CN102513638B - 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 urban light rail aluminium/stainless steel used conductor rail, for improving anti-vibration ability, arc control, increases conductive area, occurs replacing by solder technology the demand trend of conventional extruded technology.Yet the welding of aluminium and hard foreign material (as stainless steel, copper, titanium, steel) is an ancient technical barrier, does not set up yet so far generally acknowledged technique of high quality and at a reasonable price.And with the increase of thickness of slab increase or bonding area, welding difficulty also increases.Aluminium/the stainless steel (Al/SUS) of take is example, and this is a kind of typical difficult weldering combination, adopts arc welding method or method for welding all very difficult
[1].Its reason is except being easy to form intermetallic beyond the region of objective existence, also have both surface film oxides to be all difficult to abolish, and both exists very big-difference with reacting of solder.When adopting arc welding method, identical with aluminium/steel combination, be mainly that Fe-Al intermetallic compound (IMC) can make joint embrittlement.When adopting method for welding, although mother metal is to be solid-stately conducive to avoid intermetallic compound rapidly, excessively thicken in brazing process, but the oxide-film of surface both is fine and close, stable, infusibility, strong and be difficult to abolish all, causes thus the wetability variation of solder to mother metal.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, the people such as the Roulin of Switzerland used Al-12Si eutectic solder and fluoride flux K
3alF
6-KAl F
4furnace brazing aluminium and stainless steel at 600 ℃ of temperature, the shearing strength of joint obtaining under standard when temperature retention time is 10 minutes is the highest, but this peak shear strength is only also 21MPa; The reason that strength of joint is low is that boundary zone exists two differential responses layer FeSiAl
5and FeAl
3 [2,3].
The Liu of Tokyo polytechnical university adopts Al-12Si solder to coordinate F19 brazing flux (the active brazing flux being comprised of chloride, fluoride) to carry out fine aluminium/stainless soldering experiment with Suzumura
[4].Be necessary to emphasize the transition liquid phase diffusion weld that the brazing process essence of this combination is dissimilar metal.Its result of the test shows, transition liquid phase diffusion weld for this dissimilar metal, Al-12Si solder is different from the reaction speed of two kinds of mother metals, be (special when using the brazing flux that contains Zn within Si atom can diffuse into aluminum mother plate rapidly, Si also can further be accelerated to the diffusion in aluminum mother plate), but Al-12Si solder and stainless reaction speed are slow, cause thus Al-12Si solder too early isothermal solidification before not yet having an effect with stainless steel mother metal, although like this aluminium/solder interface in conjunction with still can, aluminium/stainless steel interface is in conjunction with extreme difference.In addition,, owing to having adopted brazing flux, postwelding also must add the operation of cleaning brazing flux, in case the corrosion of brazing flux to aluminum mother plate.
Osaka, Japan university just Tian Yixing has proposed the technical scheme at the previously prepared soft Ag of stainless steel one side, Cu, Ni active layer
[5].Recently, Wu Mingfang is to adopting Cu paper tinsel to carry out Al/Cu/SUS (the thick 10 μ m of Cu paper tinsel, 570 ℃ * 20min * 0.1MPa) contact reaction brazing (contactreactive brazing), after long-time insulation, though interface is gradually fine and close, but still have a large amount of Cu not spread the mother metal as Al, the conversion zone width that comprises IMC approaches 50 μ m, and the thickness of IMC needs further to be reduced
[6].
Separately there are France and Japanology personnel to adopt laser braze welding technique, though heat input is little, be conducive to suppress intermetallic compound and excessively thicken, but still need brazing flux striping, and equipment investment is high
[7,8].
