铝/钢电阻点焊熔核流动行为及其作用机制研究

doi:10.3901/JME.2024.22.058

机械工程学报 ›› 2024, Vol. 60 ›› Issue (22): 58-67.doi: 10.3901/JME.2024.22.058

• 特邀专栏：异种材料焊接与连接 • 上一篇下一篇

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铝/钢电阻点焊熔核流动行为及其作用机制研究

李卓然^1,2, 杨炳鑫^3,4, 夏裕俊^1,2, 黄霜^1,2, 陆润东^1,2, 李永兵^1,2

1. 上海交通大学上海市复杂薄板结构数字化制造重点实验室上海 200240;
2. 上海交通大学机械系统与振动国家重点实验室上海 200240;
3. 宝山钢铁股份有限公司宝武铝业技术中心上海 201999;
4. 上海运输工具轻量化金属材料应用工程技术研究中心上海 201999

收稿日期:2024-05-06 修回日期:2024-07-26 出版日期:2024-11-20 发布日期:2025-01-02
作者简介:李卓然,男,1998年出生,博士研究生。主要研究方向为异质材料电阻点焊。E-mail:sjtu-lzr@sjtu.edu.cn;夏裕俊(通信作者),男,1991年出生,博士,助理教授。主要研究方向为高性能电阻焊及智能装备。E-mail:xyjdbgt6509@sjtu.edu.cn
基金资助:
国家自然科学基金(52025058，52205396)和中国科协青年人才托举工程(2022QNRC001)资助项目。

Study on the Flow Behavior and Mechanism of Molten Nuggets in Aluminum/Steel Dissimilar Resistance Spot Welding

LI Zhuoran^1,2, YANG Bingxin^3,4, XIA Yujun^1,2, HUANG Shuang^1,2, LU Rundong^1,2, LI Yongbing^1,2

1. Shanghai Key Laboratory of Digital Manufacture for Thin-walled Structures, Shanghai Jiao Tong University, Shanghai 200240;
2. State Key Laboratory of Mechanical System and Vibration, Shanghai Jiao Tong University, Shanghai 200240;
3. Baowu Aluminum Technical Center, Baoshan Iron & Steel Co., Ltd., Shanghai 201999;
4. Shanghai Engineering Research Center of Metals for Lightweight Transportation, Shanghai 201999

Received:2024-05-06 Revised:2024-07-26 Online:2024-11-20 Published:2025-01-02
About author:10.3901/JME.2024.22.058

摘要/Abstract

摘要： 汽车轻量化作为节能减排的重要手段，以铝/钢混合为代表的多材料混合车身已经成为汽车车身发展的重要趋势。面向轻量化铝/钢异质材料混合汽车车身制造，建立适用于铝/钢电阻点焊过程的“电-热-磁-流”多场耦合三维磁流体动力学仿真模型，研究电阻点焊过程中铝熔核的流动行为及其对温度分布的影响，揭示铝/钢异质材料点焊铝熔核形貌的形成机理。结果表明，铝侧熔核呈现内侧顺时针流动为主、外侧逆时针流动为辅的流动模式。这种熔核流动行为促使铝熔核高温区向熔核中部集中，强化了内侧流动，促进了热量由钢板通过界面进入铝板，并沿铝熔核厚度方向的传导。铝侧熔核因此形成内厚外薄的特征，呈现出紧贴铝/钢界面生长的独特“钟形”形貌。

关键词: 电阻点焊, 异质材料, 磁流体动力学仿真, 流动模式, 钟形熔核

Abstract: The adoption of lightweight materials, especially Al/steel hybrids, is a key trend in automotive lightweighting for energy efficiency and emissions reduction. For the manufacturing of Al-steel hybrid automobile bodies, a three-dimensional magnetohydrodynamic(MHD) simulation model is developed to simulate the resistance spot welding(RSW) process of heterogeneous materials by coupling electrical, thermal, magnetic, and fluid fields. The flow behavior of aluminum nuggets and their influence on temperature evolution during welding are investigated. The results indicate that the Al nugget exhibits an outer counterclockwise flow driving and an inner clockwise flow-dominated pattern. The nuggets’ flow behavior promotes the concentration of high-temperature zones in the middle of the Al nugget, enhancing the clockwise flow on the inner side and the heat transfer from the steel sheet through the interface to the aluminum sheet, resulting in the unique “bell-shaped” morphology of the Al nugget closely adhered to the Al/steel interface.

Key words: RSW, dissimilar materials, magnetohydrodynamic(MHD)simulation, flow behavior, nugget formation

中图分类号:

TG444

李卓然, 杨炳鑫, 夏裕俊, 黄霜, 陆润东, 李永兵. 铝/钢电阻点焊熔核流动行为及其作用机制研究[J]. 机械工程学报, 2024, 60(22): 58-67.

LI Zhuoran, YANG Bingxin, XIA Yujun, HUANG Shuang, LU Rundong, LI Yongbing. Study on the Flow Behavior and Mechanism of Molten Nuggets in Aluminum/Steel Dissimilar Resistance Spot Welding[J]. Journal of Mechanical Engineering, 2024, 60(22): 58-67.

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铝/钢电阻点焊熔核流动行为及其作用机制研究

Study on the Flow Behavior and Mechanism of Molten Nuggets in Aluminum/Steel Dissimilar Resistance Spot Welding

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