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超声波点焊Al/Mg/Al三层板试验与数值仿真

Experimental investigation and numerical simulation of ultrasonic spot welding for Al/Mg/Al three-layer plates

  • 摘要: 铝/镁合金以其优异的力学性能在运载器轻量化设计与制造中有着愈发重要的应用.新能源汽车车身及车身覆盖件包含众多点焊三层板结构. 文中针对异质金属难焊接的共性难题,采用超声波焊技术实现了Al/Mg/Al 三层板点焊连接,同时建立了超声波点焊过程热–力耦合分析模型并验证了模型准确性.研究结果表明随着焊接能量增加,接头拉伸载荷先增大后降低,接头失效模式均为界面破坏,最大拉伸载荷达到683.2 N,界面结合机制主要是塑性变形形成的机械咬合,并未发生冶金反应.通过数值模型获得了不同参数下温度场及应力场的分布及演变规律,焊接过程最高温度可达600 ℃.研究成果将为超声波点焊异质金属三层板研究提供参考.

     

    Abstract: Aluminum/magnesium alloys have increasingly important applications in the lightweight design and manufacturing of launch vehicles due to their excellent mechanical properties. The bodies and body cover panels of new energy vehicles contain numerous three-layer plate spot welding structures. In view of the common problem of difficult welding of dissimilar metals, the spot welding of Al/Mg/Al three-layer plates was realized by using ultrasonic welding technology. Meanwhile, a thermo-mechanical coupled analysis model of the ultrasonic spot welding process was established, and the accuracy of the model was verified. The results indicate that with the increase in welding energy, the tensile shear strength of the joints first increases and then decreases. The failure modes of the joints are all interfacial failures, and the maximum tensile load reaches 683.2 N. The interfacial bonding mechanism is mainly the mechanical interlocking formed by plastic deformation, and no metallurgical reaction occurs. The distributions and evolution laws of the temperature field and the stress field under different parameters are obtained through the numerical model, and the maximum temperature during the welding process can reach 600 °C. The research results provide new ideas and theoretical support for the research on spot welding structures of dissimilar metal three-layer plates

     

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