In recent years, domestic Harbin Institute of Technology welds and has carried out the comparatively research of series aluminium/stainless steel.The main method proposing has: contact reaction brazing, stainless steel surfaces be soldering again after hot aluminizing, welding-braze (can adopt the thermals source such as TIG, MIG, Laser) in advance
[9-11]." contact reaction brazing " of the propositions such as He Peng adopts Si powder to do intermediate layer, can effectively remove the oxide-film of aluminum mother plate side surface, but welding temperature higher (600 ℃) is difficult to use in aluminium alloy and stainless soldering that some fusing points are lower
[12].There is the blemisies in an otherwise perfect thing such as complex procedures, extra power consumption in " stainless steel surfaces in advance hot aluminizing after soldering again ".Although welding-braze has avoided stainless fusing to suppress the generation of compound between excess metal, but still has arc light radiation or splash; Need use brazing flux (by extraordinary brazing flux---the Nocolock brazing flux after modification is in harmonious proportion and is coated in equably stainless steel groove end face and near steel plate upper and lower surface with acetone, and coated weight was advisable just to cover stainless steel surfaces) to improve liquid aluminium alloy to stainless wetability; Owing to need to be in very narrow welding bead heated perimeter making on the one hand aluminium fusing and still making on the other hand stainless steel keep solid-state, thus to operating technology require high
[13].When adopting Laser Power Supply to carry out welding-braze, the large scale application that equipment investment is large, the aluminium deficiencies such as high and absorptivity is low to the reflectivity of laser have also limited this technology
[14].
Sum up above-mentioned method for welding, can summarize at process aspect and have following inconvenience: the one, use brazing flux; The 2nd,, at the previously prepared active layer of stainless steel surfaces, for this reason, must add the power consumption operations such as plating, hot dipping; The 3rd, there is the shortcoming (often adopting heating in stove, electric arc heated, LASER HEATING) that power consumption is high, environment is poor in heat source.
On the other hand, when adopting transition liquid phase diffusion weld (TLP) (take Cu, Ag, Ni be intermediate layer), although its have advantages of can so as not to brazing flux, reduce welding temperature, but its shortcoming is also more, be listed below: (1) required diffusion time is very long, even needs about a few hours; (2) extremely long diffusion temperature retention time requires vacuum or protection of the environment; (3) dissimilar metal TLP exist intermediate layer and two kinds of mother metal reaction rates inconsistent, cause interface, both sides be combined with quality minute
[15]; (4) theoretically, there is the contradiction that between two class different metals, compound is difficult to eradicate simultaneously: when isothermal solidification completes, brazed seam center there will be Al-Cu class IMC; When isothermal solidification completes, brazed seam center there will be the Al-Fe class IMC of rich aluminium, there will be the Fe-Al class IMC of rich Fe and interface is become fragile at brazed seam edge
[16].
In recent years, carried out successively aluminium/stainless friction stir welding research both at home and abroad, but the documents and materials of the correlative study that can find are few, and need to be deepened.The researcher Uzun of Germany, has carried out aluminium/stainless docking friction stir welding, and instrument is for band pin stirring-head, and for weakening the sharp wear of pin, cushion implantation site is most of in aluminum mother plate side, and few part contacts stainless steel mother metal.Postwelding has carried out micro-hardness testing, the hardness of finding nugget district has fluctuation to change, and then carried out Metallographic Analysis, reach a conclusion: due to the mechanical agitation of stirring tool, the stainless steel particle of high rigidity or even large-sized block stainless steel have been dragged to aluminum alloy surface, and have 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, find that the fatigue life of aluminium/stainless steel welded joint is low by 30% compared with aluminium alloy mother metal; A little less than the mechanical agitation due to weld seam bottom is found in Metallographic Analysis, 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 apparent, i.e. the pernicious wearing and tearing of (1) stainless steel to instrument; (2) stainless steel particle or even large scale piece of stainless steel are stirred and are drawn to aluminum substrate, and if the outer surface that is stirred the large scale piece of stainless steel that is drawn to aluminum substrate can not well engage with aluminum substrate, its existence is tantamount to the inclusion defect of bulk; (3) weld seam bottom, because mechanical agitation weakens, can not reach the mechanical mixture effect of expection, thereby the kiss having formed bottom weld seam connects phenomenon.
Aspect aluminium/copper friction stir welding, there is equally the problems such as the wearing and tearing of pin, root kiss connect, keyhole.In addition,, because of copper rapid heat dissipation, shaping surface is also rough
[18].
