CN102513638A - Step-by-step friction stir brazing method for thick aluminium plate and rigid dissimilar material - Google Patents
Step-by-step friction stir brazing method for thick aluminium plate and rigid dissimilar material Download PDFInfo
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Abstract
The invention discloses a step-by-step friction stir brazing method for a thick aluminium plate and a rigid dissimilar material. The method can be used for avoiding various problems such as needle abrasion (when a tool with a needle is used), insufficient interface heat, poor mechanical membrane rupture effect and the like existing in the direct friction stir brazing process of the thick aluminium plate and the rigid dissimilar material (such as stainless steel, copper, titanium and steel). The method comprises the following steps of: firstly brazing a thin aluminium plate on the to-be-brazed surface of a rigid dissimilar material through needle-free friction stir brazing, striping by virtue of a metallurgical factor and a mechanical factor, and extruding brazing filler metal, thus realizing a compact joint between the thin aluminium plate and the rigid dissimilar material; and welding the thin aluminium plate brazed on the rigid dissimilar material and a thick aluminium plate through friction stir brazing or friction stir welding, wherein when friction stir brazing is utilized to weld lap joint in the second step, the welding-on area can be obviously enlarged. The process can be used for completely preventing rigid parent metal from abrading a tool; and the interface welding-on of the thin aluminium plate and the dissimilar material is reliable. The method disclosed by the invention can be used for preparing aluminium/stainless steel contact rails and aluminium/copper transition joints.
Description
Technical field:
The invention belongs to welding field, relate to a kind of substep stirring friction braze welding method, the substep stirring friction braze welding method of especially a kind of thick aluminium sheet and hard foreign material.
Background technology:
At present, aspect the preparation of the used aluminium of urban light rail/stainless steel conductor rail, for improving the anti-vibration ability, arc control increases conductive area, occurs replacing conventional extruded technology requirement trend with solder technology.Yet the welding of aluminium and hard foreign material (like stainless steel, copper, titanium, steel) is an ancient technical barrier, does not set up the technology of generally acknowledged super quality and competitive price so far yet.And with the increase of thickness of slab increase or bonding area, the welding difficulty also increases.With aluminium/stainless steel (Al/SUS) is example, and this is a kind of typical difficult weldering combination, and adopting arc welding method still is that method for welding is all very difficult
[1]Its reason is except being easy to form the intermetallic beyond the region of objective existence to also have both surface film oxides all to be difficult to abolish, and there is very big-difference in the reaction of both and solder.When adopting arc welding method, identical with aluminium/steel combination, mainly be that Fe-Al intermetallic compound (IMC) can make the joint embrittlement.When adopting method for welding; Though mother metal is solid-stately to help avoiding intermetallic compound rapidly, excessively thicken in brazing process; But the oxide-film of surface both is all fine and close, stable, infusibility, strong and be difficult to abolish, and causes the wetability variation of solder to mother metal thus.In view of aluminium/stainless steel arc welding solderability extreme difference, below main its soldering tech general situation of development of summary.
As far back as 1999, human Al-12Si eutectic solder and fluoride flux K such as the Roulin of Switzerland
3AlF
6-KAl F
4Furnace brazing aluminium and stainless steel under 600 ℃ of temperature, the shearing strength of joint that obtains under the standard when temperature retention time is 10 minutes is the highest, but this peak shear strength also is merely 21MPa; The reason that strength of joint is low is that there are two differential responses layer FeSiAl in the boundary zone
5And FeAl
3 [2,3]
The Liu of Tokyo polytechnical university and Suzumura adopt the Al-12Si solder to cooperate F19 brazing flux (the active brazing flux of being made up of chloride, fluoride) to carry out fine aluminium/stainless soldering and test
[4]Be necessary to point out emphatically, the brazing process essence of this combination is the transition liquid phase diffusion weld of dissimilar metal.Its result of the test shows; Transition liquid phase diffusion weld for this dissimilar metal; The Al-12Si solder is different with the reaction speed of two kinds of mother metals, and promptly the Si atom can diffuse within the aluminum mother plate (especially when use contains the brazing flux of Zn, the diffusion of Si in aluminum mother plate also can be by further acceleration) rapidly; But Al-12Si solder and stainless reaction speed are slow; Cause Al-12Si solder too early isothermal solidification before not having an effect as yet thus with the stainless steel mother metal, although like this aluminium/solder interface combine still can, aluminium/stainless steel interface combination extreme difference.In addition, owing to adopted brazing flux, postwelding also must add the operation of cleaning brazing flux, in case brazing flux is to the corrosion of aluminum mother plate.
