超声自冲铆复合连接成形性及力学行为研究

该文选用6061和2A12航空铝合金薄板材料,进行自冲铆接和超声自冲铆复合连接试验,基于拉伸-剪切和电子显微镜测试,研究超声自冲铆接成形性及力学行为。结果表明：超声自冲铆接头较自冲铆接头的内锁量提升了44.8%;其钉头高度下降了34.4%;超声自冲铆接头的静载强度提升了18.1%,缓冲吸震性能提升了17.5%;超声焊接致使自冲铆接头的铆钉颈部与上板接触区域、铆钉腿部与上板接触区域形成固相焊;超声焊接可有效提高自冲铆接头的稳定性。     

石墨/铝合金复合导热板强化石蜡相变蓄热研究

本文对“三明治”结构的石墨/铝合金复合导热板强化石蜡的相变蓄热特性进行了数值研究,探究泡沫金属、平板翅片以及复合导热板三种传热结构对石蜡相变蓄热过程的影响。然后本文在石墨/铝合金复合导热板的结构基础上添加了二级翅片来强化传热。研究表明：石墨/铝合金复合导热板强化石蜡相变蓄热的性能明显优于其他传热结构,呈现出自导热板向垂直于板两侧方向递减的温度分布,使得腔体内融化最为均匀,芯片温升最小。添加二级肋片后热源温升减小了15.87%,有效工作时间延长64.68%。     

5083铝合金光纤激光-TIG复合焊接工艺研究

采用IPG YLS-6000光纤激光器和Fronius MagicWave3000job数字化焊机,对4mm厚5083H116铝合金进行了复合焊接试验。研究了电源特性、电流大小和热源间距等工艺参数对光纤激光-钨极惰性气体保护焊(TIG)复合焊接焊缝成形的影响规律,并分析了焊接接头的缺陷、显微硬度及力学性能。结果表明,光纤激光-TIG复合焊接5083铝合金,能够明显改善焊缝成形,提高焊接过程稳定性,特别是与变极性TIG电弧复合效果更为显著;光纤激光与变极性TIG电弧复合焊接,采用激光在前的方式,电弧电流150A,且热源间距不大于4mm,可以得到具有明亮金属光泽和均匀鱼鳞纹的焊缝,焊缝无气孔和裂纹缺陷,其表面有少量的下凹;复合焊接接头抗拉强度为318MPa,达到母材强度的93%,延伸率为7.6%,高于单光纤激光焊接,断口分析为韧性断裂。     

激光辐照超音速气流下TA15钛合金和LY12铝合金的热响应

利用超音速气流环境模拟装置,开展了自然对流和马赫数为3切向气流下,1064nm连续激光辐照TA15钛合金和LY12铝合金热响应实验研究,得到了材料在两种条件下的温升曲线及熔穿时间。结果表明:在激光辐照材料未使得其表面发生熔化前,气流对材料激光辐照过程中的冷却效应较为明显,在表面发生熔化时,熔化的液态物质在气流切向力剥蚀作用下被吹离材料表面,使得激光继续作用在材料上,熔化→剥离→熔化→剥离如此反复,可加速熔穿过程;此外,切向气流将影响钛合金这类热扩散系数较低材料的温度场分布,使得气流下游处的温度高于上游,而对铝合金这类热扩散系数较高的材料而言,影响不明显。     

第二代高温超导带材焊接及力学性能研究

第二代高温超导已进入产业化初期, 尽管单根带材长度已达千米量级, 但由于千米级单根带材生产成品率偏低以及大型超导装置对带材长度实际需求远超出单根长度制备能力, 因此, 焊接技术成为高温超导大规模应用的关键技术之一. 接头电阻及其力学性能是评估焊接接头的重要技术指标. 本文提出了改进型接头和“隐形”接头两种制作方法, 并对其接头电阻以及力学性能进行了表征, 同时与常规搭接接头进行了对比分析. 结果发现,(1) 与常规搭接头相比, 改进型和“隐形”接头的厚度分别降低了15 % 和36 % , 有效减小了焊接头处和原带材厚度差异. (2) 超导面-超导面焊接, 获得接头电阻最小; 接头电阻随接头长度的增加而减小, 但幅度降低. (3) 常规搭接头、 改进型和“隐形”焊接头均具有良好的轴向抗拉性能, 通过扭转和8 天液氮浸泡后, 临界电流无衰退, 电阻保持一致. (4) 改进型和“隐形”接头的临界弯曲直径(20 mm) 与原带材(非接头处) 相当, 通过卷对卷传输法测试时接头无损伤, 而常规搭接头的临界弯曲直径(40 mm) 大于原带材, 在通过卷对卷测试时, 接头出现开裂甚至断开现象.根据具体应用场景, 选择合适接头制作方式, 对推动第二代高温超导产业化具有重要意义.     