Recently, Xi'an Communications University (applicant place seminar) is for avoiding the wearing and tearing of pin to develop the stirring friction braze welding technology of aluminum/steel dissimilar metal
[19].This technology tool has the following advantages: clean, the concentrated frictional heat of take is thermal source, and energy consumption is low, simple to operate and working condition good (without splashing and arc light), without any protective gas and brazing flux; Adopt needleless instrument to eliminate the wearing and tearing of pin, guarantee that welding process can continue to carry out smoothly; For the overlap joint ubiquitous up/down of friction stir welding interface Plastic Flow, mix the problem that is difficult to realization, realize between interface densified mix with up/down aspect, utilize mother metal to replace plastic deformation to the quick dissolving in solder, thereby reduced to interface plastic deformation and by Plastic Flow, realize the overcritical of up/down mixing; Can be by " interface is reversed
[20], extruding
[21]undercurrent under+film (adding of Zn solder)
[19]+ pressurization is extruded
[19]" number of mechanisms effectively removes the oxide-film on aluminum mother plate surface, interface oxidation film is abolished satisfactory for result; After oxide-film is extruded with eutectic, low strong liquid phase, final gained Interface Microstructure essence is clean, fine and close, continuous micron order diffusion layer, has guaranteed reliably thus the quick seam (welding at present scooter 150～300mm/min) between cover/substrate interface.
But, when needleless stirring friction braze welding technology is during for thick aluminium sheet mother metal (5mm and more than), although Zn solder also can be melted smoothly and extrude by frictional heat, all right at aluminium side striping, interface seam, but the variation of mechanical rupture of membranes effect by torsional effect in interface own, in addition stainless steel watch surface oxidation film is form compact and stable, double factor cause thick aluminium sheet and stainless stirring friction braze welding unsatisfactory, 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 be conducive to weld interface machinery striping, but unavoidably cause the wearing and tearing of pin end, force welding process hard to carry on, or be forced to use and be worth high wear-resistant mixing head (as maximum in external report is cubic boron nitride ceramic instrument or W, Mo class instrument).Obviously, adopt tradition band pin stirring-head still difficult.But, when adopting the thick aluminium sheet/xenogenesis of needleless stirring-head welding high tensile metal joint, though can avoid the wearing and tearing of pin end, for stainless steel-like mother metal needleless stirring friction braze welding, exist stainless steel side interface oxidation film to abolish this fatal problem of effect extreme difference.Analyze its reason as follows:
(1) instrument aspect: needleless instrument has been lost the direct mechanical immixture to weld interface, causes 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 comprehensively hot in nature-Li synergy effect that heating, torsion, forging and stamping to weld interface intercouple and produce, thickness of slab direction plastic strain gradient reduces, therefore, larger thickness of slab has also worsened the mechanical twisting rupture of membranes of weld interface.(3) material aspect: when hard mother metal is the stable mother metal that is difficult to removal of stainless steel-like oxide-film, the oxide-film of weld interface is abolished effect will be poorer.
The intermixing, the striping that exist when solving needleless stirring friction braze welding technology for hard foreign material welding such as thick aluminium sheet and stainless steels be bad causes this problem of strength of joint extremely low (postwelding is ftractureing voluntarily with handsaw sample making course or also ftractureing voluntarily with the sand papering sample preparation stage), the present invention proposes " method of fractional steps stirring friction braze welding technology of a kind of thick aluminium sheet and hard foreign material ".Its technical scheme is first by needleless stirring friction braze welding technology, at stainless steel surfaces, to press pricker one deck " thin " aluminium sheet (object is to make full use of the relatively significant advantage of the mechanical rupture of membranes effects such as interface torsions in " thin " aluminium sheet situation, extruding), and then at this, by pricker, is pressed on above the thin aluminum sheet on hard dissimilar metal surface with thick aluminum layer on stirring friction braze welding technology (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 aluminium of the same race, now also available with pin instrument without carrying out the welding of overlap joint between thin aluminium/thick aluminium under abrasion condition; If add Zn make mixing between striping, up/down interface or densifiedly do not rely on Plastic Flow and mainly rely on metallurgical reaction, thereby closely sealed the becoming in interface easily realize simultaneously, and can enlarge markedly seam area.This technology can be used for the preparation of aluminium/stainless steel conductor rail, aluminium/copper transit joint.