The ability Tian Yixing of Osaka, Japan university has proposed to prepare in advance in stainless steel one side the technical scheme of soft Ag, Cu, Ni active layer
[5]Recently; Wu Mingfang to adopt the Cu paper tinsel carry out Al/Cu/SUS (the thick 10 μ m of Cu paper tinsel, 570 ℃ * 20min * 0.1MPa) contact reaction brazing (contactreactive brazing), after the long-time insulation; Though the interface is gradually fine and close; But still have a large amount of Cu not spread the mother metal like Al, the conversion zone width that comprises IMC is near 50 μ m, and the thickness of IMC remains further to be reduced
[6]
Other has France and Japanology personnel to adopt laser braze welding technology, though the heat input is little, help suppressing intermetallic compound and excessively thicken, but still need the brazing flux striping, and equipment investment is high
[7,8]
In recent years, domestic Harbin Institute of Technology has carried out the comparatively research of series to aluminium/stainless steel welding.The main method that proposes has: contact reaction brazing, stainless steel surfaces be soldering again behind the hot aluminizing, welding-braze (can adopt thermals source such as TIG, MIG, Laser) in advance
[9-11]" contact reaction brazing " of propositions such as He Peng adopts the Si powder to do the intermediate layer, can effectively remove the oxide-film of aluminum mother plate side surface, but welding temperature higher (600 ℃) is difficult to use in lower aluminium alloy of some fusing points and stainless soldering
[12]There are blemisies in an otherwise perfect thing such as complex procedures, extra power consumption in " stainless steel surfaces hot aluminizing after soldering again " in advance.Though welding-braze has avoided stainless fusing suppressing the generation of compound between excess metal, but still there is the arc light radiation or splashes; Need to use brazing flux (with extraordinary brazing flux---Nocolock brazing flux after the modification be in harmonious proportion with acetone and be coated in equably stainless steel groove end face and near the steel plate upper and lower surfaces, coated weight was advisable just to cover stainless steel surfaces) to improve liquid aluminium alloy to stainless wetability; Still make stainless steel keep solid-state on the other hand owing to need in very narrow welding bead heated perimeter, make the aluminium fusing on the one hand, so high to the requirement of operating technology
[13]When adopting Laser Power Supply to carry out welding-braze, equipment investment is big, aluminium is to the reflectivity height of laser and the large scale application of deficiency also limited this technology such as absorptivity is low
[14]
Sum up above-mentioned method for welding, can summarize at process aspect has following inconvenience: the one, use brazing flux; The 2nd, prepare active layer in advance at stainless steel surfaces, for this reason, must add power consumption operations such as plating, hot dipping; The 3rd, there is the shortcoming (often adopting heating in the stove, arc heated, LASER HEATING) of power consumption height, environment difference in the heating thermal source.
On the other hand; When adopting transition liquid phase diffusion weld (TLP) (is the intermediate layer with Cu, Ag, Ni), though have can be in order to avoid with the advantage of brazing flux, reduction welding temperature, its shortcoming be also more for it; Be listed below: (1) required diffusion time is very long, even needs about several hours; (2) extremely long diffusion temperature retention time requires vacuum or protection environment; (3) dissimilar metal TLP exists intermediate layer and two kinds of mother metal reaction rates inconsistent, causes the interface, both sides to be combined with the branch of quality
[15](4) theoretically, have the contradiction that compound is difficult to eradicate simultaneously between two types of different metals: when isothermal solidification was accomplished, Al-Cu class IMC can appear in the brazed seam center; When isothermal solidification was accomplished, the Al-Fe class IMC of rich aluminium can appear in the brazed seam center, can occur the Fe-Al class IMC of rich Fe at the brazed seam edge and the interface is become fragile
[16]
In recent years, carried out aluminium/stainless friction stir welding research both at home and abroad successively, but the documents and materials of the correlative study that can find are few, and remain to be deepened.The researcher Uzun of Germany has carried out aluminium/stainless butt joint friction stir welding, and instrument is band pin stirring-head, and for weakening the sharp wear of pin, the cushion implantation site is most of in the aluminum mother plate side, and few part contacts the stainless steel mother metal.Postwelding has carried out micro-hardness testing; The hardness of finding weldering nuclear district has fluctuation to change; And then carried out Metallographic Analysis; Reach a conclusion: because the mechanical agitation of stirring tool, stainless steel particle or even large-sized block stainless steel of high rigidity has been dragged to aluminum alloy surface, and formed the phenomenon of dissimilar metal mechanical mixture.And then the contrast test of having carried out the fatigue fracture of aluminium/stainless steel welded joint and aluminium alloy mother metal, the fatigue life of finding aluminium/stainless steel welded joint is than aluminium alloy mother metal low 30%; Metallographic Analysis is found because a little less than the mechanical agitation of weld seam bottom, the mechanical mixture effect is not obvious, thus the phenomenon that causes weld seam bottom kiss to connect
[17]Though this research shows that aluminium/stainless friction stir welding is feasible, its shortcoming is conspicuous, and promptly (1) stainless steel is to the pernicious wearing and tearing of instrument; (2) stainless steel particle or even large scale piece of stainless steel are stirred and are drawn to aluminum substrate, and are stirred the outer surface of the large scale piece of stainless steel that is drawn to aluminum substrate if can not well engage with aluminum substrate, and its existence is tantamount to the inclusion defect of bulk; (3) the weld seam bottom can not reach the mechanical mixture effect of expection because mechanical agitation weakens, thereby the kiss that has formed the weld seam bottom connects phenomenon.
