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数字图像相关法检测铝合金激光-MIG复合焊残余应力

Measurement of aluminum alloy laser-MIG hybrid welding residual stress based on digital image correlation method

  • 摘要: 采用数字图像相关(Digital Image Correlation, DIC) 法快速、无损地检测了6061铝合金激光-MIG复合焊残余应力. 在DIC法检测焊接残余应力过程中,采用铅笔在待测件表面刻画密集的网格状标记,选择对光强变化不敏感的零均值归一化互相关函数实现了检测点在复合焊前后的精确匹配. 在接头的热影响区和母材区,DIC法获得了与X射线衍射法相一致的结果,且距离焊缝中心线越远,偏差越小. 通过综合分析8 mm 6061铝合金板材在不同复合热源能量配比下残余应力分布与接头形貌,优化了激光-MIG复合焊参数. 结果表明,由DIC法测得的残余应力最大值(峰值)会随激光功率占比的增大而增大,选择MIG电弧与激光的能量配比为1.1、1.0、0.9时的焊接参数,焊后纵向残余应力峰值分别为188 MPa、195 MPa、199 MPa,横向残余应力峰值分别为84 MPa、94 MPa、99 MPa,不会出现过高的应力峰值,接头的成形系数较小、可以获得成形效果良好的焊缝.

     

    Abstract: The ‌Digital Image Correlation (DIC)‌ method was employed for rapid, non-destructive measurement of residual stress of 6061aluminum alloy laser-MIG hybrid welded joints. In the process of the measurement of residual stress using the DIC method, dense grid markers were drawn on the surface of the test piece with a pencil, and the zero-mean normalized cross-correlation function insensitive to light intensity variation was selected to achieve precise matching of measurement points before and after hybrid welding. In the heat-affected zone and base metal zone of aluminum alloy laser-MIG hybrid welded joints, DIC method obtained results consistent with those measured by X-ray diffraction method. Moreover, the deviation between the results measured by both methods decreased with increasing distance from the weld center line. The residual stress distribution and morphology of the welded joints of 8 mm 6061 aluminum alloy plates under different hybrid heat source energy ratios were comprehensively analyzed, and the laser-MIG hybrid welding parameters were optimized. The results demonstrate that the maximum value (peak) of residual stress measured by DIC method increases with the increase of laser power proportion in the total energy input. When selecting welding parameters for MIG arc to laser energy ratios of 1.1, 1.0, and 0.9, the measured peak magnitude of longitudinal stresses in the joint were 188 MPa, 195 MPa, and 199 MPa respectively, while the measured peak magnitude of transverse residual stress were 84 MPa, 94 MPa, and 99 MPa respectively. This ensures no excessive stress peaks will occur, and the joint has a small form factor, thus achieving satisfactory welding formation.

     

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