CN114523187A - Friction stir point connection process based on concave pin-free shoulder reinforced light alloy/thermoplastic composite material connection strength - Google Patents
Friction stir point connection process based on concave pin-free shoulder reinforced light alloy/thermoplastic composite material connection strength Download PDFInfo
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- CN114523187A CN114523187A CN202210073620.2A CN202210073620A CN114523187A CN 114523187 A CN114523187 A CN 114523187A CN 202210073620 A CN202210073620 A CN 202210073620A CN 114523187 A CN114523187 A CN 114523187A
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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 relates to the technical field of friction solid phase connection of metal and thermoplastic non-metal composite materials, in particular to a friction stir point connection process based on concave pin-free shaft shoulder reinforced light alloy/thermoplastic composite material connection strength. The invention provides a method for adopting a pin-free concave shaft shoulder tool head on the basis of a conventional friction stir point connecting process, which promotes the outer side metal below a shaft shoulder to be pressed and deformed, forms outer side high pressure on a lap joint interface, improves the interface heat distribution state and strengthens the mechanical anchoring and physical bonding connection between a metal surface and a melting layer. The method has the advantages of high applicability, simplicity in operation, no obvious increase in production cost and the like, ensures the surface quality of the joint, overcomes the defects of low bonding strength, obvious joint thinning and the like in the conventional technology, and obviously improves the performance of the joint.
Description
Technical Field
The invention relates to the technical field of friction solid phase connection of light metal and metal composite materials, in particular to a friction stirring point connection method of a metal and carbon fiber reinforced thermoplastic polymer matrix composite material by adopting a pin-free concave shaft shoulder stirring head.
Background
The information in this background section is only for enhancement of understanding of the general background of the invention and is not necessarily to be construed as an admission or any form of suggestion that this information forms the prior art that is already known to a person of ordinary skill in the art.
The urgent need for structural lightweighting has prompted further application of overlapping composite structures of lightweight metals and thermoplastic composites. The carbon fiber reinforced thermoplastic polymer matrix Composite (CFRP) with high specific strength and high specific stiffness is adopted to replace the traditional single metal structure, so that the structural self weight can be remarkably reduced while the requirement on the mechanical performance of the structure is met. The great difference in physical and chemical properties between metal and CFRP makes it very challenging how to optimize the connection process conditions to achieve high strength bonding between the two. At present, the friction solid phase connection process has been developed into one of the advanced connection technologies of metal and thermoplastic composite materials by virtue of the technical advantages of low heat input, few process parameters, high process flexibility and the like, and is concerned by researchers at home and abroad. Among these, friction stir spot joining is particularly useful for lap joints between metal and CFRP panel structures. In the friction stirring connection process, a stirring head rotating at a high speed is pressed down to contact the upper side metal plate, and the temperature of the metal plate is quickly increased due to heat generated by friction; meanwhile, heat is conducted to the joint surface of the upper side metal plate and the lower side CFRP plate, and the thermoplastic matrix in the CFRP is heated and melted; the upper metal plate is concave and deformed along with the downward pressing of the stirring tool head; under the influence of the pressure action and plastic deformation of the upper metal plate, the lower surface of the metal plate and the melting area of the upper surface of the CFRP complete the physical bonding and chemical connection processes to form a lap joint. At present, the stirring head used for connecting friction stir points is mostly a stirring head for friction stir welding, namely a shaft shoulder and a stirring pin, or the stirring head with a flat shaft shoulder without the stirring pin. Wherein, the conventional stirring head is adopted, the pressing amount is too large, and the penetrated stirring pin or large concave deformation is large and can damage the fiber structure at the CFRP side; the former does not have the problem of penetration of a stirring needle, but the strength of the faying surface of the obtained metal and the CFRP joint is limited, the integral load-resisting strength can be improved to a certain extent by improving the heat input and increasing the fusion area, but the bearing capacity per unit area of a combination area is obviously reduced due to the defects of outflow of a large amount of molten resin and residual bubbles caused by overheating.
