CN104227225A - Agitation friction point braze welding method for metal plate overlap joint combination - Google Patents
Agitation friction point braze welding method for metal plate overlap joint combination Download PDFInfo
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- CN104227225A CN104227225A CN201410440848.6A CN201410440848A CN104227225A CN 104227225 A CN104227225 A CN 104227225A CN 201410440848 A CN201410440848 A CN 201410440848A CN 104227225 A CN104227225 A CN 104227225A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K1/00—Soldering, e.g. brazing, or unsoldering
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
- B23K20/122—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
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Abstract
The invention discloses an agitation friction point braze method for a metal plate overlap joint combination. The method comprises the following steps: placing a brazing filler metal at a to-be-welded position in advance, starting a needle-free tool to rotate, and melting the brazing filler metal by virtue of frictional heat between a shoulder and the surface of an upper plate; after in-situ friction is performed for few seconds, shutting down, and applying upset forging, thereby finishing a large-area spot welding process under the condition of no abrasion and no key holes. By virtue of the twisting effect of a tool on an interface in a friction stage, the dissolution effect of the brazing filler metal on a mother metal in an in-situ friction stage and the upset forging effect of the tool on the interface in a shutdown stage, an oxidation film is easily broken, and oxidation film fragments are easily extruded along with the molten brazing filler metal which is alloyed; meanwhile, the interface wetting property and final compactness are improved, crystal structures containing brittle phases are eliminated, the soldering seam tenacity is improved, and the method can be used in occasions such as electric power fittings, electric contacts, cookers, hybrid electric vehicle series welding and overlap joint welding of thin aluminum plates in automobile and aircraft manufacturing.
Description
Technical field
The invention belongs to welding field, relate to the local bridging method of the combination lap joints such as copper, aluminium, silver, be specifically related to a kind of friction stir spot method for welding for sheet metal overlap joint combinations such as copper, aluminium, silver.
Background technology
Traditional resistor spot welding has the remarkable advantage that efficiency is high, exempt from protection, but has the following disadvantages: (1) energy consumption is high: require that power supply provides high-power instantaneously, have overcritical to power supply capacity; (2) being unsuitable for mother metal is copper, aluminium, mother metal that silver-colored quasi-resistance rate is very low.In recent years, by the enlightenment of the friction stir welding method of Britain's institute of welding invention in 1991, Japan and Germany in succession report two kinds and realize the new technology of spot welding by rubbing: (1) adopts friction stir spot welding (Friction Stir Spot Welding, the FSSW) technology of conventional belt pin instrument; (2) the backfill type stirring friction spot welding technology (Refilling friction stir spot welding) of the patent instrument adopting design complicated.Compared with traditional resistor spot welding, they all have energy-conservation clear superiority.
First method is friction stir spot welding (Friction Stir Spot Welding, the FSSW) method that Japanese Mazda motor corporation and Kawasaki Heavy Industries were invented in 1993.The instrument that this technology adopts is still the conventional band pin instrument of normal agitation friction welding (FW), just eliminate mobile process, therefore can be used for spot welding operating mode, concrete welding process can be divided into 3 stages: a. presses down process: in High Rotation Speed stirring-head press-in workpiece, frictional heat between workpiece and stirring-head under pressure, softening adjacent material, stirring-head is pressed into workpiece further, until shoulder contacts with upper panel surface, pin is through weld interface; B. welding process: stirring-head inserts lower plate upper surface certain depth, makes the shaft shoulder also be pressed into the input of upper plate upper surface minimum degree of depth guarantee welding process frictional heat, keeps stirring-head pressure to rotate certain hour; C. fallback procedure: after spot welding terminates, stirring-head departs from workpiece, stays and typically exits shrinkage pool, be i.e. keyhole at spotweld center.The advantage of this " friction stir spot welding with keyhole " method is that speed of welding is very fast, and welding equipment and control system fairly simple, be easily integrated in large batch of automobile production line, current Mazda company by this technology for the production of.Ingenious heat-power the zone of influence that make use of the distinctive pin periphery of friction stir welding of this technology achieves the seam at up/down interface.The instrument of this technology because continuing to use classical friction stir welding, the shortcoming brought thus mainly contains: (1) bonding area is limited, depends on the diameter of pin; (2) postwelding has keyhole to remain; (3) if wherein a kind of mother metal is comparatively hard, the serious wear of pin; (4) keyhole makes lower plate thinning.
Second method is that German GKSS research center is in the backfill type friction stir spot welding (Refilling friction stir spot welding) of invention in 1999.The core of this technology has carried out Curve guide impeller to instrument, and its patent tool design is complicated.Feature is mainly: (1) its pin can pumpback; (2) pin periphery design have equally can pumpback, rotation inner sleeve; (3) outside inner sleeve, separately outer sleeve is designed with.By the press-in moment of stagger inner sleeve and pin, realize the mixing of up/down mother metal on the one hand; Backfill keyhole on the one hand.Though this technology has the advantage that can backfill keyhole, shortcoming is: (1) tool design is complicated with preparation, complicated operation; (2) bonding area is limited; (3) when there being a kind of strength of parent higher, pin serious wear.
Summary of the invention
The object of the present invention is to provide a kind of friction stir spot soldering (FSSB:Friction Stir Spot Brazing) method for the combination of sheet metal overlap joint, interface densification can be obtained, without fragility crystalline structure, without keyhole, exempt from wearing and tearing, large area, efficient, energy-conservation welding effect.
For achieving the above object, present invention employs following technical scheme.
