摘要
随着高强钢、铝合金轻量化材料在汽车制造中应用量的增加,铝合金/高强钢异种金属连接科学技术便成为亟待解决的问题。由于铝合金与高强钢异种金属间物理性能存在显著的差异,且Fe在Al中的固溶度极低,导致铝合金/高强钢异种金属的焊接性极差,焊接接头中容易产生缩孔、裂纹等缺陷及硬脆的金属间化合物,大幅度降低了接头的力学性能,这已成为铝合金与高强钢在汽车制造中更广泛应用的主要技术瓶颈之一。
本文开展6088-T66铝合金/H220YD高强钢异种金属电阻点焊研究,首先较系统地研究了铝合金/高强钢异种金属电阻点焊接头的组织与性能。研究结果表明,铝合金/高强钢点焊接头主要由铝合金熔核和热影响区组成,本质上属于熔钎焊接头。铝合金与高强钢之间存在着明显的界面,界面处形成了厚度不均匀的金属间化合物层,其主要相组成为靠近高强钢侧的Fe_2Al_5和靠近铝合金侧的Fe_4Al_(13)。铝/钢界面区的硬度分布是不均匀的,界面金属间化合物层的纳米硬度值显著高于两侧区域。点焊接头在拉剪试验中主要以结合面断裂方式破坏,铝合金熔核在铝/钢界面区与高强钢分离。裂纹首先在靠近高强钢侧铝/钢界面金属间化合物层(Fe_2Al_5)内部及金属间化合物层与高强钢界面处萌生,随后易沿着金属间化合物层扩展。研究了点焊过程中铝/钢界面反应机制,通过热力学与动力学分析揭示了界面金属间化合物层的生长过程。与Fe_4Al_(13)和FeAl相比,Fe_2Al_5具有相对更高的生长动力学系数,它在界面反应过程中的生长速度高于另外两相的生长速度。
较为系统地研究了点焊参数(焊接电流、焊接时间和电极压力)对铝合金/高强钢电阻点焊接头组织及力学性能的影响规律。结果表明,点焊接头的拉剪力大小与焊接电流、焊接时间和电极压力相关,而点焊接头熔核直径及铝/钢界面硬脆的金属间化合物厚度是决定点焊接头拉剪力的直接因素。在一定熔核直径的条件下(2.4mm-5.7mm),熔核直径是决定点焊接头拉剪力的主要因素,当界面金属间化合物层达到一定厚度时(5.6μm),它对接头拉剪力的限制作用才可体现出来。
研究不锈钢电极板辅助铝合金/高强钢异种金属电阻点焊接头的组织结构特点及点焊参数对电极板辅助点焊接头组织及性能的影响。电极板辅助铝合金/高强钢异种金属电阻点焊接头压痕较小,未出现与电极的粘连以及外部喷溅等缺陷,接头表面成形质量良好;电极板辅助点焊接头熔核尺寸提高约60%,拉剪力提高约30%;铝/钢界面金属间化合物层厚度也有一定程度的减小。
对电极形貌进行优化,得到优化的电极形貌为:高强钢侧为直径φ10mm的圆形平端面电极,铝合金侧为球面半径为R35mm的球形端面电极。随后在在优化电极形貌的基础上对点焊参数进行优化,在优化的点焊参数下(电极压力3.5kN、焊接电流22kA、焊接时间300ms)得到的点焊接头熔核直径为10.1mm、拉剪力为5.4kN、压痕率为16.8%。与采用F型电极的点焊接头相比,熔核直径和拉剪力分别提高了77%和69%,压痕率降低了43%,铝/钢界面金属间化合物层的厚度也有较大幅度的减小。点焊接头拉剪试样的破坏方式为钮扣断裂,与采用F型电极的点焊接头的结合面断裂方式相比有明显的改善。
通过加入中间层进行铝合金/高强钢电阻点焊的方式研究了合金元素(Cu和Si)对接头组织及性能的影响,结果表明,Cu和Si元素均对接头组织及性能具有显著的影响。当填加100μm厚铜中间层时,接头中心界面处产生了厚度为1.1μm的具有单层结构的金属间化合物,其Cu含量为5.36wt.%,相组成主要为(Fe,Cu)_4Al_(13)。Cu元素的加入对铝合金/高强钢界面反应有一定的抑制作用。拉剪试验结果表明,铝/钢界面附近的CuAl_2成为限制点焊接头力学性能的主要因素。当填加300μm厚的4047 AlSi12中间层时,铝/钢界面金属间化合物层具有锯齿状形貌,其厚度为0.9μm,Si含量为4.26wt.%。接头拉剪力最高(6.2kN),比未加中间层时的拉剪力提高约15%。,拉剪试样为纽扣断裂形式。
通过ANSYS有限元模拟软件建立轴对称有限元模型,对采用铝合金/高强钢异种金属点焊过程进行模拟。预压接触行为弹塑性力学分析的结果表明,采用F型电极条件下各接触面(结合面)上的接触压力分布是不均匀的,采用优化电极条件下各接触面(结合面)上的接触压力分布状态较F型电极时有一定程度的改善。对两种电极条件下点焊热过程进行热、电、力多物理场耦合分析,结果表明,F型电极条件下工件与电极的电流密度分布是不均匀的,在点焊参数为电极压力2.5kN、焊接电流9kA、焊接时间250ms时,电流密度在电极端面边缘处出现峰值(3.7×10~3A/mm~2),接头中心界面处温度最高达973℃;优化电极条件下工件与电极的电流密度分布较F型电极时有明显的改善,当点焊参数为电极压力3.5kN、焊接电流22kA、焊接时间300ms时,电流密度在电极端面边缘处出现峰值(2.71×10~3A/mm~2),接头中心界面处温度的最高值为925℃。两种电极条件下数值模拟得到的熔核直径(5.9mm、9.7mm)均与试验结果相吻合。
