CN111185660B - Dynamic detection method for quality of friction stir welding seam based on laser ranging - Google Patents
Dynamic detection method for quality of friction stir welding seam based on laser ranging Download PDFInfo
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- CN111185660B CN111185660B CN201911325617.XA CN201911325617A CN111185660B CN 111185660 B CN111185660 B CN 111185660B CN 201911325617 A CN201911325617 A CN 201911325617A CN 111185660 B CN111185660 B CN 111185660B
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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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- 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
- B23K20/123—Controlling or monitoring the welding process
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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
- B23K20/26—Auxiliary equipment
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Abstract
The invention discloses a dynamic detection method for the quality of a friction stir welding seam based on laser ranging. In consideration of the fact that high-low periodically fluctuated surface arcs appear in the friction stir welding process, the invention indirectly measures the distance between the surface arcs through the high-precision laser displacement sensor, establishes a criterion with the periodic airspace characteristics (step length) of the friction stir welding and the flow quality conservation criterion of the viscoplastic material, and achieves the dynamic detection of the welding seam quality. The invention takes the essential reason of the formation of welding defects as the detection basis, and when the surface arc line spacing is greatly deviated from the step length, the generation of defects related to the flow of the viscoplastic material is indicated. Compared with postweld detection, the method and the device are simple and convenient to operate, cost is saved, and welding automation is easy to realize.
Description
Technical Field
The invention belongs to the field of quality detection and analysis of friction stir welding seams, and particularly provides a dynamic detection method and device for the quality of friction stir welding seams based on laser ranging
Background
Friction Stir Welding (FSW) is a high-speed rotating insertion of a non-consumable stir head into a workpiece to be welded, the FSw advances along a preset welding direction, heat generated by Friction heat generation and plastic deformation enables local materials of the workpiece to reach a viscoplastic state, the viscoplastic material at the front edge of the stir head is accumulated backwards under the combined action of forging pressure and advancing force to fill in a gap generated by the advancing of the stir head, and finally a high-quality and high-performance FSw weld joint is formed. FSW was vigorously developed since its invention by the british welding institute (TWI) in 1991 because of its own unique advantages over other welding processes, particularly in aluminum alloy joining techniques; other traditional aluminum alloy connecting technologies, such as argon tungsten-arc welding, laser welding and the like, cannot meet the requirement of high-strength aluminum alloy connection, welding seams have welding defects such as air holes and cracks caused by melting metallurgy, FSW belongs to the category of solid-phase welding, metallurgical defects such as air holes, cracks and inclusions caused by melting cannot be formed, the formation of FSW joints is close to that of forging structures, and welded areas are fine isometric crystal structures due to a recrystallization mechanism, so that the formed welding seam joints have excellent mechanical properties. In addition, the FSW technology is used as a green connection technology, the welding process is free of pollution, damages of arc light, radiation and the like, control is convenient, and automatic production is easy to form.
At present, in the FSW process, the local part of a workpiece material to be welded may have nonuniformity and inconsistency of mechanical properties, and although the probability is small, the local part often becomes a catastrophic hidden danger of embedding a key connecting part in service. In addition, the FSW process has the phenomenon that the technological parameters deviate from the preset values due to system control factors, or unexpected interference occurs, so that the welding seam connection quality is influenced. The Liu Song Ping team of Beijing aviation manufacturing engineering institute shows that FSW defects are more in a welding seam area and a base metal connection interface area; the defect orientation is complex, and a streamline formed in the stirring process along with the connection interface of the welding seam area and the base metal is generated and developed; the defects are tight and fine, and the area orientation is obvious (see Liu Song Ping, Liu Feifei, Li le gang, et al. nondestructive testing method of aluminum alloy friction stir welding line [ J ]]Aeronautical manufacturing techniques, 2006(03): 78-81). The existing FSW welding detection method mainly comprises post-welding detection, which comprises the following steps: the detection of surface defects is observed and detected by naked eyes on the surface appearance, and only obvious external characteristics such as flash, furrow and the like can be detected; and non-destructive testing techniques, e.g. ultrasonic reflectometry, penetrant testing,xRadiographic inspection and eddy current inspection, which are generally complicated and cannot monitor the FSW in real time, increase the FSW production cost and time in post-welding inspection no matter whether the FSW welding connector joint is good or bad.