1) with the assembling of lap joint form (namely sheet material A and sheet material B forms the position relationship of upper plate and lower plate after assembling) after the polishing of the surface to be welded of sheet material A and sheet material B being cleaned up, solder is preset at the overlap joint interface of sheet material A and sheet material B;
2) be fixed on workbench after sheet material A, sheet material B and solder being assembled by mentioned above principle, then start stirring tool to rotate, press down, stirring tool is without the need to tilting, tool shoulder to be mixed and upper panel surface contact rear press-in upper panel surface certain depth completely, keep original position friction certain hour, to melt solder by frictional heat, liquid solder is extruded smoothly;
3) original position friction terminates rear cut-out motor power, simultaneously by lift operation platform or press down stirring tool and apply upset active force to tack-weld (weld interface), to eliminate defect, improve compactness, and extrude residual liquid phase as far as possible, keep upset active force until lap joint cooling, then make stirring tool withdraw, thus realize the some brazing of sheet material A and sheet material B.
The material of described sheet material A and sheet material B be Cu, containing Cu alloy, Al, containing Al alloy, Ag or containing Ag alloy, described solder is zinc paper tinsel.
When upper plate thickness is less than 5mm, use needleless stirring tool; When upper plate thickness is more than or equal to 5mm, for strengthening stirring tool to the mechanical function at interface, using band pin stirring tool, and make the end of pin close to weld interface but do not penetrate weld interface.
The sheet material that in selection sheet material A and sheet material B, yield strength is lower, as upper plate, to alleviate tool wear, strengthens instrument to the mechanical function effect of weld interface simultaneously.
When tack-weld (lap joint) combines for Al/Cu or Ag/Cu, sticking together for avoiding Al and stirring tool and the loss of precious metal Ag, selecting Cu plate as upper plate.
When upper plate material can only be fine aluminium, for preventing aluminium and steel tool end from sticking together, adopt carbide alloy stirring tool or other stirring tools made by material not easily sticked together with aluminium.
When shaping surface require high and need restriction overlap height time, the secondary shaft shoulder for flattening overlap that described stirring tool comprises spindle shoulder and arranges outward at spindle shoulder.
When requiring the diameter≤10mm that effectively rubs, the stirring tool of pyramidal structure should be adopted.
As upper plate thickness <5mm, the span of the degree of depth h of stirring tool press-in upper panel surface is 0.1mm≤h≤0.3mm.
Beneficial effect of the present invention is embodied in:
Compared with existing stirring friction spot welding technology, the present invention increases bonding area (bonding area depends on the diameter of shoulder, the diameter much larger than pin) simultaneously, eliminates the wearing and tearing of pin, simplifies tool design manufacture.Compared with traditional furnace brazing; apply flexibly the mechanical function of instrument; comprise throw to the twisting action at interface and upset effect; both interface striping ability, wetability had been improved; turn eliminate the defects such as fragility crystalline structure and crackle, have energy-conservation, efficient (heating/cooling rapidly) concurrently, exempt from the advantages such as protection.Excellent striping ability makes friction stir spot soldering tech of the present invention particularly be suitable for aluminium (magnesium) with the ability eliminating fragility crystalline structure and welds operating mode with the quick small size of dissimilar metal, can be used for electric armour clamp, electrical contact, cooker, hybrid vehicle electrode connect weld, automobile and the occasion such as the overlap joint of thin aluminum sheet in aircraft manufacturing welds.
Accompanying drawing explanation
Fig. 1 is friction stir spot soldering (FSSB:Friction Stir Spot Brazing) the method schematic diagram for the combination of sheet metal overlap joint of the present invention; Wherein: after (a) Workpiece clamping, needleless stirring-head presses down; B () presses down certain depth after, needleless stirring-head original position friction certain hour; C the friction of () original position terminates after, needleless stirring-head presses down rapidly and applies certain upset force to weld interface; D () weld seam fully cools after, needleless stirring-head is withdrawn, and friction stir spot brazing process completes; E, after () Workpiece clamping, band pin stirring-head presses down; F () presses down certain depth after, band pin stirring-head original position friction certain hour; G the friction of () original position terminates after, band pin stirring-head presses down rapidly and applies certain upset force to weld interface; H () weld seam fully cools after, band pin stirring-head is withdrawn, and friction stir spot brazing process completes; In Fig. 1: 1 is solder paper tinsel, and 2 for extruding liquid solder, and 3 is cooling liquid state solder;
Fig. 2 is friction stir spot welding (Friction Stir Spot Welding, the FSSW) process schematic of band keyhole; Wherein: (a) presses down process; (b) welding process; (c) fallback procedure; In Fig. 2: 4 is keyhole;
Fig. 3 is backfill type friction stir spot welding schematic diagram; Wherein: (a) welds beginning-frictional heat-plasticize, 5 is probe, and 6 is chuck, and 7 is sleeve; B () second stage-probe moves, sleeve moves down; (c) phase III-motion in the other direction of probe sleeve; (d) fourth stage-welded-depart from workpiece;
Fig. 4 is that needleless stirring-head (a) with pyramidal structure for raising instrument rigidity and stability of the present invention eliminates needleless stirring-head (b) schematic diagram certainly with overlap; In Fig. 4: 8 is bare terminal end, 9 is baffle plate, and 10 is pyramidal structure, and 11 is spindle shoulder, and 13 is the secondary shaft shoulder;
Fig. 5 is stirring-head material on the impact of a soldered fitting shaping surface and joint quality, and (a) is stainless steel stirring-head and the adhesion of Al mother metal, and 12 is the column Al mother metal of adhesion; B () is carbide alloy stirring-head and Al mother metal adhesion;
Fig. 6 is that Cu/Al combines friction stir spot soldering original position fraction time and weld temperature curve figure;
