CN103934566A - 一种提高搅拌摩擦焊接高强铝合金的搅拌头耐磨性的方法 - Google Patents
一种提高搅拌摩擦焊接高强铝合金的搅拌头耐磨性的方法 Download PDFInfo
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Abstract
本发明涉及一种提高搅拌摩擦焊接高强铝合金的搅拌头耐磨性的方法,其目的是解决现有技术存在的搅拌摩擦焊接高强铝合金的搅拌头耐磨性差等问题。所提出的一种提高搅拌摩擦焊接高强铝合金的搅拌头耐磨性的方法,是通过激光熔覆技术在搅拌头轴肩和搅拌针表面均匀熔敷一层由激光熔敷合金和WC颗粒混合组成的条纹状激光熔覆耐磨涂层。激光熔覆耐磨涂层,其WC颗粒与激光熔敷合金的重量百分比为WC颗粒占总重量的10-20%,激光熔敷合金成分按重量百分比计算Wt%:Cr:5-15;Co:5-10;Si:2-5;W:3-6;Pd:1-4;Ni:余量,利用高能密度的激光束加热在轴肩和搅拌针表面形成条纹状耐磨涂层,条纹状耐磨涂层宽度为2-3mm,高度为0.05-0.2mm;轴肩和搅拌针表面条纹数为3-8条。
Description
技术领域
本发明涉及一种提高搅拌摩擦焊接高强铝合金的搅拌头耐磨性的方法,属于焊接与连接技术领域。
背景技术
铝合金具有密度低、强度高、导热性好、耐腐蚀,易于成形和回收等优点,其在汽车上的用量呈持续增长的趋势,正在由铸造零部件缸体、缸盖、活塞、变速器壳体、轮毂等朝着车身零部件及结构件的方向发展,成为仅次于钢铁的第二大汽车用材料。铝合金在汽车中的应用不断增加是汽车工业发展的趋势,也是社会发展的需求。目前,适合汽车结构件用的铝合金主要是热处理强化高强铝合金,有Al-Mg(5000系列)、Al-Mg-Si(6000系列)及Al-Mg-Zn(7000系列)三大系列,制造强度要求较高的车身零部件和结构件如梁、柱、安全钩、前端翼子板、发动机支架等。由于热处理强化高强铝合金的物理化学性能特殊,对温度和成分变化非常敏感,焊接时有一定困难,要求焊接技术更高,是所有金属中比较难焊接的材料,很大程度上制约了其在汽车结构件中的广泛应用。近年来,随着焊接技术和铝合金焊接新工艺的发展,为铝合金在汽车中的应用提供了坚实的技术支撑,也为我国汽车结构件铝合金化程度的进一步提高提供了宝贵的经验。汽车铝合金零部件及结构件采用较多焊接技术有点焊、MIG、TIG、激光焊、激光-电弧复合焊、钎焊及搅拌摩擦焊等。
点焊、MIG、TIG、激光焊和激光-电弧复合焊实质上都属于熔化焊范畴,热处理强化铝合金在焊接过程中接头区域由于受到热作用局部熔化导致强化相析出,接头区软化,焊缝区组织将发生变化,接头力学性能和耐腐蚀性低于母材。热处理强化铝合金含有较多低熔点元素,熔化温度低,硬钎焊时,钎料的熔化温度与铝合金的熔化温度相近,铝合金易过烧,钎焊质量难以控制。
搅拌摩擦焊接是通过搅拌头高速旋转与工件间的搅拌摩擦,摩擦产生热使该部位金属处于热塑性状态,并在搅拌头的压力作用下从其前端向后部塑性流动,从而使焊件焊接在一起。搅拌摩擦焊是一种在机械力和摩擦热作用下的固相连接技术,焊接后结构的残余应力和变形较小,可避免熔化焊接带来的诸多焊接性问题,适于有色金属材料的焊接。搅拌摩擦焊在铝合金的焊接方面研究应用较多,已经成功地进行了搅拌摩擦焊接的铝合金包括2000列(Al-Cu)、5000系列(Al-Mg)、6000系列(Al-Mg-Si)、7000系列(Al-Mg-Zn)和8000系列(Al-Li)等。目前,搅拌摩擦焊焊接铝合金存在的核心问题是搅拌头适应性差且磨损快,尤其是热处理强化的铝合金,其强度和硬度高,在焊接过程中搅拌头磨损更快。搅拌头磨损将使机械力和摩擦热发生变化,最终影响接头的结合和力学性能。搅拌摩擦焊接对设备的要求并不高,最基本的要求是通过搅拌头的旋转运动和工件的相对运动产生机械摩擦热,因此,搅拌摩擦焊接热处理强化的铝合金的核心部件就是搅拌头。