With the increasing use of high strength steel and aluminum alloy in automotive manufacturing industry, it has became an indispensible problem to be solved to study the joining technology of dissimilar materials of aluminum alloy and high strength steel. Due to the great discrepancies concerning the physical and chemical properties between aluminum alloy and high strength steel, and the extremely low solid solubility of Fe in Al, the weldability of dissimilar materials of aluminum alloy and high strength steel is poor. Plenty of defects suck as shrinkage cavities, cracks as well as intermetallic compound layer are readily to be formed in the welded joint, and they will lower mechanical properties of the welded joint greatly, which thereby turns out to be one of the main technical bottlenecks in further extensive use of aluminum alloy and high strength steel in the domain of vehicle manufacturing.
The study on resistance spot welding of dissimilar materials of aluminum alloy and high strength steel was carried out in the paper. Microstructures and mechanical properties of dissimilar material resistance spot welded joints were studied systematically firstly. The results showed that the resistance spot welded joint of dissimilar materials of aluminum alloy and high strength steel was composed of aluminum nugget and heat affected zone, which belonged to an especial welding-brazing joint in essential. An evident interface was observed between aluminum nugget and high strength steel, and intermetallic compound layers with unequal thicknesses were formed in the aluminum/steel interface, which were composed of Fe_2Al_5 on high strength steel side and Fe_4Al_(13) on aluminum alloy side. It was not uniform in the nanohardness distribution at the interfacial zone, and the value of nanohardness of the intermetallic compound layer was higher than that of other regions. Interfacial failure mode was obtained during the tensile shear testing, with aluminum nugget detaching from the high strength steel at the interfacial zone. The cracking tended to initiate at the inetrmetallic compound layer as well as the interface between the intermetallic compound layer and high strength steel, and then propagate through the intermetallic compound layer. Besides, the interfacial reaction mechanism was studied, and the growth process of the intermetallic compound layer was studied by means of thermal dynamics and kinetic analysis. The results showed that the growth kinetic coefficient for Fe_2Al_5 was higher than those of Fe_4Al_(13) and FeAl, which resulted in the faster growth for the former phase.