Therefore, in order to reduce the production cost of the FSW, the invention provides a device and a method for dynamically detecting the quality of a friction stir welding weld joint, which have great application value, and the device and the method consider that high-low periodically fluctuating surface arcs can appear in the FSW welding process, indirectly measure the distance between the surface arcs through a high-precision laser displacement sensor, and establish a criterion for dynamically detecting the FSW weld joint with FSW periodic airspace characteristics (step length lambda) and a flow quality conservation principle of a viscoplastic material in welding (Qian J, Li J, Sun F, et al. The invention is based on the essence of FSW welding defect generation, and when the surface arc pitch in FSW deviates from the step length too much, the defect generation related to the flow of the viscoplastic material is indicated. The invention achieves dynamic detection of the weld joint by indirectly measuring and analyzing the surface arc line spacing in real time.
Disclosure of Invention
Aiming at the problems at present, the invention discloses a dynamic detection method for the quality of a friction stir welding seam based on laser ranging, which is based on the characteristic that the FSW periodic airspace characteristic (step length lambda) is highly consistent with surface arc lines, banded structures and onion rings, and the height of the generated surface arc lines is sampled in real time by a high-precision laser displacement sensor in the FSW process, wherein the number of the acquisition points is x as shown in figure 3iThe collection height is hiAnd processing and analyzing the sampling data through a computer to indirectly obtain the distance between the surface arcs in the FSW process, and comparing and analyzing the distance with the step length lambda so as to detect the FSW welding seam quality in real time. The method considers the principle of conservation of flow quality of the viscoplastic material, analyzes the root cause of the defect, and shows the generation of the defect related to the flow of the viscoplastic material when the distance between the surface arcs in the FSW is greatly deviated from the step length. The device includes: friction stir welding main shaft (6), stirring head (1) and laser displacement sensor detection module: the device consists of a cylinder (5), a laser displacement sensor (2), a controller (3) and a computer (4).
In order to achieve the purpose, the technical scheme adopted by the invention is as follows:
a friction stir welding weld quality dynamic detection method based on laser ranging relates to a device comprising the following steps: friction stir welding main shaft (6), stirring head (1) and laser displacement sensor detection module: the device consists of a cylinder (5), a laser displacement sensor (2), a controller (3) and a computer (4). The method is characterized in that scanning sampling is carried out on surface arc lines generated in the friction stir welding process through a laser displacement sensor (2), sampling data are transmitted into a computer (4) through a controller (3), the computer (4) obtains real-time indirect measurement on the surface arc line distance through a wave crest/wave trough extraction algorithm, and finally dynamic detection on the quality of a welding seam is realized through analysis on the change condition of the surface arc line distance, and the method comprises the following steps:
(1) setting parameters: selecting parameters of a friction stir welding process according to welding materials, wherein the parameters comprise a forward speed v and a rotating speed omega, setting the sampling frequency of the laser displacement sensor through a controller, and calculating the step length lambda = v/omega in the welding process.
(2) Adjusting the scanning height of the laser displacement sensor: and (3) starting the friction stir welding, connecting the laser displacement sensor with the air cylinder, and adjusting the scanning height of the laser displacement sensor by adjusting the air flow of the air cylinder.
(3) Data preprocessing: the stirring head advances along the welding direction, the laser displacement sensor is positioned at the positive rear side of the advancing direction of the stirring head to collect the height change characteristics of the surface arc lines in real time, the height change characteristics can be obtained according to the attached figure 3, and the number of the collected points is xiThe collection height is hiAnd the generation of surface arc lines is caused by the heat cycle accumulation and dissipation, macroscopically, highly obvious periodic change exists, a threshold value is set, and data are screened in real time.
(4) And (3) data analysis: defining the data obtained after preprocessing as a data point set { Qi(xi，hi) In which i>0, analyzing by a peak/trough extraction algorithm, and h if a data point meets the requirement of surface arc ripple troughi>hi-1And h isi>hi+1With the surface arc ripple peak requirement, hi<hi-1And h isi<hi+1Data extraction as a set of peak/trough data points { K }i(bi,hi) In which b isiIs a set of data points Qi(xi，hi) Extracting corresponding point sequence number from wave crest/wave trough, collecting data points { Q }i(xi，hi) Every two adjacent data points in the data are c from the base value, then the distance L between adjacent peaks and troughs or between troughs and peaks can be obtainedi=(bi-bi-1)c，LiIs an indirect measurement value of the size of the arc lines on the welding surface of the friction stir welding through a laser displacement sensor.
