Advances in friction welding technology based on friction between workpiece and external consumable tool
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摘要: 摩擦焊是一类依靠摩擦产热来实现材料连接的固相焊接技术，具有接头质量高、焊接变形小、节能环保等优点，广泛应用于航空航天、交通运输、矿山机械、海洋装备等领域. 近年来，摩擦焊技术发展迅速，一些改型的工艺相继产生. 根据相互摩擦对象的属性对摩擦焊技术进行了分类，归纳了各自的主要工艺特点.对基于工件与外部可消耗工具相互摩擦的焊接技术进行了系统综述，重点介绍了径向摩擦焊、摩擦-铆接、摩擦塞补焊、摩擦堆焊和涡流搅拌摩擦焊的基本工艺原理和最新研究进展，同时对以上工艺技术的未来发展展开了讨论，以期为相关领域的科研工作者提供参考.Abstract: Friction welding is a kind of solid-state welding technology that depends on the friction heat generation to realize materials joining. Owing to the advantages of high joint quality, low welding distortion, energy saving and environmental protection, etc., it is widely used in aerospace, transportation, mining machinery, marine equipment and other fields. In the last few decades, friction welding technology has developed rapidly, and some modified processes have been born. In this paper, the current friction welding methods were summarized according to the properties of mutual friction objects, and then the methods based on the friction between workpiece and consumable external tool were principally reviewed. The process principles and latest research progresses of radial friction welding, friction riveting, friction plug welding, friction surfacing and vortex- friction stir welding were mainly introduced, and the future development of the above welding methods is discussed, to provide reference for researchers in the related field.
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0. 序 言
随着我国经济的快速发展及高性能铝合金的不断研发，凭借自身优良的物理性能，较小的比重、较高的比强度及良好的导电导热性、延展性，在船舶制造、海洋工程、核电设备等领域对高性能铝合金厚板结构的需求越来越大，相应的对厚板的焊接技术要求也越来越高[1-4]. 对于厚板的焊接，窄间隙焊接技术已经广泛应用在工业生产中[5-7]，而激光焊接由于其具有热输入小、热影响区小、焊接变形小等优点，日本焊接界将窄间隙同激光焊并称为21世纪现代工业生产中最适合厚板焊接的两种技术[8-9].
对于铝合金厚板的激光焊接来说，气孔问题是铝合金焊接的常见问题，也是最难解决的问题之一. 文献[10-11]中认为铝合金激光焊接极易产生工艺型气孔的主要原因是因为焊接过程中匙孔底部易被剧烈运动的液态熔池金属所封闭及等离子体波动时会卷入保护气体，又由于铝合金较高的冷却速率，这些被封闭在液态金属中的气泡很难逸出，最终以气孔的形式留于焊缝中. 赵琳等人在焊接钢时采用激光光束摆动的方式来控制气孔，通过采用聚焦光束摆动的方式并调节光束摆动频率等参数可获得极低气孔率的焊接接头[12]. 高频振荡扫描激光束能够改变焊接温度场分布和熔池流动状态，进而改善焊缝成形，消除冶金缺陷，提高焊接质量[13]. 扫描焊接在解决钢的焊接缺陷国内外已有较多研究，但是将激光扫描焊接技术应用到铝合金的气孔抑制方面的研究还很少.
为了克服铝合金焊接的气孔问题，文中采用了激光扫描填丝焊接方法，以5A06铝合金为研究对象，重点讨论在窄间隙填丝焊接条件下，激光扫描填丝焊接工艺参数对气孔率的影响规律.
1. 试验方法
试验所用的母材为开有一定坡口角度的150 mm × 150 mm × 18 mm，与300 mm × 300 mm × 130 mm厚5A06铝合金，焊前状态为H112，为了补偿在焊接过程铝合金中镁元素的烧损，选用含镁元素含量较高的ER5356焊丝与母材等成分匹配，焊丝直径选择1.2 mm，母材及焊丝的化学成分见表1.