Disclosure of Invention
In order to solve the problems, the invention provides a novel needleless concave shaft shoulder-based metal and CFRP friction stir point connecting process, designs a needleless concave shaft shoulder tool head suitable for connecting a metal and a CFRP friction stir point, and sets a corresponding connecting process, thereby solving the technical problems of the conventional process and the needleless tool head.
In order to achieve the technical purpose, the invention adopts the following technical scheme:
the invention provides a friction stir point connection process for strengthening connection strength of light alloy/thermoplastic composite material based on a concave pin-free shaft shoulder, which comprises the following steps:
selecting die steel or common alloy steel material to prepare a cylindrical tool head, wherein a groove surface with certain concavity is designed on the inner side of the shaft shoulder end surface of the tool head, and a 45-degree chamfer transition mode is adopted at the joint of the groove surface and the original end surface; fixing the tool head in a welding equipment stirring tool head fixing device;
preprocessing a workpiece, clamping and fixing the workpiece, wherein the workpiece is a metal plate to be welded and a CFRP plate to be connected;
and welding the workpiece by adopting a process of connecting pin-shoulder-free stirring points.
The research finds that: in the friction stir point connecting metal and CFRP process, the connection mechanism of the bonding area mainly relates to the macro/micro mechanical interlocking effect, the physical adhesion effect and the chemical bonding effect of the molten viscous flowing resin matrix on the metal surface. The formation of the three main connection mechanisms is closely related to the thermal distribution state of the lap joint interface area, so one of the keys to improving the bonding performance lies in how to optimize the process conditions to create favorable temperature and pressure distribution conditions. In order to achieve the purpose, the invention provides a novel metal and CFRP friction stir point connecting process based on a needleless concave shaft shoulder, and the joint performance is further improved by changing the heat generation distribution and the pressure distribution of a friction contact surface between a tool head and a metal plate so as to improve the bonding thermal state of a lap joint surface between metal and CFRP plastic.
In a second aspect of the invention, there is provided a light alloy/thermoplastic composite material prepared by the above method.
The invention provides a pin shoulder-free tool head based on a stirring friction point connection process for strengthening connection strength of light alloy/thermoplastic composite material by using a concave pin shoulder-free tool head, the tool head is cylindrical, a groove surface with certain concavity is designed on the inner side of the end surface of the pin shoulder, and a 45-degree chamfer transition mode is adopted at the joint of the groove surface and the original end surface.
The invention has the beneficial effects that:
(1) the invention has simple process, can be completed by only adopting the concave shaft shoulder tool head on the original process and matching proper connecting process parameters, and has few connecting parameters and easy control. The design scheme of the concave shaft shoulder avoids larger metal concave deformation under the same pressing amount, and reduces the reduction of the lapping interface; on one hand, the friction contact mode can be changed to reduce the heat input under the same rotating speed, and the adjustable range of the rotating speed is expanded. In the forming process of a connection mechanism, the concave shaft shoulder forcibly changes the plastic deformation stress characteristic of the metal side and the distribution characteristic of friction heat generation, so that the metal right below the tool head and the outer side area of a CFRP (carbon fiber reinforced plastics) lap joint interface form the annular high-pressure distribution characteristic, and meanwhile, the concave deformation of the metal is reduced, so that a fusion layer is favorably enabled to be more concentrated on a combination area right below the stirring head to be connected with the lower surface of the metal; in addition, the restriction of the outside annular high pressure to the flow of the molten layer from outside to inside is beneficial to strengthening mechanical occlusion and physical adhesion which are formed on the interface, and the bonding strength is further improved.
(2) The method has the advantages of simple operation method, low cost, universality and easy large-scale production.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this specification, are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification, illustrate exemplary embodiments of the invention and together with the description serve to explain the invention and not to limit the invention.