Aspect aluminium/copper friction stir welding, there are problems such as the wearing and tearing of pin, root kiss connect, keyhole equally.In addition, because of the copper rapid heat dissipation, shaping surface is also rough
[18]
Recently, Xi'an Communications University's (applicant belongs to seminar) has developed the stirring friction braze welding technology of aluminum/steel dissimilar metal for the wearing and tearing of avoiding pin
[19]This technology has following advantage: with frictional heat clean, that concentrate is thermal source, and energy consumption is low, simple to operate and working condition good (nothing is splashed and arc light), need not any protective gas and brazing flux; Adopt the needleless instrument to eliminate the wearing and tearing of pin, guarantee that welding process can continue to carry out smoothly; To the overlap joint friction stir welding ubiquitous on/lower bound dough model property flow to mix the problem that is difficult to realize; Realize between the interface densified with on/following the mixing aspect; Utilize the quick dissolving of mother metal in solder to replace plastic deformation, thus reduced to plastic deformation at the interface and realize/mix down through plastic flowing overcritical; Can be through " interface is reversed
[20], the extruding
[21]Undercurrent under the+film (adding of Zn solder)
[19]+ pressurization is extruded
[19]" number of mechanisms effectively removes the oxide-film on aluminum mother plate surface, the interface oxidation film is abolished satisfactory for result; After oxide-film was extruded with eutectic, low strong liquid phase, final gained Interface Microstructure essence be clean, densification, continuous micron order diffusion layer, guaranteed reliably thus to cover/quick seam between substrate interface (welds scooter 150～300mm/min) at present.
But; When needleless stirring friction braze welding technology is used for thick aluminium sheet mother metal (5mm and more than),, all right at aluminium side striping, interface seam although the Zn solder also can be melted and extrudes by frictional heat smoothly; But through torsional effect at the interface the variation of mechanical rupture of membranes effect own; Stainless steel watch surface oxidation film form compact and stable in addition, double factor cause thick aluminium sheet and stainless stirring friction braze welding unsatisfactory, and outstanding problem shows stainless steel mother metal side interface seam variation.
For thick aluminium sheet and hard dissimilar metal overlap joint welding operating mode; Though when adopting band pin stirring-head to help weld interface machinery striping; But unavoidably cause the wearing and tearing of pin end; Force welding process hard to carry on, or the high wear-resisting stirring-head of compelled use value (as external report maximum be cubic boron nitride ceramic instrument or W, Mo kind tool).Obviously, adopt tradition band pin stirring-head still difficult.But, when adopting the needleless stirring-head to weld thick aluminium sheet/xenogenesis high tensile metal joint,, exist stainless steel side interface oxidation film to abolish this fatal problem of effect extreme difference for stainless steel-like mother metal needleless stirring friction braze welding though can avoid the wearing and tearing of pin end.It is following to analyze its reason:
(1) instrument aspect: the needleless instrument has been lost the direct mechanical immixture to weld interface, causes the interface oxidation film to be difficult to abolish.(2) thickness of slab aspect: thicker aluminium sheet makes weld interface far away apart from rubbing surface; Reduced heating, reversed, forged and pressed the comprehensively hot in nature-Li synergy effect that intercouples and produce weld interface; Thickness of slab direction plastic strain gradient reduces; Therefore, the bigger thickness of slab machinery that also worsened weld interface reverses rupture of membranes.(3) material aspect: when hard mother metal is stablized the mother metal that is difficult to remove for the stainless steel-like oxide-film, the oxide-film of weld interface is abolished effect will be poorer.
Mix at the interface that exists when needleless stirring friction braze welding technology is used for hard foreign material welding such as thick aluminium sheet and stainless steel in order to solve, bad this problem of strength of joint extremely low (postwelding is ftractureing voluntarily with the handsaw sample making course or also ftractureing voluntarily with the sand papering sample preparation stage) that causes of striping, the present invention proposes " method of fractional steps stirring friction braze welding of a kind of thick aluminium sheet and hard foreign material is technological ".Its technical scheme is earlier to press pricker one deck " approach " aluminium sheet (purpose is to make full use of under " approach " aluminium sheet situation the significant relatively advantages of mechanical rupture of membranes effect such as the interface is reversed, extruding) with needleless stirring friction braze welding technology at stainless steel surfaces, and then thick aluminum layer on technological with stirring friction braze welding on this is pressed on the surperficial thin aluminum sheet of hard dissimilar metal by pricker (can also can be not with pin with pin) pressure pricker.Like this, aluminium/stainless steel dissimilar metal solder is converted into the welding between the aluminium of the same race, this moment, also available band pin instrument was in the overlap joint welding that approaches under the no abrasion condition between aluminium/thick aluminium; Simultaneously if add Zn make striping, on/mixing between following interface or densifiedly do not rely on plastic flowing and mainly rely on metallurgical reaction, thereby the interface driving fit becomes and realizes easily, and can enlarge markedly the seam area.This technology can be used for the preparation of aluminium/stainless steel conductor rail, aluminium/copper transit joint.
