steel joints[J]. Journal of Mechanical Engineering,2017,53(20):28-37.
[18] IBRAHIM I J,YAPICI G G. Application of a novel friction stir spot welding process on dissimilar aluminum joints[J]. Journal of Manufacturing Processes,2018,35:282-288.
[19] ROSENDO T,PARRA B,TIER M A D,et al. Mechanical and microstructural investigation of friction spot welded AA6181-T4 aluminium alloy[J]. Materials & Design,2011,32(3):1094-1100.
[20] AMANCIO-FILHO S T,CAMILLO A P C,BERGMANN L,et al. Preliminary investigation of the microstructure and mechanical behaviour of 2024 aluminium alloy friction spot welds[J]. Materials Transactions,2011,52(5):985-991.
[21] AMANCIO-FILHO S T,BUENO C,DOS SANTOS J F,et al. On the feasibility of friction spot joining in magnesium/fiber-reinforced polymer composite hybrid structures[J]. Materials Science and Engineering A-Structural Materials Properties Microstructure and Processing,2011,528(10-11):3841-3848.
[22] PRAMANIK A,BASAK A K,DONG Y,et al. Joining of carbon fibre reinforced polymer (CFRP) composites and aluminium alloys-a review[J]. Composites Part A-Applied Science and Manufacturing,2017,101:1-29.
[23] ANDRE N M,DOS SANTOS J F,AMANCIO-FILHO S T. Evaluation of joint formation and mechanical performance of the AA7075-T6/CFRP spot joints produced by frictional heat[J]. Materials,2019,12(6):1-14.
[24] BALLE F,WANGNER G,EIFLER D. Ultrasonic metal welding of aluminium sheets to carbon fibre reinforced thermoplastic composites[J]. Advanced Engineering Materials,2009,11(1-2):35-39.
[25] GOUSHEGIR S M,DOS SANTOS J F,AMA NCIO-FIL HO S T. Friction spot joining of aluminum AA2024/c arbon-fiber reinforced poly (phenylene sulfide) composite single lap joints:microstructure and mechanical performance[J]. Materials & Design,2014,54:196-206.
[26] GOUSHEGIR S M,DOS SANTOS J F,AMANCIO-FIL HO S T. Influence of process parameters on mechanical performance and bonding area of AA2024/c arbon-fiber-reinf orced poly (phenylene sulfide) friction spot single lap joints[J]. Materials & Design,2015,83:431-442.
[27] ESTEVES J V,GOUSHEGIR S M,DOS SANTOS J F,et al. Friction spot joining of aluminum AA6181-T4 and carbon fiber-reinforced poly (phenylene sulfide):effects of process parameters on the microstructure and mechanical strength[J]. Materials & Design,2015,66:437-445.
[28] SATO Y S,SHIOTA A,KOKAWA H,et al. Effect of interfacial microstructure on lap shear strength of friction stir spot weld of aluminium alloy to magnesium alloy[J]. Science and Technology of Welding and Joining,2010,15(4):319-324.
[29] HEIDEMAN R,JOHNSON C,KOU S. Metallurgical analysis of Al/Cu friction stir spot welding[J]. Science and Technology of Welding and Joining,2010,15(7):597-604.
[30] GERLICH A,YAMAMOTO M,NORTH T H. Local melting and tool slippage during friction stir spot welding of Al-alloys[J]. Journal of Materials Science,2008,43(1):2-11.
[31] GOUSHEGIR S M,DOS SANTOS J F,AMANCIO-FIL HO S T. Failure and fracture micro-mechanisms in metal-composite single lap joints produced by welding-based joining techniques[J]. Composites Part A:Applied Science and Manufacturing,2016,81:121-128.
[32] OGAWA Y,XIONG Y,AKEBONO H,et al. Fatigue properties of friction stir welds of treated Al to carbon fibre-reinforced plastic[J]. Science and Technology of Welding and Joining,2018,23(1):79-86.
