Process optimization on friction stir lap welding of 6061-T6 aluminum alloy/Q235 steel with ultrasonic vibration
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摘要: 采用超声振动强化搅拌摩擦焊接工艺实现了6061-T6铝合金和Q235钢异种金属的有效连接，考察了超声能量对焊缝成形、接头组织、力学性能以及焊接载荷的影响.结果表明，施加超声能量可以显著改善焊缝表面成形，增加铝/钢界面区和焊核区的宽度.超声振动细化了焊核区和热力影响区的晶粒组织，改变了搭接接头的断裂机制和断裂位置，提高了接头的力学性能.对焊接过程中焊接载荷的变化进行分析，发现施加超声能量后搅拌头扭矩、焊接轴向力和主轴输出功率均有所下降.Abstract: The effective connection between 6061-T6 aluminum alloy and Q235 steel was realized by ultrasonic vibration enhanced friction stir welding (UVeFSW) process. The effects of ultrasonic energy on weld formation, joint microstructure, mechanical properties and welding load were investigated. The results show that the application of ultrasonic energy can significantly improve the weld surface forming and expand the width of aluminum / steel interface zone and weld nugget zone. Ultrasonic energy refines the grain structure of weld nugget zone and thermal mechanically affected zone, changes the fracture mechanism and cracking location of lap joint, improves the mechanical properties of joint. The variation of welding loading during welding was analyzed. It is found that the tool torque, the welding axial force and the spindle power decrease after applying ultrasonic energy.
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图 3 不同焊接速度时焊缝横截面宏观形貌(mm)
Figure 3. Cross-section macroscopic morphologies of weld at different welding speeds. (a) v = 25 mm/min; (b) v = 50 mm/min; (c) v = 100 mm/min
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图 4 焊接接头微观组织(v = 50 mm/min)(左图：FSW；右图：UVeFSW)
Figure 4. Microstructure of welded joint. (a) base metal zone; (b) heat affected zone; (c) thermal mechanically affected zone; (d) weld nugget zone
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图 5 焊接接头显微硬度分布(v = 50 mm/min)
Figure 5. Microhardness distribution of welded joint. (a) aluminum alloy side; (b) steel side
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图 7 试样的断裂位置(v = 50 mm/min)
Figure 7. Fracture location of sample. (a) conventional FSW; (b) UVeFSW
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图 8 断口微观形貌及扫描结果(v = 50 mm/min)
Figure 8. Fracture micro-morphology and scanning results. (a) conventional FSW; (b) UVeFSW
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图 9 常规FSW断口处的XRD分析结果(v = 50 mm/min)
Figure 9. XRD analysis results obtained from fracture surfaces of conventional FSW
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图 10 焊接载荷随焊接时间变化曲线图(v=100 mm/min)
Figure 10. Variation curve of welding load with welding time. (a) tool torque; (b) axial force; (c) spindle power
表 1 6061-T6主要化学成分(质量分数，%)
Table 1 Main chemical compositions of 6061-T6
Cu Mg Si Fe Ti Mn Zn Cr Al 0.15 ~ 0.4 0.8 ~ 1.2 0.4 ~ 0.8 0.7 0.15 0.15 0.25 0.04 ~ 0.35 余量 
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表 2 Q235主要化学成分(质量分数，%)
Table 2 Main chemical compositions of Q235
C Mn Si P S Fe 0.13 0.37 0.22 0.018 0.012 余量
下载: 导出CSV
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