Analysis on interface characteristics and metal particle distributions in electromagnetic pulse welding with aluminum to steel
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摘要: 为明确铝/钢电磁脉冲焊接过程金属粒子运动对界面连接性能的影响，基于金属粒子流形成机理，对界面形貌及抗剪强度进行分析.结果表明，金属粒子滞留界面造成铝局部熔化，钢粒子原位生成FeAl，形成未结合区；沿着焊接方向，分射流对铝板压入作用逐渐增大，形成冶金结合的界面，并伴有富铝金属间相，直缝区为FeAl + Fe2Al5，小波区为Fe2Al5 + FeAl3，大波区为FeAl + FeAl3；铝钢焊接界面过渡区由塑变铝压入钢形成，铝侧焊缝的外边缘存在钢粒子，而钢侧焊缝存在熔融铝携带钢粒子，主要为FeAl + Fe2Al5 + FeAl3，且在焊缝内侧滞留了大量金属粒子，并以椭圆环的形式分布，在焊缝外侧，金属粒子滞落铝板表面造成凹坑，但在钢板表面为嵌入的片状铝；因此，在金属粒子滞留，并产生较多金属间化合物的位置成为剪切试验断裂源；通过波长公式调整搭接间隙，减少粒子滞留界面，椭圆焊缝断裂于铝材，提高了接头强度.Abstract: In order to investigate the effect of metal particle movement on interface connection performance in electromagnetic pulse welding of aluminum to steel, based on the formation mechanism of metal particles, the interfacial structure and tensile shear strength were analyzed. The results showed that metal particle entrapment at the interface caused local melting of aluminum. Steel particles generated in situ FeAl, forming an unbonded zone. Along the welding direction, the impact effect of the separate jet on the aluminum plate gradually increased, forming a metallurgical bond, accompanied by aluminum-rich intermetallic phases. FeAl + Fe2Al5 existed in the straight seam. Fe2Al5 + FeAl3 existed in the corrugated zone. FeAl + FeAl3 existed in the large corrugated zone. The transition zone of the welding interface was formed by plastic deformation of aluminum pressed into the steel. There were steel particles on the outer side of the aluminum plate weld, while there were molten aluminum carrying steel particles at the steel plate weld, mainly composed of FeAl + Fe2Al5 + FeAl3. A large number of metal particles gathered on the inner side of the weld and were distributed in the form of elliptical rings. Metal particles remained on the surface of the aluminum plate, causing pits, but there were embedded sheets of aluminum on the surface of the steel plate. Therefore, locations where metal particles were trapped and more intermetallic compounds were produced became shear fracture sources. The wavelength formula was used to adjust the lap gap to reduce particle entrapment, breaking the elliptic weld at the aluminum, and improving joint strength.
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图 1 电磁脉冲焊接过程
Figure 1. The welding process for the EMPW joint. (a) welding principle; (b) weldment assembly
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图 2 焊接接头抗剪试样及界面特征
Figure 2. Tensile shear specimen and interface characteristic of welded joint. (a) shear specimen; (b) macroscopic morphology of welding interface
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图 3 金属粒子流动行为与界面波形的关系[13]
Figure 3. Relationship between flow behavior of metal particles and interface waveform. (a) metal particle flow distribution; (b) formation of interface waveform
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图 4 焊接界面波形特性
Figure 4. Characteristics of welding interface. (a) unbound zone; (b) straight seam zone; (c) Wavelet zone; (d) large wave zone
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图 5 椭圆环形焊缝特征
Figure 5. Characteristics of elliptical annular weld. (a) shear fracture; (b) four positions for SEM
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图 6 区域1的断口表面特征(图5b的区域)
Figure 6. Fracture surface characteristics of zone 1 (zone in Fig.5b). (a) Fe element distribution at aluminum fracture surface; (b) Al element distribution at steel fracture surface
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图 7 区域2的断口表面特征(图5b的区域)
Figure 7. Fracture surface characteristics of zone 2 (zone in Fig.5b). (a) Fe element distribution at aluminum fracture surface; (b) Al element distribution at steel fracture surface
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图 8 区域3的断口表面特征(图5b的区域)
Figure 8. Fracture surface Characteristics of zone 3 (zone in Fig.5b). (a) Fe element distribution at aluminum fracture surface; (b) Al element distribution at steel fracture surface
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图 9 区域4的断口表面特征(图5b的区域)
Figure 9. Fracture surface characteristics of zone 4 (zone in Fig.5b). (a) Fe element distribution at aluminum fracture surface; (b) Al element distribution at steel fracture surface; (c) Lorentz force distribution of aluminum plate
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图 10 焊缝断口表面金属粒子分布
Figure 10. Metal particle distribution at the fracture surface of weld. (a) fracture surface of the weld at the aluminum side; (b) fracture surface of the weld at the steel side
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图 11 铝钢焊接接头抗剪的断裂位置
Figure 11. Fracture position of shear of welded joint with aluminum to steel
表 1 6061铝合金的化学成分(质量分数，%)
Table 1 Chemical compositions of 6061 aluminum alloy
Al Cu Mn Mg Zn Fe Si Cr 余量 0.246 0.15 0.96 0.25 0.7 0.493 0.05 
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表 2 304不锈钢的化学成分(质量分数，%)
Table 2 Chemical compositions of 304 stainless steel
Fe Si Cr C Mn P S Ni 余量 0.75 ≤1.0 0.08 2.0 0.035 0.015 11
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表 3 图4的4个区上的点扫描(原子分数，%)
Table 3 EDS results of four zones in Fig.4
测点 Al Fe Cr 可能的相 1 66.35 26.09 7.56 Fe2Al5 2 59.02 32.01 8.97 FeAl 3 65.94 26.19 7.87 Fe2Al5 4 76.72 18.20 5.07 FeAl3 5 69.82 23.46 6.72 FeAl3 6 51.96 33.85 14.19 FeAl
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