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Summary of the invention:
The object of the invention is to solve hard mother metal side interface heating pressurization that needleless stirring friction braze welding technology exists during directly with hard xenogenesis mother metal (as steel, stainless steel, titanium, copper etc.) for " thick aluminium sheet " and interface and reverses deficiency, striping and mix bad and cause strength of joint extremely low (for example, although aluminium side interface striping and seam are good, postwelding is with still ftractureing voluntarily in handsaw sample making course or can ftracture voluntarily along the interface of hard foreign material side with the 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:
First use needleless stirring friction braze welding technology (depending on product requirement) on the surfaces to be welded such as stainless surface, end face or side to press pricker one deck " thin " aluminium sheet, object is to make full use of the significant advantages of mechanical rupture of membranes effect such as interface torsion in " thin " aluminium sheet situation, extruding, to pass through metallurgical and mechanical double factor striping, extrude solder, realize thin aluminum sheet and engage with the densification between hard foreign material; Then at pricker, be pressed on above the thin aluminum sheet on hard foreign material and with needleless stirring friction braze welding technology pricker, press thick aluminium sheet again, also can directly with friction stir welding, complete the welding between thin/thick aluminium sheet, object is by aluminium/stainless steel dissimilar metal solder is converted into the welding between aluminium of the same race, to eliminate the wearing and tearing of pin completely.Wherein, second step flexibility is large, can adapt to various working condition requirements: for example, available with pin instrument without carrying out the welding of overlap joint between aluminium/aluminium under abrasion condition; Add Zn to make mixing and the densified Plastic Flow that do not rely between striping, up/down interface simultaneously, thereby the easily realization that becomes, and can enlarge markedly seam area.Second step also can directly carry out docking friction stir welding between thin/thick aluminium sheet, and for example thick aluminium/copper transit joint just can adopt this scheme.
The basic concrete operation of the present invention and reason thereof are as follows:
The first step: separately get the thin aluminum sheet of a thick approximately 1～3mm, first this thin aluminum sheet and hard dissimilar metal (as stainless steel, steel, titanium, copper etc.) are carried out to stirring friction braze welding, the pricker that completes thin aluminum sheet is pressed: used tool is needleless column instrument; Solder used is Zn paper tinsel; Welding in air, without any brazing flux and protective gas.The object that why adds Zn is to abolish the lip-deep oxide-film of thin aluminum sheet.The object of why first about 2mm thickness aluminium sheet and the hard mother metal of xenogenesis (corrosion resistant plate) being carried out to stirring friction braze welding is to be difficult to remove due to the oxide-film on hard xenogenesis mother metal (stainless steel) surface, when adopting thin aluminum sheet, the heating of shoulder, forging and stamping effect and interface torsional effect will become remarkable in the Re-Li of weld interface synergy effect, be conducive to utilize 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 carry out stirring friction braze welding, although Zn solder can melt, the effect of forging and stamping effect and interface torsional effect, by variation, causes interfacial combined function poor (even ftractureing voluntarily when with handsaw sample preparation) thus.And, postwelding, unnecessary eutectic, the low strong Zn solder in interface can almost be extruded completely, thereby obtains cleaning, densification, continuous, the moderate diffusion layer of thickness, thereby in the situation that there is no directly stirring, utilizes metallurgical approach to obtain direct proliferation welding between parent material interface.
Second step: be pressed on preseting solder and thick aluminium sheet above the thin aluminum sheet on 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, to obtain lap joint.Equally, used tool is cheap medium carbon steel instrument; Solder used is Zn paper tinsel; Welding in air, without any brazing flux and protective gas.When thick aluminium sheet itself is thicker as surpass 8mm, should adopt band pin instrument, suitably to add severe deformation heat and intermixing effect; When thick aluminium plate thickness can adopt needleless instrument in 5～8mm scope, to eliminate keyhole.