List of references
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Summary of the invention:
The hard mother metal side interface heating and pressurizing of existence and interface were reversed deficiency, striping and are mixed bad and cause strength of joint extremely low (for example when the object of the invention was to solve needleless stirring friction braze welding technology and is used for " thick aluminium sheet " directly with hard xenogenesis mother metal (like steel, stainless steel, titanium, copper etc.); Though aluminium side interface striping and seam are good, postwelding still can ftracture voluntarily in the handsaw sample making course or ftracture voluntarily along the interface of hard foreign material side with the meeting of sand papering sample preparation stage) this fatal problem.For this reason, the present invention proposes a kind of " method of fractional steps stirring friction braze welding technology of thick aluminium sheet and hard foreign material ", its scheme is:
Earlier " approach " aluminium sheet with needleless stirring friction braze welding technology (look product requirement and decide) pressure pricker one deck on surfaces to be welded such as stainless surface, end face or side; Purpose is to make full use of under " approaching " aluminium sheet situation mechanical rupture of membranes obvious results advantages such as the interface is reversed, extruding; To pass through metallurgical and mechanical double factor striping; Extrude solder, realize that thin aluminum sheet engages with densification between hard foreign material; Be pressed on above the thin aluminum sheet on the hard foreign material at pricker then and press thick aluminium sheet with needleless stirring friction braze welding technology pricker again; Also can directly accomplish the welding between thin/thick aluminium sheet with friction stir welding; Purpose is through aluminium/stainless steel dissimilar metal solder is converted into the welding between the aluminium of the same race, to eliminate the wearing and tearing of pin fully.Wherein, the second step flexibility is big, can adapt to various working condition requirements: for example, available band pin instrument is in the overlap joint welding of carrying out under the no abrasion condition between aluminium/aluminium; Add simultaneously Zn make striping, on/mixing and the densified plastic flowing that do not rely between following interface, thereby become and realize easily, and can enlarge markedly the seam area.Second step also can directly approach/dock friction stir welding between the thick aluminium sheet, and for example thick aluminium/copper transit joint just can adopt this scheme.
Basic concrete operation of the present invention and reason thereof are following:
The first step: other gets the thin aluminum sheet of thick about a 1～3mm, earlier this thin aluminum sheet and hard dissimilar metal (like stainless steel, steel, titanium, copper etc.) is carried out stirring friction braze welding, and accomplish the pricker of thin aluminum sheet and press: used tool is a needleless column instrument; Used solder is the Zn paper tinsel; In air, weld, need not any brazing flux and protective gas.The purpose that why adds Zn is to abolish the lip-deep oxide-film of thin aluminum sheet.The purpose of why earlier about 2mm thickness aluminium sheet and the hard mother metal of xenogenesis (corrosion resistant plate) being carried out stirring friction braze welding is because the surperficial oxide-film of hard xenogenesis mother metal (stainless steel) is difficult to removal; When adopting thin aluminum sheet; The heating of shoulder, forging and pressing effect and interface torsional effect will become remarkable in the Re-Li synergy effect of weld interface; Help utilizing mechanical system to abolish the oxide-film of stainless steel surfaces, and strengthen the diffusion between mother metal; Otherwise when the thick aluminium sheet of direct employing and stainless steel carried out stirring friction braze welding, though the Zn solder can melt, the effect of forging and pressing effect and interface torsional effect caused interfacial combined function poor (even with the handsaw sample preparation time, ftractureing voluntarily) thus with variation.And; Postwelding; Unnecessary at the interface eutectic, low strong Zn solder can almost be extruded fully, thus obtain clean, fine and close, continuously, the moderate diffusion layer of thickness, thereby do not having to utilize under the direct condition of stirring metallurgical approach to obtain between parent material interface directly proliferation welding.
Second step: be pressed on preseting solder and thick aluminium sheet above the thin aluminum sheet on the hard foreign material at pricker again, carry out the metal stirring friction braze welding of the same race between thick aluminium sheet and thin aluminum sheet, with the acquisition lap joint.Equally, used tool is cheap medium carbon steel instrument; Used solder is the Zn paper tinsel; In air, weld, need not any brazing flux and protective gas.Should adopt band pin instrument when thick aluminium sheet itself is thicker as surpassing 8mm, suitably to add severe deformation heat and interface mixed effect; When thick aluminium plate thickness can adopt the needleless instrument in 5～8mm scope, to eliminate keyhole.
Product joint for the requirement of second step achieves a butt joint can adopt more simple technology, and promptly directly by traditional friction stir welding technology welding: adopt band pin instrument, exempt to use solder, the agitating friction of directly accomplishing between thin aluminum sheet/thick aluminium sheet docks.This interface mixing ratio lap joint that has benefited from banjo fixing butt jointing is realized (because in the banjo fixing butt jointing preparation, instrument rotational line speed is perpendicular to weld interface, thereby two interfaces mix easily more easily; And in the lap joint preparation, instrument rotational line speed is parallel to solder side, thereby two interfaces are difficult to mix).At this moment, because institute's wlding material is aluminium, therefore the pernicious wearing and tearing to pin can't appear.
