6061-T6铝合金中空薄壁型材双轴肩搅拌摩擦焊工具设计与工艺分析

张颖川; 马国栋; 代鹏; 王敬水; 金炜

doi:10.12073/j.hjxb.20210512001

6061-T6铝合金中空薄壁型材双轴肩搅拌摩擦焊工具设计与工艺分析

张颖川^{1, 2,},
马国栋^{1, 2},
代鹏¹,
王敬水¹,
金炜^{1, 2, ,}

1.
北京纵横机电科技有限公司，北京，100091
2.
中国铁道科学研究院集团有限公司，机车车辆研究所，北京，100081

基金项目: 中国铁道科学研究院集团有限公司院基金重点课题 (2019YJ021)

详细信息

作者简介:
张颖川，博士；主要从事材料焊接结构设计、复合材料设计等研究工作；Email: zhangyingchuan@zemt.cn

通讯作者:
金炜，副研究员；Email: jinwei@zemt.cn.

中图分类号: TG 47
计量
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- HTML全文浏览量: 49
- PDF下载量: 29
出版历程
- 收稿日期: 2021-05-20
- 网络出版日期: 2022-05-29
- 刊出日期: 2022-07-07

Tool design and process analysis of bobbing tool friction stir welding for thin-walled extrude profile of 6061-T6 aluminum alloy

ZHANG Yingchuan^{1, 2,},
MA Guodong^{1, 2},
DAI Peng¹,
WANG Jingshui¹,
JIN Wei^{1, 2, ,}

1.
Beijing Zhongheng Electro-Mechanical Technology Co., Ltd., Beijing, 100091, China
2.
Locomotive & Car Research Institute, China Academy of Railway Sciences Co., Ltd., Beijing, 100081, China

摘要

摘要: 基于双轴肩搅拌摩擦焊热输入的理论分析，建立了焊接工具结构尺寸特征值与待焊工件厚度之间的工程模型.利用该工程模型，设计并优化得到适用于厚度为2.5 mm的6061-T6铝合金薄板的双轴肩搅拌摩擦焊工具.使用该工具对中空薄壁型材进行焊接，并对焊接工艺参数进行优化. 结果表明，当焊接工具转速为1 000 r/min、焊接速度为600 mm/min时，可以得到综合力学性能最佳的焊接接头，其中正面焊缝焊接接头抗拉强度可达231 MPa，为母材抗拉强度的77%，弯曲角度达180°；反面焊缝焊接接头抗拉强度可达226 MPa，为母材抗拉强度的76%，弯曲角度达180°.
- 双轴肩搅拌摩擦焊 /
- 6061-T6铝合金 /
- 中空薄壁型材 /
- 焊接工具设计
Abstract: An engineering model between characteristic value of welding tool and specimen thickness was established based on heat input theoretical analysis of bobbing tool friction stir welding. According to this model, a welding tool was designed and optimized, which was used for join 2.5 mm thin-walled extrude profile of 6061-T6 aluminum alloy. Friction stir welding parameters were optimized as well. When the rotation speed of the tool was 1 000 r/min and welding speed was 600 mm/min, the joint obtained a maximum mechanical properties. The front side joint had a tensile strength of 231 MPa, 77% of the base material, and a bend angle of 180°, while the back side joint had a tensile strength of 226 MPa, 76% of the base material, and a bend angle of 180°.
- bobbing tool friction stir welding /
- 6061-T6 aluminum alloy /
- thin-walled cavity extrude profile /
- welding tool design

HTML全文

图 1 焊接设备及工装

Figure 1. Welding equipment and fixture. (a) FSW-HD type friction stir welding equipment; (b) welding fixture

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图 2 型材结构

Figure 2. Extruded profile structure. (a) cross section schematic of extruded profile; (b) large area structure formed by multiple components

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图 3 轴肩与工件摩擦的圆环面示意图

Figure 3. Schematic diagram of the ring area of friction between shoulder and workpiece

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图 4 S-d曲线的拟合方程

Figure 4. Fitted curve of S-d relation

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图 5 1号工具焊接接头照片

Figure 5. Picture of welded joints by tool No.1

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图 6 2号工具焊接接头照片

Figure 6. Pictures of welded joints by tool No.2

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图 7 3号工具焊接接头照片

Figure 7. Picture of welded joints by tool No.3

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图 8 不同转速下焊接接头的力学性能

Figure 8. Mechanical properties of FSW joints with different rotation speeds

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图 9 不同焊接速度下焊接接头的力学性能

Figure 9. Mechanical properties of FSW joints with different weld speeds. (a) rotation speed of 1 000 r/min; (b) rotation speed of 1 500 r/min

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表 1 6061铝合金中空薄壁型材化学成分(质量分数，%)

Table 1 Chemical compositions of 6061-T6 aluminum alloy extruded profile

项目	Mg	Si	Cu	Cr	Fe	Zn	Mn	Al
实测值	0.851	0.688	0.161	0.086	0.143	0.016	0.081	余量
标准值	0.8 ~ 1.2	0.4 ~ 0.8	0.15 ~ 0.4	0.04 ~ 0.35	0 ~ 0.7	0 ~ 0.25	0 ~ 0.15	余量

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表 2 6061铝合金中空薄壁型材的力学性能

Table 2 Mechanical properties of 6061-T6 aluminum alloy extruded profile

编号	抗拉强度 R_m/MPa	屈服强度 R_eL/MPa	断后伸长率 A(%)	显微硬度 H(HV0.2)
母材1	297	273	8.02	110
母材2	298	276	6.75	113
母材3	300	279	6.45	111
平均	298	276	7.07	111

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表 3 部分6061-T6铝合金双轴肩搅拌摩擦焊研究结果

Table 3 Reported results of 6061-T6 aluminum alloy bobbing tool FSW

文献编号	待焊材料厚度 d/mm	上轴肩直径 R_u/mm	下轴肩直径 R_d/mm	轴肩间距 H/mm	搅拌针直径 R_p/mm	抗拉强度 R_m/MPa	接头系数 η(%)	特征值 S
[21]	4	18	16	3.8	8	230	72	1 295.4
[22]	5	18	16	4.9	8	221	77	1 348.2
[23]	6	16	16	5.8	8	203	59	1 174.4
[24]	7.8	23	23	7.65	10	191	74	3 365.5
[25]	4	18	16	3.94	8	188	66	1 302.1
[26]	4	18	16	3.9	8	195	69	1 300.2
[27]	4	18	18	4	8	182	66	1 522
[28]	5	18	16	4.95	8	224	75	1 350.6
[29]	6.35	22	22	6	8	229	93	2 822
[30]	8	24	24	7.7	11.9	237	82	3 852.5

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表 4 FSW工具结构的尺寸参数

Table 4 Dimension parameter of the FSW tool

工具编号	上轴肩直径 R_u/mm	下轴肩直径 R_d/mm	轴肩间距 H/mm	搅拌针直径 R_p/mm	特征值S
1	16	16	2.3	6	1 032
2	12	12	2.3	6	440
3	14	12	2.3	6，4.5	552

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