For second step, require the product joint achieving a butt joint, can adopt more simple technique, directly by traditional Friction stir welding welding: adopt band pin instrument, exempt from solder, directly complete the agitating friction docking between thin aluminum sheet/thick aluminium sheet.This intermixing that has benefited from banjo fixing butt jointing more easily realizes than lap joint that (due in banjo fixing butt jointing preparation, instrument rotational line speed is perpendicular to weld interface, thereby two interfaces are easily uniformly mixed; And in lap joint preparation, instrument rotational line speed is parallel to solder side, thereby two interfaces are difficult to be uniformly mixed).Now, because institute's wlding material is aluminium, therefore can't there are the pernicious wearing and tearing to pin.
The substep stirring friction braze welding method of thick aluminium sheet of the present invention and hard foreign material, makes needleless stirring friction braze welding technology for " thick aluminium sheet " during directly with hard xenogenesis mother metal (as steel, stainless steel, titanium, copper etc.), the advantage that strength of joint is high.
Accompanying drawing explanation:
Fig. 1. method of fractional steps stirring friction braze welding technology schematic diagram: (a) the needleless stirring friction braze welding of first step thin aluminum sheet and hard foreign material; (b) the thin aluminium of second step/thick aluminium has pin overlap joint stirring friction braze welding, (c) the thin aluminium of second step/thick aluminium needleless overlap joint stirring friction braze welding, (d) the thin aluminium of second step/thick aluminium has pin overlap joint stirring friction braze welding (pin runs through aluminium/aluminium interface), (e) the thin aluminium of second step/thick aluminium has for connecing stirring friction braze welding, and (f) the thin aluminium of second step/thick aluminium has for 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 fracture position (being positioned at thin aluminum sheet mother metal but not weld interface) after test: weld that speed is respectively 23.5,150,300,375,475mm/min; (a) (c) (e) (g) (i) be corresponding top view; (b) (d) (f) (h) (j) be 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 ftractures voluntarily in sample making course: (a) outer surface; (b) fracture is (smooth; On stainless steel, nothing adheres to Al and Zn).
Fig. 7. two-step method " thick aluminium sheet/thin aluminum sheet/stainless steel " joint draws cuts photo (remarkable plastic deformation has occurred thick aluminium sheet mother metal) after experiment: weldering speed is respectively 23.5,150,300,375,475mm/min; (a) (c) (e) (g) (i) be corresponding plane of disruption top 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 for 23.5mm/min) cross section interface low power subregion schematic diagram: I, III are gapped district, II accounts for the whole district 57.5% for the district that combines closely, and remainder is for takeing on outskirt;
Figure 10. weldering speed is aluminium/stainless joint interface 100 * back scattering serialograph of 23.5mm/min;
Figure 11. corresponding to Figure 10 median surface, iris out region c, f, h, i high power (more than 2000 times) amplification back scattering photo: still fine and close under high power, and thicken without intermetallic compound;
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 the rear photo of test: (a) plane of disruption top view (being stained with aluminium on copper); (b) plane of disruption side view (obvious flexural deformation has occurred aluminum mother plate).
Note: in Fig. 1 .a the 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 the first footwork postwelding, 3 (corrosion resistant plates) are that Fig. 1 .b～f the second footwork is used; In Fig. 1 .b～f the second footwork, 4,6,8,10,12 is mutual discrete thick aluminium sheet, and 5,7,9,11 is mutual discrete zinc paper tinsel.
The specific embodiment:
Below in conjunction with accompanying drawing, the present invention is described 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 saving experimentation cost, corrosion resistant plate used (304) is the thin plate that 2mm is thick, 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; Aluminium sheet size is also 100mm * 60mm.Stirring tool is that the diameter of being made respectively by 45 common steel is 20mm needleless instrument and has pin instrument.Zn paper tinsel is the thick foil of commercially available 100 μ m, and width is also got 20mm.
Ground floor welding procedure is: method as shown in schematic diagram 1 (a).
(1) method of clamping: thin aluminum sheet is held on to (two plates all clean through sand papering and with alcohol) on corrosion resistant plate, and between two plates, the pre-solder Zn paper tinsel of placing, is placed in advance side by corrosion resistant plate.The lap of splice is 20mm.
(2) parameter adjustment: 1500 revs/min of rotating speeds; Approximately 3 °, instrument inclination angle; Speed of welding trial stretch is got 5 levels:
23.5,150,300,375,475 (mm/min), to distinguish the production efficiency of this technique.