The substep stirring friction braze welding method of thick aluminium sheet of the present invention and hard foreign material, when making needleless stirring friction braze welding technology be used for " thick aluminium sheet " directly with hard xenogenesis mother metal (like steel, stainless steel, titanium, copper etc.), the advantage that strength of joint is high.
Description of drawings:
Fig. 1. method of fractional steps stirring friction braze welding technology sketch map: (a) the needleless stirring friction braze welding of first step thin aluminum sheet and hard foreign material; (b) thin aluminium of second step/thick aluminium has pin overlap joint stirring friction braze welding; (c) thin aluminium of second step/thick aluminium needleless overlap joint stirring friction braze welding; (d) thin aluminium of second step/thick aluminium has pin overlap joint stirring friction braze welding (pin runs through aluminium/aluminium interface); (e) thin aluminium of second step/thick aluminium has to connecing stirring friction braze welding, and (f) thin aluminium of second step/thick aluminium has to connecing friction stir welding (exempting from zinc paper tinsel solder).
Fig. 2. the smooth shaping of homogeneous of first step thin aluminum sheet (2mm is thick) and corrosion resistant plate needleless stirring friction braze welding gained joint welding bead: weldering speed is respectively (a) 23.5, (b) 150, (c) 300, (d) 375, (e) 475mm/min;
Fig. 3. the smooth shaping of homogeneous of the joint welding bead of two-step method stirring friction braze welding gained " thick aluminium sheet (5mm is thick)/thin aluminum sheet/corrosion resistant plate ": weldering speed is respectively (a) 23.5, (b) 150, (c) 300 (d) 375, (e) 475mm/min;
Fig. 4. ground floor (2mm is thick) thin aluminum sheet/stainless steel needleless stirring friction braze welding joint draws cuts test back fracture position (being positioned at the thin aluminum sheet mother metal but not weld interface): weld that speed is respectively 23.5,150,300,375,475mm/min; (a) (c) (e) (g) (i) be corresponding vertical view; (b) (d) (f) (h) (j) be the respective side view.
Fig. 5. directly carry out thick aluminium sheet and stainless steel stirring friction braze welding gained joint outward appearance (contrast experiment welds fast 23.5mm/min): (a) front; (b) back side.
Fig. 6. directly carry out thick aluminium sheet and the stainless steel stirring friction braze welding gained joint situation (contrast experiment welds fast 23.5mm/min) that in sample making course, ftractures voluntarily: (a) outer surface; (b) fracture is (smooth; There are not the Al of adhesion and Zn on the stainless steel).
Fig. 7. two-step method " thick aluminium sheet/thin aluminum sheet/stainless steel " joint draws cuts experiment back photo (remarkable plastic deformation has taken place thick aluminium sheet mother metal): weldering speed is respectively 23.5,150,300,375,475mm/min; (a) (c) (e) (g) (i) be corresponding plane of disruption vertical view; (b) (d) (f) (h) (j) be corresponding plane of disruption side view.
Fig. 8. weldering speed and tensile load relation curve: (a) first step " thin aluminum sheet/stainless steel " stirring friction braze welding joint; (b) two-step method " thick aluminium sheet/thin aluminum sheet/stainless steel " stirring friction braze welding joint.
Fig. 9. aluminium/stainless steel dissimilar metal joint (weldering speed is 23.5mm/min) cross section interface low power subregion sketch map: I, III are gapped district, and II accounts for the whole district 57.5% for the district that combines closely, and remainder is the shoulder outskirt;
Figure 10. weldering speed is aluminium/stainless joint interface 100 * back scattering serialograph of 23.5mm/min;
Figure 11. iris out regional c, f, h, i high power (more than 2000 times) corresponding to Figure 10 median surface and amplify the back scattering photo: still fine and close under the high power, and do not have intermetallic compound and thicken;
Figure 12. the first step " thin aluminum sheet (2mm is thick)/copper coin " stirring friction braze welding joint smooth appearance;
Figure 13. two-step method " thick aluminium sheet/thin aluminum sheet/copper coin " stirring friction braze welding joint smooth appearance;
Figure 14. two-step method " thick aluminium sheet/thin aluminum sheet/copper coin " stirring friction braze welding joint draws cuts test back photo: (a) plane of disruption vertical view (being stained with aluminium on the copper); (b) plane of disruption side view (obvious flexural deformation has taken place aluminum mother plate).
Annotate: in Fig. 1 .a first footwork mark 1,2,3 and be respectively thin aluminum sheet, zinc paper tinsel, corrosion resistant plate.1 (thin aluminum sheet) of Fig. 1 .a first footwork postwelding, 3 (corrosion resistant plates) are that Fig. 1 .b～f second footwork is used; 4,6,8,10,12 is mutual discrete thick aluminium sheet in Fig. 1 .b～f second footwork, and 5,7,9,11 is mutual discrete zinc paper tinsel.
