铝/钢异种金属搅拌摩擦搭接传热与材料流动行为

耿培皓; 秦国梁; 马宏; 麻宁绪

doi:10.7512/j.issn.1001-2303.2023.03.01

搅拌摩擦焊接 | 浏览量 : 0 下载量: 1250 CSCD: 0

PDF
导出
分享
收藏
专辑

铝/钢异种金属搅拌摩擦搭接传热与材料流动行为
Heat Transfer and Material Flow in Friciton Stir Lap Welding of Al Alloy/ Steel
2023年53卷第3期页码：1-14
收稿：2023-02-10，

纸质出版：2023-03-20
DOI： 10.7512/j.issn.1001-2303.2023.03.01
稿件说明：

移动端阅览

耿培皓，秦国梁，马宏，等.铝/钢异种金属搅拌摩擦搭接传热与材料流动行为［J］.电焊机，2023，53（3）：1-14. DOI： 10.7512/j.issn.1001-2303.2023.03.01.

GENG Peihao, QIN Guoliang, MA Hong, et al.Heat Transfer and Material Flow in Friciton Stir Lap Welding ofAl Alloy/ Steel[J].Electric Welding Machine, 2023, 53(3): 1-14. DOI： 10.7512/j.issn.1001-2303.2023.03.01.

摘要

基于耦合欧拉-拉格朗日有限元法数值模拟了铝合金5052与高强钢DP590搅拌摩擦搭接过程中的温度场演变和材料流动行为。结果表明，有限元预测温度场和焊缝变形轮廓与实验测量结果吻合良好。当移动速度保持300 mm/min恒定不变时，随着转速由500 r/min增至1 000 r/min，搅拌区峰值温度位置由前进侧的轴肩后方的铝合金表面转移至搅拌针底部与钢搅拌区的界面，峰值温度由545 ℃增加至635 ℃；在焊接过程中，前进侧温度始终高于后退侧温度，与转速无关。采用示踪粒子法研究材料迁移轨迹，发现前进侧铝合金从更靠近搅拌针的内侧剪切层绕过搅拌针填埋在搅拌针前进侧后方，而后退侧铝合金主要迁移至搅拌针后退侧后方，迁移轨迹比较发散；搅拌针作用在铝/钢搭接面，驱使前进侧钢材料迁移至搅拌针后退侧后方，并在垂直方向上挤入上侧铝合金焊缝区。随着搅拌针转动，由前进侧迁移至后退侧的钢材料最终促使后退侧形成尺寸较大的钩状结构。相比于铝合金侧，转速的增加更为显著地加强了钢表面的材料流动。

Abstract

The heat transfer and material flow behavior during friction stir lap welding (FSLW) of Al alloy 5052 and high-strength steel DP590 were numerically simulated based on the coupled Euler-Lagrangian finite element method (CEL-FEM). The predicted results of the temperature histories and the deformation profile of the weld matched well with the experimental measurements. The simulation results show that when the welding speed is kept constant at 300 mm/min

as the rotation speed increases from 500 r/min to 1 000 r/min

the peak temperature position of the stirring zone is transferred from the Al alloy surface behind the shoulder on the advancing side (AS) to the bottom of the stirring pin

that is

the interface of the steel stirring zone. Meanwhile

the peak temperature increases from 545 °C to 635 °C during the welding process. Regardless of rotation speed

the temperature on the AS is always higher than that of the retreating side (RS). The material migration was studied by the tracer particle method. The Al alloy materials on the AS are eventually transferred to the rear region of the AS

bypassing the RS via the inner shear region

which is close to the stirring pin and shoulder root. The Al alloy materials on the RS were mainly migrated to the ipsilateral rear

and the migration trajectory is more divergent. The stirring pin acts on the Al/steel overlapping surface

driving the steel materials on the AS to move to the RS rear of the stirring pin and simultaneously extruding the steel materials into the Al weld area in the vertical direction. The steel material that migrates from the AS to the RS as the pin rotates eventually causes the RS to form a larger-sized hook-like structure. Compared with the Al alloy side

the increase in rotating speed more significantly enhances the material flow on the steel surface.

关键词

Keywords

references

Christy J V ， MOURAD A H ， Sherif M M ， et al . Review of recent trends in friction stir welding process of aluminum alloys and aluminum metal matrix composites ［J］. Transactions of Nonferrous Metals Society of China ， 2021 ， 31 （ 11 ）： 3281 - 309 .

Liu F C ， Hovanski Y ， Miles M P ， et al . A review of friction stir welding of steels： Tool， material flow， microstructure，and properties ［J］. Journal of Materials Science & Technology ， 2018 ， 34 （ 1 ）： 39 - 57 .