[33] OGAWA Y,AKEBONO H,TANAKA K,et al. Effect of welding time on fatigue properties of friction stir spot welds of Al to carbon fibre-reinforced plastic[J]. Science and Technology of Welding and Joining,2019,24(3):235-242.
[34] ANDRE N M,GOUSHEGIR S M,DOS SANTOS J F,et al. Friction spot joining of aluminum alloy 2024-T3 and carbon-fiber-reinforced poly (phenylene sulfide) laminate with additional PPS film interlayer:microstructure,mechanical strength and failure mechanisms[J]. Composites Part B,2016,94:197-208.
[35] ANDRE N M,GOUSHEGIR S M,DOS SANTOS J F,et al. Influence of the interlayer film thickness on the mechanical performance of AA2024-T3/CF-PPS hybrid joints produced by friction spot joining[J]. Welding International,2018,32(1):1-10.
[36] NAGATSUKA K,YOSHIDA S,TSUCHIYA A,et al. Direct joining of carbon-fiber-reinforced plastic to an aluminum alloy using friction lap joining[J]. Composites Part B,2015,73:82-88.
[37] HECKERT A,ZAEH M F. Laser surface pre-treatment of aluminium for hybrid joints with glass fibre reinforced thermoplastics[C]//Physics Procedia. Netherlands:Elsevier Science BV,2014:1171-1181.
[38] ZHANG Z,SHEN J G,TAN X H,et al. Effect of anodizing pretreatment on laser joining CFRP to aluminum alloy A6061[J]. International Journal of Adhesion and Adhesives,2016,70:142-151.
[39] VAN DER LEEDEN M C,FRENS G. Surface properties of plastic materials in relation to their adhering performance[J]. Advanced Engineering Materials,2002,4(5):280-289.
[40] GOUSHEGIR S M,DOS SANTOS J F,AMANCIO-FIL HO S T. Influence of aluminum surface pre-treatments on the bonding mechanisms and mechanical performance of metal-composite single-lap joints[J]. Welding in the World,2017,61(6):1099-1115.
[41] GOUSHEGIR S M. Friction spot joining (FSpJ) of aluminum-CFRP hybrid structures[J]. Welding in the World,2016,60(6):1073-1093.
[42] KHODABAKHSHI F,HAGHSHENAS M,CHEN J,et al. Bonding mechanism and interface characterisation during dissimilar friction stir welding of an aluminium/polymer bi-material joint[J]. Science and Technology of Welding and Joining,2017,22(3):182-190.
[43] 张云鹤.碳纤维增强铝基复合材料金属Z-pin层间强化技术[M].北京:科学出版社,2018. ZHANG Yunhe. Interlaminar strengthening technology by metal Z-pin of carbon fiber reinforced Al-matrix composites[M]. Beijing:Science Press,2018.
[44] PABANDI H K,MOVAHEDI M,KOKABI A H. A new refill friction spot welding process for aluminum/polymer composite hybrid structures[J]. Composite Structures,2017,174:59-69.
[45] GOUSHEGIR S M,SCHARNAGL N,DOS SANTOS J F, et al. XPS analysis of the interface between A A2024-T3/CF-PPS friction spot joints[C]//Surface and interface analysis. 7th Symposium of Aluminium Surface Science and Technology (ASST),2016:706-711.
[46] ABBASS M K,HUSSEIN S K,KHUDHAIR A A. Optimization of mechanical properties of friction stir spot welded joints for dissimilar aluminum alloys (AA2024-T3 and AA 5754-H114)[J]. Arabian Journal for Science and Engineering,2016,41(11):4563-4572.
[47] SIDDHARTH S,SENTHILKUMAR T,CHANDRASEK AR M. Development of processing windows for friction stir spot welding of aluminium Al5052/copper C27200 dissimilar materials[J]. Transactions of Nonferrous Metals Society of China,2017,27(6):1273-1284.
[48] 周炜璐.铝/铜搅拌摩擦点焊工艺及机理研究[D].哈尔滨:哈尔滨工业大学,2016. ZHOU Weilu. Research on process and mechanism of friction stir spot welding for Al/Cu[D]. Harbin:Harbin Institute of Technology,2016.