FIG. 1 is a schematic view of a friction stir spot joining tool head designed in accordance with the present invention;
FIG. 2 is a schematic diagram of the connection of friction stir points of metal and thermoplastic composite materials designed according to the present invention;
FIG. 3 is a schematic diagram of the strengthening effect of mechanical anchoring and physical bonding to the bonding area of the lap joint interface during depression of the female shoulder during welding;
FIG. 4 shows the results of the female shoulder reinforced aluminum alloy/CFRP friction stir spot bond joint interface of the embodiment.
Detailed Description
It is to be understood that the following detailed description is exemplary and is intended to provide further explanation of the invention as claimed. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.
A friction stir point connection process based on concave pin-free shoulder reinforced light alloy/thermoplastic composite connection strength comprises the following steps:
the method comprises the following steps: design of novel needle-free shaft shoulder tool head
Selecting die steel or common alloy steel material to prepare a cylindrical tool head, wherein the main body shape of the tool head is similar to that of a conventional friction stir welding tool head, and the size of a fixed end is based on the specification of a matched welding machine shaft sleeve; the difference is that the inner side of the shaft shoulder end surface is designed with a groove surface with certain concavity, and the joint of the groove surface and the original end surface adopts a 45-degree chamfer transition form to fix the groove surface in a stirring tool head fixer of welding equipment;
step two: preparation before welding and workpiece clamping and fixing
Firstly, wiping clean the surface to be welded of the metal and the surface of a CFRP plate to be connected by alcohol, and stacking the surface to be welded of the metal and the surface of the CFRP plate to be connected together to form a lap joint area, wherein the upper side is a metal plate, and the lower side is a CFRP plate; the metal upper surface is fixed by a clamp, so that rigid sliding is prevented in the connection process;
step three: selecting welding parameters and starting and finishing welding;
setting technological parameters of the connection of the friction stir points, such as the rotating speed, the pressing amount, the pressing speed, the retention time and the like of the stirring tool head; and then, starting the connection process of the friction stir points, pressing the tool head to contact the metal plate, and then drawing away the metal plate after reaching a certain pressing amount or drawing away the metal plate after keeping a certain time. And after cooling for a period of time, unloading the rotating speed, and unloading the tool to finish the welding process.
Wherein the content of the first and second substances,
the diameter range of the needleless shaft shoulder stirring tool head in the step one relates to 10-30mm, wherein the depth adjustable range of the concave groove in the end face of the shaft shoulder is 1/10-1/5 mm of the thickness of the metal plate, about 0.1-1mm (taking 1-5mm of the metal plate as reference), and the diameter adjustable range is 1/2-2/3 mm of the diameter of the shaft shoulder, about 5-20 mm;
firstly, the roughness of the surface of the stirring tool head is based on the appearance of original metallic luster, and the stirring tool head is clamped and fixed on a tool head fixer of a conventional friction stir welding machine or a spot welding machine without special design;
the light metal material in the second step comprises titanium alloy, aluminum alloy, magnesium alloy and the like, and the plate thickness is 1-5 mm; the carbon fiber reinforced thermoplastic composite material comprises polyether ether ketone (PEEK), polyphenylene sulfide (PPS) or nylon six (PA6) and the like which are short-distance or continuous carbon fiber reinforced, and the thickness of the composite material plate is 2-5 mm;
the metal surface in the second step can be pretreated by a method including but not limited to surface microtexture preparation, silane coupling agent coating, mechanical polishing and roughness increasing and the like; wherein the microtexture can be prepared by femtosecond, picosecond or nanosecond laser processing technology, the microtexture is recommended to be composed of an elliptical groove array structure, the distance is 80-200 mu m, and the depth is 200-450 mu m; the silane coupling agent coating is preferably finished by heat preservation at the temperature of 100-120 ℃ for 40-60 min;
the connection process parameters in the third step are as follows, the rotating speed of the tool head is 250-2000rpm, the pressing speed is 0.05-0.2mm/s, and the pressing amount is 1-2 times of the groove depth of the selected tool head; after the pressing is finished, the tool head continuously rotates for 0-10 s;
in some embodiments, the tool bit diameter DsThe range of 10-30mm, wherein the depth d of the groove in the end face of the shaft shoulder can be adjusted to 1/10-1/5 of the thickness of the metal plate, and is about 0.1-1mm (taking 1-5mm of the metal plate as reference))，DcThe diameter adjustable range is 1/2-2/3 of the diameter of the shaft shoulder, and is about 5-20 mm;
the present invention is described in further detail below with reference to specific examples, which should be construed as illustrative rather than restrictive.
