搅拌摩擦焊下压力控制系统的开发及在模拟非刚性环境下的验证试验

doi:10.3901/JME.2015.22.060

机械工程学报

搅拌摩擦焊下压力控制系统的开发及在模拟非刚性环境下的验证试验

李晗^{1, 2}, 史清宇^{1, 2}, 刘瞿^{1, 2}, 曹雄^{1, 2}, 朱宇灿^{1, 2}

1. 清华大学机械工程系北京 100084；
2. 清华大学摩擦学国家重点实验室北京 100084

收稿日期:2015-04-29 修回日期:2015-08-17 出版日期:2015-11-15 发布日期:2015-11-15
通讯作者: 史清宇，男，1971年出生，博士，教授，博士研究生导师。主要研究方向为搅拌摩擦焊接与加工，焊接应力变形控制，焊接过程模拟仿真。 E-mail：shqy@mail.tsinghua.edu.cn
作者简介:作者简介：李晗，男，1986年出生，博士研究生。主要研究方向为搅拌摩擦焊下压力控制。 E-mail：lihan12@mails.tsinghua.edu.cn

Development of Pressure Control System for Friction Stir Welding and Experiment in Simulated Non-rigid Environment

LI Han, SHI Qingyu, LIU Qu, CAO Xiong, ZHU Yucan

1. Department of Mechanical Engineering, Tsinghua University, Beijing 100084;
2. State Key Laboratory of Tribology, Tsinghua University, Beijing 100084

Received:2015-04-29 Revised:2015-08-17 Online:2015-11-15 Published:2015-11-15

摘要/Abstract

摘要： 搅拌摩擦焊接(Friction stir welding, FSW)是材料固态连接新技术，但FSW在焊接过程中一般会对工件施加较大的下压力，焊接设备和被焊工件在下压力的作用下均可能产生变形，使得常规FSW中设定的下压量这一关键参数偏离预期值，无法保证焊接工艺的稳定性。为了解决这一问题，开发一套下压力反馈控制系统，通过调节搅拌头对工件的下压量来调节下压力，使焊接过程中下压力保持稳定。该系统使用一台计算机作为顶层控制器，根据压力传感器反馈的实时下压力调节FSW设备Z轴的进给。使用该系统在悬空的钢板上焊接6082-T6铝合金平板对接焊缝，焊接过程中工件在下压力的作用下产生的弯曲变形高达0.931 mm，但所得的焊缝成形良好，沿焊缝方向不同位置的接头的横截面形貌基本一致，其横向拉伸应力应变曲线高度重合，接头的平均抗拉强度为222.8 MPa。结果表明，工件在下压力作用下产生变形的条件下，下压力控制的FSW系统仍能保证工艺稳定性。

关键词: 搅拌摩擦焊接, 接头强度, 下压力控制

Abstract: Friction stir welding(FSW) is a new solid state joining technique. Generally the FSW process would apply large pressure on to workpiece which would cause deformation of either the welding equipment or the workpiece. This deformation would cause the plunge depth, a key welding parameter, deviate from its setting value, and damage the stability of the FSW process. To solve this problem, a FSW pressure control system is developed, which keeps the pressure steady by adjusting the plunge depth. The system uses a computer as top layer controller, controlling the Z axis of a FSW equipment according to the feedback of a force sensor. Using this system, butt welds of 6082-T6 aluminum alloy plates are welded on a suspended steel plate. The deformation of the 6082 plate is up to 0.931 mm during the FSW process. The produced weld shows good surface formation, uniform macro sections and mechanical properties along the weld, and the tensile strength is 222.8 MPa. The experiment result proves that the FSW pressure control system could stabilize the welding process despite the workpiece deforms under pressure.

Key words: friction stir welding, joint strength, pressure control

李晗, 史清宇, 刘瞿, 曹雄, 朱宇灿. 搅拌摩擦焊下压力控制系统的开发及在模拟非刚性环境下的验证试验[J]. 机械工程学报, doi: 10.3901/JME.2015.22.060.

LI Han, SHI Qingyu, LIU Qu, CAO Xiong, ZHU Yucan. Development of Pressure Control System for Friction Stir Welding and Experiment in Simulated Non-rigid Environment[J]. Journal of Mechanical Engineering, doi: 10.3901/JME.2015.22.060.

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搅拌摩擦焊下压力控制系统的开发及在模拟非刚性环境下的验证试验

Development of Pressure Control System for Friction Stir Welding and Experiment in Simulated Non-rigid Environment

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