[49] COLMENERO A N,OROZCO M S,MACIAS E J,et al. Optimization of friction stir spot welding process parameters for Al-Cu dissimilar joints using the energy of the vibration signals[J]. The International Journal of Advanced Manufacturing Technology,2019,100(9-12):2795-2802.
[50] CARDILLO M E B,SHEN J J,DE ALCANTARA N G,et al. Effect of friction spot welding parameters on the joint formation and mechanical properties of Al to Cu[J]. Welding in the World,2019,63(1):33-41.
[51] MUBIAYI M P,AKINLABI E T,MAKHATHA M E,et al.,Effect of process parameters on tensile strength and morphology of friction stir spot welds of aluminium and copper[C]//8th International Conference on Mechanical and Intelligent Manufacturing Technologies (ICMIMT),2017:48-53.
[52] ZHOU L,LI G H,ZHANG R X,et al. Microstructure evolution and mechanical properties of friction stir spot welded dissimilar aluminum-copper joint[J]. Journal of Alloys and Compounds,2019,775:372-382.
[53] MUBIAYI M P,AKINLABI E T. Evolving properties of friction stir spot welds between AA1060 and commercially pure copper C11000[J]. Transactions of Nonferrous Metals Society of China,2016,26(7):1852-1862.
[54] FENG J,XUE S B. Growth behaviors of intermetallic compound layers in Cu/Al joints brazed with Zn-22Al and Zn-22Al-0.05Ce filler metals[J]. Materials & Design,2013,51:907-915.
[55] MEHTA K P,BADHEKA V J. A review on dissimilar friction stir welding of copper to aluminum:process,properties,and variants[J]. Materials and Manufacturing Processes,2016,31(3):233-254.
[56] JI F,XUE S B,DAI W. Effects of Ti on the brazability of Zn-22Al-xTi filler metals as well as properties of Cu/Al brazing joints[J]. Rare Metal Materials and Engineering,2013,42(12):2453-2457.
[57] KUANG B,SHEN Y F,CHEN W H,et al. The dissimilar friction stir lap welding of 1A99 Al to pure Cu using Zn as filler metal with "pinless" tool configuration[J]. Materials & Design,2015,68:54-62.
[58] BOUCHERIT A,AVETTAND-FENOEL M N,TAILLARD R. Effect of a Zn interlayer on dissimilar FSSW of Al and Cu[J]. Materials & Design,2017,124:87-99.
[59] XIAO Y,JI H J,LI M Y,et al. Ultrasound-assisted brazing of Cu/Al dissimilar metals using a Zn-3Al filler metal[J]. Materials & Design,2013,52:740-747.
[60] FEREIDUNI E,MOVAHEDI M,KOKABI A H. Dissimilar Al/steel friction stir spot welding:to penetrate into the lower steel sheet or not?[J]. Science and Technology of Welding and Joining,2016,21(6):466-472.
[61] MIYAGAWA K,TSUBAKI M,YASUI T,et al. Spot welding between aluminium alloy and low-carbon steel by friction stirring[J]. Welding International,2009,23(8):559-564.
[62] BOZZI S,ETTER A L,BAUDIN T,et al. Mechanical behaviour and microstructure of aluminum-steel sheets joined by FSSW[J]. Textures,Stress and Microstructures,2008,2007:1-8.
[63] FIGNER G,VALLANT R,WEINBERGER T,et al. Friction stir spot welds between aluminium and steel automotive sheets:influence of welding parameters on mechanical properties and microstructure[J]. Welding in the World,2009,53(1-2):13-23.
[64] FEREIDUNI E,MOVAHEDI M,KOKABI A H. Aluminum/steel joints made by an alternative friction stir spot welding process[J]. Journal of Materials Processing Technology,2015,224:1-10.
[65] MEHTA K P. A review on friction-based joining of dissimilar aluminum-steel joints[J]. Journal of Materials Research,2019,34(1):78-96.
