Welding Process Simulation Analysis and Optimization of 5056 Aluminum Alloy Water Distributors

HE Xu; HU Zixiang; YAN Yinfei; BU Yifan; YAN Wenqiang; ZHANG Xiangxiang

doi:10.7512/j.issn.1001-2303.2025.12.14

Welding Technology | Views : 0 下载量: 8 CSCD: 0

PDF
Export
Share
Collection
Album

Welding Process Simulation Analysis and Optimization of 5056 Aluminum Alloy Water Distributors
Vol. 55, Issue 12, Pages: 100-106(2025)
Received：25 November 2024，

Revised：2025-04-02，

Published：20 December 2025
DOI： 10.7512/j.issn.1001-2303.2025.12.14
稿件说明：

移动端阅览

何旭，胡子翔，严银飞，等.5056铝合金水分配器焊接工艺仿真分析与优化［J］.电焊机，2025，55（12）：100-106. DOI： 10.7512/j.issn.1001-2303.2025.12.14.

HE Xu, HU Zixiang, YAN Yinfei, et al.Welding Process Simulation Analysis and Optimization of 5056 Aluminum Alloy Water Distributors[J].Electric Welding Machine, 2025, 55(12): 100-106. DOI： 10.7512/j.issn.1001-2303.2025.12.14.

摘要

针对5056铝合金水分配器电子束焊接后焊缝区域出现开裂的问题，本研究采用Simufact.welding软件，通过焊接过程仿真方法，系统分析了不同结构形式与焊接工艺方案对焊接热影响区（HAZ）及焊后残余应力的影响规律。设计了五种对比方案：原始结构（方案1）、切线收弧（方案2）、盖板增加凸台（方案3）、增加盖板厚度（方案4）及降低焊接速度（方案5）。仿真结果表明：在盖板增加凸台（方案3）可显著减小热影响区宽度，盖板侧与壳体侧分别降低35.67%与15.67%；采用切线收弧（方案2）可使焊后最大残余应力降低2.56%。而增加盖板厚度（方案4）虽能减小盖板侧HAZ宽度22.82%，但对残余应力影响甚微；降低焊接速度（方案5）则会导致HAZ宽度增加。基于仿真结果，综合选取“盖板增加凸台并采用切线收弧”的优化方案进行试验验证。经1.5 MPa气压测试30分钟及导电氧化处理后，焊缝无裂纹出现，且批量生产质量稳定。本研究通过仿真与试验相结合，为5056铝合金水分配器的焊接工艺优化与开裂控制提供了有效依据。

Abstract

To address the cracking problem in the weld zone of a 5056 aluminum alloy water distributor after electron beam welding

this study employed Simufact.welding software to systematically analyze the effects of different structural designs and welding process parameters on the heat-affected zone (HAZ) and post-weld residual stress through welding process simulation. Five comparative schemes were designed: the original structure (Scheme 1)

tangential arc closing (Scheme 2)

adding a boss on the cover plate (Scheme 3)

increasing the cover plate thickness (Scheme 4)

and reducing the welding speed (Scheme 5). Simulation results indicated that adding a boss on the cover plate (Scheme 3) significantly reduced the HAZ width

with decreases of 35.67% on the cover side and 15.67% on the shell side

respectively. Using tangential arc closing (Scheme 2) reduced the maximum residual stress by 2.56%. While increasing the cover plate thickness (Scheme 4) reduced the HAZ width on the cover side by 22.82%

it had a negligible effect on residual stress. Reducing the welding speed (Scheme 5) increased the HAZ width. Based on the simulation results

an optimized scheme combining "adding a boss on the cover plate with tangential arc closing" was selected for experimental verification. After pressure testing at 1.5 MPa for 30 minutes and conductive oxidation treatment

no cracks were observed in the weld

and batch production demonstrated consistent quality. This study

combining simulation and experiment

provides an effective basis for welding process optimization and crack control in 5056 aluminum alloy water distributors.

关键词

Keywords

references

方大勇 . 现代焊接技术发展的现状与展望［J］. 中国设备工程， 2019 （ 9 ）： 206 - 207 .

