铝合金搅拌摩擦焊力的周期性波动特征与机制

doi:10.3901/JME.2022.12.055

机械工程学报 ›› 2022, Vol. 58 ›› Issue (12): 55-63.doi: 10.3901/JME.2022.12.055

扫码分享

铝合金搅拌摩擦焊力的周期性波动特征与机制

康粟^1,2, 李冬晓³, 李晓光^1,4, 管卫^1,2, 武少杰^1,2, 崔雷^1,2

1. 天津大学材料科学与工程学院天津 300350;
2. 天津市现代连接技术重点实验室天津 300350;
3. 北京卫星制造厂有限公司北京 100080;
4. 中国航发沈阳黎明航空发动机有限责任公司沈阳 110043

收稿日期:2021-09-27 修回日期:2022-01-15 出版日期:2022-06-20 发布日期:2022-09-14
通讯作者: 崔雷(通信作者),男,1985年出生,博士,副教授。主要研究方向为搅拌摩擦焊与摩擦塞补焊。E-mail:leicui@tju.edu.cn
作者简介:康粟,男,1998年出生。主要研究方向为铝合金的搅拌摩擦焊。E-mail:kangsu@tju.edu.cn
基金资助:
天冿市科技计划资助项目（18ZXCLGX00060）

Characteristic and Mechanism of Periodic Oscillation of Force in Friction Stir Welding of Aluminum Alloy

KANG Su^1,2, LI Dongxiao³, LI Xiaoguang^1,4, GUAN Wei^1,2, WU Shaojie^1,2, CUI Lei^1,2

1. School of Materials Science and Engineering, Tianjin University, Tianjin 300350;
2. Tianjin Key Laboratory of Advanced Joining Technology, Tianjin 300350;
3. Beijing Satellite Manufacturing Co., Ltd., Beijing 100080;
4. AECC Shenyang Liming Aero Engine Co., Ltd., Shenyang 110043

Received:2021-09-27 Revised:2022-01-15 Online:2022-06-20 Published:2022-09-14

摘要/Abstract

摘要： 利用三分量力传感器测得了8 mm厚5A06-H112铝合金搅拌摩擦焊过程中的轴向压力(F_z)、前进阻力(F_x)、侧向力(F_y)信号，着重分析了力周期性波动的规律及其与焊接缺陷的关系。研究发现：在稳定焊接过程中，F_x和F_y均呈现了周期性波动，波动频率与搅拌头的旋转频率一致；F_y波形滞后于F_x，相位差为π/2；F_z波动较小。F_x和F_y的均值随搅拌头转速的提高而降低，随焊接速度的增加而升高。在一定工艺参数范围内，焊接缺陷与F_x和F_y波动特征有良好的对应关系：当焊缝中无孔洞缺陷时，F_x与F_y值域无重叠且波形接近正弦波；当焊缝中存在孔洞缺陷时，F_x与F_y值域部分重叠且波形发生畸变。模拟分析表明，搅拌头偏心为0.01 mm时，F_x呈现周期性波动，搅拌头不存在偏心时，F_x未呈现周期性波动，因此认为搅拌头的偏心旋转是造成F_x呈周期性波动的主要原因，而且搅拌头偏心旋转导致了周围材料应力场和流场的周期性变化。随着搅拌头的持续旋转和进给，形成了周期性的焊缝内部组织和表面成形。

关键词: 铝合金, 搅拌摩擦焊, 三分力, 周期性波动

Abstract: A three-component force sensor is used to measure the plunge force (F_z), traverse force (F_x), and lateral force (F_y) of friction stir welding (FSW) of 8 mm thick 5A06-H112 aluminum alloy. The cause of the periodic oscillation of the force signals and its relationship with welding defects are analysed. Both F_x and F_y showed periodic oscillations, and the frequency is consistent with the rotation frequency of the tool. The waveform of F_y lags behind F_x and the phase difference is π/2. The oscillation amplitude of F_z is small. The average values of F_x and F_y decrease with increasing the rotating speed of the FSW tool, and increases with increasing of the welding speed. When the defective-free joint is obtained, F_x and F_y have no overlap and the waveforms of F_x and F_y are both sinusoidal waves. F_x and F_y overlapped partially and the waveforms of F_x and F_y show distortion when the defective joint is obtained. The numerical simulation results show that F_x presents periodic oscillations with the eccentricity of the tool of 0.01 mm. Furthermore, F_x keeps constant when the tool has no eccentric motion. Therefore, the eccentric rotation of the tool is the main reason for the periodic oscillation of F_x. In addition, the eccentric rotation of the tool causes the periodic variation of the stress and flow of the plasticized material around the tool. With continuous rotating and traversing of the tool, the weld has the periodic internal microstructure and surface morphology.

