Simulation study of laser joining of carbon fiber reinforced plastics and 6061 aluminum
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摘要:
为研究碳纤维增强复合材料和铝合金搭接激光焊接过程的温度变化规律，文中以6061铝合金和碳纤维增强尼龙66复合材料(CF/PA66)为研究对象，建立了基于热传导的有限元模型，使用SYSWELD软件对两种材料搭接激光焊接过程进行数值模拟，并通过试验验证了模型的准确性；在此基础上研究了激光功率、焊接速度、搭接宽度、冷却条件、工装导热条件对接头温度场的影响规律；研究发现， CF/PA66树脂熔化区域随着激光功率的增大而增加，随冷却速度的增大而减小，同种工艺参数下材料搭接尺寸对界面树脂最大熔化宽度无影响，水冷条件能够显著降低CF/PA66树脂熔化量，导热材料热导率越大，对PA66树脂熔化量的降低作用越显著.
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关键词:
- 激光焊接 /
- 6061铝合金 /
- 碳纤维增强尼龙66复合材料 /
- 数值模拟
Abstract:In order to study the temperature variation of the laser welding process of carbon fiber reinforced composite and aluminum alloy, this paper took 6061 aluminum alloy and carbon fiber reinforced Nylon 66 composite (CF/PA66) as the research object, established the finite element model based on heat conduction, and used SYSWELD software to conduct numerical simulation of the laser welding process of the two materials. The accuracy of the model was verified by experiments. On this basis, the influence laws of laser power, welding speed, lap width, cooling conditions and tooling thermal conductivity on the joint temperature field were studied. It is found that the size of aluminum alloy molten pool and the melting zone of PA66 resin increase with the increase of laser power and decrease with the increase of cooling rate. Under the same process parameters, the material lap size has no effect on the maximum melting width of interfacial resin. The water cooling condition can significantly reduce the melting pool size and the melting capacity of PA66 resin. The reduction of melt pool size and melting amount of PA66 resin is more significant.
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图 3 有限元网格模型
Figure 3. Finite element mesh model. (a) contact interface; (b) overlap area
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图 5 6061铝合金热物理性能够参数
Figure 5. Thermal properties of 6061 aluminum alloy. (a) thermal conductivity; (b) specific heat
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图 8 实际焊缝形貌与有限元仿真结果对比
Figure 8. Comparison of experimental and finite element simulation
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图 12 CFRTP表面实际熔化宽度与温度场云图对比
Figure 12. Comparison of actual melting width and temperature field nephogram of CFRTP surface
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图 13 不同激光功率下CFRTP上表面温度场云图
Figure 13. Temperature field of upper surface of CFRTP with varying laser power. (a) 400 W; (b) 450 W; (c) 500 W; (d) 550 W; (e) 600 W
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图 14 CFRTP熔化情况
Figure 14. Melting condition of CFRTP. (a) melting depth; (b) decomposition depth; (c) decomposition depth ratio
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图 15 不同焊接速度下CFRTP上表面温度场云图
Figure 15. Temperature field of upper surface of CFRTP with varying welding speed. (a) 3 mm/s; (b) 5 mm/s; (c) 7 mm/s; (d) 9 mm/s; (e) 11 mm/s; (f) 13 mm/s
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图 16 CFRTP熔化情况
Figure 16. Melting condition of CFRTP. (a) melting depth; (b) decomposition depth; (c) decomposition depth ratio
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图 17 不同搭接宽度下CFRTP上表面温度场云图
Figure 17. Temperature field of upper surface of CFRTP with varying lap width. (a) 25 mm; (b) 30 mm; (c) 35 mm
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图 18 不同冷却条件下CFRTP上表面温度场云图
Figure 18. Temperature field of upper surface of CFRTP with varying cooling condition. (a) air cooling; (b) water cooling
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图 19 不同导热条件下CFRTP上表面温度场云图
Figure 19. Temperature field of upper surface of CFRTP with different thermal conductivity condition. (a) without fixture; (b) T2; (c) 6061; (d) Q345
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图 20 距CFRTP上表面0.05 mm厚度处温度循环曲线
Figure 20. Temperature cycle curve at 0.05 mm thickness from the upper surface of CFRTP
表 1 CFRTP热物性参数
Table 1 Thermal properties of CFRTP
材料 比热c/(J∙kg−1∙K−1) 热导率λ/(W∙m−1∙K−1) PA66 1.672 0.2 CF 1.76 6.5 
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表 2 3种材料热导率 (W∙m−1∙K−1)
Table 2 Thermal conductivity of three materials
温度T/℃ T2 6061 Q345 25 397 154 46 100 380 158 46 200 367 163 45 300 355 164 43 400 349 167 41 500 345 170 38
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表 3 工艺参数
Table 3 Welding parameters
序号 激光功率
P/W焊接速度
v/(mm∙s−1)搭接宽度
d/mm冷却
条件导热 1 400 5 25 空冷 无 2 450 5 25 空冷 无 3 500 5 25 空冷 无 4 550 5 25 空冷 无 5 600 5 25 空冷 无 6 500 3 25 空冷 无 7 500 5 25 空冷 无 8 500 7 25 空冷 无 9 500 9 25 空冷 无 10 500 11 25 空冷 无 11 500 13 25 空冷 无 12 500 5 30 空冷 无 13 500 5 35 空冷 无 14 500 5 25 水冷 无 15 500 5 25 空冷 T2 16 500 5 25 空冷 6061 17 500 5 25 空冷 Q345
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表 4 不同导热条件下CFRTP熔化情况
Table 4 Melting condition of CFRTP at different thermal conductivity condition
导热条件 熔化深度
H1/mm分解深度
H2/mm分解深度占比
A(%)无导热块 0.31 0.11 35.5 T2 0.15 0.01 6.7 6061 0.18 0.03 16.7 Q345 0.19 0.04 21.1
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