(3) position check and correction: as shown in schematic diagram, stirring-head right side edge is aimed to aluminium sheet right side edge.
(4) Control Welding Process: during welding, when needleless instrument is when the compression distance that is positioned at the aluminum mother plate inside of upside reaches 0.2～0.5mm, stop pressing down, stirring-head is kept about 10 seconds, to guarantee that enough heat inputs make aluminum mother plate fully softening to the original position friction of aluminum mother plate initiating terminal.Then, unlatching workbench moves by default weldering speed; Treat that fusion length reaches 80～90mm or apart from plate leading edge 5mm place, stops friction welding and movement.
Second layer welding procedure is: only introduce the intermixing welding of the lap joint of difficulty relatively, the method as shown in schematic diagram 1 (b) of realizing here.(in addition, the second layer welding method as shown in schematic diagram 1.c～f is similar to Fig. 1 .b, seldom explains here, and they all belong to the derived method of Fig. 1 .b, or more simple docking calculation, as Fig. 1 .f)
Preparation: the part that the aluminium sheet in above-mentioned weldering sample is had more to stainless steel mother metal amputates, prepares second layer welding.
(1) method of clamping: thick aluminium sheet is held on the weldering sample of the above-mentioned thin aluminum sheet making and corrosion resistant plate to middle preseting solder Zn paper tinsel.Welding method is identical with ground floor.
(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: for proof method of fractional steps stirring friction braze welding technology is in the superiority aspect thick aluminium sheet and hard foreign material, also introduced in the lump at this fracture behaviour that directly carries out thick aluminium sheet and stainless single step stirring friction braze welding technology gained defective joint.
Postwelding evaluation mainly comprises following content: outward appearance; Draw and cut test breaking load (drawing and cutting specimen size is 100mm * 25mm) and fracture position; Microstructure of interface.In Analysis on Microstructure, pay close attention to the striping effect of following problem: Al, stainless steel both sides; Separate and the thickness of compound between interface metal; Whether Zn is extruded.
Be below experimental result:
Joint outward appearance (seeing Fig. 2 and Fig. 3): the 1st layer of joint positive and negative outward appearance is as shown in Fig. 2 (a～e), and second layer two-step method integrity of welded joint positive and negative outward appearance is as shown in Fig. 3 (a～e).To no matter the 1st layer or the 2nd layer all can obtain ganoid figuration of bead of above-mentioned weldering speed scope (23.5～475mm/min), visible, height is welded to fast adaptability and also stablize, well.But it should be noted, when welding experiment, stirring-head compression distance is controlled conventionally as 0.5mm is below to provide enough large forging force and strong interface twisting resistance, but cause heat input reduction, the metal softening of unit are insufficient with weldering speed rising (more than welding fast 300mm/min), plasticity is not enough, make the surface cannot moulding (tear on surface) under large interface twisting resistance condition, so have to, reduce the compression distance of stirring-head to weaken frictional interface torsional deflection degree, thereby obtain complete smooth face of weld.
Ground floor joint breaking position (seeing Fig. 4): the drawing of ground floor joint cut the performance test results and shown, thin aluminium and stainless steel dissimilar metal joint draw cuts sample fracture position all within aluminum mother plate, do not rupture in 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 the thick aluminium sheet of 5mm is adopted needleless stirring friction braze welding technology pricker to be pressed on stainless steel, although Zn base solder also can melt, welding bead shaping surface is smooth (being shown in Fig. 5) also, but joint quality extreme difference, postwelding is with i.e. cracking or with the sand papering sample preparation stage also cracking voluntarily, stainless steel fracture one side adheres to (seeing Fig. 6) without any Al and Zn voluntarily in handsaw sample making course, as seen root problem be stainless steel one side interface because of mechanical rupture of membranes weak effect cannot seam.Pricker pressure effect by contrast thin aluminum sheet and thick aluminium sheet is known, and when its reason is that direct pricker is pressed thick aluminium sheet, the heating of stainless steel interface one side, forging and stamping, the torsion effect effect during all not as good as the ironed aluminium sheet of pricker is remarkable.