表 1 试验材料化学成分(质量分数，%)Table 1. Chemical composition of the material材料 Cu Si Fe Ti Zn Mn Mg Cr Al 母材5A06 0.1 0.4 0.4 0.15 0.25 0.5 6.0 — 余量 焊丝ER5356 0.1 0.25 0.4 0.15 0.25 0.1 5.0 0.03 余量 铝合金激光扫描焊接试验在激光扫描焊接工作站进行，激光扫描焊接试验工作站主要包括以下几部分组成：Trumpf公司生产的Trudisk6002 disk型激光器，激光波长1 070 nm，额定最大输出功率为6 000 W；激光枪枪头为Trumpf公司生产的可编程聚焦镜组，聚焦镜焦距为550 mm，最大扫描速度为1 000 mm/min；MOTOMAN机器人；福尼斯送丝机.
焊接方法如图1所示，填充焊丝以前送丝方式进入焊接区，通过激光加热及熔池热辐射共同作用下熔化，激光束以一定运动轨迹、运动速度、运动半径与竖直平面呈15°角方向作用到焊缝，保护气体为99.9%的纯氩气. 试验均采用未熔透的焊接方式.
2. 试验结果与分析
试验首先研究了扫描方式(圆形扫描轨迹、垂直轨迹、平行轨迹)、扫描幅度、扫描频率对单层单道激光填丝焊缝气孔率的影响规律，扫描轨迹的定义方式为激光束运动方向与焊接方向的相对位置关系，四种光束运动特征如图2所示. 然后根据所得到的单层单道焊缝最佳工艺区间，选取合理的窄间隙坡口形式完成130 mm铝合金大厚板焊接.
试验中固定不变参数为激光功率6 kW，焊接速度1 m/min，送丝速度9 m/min，保护气体为氩气，保护气体流量为15 ~ 25 L/min，激光束焦点位于焊接区表面.
2.1 扫描方式对气孔率的影响
不同扫描轨迹直接表现为激光束对熔池不同热输入方式，不同激光输入方式对熔池搅拌作用不同，液态熔池的稳定性及金属液流动方式必定有所差别. 试验主要研究了四种不同激光束运动轨迹对焊接气孔率的影响规律. 图3反映的是四种不同激光运动模式下铝合金填丝焊接气孔RT图.
可以看到常规单激光填丝焊接及光束以垂直或平行方式运动时，焊缝中所形成的气孔尺寸较大，数量也较多，而当激光束以圆形方式扫描时，能大幅度降低焊缝的气孔率，对铝合金工艺型气孔有极好的抑制作用. 这说明当激光束以圆形方式运动起来后，能极大地稳定窄间隙内的熔池流动，使激光焊接产生的匙孔闭合率大大降低.
图4为四种扫描轨迹焊缝气孔率的定量对比. 常规单激光焊接和光束以垂直轨迹扫描的焊缝气孔率较高，达到了13%以上；当激光束的运动方向采用与焊接方向平行时，能达到一定的抑制气孔的作用，但效果并不是十分明显，气孔率达到了9.6%；当激光束以圆形轨迹扫描运动后，焊缝的气孔率急剧降低，仅仅为0.59%，不但气孔的数量上大幅减少，焊道单个气孔的尺寸相比于其他扫描轨迹也有大幅降低.
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图 4 不同扫描轨迹对填丝焊缝气孔率的影响Figure 4. Effect of different scanning trajectories on porosity of welds综上所述，当激光束以圆形的方式扫描时焊缝气孔率非常低，因此后续的试验均在圆形轨迹的条件下进行研究.
2.2 扫描幅度对气孔率的影响
扫描幅度决定了热源的作用面积，扫描幅度越大，激光束作用面积越大，能量越分散，从而对焊缝的气孔率产生影响. 为了考虑单一变量对试验结果的影响，激光束的扫描频率定为100 Hz.
图5给出了扫描频率在100 Hz条件下，扫描幅度从0.4 ~ 1.5 mm变化时焊缝气孔率的X射线图，图6为气孔率随扫描幅度的变化规律，可以看出气孔率的变化与扫描幅度成反比趋势，气孔率随着扫描幅度的增加而逐渐降低，值得注意的，扫描幅度在1 mm时气孔率发生突变，气孔率急剧减少，当扫描幅度达到1.2 mm时已经几乎没有工艺型气孔的产生.
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图 6 不同扫描幅度对填丝焊缝气孔率的影响Figure 6. Effect of different scanning amplitudes on porosity of welds2.3 扫描频率对气孔率的影响
扫描频率决定激光束对熔池的搅拌速度，频率越快，搅拌速度越高. 同样的，扫描频率也会极大的影响了焊接过程中熔池、匙孔和等离子体的稳定性，进而对焊缝的气孔率造成较大影响.
