2219铝合金拉拔式摩擦塞补焊成形行为及其对界面结合质量的影响

高宝祺; 赵衍华; 张丽娜; 邵震; 管卫; 黄一鸣; 崔雷

doi:10.12073/j.hjxb.20240831002

2219铝合金拉拔式摩擦塞补焊成形行为及其对界面结合质量的影响

高宝祺^{1, 2,},
赵衍华³,
张丽娜³,
邵震^{1, 2},
管卫^{1, 2},
黄一鸣^{1, 2, ,},
崔雷^{1, 2}

1.
天津大学, 材料科学与工程学院, 天津, 300350
2.
天津市现代连接技术重点实验室, 天津, 300350
3.
首都航天机械有限公司, 北京, 100076

基金项目: 国家自然科学基金资助项目(52075376)

详细信息

作者简介:
高宝祺，硕士研究生；主要从事铝合金摩擦塞补焊研究； Email: baoqigao@tju.edu.cn

通讯作者:
黄一鸣，博士，副教授，博士研究生导师； Email: ymhuang26@tju.edu.cn.

中图分类号: TG 453
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出版历程
- 收稿日期: 2024-08-30
- 网络出版日期: 2024-12-29
- 刊出日期: 2025-02-24

Forming behavior of friction pull plug welding for 2219 aluminum alloy and its effect on interfacial bonding quality

GAO Baoqi^{1, 2,},
ZHAO Yanhua³,
ZHANG Lina³,
SHAO Zhen^{1, 2},
GUAN Wei^{1, 2},
HUANG Yiming^{1, 2, ,},
CUI Lei^{1, 2}

1.
School of Material Science and Engineering, Tianjin University, Tianjin, 300350, China
2.
Tianjin Key Laboratory of Advanced Joining Technology, Tianjin, 300350, China
3.
Capital Aerospace Machinery Co., Ltd., Beijing, 100076, China

摘要

摘要:
针对2219铝合金拉拔式摩擦塞补焊(friction pull plug welding, FPPW)接头界面结合质量提升的问题，基于FPPW试验和仿真分析了接头成形过程中温度场、应变场和正应力场演变规律，及这些因素对界面结合质量的影响. 结果表明，在焊接过程中，当塞棒旋转进给时，摩擦界面上的峰值温度可达到约525 ℃，周围材料产生剧烈的塑性变形. 分析界面上的正应力场可知，沿板厚方向正应力的分布不均匀，呈现先上升后下降的趋势；当塞棒停转后，界面上的温度降低，塑性变形没有明显增加，上部界面的正应力增加，显著大于下部界面的正应力. 分析认为，相对于温度和塑性应变，正应力对界面结合质量的影响更加显著. 通过调整界面附近发生塑性流动的材料体积，可以增大正应力并改善其分布均匀性，将更多新鲜金属挤入氧化膜破碎的区域，增加新鲜金属实际接触面积，进而显著提高界面结合质量和接头拉伸性能.
- 拉拔式摩擦塞补焊 /
- 铝合金 /
- 接头成形 /
- 拉伸性能
Abstract:
Aiming at improving the interfacial bonding quality of friction pull plug welding (FPPW) joints for 2219 aluminum alloy, the evolutions of temperature, plastic strain, and normal stress field during forming of joints were investigated on the basis of both experimental and simulation results, as well as their influence on interfacial bonding quality. The results indicate that during the welding process, when the rotating plug rotates and feeds, the interfacial temperature increases to about 525 ℃, and the material around the interface experiences severe plastic deformation. It can be analyzed that the interfacial normal stress shows non-uniformity throughout the thickness of the plate, exhibiting an initial increase followed by a subsequent decrease. When the plug stops rotating, the interfacial temperature decreases and plastic strain shows no obvious increase. The normal stress at the upper interface increases and exceeds that at the lower interface. It can be analyzed that the normal stress shows more obvious effect on the interfacial bonding quality compared with temperature and plastic strain. By adjusting the volume of plastic flow material near the interface, the normal stress increases and exhibits uniform, resulting in more fresh metal being extruded into the broken area of oxide film, and increasing the real contact area of fresh metal. The interfacial bonding quality and tensile property of joints can be effectively improved.
- friction pull plug welding /
- aluminum alloy /
- joint forming /
- tensile property

HTML全文

图 1 试板、塞棒和成形环尺寸及装配体示意图(mm)

Figure 1. Geometric dimensions of plate, plug, supporting frame and schematic diagram of assembly. (a) plate; (b) plug; (c) supporting frame; (d) assembly

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图 2 FPPW接头对应的转速曲线示意图

Figure 2. Schematic diagram of rotation speed curves for different FPPW joints

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图 3 金相和拉伸试样取样位置示意图(mm)

Figure 3. Schematic diagram of metallographic and tensile specimens

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图 4 FPPW模型示意图

Figure 4. Schematic diagram of FPPW model

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图 5 FPPW接头横截面与模拟宏观成形

Figure 5. Cross-section appearance of FPPW joint from the experiment and the model

