Microstructure and mechanical performance of induction-pressure welding joints interface between Q235 steel and 5052 aluminium alloy
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摘要: 为了有效实现车身上的钢/铝复合结构连接，提出了一种新型的焊接与连接技术−感应-静压焊(induction-pressure welding，IPW). 通过光学显微镜、电子扫描显微镜对钢/铝合金连接界面的组织形貌进行观察，通过X射线色散能谱仪、X射线衍射仪及显微硬度计测试了钢/铝连接界面的化学成分、金属间化合物种类以及显微硬度. 结果表明，采用感应-静压焊工艺可以实现Q235钢与5052铝合金的有效连接. 接头界面上1、2号试样的金属间化合物平均厚度分别为115，85 μm. 接头界面的微观组织形貌呈锯齿状，并且组织向钢侧生长. 接头界面组织的硬度明显高于两侧钢铝基体组织的硬度，1，2号试样接头的抗拉强度分别为49，158 MPa. 同时，在整个感应-静压焊工艺过程中，随着加热温度的降低，金属间化合物厚度呈线性减少. 此外，还发现铝原子的扩散能力显著高于铁原子. 故而，在钢/铝感应-静压焊接头界面生成了富铝的金属间化合物Fe2Al5和FeAl2.Abstract: In order to realize the efficient connection between steel and aluminum alloy on vehicle body, a novel welding method—induction-pressure welding (IPW) was presented. The chemical compositions, intermetallic compounds, micro-structure and hardness on interface between Q235 steel and 5052 aluminum alloy after IPW process were tested by optical microscope, scanning electron microscopy, X-ray diffraction and microhardness tester. The results showed that the connection between Q235 steel and 5052 aluminum alloy can be realized by IPW process. The thickness of the intermetallic compound of No.1 and No.2 samples is approximately 115 μm and 85 μm, respectively. The morphology of interface microstructure is saw-tooth formation and the tooth tip is pointed towards the steel. The hardness of joints interface microstructure is higher than that of matrix for steel and aluminum alloy. The tensile strength of the No.1 and No.2 samples joint is 49 MPa and 158 MPa, respectively. Meanwhile, the thickness of intermetallic compound decreases linearly with the decrease of heating temperature during IPW process. In addition, the diffusibility of aluminum atom is higher than that of iron atom. The intermetallic compound with aluminum-rich such as Fe2Al5 and FeAl2 will be formed on interface between steel and aluminum alloy during IPW process.
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图 1 基体材料的初始微观组织形貌
Figure 1. Initial microstructures before IPW process. (a) 5052 aluminum alloy; (b) Q235 steel
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图 4 感应-静压焊接后钢/铝界面连接形貌
Figure 4. Interface morphology of steel/aluminum after IPW process. (a) No.1; (b) No.2; (c) No.3
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图 5 钢/铝感应-静压焊接头界面的扫描电镜照片
Figure 5. Scanning electron microscope images of the two samples on interface between steel and aluminum alloy after IPW process. (a) No.1; (b) No.2; (c) shrinkage cavity in No.1
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图 6 感应-静压焊接接头的能谱仪测试点分布
Figure 6. Energy dispersive spectrum point distribution of IPW welded joints. (a) No.1; (b) No.2
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图 7 感应-静压焊接头的能谱仪点扫描结果
Figure 7. Energy dispersive spectrum point scanning results of IPW welded joints. (a) No.1; (b) No.2
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图 8 钢铝感应-静压焊接接头的EDS线扫描结果
Figure 8. Energy dispersive spectrum line scanning of IPW welded joints. (a) scanning position of No.1；(b) scanning position of No.2；(c) scanning result of No.1；(d) scanning result of No.2
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图 9 焊接试样的X射线衍射图谱
Figure 9. X-ray diffraction pattern of welding samples after IPW process. (a) steel; (b) aluminum alloy ; (c) No.1; (d) No.2
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图 10 感应-静压焊界面的硬度分布
Figure 10. Interface hardness distribution after IPW process. (a) test path of No.1； (b) hardness distribution of No.1； (c) test path of No.2； (d) hardness distribution of No.2
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图 12 接头的温度-金属化合物厚度曲线
Figure 12. Temperature-metal compound thickness curve of the join
表 1 基体材料主要化学成分(质量分数，%)
Table 1 Chemical compositions of Q235 steel and 5052 aluminum alloy
材料 Mg Cr Cu Mn Ti Si Zn C Al Fe Q235 — 0.70 0.10 0.44 0.16 0.10 — 0.10 — 余量 5052 2.22 0.22 0.01 0.01 0.03 0.08 0.01 — 余量 0.20 
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表 2 感应-静压焊过程的具体工艺参数
Table 2 Detailed parameters during IPW process
电源功率
P/kW频率
f/kHz空气间隙
G/mm加热时间
t/mm静压力
F/N50 30 4 4 200
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