Material Flow and Its Induced Joint Formation of FSLW Process by X-shaped Reverse-threaded Pin

YU Zhanxing; CHEN Zhengshuo; JI Xinqi; JIN Chen; SONG Qi

doi:10.7512/j.issn.1001-2303.2024.08.04

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Material Flow and Its Induced Joint Formation of FSLW Process by X-shaped Reverse-threaded Pin
Vol. 54, Issue 8, Pages: 29-35(2024)
Published： 25 August 2024 ，
DOI： 10.7512/j.issn.1001-2303.2024.08.04
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余占兴，陈政硕，姬新淇，等.基于X形正反螺纹搅拌针的搅拌摩擦搭接焊材料流动及其影响下的接头成形规律［J］.电焊机，2024，54（8）：29-35.

YU Zhanxing, CHEN Zhengshuo, JI Xinqi, et al.Material Flow and Its Induced Joint Formation of FSLW Processby X-shaped Reverse-threaded Pin[J].Electric Welding Machine, 2024, 54(8): 29-35.
余占兴，陈政硕，姬新淇，等.基于X形正反螺纹搅拌针的搅拌摩擦搭接焊材料流动及其影响下的接头成形规律［J］.电焊机，2024，54（8）：29-35. DOI： 10.7512/j.issn.1001-2303.2024.08.04.

YU Zhanxing, CHEN Zhengshuo, JI Xinqi, et al.Material Flow and Its Induced Joint Formation of FSLW Processby X-shaped Reverse-threaded Pin[J].Electric Welding Machine, 2024, 54(8): 29-35. DOI： 10.7512/j.issn.1001-2303.2024.08.04.

摘要

搅拌针大扎入下板是搅拌摩擦搭接焊（FSLW）常见的工艺方法，但向上弯曲的钩状缺陷会减小接头的有效搭接厚度，不利于获得高承载的接头。为实现钩状缺陷向下弯曲，设计了X形正反螺纹搅拌针并进行搅拌摩擦搭接焊过程材料流动行为的数值模拟，进而研究材料流动与接头成形间的关系。结果表明，在X形正反螺纹搅拌针作用下，焊接过程中焊核区下部与上部的材料分别向上与向下流动，在焊核区中间交汇后向沿水平方向流动；当材料交汇形成的材料集聚区位于原始搭接界面上方时，既可实现钩状缺陷的向下弯曲又可获得大宽度的焊核。在转速为800 rpm且焊速为300 mm/min时，2024-T4铝合金搭接焊接头的拉伸强度达到299.6 MPa，其大于已报道的2000系列铝合金接头强度值。

Abstract

Making the pin largely plunge into the lower plate is a common process of friction stir lap welding (FSLW) technology

but the induced hook with an up-bending morphology reduces the effective sheet thickness of the joint

which is not conducive to obtaining the joint with high bearing capacity. In this paper

in order to realize the down-bending morphology of hook

the X-shaped reverse-threaded pin was self-designed. By this pin

the material flow behavior was simulated numerically during FSLW

and the relationship between material flow and joint formation was studied. The results showed that under the driving action of pin

the materials in stir zone (SZ) top and SZ bottom respectively flowed downwards and upwards and then accumulated in the middle of SZ

and these accumulated materials had a flowing trend along the horizontal direction. When the material accumulated zone was located above the original lap interface

the hook bent downward and the SZ width was enlarged. At the rotating velocity of 800 rpm and the welding speed of 300 mm/min

the 2024-T4 aluminum alloys FSLW joint had a 299.6 MPa tensile strength

and this value was greatly higher than the reported tensile strengths of 2000 series aluminum alloys FSLW joint.

关键词

搅拌摩擦搭接焊X形正反螺纹搅拌针数值模拟材料流动接头成形

Keywords

friction stir lap weldingX-shaped reverse-threaded pinnumerical simulationmaterial flowformation

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