Meschut G ， Janzen V ， Olfermann T . Innovative and highly productive joining technologies for multi-material lightweight car body structures ［J］. Journal of Materials Engineering and Performance ， 2014 ， 23 （ 5 ）： 1515 - 23 .

Wan L ， Huang Y . Friction stir welding of dissimilar aluminum alloys and steels： a review ［J］. The International Journal of Advanced Manufacturing Technology ， 2018 ， 99 （ 5 ）： 1781 - 811 .

Simar A ， Avettand-Fènoël MN . State of the art about dissimilar metal friction stir welding ［J］. Science and Technology of Welding and Joining ， 2017 ， 22 （ 5 ）： 389 - 403 .

Hussein S A ， Hadzley A B . Characteristics of aluminum-to-steel joint made by friction stir welding： A review ［J］. Materials Today Communications ， 2015 ， 5 ： 32 - 49 .

黄永宪，黄体方，万龙，等 . 铝/钢异种材料搅拌摩擦焊研究进展［J］. 精密成形工程， 2018 ， 10 （ 1 ）： 23 - 30 .

HUANG Y X ， HUANG T F ， WAN L ， et al . Research Progress of Dissimilar Friction Stir Welding between Aluminium and Steel ［J］. Journal of Netshape Forming Engineering ， 2018 ， 10 （ 1 ）： 23 - 30 .

黄幸，周林，姜进京 . 搅拌摩擦焊工艺参数对超薄铝合金板/高强钢搭接焊接头组织及性能的影响［J］. 有色金属材料与工程， 2019 ， 40 （ 1 ）： 13 - 19 .

HUANG X ， ZHOU L ， JIANG J J ， et al . Effect of Friction Stir Welding Parameters on Microstructure and Mechanical Properties of Ultra-thin Aluminium Alloy Plate/high Strength Steel Lap Joints ［J］. Nonferrous Metal Materials And Engineering ， 2019 ， 40 （ 1 ）： 13 - 19 .

杜岩峰，白景彬，田志杰，等 . 2219铝合金搅拌摩擦焊温度场的三维实体耦合数值模拟［J］. 焊接学报， 2014 ， 35 （ 8 ）： 57 - 60，70 .

DU Y F ， BAI J B ， TIAN Z J ， et al . Investigation on three-dimensional real coupling numerical simulation of temperature field of friction stir welding of 2219 aluminum alloy ［J］. Transactions of The China Welding Institution ， 2014 ， 35 （ 8 ）： 57 - 60，70 .

Gao E Z ， Zhang X X ， Liu C Z . Numerical simulations on material flow behaviors in whole process of friction stir welding ［J］. Transactions of Nonferrous Metals Society of China ， 2018 ， 28 （ 11 ）： 2324 - 34 .

武传松，宿浩，石磊 . 搅拌摩擦焊接产热传热过程与材料流动的数值模拟［J］. 金属学报， 2018 ， 54 （ 2 ）： 265 - 277 .

WU C S ， SU H ， SHI L . Numerical Simulation of Heat Generation， Heat Transfer and Material Flow in Friction Stir Welding ［J］. Acta Metall Sin ， 2018 ， 54 （ 2 ）： 265 - 277 .

Meyghani B ， WU C S . Progress in Thermomechanical Analysis of Friction Stir Welding ［J］. Chin. J. Mech. Eng. ， 2020 （ 12 ）： 1 - 33 .

Das D ， Bag S ， Pal S . A finite element model for surface and volumetric defects in the FSW process using a coupled Eulerian–Lagrangian approach ［J］. Science and Technology of Welding and Joining ， 2021 ， 26 （ 5 ）： 412 - 9 .

Geng P ， Ma Y ， Ma N ， et al . Effects of rotation tool-induced heat and material flow behaviour on friction stir lapped Al/steel joint formation and resultant microstructure ［J］. International Journal of Machine Tools and Manufacture ， 2022 ， 174 ： 103858 .

Benson D J . A mixture theory for contact in multi-material Eulerian formulations ［J］. Comput. Methods Appl. Mech. Eng. ， 1997 ， 140 （ 1-2 ）： 59 - 86 .

Zhang X X ， Xiao B L ， Ma Z Y . A transient thermal model for friction stir weld. Part I： the model ［J］. Metall. Mater. Trans. ， 2011 ， 42 （ 10 ）： 3218 - 3228 .

Jalili N ， Tabrizi H B ， Hosseini M M . Experimental and numerical study of simultaneous cooling with CO 2 gas during friction stir welding of Al-5052 ［J］. Mater. Process. Technol. ， 2016 ， 237 ： 243 - 253 .

Zhang G ， Li Y ， Lin Z . Evolution mechanism of geometry morphology for metallic bump assisted resistance spot welded （MBaRSW） joints ［J］. Manuf. Process ， 2020 ， 59 ： 432 - 443 .

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