The specific embodiment:
Below in conjunction with accompanying drawing the present invention is done and to describe in further detail:
Embodiment 1: the method for fractional steps stirring friction braze welding technology between thick aluminium sheet/stainless joint
As feasibility test, for practicing thrift experimentation cost, used corrosion resistant plate (304) is the thick thin plate of 2mm, is of a size of 100mm * 60mm.Thick aluminium sheet (1060) is that 5mm is thick; Thin aluminum sheet (1060) is that 2mm is thick; The aluminium sheet size also is 100mm * 60mm.Stirring tool is 20mm needleless instrument for the diameter of being processed respectively by 45 common steel and the pin instrument is arranged.The Zn paper tinsel is the thick paper tinsel bands of commercially available 100 μ m, and width is also got 20mm.
The ground floor welding procedure is: method shown in sketch map 1 (a).
(1) method of clamping: thin aluminum sheet is held on (two plates are all also used alcohol wash through sand papering) on the corrosion resistant plate, places solder Zn paper tinsel between two plates in advance, corrosion resistant plate is placed advance side.The lap of splice is 20mm.
(2) parameter adjustment: 1500 rev/mins of rotating speeds; About 3 ° of instrument inclination angle; The speed of welding trial stretch is got 5 levels:
23.5,150,300,375,475 (mm/min), to distinguish the production efficiency of this technology.
(3) position check and correction: shown in sketch map, the stirring-head right side edge is aimed at the aluminium sheet right side edge.
(4) Control Welding Process: during welding; When the compression distance of needleless instrument in the aluminum mother plate inside that is positioned at upside reaches 0.2～0.5mm; Stop to press down, stirring-head was kept about 10 seconds the original position friction of aluminum mother plate initiating terminal, make aluminum mother plate fully softening to guarantee enough hot input quantities.Then, opening workbench moves by preset weldering speed; Treat that weld seam length reaches 80～90mm or apart from plate leading edge 5mm place, stops friction welding with mobile.
Second layer welding procedure is: only introduce the interface mixing welding of the lap joint of difficulty relatively, the method shown in sketch map 1 (b) of realizing here.(in addition, the second layer welding method shown in sketch map 1.c～f is similar to Fig. 1 .b, seldom does explanation here, and they all belong to the derived method of Fig. 1 .b, or more simple docking calculation, like Fig. 1 .f)
Preparation: the part that the aluminium sheet in the above-mentioned weldering appearance is had more the stainless steel mother metal amputates, and prepares second layer welding.
(1) method of clamping: thick aluminium sheet is held on the weldering appearance of above-mentioned thin aluminum sheet that makes and corrosion resistant plate middle preseting solder Zn paper tinsel.Welding method and ground floor are identical.
(2) parameter adjustment: with above-mentioned ground floor.
(3) position check and correction: with above-mentioned ground floor.
(4) Control Welding Process: with above-mentioned ground floor (stirring tool is elected band pin instrument as).
Contrast experiment:, also introduced the fracture behaviour that directly carries out thick aluminium sheet and stainless single step stirring friction braze welding technology gained defective joint in the lump at this for proving method of fractional steps stirring friction braze welding technology in the superiority aspect thick aluminium sheet and the hard foreign material.
The postwelding evaluation mainly comprises following content: outward appearance; Draw and cut the test breaking load (drawing and cutting specimen size is 100mm * 25mm) and fracture position; The interface microstructure is analyzed., microstructure pays close attention to the striping effect of following problem: Al, stainless steel both sides in analyzing; Separate and the thickness of compound between interface metal; Whether Zn is extruded.
Below be experimental result:
Joint outward appearance (seeing Fig. 2 and Fig. 3): (shown in a～e), second layer two-step method integrity of welded joint positive and negative outward appearance is like Fig. 3 (shown in a～e) like Fig. 2 for the 1st layer of joint positive and negative outward appearance.To above-mentioned weldering speed scope (23.5～475mm/min) no matter the 1st layer still the 2nd layer all can obtain ganoid figuration of bead, visible, the adaptability that the height weldering is fast is also stablized, well.But it should be noted; When the welding experiment; The stirring-head compression distance is controlled to be below the 0.5mm so that enough big forging force and strong interface twisting resistance to be provided usually; But with weldering speed raise (welding more than the fast 300mm/min) cause that the heat input of unit are reduces, metal softening is insufficient, plasticity is not enough, makes that the surface can't moulding (tear on the surface) under big interface twisting resistance condition; The compression distance that reduces stirring-head so have to be weakening frictional interface torsional deflection degree, thereby obtains complete smooth face of weld.