Key words: aluminum alloy, friction stir welding, three component force, periodic oscillation

中图分类号:

TG156

康粟, 李冬晓, 李晓光, 管卫, 武少杰, 崔雷. 铝合金搅拌摩擦焊力的周期性波动特征与机制[J]. 机械工程学报, 2022, 58(12): 55-63.

KANG Su, LI Dongxiao, LI Xiaoguang, GUAN Wei, WU Shaojie, CUI Lei. Characteristic and Mechanism of Periodic Oscillation of Force in Friction Stir Welding of Aluminum Alloy[J]. Journal of Mechanical Engineering, 2022, 58(12): 55-63.

参考文献

[1] THOMAS W M. Friction stir butt welding[P]. British:No. PCT/GB92/0220, 1991.
[2] 张田仓, 郭德伦, 陈沁刚, 等. 铝合金搅拌摩擦焊技术研究[J]. 机械工程学报, 2002, 38(2):127-130. ZHANG Tiancang, GUO Delun, CHEN Qingang, et al. Study on friction stir welding of aluminum alloy[J]. Journal of Mechanical Engineering, 2002, 38(2):127-130.
[3] 张忠科. 搅拌摩擦焊接过程的多场检测及耦合关键问题研究[D]. 兰州:兰州理工大学, 2010. ZHANG Zhongke. The measurement and coupling key problems study of multifield during friction stir welding[D]. Lanzhou:Lanzhou University of Technology, 2010.
[4] 张雪超, 熊江涛, 李京龙, 等. 恒进给旋转摩擦条件下金属力学参量周期响应行为[J]. 机械工程学报, 2015, 51(2):65-70. ZHANG Xuechao, XIONG Jiangtao, LI Jinglong, et al. Periodic variation of torque and axial force of tubular aluminum alloy at constant downward and rotational speed[J]. Journal of Mechanical Engineering, 2015, 51(2):65-70.
[5] FRANKE D, ZINN M, PFEFFERKORN F. Intermittent flow of material and force-based defect detection during friction stir welding of aluminum alloys[M]//Friction Stir Welding and Processing X. Springer, Cham. 2019:149-160.
[6] YAN J, SUTTON M, REYNOLDS A. Processing and banding in AA2524 and AA2024 friction stir welding[J]. Science and Technology of Welding and Joining, 2007, 12(5):390-401.
[7] BOLDSAIKHAN E, BURFORD D, BRITOS P. Effect of plasticized material flow on the tool feedback forces during friction stir welding[C]//Proc. Conf. On ‘Friction stir welding and processing VI’. John Wiley & Sons, Ltd, San Francisco, CA, USA. 2011:335-343.
[8] 王卫兵, 栾国红, 张坤, 等. 搅拌摩擦焊塑性金属流动基本模型[J]. 焊接学报, 2016, 37(12):71-74. WANG Weibing, LUAN Guohong, ZHANG Kun, et al. Fundamental model of plastic material flow in FSW[J]. Transactions of The China Welding Institution, 2016, 37(12):71-74.
[9] ZAEH M, GEBHARD P. Dynamical behaviour of machine tools during friction stir welding[J]. Production Engineering, 2010, 4(6):615-624.
[10] PANZER F, WERZ M, WEIHE S. Experimental
investigation of the friction stir welding dynamics of 6000 series aluminum alloys[J]. Production Engineering, 2018, 12(5):667-677.
[11] FRANKE D, RUDRARAJU S, ZINN M, et al. Understanding process force transients with application towards defect detection during friction stir welding of aluminum alloys[J]. Journal of Manufacturing Processes, 2020, 54:251-261.
[12] GUO N, WANG M, MENG Q, et al. Effect of tool eccentricity on surface periodic banded structures in friction stir welding[J]. IOP Conference Series:Materials Science and Engineering, 2015, 103(1):12-20.
[13] LUQMAN H, ABDELBASET R, SCOTT W, et al. Influence of tool eccentricity on the material flow and microstructural properties of AA6061 aluminum alloy friction stir welds[J]. Journal of Alloys and Compounds, 2020, 826:154-219.
[14] SHAH L, WALBRIDGE S, GERLICH A. Tool eccentricity in friction stir welding:a comprehensive review[J]. Science and Technology of Welding and Joining, 2019, 24(6):566-578.
[15] 王战锋, 张辉, 张昊, 等. 喷射沉积5A06铝合金热压缩变形的流变应力行为[J]. 中国有色金属学报, 2006(11):1938-1944. WANG Zhanfeng, ZHANG Hui, ZHANG Hao, et al. Flow stress behaviors of spray-deposited 5A06 aluminum alloy under hot compression deformation[J]. The Chinese Journal of Nonferrous Metals, 2006(11):1938-1944.
[16] QIAN J, LI J, XIONG J, et al. Periodic variation of torque and its relations to interfacial sticking and slipping during friction stir welding[J]. Science and Technology of Welding and Joining, 2012, 17(4):338-341.