Fig. 7 is that Cu/Al combines friction stir spot soldering original position fraction time and joint draws shearing load graph of relation; A () does not add upset; B () adds upset;
Fig. 8 is that Cu/Al combines friction stir spot soldering and do not add upset sample and draw and cut sample and to rupture after extension test macro morphology (a) and draw shearing load-displacement curve (b) figure;
Fig. 9 is that Cu/Al combines friction stir spot soldering and adds upset sample and draw and cut sample and to rupture after extension test macro morphology (a) and draw shearing load-displacement curve (b) figure;
Figure 10 is that Cu/Al friction stir spot soldered fitting and aluminum mother plate tensile strength contrast block diagram; Wherein: (a) rolling state aluminum mother plate (1060) tensile strength; B () does not add upset Cu/Al point soldered fitting tensile strength; C () adds upset Cu/Al point soldered fitting tensile strength;
Figure 11 is not for add upset Cu/Al combined spot soldered fitting representative region micro-organization chart; Wherein: (a) does not add upset Cu/Al combined spot soldered fitting macrograph; (b) corresponding A district 2000 magnification micrographs; (c) corresponding B district 2000 magnification micrographs; (d) corresponding C district 3000 magnification micrographs;
Figure 12 is for applying upset active force Cu/Al combined spot soldered fitting representative region micro-organization chart; Wherein: (a) applies upset Cu/Al combined spot soldered fitting macrograph; (b) corresponding D district 1000 magnification micrographs; (c) corresponding E district 3000 magnification micrographs; (d) corresponding F district 1000 magnification micrographs;
Figure 13 is not for add upset active force Cu/Ag combined spot soldered fitting macro morphology and representative region microstructure picture; Wherein: (a) puts soldered fitting front macro morphology; (b) some soldered fitting back side macro morphology; (c) Cu/Ag combined spot soldered fitting cross section macrograph; (d) corresponding G district 3000 magnification micrographs; (e) corresponding H district 3000 magnification micrographs; (f) corresponding I district 3000 magnification micrographs; (g) corresponding J district 3000 magnification micrographs.
Detailed description of the invention
Below in conjunction with drawings and Examples, the present invention is described in detail.
(bonding area is limited for the common problem that applicant exists for existing stirring friction spot welding technology; The wearing and tearing of pin), specific question (residual keyhole; Tool design manufactures complicated), by adopting needleless instrument, preseting solder increase upset operation, propose a kind of friction stir spot soldering tech (FSSB:Friction Stir Spot Brazing) adopting needleless instrument, obtain interface densification, without fragility crystalline structure, without keyhole, exempt from wearing and tearing, large area, efficient, energy-conservation welding effect.Basic working procedure (containing instrument and solder) is shown in Fig. 1 (a) ~ (d).But, if when the upper plate of spot welding combination is slab (thickness is more than or equal to 5mm), consider the increase of plate thickness on the intensity that stress-strain field is delivered to weld interface and reduce rapidly, answer select tape pin stirring-head, concrete condition is shown in Fig. 1 (e) ~ (h), the length of pin is chosen according to upper plate thickness, ensure mixing needle press-in upper plate certain depth but do not penetrate, by the interpolation of pin, strengthen the mechanical function of stirring tool to interface, but the selection principle of the compression distance of the stirring-head shaft shoulder and needleless stirring-head compression distance is consistent.
A kind of friction stir spot method for welding being used for sheet metal overlap joint combination (such as copper, aluminium, silver combination lap joint):
(1) first the surface to be welded of commercially pure Zn paper tinsel thick for 0.1mm and upper and lower plate (upper plate thickness 2 ~ 4mm) is all removed surface film oxide with the waterproof abrasive paper of No. 600, after totally drying up with washes of absolute alcohol, Zn solder is preset at overlap joint interface, and by lap joint clamping on the table (installation way adjusts according to actual operating conditions);
(2) columned needleless stirring-head is prepared, stirring-head effectively rub diameter size according to actual operating conditions need choose, when stirring-head effectively rubs diameter less (being less than or equal to 10mm), for improving rigidity and the stability of needleless stirring-head, the friction side of stirring-head chooses pyramidal structure, sees Fig. 4 (a);
(3) start needleless stirring-head rotate and press down, after head press-in upper plate upper surface to be mixed 0.1 ~ 0.3mm is dark, original position friction 1 ~ 30 second, first utilizes and rotates twisting action (fricative plastic deformation field) the broken interface oxidation film in advance that shaft shoulder butt welding connects interface; Utilize the frictional heat between shoulder and upper plate to melt solder simultaneously; Because original position friction can extrude liquid solder smoothly, therefore original position friction phase solder can be utilized the stirring of the torsional effect liquid towards alloy of the dissolution of mother metal and throw, driving effect, the dispersion effect (particularly effective to the liquid alloy of poor fluidity especially) of reinforced film subsurface flow and oxide-film; Namely the oxide-film on mother metal surface is effectively removed by " mechanism, film subsurface flow and mutual promoting action thereof are reversed in interface " number of mechanisms.
(4) original position friction phase proceeds to shutdown phase and applies upset pressure effect (lift operation platform or stirring-head is pressed down certain depth rapidly to interface, still be on seam organization recrystallization temperature with weld interface temperature after having pressed down and be advisable), apply certain upset effect by stirring-head to weld interface, (mobility is deteriorated with the liquid solder after alloying to make oxide-film fragment; Containing brittlement phase) extrude in the lump, improve interface wet ability, and make the crackle in weld seam and crystallization shrinkage cavity seam again, the densification realizing interface combines; Eliminate the crystalline structure containing brittlement phase simultaneously, improve brazed seam toughness.