(5) And (3) quality evaluation: establishing a detection criterion for the surface arc indirect measurement value obtained in the step (4) and the step length lambda obtained in the step (1) when the step length lambda is 0.8<Li/(λ-Li)<At 1.25, L is considerediSegment is not defective, loop pair Li+1Judging the section; otherwise, LiIf this relationship is not satisfied, L is considered to beiIf the segment has defects, the computer analyzes the interface to display the warning lamp and generate and store the defect record, and the L is circularly pairedi+1Segment is judged, when L isiIf =0, the loop detection command ends and the detection is completed.
The dynamic detection method for the quality of the welding line of the friction stir welding based on the laser ranging is characterized in that the surface arc length L is indirectly measured in real time through a wave crest/wave trough extraction algorithmiSatisfies 0.8<Li/(λ-Li)<1.25, then L is considerediSegment is not defective, otherwise LiIf this relationship is not satisfied, L is considered to beiThe section has defects, the relation considers the principle of conservation of flow mass of the viscoplastic material, the root cause generated by the local fluidity defects of the material is analyzed, the existence of the defects can be accurately and quickly judged, and the whole FSW process is detected in real time.
The dynamic detection method for the quality of the friction stir welding seam based on the laser ranging is characterized in that the formed data point set { Q }i(xi，hi) And constructing a data point curve for the data point set, and performing segmented fitting on the data point curve through a B spline.
The dynamic detection method for the quality of the friction stir welding seam based on laser ranging is characterized by comprising the following steps of: the method predicts the advancing distance of one period through v and omega by the aid of the stepping length lambda = v/omega.
Further, the friction stir welding weld quality dynamic detection method based on laser ranging is characterized by comprising the following steps: the method is only suitable for the welding stage with uniform welding speed, so the method is not suitable for the initial insertion stage of the stirring head and the final drawing stage of the stirring head.
The invention has the following advantages:
1) the device and the method can detect the quality of the welding seam in real time, and can save production cost and time compared with postweld detection.
2) The online control can be performed by detecting data in real time.
3) The device and the method are simple and easy to implement, and the analysis is carried out from the source of defect generation.
Drawings
FIG. 1 is a flow chart of the present invention
FIG. 2 is a schematic diagram of the device used in FSW
The device comprises a stirring head 1, a laser displacement sensor 2, a controller 3, a computer 4, a cylinder 5, a friction stir welding spindle 6 and a workpiece 7.
FIG. 3 is a schematic view of the measurement of the surface profile pitch during FSW welding
Detailed Description
The present invention will be described in further detail with reference to the accompanying drawings and examples.
As shown in the attached drawings, the dynamic detection method for the quality of the friction stir welding seam based on laser ranging relates to a device comprising the following steps: friction stir welding main shaft (6), stirring head (1) and laser displacement sensor detection module: the device consists of a cylinder (5), a laser displacement sensor (2), a controller (3) and a computer (4). In the FSW welding process, the stirring head (1) advances along a preset welding direction, the laser displacement sensor (2) is positioned at the front rear side of the stirring head (1) and scans a surface arc line area generated after the stirring head advances in real time to obtain a height real-time change characteristic, sampling data are transmitted into the computer (4) through the controller (3), the computer (4) obtains real-time indirect measurement on the surface arc line distance through a peak/trough extraction algorithm, and finally, the dynamic detection on the welding seam quality is realized by analyzing the change condition of the surface arc line distance, and the specific implementation comprises the following steps:
(1) setting parameters: selecting parameters of a friction stir welding process according to welding materials, wherein the parameters comprise a forward speed v and a rotating speed omega, setting the sampling frequency of the laser displacement sensor through a controller, and calculating the step length lambda = v/omega in the welding process.