陶瓷球金属复合结构的抗弹性能和梯度设计

陶瓷是具有轻质高强特性的常用抗弹材料,但其本身的脆性特点使得陶瓷利用率较低,局部的击穿往往导致整块陶瓷破碎。为了提高陶瓷的利用率,提出了一种分层梯度陶瓷球金属复合结构,并通过数值模拟研究了陶瓷球尺寸及着弹点的影响。从子弹和靶板的变形、弹速变化和塑性波传播等角度分析了陶瓷球金属复合结构的抗弹机理,并对结构进行了梯度优化设计。研究结果表明,直径为7.2 mm的陶瓷球结构的综合抗弹性能良好,在此基础上设计的梯度陶瓷球结构能进一步提升抗弹性。陶瓷球金属复合靶板呈局部破坏,靶板其他位置仍具有抗打击能力。     

Ag箔钎焊YBCO高温超导块材

采用Ag箔在两种不同的工艺条件下对YBCO高温超导块材进行了钎焊连接,钎焊完成后,分别对原始超导块材和钎焊接头进行磁悬浮力测量和俘获磁场测试、以评价钎焊质量.磁悬浮力的测试结果表明,在两种工艺条件下,钎焊接头的磁悬浮力分别可达原始块材的69.88%和79.37%.俘获场测试结果表明,单畴原始母材的俘获场为单峰,钎焊接头的俘获场为双峰;同时,钎缝区域的俘获磁场强度较低,没有完全恢复接头母材的超导环流,而限制了钎焊接头超导性能的提高.     

磁控溅射(Ti,N)/Al纳米复合薄膜的微结构和力学性能

采用Al和TiN靶通过磁控共溅射方法, 制备了一系列Ti:N≈1的不同(Ti, N) 含量的铝基纳米复合薄膜, 利用X射线能量分散谱仪、X射线衍射仪、透射电子显微镜和纳米力学探针表征了薄膜的成分、 微结构和力学性能, 研究了(Ti, N)含量对复合薄膜微结构和力学性能的影响. 结果表明: Ti, N原子的共同加入使复合薄膜形成了同时具有置换固溶和间隙固溶特征的"双超过饱和固溶体", 薄膜的晶粒随着溶质含量的增加逐步纳米化, 并进一步形成非晶结构, 晶界区域形成溶质原子的富集区. 相应地, 复合薄膜的硬度在含1.8 at.%(Ti, N) 时就可迅速提高到3.9 GPa; 随着TiN含量的增加, 薄膜的硬度进一步提高到含17.1 at.%(Ti, N)时的8.8 GPa. 以上结果显示出Ti和N"双超过饱和固溶"对Al薄膜极其显著的强化效果.     

溅射Al对AlN的“润湿”与钎焊

由于润湿性不佳, 难以实现金属钎料对陶瓷的无过渡层直接钎焊, 本文在研究了溅射Al薄膜对AlN的“润湿”作用的基础上, 通过磁控溅射的方法在AlN表面沉积Al基薄膜作为钎料, 在真空条件下对AlN陶瓷进行了直接钎焊. 采用高景深光学显微镜、扫描电子显微镜和X射线能量分散谱表征了钎焊接头和剪切断口的组织及形貌. 结果表明, 高能量溅射Al粒子对AlN的撞击可以形成只有850 ℃以上高温才可获得的Al-N化学键, 实现Al对AlN的“润湿”, 使Al基薄膜钎料能够在较低的温度(≥ 510 ℃)对AlN直接钎焊. 此方法获得的Al/AlN接头的剪切强度达到104 MPa, 含3.8 at.% Cu的Al合金钎料接头强度可进一步提高到165 MPa, 它们的剪切断裂都产生于钎缝金属之中; 增加钎料中的Cu含量至9.1 at.%后, Cu在钎缝与陶瓷界面的偏聚使接头的剪切强度降低为95 MPa. Al-20 at.% Ge合金可以将钎焊温度降低至510 ℃, 但Ge在钎缝与陶瓷界面的偏聚使接头在48 MPa发生断裂.     