当扫描幅度在1 mm以下时，随着扫描频率增加气孔变化幅度不大，都维持在一个较高水平，选取具有代表性的扫描幅度0.6 mm，如图7所示，扫描频率变化区间为50 ~ 300 Hz，气孔率维持在12%左右，如图8；而当扫描幅度在1 mm以上时，随着扫描频率的增加气孔率逐渐减小，选取具有代表性的扫描幅度1.2 mm，如图9所示，扫描频率变化区间为50 ~ 200 Hz，在最高频率附近时几乎不产生工艺型气孔，如图8所示.
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图 7 幅度0.6 mm，不同扫描频率下焊缝X射线图片Figure 7. Scanning amplitudes 0.6 mm, X-Ray under different Scanning frequencies![]()
图 8 不同扫描频率对填丝焊缝气孔率的影响Figure 8. Effect of different frequencies amplitudes on porosity of welds![]()
图 9 幅度1.2 mm时不同扫描频率下焊缝X射线图片Figure 9. Scanning amplitudes 1.2 mm, X-Ray under different Scanning frequencies2.4 130 mm厚铝合金单道多层填充焊接验证
根据以上总结单道单层填丝焊焊接参数扫描方式、扫描幅度、扫描频率对焊缝的气孔率的影响规律，选取完成130 mm大厚板焊接优化后的工艺参数如表2、表3所示.
表 2 扫描类工艺参数Table 2. Scanning process parameters扫描方式 扫描幅度 d/mm 扫描频率 f/Hz 圆形扫描 1 ~ 1.5 100 ~ 150 表 3 非扫描类工艺参数Table 3. Laser without scanning process parameters激光功率 P/kW 焊接速度v/(m·min−1) 送丝速度 vf/(m·min−1) 6 0.8 ~ 1 7.5 ~ 9 图10为优化后的单层单道激光扫描填丝焊接焊缝成形、气孔率与常规单激光焊缝的对比. 常规激光焊的焊缝表面成形不良，平整度极差，焊接过程极不稳定，与常规激光焊相比摆动焊接焊缝成形有较大改善，成形光滑均匀. 这是因为当激光束在窄间隙内以圆形运动时，熔融金属在窄间隙内的流动方式由无序变为有序，这种有序的熔池运动方式大大降低了由于匙孔蒸汽反冲压力不能克服由重力引起的流体静压力及由金属流动产生的流体静压力和表面张力而导致的匙孔湮灭的可能，匙孔及熔池的动态行为又与金属蒸汽/等离子体相互作用并动态关联着，因此圆形扫描轨迹在稳定匙孔的同时也增强了等离子体的稳定性，整个熔池处于一种稳定的动态平衡.
根据前期大量的试验研究，我们最终选择的130 mm厚板坡口尺寸如图11所示，窄间隙底部宽度3 mm，钝边15 mm，单边坡口角度为2度.
对130 mm铝合金大厚板采用优化后的单层单道激光扫描填丝工艺进行多层填充焊接，图12为焊接后所得到的焊缝接头宏观形貌，除却打底层，试验共计45层完成填充，且均为单道多层填充，每层焊后都需要用特制的钢刷清理焊道表面的氧化物黑灰，并用酒精擦拭干净，在确保焊道表面没有明显杂质后才能进行下一层填充焊接，每层焊后都需要进行特殊的去应力处理，最终焊后变形角度为1.5度，每层填充熔深约为2.8 mm，焊缝宽度约为6 mm，焊缝形状整齐，稳定性很好，无明显焊接缺陷. 对铝合金焊后试件沿焊缝厚度方向进行9 MeV的ICT探伤，对焊缝宽度方向共分8层进行检测，得到每个纵截面的CT图像，如图13所示. 对每个纵截面的CT图像进行气孔率计算，结果显示平均气孔率为1%，无侧壁及层间未熔合、裂纹等焊接缺陷.
3. 结 论
(1)当扫描激光焊的激光束运动轨迹设计为圆形时，能有效抑制铝合金焊缝中工艺型气孔产生.
(2)扫描幅度的增大能显著降低焊缝的气孔率，当扫描幅度大于1 mm，扫描频率选取相应幅度对应的最高频率时，能够很好抑制工艺型气孔产生.
