SiCp/6061Al基复合材料超声频脉冲等离子弧原位合金化焊接的研究
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摘要
颗粒增强铝基复合材料以其高的比强度、比刚度、比模量、优异的耐磨性能以及在性能和加工方面较强的可设计性等特点,在航天、航空、汽车工业、光学仪器和体育用品等领域具有重要的应用价值。但是,铝基复合材料的焊接性很差,是其走向工业化必须克服的“瓶颈”。为此,本研究提出了一种超声频脉冲等离子弧原位合金化焊接的新方法,为铝基复合材料的应用探索了一条新思路。
通过将小功率超声频脉冲电源与等离子焊机并联,超声频交流信号经过阻容耦合进入焊接回路,建立了超声频脉冲等离子弧焊接系统,使等离子焊接电弧受外加高频调制,其作为焊接热源的同时成为一种可控的超声发射源。本文以SiCp/6061Al MMCs为研究对象,研究了超声频脉冲等离子弧原位合金化焊接工艺对接头组织与性能的影响,并对焊接冶金机理进行了系统的分析。利用金相显微镜、扫描电镜及X射线衍射分析仪研究了不同焊接工艺下铝基复合材料的焊接接头组织及成分的变化,进行硬度及拉伸试验,探讨了影响等离子弧焊接接头力学性能的因素。
试验结果表明,将超声频激励信号引入SiCp/6061Al基复合材料等离子弧原位合金化工艺过程中,以Ti-60Al为填充材料,Ar+N_2为离子气,Ar为保护气,能有效抑制脆性相Al_4C_3的形成,在焊缝中形成了Al_3Ti、TiC、TiN等新生增强相;在脉冲调制频率30KHz的情况下对等离子焊接电弧施以超声频调制,可以激励出相应频率的超声信号,较之未施加激励信号时,由于超声振动直接作用于焊接熔池,明显细化了焊缝区组织,使得增强颗粒趋向于均匀分布,提高了焊接接头的强度,达到了240MPa。
对不同激励频率作用下焊缝中的增强颗粒分布情况进行观察,发现随着超声频率的提高,颗粒分布越均匀。尤其是在谐振区间内的40KHz、50KHz时,颗粒分布较其他频率段均匀,直接影响了接头强度的提高,在40KHz时焊接接头的强度最大达到了263MPa。
Aluminum metal matrix composites are more and more widely applied in aerospace,spaceflight,auto manufacturing due to their excellent combination properties of high specific strength,high specific stiffness,high elastic modulus, better wear-resistance.But Aluminum metal matrix composites is not applied widely in industry because of its poor welding ability.The welding technique is the key to expand its industry application for Aluminum metal matrix composites.Therefore,we propose a new method named ultrasonic frequency pulse "in-situ" plasma arc welding to make an exploration for the application of SiCp/6061Al MMCs.
Combining low-power ultrasonic frequency pulse power and plasma welding,we set up a ultrasonic frequency pulse arc welding system,so that the plasma arc welding is modulated by high frequency to be a kind of controllable ultrasound emission source at the same time as a welding heat source.The effects of this welding process on microstructures and mechanical properties(Ar and N_2 as ionized gas,Ar as fielded gas) of SiCp/6061Al MMCs and mechanism of its alloying process is investigated in the present work.The changes of microstructure and composition of fusion welded joints of composites was in observation with OM(optics microscopy),SEM(scanning microscopy) and XRD(X-ray diffraction).And mechanical properties of fusion welded joints were measured by microhardness and tensile tests.
The experimental results show that the same frequency arc-ultrasonic could be excited.The formation of Al_4C_3 was effectively prohibited and the new weld reinforced such as Al_3Ti、TiC、TiN was produced.Compared with not modulated,the arc-ultrasonic could significantly reduce the size of the reinforced and also improve its distribution to make the welding joints denser.The hardness of the weld middle zone had become lower and the strength of welding joints had been increased, reaching 240MPa.