Example 1
A process method for reinforcing a friction stir point joint of metal and carbon fiber reinforced composite material based on an inwards concave shaft shoulder comprises the following steps:
step one, processing and preparing the needleless concave stirring tool head as shown in figure 1. Wherein the diameter sizes of the shaft shoulder and the end face groove are respectively DsAnd DcThe depth of the groove is d.
And step two, cleaning the metal surface by alcohol, and coating the lap joint area by adopting silane coupling alloy. Clamping the workpiece and fixing the center position of the stirring tool head as shown in fig. 2. The metal is arranged on the upper layer of the lap joint structure, and the upper surface is fixed and compressed by a clamp to prevent rigid sliding.
Setting the rotating speed, the pressing speed and the time of the tool head; after the tool head is moved downwards to contact the upper surface of the metal, recording the original position of the friction end surface of the tool head through a welding machine displacement sensor; after a welding program is started, recording the change of the pressing amount after the tool head contacts the upper surface of the metal, and keeping the horizontal position after the set pressing time is reached; the resin matrix on the upper surface of the CFRP melts to form a thin molten layer that makes dense contact with the lower surface of the metal (as shown in fig. 2).
Step four, the tool head continues to keep a rotating state, and after the staying time is finished, the tool head is upwards pulled away; the molten resin matrix cools and solidifies, forming mechanical anchoring, physical bonding and chemical bonding with the metal upper surface (as shown in fig. 2).
In this embodiment, the adopted metal material is 6061 aluminum alloy and has a thickness of 2mm, and the carbon fiber reinforced thermoplastic composite material is short-distance non-continuous carbon fiber reinforced nylon six (CF-PA6) and has a thickness of 3 mm.
In this example, the metal surface was coated with a silane coupling agent at a concentration of 5%, and was kept at a constant temperature of 120 ℃ for 50 min.
In the embodiment, the diameter of the shaft shoulder is 20mm, the diameter and the depth of the groove are 12mm and 0.2mm, and the material is SKD steel.
In this embodiment, the tool bit has a rotation speed of 1500rpm, a pressing speed of 0.1mm/s, a pressing time of 3s, and a pressing amount of 0.3 mm.
In the embodiment, a needleless concave shaft shoulder tool head is adopted, in the pressing process, the metal plate is plastically deformed to be characterized by high outside and small inside, and meanwhile, the internal heat production is reduced; the pressure distribution of the lap joint interface is annularly distributed, the free flow of the internal molten resin matrix towards the outside is restrained, the contact action time of the internal molten resin matrix and the lower surface of the metal is relatively increased, the micro-mechanical anchoring effect and the physical adhesion are favorably strengthened, and the principle is shown in figure 3.
In this embodiment, a needleless flat shoulder tool head with a diameter of 20mm is used as a reference, and the tensile-shear strength and the interface fracture morphology of the two stirring tool heads are compared under the condition that other process conditions are consistent, as shown in fig. 4; the concave shoulder tool head is adopted, the concave area on the aluminum alloy side is annular, and more fibers and resin are remained on the CFRP side adhered to the metal surface after the tool head is broken, which shows that the interface combination state is strengthened by adopting the pin-free concave stirring tool head, and the tensile and shearing strength results of the joint also prove the findings.