搅拌头由夹持部分、轴肩和搅拌针组成,受损部位主要是轴肩和搅拌针。搅拌头轴肩和工件表面相互摩擦产生摩擦热,并防止搅拌头在高速旋转时塑性变形的金属材料从焊缝区喷射出来,同时起到清除表面氧化膜的作用。随着搅拌头的移动,高温塑性变形的金属材料流向搅拌头的背后,搅拌头后方的金属材料冷却后形成固态焊缝。搅拌头的搅拌针在摩擦焊过程中不仅提供热输入,而且起到机械搅拌作用。搅拌头作为搅拌摩擦焊接铝合金生产中的易耗品,不仅消耗量大,而且其质量的好坏直接影响焊接质量、生产率和成本。搅拌头的材料和结构设计是搅拌摩擦焊接工艺中最重要技术之一,对焊缝成形质量和金属流动性有重要的影响。搅拌头材料应具有热强性、耐磨性、抗蠕变性、耐冲击性、易加工性、材料惰性、热稳定性、摩擦效果优良等特性。合适材料的搅拌头能够增加摩擦,提高热量的输入,有利于焊缝金属材料高温塑性变形和提高焊接质量。
近几年,搅拌头的材料和结构设计一直受到焊接工作者和搅拌摩擦焊接工艺使用者的关注,并在相关学术期刊发表多篇论文,见〔1〕Journal of Materials Processing technology,2006,178(1-3):342-349;〔2〕Materials Transactions,2005,46(10):2211-2217;〔3〕Proceedings of the Japan Welding Society,2005,23(2):186-193等学术期刊。相关发明专利也很多,如中国专利201310410290.2,201180065081.8,201310316992.4等。查阅已有文献可见,可用作搅拌摩擦焊接的搅拌头材料很多,均为耐磨性较好且具有一定高温热稳定性能的金属材料,如热处理的工具钢、模具钢、镍基合金、WC-Co合金钢、纯钨、钼合金、Co-Al-W合金以及采用两种金属材料组合的搅拌头:轴肩采用模具钢,搅拌针材料为WC-Co合金钢等。
采用单一金属材料制造的搅拌头很难同时满足对高温热稳定性和耐磨性的要求,并且金属材料的耐磨性是非常有限的,搅拌头轴肩和搅拌针的磨损必将使机械力和摩擦热发生变化,影响后续焊接接头的可靠性和稳定性。而双材料组合的搅拌头轴肩和夹持部位与搅拌针材料的成分、组织和性能差别较大,连接界面发生突变,导致接头抗冲击性差;同时,双材料组合的搅拌头仅考虑提高搅拌针的耐磨性,并未兼顾轴肩的作用和耐磨性,轴肩的耐磨性低于搅拌针的耐磨性,二者耐磨性不匹配,轴肩先于搅拌针磨损,结果是因轴肩的磨损使搅拌头提前失效。可见,急需找到一种有效方法来提高搅拌摩擦焊接搅拌头的高温热稳定性和耐磨性。
发明内容
本发明的目的是提供一种提高搅拌摩擦焊接高强铝合金的搅拌头耐磨性的方法,通过激光熔覆技术在搅拌头轴肩和搅拌针表面均匀熔敷一层条纹状耐磨涂层,同时提高搅拌头轴肩和搅拌针的耐磨性,并且通过增加轴肩和搅拌针表面的比表面积和摩擦系数,提高热量输入,从而便于焊缝金属材料高温塑性变形,提高焊接速度与质量。
本发明的上述目的可以通过以下技术方案实现,结合附图说明如下:
1、一种提高搅拌摩擦焊接高强铝合金的搅拌头耐磨性的方法,通过激光熔覆技术在搅拌头轴肩2和搅拌针3表面均匀熔敷一层由激光熔敷合金和WC颗粒混合组成的条纹状激光熔覆耐磨涂层,其激光熔敷合金成分为,以镍Ni为基础合金成分,添加铬Cr、钴Co、硅Si、钨W、钯Pd,按重量百分比计算Wt%:Cr:5-15;Co:5-10;Si:2-5;W:3-6;Pd:1-4;Ni:余量。
2、所述的激光熔覆耐磨涂层,其WC颗粒与激光熔敷合金的重量百分比为WC颗粒占总重量的10-20%。
3、所述的激光熔覆耐磨涂层,其条纹状耐磨涂层宽度为2-3mm,高度为0.05-0.2mm;轴肩和搅拌针表面条纹数为3-8条。
4、所述的一种提高搅拌摩擦焊接高强铝合金的搅拌头耐磨性的方法,包括以下工艺步骤:
第一步,采用热处理的合金工具钢通过锻造和机械加工工艺加工制造搅拌头;
