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单静止上轴肩BT-FSW工艺过程及成形机理

Forming mechanism and processing of stationary upper shoulder BT-FSW

  • 摘要: 以AA6056铝合金单静止上轴肩双轴肩搅拌摩擦焊(stationary upper shoulder bobbin tool friction stir welding,SSUBT-FSW)接头为研究对象,通过数值模拟与试验相结合的方法,阐明了SSUBT-FSW温度场与应变场分布规律及接头成形机理. 结果表明,SSUBT-FSW的上轴肩处于静止状态,有效增加了焊接稳定性,并将最大扭矩减小至55 N·m(常规双轴肩搅拌摩擦焊最大扭矩65 N·m). 静止上轴肩对焊缝表面施加顶锻压力,促使弧纹的波峰与波谷的高度差从60 μm减小至10 μm,显著提高了接头表面光洁度. 下轴肩旋转所产生的塑性应变区直径大于搅拌针,促使接头横截面等效塑性应变场呈梯形分布,与横截面温度场具有高度吻合性. SSUBT-FSW过程中产生材料非对称性流动行为,靠近下轴肩的材料流动性显著优于静止上轴肩.

     

    Abstract: Taking the stationary upper shoulder bobbin tool friction stir welding (SSUBT-FSW) welded joint of AA6056 aluminum alloy as the research object, the distributions of temperature and strain fields have been clarified based on combining with experimental and numerical simulation methods. Results show that the upper shoulder of SSUBT-FSW is in a static state, which effectively increases the welding stability and decreases the maximum torque to 55 N·m (the maximum torque of conventional bobbin tool friction stir welding is 65 N·m). The pressure of the stationary upper shoulder on the weld surface reduces the height difference between the peak and trough of the arc corrugations from 60 μm to 10 μm, which significantly improves the surface finish of the joint. The diameter of plastic strain zone driven by the lower rotating shoulder is larger than that developed by the probe, promoting the plastic strain field shows a trapezoidal shape on the cross section of the joint, which is good agreement with the shape of the temperature field. In the SSUBT-FSW process, the material flow of the lower shoulder is significantly better than that of the stationary upper shoulder, and the material asymmetry flow characteristics are formed along the thickness direction of the joint.

     

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