Two-step method integrity of welded joint fracture position (Fig. 7): two-step method is soldered after thick aluminium sheet, welding point draws to be cut sample fracture position and is all aluminium/stainless steel interface, though interface bond strength is not enough, thicker aluminum mother plate ruptures, but cut (Fig. 7 .b, d, f, h, j) sample side view and can find out from drawing, interface bond strength has been enough to make slab aluminum mother plate that flexural deformation largely occurs, even can make stainless steel mother metal occur bending and deformation.
Be appreciated that in addition, integrity of welded joint does not all have from thin/thick aluminium sheet metal interface cracking of the same race, and the stirring friction braze welding technique that shows this interface is successful.
Performance test (Fig. 8): pricker presses the curve of load of gained " thin aluminum sheet/stainless steel " joint after ground floor thin aluminum sheet and complete two step stirring friction braze welding method gained " thick aluminium sheet/thin aluminum sheet/stainless steel " respectively as Fig. 8 (a), (b) shown in.Wherein the latter is more meaningful, because the former easy tension is cut the impact of sample stirring area actual thickness (relevant with attenuate degree with compression distance, shaping surface) and fluctuateed.From the latter (Fig. 8 .b), can find out, 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 lower the 1st layer of height weldering speed, draw shearing load high and be soldered 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 the trend that raises, and it is fast higher than low weldering to be not equal to the fast joint " intensity " of high weldering.Because thin aluminum sheet and stainless joint draw and cut sample fracture position and be all thin aluminum sheet mother metal, so the size of tension shearing load depends on the thickness of aluminum mother plate.And when welding experiment, stirring-head compression distance is controlled conventionally as 0.5mm is to provide enough large forging force and strong interface twisting resistance, but with weldering speed raise cause the heat input of unit are to reduce, metal softening is insufficient, plasticity is not enough makes the surface cannot moulding (tear on surface) under large interface twisting resistance condition, think and obtain complete smooth face of weld, have to reduce the compression distance of stirring-head, thereby the torsion rupture of membranes at Al/SUS different-metal material welding interface is slightly affected.On the other hand, stirring-head compression distance is little just means that the attenuate amount of commissure aluminum mother plate is little, the fast commissure aluminum mother plate thickness of high weldering is greater than low weldering speed, and height welds fast interface bond strength and is all enough to make to draw and cuts experimental sample and break in aluminum mother plate, so the tensile load that has occurred the lower sample of high weldering speed is higher than the fast situation of low weldering.
Interface microstructure: adopt 23.5mm/min to weld fast gained dissimilar metal joint interface micro-organization chart (Fig. 9～Figure 11) and show, though aluminium/stainless steel interface is without obviously intermetallic compounds layer generation, but the oxide-film of aluminium and stainless steel side is abolished, interface is in conjunction with fine and close (fine and close combination interface account for full interface 57.5%).In central area, even if be amplified to 2000 times, both do not observed above interfacial voids especially, and do not observed intermetallic compound yet and thicken, shown that Al/SUS interface was in conjunction with good.What a small amount of Zn remained in interface retreats 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 304 corrosion resistant plates replace with copper coin (being of a size of 100mm * 60mm * 2mm), material therefor, specification and instrument are identical with embodiment 1.
First step welding process: identical with method in embodiment 1, first on copper coin surface, with needleless stirring friction braze welding technology pricker, press one deck thin aluminum sheet.Get the thin aluminum sheet that copper coin that thickness is 2mm and thickness are 2mm and carry out first step pricker pressure, solder used is still Zn paper tinsel, and weldering speed is 150mm/min.
Second step welding process: identical with method in embodiment 1, with the thick aluminium sheet of 5mm being welded on the thin aluminum sheet of the resulting thin aluminium/copper sleeve of the first step with pin instrument, solder used is also Zn paper tinsel, weldering speed is still 150mm/min.
Welding design sketch: ground floor joint outward appearance is as Figure 12, and second layer joint outward appearance is as Figure 13.