Ground floor joint breaking position (see figure 4): the drawing of ground floor joint cut The performance test results and shown; Thin aluminium and stainless steel dissimilar metal joint draw cuts the sample fracture position all within aluminum mother plate; Do not rupture in the Al/SUS interface, this is that ground floor adopts one of strong evidence that the ironed aluminium sheet transition zone of needleless stirring friction braze welding technology pricker on hard foreign material can succeed.On the contrary; If directly adopt needleless stirring friction braze welding technology pricker to be pressed on the stainless steel the thick aluminium sheet of 5mm, though Zn base solder also can melt the also smooth (see figure 5) of welding bead shaping surface; But joint quality extreme difference; Postwelding i.e. cracking or with the sand papering sample preparation stage yet cracking voluntarily, stainless steel fracture one side does not have any Al and Zn and adheres to (see figure 6), it is thus clear that root problem is that stainless steel one side interface can't seam because of mechanical rupture of membranes weak effect voluntarily in the handsaw sample making course.Pricker pressure effect through contrast thin aluminum sheet and thick aluminium sheet can know, when its reason was that direct pricker is pressed thick aluminium sheet, the heating of stainless steel interface one side, forging and pressing, the torsion effect effect during all not as good as the ironed aluminium sheet of pricker was remarkable.
Two-step method integrity of welded joint fracture position (Fig. 7): after two-step method has been welded thick aluminium sheet; Welding point draws to be cut the sample fracture position and is all aluminium/stainless steel interface; Thicker aluminum mother plate ruptures though interface bond strength is not enough; But cut from drawing that (Fig. 7 .b, d, f, h, j) can find out the sample side view, interface bond strength has been enough to make the slab aluminum mother plate that flexural deformation largely takes place, even the stainless steel mother metal is occured bending and deformation.
Be appreciated that in addition integrity of welded joint does not all have to show that from thin/thick aluminium sheet metal interface cracking of the same race the stirring friction braze welding technology at this interface is successful.
Performance test (Fig. 8): pricker presses the curve of load of gained " thin aluminum sheet/stainless steel " joint behind the ground floor thin aluminum sheet and complete two step stirring friction braze welding method gained " thick aluminium sheet/thin aluminum sheet/stainless steel " respectively like Fig. 8 (a), (b) shown in.Wherein the latter is more meaningful, because the former is subject to draw the influence of cutting sample stirring area actual thickness (relevant with the attenuate degree with compression distance, shaping surface) and fluctuates.Can find out that from the latter (Fig. 8 .b) the average tensile shearing load of joint is 1/3～1/2 (unidimensional aluminum mother plate tensile load is 13.8KN) of unidimensional aluminum mother plate tensile load.
In addition; About height weldering speed down the 1st layer draw shearing load high and weld the 2nd layer of reason that after load is low and be explained as follows: although the tension of the 1st layer of thin aluminum sheet/stainless joint cut " load " have with weldering speed increase progressively and trend of rising, and the joint " intensity " that is not equal to high weldering speed be higher than low weld fast.Because thin aluminum sheet and stainless joint draw and cut the sample fracture position and be all the thin aluminum sheet mother metal, so the size of tension shearing load depends on the thickness of aluminum mother plate.And when the welding experiment; The stirring-head compression distance is controlled to be 0.5mm usually so that enough big forging force and strong interface twisting resistance to be provided; But can't moulding (tear on the surface) under big interface twisting resistance condition with the weldering speed surface that raises that the heat input that causes unit are reduces, metal softening is insufficient, plasticity is not enough and feasible; Think and obtain complete smooth face of weld, have to reduce the compression distance of stirring-head, thus to Al/SUS dissimilar metal welding interface to reverse rupture of membranes slightly influential.On the other hand; The stirring-head compression distance is little just to mean that the attenuate amount of commissure aluminum mother plate is little; The commissure aluminum mother plate thickness of promptly high weldering speed is greater than low weldering speed; And the interface bond strength of height weldering speed all is enough to make draw and cuts experimental sample and break in aluminum mother plate, thus occurred high weldering speed down the tensile load of sample be higher than the situation of low weldering speed.
Interface microstructure: adopt 23.5mm/min to weld fast gained dissimilar metal joint interface (Fig. 9～Figure 11) show of micro-organization chart; Though having obvious intermetallic compounds layer, aluminium/stainless steel interface do not generate; But the oxide-film of aluminium and stainless steel side is abolished, and that the interface combines is fine and close (fine and close combination interface account for full interface 57.5%).In the central area, both do not observed interfacial voids more than 2000 times even be amplified to especially, and also do not observed intermetallic compound and thicken, it is good to show that the Al/SUS interface combines.What a small amount of Zn remained in the interface retreats the side transitional region, and all the other a large amount of Zn are extruded.
Embodiment 2: the method for fractional steps stirring friction braze welding technology between thick aluminium sheet/copper transit joint
Except that 304 corrosion resistant plates replace with copper coin (be of a size of 100mm * 60mm * 2mm), identical among material therefor, specification and instrument and the embodiment 1.
First step welding process: identical with method among the embodiment 1, press one deck thin aluminum sheet on the copper coin surface with needleless stirring friction braze welding technology pricker earlier.Get thin aluminum sheet that copper coin that thickness is 2mm and thickness is 2mm and carry out first step pricker and press, used solder still be the Zn paper tinsel, and welding speed is 150mm/min.
The second step welding process: identical with method among the embodiment 1, with band pin instrument the thick aluminium sheet of 5mm is welded on the thin aluminum sheet of the resulting thin aluminium/copper sleeve of the first step, used solder also is the Zn paper tinsel, weldering speed still is 150mm/min.