FANG D Y . Current situation and prospect of modern welding technology development ［J］. China Equipment Engineering ， 2019 （ 9 ）： 206 - 207 .

Mohandas T . Welding technologies in aerospace applications ［J］. Aerospace Materials and Material Technologies ， 2016 （ 2 ）： 65 - 83 .

Liu J F ， Cheng Y F ， Jing X W ， et al . Prediction and optimization method for welding quality of components in ship construction ［J］. Scientific Reports ， 2024 ， 14 （ 1 ）： 9353 .

朱浩，陈强，陈剑虹 . 热影响区几何尺寸对铝合金焊接结构变形及强度影响规律［J］. 焊接学报， 2012 ， 33 （ 5 ）： 77 - 81+117 .

ZHU H ， CHEN Q ， CHEN J H . Influence rule of Heat Affected Zone geometrical dimension to aluminum alloy joint deformation and strength ［J］. Transactions of the China Welding Institution ， 2012 ， 33 （ 5 ）： 77 - 81+117 .

樊亚玲，杨宏亮，王二建 . 焊接热影响区应力腐蚀裂纹尖端力学特性分析［J］. 山西科技， 2020 ， 35 （ 6 ）： 35 - 37 .

FAN Y L ， YANG H L ， WANG E J . Analysis on Mechanical Characteristics of Stress Corrosion Crack Tip in Welding Heat Affected Zone ［J］. Shanxi Science and Technology ， 2020 ， 35 （ 6 ）： 35 - 37 .

James M N . Residual stress influences on structural reliability ［J］. Engineering Failure Analysis ， 2011 ， 18 （ 8 ）： 1909 - 1920 .

Jie Z ， Wang K ， Liang S . Residual stress influence on fatigue crack propagation of CFRP strengthened welded joints ［J］. Journal of Constructional Steel Research ， 2022 ， 196 ： 107443 .

Alipooramirabad H ， Paradowska A ， Ghomashchi R ， et al . Investigating the effects of welding process on residual stresses， microstructure and mechanical properties in HSLA steel welds ［J］. Journal of Manufacturing Processes ， 2017 ， 28 ： 70 - 81 .

Zhang Y Q ， Zhao P ， Tong Y Q ， et al . Microstructure and Mechanical Properties of Powder Metallurgy Superalloy Joints Welded by Inertia Friction Welding ［J］. Materials ， 2024 ， 17 （ 6 ）： 1342 .

徐斌荣，王军，罗震，等 . 预制槽尺寸对30CrMo板再制造残余应力的影响［J］. 焊接， 2024 （ 8 ）： 22 - 30 .

XU B R ， WANG J ， LUO Z ， et al . Influence of prefabricated slot size on residual stresses in remanufactured 30CrMo plates ［J］. Welding & Joining ， 2024 （ 8 ）： 22 - 30 .

赵艳丽，张安锐，辛勇，等 . 接头性能差异对Zr-Sn-Nb合金电子束焊接头残余应力的影响［J］. 焊接学报， 2024 ， 45 （ 5 ）： 105 - 112 .

ZHAO Y L ， ZHANG A R ， XIN Y ， et al . Effect of joint property differences on residual stresses in Zr-Sn-Nb alloy electron beam welded joints ［J］. Transactions of the China Welding Institution ， 2024 ， 45 （ 5 ）： 105 - 112 .

Ahmed S ， Singh P ， Ekkad S V . Three-Dimensional Transient Heat Conduction Equation Solution for Accurate Determination of Heat Transfer Coefficient ［J］. Journal of Heat Transfer ， 2020 ， 142 （ 5 ）： 051302 .

段成凯，霍世慧，刘永寿 . 典型接头的焊接热过程数值仿真与试验研究［J］. 兵器装备工程学报， 2021 ， 42 （ 6 ）： 38 - 44 .

DUAN C K ， HUO S H ， LIU Y S . Numerical simulation and experimental study on welding thermal process of typical joints ［J］. Journal of Ordnance Equipment Engineering ， 2021 ， 42 （ 6 ）： 38 - 44 .

编辑部网址： http：//www.71dhj.com http://www.71dhj.com