第二步,采用颗粒大小为30-50μm,纯度为99.99%的Ni、Cr、Co、Si、W、Pd金属按设计成分配比组合均匀混合制备成熔敷合金,WC颗粒选择在30-50μm范围内,将制备好的熔敷合金与WC颗粒混合均匀;
第三步,将混合均匀的熔敷合金与WC颗粒通过粘结剂均匀涂敷搅拌头轴肩2和搅拌针3表面,利用高能密度的激光束加热在轴肩2和搅拌针3表面形成条纹状耐磨涂层。
与现有技术相比本发明的有益效果是:
通过在搅拌头轴肩2和搅拌针3表面均匀熔敷一层条纹状耐磨涂层,提高搅拌头轴肩2和搅拌针3的耐磨性,同时增加轴肩2和搅拌针3表面的比表面积和摩擦系数,提高热量的输入,有利于焊缝金属材料高温塑性变形和提高焊接速度与质量。
附图说明
图1是本发明的搅拌头轴肩和搅拌针表面条纹状激光熔敷涂层结构示意图;
图2是搅拌头轴肩表面激光熔敷条纹状耐磨层。
图中:1.夹持部位;2.轴肩;3.搅拌针。
具体实施方式
下面结合附图进一步说明本发明的详细内容及其具体实施方式:
一、本发明所采用的激光熔覆方法是在基体表面添加熔覆合金材料,并利用高能密度的激光束使添加的熔覆合金材料和基体表面层同时熔化,并快速凝固后形成与基体成冶金结合的表面耐磨涂层。通过调整熔覆合金成分、粒度及增强相含量等,可获得具有一定耐磨性能的耐磨涂层。激光熔覆合金成分的确定非常重要。热处理的合金工具钢含碳量较高,并含有Cr、Si、Mn、W、Ni、Mo、V等合金元素,用以提高钢的淬透性、耐回火性、热硬性和耐磨性。激光熔敷处理后的基体材料表面容易产生脆性相,导致熔敷层与基体材料结合强调降低。因此,熔敷合金自身应具有良好的塑韧性,且与基体材料结合强度要高。
本发明所采用的激光熔覆合金以镍(Ni)为基础合金成分,添加铬(Cr)、钴(Co)、硅(Si)、钨(W)、钯(Pd)。采用颗粒大小为30-50μm,纯度为99.99%的Ni、Cr、Co、Si、W、Pd金属按一定成分配比组合均匀混合制备成熔敷合金。激光熔覆合金成分(按重量百分比计算Wt%):Cr:5-15;Co:5-10;Si:2-5;W:3-6;Pd:1-4;Ni:余量。本发明所确定的激光熔覆合金成分充分考虑合金的高温性能与基体材料和增强相的结合性能。镍具有较好的延展性、高温性、抗腐蚀性和抗氧化性能,镍基合金常用于制造高温工作的零件和高温粘结合金。铬可以提高熔敷合金的抗氧化性和强化镍固溶体。钴延展性好,且与镍互溶性较好,在高温下能保持其原有的强度,提高熔敷合金的高温强度。硅能强化固溶体,提高耐磨性。钨可以强化熔敷合金,提高熔敷合金的高温性能。钯能改善熔敷合金与基体材料和增强相的结合性能。
二、为了提高熔敷层的耐磨性,在激光熔覆合金中添加10-20(按重量百分比计算Wt%)碳化钨颗粒,通过粘结剂均匀涂敷搅拌头轴肩和搅拌针表面,利用高能密度的激光束使添加的熔覆合金和基体表面层同时熔化,快速凝固后形成与基体成冶金结合的表面条纹状耐磨涂层。其中,WC颗粒尺寸应选择在30-50μm范围内。
三、参阅图2和3,根据搅拌头结构尺寸,在搅拌头的轴肩2和搅拌针3表面均匀分布3-8条激光熔敷条纹状耐磨涂层,条纹状耐磨涂层宽度控制在2-3mm,高度0.05-0.2mm。条纹状耐磨涂层的层高过高,搅拌摩擦焊接过程中焊件容易产生震动,影响焊接质量。条纹状耐磨涂层的层高过高应通过机械修整。
四、本发明所述的一种提高搅拌摩擦焊接高强铝合金的搅拌头耐磨性的方法,其具体的制造工艺步骤为:
第一步,加工制造搅拌头。搅拌头由夹持部分、轴肩和搅拌针组成,采用市售热处理的合金工具钢通过锻造和机械加工工艺加工制造搅拌头。热处理后的合金工具钢硬度可达63-65HRC,采用热处理的合金工具钢加工制造搅拌头,即可保持夹持部分的刚性,又可保持轴肩和搅拌针的高温稳定性。
第二步,加工制造激光熔敷合金及其耐磨涂层。熔覆合金以镍为基础合金成分,添加铬(Cr)、钴(Co)、硅(Si)、钨(W)、钯(Pd)。熔覆合金成分(按重量百分比计算Wt%):Cr:5-15;Co:5-10;Si:2-5;W:3-6;Pd:1-4;Ni:余量。采用颗粒大小为30-50μm,纯度为99.99%的Ni、Cr、Co、Si、W、Pd金属按一定成分配比组合均匀混合制备成熔敷合金。将按设计成分制备好的熔敷合金再与WC颗粒按一定配比混合均匀。WC颗粒尺寸应选择在30-50μm范围内,WC颗粒与熔敷合金的重量百分比应控制WC颗粒所占重量百分比在10-20%。