(2) Adjusting the scanning height of the laser displacement sensor: and (3) starting the friction stir welding, connecting the laser displacement sensor with the air cylinder, and adjusting the scanning height of the laser displacement sensor by adjusting the air flow of the air cylinder.
(3) Data preprocessing: the stirring head advances along the welding direction, the laser displacement sensor is positioned at the positive rear side of the advancing direction of the stirring head to collect the height change characteristics of the surface arc lines in real time, the height change characteristics can be obtained according to the attached figure 3, and the number of the collected points is xiThe collection height is hiAnd the generation of surface arc lines is caused by the heat cycle accumulation and dissipation, macroscopically, highly obvious periodic change exists, a threshold value is set, and data are screened in real time.
(4) And (3) data analysis: defining the data obtained after preprocessing as a data point set { Qi(xi，hi) In which i>0, analyzing by a peak/trough extraction algorithm, and h if a data point meets the requirement of surface arc ripple troughi>hi-1And h isi>hi+1With the surface arc ripple peak requirement, hi<hi-1And h isi<hi+1Data extraction as a set of peak/trough data points { K }i(bi,hi) In which b isiIs a set of data points Qi(xi，hi) Extracting corresponding point sequence number from wave crest/wave trough, collecting data points { Q }i(xi，hi) Every two adjacent data points in the data are c from the base value, then the distance L between adjacent peaks and troughs or between troughs and peaks can be obtainedi=(bi-bi-1)c，LiIs an indirect measurement value of the size of the arc lines on the welding surface of the friction stir welding through a laser displacement sensor.
(5) And (3) quality evaluation: establishing a detection criterion for the surface arc indirect measurement value obtained in the step (4) and the step length lambda obtained in the step (1) when the step length lambda is 0.8<Li/(λ-Li)<At 1.25, L is considerediSegment is not defective, loop pair Li+1Judging the section; otherwise, LiIf this relationship is not satisfied, L is considered to beiIf the segment has defects, the computer analyzes the interface to display the warning lamp and generate and store the defect record, and the L is circularly pairedi+1Segment is judged, when L isiIf =0, the loop detection command ends and the detection is completed.
The detection method and the device consider the flow mass conservation principle of the viscoplastic material, analyze the root cause generated by the local fluidity defect of the FSW welding material, and accurately and quickly judge whether the welding defect exists, thereby detecting the whole FSW process in real time.
While the present invention has been described with reference to the embodiments, the scope of the present invention should not be limited by the embodiments described above, and it should be understood by those skilled in the art that various modifications can be made without inventive efforts based on the technical solutions of the present invention.
Claims (4)
1. A friction stir welding weld quality dynamic detection method based on laser ranging relates to a device comprising the following steps: friction stir welding main shaft (6), stirring head (1) and laser displacement sensor detection module: the device consists of a cylinder (5), a laser displacement sensor (2), a controller (3) and a computer (4); the method is characterized in that real-time scanning sampling is carried out on surface arc lines generated in the friction stir welding process through a laser displacement sensor (2), sampling data are transmitted into a computer (4) through a controller (3), the computer (4) obtains real-time indirect measurement on the surface arc line distance through a wave crest/trough extraction algorithm, and finally, the dynamic detection on the quality of a weld joint is realized by analyzing the change condition of the surface arc line distance, and the method comprises the following steps:
(1) setting parameters: selecting parameters of a friction stir welding process according to welding materials, wherein the parameters comprise a forward speed v and a rotating speed omega, setting the sampling frequency of a laser displacement sensor through a controller, and calculating the step length lambda = v/omega in the welding process;
(2) adjusting the scanning height of the laser displacement sensor: when the friction stir welding is started, the laser displacement sensor is connected with the air cylinder, and the scanning height of the laser displacement sensor is adjusted by adjusting the air flow of the air cylinder;