(5) withdraw needleless stirring-head, pull down lap joint, removing overlap (if select overlap can omit this step from eliminating needleless stirring-head, seeing Fig. 4 (b)), making welding point smooth surface attractive in appearance.
Like this, by friction phase instrument to the twisting action at interface, original position friction phase solder to the dissolution of mother metal, shutdown phase instrument to the upset pressure effect at interface, oxide-film is made to be easy to broken, and oxide-film fragment is easy to the liquid solder after with alloying extrudes, improve interface wet ability and final compactness simultaneously, eliminate the crystalline structure containing brittlement phase, improve brazed seam toughness.
All need to remove surface film oxide until expose fresh base material metal, by the method for chemical attack or mechanical grinding, depending on actual operating conditions before described Zn solder and the weldering of upper and lower plate surface to be welded.When particularly welding is containing the combination of aluminium, more should pay attention to the impact of removal situation Welded Joints quality before the weldering of aluminum mother plate surface film oxide.In welding process, aluminum mother plate surface infusibility and the Al of densification
2o
3oxide-film can form weld seam slag inclusion, directly hinders again the fusion of weld metal.So the Al on the front aluminum mother plate surface of weldering
2o
3it is more abundant that oxide-film is removed, and the weld quality that postwelding obtains is better, weld strength is higher.
Described needleless stirring-head does not need, and simultaneously needleless stirring-head is can Reusability, cylindric non-expendable instrument without the need to changing.Stirring-head shaft shoulder radius R
1the size of (i.e. the effective friction radius of stirring-head) needs to choose according to actual operating conditions, stirring-head shaft shoulder radius R
1, mixing needle radius R
2following corresponding relation is had with the heat production of stir friction welding process,
Wherein, Q inputs the total thermal power (W) of workpiece; ω is stirring-head rotating speed; μ is coefficient of friction, and P is welding pressure.Visible, needleless stirring tool shaft shoulder radius R
1linear with Q, R
1larger Q is larger, and welding temperature is higher, and technical staff should consider according to actual conditions, chooses suitable radius R
1numerical value.Research shows, thrust in downward direction increases with the increase of the stirring-head press-in workpiece degree of depth, moment of friction and stirring-head shaft shoulder diameter about and increase with the increase of Rotating speed.Choosing the effective friction radius R of stirring-head
1when less, for improving rigidity and the stability of needleless stirring-head, the friction side of stirring-head chooses pyramidal structure, as shown in Fig. 4 (a).
Described needleless stirring-head press-in upper plate upper surface degree of depth h chooses, and is advisable, therefore chooses h=0.1 ~ 0.3mm to compress upper and lower board interface to be welded and to be conducive to extruding smoothly of liquid solder.Consider the thickness t=0.1mm of Zn paper tinsel, and unavoidably error is there is in practical operation, if h < is 0.1mm, welding pressure is too small, may cause weld interface malcompression, seam organization loosens, and liquid solder may be made fully not extrude simultaneously, mostly be brittle intermetallic thing after remaining liquid phase cools crystallization, be unfavorable for obtaining good welding point; Consider the diameter of needleless stirring-head, if h > is 0.3mm, first there is to a certain extent thinning in Welded Joints, strength of joint is made to occur declining significantly, secondly can form a molten metal at spot welding position and assemble pond, be unfavorable for extruding smoothly of liquid solder, easily there is overlap, burr in face of weld simultaneously.
With stirring friction braze welding (Friction stir brazing, FSB) compare, friction stir spot soldering (Friction stir spot brazing, FSSB) in the following aspects, there is unique feature: 1, in welding process, friction stir spot soldering is applied with upset effect to weld interface, upset force squeeze broken and while disperseing large area continuous print crystalline structure (mostly being brittle intermetallic thing), make in process of setting, come across the crackle in weld seam and crystallization shrinkage cavity seam again, the densification realizing interface combines; 2, combine (as Al/Cu, Al/Al combination) for the spot welding containing Al, easily there is the situation of stirring-head and the adhesion of Al mother metal, cause postwelding joint surface to be shaped to be deteriorated (see Fig. 5 a), lap joint is combined for Al/Cu, can take to improve joint surface in the way of Cu side friction to be shaped, combine lap joint for Al/Al, select carbide alloy as the raw material of needleless stirring-head, the problem (Fig. 5 b) of stirring-head and the adhesion of Al mother metal can be solved; 3, require high tack-weld for shaping surface, the invention discloses a kind of overlap from eliminating needleless stirring-head, after welding process completes, overlap by instrument automatic plastering, can obtain good joint appearance; 4, in pinpoint welding procedure, needleless instrument is without the need to tilting, and welding process is easy to control more, and joint surface is shaped flat smooth more.
Advantage of the present invention: tool design makes simple (needleless instrument), the wearing and tearing of mother metal to mixing needle are avoided in welding process, replacing instrument is not needed during batch production, postwelding remains without keyhole, therefore mother metal is without thinning (not adding upset) or Reducing thickness less (adding upset), the interpolation in Zn solder intermediate layer simultaneously, not only can utilize (the friction of the distinctive mechanism of friction stir welding, stir, interface torsional deflection) realize the mixing of weld interface, abolish the oxide-film of interface mother metal, also can utilize the oxide-film of metallurgy action (film subsurface flow) the further tear interface mother metal of middle preseting solder, namely by " interface is reversed, the mechanisms such as extruding+film subsurface flow+pressurization is extruded " number of mechanisms effectively removes the oxide-film on mother metal surface, interface oxidation film is abolished satisfactory for result, after original position friction terminates simultaneously, by pressing down rapidly of stirring-head, certain upset effect is applied to weld interface, squeeze broken and while disperseing large area continuous print crystalline structure (mostly being brittle intermetallic thing), make in process of setting, come across the crackle in weld seam and crystallization shrinkage cavity seam again, the densification realizing interface combines, if select overlap from eliminating needleless stirring-head, shaft shoulder automatic plastering overlap can be utilized in welding process, make postwelding joint non-trimming or few overlap, joint appearance is shaped smooth attractive in appearance.