It should be noted that the above-mentioned embodiments are only preferred embodiments of the present invention, and the present invention is not limited thereto, and although the present invention has been described in detail with reference to the foregoing embodiments, it will be apparent to those skilled in the art that modifications and equivalents can be made in the technical solutions described in the foregoing embodiments, or equivalents thereof. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (10)
1. A friction stir point connection process based on concave pin-free shoulder reinforced light alloy/thermoplastic composite connection strength is characterized by comprising the following steps of:
selecting die steel or common alloy steel material to prepare a cylindrical tool head, wherein a groove surface with certain concavity is designed on the inner side of the shaft shoulder end surface of the tool head, and a 45-degree chamfer transition mode is adopted at the joint of the groove surface and the original end surface; fixing the tool head in a welding equipment stirring tool head fixing device;
preprocessing a workpiece, clamping and fixing the workpiece, wherein the workpiece is a metal plate to be welded and a CFRP plate to be connected;
and welding the workpiece by adopting a process of connecting pin-shoulder-free stirring points.
2. The friction stir spot joining process for strengthening the joint strength of a lightweight alloy/thermoplastic composite material based on a concave pin-free shoulder as claimed in claim 1, wherein the metal plates to be welded and the CFRP plates to be joined are stacked to form a faying surface region, the upper side is the metal plate and the lower side is the CFRP plate.
3. The friction stir spot joining process for concave pin-free shoulder-reinforced lightweight alloy/thermoplastic composite joint strength according to claim 1, wherein the tool bit diameter DsThe range is 10-30mm, wherein the depth D of the concave groove in the end surface of the shaft shoulder is adjustable within the range of 1/10-1/5, D of the thickness of the metal platecThe diameter adjustable range is 1/2-2/3 of the diameter of the shaft shoulder.
4. The friction stir point connection process based on concave pin-free shoulder-reinforced lightweight alloy/thermoplastic composite material connection strength as claimed in claim 1, wherein the material of the metal plate to be welded is titanium alloy, aluminum alloy or magnesium alloy, preferably the plate thickness is 1-5 mm;
or the carbon fiber reinforced thermoplastic composite material CFRP is polyether ether ketone, polyphenylene sulfide or nylon six reinforced by short-distance or continuous carbon fibers, and the thickness of the composite material plate is preferably 2-5 mm.
5. The friction stir spot joining process for strengthening the joining strength of a light alloy/thermoplastic composite material based on a concave pin-free shoulder according to claim 1, wherein the surface of the metal plate to be welded is pretreated by: preparing a surface micro-texture, coating a silane coupling agent and mechanically polishing.
6. The friction stir point connection process based on the concave pin-free shoulder-reinforced light alloy/thermoplastic composite material connection strength as claimed in claim 5, wherein the microtexture is prepared by femtosecond, picosecond or nanosecond laser processing technology, the microtexture is composed of an elliptical groove array structure, the distance is 80-200 μm, and the depth is 200-;
or, the silane coupling agent is coated at the temperature of 100-120 ℃ and is insulated for 40-60 min.
7. The friction stir spot joining process for strengthening the joining strength of a light alloy/thermoplastic composite material based on a concave pin-free shoulder according to claim 1, wherein the welding comprises the following specific steps: setting technological parameters of friction stir point connection; then, starting the connection process of the friction stir points, pressing the tool head to contact the metal plate, and then drawing away the metal plate after reaching a preset pressing amount or drawing away the metal plate after keeping the metal plate for a certain time; and after cooling for a period of time, unloading the rotating speed, and unloading the tool to finish the welding process.
8. The friction stir point connection process based on the concave pin-free shoulder-reinforced lightweight alloy/thermoplastic composite material connection strength as claimed in claim 1, wherein the connection process parameters are as follows, the tool head rotation speed is 250-2000rpm, the pressing speed is 0.05-0.2mm/s, and the pressing amount is 1-2 times of the groove depth of the selected tool head; after the pressing is finished, the dwell time of the tool head for continuous rotation is 0-10 s.
9. A light weight alloy/thermoplastic composite prepared by the method of any one of claims 1-8.
10. A pin shoulder-free tool head based on a concave pin shoulder-free reinforced lightweight alloy/thermoplastic composite material connection strength friction stir point connection process is characterized in that the tool head is cylindrical, a groove surface with a certain concavity is designed on the inner side of the end face of a pin shoulder, and a 45-degree chamfer transition form is adopted at the joint of the groove surface and the original end face.
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