5083铝合金搅拌摩擦搭接接头强化策略

沈宇佳; 王继杰; 王贝贝; 薛鹏; 刘峰超; 倪丁瑞; 肖伯律; 马宗义

doi:10.1007/s12613-024-2847-2

Volume 31 Issue 11

Nov. 2024

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文章导航 > 矿物冶金与材料学报（英文） > 2024 > 31(11): 2498-2507

Yujia Shen, Jijie Wang, Beibei Wang, Peng Xue, Fengchao Liu, Dingrui Ni, Bolv Xiao, and Zongyi Ma, Strengthening strategy for high-performance friction stir lap welded joints based on 5083 Al alloy, Int. J. Miner. Metall. Mater., 31(2024), No. 11, pp. 2498-2507. https://doi.org/10.1007/s12613-024-2847-2

Cite this article as:

Yujia Shen, Jijie Wang, Beibei Wang, Peng Xue, Fengchao Liu, Dingrui Ni, Bolv Xiao, and Zongyi Ma, Strengthening strategy for high-performance friction stir lap welded joints based on 5083 Al alloy, Int. J. Miner. Metall. Mater., 31(2024), No. 11, pp. 2498-2507. https://doi.org/10.1007/s12613-024-2847-2

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研究论文

5083铝合金搅拌摩擦搭接接头强化策略

1)
沈阳航空航天大学材料科学与工程学院, 沈阳 110136, 中国
2)
中国科学院金属研究所师昌绪先进材料创新中心, 沈阳 110016, 中国
3)
中国科学院金属研究所核材料与安全评价重点实验室, 沈阳 110016, 中国
4)
滨州魏桥国科高等技术研究院, 滨州 256606, 中国
5)
东莞材料基因高等理工研究院, 东莞 523808, 中国

通讯作者:
王贝贝 E-mail: bbwang@imr.ac.cn

薛鹏 E-mail: pxue@imr.ac.cn

文章亮点

(1) 开发一种水下两道次搅拌摩擦搭接焊工艺，消除搭接Hook缺陷，细化搭接区组织

(2) 该工艺显著增加搭接面积，接头力学性能与7xxx铝合金搭接接头相当

(3) 本研究提出一种预测搭接接头断裂模式的断裂判据

中文摘要

在飞机、船舶和汽车制造过程中，铝合金蒙皮、壁板和加强筋之间经常采用搭接形式连接。这种铝合金搭接结构在熔焊过程中，易出现孔隙缺陷和元素烧损，导致接头强度系数下降。搅拌摩擦焊作为一种固相焊接方法，因其高质量、高效率以及节能环保等特点受到广泛关注，并已成功应用于汽车、轨道交通、航空航天等领域。然而，在搅拌摩擦搭接焊（FSLW）过程中，搭接特有的冷焊和钩状（Hook）缺陷会严重影响接头的力学性能。本研究重点探讨了转速、两道次焊接以及冷却方式对搭接缺陷形成、微观组织演变及力学性能的影响。研究发现通过降低焊接转速、采用小尺寸焊接工具并结合强制水冷技术进行两道次FSLW，可以有效消除搭接缺陷，显著增加有效搭接厚度和宽度。该工艺成功将Hook附近组织细化至超细晶尺度，使接头薄弱区组织得到强化，拉伸剪切力从298 N/mm提高到551 N/mm，其强度可媲美7xxx系列铝合金的搭接焊接头性能。此外，本文系统研究了FSLW接头的断裂行为，并提出了一种预测搭接接头断裂模式的断裂判据。本研究为消除搭接缺陷并提高接头性能提供了一种有效并值得借鉴的焊接方法。

关键词:

Research Article

Strengthening strategy for high-performance friction stir lap welded joints based on 5083 Al alloy

+ Author Affiliations

1)
College of Material Science and Engineering, Shenyang Aerospace University, Shenyang 110136, China
2)
Shi-changxu Innovation Center for Advanced Materials, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China
3)
CAS Key Laboratory of Nuclear Materials and Safety Assessment, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China
4)
Binzhou Institute of Technology, Shandong Key Laboratory of Advanced Aluminium Materials and Technology, Weiqiao-UCAS Science and Technology Park, Binzhou 256606, China
5)
Centre of Excellence for Advanced Materials, Dongguan 523808, China

The authors declare no conflict of interest.

Corresponding authors:
Beibei Wang E-mail: bbwang@imr.ac.cn

Peng Xue E-mail: pxue@imr.ac.cn
Received: 10 November 2023; Revised: 12 January 2024; Accepted: 4 February 2024; Available online: 6 February 2024

Abstract

Abstract

During aircraft, ship, and automobile manufacturing, lap structures are frequently produced among Al alloy skins, wall panels, and stiffeners. The occurrence of welding defects severely decreases mechanical properties during friction stir lap welding (FSLW). This study focuses on investigating the effects of rotation rate, multipass welding, and cooling methods on lap defect formation, microstructural evolution, and mechanical properties. Hook defects were eliminated by decreasing welding speed, applying two-pass FLSW with a small welding tool, and introducing additional water cooling, thus leading to a remarkable increase in effective sheet thickness and lap width. This above strategy yielded defect-free joints with an ultrafine-grained microstructure and increased tensile shear force from 298 to 551 N/mm. The fracture behavior of FSLW joints was systematically studied, and a fracture factor of lap joints was proposed to predict their fracture mode. By reducing the rotation rate, using two-pass welding, and employing additional water cooling strategies, an enlarged, strengthened, and defect-free lap zone with refined ultrafine grains was achieved with a quality comparable to that of lap welds based on 7xxx Al alloys. Importantly, this study provides a valuable FSLW method for eliminating hook defects and improving joint performance.
- friction stir lap welding;
- defect control;
- microstructure;
- fracture mechanisms;
- mechanical properties

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