Observing the distribution of the reinforce on different exciting frequency,we found the distribution become more uniform.Especially in the resonant interval 40KHz、50KHz,the distribution was better and the strength of welding joints was bigger.And the strength reached 263MPa at 40KHz.
通过将小功率超声频脉冲电源与等离子焊机并联,超声频交流信号经过阻容耦合进入焊接回路,建立了超声频脉冲等离子弧焊接系统,使等离子焊接电弧受外加高频调制,其作为焊接热源的同时成为一种可控的超声发射源。本文以SiCp/6061Al MMCs为研究对象,研究了超声频脉冲等离子弧原位合金化焊接工艺对接头组织与性能的影响,并对焊接冶金机理进行了系统的分析。利用金相显微镜、扫描电镜及X射线衍射分析仪研究了不同焊接工艺下铝基复合材料的焊接接头组织及成分的变化,进行硬度及拉伸试验,探讨了影响等离子弧焊接接头力学性能的因素。
试验结果表明,将超声频激励信号引入SiCp/6061Al基复合材料等离子弧原位合金化工艺过程中,以Ti-60Al为填充材料,Ar+N_2为离子气,Ar为保护气,能有效抑制脆性相Al_4C_3的形成,在焊缝中形成了Al_3Ti、TiC、TiN等新生增强相;在脉冲调制频率30KHz的情况下对等离子焊接电弧施以超声频调制,可以激励出相应频率的超声信号,较之未施加激励信号时,由于超声振动直接作用于焊接熔池,明显细化了焊缝区组织,使得增强颗粒趋向于均匀分布,提高了焊接接头的强度,达到了240MPa。
对不同激励频率作用下焊缝中的增强颗粒分布情况进行观察,发现随着超声频率的提高,颗粒分布越均匀。尤其是在谐振区间内的40KHz、50KHz时,颗粒分布较其他频率段均匀,直接影响了接头强度的提高,在40KHz时焊接接头的强度最大达到了263MPa。
Aluminum metal matrix composites are more and more widely applied in aerospace,spaceflight,auto manufacturing due to their excellent combination properties of high specific strength,high specific stiffness,high elastic modulus, better wear-resistance.But Aluminum metal matrix composites is not applied widely in industry because of its poor welding ability.The welding technique is the key to expand its industry application for Aluminum metal matrix composites.Therefore,we propose a new method named ultrasonic frequency pulse "in-situ" plasma arc welding to make an exploration for the application of SiCp/6061Al MMCs.
Combining low-power ultrasonic frequency pulse power and plasma welding,we set up a ultrasonic frequency pulse arc welding system,so that the plasma arc welding is modulated by high frequency to be a kind of controllable ultrasound emission source at the same time as a welding heat source.The effects of this welding process on microstructures and mechanical properties(Ar and N_2 as ionized gas,Ar as fielded gas) of SiCp/6061Al MMCs and mechanism of its alloying process is investigated in the present work.The changes of microstructure and composition of fusion welded joints of composites was in observation with OM(optics microscopy),SEM(scanning microscopy) and XRD(X-ray diffraction).And mechanical properties of fusion welded joints were measured by microhardness and tensile tests.
The experimental results show that the same frequency arc-ultrasonic could be excited.The formation of Al_4C_3 was effectively prohibited and the new weld reinforced such as Al_3Ti、TiC、TiN was produced.Compared with not modulated,the arc-ultrasonic could significantly reduce the size of the reinforced and also improve its distribution to make the welding joints denser.The hardness of the weld middle zone had become lower and the strength of welding joints had been increased, reaching 240MPa.
Observing the distribution of the reinforce on different exciting frequency,we found the distribution become more uniform.Especially in the resonant interval 40KHz、50KHz,the distribution was better and the strength of welding joints was bigger.And the strength reached 263MPa at 40KHz.
引文
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