Welding design sketch: ground floor joint outward appearance such as Figure 12, second layer joint outward appearance such as Figure 13.
Performance test: the two-step method integrity of welded joint drawn cut experiment (drawing and cutting specimen size is 100mm * 25mm); Welding point draws to be cut the sample fracture position and is all aluminium/copper interface (Figure 14); Tensile load is 3.74KN, though the interface bond strength deficiency so that aluminum mother plate fracture, is cut fracture surface of sample vertical view (Figure 14 .a) and can be found out from drawing; Obviously be stained with aluminium on the copper coin, show that the seam of Al/Cu dissimilar metal joint interface is firm; Simultaneously, can find out from plane of disruption side view (Figure 14 .b) that interface bond strength has been enough to make the slab aluminum mother plate that flexural deformation largely takes place, even copper base metal is occured bending and deformation.
Engineering background of the present invention is the preparation of thick aluminium/stainless steel transit joint, thick aluminium/copper transit joint.Detailed description based on foregoing invention content and embodiment can be known; The advantage of " method of fractional steps stirring friction braze welding new technology " is: thin aluminum sheet is had a mind to select for use in first road; Help strengthening takeing on Re-Li synergy effect,, make aluminium and the seam of foreign material interface reliable by thin aluminum sheet to weld interface; Second road is the stirring friction braze welding of aluminium/aluminium same material, has avoided the wearing and tearing of hard mother metal to instrument fully; All welding beads can be used cheap carbon steel instrument and in air, weld, and need not any brazing flux and protective gas; The welding of thick aluminium sheet and hard dissimilar metal is converted into the welding of thick aluminium/thin aluminium soft metal of the same race, has widened the range of application of stirring friction braze welding, solved actual engineering roadblock.
The above only is preferred embodiment of the present invention, is not the present invention is done any pro forma restriction; Though the present invention discloses as above with preferred embodiment; Yet be not in order to limiting the present invention, anyly be familiar with the professional and technical personnel, in not breaking away from technical scheme scope of the present invention; When the method for above-mentioned announcement capable of using and technology contents are made a little change or be modified to the equivalent embodiment of equivalent variations; In every case be the content that does not break away from technical scheme of the present invention, to any simple modification, equivalent variations and modification that above embodiment did, still belong in the scope of technical scheme of the present invention according to technical spirit of the present invention.
Claims (6)
1. the substep stirring friction braze welding method of thick aluminium sheet and hard foreign material is characterized in that:
(1) adopt needleless stirring friction braze welding technology to be positioned at welding surface pricker pressure one deck thin aluminum sheet of surface, end face or side earlier at hard foreign material; To pass through metallurgical and mechanical double factor striping; Extrude solder, realize that thin aluminum sheet engages with densification between hard foreign material;
(2) be pressed at pricker and look thickness of slab above the thin aluminum sheet on the hard foreign material again and press thick aluminium sheet, perhaps directly accomplish the welding between thin/thick aluminium sheet with friction stir welding with needleless or band pin stirring friction braze welding technology pricker.
2. the substep stirring friction braze welding method of thick according to claim 1 aluminium sheet and hard foreign material is characterized in that: said step (1) is to carry out the thin aluminum sheet of the thick 1～3mm of being and the stirring friction braze welding of hard dissimilar metal earlier, accomplishes the pricker of thin aluminum sheet and presses; Used tool is medium carbon steel or tool steel needleless column instrument; Used solder is the Zn paper tinsel; In air, weld.
3. the substep stirring friction braze welding method of thick according to claim 1 aluminium sheet and hard foreign material; It is characterized in that: the column tool diameter and must be greater than the width of column tool diameter and hard mother metal surface to be welded as the width of the thin aluminum sheet of transition zone more than 15mm in the said step (1); After accomplishing the first road pricker pressure, remove the redundance that surpasses on the thin aluminum sheet beyond the hard mother metal surface to be welded.
4. the substep stirring friction braze welding method of thick according to claim 1 aluminium sheet and hard foreign material; It is characterized in that: said step (2) is to be pressed at pricker to preset Zn paper tinsel solder and thick aluminium sheet above the lip-deep thin aluminum sheet of hard foreign material; Carry out the welding between thin aluminum sheet and thick aluminium sheet lap joint with stirring friction braze welding, increase the seam area with this; Used tool is medium carbon steel or tool steel instrument; Band pin or needleless; Used solder is the Zn paper tinsel; In air, weld.
5. the substep stirring friction braze welding method of thick according to claim 1 aluminium sheet and hard foreign material; It is characterized in that: said step exempts to use solder in (2), directly directly approaches/thick aluminium sheet intermetallic overlap joint friction stir welding of the same race or butt joint friction stir welding with band pin instrument.
6. like the substep stirring friction braze welding method of claim 1,2,3,4,5 or 6 said thick aluminium sheets and hard foreign material, it is characterized in that: said hard foreign material is stainless steel, steel, titanium or copper.
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