In the operation of " a kind of friction stir spot method for welding for the combination of sheet metal overlap joint " that the present invention proposes:
(1) all need to remove surperficial grease, organic matter and oxide-film until expose fresh base material metal before solder and the weldering of upper and lower plate surface to be welded, by the method for chemical attack or mechanical removal, depending on actual operating conditions, then after totally drying up with washes of absolute alcohol, solder is preset at overlap joint interface, and by lap joint clamping on the table (installation way adjusts according to actual operating conditions).The grease on mother metal welding surface and solder surface, organic matter and oxide-film not only hinder liquid solder to sprawl joint filling on mother metal, and grease and organic matter can release gas when soldering is heated, and may leave at surface of the work the residue affecting solder wetting, make soldered fitting Quality Down.And mother metal surface film oxide, particularly aluminum mother plate surface infusibility and the Al of densification
2o
3oxide-film can form weld seam slag inclusion, directly hinders again the fusion of weld metal, so the Al on the front aluminum mother plate surface of weldering
2o
3it is more abundant that oxide-film is removed, and the weld quality that postwelding obtains is better, weld strength is higher.
(2) columned needleless stirring-head is prepared, needleless stirring tool shaft shoulder radius R
1linear with Q, R
1larger Q is larger, welding temperature is higher, the size of the effective friction radius of stirring-head should need to choose according to actual operating conditions, when the effective friction radius of stirring-head is less, for improving rigidity and the stability of needleless stirring-head, particularly when welding harder mother metal, the friction side of stirring-head is advisable with pyramidal structure, sees Fig. 4 (a);
(3) start needleless stirring-head rotate and press down, after head press-in upper plate upper surface to be mixed 0.1 ~ 0.3mm is dark, original position friction certain hour (this time is determined in conjunction with general knowledge according to actual conditions by technical staff), the synergy of the frictional heat between the shaft shoulder and upper plate and needleless stirring-head downforce is utilized to make brazing filler metal melts and extruded smoothly, the oxide-film of tear interface mother metal under the metallurgy action (film subsurface flow) of middle preseting solder helps, namely by " interface is reversed, the mechanisms such as extruding+film subsurface flow+pressurization is extruded " number of mechanisms effectively removes the oxide-film on mother metal surface.Research shows, thrust in downward direction increases with the increase of the stirring-head press-in workpiece degree of depth, and suitable pressure can increase heat input, improves the density of seam organization.If pressure is too small, seam organization is loose there is hole, and fully can not extrude liquid solder, mostly is brittle intermetallic thing joint is become fragile after remaining liquid phase cools crystallization; If pressure is excessive, namely compression distance is excessive, exist to a certain extent to some soldered fitting thinning, strength of joint is made to occur declining significantly, secondly can form a molten metal at spot welding position and assemble pond, be unfavorable for extruding smoothly of liquid solder, easily there is a large amount of overlaps, burr in face of weld simultaneously.
(4) original position fraction time complete after cut-out motor power, and stirring-head is pressed down certain depth rapidly, still be on seam organization recrystallization temperature with weld interface temperature after having pressed down and be advisable, by the extruding of stirring-head, certain upset effect is applied to weld interface, squeeze broken and while disperseing large area continuous print crystalline structure (mostly being brittle intermetallic thing), make the crackle in weld seam and crystallization shrinkage cavity seam again, the densification realizing interface combines;
(5) after joint cooling fully, needleless stirring-head is withdrawn, and pulls down lap joint, removing overlap (if selecting overlap can omit this step from eliminating needleless stirring-head), making welding point smooth surface attractive in appearance.
Choosing and determining (for the soldering of Cu/Al friction stir spot) about original position fraction time:
In general original position fraction time is longer, and welding process heat production is more, and the heat input of some soldered fitting is larger.As shown in Figure 6, when stirring-head has just contacted upper end copper coin, owing to there is slight friction, frictional heat makes welding temperature rise to about 100 DEG C.Stirring-head is pressed into rapidly upper end copper coin 0.2mm subsequently, severe friction is produced between stirring-head and copper base metal, frictional heat also sharply increases thereupon, make the welding temperature of tack-weld within the short time of about 2s, 450 DEG C are sharply risen to by 100 DEG C, as can be seen from curve map, at this moment, in section, welding temperature is almost vertical rising.Along with the increase of original position fraction time, welding temperature maintains about 5s again maintain about 5s near 480 DEG C (fusing point of Zn is 419.6 DEG C) after between 480 ~ 450 DEG C.When original position fraction time reaches 15s, cutting-off machine power supply, stirring-head presses down rapidly and applies upset active force to weld interface, and naturally cool in atmosphere subsequently, welding process terminates.
Composition graphs 6 and Fig. 7 can analyze, in a brazing process, when original position fraction time is 2s, weld interval is shorter, solder and the mother metal metallurgy action time shorter, the amount that Cu/Al/Zn forms fragility Ternary intermetallic compounds is just less, therefore the tensile load of joint is comparatively large and dispersiveness is less, average 2.8kN; When fraction time is increased to 4s, welding temperature is stabilized on 450 DEG C, and the fusing point of Zn is 419.6 DEG C, therefore the fusing of preseting solder can be ensured, and extruded smoothly under the extruding and turning effort of stirring-head, therefore the tensile load of tack-weld is more stable, fluctuation within a narrow range near 2.3KN; When fraction time continues to increase, the tensile load of joint drops near 1.7KN when 6s; Extend to 8s when fraction time, the tensile load of welding point is increased to maximum 2.9KN gradually; When fraction time is increased to 10s, the tensile load of joint is decreased to 2.2KN a little.From Fig. 7 curve fluctuation pattern, the tensile load of Cu/Al friction stir spot Welding joint is better dispersed, and strength of joint is with fraction time (t
0=0 increase s) presents first to increase and reduces (t afterwards
3=6 s), is increased to maximum (t subsequently
4=8 s) after slightly decline (t
5=10 s).
