Assisting controlling of deformation mechanism and stress evolution in high-strength aluminum alloy thin plate welding by trailing hybrid high-speed gas fluid field
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摘要: 从力学角度出发提出了“随焊高速气流场”柔性控制高强铝合金薄板焊接失稳变形的新方法，研究了该方法控制2A12高强铝合金薄板焊接变形的有效可行性，分析了随焊高速气流载荷对薄板应力演变规律的影响，阐明了其控制焊接残余应力及变形机理. 基于有限元法分析了温度场及应力场，确定了气动载荷与热源作用距离这一关键因素，并获得了气体压力的合理有效范围. 在自行研制的随焊高速气流场装置上进行试验验证. 结果表明，当气动载荷作用距离为20 mm、气动载荷为30 MPa时，焊接失稳变形基本消失，焊缝中截面上的纵向残余拉应力峰值较常规焊下降了77.73%，残余压应力峰值下降了69.23%，板边变形最大挠度仅为0.9 mm，较常规焊的8.5 mm下降了89.41 %. 试验结果与模拟结果吻合良好，验证了随焊控制模型的正确性.Abstract: A new method of welding with trailing gas fluid field to control flexibly unstable deformation of high-strength aluminum alloy 2A12 thin plate, and the feasibility was analyzed. The influence of high-speed gas fluid load on the welding stress evolution law of the thin plate was studied. The mechanism of controlling of welding residual stress and deformation was illustrated. Based on the finite element method, the temperature field and stress field were analyzed to determine the distance between aerodynamic load and heat source, which was the key factor, obtaining the reasonable and effective range of gas pressure. Welding experiments were conducted using a self-developed device. The results show that when the distance between aerodynamic load and heat source is 20 mm and the gas pressure is 30 MPa, the welding instability deformation is basically eliminated . The longitudinal residual tensile stress peak value on the cross section of the weld seam decreases by 77.73% compared to conventional welding, and the residual compressive stress peak value decreases by 69.23%. The maximum deflection of the plate edge deformation is only 0.9 mm, which is a drop of 89.41% compared to 8.5 mm of conventional welding. The experimental results are in good agreement with the simulation results.
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图 1 随焊高速气流场控制薄板焊接变形原理图
Figure 1. Schematic diagram of distortion controlled by trailing hybrid high-speed gas fluid field
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图 5 不同条件下相同位置处温度历程曲线
Figure 5. Temperature history curves at the same location under different conditions
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图 6 距热源不同距离的温度和屈服强度的关系
Figure 6. Relationship between temperature and yield strength at different distances from the heat source
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图 8 焊后变形对比
Figure 8. Comparison of deformation after welding. (a) conventional welding; (b) welding with trailing hybrid high-speed gas fluid field
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图 9 中截面不同时刻纵向焊接应力的演变过程
Figure 9. Evolution of longitudinal welding stresses in the middle section at different moments
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图 10 各点纵向焊接应力随焊接时间的变化曲线
Figure 10. Variation curve of longitudinal welding stress at each point with welding time
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图 11 焊接瞬时温度场分布
Figure 11. Welding transient temperature field distribution. (a) longitudinal observation; (b) transverse observation
表 1 材料性能参数
Table 1 Material performance parameters
温度T/℃ 弹性模量E/GPa 线膨胀系数α/10−6℃−1 屈服极限σs/MPa 比热c/(J·kg−1·℃−1) 热导率K/(W·m−1·℃−1) 20 70.0 22.8 300 900 117 100 60.8 23.1 280 921 121 200 54.4 24.7 240 1 005 126 300 43.1 25.5 160 1 047 130 400 32.0 26.5 113 1 089 138 
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表 2 不同气动载荷作用距离下的等效应力
Table 2 Equivalent stress with different aerodynamic loading distances
气动载荷作用距离d/mm 气动载荷P/MPa 121620242832 5 ~ 155 ~ 255 ~ 3510 ~ 4010 ~ 8010 ~ 120
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表 3 自动钨极氩弧焊的焊接工艺参数
Table 3 Welding process parameters of automatic TIG welding
板厚B/mm 钨极直径D/mm 焊接电流I/A 电弧电压U/V 焊接速度v/(mm·s−1) 氩气流量Q/(L·min−1) 2 1.6 95 12 ~ 15 4 17
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