(3) data preprocessing: the stirring head advances along the welding direction, the laser displacement sensor is positioned at the positive rear side of the advancing direction of the stirring head to collect the height change characteristics of the surface arc lines in real time, and the number of the collected points is xiThe collection height is hiGenerating surface arc lines caused by heat cycle accumulation and dissipation, macroscopically having highly obvious periodic variation, setting a threshold value, and screening data in real time;
(4) and (3) data analysis: defining the data obtained after preprocessing as a data point set { Qi(xi，hi) In which i>0, analyzing by a peak/trough extraction algorithm, and h if a data point meets the requirement of surface arc ripple troughi>hi-1And h isi>hi+1And surface arc ripple peak requirement, hi<hi-1And h isi<hi+1Data extraction as a set of peak/trough data points { K }i(bi,hi) In which b isiIs a set of data points Qi(xi，hi) Extracting corresponding point sequence number from wave crest/wave trough, collecting data points { Q }i(xi，hi) Every two adjacent data points in the data are c from the base value, then the distance L between adjacent peaks and troughs or between troughs and peaks can be obtainedi=(bi-bi-1)c，LiFor welding surface arc line size by friction stir welding through laser displacement sensorReceiving a measured value;
(5) and (3) quality evaluation: establishing a detection criterion for the surface arc indirect measurement value obtained in the step (4) and the step length lambda obtained in the step (1) when the step length lambda is 0.8<Li/(λ-Li)<At 1.25, L is considerediSegment is not defective, loop pair Li+1Judging the section; otherwise, LiIf this relationship is not satisfied, L is considered to beiIf the segment has defects, the computer analyzes the interface to display the warning lamp and generate and store the defect record, and the L is circularly pairedi+1Segment is judged, when L isiIf =0, the loop detection command ends and the detection is completed.
2. The dynamic detection method for the quality of the friction stir welding seam based on the laser ranging as recited in claim 1, characterized in that: for the formed set of data points Qi(xi，hi) And (4) constructing a data point curve for the data point set and performing segmented fitting on the data point curve through a B sample line.
3. The dynamic detection method for the quality of the friction stir welding seam based on the laser ranging as recited in claim 1, characterized in that: the method predicts the advancing distance of one period through v and omega by the aid of the stepping length lambda = v/omega.
4. The dynamic detection method for the quality of the friction stir welding seam based on the laser ranging as recited in claim 1, characterized in that: the method is only suitable for the constant-speed welding stage of friction stir welding, and is not suitable for the initial insertion stage and the final withdrawal stage of the stirring head.
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| CN101559512A (en) * | 2009-05-21 | 2009-10-21 | 山东大学 | Welding track detection and control method of plate butt weld based on laser ranging |
| DE102008046692A1 (en) * | 2008-09-10 | 2010-03-11 | Eads Deutschland Gmbh | Destruction-free testing of welding seam, which is produced by a friction stir welding process using a friction stir tool between two joining partners, comprises locally introducing heat in an area of the welding seam |
| EP3090828A1 (en) * | 2013-12-27 | 2016-11-09 | Kawasaki Jukogyo Kabushiki Kaisha | Friction stir spot welding apparatus, friction stir spot welding method, and device for detecting perpendicularity to surface for friction stir spot welding |
| CN107138848A (en) * | 2017-05-09 | 2017-09-08 | 沈阳理工大学 | Pressure and moment of torsion On-line sampling system device for agitating friction weldering |
| CN109014560A (en) * | 2018-08-13 | 2018-12-18 | 燕山大学 | The on-line measuring device and detection method of stirring-head drafts |
| CN109570729A (en) * | 2018-11-28 | 2019-04-05 | 湘潭大学 | A method of stirring friction welding seam penetration quality dynamic is detected based on torque |
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Patent Citations (6)
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|---|---|---|---|---|
| DE102008046692A1 (en) * | 2008-09-10 | 2010-03-11 | Eads Deutschland Gmbh | Destruction-free testing of welding seam, which is produced by a friction stir welding process using a friction stir tool between two joining partners, comprises locally introducing heat in an area of the welding seam |
| CN101559512A (en) * | 2009-05-21 | 2009-10-21 | 山东大学 | Welding track detection and control method of plate butt weld based on laser ranging |
| EP3090828A1 (en) * | 2013-12-27 | 2016-11-09 | Kawasaki Jukogyo Kabushiki Kaisha | Friction stir spot welding apparatus, friction stir spot welding method, and device for detecting perpendicularity to surface for friction stir spot welding |
| CN107138848A (en) * | 2017-05-09 | 2017-09-08 | 沈阳理工大学 | Pressure and moment of torsion On-line sampling system device for agitating friction weldering |
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