The fluctuation pattern of joint tensile strength is relevant with the tissue of weld interface, main relevant with content with the composition of brittlement phase in seam organization (Cu/Al/Zn Ternary intermetallic compounds).Time shorter when soldered, in weld seam, intermetallic compound is less, therefore strength of joint is higher; Along with the increase of fraction time, the amount that mother metal dissolves in solder constantly increases, and in weld seam, intermetallic compounds layer constantly thickens, and weld seam is become fragile, and strength of joint constantly reduces; In the process that mother metal dissolves in solder, solder also constantly spreads in mother metal, the speed v that early stage dissolves
moltenbe greater than the speed v of diffusion
expand, work as v
molten=v
expandtime, the intensity of joint is minimum; V subsequently
molten< v
expand, solder constantly spreads in mother metal, and joint fragility reduces, and the intensity of joint increases gradually, and reach the prolongation along with fraction time after maximum, the probability of crack initiation in weld seam is brought out in lathe whirling vibration constantly to be increased, and the intensity of joint is slightly declined.Comprehensive Experiment data, known by above analysis, choosing of weld interval should consider in conjunction with many factors such as material to be welded, experiment condition, production efficiencys, is not that the longer the better.
Necessity and rationality about upset force adds:
In general, the interpolation of upset force is to squeeze broken and getting rid of the oxide-film of weld interface and to be harmfully mingled with, but in a soldering processes except will achieving the above object, simultaneously also will by the interpolation of forging force, squeeze broken and while disperseing large area continuous print crystalline structure (mostly being brittle intermetallic thing), make the crackle in weld seam and crystallization shrinkage cavity seam again, the densification realizing interface combines.
In analysis chart 7, the curve fluctuation pattern of (a) is known, that does not add upset welding point draws shearing load dispersiveness larger, when variable original position fraction time changes, draw the value of shearing load to occur larger fluctuation, namely show as slope of a curve (absolute value) in figure larger.And when variable original position fraction time is constant, the fluctuation that actual measurement draws shearing load value also to occur by a relatively large margin, the spacing namely showing as measured value in figure is larger.In summary, upset quality of weld joint is not added unstable.Comparison diagram 7 (a), in analysis chart 7, the curve fluctuation pattern of (b) is known, and that adds upset welding point draws shearing load comparatively stable, and namely dispersiveness is less.Not only show on X-axis (original position fraction time) variable, also show on Y-axis (drawing shearing load) direction.In Fig. 7 (b), trend is comparatively mild in the X direction for curve, does not significantly suddenly increase and suddenly falls, in the Y direction, except t
1outside the data point of=2 s, other draw shearing load measured value all comparatively close.As from the foregoing, after adding upset, Cu/Al combined spot soldered fitting performance is more reliable, dispersed better.
From the contrast of the representative region micro-organization chart of Figure 11 and Figure 12 center tap, do not add in the weld seam of the Cu/Al combined spot soldered fitting of upset and there is obvious large area continuous print crystalline structure, EDAX results is Al-38Cu-3Zn (at.%), belong to brittle intermetallic thing, and brazed seam layer is thicker, thickly reach 16 μm, therefore in brazed seam, there is obvious crackle and crystallization shrinkage cavity, even if in center, spot welding region, also there is obvious solidification and crystallization tissue (thick about 6 μm); After applying upset active force, the microscopic structure of Cu/Al combined spot soldered fitting obtains to be improved significantly, as seen from Figure 12, large area continuous print crystalline structure is squeezed broken and spread out, center, spot welding region obtains the seam organization (thickness is about 2 μm) of even compact, almost not residual fragility crystalline structure, and at spot welding region boundary position, the not only squeezed broken dispersion of large area continuous print crystalline structure, but also obvious densification can be observed in conjunction with weld interface, the crackle in weld seam and crystallization shrinkage cavity are also obviously reduced.In summary, upset force be added with the microscopic structure being beneficial to and improving Cu/Al combined spot soldered fitting.
Below introduce concrete case study on implementation and illustrate how to implement this method, and the densified observed result of test result and weld interface of the some soldered fitting of place of matchmakers's acquisition, to prove practicality of the present invention and novelty.
Case one: Cu/Al combines friction stir spot soldering
Select thickness be the commercially available fine copper plate T2 of 2mm (actual measurement 1.96m) and pure aluminum plate 1060 for treating weldment, specification is the sample of 60 × 20 × 2mm.Intermediate solder layer is the commercially available pure zinc paper tinsel of thickness 0.1mm, and specification is the sample of 20 × 20 × 0.1mm.Take the assembling mode overlapped, overlapping regions area 20 × 20mm, upper end is copper coin, and lower end is aluminium sheet, and spot welding position is overlapping regions center.Stirring-head is the needleless stirring-head with pyramidal structure, and effective friction radius is 5mm, and material is 1Cr13 martensitic stain less steel.Welding condition is as shown in table 1:
Table 1 Cu/Al combines friction stir spot Welding technological parameter
With the temperature data of soldered fitting commissure, K type thermocouple collection point, obtain Fig. 6 original position fraction time and connector temperature graph of relation, know that the highest weld seam that makes of frictional heat source is warming up to 480 DEG C, and pure Zn solder fusing point is 420 DEG C, therefore frictional heat can make solder melt smoothly, dripped can be verified by the fusing solder extruded in Figure 12 (a).This is one of strong evidence proving " friction stir spot soldering " proposed by the invention method feasibility.