铝合金搅拌摩擦焊力的周期性波动特征与机制

Characteristic and Mechanism of Periodic Oscillation of Force in Friction Stir Welding of Aluminum Alloy

PDF

可视化

摘要/Abstract

引用本文

使用本文

参考文献

相关文章 15

编辑推荐

Metrics

本文评价

[1]	方进秀, 张兴权, 王会廷, 谢玲玲. 5052铝合金的动态拉伸性能及其本构模型[J]. 机械工程学报, 2022, 58(8): 160-169.
[2]	李勇, 石朱生, 吕凤工, 荣琦, 李东升, 林建国. 基于热激活变形理论的铝合金弹塑性应力松驰机理与建模[J]. 机械工程学报, 2022, 58(6): 42-51.
[3]	张嘉恒, 胡志力. 铝合金搅拌摩擦焊接头组织热稳定性[J]. 机械工程学报, 2022, 58(6): 73-80.
[4]	杨智勇, 李武鹏, 李志强, 刘小龙, 李卫京. 搅拌摩擦焊多平面搅拌头对材料流动行为的影响[J]. 机械工程学报, 2022, 58(6): 81-90.
[5]	贺鹏飞, 魏正英, 杜军, 蒋敏博, 马琛. 铝合金熔滴复合电弧沉积同步WC颗粒强化增材制造工艺研究[J]. 机械工程学报, 2022, 58(5): 258-267.
[6]	方远方, 张华. 厚板5083铝合金搅拌摩擦焊接头沿厚度方向组织与力学性能[J]. 机械工程学报, 2022, 58(4): 94-101.
[7]	宋燕利, 郝川川, 宁世儒, 吴文林, 刘鹏. 极低频电脉冲处理对Al-Zn-Mg-Cu铝合金力学性能的影响规律与机理[J]. 机械工程学报, 2022, 58(10): 68-77.
[8]	梁伟, 郑颖, 邓德安. 外拘束对铝合金薄板结构焊接变形的影响[J]. 机械工程学报, 2021, 57(6): 70-77.
[9]	雷正龙, 郭亨通, 张登明, 李谦. 5A06 铝合金超声辅助激光填丝焊接熔池流动与结晶行为研究[J]. 机械工程学报, 2021, 57(6): 78-86.
[10]	李欢, 周亢, 曹彪, 张锦洲. 铝合金大功率超声波焊接界面及接头性能研究[J]. 机械工程学报, 2021, 57(6): 87-95.
[11]	翟明, 武传松. 搅拌头/工件界面峰值温度的测量及预测[J]. 机械工程学报, 2021, 57(4): 36-43.
[12]	安剑, 李永丰, 张云光, 李淑慧. 热冲压条件下2219铝合金的本构行为测试与建模[J]. 机械工程学报, 2021, 57(4): 44-52.
[13]	茹一帆, 张乐乐, 刘文, 陈耕, 窦伟元. 基于缺口试件应力状态试验的Johnson-Cook模型参数反演标定方法[J]. 机械工程学报, 2021, 57(22): 60-70.
[14]	郭晓曦, 李恒, 冯振勇, 张铎. 铝合金管弯曲成形表面粗化宏细观耦合建模仿真[J]. 机械工程学报, 2021, 57(22): 209-217.
[15]	付佳伟, 马臻, 聂祥樊, 谢稳伟, 齐乐华. 基于虚场法的铝合金各向异性屈服及硬化属性参数同步表征[J]. 机械工程学报, 2021, 57(20): 68-78,88.