钢/铝/钢大功率超声波焊接过程计算与接头性能

doi:10.3901/JME.260499

机械工程学报 ›› 2026, Vol. 62 ›› Issue (10): 170-178.doi: 10.3901/JME.260499

• 材料科学与工程 • 上一篇

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钢/铝/钢大功率超声波焊接过程计算与接头性能

李欢¹, 李俊¹, 王善林², 高振泽¹, 张长鑫¹, 陈玉华²

1. 长江大学机械工程学院荆州 434023;
2. 南昌航空大学高端装备极端制造技术江西省重点实验室南昌 330063

收稿日期:2025-05-14 修回日期:2025-11-24 发布日期:2026-07-29
作者简介:李欢,男,1983年出生,博士,副教授。主要研究方向为新能源汽车车身及动力锂电池的精密焊接工艺及过程数值模拟。E-mail:lihuan@yangtzeu.edu.cn;王善林(通信作者),男,1977年出生,博士,教授。主要研究方向为航空高强钢的制备与应用。E-mail:slwang70518@nchu.edu.cn
基金资助:
高端装备极端制造技术江西省重点实验室开放课题(EG202380302)、国家自然科学基金(51605103)和湖北省教育厅科研计划重点(D20221306)资助项目。

Calculation and Joint Performance in Steel/Al/Steel High-power Ultrasonic Welding Process

LI Huan¹, LI Jun¹, WANG Shanlin², GAO Zhenze¹, ZHANG Changxin¹, CHEN Yuhua²

1. College of Mechanical Engineering, Yangtze University, Jingzhou 434023;
2. Jiangxi Provincial Key Laboratory of Extreme Manufacturing Technology for High-end Equipment, Nanchang Hangkong University, Nanchang 330063

Received:2025-05-14 Revised:2025-11-24 Published:2026-07-29

摘要/Abstract

摘要： 钢/铝/钢层叠接头在轻量化汽车应用较多，但其焊接较困难，因此可靠的钢/铝/钢焊接接头是实现汽车轻量化需解决的难点。以6061-T6铝合金、DC04低碳钢为工件，采用LS-DYNA软件建立一个与实际一致的钢/铝/钢超声波焊接显式动力学模型，将焊头的振动位移作为初始条件加载至模型，研究焊接过程中工件振幅、温度场以及材料的塑性应变分布；最后测试了接头的力学性能。结果表明，在焊接过程中，焊头的振动能量同步传递至铝合金和下工件；上工件与铝板的位移呈近似的波动规律，与下工件的位移波动差异较大。在焊接初始时工件逐渐以较小振幅偏离其平衡位置，之后上工件、铝板和下工件的平均振幅增加，分别达到焊头振幅的63.0%、38.9%和10.2%。较高的上工件振幅导致上层钢/铝界面的温度及塑性变形均比下层钢/铝界面高；上层、下层钢/铝界面中间相厚度分别为1.52 μm和1.07 μm；上层钢/铝界面拉伸剪切力为3.6 kN，为焊核拔出式断裂；而下层钢/铝界面的拉伸剪切力为3.1 kN，在界面处断裂。钢/铝/钢超声波焊接断裂模式为韧性-脆性混合断裂。研究结果为进一步推进轻量化汽车的应用提供参考。

关键词: 超声波焊接, 钢/铝/钢复合结构, 振动位移, 接头性能

Abstract: Steel/aluminum/steel welded joints are extensively utilized in lightweight automotive applications, but welding it is challenging. Consequently, sound steel/Al/steel welded joints are crucial for achieving automotive lightweighting. A steel/Al/steel ultrasonic welding explicit dynamic model consistent with actual welding conditions was established using LS-DYNA software with 6061-T6 aluminum alloy and DC04 low carbon steel as welding specimens. The vibration displacement of the sonotrode was defined as the initial condition input into the model. The vibration amplitude, temperature field, and plastic strain distribution of the specimens during ultrasonic welding were investigated. The mechanical properties of the steel/Al/steel joints were also proposed. The results indicate that during the welding process, the vibration energy of the sonotrode is synchronously transmitted to the aluminum alloy and the lower specimen. The fluctuation of the upper specimen displacement is similar with the middle aluminum specimen, but there is a significant difference compared to the lower specimen. At the initial of welding, the upper specimen and the middle aluminum specimen gradually deviate from their equilibrium position with a small amplitude. After a welding time of 0.2 s, the average amplitude of the upper specimen, middle aluminum workpiece, and lower workpiece increased, reaching 63.0%, 38.9%, and 10.2% of the vibration amplitude of the sonotrode, respectively. The higher amplitude of the upper specimen results in higher temperature and plastic deformation at the upper steel/Al interface compared to the lower steel/Al interface. The thickness of the intermetallic compound layer is 1.52 μm at the upper steel/Al interface and 1.07 μm at the lower steel/Al interface, respectively. The tensile shear force at the upper steel/Al joint is 3.6 kN, indicating a weld nugget pull-out fracture; the tensile-shear force at the lower steel/Al joint is 3.1 kN, and the joint fractures at the interface. The fracture mode of steel/Al/steel ultrasonic welded joints are ductile-brittle hybrid fracture. The results provide guidance for further advancing lightweight automotive applications.

Key words: ultrasonic welding, steel/aluminum/steel laminated structures, vibration displacement, joint performance

中图分类号:

TP453

李欢, 李俊, 王善林, 高振泽, 张长鑫, 陈玉华. 钢/铝/钢大功率超声波焊接过程计算与接头性能[J]. 机械工程学报, 2026, 62(10): 170-178.

LI Huan, LI Jun, WANG Shanlin, GAO Zhenze, ZHANG Changxin, CHEN Yuhua. Calculation and Joint Performance in Steel/Al/Steel High-power Ultrasonic Welding Process[J]. Journal of Mechanical Engineering, 2026, 62(10): 170-178.

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钢/铝/钢大功率超声波焊接过程计算与接头性能

Calculation and Joint Performance in Steel/Al/Steel High-power Ultrasonic Welding Process

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