Adopt tensile shear testing test to carry out evaluation point soldered fitting performance, Fig. 8 and Fig. 9 is respectively not add upset and add upset joint and draws and cut rear fracture macro pattern and draw shearing load-displacement curve.As can be seen from Fig. 8 and Fig. 9, under identical welding conditions, joint surface is shaped smooth, draw to cut in experimentation and all rupture in weld interface, but after the some soldered fitting not adding upset is broken, mother metal does not have obvious macroscopic deformation, and after the some soldered fitting adding upset breaks, Al mother metal there occurs obvious macroscopic deformation in bond pad locations.In conjunction with both draw shearing load-displacement curve figure known, the shearing load of drawing not adding upset joint is 3.5kN, and the shearing load of drawing adding upset joint is 5kN, and getting tack-weld efficient weld area is π R
2≈ 78.5mm
2, be converted into shear strength, then σ
do not add≈ 44.6MPa (63.7% σ
al), σ
add≈ 63.7 MPa (91% σ
al), as shown in Figure 10.Because the tensile-sbear strength adding upset point soldered fitting is about 91% of Al mother metal shear strength, therefore obvious macroscopic deformation can be there is drawing in the process of cutting.This is the strong evidence two proving " friction stir spot soldering " proposed by the invention method feasibility.
By the high power microscopic examination to friction stir spot soldered fitting representative region, the data of comprehensive Figure 11 and Figure 12 are known: whether (1) is no matter add upset active force, the oxide-film of some soldered fitting weld seam mother metal can be abolished fully, and solder is abundant to soaking of weld interface, (2) after adding upset active force, large area continuous print crystalline structure (mostly being brittle intermetallic thing) is squeezed broken and spread out, not only obtain the seam organization of even compact (thickness is about 2 μm in center, spot welding region, almost not residual fragility crystalline structure), and also can observe obvious densification in conjunction with weld interface at spot welding region boundary position, crackle in weld seam and crystallization shrinkage cavity are also obviously reduced, the anti-tensile-sbear strength of joint is made to be significantly improved (relative to not adding upset joint, tensile-sbear strength increase about 42.8%).This is the strong evidence three proving " friction stir spot soldering " proposed by the invention method feasibility.
Case two: Cu/Ag combines friction stir spot soldering
Select thickness to be the commercially available fine copper plate T2 of 4mm (actual measurement 3.94mm) and thickness to be the fine silver plate of 3mm (actual measurement 2.98mm) for treating weldment, specification is respectively the sample of 110 × 50 × 4mm and 35 × 15 × 3mm.Intermediate solder layer is the commercially available pure zinc paper tinsel of thickness 0.03mm, is cut to the sample of specification 35 × 15 × 0.03mm.Take the assembling mode of copper coin all standing on silver plate, spot welding position is overlapping regions center.Stirring-head is the major diameter needleless stirring-head of diameter 40mm, and material is 1Cr13 martensitic stain less steel.Welding condition is as shown in table 2:
Table 2 Cu/Ag combines friction stir spot Welding technological parameter
Adopt the welding manner not applying upset active force, the point soldered fitting macro morphology of acquisition after welding process completes is as shown in Figure 13 (a) He (b), wherein in Figure 13 (b), (1), (2), (3) region are for shearing sample sampling position, and microstructure cross section chosen position is as shown in Figure 13 (b).
Shearing test test is adopted to carry out evaluation point soldered fitting performance, wherein (1), (2), (3) number sample are surveyed shear strength is respectively 58.8 MPa, 74.2 MPa, 65.7MPa, therefore Cu/Ag combines the combination of friction stir spot soldered fitting firmly, can bear load to a certain degree.
Figure 13 (c) ~ (g) is Cu/Ag combination friction stir spot soldered fitting representative region microstructure picture, by known to the analysis of representative region high power microscopic structure, when not adding upset active force, the oxide-film of some soldered fitting commissure mother metal can be abolished fully, solder is abundant to soaking of weld interface, seam district, Weld pipe mill position is fine and close, but there is the micro-crack be interrupted in whole weld interface, is improved by the interpolation of upset active force.
Case three: Cu/Cu combines friction stir spot soldering
Select thickness be the commercially available fine copper plate T2 of 2mm (actual measurement 1.96m) for treating weldment, specification is the sample of 60 × 20 × 2mm.Intermediate solder layer is the commercially available pure zinc paper tinsel of thickness 0.1mm, and specification is the sample of 20 × 20 × 0.1mm.Take the assembling mode overlapped, overlapping regions area 20 × 20mm, spot welding position is overlapping regions center.Stirring-head is the needleless stirring-head with pyramidal structure, and effective friction radius is 5mm, and material is 1Cr13 martensitic stain less steel.Welding condition is as shown in table 3:
Table 3 Cu/Cu combines friction stir spot Welding technological parameter
Adopt tensile shear testing test to carry out evaluation point soldered fitting performance, the shearing load of drawing not adding upset joint is 5.3kN, and the shearing load of drawing adding upset joint is 7.6kN, and getting tack-weld efficient weld area is π R
2≈ 78.5mm
2, be converted into shear strength, then σ
do not add≈ 67.5MPa, σ
add≈ 96.8MPa, therefore Cu/Cu combines the combination of friction stir spot soldered fitting firmly, can bear load to a certain degree.