[66] WATANABE M,FENG K Y,NAKAMURA Y,et al. Growth manner of intermetallic compound layer produced at welding interface of friction stir spot welded aluminum/steel lap joint[J]. Materials Transactions,2011,52(5):953-959.
[67] BOUCHE K,BARBIER F,COULET A. Intermetallic compound layer growth between solid iron and molten aluminium[J]. Materials Science and Engineering a-Structural Materials Properties Microstructure and Processing,1998,249(1-2):167-175.
[68] BOUAYAD A,GEROMETTA C,BELKEBIR A,et al. Kinetic interactions between solid iron and molten aluminium[J]. Materials Science and Engineering a-Structural Materials Properties Microstructure and Processing,2003,363(1-2):53-61.
[69] HSIEH M J,LEE R T,CHIOU Y C. Friction stir spot fusion welding of low-carbon steel to aluminum alloy[J]. Journal of Materials Processing Technology,2017,240:118-125.
[70] FEREIDUNI E,MOVAHEDI M,KOKABI A H,et al. Effect of dwell time on joint interface microstructure and strength of dissimilar friction stir spot-welded Al-5083 and St-12 alloy sheets[J]. Metallurgical and Materials Transactions A,2017,48A (4):1744-1758.
[71] BOZZI S,HELBERT-ETTER A L,BAUDIN T,et al. Intermetallic compounds in Al 6016/IF-steel friction stir spot welds[J]. Materials Science and Engineering A,2010,527(16-17):4505-4509.
[72] SHEN Z,DING Y,CHEN J,et al. Interfacial bonding mechanism in Al/coated steel dissimilar refill friction stir spot welds[J]. Journal of Materials Science & Technology,2019,35(6):1027-1038.
[73] DA SILVA A A M,ALDDANONDO E,ALVAREZ P,et al. Friction stir spot welding of AA 1050 Al alloy and hot stamped boron steel (22MnB5)[J]. Science and Technology of Welding and Joining,2010,15(8):682-687.
[74] DONG H G,CHEN S,SONG Y,et al. Refilled friction stir spot welding of aluminum alloy to galvanized steel sheets[J]. Materials & Design,2016,94:457-466.
[75] SHEN Z,CHEN J,DING Y,et al. Role of interfacial reaction on the mechanical performance of Al/steel dissimilar refill friction stir spot welds[J]. Science and Technology of Welding and Joining,2018,23(6):462-477.
[76] CHEN N N,WANG M,WANG H P,et al. Microstructural and mechanical evolution of Al/steel interface with Fe₂Al₅ growth in resistance spot welding of aluminum to steel[J]. Journal of Manufacturing Processes,2018,34:424-434.
[77] LEI H Y,LI Y B,CARLSON B E,et al. Microstructure and mechanical performance of cold metal transfer spot joints of AA6061-T6 to galvanized DP590 using edge plug welding mode[J]. Journal of Manufacturing Science and Engineering,2016,138(7):1-13.
[78] CHEN Y C,GHOLINIA A,PRANGNELL P B. Interface structure and bonding in abrasion circle friction stir spot welding:a novel approach for rapid welding aluminium alloy to steel automotive sheet[J]. Materials Chemistry and Physics,2012,134(1):459-463.
[79] CHEN K,LIU X,NI J. Keyhole refilled friction stir spot welding of aluminum alloy to advanced high strength steel[J]. Journal of Materials Processing Technology,2017,249:452-462.
[80] UEMATSU Y,TOKAJI K,TOZAKI Y,et al. Fatigue behaviour of dissimilar friction stir spot welds between A6061-T6 and low carbon steel sheets welded by a scroll grooved tool without probe[J]. Fatigue & Fracture of Engineering Materials & Structures,2011,34(8):581-591.
[81] IBRAHIM I,UEMATSU Y,KAKIUCHI T,et al. Fatigue behaviour of dissimilar Al alloy/galvanised steel friction stir spot welds fabricated by scroll grooved tool without probe[J]. Science and Technology of Welding and Joining,2015,20(8):670-678.