(3)在国内首次完成了130 mm厚5A06铝合金大厚板激光扫描填丝优质焊接，焊缝形状整齐，稳定性较好，沿焊缝厚度方向进行9MeV-ICT探伤，探伤结果显示焊缝平均气孔率为1%，无侧壁及层间未熔合、裂纹等焊接缺陷.
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图 2 超级马氏体不锈钢径向摩擦焊接头
Figure 2. Typical radial friction welding joint of super martensitic stainless steel. (a) macrostructure of the joint cross-section; (b) corresponding microstructure of the region I in Fig.2a
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图 3 周向摩擦焊工艺
Figure 3. Girth friction welding process. (a) schematic of the process; (b) morphology of the welds
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图 4 双相不锈钢周向摩擦焊接头微观组织
Figure 4. Microstructure of the duplex stainless steel joint produced by girth friction welding. (a) phase of weld zone; (b) phase of thermo-mechanically affected zone; (c) phase of base metal; (d) grain of weld zone; (e) grain of thermo-mechanically affected zone; (f) grain of base metal
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图 5 搅拌摩擦盲铆接工艺原理示意图
Figure 5. Schematic of friction stir blind riveting process. (a) positioning; (b) plunging; (c) self-plugging
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图 6 搅拌摩擦盲铆接头宏观结构及力学性能
Figure 6. Macrostructure and mechanical properties of friction stir blind riveting joint. (a) cross-section of the joint; (b) comparison of tensile properties with resistance spot welding joint
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图 7 摩擦单元焊工艺原理示意图
Figure 7. Schematic of friction element welding. (a) positioning; (b) plunging; (c) dwelling; (d) forging
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图 8 铝/钢摩擦单元焊接头截面宏观和微观组织
Figure 8. Macroscopic and microstructure of the Al/steel joints produced by friction element welding
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图 9 自冲式摩擦铆接工艺原理示意图
Figure 9. Schematic of friction self-piercing riveting. (a) rotating; (b) plunging; (c) forming; (d) stopping; (e) retracting
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图 10 自冲式摩擦铆接接头界面微观结构
Figure 10. Interface microstructure of friction self-piercing riveting joint. (a) joint longitudinal cross-section and the corresponding horizontal cross-section on the dotted line; (b) element analysis of the interface between rivet and its outside workpiece; (c) element analysis of the interface between rivet and its inside workpiece
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图 11 搅拌摩擦铆接工艺原理示意图
Figure 11. Schematic of friction stir riveting welding. (a) positioning; (b) riveting; (c) forming; (d) retracting
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图 12 搅拌摩擦铆焊接头的微观组织和力学性能
Figure 12. Microstructure and mechanical properties of the friction stir riveting welding joint. (a) microstructure near the rivet; (b) metallurgical connection; (c) thread riveting
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图 13 摩擦塞补焊工艺原理示意图
Figure 13. Schematic of friction plug welding. (a) friction push plug welding; (b) friction pull plug welding
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图 14 低合金结构钢S355水下盲孔摩擦塞补焊接头的微观组织
Figure 14. Microstructure of the S355 steel joint produced by underwater blind hole friction plug welding. (a) macrostructure of the joint cross-section; (b) base metal (region A); (c) upper weld metal (region B); (d) lower weld metal (region C); (e) heat affected zone (region D)
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图 15 通孔摩擦塞补焊
Figure 15. Through-hole friction plug welding. (a) schematic of the process; (b) macrostructure of the joint; (c) friction interface (region c); (d) weld root zone (region d)
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图 16 拉锻式摩擦塞补焊
Figure 16. Friction pull plug welding. (a) geometry of the plug (mm); (b) morphology of the joints; (c) macrostructure of the joint cross-section
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图 18 AA6082-T6铝合金摩擦堆焊增材
Figure 18. Additive manufacturing of AA6082-T6 by friction surfacing. (a) successive deposition; (b) bulk produced from four overlapped passes; (c) detail of final thickness achieved; (d) milling of linear rail
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图 19 搅拌摩擦沉积增材制造
Figure 19. Additive friction stir deposition. (a) schematic of process principle; (b) deposition process; (c) workblank and machined component
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图 21 涡流搅拌摩擦焊焊缝成形及对应的搅拌棒形状
Figure 21. Weld formation and stir bar shape in VFSW. (a) weld top surface; (b) weld bottom surface; (c) lug boss at weld end; (d) stir bar
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