In sum, by the introduction of above-described embodiment, the feasibility of " a kind of sheet metal overlap joint that is used for combines friction stir spot method for welding " that the present invention proposes obtains real example.The advantage of this technology can be summarized as follows:
(1) tool design makes simple (needleless instrument), the wearing and tearing of mother metal to mixing needle are avoided in welding process, replacing instrument is not needed during batch production, postwelding remains without keyhole, therefore mother metal is without thinning (not adding upset) or Reducing thickness less (adding upset).
(2) interpolation in Zn solder intermediate layer, the distinctive mechanism of friction stir welding (friction, stirring, interface torsional deflection) not only can be utilized to realize the mixing of weld interface, abolish the oxide-film of interface mother metal, also can utilize the oxide-film of metallurgy action (film subsurface flow) the further tear interface mother metal of middle preseting solder, namely effectively remove the oxide-film on mother metal surface by " mechanism+film subsurface flow+pressurization such as interface torsion, extruding is extruded " number of mechanisms, interface oxidation film is abolished satisfactory for result.
(3) after original position friction terminates, by pressing down rapidly of stirring-head, certain upset effect is applied to weld interface, squeeze broken and while disperseing large area continuous print crystalline structure (mostly being brittle intermetallic thing), make in process of setting, come across the crackle in weld seam and crystallization shrinkage cavity seam again, the densification realizing interface combines.
(4) if select overlap from eliminating needleless stirring tool, can utilize shaft shoulder automatic plastering overlap, make postwelding joint non-trimming or few overlap in welding process, joint appearance is shaped smooth attractive in appearance.
(5) in pinpoint welding procedure, needleless instrument is without the need to tilting, and welding process is easy to control more, and joint surface is shaped flat smooth more.
The invention discloses a kind of friction stir spot method for welding for the combination of sheet metal overlap joint, namely after the preseting solder of position to be welded, start needleless instrument to rotate, solder is melted by the frictional heat of shoulder and upper panel surface, after the original position friction several seconds, stop and apply upset, exempting from wearing and tearing, without in keyhole situation, completing large area pinpoint welding procedure.The present invention has applied flexibly the heating-power effect of instrument and the metallurgy action of solder, bring following advantage: by friction phase instrument to the twisting action at interface, original position friction phase solder to the dissolution of mother metal, shutdown phase instrument to the upset pressure effect at interface, oxide-film is made to be easy to broken, and oxide-film fragment is easy to the liquid solder after with alloying extrudes, improve interface wet ability and final compactness simultaneously, eliminate the crystalline structure containing brittlement phase, improve brazed seam toughness.In addition, have without keyhole, exempt from pin wearing and tearing, obvious energy conservation, the advantage such as simple, the occasion such as can be used for electric armour clamp, electrical contact, cooker, hybrid vehicle electrode series connection welding, automobile and the overlap joint of thin aluminum sheet in aircraft manufacturing welds.
Claims (9)
1., for a friction stir spot method for welding for sheet metal overlap joint combination, it is characterized in that: comprise the following steps:
1) with the assembling of lap joint form after the polishing of the surface to be welded of sheet material A and sheet material B being cleaned up, solder is preset at the overlap joint interface of sheet material A and sheet material B;
2) be fixed on workbench after sheet material A, sheet material B and solder being assembled, then start stirring tool to rotate, press down, stirring tool is without the need to tilting, upper panel surface is pressed into after tool shoulder to be mixed contacts completely with upper panel surface, keep original position friction, to melt solder by frictional heat, liquid solder is extruded smoothly;
3) after original position friction terminates, by lift operation platform or press down stirring tool and apply upset active force to weld interface, keep upset active force until lap joint cooling, then make stirring tool withdraw, thus realize the some brazing of sheet material A and sheet material B.
2. a kind of friction stir spot method for welding for the combination of sheet metal overlap joint according to claim 1, is characterized in that: the material of described sheet material A and sheet material B be Cu, containing Cu alloy, Al, containing Al alloy, Ag or containing Ag alloy, described solder is zinc paper tinsel.
3. a kind of friction stir spot method for welding for the combination of sheet metal overlap joint according to claim 1, is characterized in that: when upper plate thickness is less than 5mm, uses needleless stirring tool; When upper plate thickness is more than or equal to 5mm, uses band pin stirring tool, and make the end of pin close to weld interface but do not penetrate weld interface.
4. a kind of friction stir spot method for welding for the combination of sheet metal overlap joint according to claim 1, is characterized in that: select yield strength is lower in sheet material A and sheet material B sheet material as upper plate.
5. a kind of friction stir spot method for welding for the combination of sheet metal overlap joint according to claim 1, is characterized in that: when lap joint is Al/Cu or Ag/Cu combination, select Cu plate as upper plate.
6. according to claim 1 a kind of for sheet metal overlap joint combination friction stir spot method for welding, it is characterized in that: when upper plate material is fine aluminium, adopt carbide alloy stirring tool or other stirring tools made by material not easily sticked together with aluminium.
7. according to claim 1 a kind of for sheet metal overlap joint combination friction stir spot method for welding, it is characterized in that: the secondary shaft shoulder for flattening overlap that described stirring tool comprises spindle shoulder and arranges outward at spindle shoulder.
8. according to claim 1 a kind of for sheet metal overlap joint combination friction stir spot method for welding, it is characterized in that: when requiring the diameter≤10mm that effectively rubs, the stirring tool of pyramidal structure should be adopted.
9. according to claim 1 a kind of for sheet metal overlap joint combination friction stir spot method for welding, it is characterized in that: as upper plate thickness <5mm, the span of the degree of depth h of stirring tool press-in upper panel surface is 0.1mm≤h≤0.3mm.
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