Performance test: two-step method integrity of welded joint is drawn and cuts experiment (drawing and cutting specimen size is 100mm * 25mm), welding point draws to be cut sample fracture position and is all aluminium/copper interface (Figure 14), tensile load is 3.74KN, though interface bond strength deficiency is so that aluminum mother plate fracture, but cut fracture surface of sample top view (Figure 14 .a) and can find out from drawing, on copper coin, be obviously stained with aluminium, show that the interface seam of Al/Cu dissimilar metal joint is firm; , from plane of disruption side view (Figure 14 .b), can find out, interface bond strength has been enough to make slab aluminum mother plate that flexural deformation largely occurs, even makes copper base metal occur bending and deformation meanwhile.
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 is known, the advantage of " method of fractional steps stirring friction braze welding new technology " is: first has a mind to select thin aluminum sheet, be conducive to strengthen the Re-Li synergy effect of shoulder to weld interface, by thin aluminum sheet, make aluminium and the seam of foreign material interface reliable; Second is the stirring friction braze welding of aluminium/aluminium same material, has avoided the wearing and tearing of hard mother metal to instrument completely; All welding beads can be with cheap carbon steel instrument welding in air, without 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 a Practical Project difficult problem.
The above, it is only preferred embodiment of the present invention, not the present invention is done to any pro forma restriction, although the present invention discloses as above with preferred embodiment, yet not in order to limit the present invention, any those skilled in the art, do not departing within the scope of technical solution of the present invention, when can utilizing the method for above-mentioned announcement and technology contents to make a little change or being modified to the equivalent embodiment of equivalent variations, in every case be the content that does not depart from technical solution of the present invention, any simple modification of above embodiment being done according to technical spirit of the present invention, equivalent variations and modification, still belong in the scope of technical solution of the present invention.
Claims (5)
1. the substep stirring friction braze welding method of thick aluminium sheet and hard foreign material, is characterized in that: comprise the following steps:
(1) adopt needleless stirring friction braze welding technology first at hard foreign material, to be positioned at welding surface pricker pressure one deck thin aluminum sheet of surface, end face or side, to pass through metallurgical and mechanical double factor striping, extrude solder, realize thin aluminum sheet and engage with the densification between hard foreign material; Wherein, first carry out the thin aluminum sheet of the thick 1～3mm of being and the stirring friction braze welding of hard dissimilar metal, the pricker that completes thin aluminum sheet is pressed; Used tool is medium carbon steel or tool steel needleless column instrument; Solder used is Zn paper tinsel; Welding in air;
(2) at pricker, be pressed on above the thin aluminum sheet on hard foreign material and depending on thickness of slab, with needleless or band pin stirring friction braze welding technology pricker, press thick aluminium sheet again, or directly with friction stir welding, complete the welding between thin/thick aluminium sheet; Wherein, be to be pressed on preset Zn paper tinsel solder and thick aluminium sheet above the lip-deep thin aluminum sheet of hard foreign material at pricker, with stirring friction braze welding, carry out the welding between thin aluminum sheet and thick aluminium sheet lap joint, with this, increase seam area; Used tool is medium carbon steel or tool steel instrument; Band pin or needleless; Solder used is Zn paper tinsel; Welding in air; Wherein, when surpassing 8mm, thick aluminium plate thickness should adopt band pin instrument; When thick aluminium plate thickness adopts needleless instrument in 5～8mm scope.
2. the substep stirring friction braze welding method of thick aluminium sheet and hard foreign material as claimed in claim 1, it is characterized in that: column tool diameter, more than 15mm, 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 in described step (1); After completing first pricker pressure, remove on thin aluminum sheet over the redundance beyond hard mother metal surface to be welded.
3. the substep stirring friction braze welding method of thick aluminium sheet and hard foreign material as claimed in claim 1, it is characterized in that: in described step (2), exempt from solder, directly with band pin instrument, directly carry out thin/thick aluminium sheet intermetallic overlap joint friction stir welding of the same race or docking friction stir welding.
4. the substep stirring friction braze welding method of thick aluminium sheet and hard foreign material as described in claim 1,2 or 3, is characterized in that: described hard foreign material is steel, titanium or copper.
5. the substep stirring friction braze welding method of thick aluminium sheet and hard foreign material as claimed in claim 4, is characterized in that: described hard foreign material is stainless steel.
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