简论金属材料JC本构模型的精确性

通过比较JC模型预测结果与6种金属(2024-T351铝合金、 6061-T6铝合金、OFHC无氧铜、4340高强钢、Ti-6Al-4V钛合金和Q235软钢)在不同应变率及温度下的实验数据,对JC本构模型的精确性进行了关键评估。为了进一步评估其精确性,采用JC本构模型和失效准则对平头弹正撞2024-T351铝合金靶板进行数值模拟,并与实验结果比较。结果表明:JC本构模型只适用于中、低应变率和温度下的Mises材料,对非Mises材料该模型预测的剪切应力-应变曲线和失效与实验结果吻合较差;同时,JC本构模型的精度随应变率和温度的提高而降低,特别是在高应变率条件下利用实验得到的动态增强因子进行相应数值模拟时,所得计算结果与弹道穿透实验结果不一致,说明其表达式(即准静态应力-应变关系×动态增强因子)是不恰当的。     

Structure and Properties of Titanium Aluminum Alloy Produced by Friction Stir Welding

Russian Physics Journal - The paper deals with the fabrication of lap joints of titanium ОТ4-1 alloy and aluminum AlMg5 alloy sheets by means of friction stir welding (FSW). The X-ray...     

Effect of welding wires on microstructure and mechanical properties of 2A12 aluminum alloy in CO2 laser-MIG hybrid welding

This paper represented the effect of welding wires on microstructure and mechanical properties of 2A12 aluminum alloy in CO₂ laser-metal inter gas (MIG) hybrid welding. Plates of 2A12 aluminum alloy were welded by ER4043 and ER2319 welding wires, respectively. Full penetration joints without any defects were produced. The X-ray diffraction was used to analyze the phase composition, while the scanning electron microscopy (SEM) was conducted to study the microstructure, segregation behaviors of major alloying elements and the eutectics formed at dendrite boundaries in the joints. The results showed that silicon and copper were concentrated at the dendrite boundaries and α-Al + Si + Al₂Cu + Mg₂Si eutectic was formed if the ER4043 welding wire was used. However, only copper was concentrated at the dendrite boundaries and α-Al + θ eutectic was formed by ER2319 welding wire. Finally, the tensile tests were performed and the fracture surfaces were analyzed. The results showed that the joint efficiency by ER2319 and ER4043 welding wires reached up to 78% and 69%, respectively. Coarse dimples and voids had been observed in the fractographs. The joints showed a transgranular type failure.     

Characteristics of large capacity ultrasonic complex vibration sources with stepped complex transverse vibration rods

Configurations of large capacity ultrasonic complex vibration sources with multiple longitudinal transducers are proposed and studied. The ultrasonic complex vibration systems are effective and essential for new applications in various industries. The complex vibration source of 27 kHz consists of a complex transverse rod with a welding tip (aluminum alloy, stainless steel and titanium alloy), a complex vibration rod with a flange and stepped part for holding the system, a circular longitudinal vibration disk (aluminum alloy) and six bolt-clamped Langevin type PLT transducers. Three transducer pairs are driven simultaneously using three driving systems at phase difference 120 degrees, and almost circular vibration locus is obtained.     

电动汽车高压线束电磁脉冲压接装置的研制及实验

采用铝合金高压线束替代铜合金高压线束可帮助电动汽车减少重量、提高续航和降低成本。针对铝与铜由于金属性质差异难以可靠连接的问题,本文提出采用电磁脉冲压接技术连接铝合金高压线束与铜合金接线端子,并研制了一套适用于两者连接的电磁脉冲压接装置,其最大放电能量为28 kJ。压接过程中,随着放电电压的升高,接线端子表面的温度升高。当放电电压为12 kV时,实现了铝合金高压线束与铜合金接线端子的可靠连接。采用光学显微镜分析连接界面的微观结构,并测试其电气性能和机械性能。分析结果表明:电磁脉冲压接技术可实现铝合金高压线束与接线端子、铝合金芯线之间的冶金结合,且连接界面出现了波纹形貌与涡旋形貌。测试结果显示:接头接触电阻测试、振动测试、拉力负荷测试均满足汽车行业标准和电缆接头国家标准。     