Effects of resistance spot welding parameters (welding current, welding time and electrode force) on microstructures and mechanical properties of dissimilar material resistance spot welded joints were studied. The results indicated that the tensile shear load of the welded joint was mainly decided by welding current, welding time and electrode force. The nugget diameter of the welded joint and the thickness of the brittle intermetallic compound layer, however, were direct factors which regulated the tensile shear load of the welded joint. When the nugget diameter varied from 2.4mm to 5.7mm, it became the major factor which decided the tensile shear load of the welded joint, while the limiting of the interfacial intermetallic compound layer on the tensile shear load began to act immediately its thickness exceeded 5.6μm. Resistance spot welding of dissimilar materials of aluminum alloy and high strength steel with electrode plate was carried out, and microstructures of welded joints were studied. Besides, effects of welding parameters on microstructures and mechanical properties of the welded joints with electrode plate were carried out. The results showed that the indentation ratio of the welded joint was shallow enough, and the surface forming quality was acceptable since no expulsion and alloying process were observed. Compared with the nugget diameter and tensile shear load of the welded joint with F type electrode, the nugget diameter and tensile shear load of the welded joint were improved by 60% and 30%, respectively. Furthermore, the thickness of of interfacial intermetallic compound layer also decreased to a certain extent.
The morphology of electrode tip was optimized, and the optimum electrode morphologies were drawn as follows: the electrode tip diameter on high strength steel side was 10mm, and the spherical electrode radius was 35mm on aluminum alloy side. Based on the optimum electrode morphologies, welding parameters were optimized. Under the optimum welding parameters (electrode force of 3.5kN, welding current of 22kA, welding time of 300ms), the nugget diameter (10.1mm) and tensile shear load (5.4kN) were improved by 77% and 69%, respectively, compared to those of the welded joint obtained with F type electrode. Meanwhile, the indentation ratio (16.8%) decreased by 43%. The tensile shear specimen of the welded joint fractured in the nugget pullout failure mode, which was improved dramatically as compared to that with F type electrode.
Effects of alloy elements (Cu, Si) on joint microstructures and properties were studied by the method of adding interlayer between high strength steel and aluminum alloy during resistance spot welding. The results showed that both Cu and Si had great effects on joint microstructures and properties. With the addition of 100μm thick Cu interlayer, the single-layer structure of the intermetallic compounds with thickness of 1.1μm was formed in the aluminum/steel interface at the joint center, which contained 5.36wt.% Cu, and the phase compositions were mainly (Fe,Cu)_4Al_(13). Cu additions led to the suppression in the interfacial reaction between aluminum alloy and high strength steel to a certain extent. The tensile shear test results showed that CuAl_2 near the aluminum/steel interface turned out to be the main reason to restrict the joint mechanical properties. With the addition of 300μm thick 4047 AlSi12, the intermetallic compound layer exhibited serrated feature, with the thickness of 0.9mm and containing 4.26wt.% Si. The joint tensile shear load reached the highest value (6.2kN), increasing by 15% compared with the welded joint without interlayer. Tensile-shear specimen of the welded joint displayed a nugget pullout failure mode.
An axisymmetrical finite element model by ANSYS finite element simulation software was developed for studying the process of resistance spot welding of dissimilar materials of aluminum alloy and high strength steel with both F type electrodes and optimized electrodes. The elastic-plastic mechanics analysis results of the pre-pressure contact behavior showed that the distribution of the contact pressure on the interfaces was un-uniform when using F type electrode, and that the distribution of the contact pressure on the interfaces improved to a certain extent when optimized electrodes were used. The multi-physics coupling analysis of heat, electricity and force on thermal process during resistance spot welding under both electrodes conditions showed that the distribution of the current density in workpieces and electrodes was un-uniform when using F type electrodes, and that when the resistance spot welding parameters was (electrode force of 2.5kN, welding current of 9kA, welding time of 250ms), the current density appeared a peak value of 3.7×10~3A/mm~2 on the region near the edge of electrode tip, and the temperature of the aluminum/steel interface at joint center reached the highest value (973℃). The distribution of the current density in workpieces and electrodes was improved greatly by using optimized electrodes, and when the resistance spot welding parameters were (electrode force of 3.5kN, welding current of 22kA, welding time of 300ms), the current density appeared a peak value of 2.7×10~3A/mm~2 on the region near the edge of the electrode tip, and the temperature of the aluminum/steel interface at joint center reached the highest temperature (925℃). The nugget sizes (5.9mm、9.7mm) obtained by means of after numerical simulation under the two types of electrodes were consistent with experimental results.
引文
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