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图 6 塞棒实际与模拟进给量曲线

Figure 6. Curves of displacement of plug from the experiment and the model

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图 7 不同时刻下FPPW接头的温度场分布

Figure 7. Distribution of temperature field at different instances in FPPW joints. (a) cross-sectional temperature in joint 1(t = 5.8 s)； (b) cross-sectional temperature in joint 2(t = 3.6 s);(c) cross-sectional temperature in joint 3(t = 2.1 s)；(d)cross-sectional temperature in joint 1(t = 6.8 s)；(e)cross-sectional temperature in joint 2(t = 4.6 s);(f) cross-sectional temperature in joint 3(t = 3.1 s)；(g) interfacial temperature when the plug is rotating； (h) interfacial temperature when the plug stops rotating

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图 8 不同时刻下FPPW接头的塑性应变场分布

Figure 8. Distribution of plastic strain field at different instances in FPPW joints. (a) cross-sectional plastic strain in joint 1(t = 5.8 s)； (b)cross-sectional plastic strain in joint 2(t = 3.6 s)； (c)cross-sectional plastic strain in joint 3(t = 2.1 s)； (d) cross-sectional plastic strain in joint 1(t = 6.8 s)；(e)cross-sectional plastic strain in joint 2(t = 4.6 s)；(f)cross-sectional plastic strain in joint 3(t = 3.1 s)；(g) interfacial plastic strain when the plug is rotating； (h) interfacial plastic strain when the plug stops rotating

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图 9 不同时刻下FPPW接头的正应力场分布

Figure 9. Distribution of normal stress field at different instances in FPPW joints. (a) cross-sectional normal stress in joint 1(t = 5.8 s)； (b)cross-sectional normal stress in joint 2(t = 3.6 s)； (c)cross-sectional normal stress in joint 3(t = 2.1 s)； (d) cross-sectional normal stress in joint 1(t = 6.8 s)；(e)cross-sectional normal stress in joint 2(t = 4.6 s)；(f)cross-sectional normal stress in joint 3(t = 3.1 s)；(g) interfacial normal stress when the plug is rotating； (h) interfacial normal stress when the plug stops rotating

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图 10 不同时刻下FPPW接头的材料流动速度分布

Figure 10. Distribution of material flow velocity field at different instances in FPPW joints. (a) cross-sectional material flow velocity in joint 1(t = 5.8 s)； (b) cross-sectional material flow velocity in joint 2(t = 3.6 s)； (c) cross-sectional material flow velocity in joint 3(t = 2.1 s)； (d) cross-sectional material flow velocity in joint 1(t = 6.8 s)；(e) cross-sectional material flow velocity in joint 2(t = 4.6 s)；(f) cross-sectional material flow velocity in joint 3(t = 3.1 s)；(g) interfacial material flow velocity when the plug is rotating； (h) interfacial material flow velocity when the plug stops rotating

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图 11 FPPW接头结合界面附近宏观形貌与微观组织

Figure 11. Macro-morphology and micro-morphology of bonding interface in FPPW joints. (a) macro-morphology of joint 1; (b) macro-morphology of joint 2; (c) macro-morphology of joint 3; (d) micro-morphology of joint 1 in region Ⅰ; (e) micro-morphology of joint 2 in region Ⅰ; (f) micro-morphology of joint 3 in region Ⅰ; (g) micro-morphology of joint 1 in region Ⅱ; (h) micro-morphology of joint 2 in region Ⅱ; (i) micro-morphology of joint 3 in region Ⅱ

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图 12 FPPW接头拉伸性能

Figure 12. Tensile properties of FPPW joints

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图 13 FPPW接头断裂位置

Figure 13. Fracture location of FPPW joints

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图 14 FPPW接头断口形貌

Figure 14. Morphology of fracture in FPPW joints. (a) joint 1; (b) joint 2; (c) joint 3

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表 1 2219铝合金热物理参数^[16]

Table 1 Thermo-physical properties of 2219 aluminum alloy

温度 T /K	密度 ρ/(kg·m⁻³)	比热容 c/(J·kg⁻¹·K⁻¹)	热导率 λ/(W·m⁻¹·K⁻¹)
298	2 840	726.3	138.6
373	2 840	801.3	142.7
573	2 840	957.3	154.2
773	2 840	1 049.0	166.6

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表 2 Arrhenius模型多项式系数取值

Table 2 Coefficients of polynomial function of Arrhenius model

α	Q	n	lnA
B₀ = 0.0196	C₀ = 2.94 × 10⁵	D₀ = 5.61	E₀ = 49.4
B₁ = −0.0776	C₁ = −6.81 × 10⁵	D₁ = −4.44	E₁ = −128.04
B₂ = 0.458	C₂ = 3.21 × 10⁶	D₂ = 30.7	E₂ = 613.59
B₃ = −0.920	C₃ = −6.56 × 10⁶	D₃ = −73.31	E₃ = −1226
B₄ = 0.652	C₄ = 4.81 × 10⁶	D₄ = 57.95	E₄ = 846.21

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表 3 FPPW模型中摩擦系数^[18]

Table 3 Friction coefficient in FPPW model

温度 T /K	摩擦系数μ
298	0.3
673	0.25
793	0.2
816	0.01

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