Effect of welding speed on butt joint quality of Ti–6Al–4V alloy welded using a high-power Nd:YAG laser

Annealed Ti–6Al–4V alloy sheets with 1 and 2 mm thickness are welded using a 4 kW Nd:YAG laser system. The effects of welding speed on surface morphology and shape, welding defects, microstructure, hardness and tensile properties are investigated. Weld joints without or with minor cracks, porosity and shape defects were obtained indicating that high-power Nd:YAG laser welding is a suitable method for Ti–6Al–4V alloy. The fusion zone consists mainly of acicular α′ martensite leading to an increase of approximately 20% in hardness compared with that in the base metal. The heat-affected zone consists of a mixture of α′ martensite and primary α phases. Significant gradients of microstructures and hardness are obtained over the narrow heat-affected zone. The laser welded joints have similar or slightly higher joint strength but there is a significant decrease in ductility. The loss of ductility is related to the presence of micropores and aluminum oxide inclusions.     

Grain fragmentation in ultrasonic-assisted TIG weld of pure aluminum

Under the action of acoustic waves during an ultrasonic-assisted tungsten inert gas (TIG) welding process, a grain of a TIG weld of aluminum alloy is refined by nucleation and grain fragmentation. Herein, effects of ultrasound on grain fragmentation in the TIG weld of aluminum alloy are investigated via systematic welding experiments of pure aluminum. First, experiments involving continuous and fixed-position welding are performed, which demonstrate that ultrasound can break the grain of the TIG weld of pure aluminum. The microstructural characteristics of an ultrasonic-assisted TIG weld fabricated by fixed-position welding are analyzed. The microstructure is found to transform from plane crystal, columnar crystal, and uniform equiaxed crystal into plane crystal, deformed columnar crystal, and nonuniform equiaxed crystal after application of ultrasound. Second, factors influencing ultrasonic grain fragmentation are investigated. The ultrasonic amplitude and welding current are found to have a considerable effect on grain fragmentation. The degree of fragmentation first increases and then decreases with an increase in ultrasonic amplitude, and it increases with an increase in welding current. Measurement results of the vibration of the weld pool show that the degree of grain fragmentation is related to the intensity of acoustic nonlinearity in the weld pool. The greater the intensity of acoustic nonlinearity, the greater is the degree of grain fragmentation. Finally, the mechanism of ultrasonic grain fragmentation in the TIG weld of pure aluminum is discussed. A finite element simulation is used to simulate the acoustic pressure and flow in the weld pool. The acoustic pressure in the weld pool exceeds the cavitation threshold, and cavitation bubbles are generated. The flow velocity in the weld pool does not change noticeably after application of ultrasound. It is concluded that the high-pressure conditions induced during the occurrence of cavitation, lead to grain fragmentation in a pure aluminum TIG weld during an ultrasonic-assisted TIG welding process.     

316L/RAFM钢电子束焊对接接头的微观组织与力学性能研究

在150kV/39mA的焊接参数下进行了316L/RAFM钢电子束焊工艺实验,对接头微观组织与力学性能进行了测试分析。在存在磁偏转的情况下,有效焊接深度达到了18mm,且焊接接头性能良好。     

Ultrasonic butt welding of aluminum,aluminum alloy and stainless steel plate specimens

Welding characteristics of aluminum, aluminum alloy and stainless steel plate specimens of 6.0 mm thickness by a 15 kHz ultrasonic butt welding system were studied. There are no detailed welding condition data of these specimens although the joining of these materials are required due to anticorrosive and high strength characteristics for not only large specimens but small electronic parts especially. These specimens of 6.0 mm thickness were welded end to end using a 15 kHz ultrasonic butt welding equipment with a vibration source using eight bolt-clamped Langevin type PZT transducers and a 50 kW static induction thyristor power amplifier. The stainless steel plate specimens electrolytically polished were joined with welding strength almost equal to the material strength under rather large vibration amplitude of 25 microm (peak-to-zero value), static pressure 70 MPa and welding time of 1.0-3.0 s. The hardness of stainless steel specimen adjacent to a welding surface increased about 20% by ultrasonic vibration.