Experimental and numerical simulation of the effect of resistance-assisted heating on formability of 2519A aluminum alloy during friction stir welding
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摘要:
采用试验与数值模拟相结合的方法探究了电阻辅助加热温度对2519A-T87铝合金搅拌摩擦焊接头成形性的影响,基于耦合欧拉-拉格朗日方法建立了电阻辅助加热搅拌摩擦焊的三维热-力耦合模型,分析了焊接过程温度场分布和材料流动行为,阐明了电阻辅助加热工艺消除搅拌摩擦焊隧道型缺陷的作用机理.结果表明,辅助加热工艺使焊接峰值温度从483 ℃提高至549 ℃,并增加了350 ℃以上高温区间的停留时间,扩大了高温分布区域,降低了材料变形抗力,增强了材料从焊核区后退侧运动至前进侧的流动性,使材料回填更充分,从而消除了焊缝内部隧道型缺陷.
Abstract:In present study, the effects of the resistance-assisted heating process on the formability of 2519-T87 friction stir welded joints were investigated by experiments and numerical simulations. Based on the coupled Eulerian-Lagrangian (CEL) method, a three-dimensional thermal mechanical coupling model of friction stir welding with a resistance-assisted heating process was established. The temperature field and material flow behavior were analyzed, and the mechanism of eliminating tunnel hole defects during resistance-assisted heating friction stir welding process was discussed. The results show that the auxiliary heating process increases the welding peak temperature from 483 ℃ to 549 ℃, increases the residence time at high temperature above 350 ℃, and expands the high-temperature distribution area. This reduces the material deformation resistance, and enhances the fluidity of materials from the retreating side of the nugget zone to the advancing side, leading to more sufficient backfilling of materials, thus eliminating the tunnel hole defects in the joint.
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图 3 模拟焊缝与实际焊缝宏观形貌照片
Figure 3. Simulated and actual image of weld surface. (a) simulated image of weld surface in C-FSW; (b) simulated image of weld surface in P-FSW(100 ℃); (c) simulated image of weld surface in P-FSW(200 ℃); (d) actual image of weld surface in C-FSW; (e) actual image of weld surface in P-FSW(100 ℃); (f) actual image of weld surface inP-FSW(200 ℃)
表 1 2519A-T87 铝合金板材化学成分和力学性能
Table 1 Chemical composition and mechanical properties of 2519A-T87 aluminum alloy sheet
化学成分(质量分数,%) 力学性能 Cu Fe Mg Mn Si Ti Zr Al 抗拉强度Rm/MPa 屈服强度RP0.2/MPa 断后伸长率A(%) 硬度H/HV 5.80 0.10 0.20 0.30 0.02 0.05 0.19 余量 467 422 9.2 144 表 2 换热系数设置
Table 2 Heat transfer coefficients
方法 表面 对流换热系数
K/(W·m−2℃−1)环境温度
Th/℃C-FSW 底面 300 30 上表面和侧面 30 30 P-FSW
(100 ℃)底面 3 100 上表面和侧面 30 30 P-FSW
(200 ℃)底面 3 200 上表面和侧面 30 30 表 3 2519A-T87铝合金Johson-Cook本构模型参数
Table 3 Material parameters in Johnson−Cook constitutive model for 2519A-T87 aluminum alloy
初始屈服应力A/MPa 材料应变硬化模量B/MPa 材料应变率强化参数C 硬化指数n 材料软化指数m 参考温度$ {{T}}_{{{\rm{ref}}}} $/℃ 材料熔点$ {{T}}_{{{\rm{melt}}}} $/℃ 参考应变率
${\dot{{ \varepsilon } } }_{{0} }$452.68 282.60 0.014 2 0.42 0.74 30 542 1.0 -
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