第三步,激光熔敷耐磨涂层。将按设计成分制备好的熔敷合金再与WC颗粒按一定配比混合均匀通过粘结剂均匀涂敷搅拌头轴肩2和搅拌针3表面,利用高能密度的激光束使添加的熔覆耐磨材料和基体表面层同时熔化,快速凝固后形成与基体成冶金结合的表面条纹状耐磨涂层。参阅图2和3,根据搅拌头结构尺寸,在轴肩2和搅拌针3表面均匀分布3-8条激光熔敷条纹状耐磨涂层,条纹状耐磨涂层宽度控制在2-3mm,高度0.05-0.2mm。表1是激光熔敷合金耐磨涂层料成分及其性能。
表1激光熔敷合金耐磨涂层料成分及其性能
五、通过反复应用磨损试验机进行磨损试验,结果显示,与采用热处理的合金工具钢单一材料制造的搅拌摩擦焊接搅拌头相比较,本发明所述的通过激光熔覆技术在搅拌头轴肩和搅拌针表面均匀熔敷一层条纹状耐磨涂层的方法,使搅拌头轴肩和搅拌针的耐磨性提高2-4倍。可见,本发明所述方法能够显著提高搅拌头轴肩和搅拌针的耐磨性,同时增加轴肩和搅拌针表面的比表面积,通过增加摩擦,增强热量的输入,有利于焊缝金属材料高温塑性变形和提高焊接速度和质量。
Claims (4)
1.一种提高搅拌摩擦焊接高强铝合金的搅拌头耐磨性的方法,通过激光熔覆技术在搅拌头轴肩(2)和搅拌针(3)表面均匀熔敷一层由激光熔敷合金和WC颗粒混合组成的条纹状激光熔覆耐磨涂层,其中的激光熔敷合金成分为,以镍Ni为基础合金成分,添加铬Cr、钴Co、硅Si、钨W、钯Pd,按重量百分比计算Wt%:Cr:5-15;Co:5-10;Si:2-5;W:3-6;Pd:1-4;Ni:余量。
2.根据权利要求1所述的一种提高搅拌摩擦焊接高强铝合金的搅拌头耐磨性的方法,其特征在于激光熔覆耐磨涂层,其WC颗粒与激光熔敷合金的重量百分比为WC颗粒占总重量的10-20%。
3.根据权利要求1所述的一种提高搅拌摩擦焊接高强铝合金的搅拌头耐磨性的方法,其特征在于激光熔覆耐磨涂层,其条纹状耐磨涂层宽度为2-3mm,高度为0.05-0.2mm;轴肩和搅拌针表面条纹数为3-8条。
4.根据权利要求1所述的一种提高搅拌摩擦焊接高强铝合金的搅拌头耐磨性的方法,其特征在于,包括以下工艺步骤:
第一步,采用热处理的合金工具钢通过锻造和机械加工工艺加工制造搅拌头;
第二步,采用颗粒大小为30-50μm,纯度为99.99%的Ni、Cr、Co、Si、W、Pd金属按设计成分配比组合均匀混合制备成熔敷合金,WC颗粒选择在30-50μm范围内,将制备好的熔敷合金与WC颗粒混合均匀;
第三步,将混合均匀的熔敷合金与WC颗粒通过粘结剂均匀涂敷搅拌头轴肩(2)和搅拌针(3)表面,利用高能密度的激光束加热在轴肩(2)和搅拌针(3)表面形成条纹状耐磨涂层。
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CN112705845A (zh) * | 2020-12-18 | 2021-04-27 | 吉林大学 | 一种耐磨涂层及其制备方法和应用 |
CN112705845B (zh) * | 2020-12-18 | 2022-02-01 | 吉林大学 | 一种耐磨涂层及其制备方法和应用 |
CN112719817A (zh) * | 2021-02-02 | 2021-04-30 | 铜陵学院 | 一种激光熔覆螺旋形耐磨条纹涂层的分体式搅拌摩擦焊搅拌头及其加工方法 |
CN114986092A (zh) * | 2022-05-26 | 2022-09-02 | 南京航空航天大学 | 一种微结构阵列的多层材料搅拌头制备方法 |
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