連續驅動摩擦焊接技術的研究與工程應用

張晗; 朱志明

doi:10.13374/j.issn2095-9389.2021.03.13.001

連續驅動摩擦焊接技術的研究與工程應用

doi: 10.13374/j.issn2095-9389.2021.03.13.001

張晗^{1, 2, 3},
朱志明^{1, 2, ,}

1.
清華大學機械工程系，北京 100084
2.
清華大學先進成形制造教育部重點實驗室，北京 100084
3.
中國人民解放軍32555部隊，廣州 510730

基金項目: 國家自然科學基金資助項目（51775301，51075231）

詳細信息

通訊作者:
E-mail: zzmdme@tsinghua.edu.cn

中圖分類號: TG453
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- 文章訪問數: 4005
- HTML全文瀏覽量: 425
- PDF下載量: 63
- 被引次數: 0
出版歷程
- 收稿日期: 2021-03-13
- 網絡出版日期: 2021-07-06
- 刊出日期: 2022-06-25

Research and engineering application of continuous-drive friction welding

ZHANG Han^{1, 2, 3},
ZHU Zhi-ming^{1, 2
, ,}

1.
Department of Mechanical Engineering, Tsinghua University, Beijing 100084, China
2.
Key Laboratory for Advanced Materials Processing Technology (Ministry of Education), Tsinghua University, Beijing 100084, China
3.
The 32555^th Unit of the People’s Liberation Army of China, Guangzhou 510730, China

More Information

Corresponding author: E-mail: zzmdme@tsinghua.edu.cn

摘要

摘要: 在對摩擦焊接進行分類并簡要說明的基礎上，對連續驅動摩擦焊接技術的研究發展和應用現狀進行了全面梳理和深入剖析，涉及焊接工藝過程特征和主要工藝參數、工藝探索及工藝參數對接頭性能的影響、數值分析和模擬及工藝參數優化、異種金屬和非金屬材料摩擦焊接與工藝創新、實際工程應用和焊接設備等方面。從摩擦焊接技術的潛在應用、核心科學問題、新型摩擦焊接設備的研發、數值分析和模擬、與新興技術的結合等方面，對連續驅動摩擦焊接技術進行了評述和探討。
- 連續驅動摩擦焊 /
- 焊接工藝參數 /
- 摩擦焊設備 /
- 有限元分析 /
- 摩擦焊應用
Abstract: The friction welding (FW) technology is a kind of solid-phase hot pressing welding method applied to the connection of similar or dissimilar materials. During the FW process, welding heat is generated by the pressure and high-speed relative motion between the joint interfaces of the workpieces. After the joint interfaces and their neighborhood arrive at the thermoplastic state, the workpieces are pressed into a whole by upsetting. FW has a wide range of weldability (e.g., carbon steel, alloy steel, non-ferrous metals, other materials of the same kind, dissimilar metal materials, and metal and non-metal materials with completely different properties) and can obtain welded joints with excellent properties (closed to base metal) and fewer defects (e.g., cracks, pores, and segregation); thus, it has high reliability to welded joints. As its advantages, FW exhibits low energy consumption (i.e., 10%–20% of fusion welding), high efficiency (i.e., only a few seconds to realize an effective joining of the workpieces), and environmental friendliness (i.e., no welding rod, wire, flux, or protective gas and no arc, spatter, smoke, or slag as in fusion welding) and can easily realize automation and large-scale production. FW is widely used in high-tech manufacturing in various industries, including in the automobile, aviation, aerospace, nuclear energy, oil drilling, marine development, and electric power industries. On the basis of the classification and the brief description of FW, the present situation of the research, development, and application of the continuous-drive FW (CDFW) technology was comprehensively sorted out and analyzed in-depth in this paper. This study involved the CDFW process characteristics and main process parameters, process exploration, influence of the process parameters on welded joint properties, numerical analysis, simulations, process parameter optimization, CDFW process innovation for dissimilar metals and non-metallic materials, practical engineering applications, and welding equipment, among others. The aspects of the potential applications of the FW technology, core scientific issues, research and development of the novel FW equipment, numerical analysis and simulation, and combination with emerging technologies associated with the CDFW technology were also reviewed and discussed.
- continuous-drive friction welding /
- welding process parameters /
- friction welding equipment /
- finite element analysis /
- application of friction welding

HTML全文

圖 1 摩擦焊接技術分類

Figure 1. Classification of the friction welding technology

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圖 2 連續驅動摩擦焊。（a）原理示意圖；（b）工藝參數變化規律

Figure 2. Continuous-drive friction welding: (a) schematic diagram; (b) change of the process parameters

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圖 3 不同轉速下的AA6061-T6鋁合金CDFW接頭界面形態演變^[12]

Figure 3. Evolution of the AA6061-T6 alloy CDFW joint interface morphologies under different rotation speeds^[12]

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圖 4 不同轉速下的GH4169 CDFW接頭飛邊形貌演變^[11]

Figure 4. Evolution of the flash appearance of the GH4169 CDFW joint with different rotation speeds^[11]

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圖 5 5A33鋁合金和AZ31B鎂合金CDFW接頭在不同摩擦時間下的宏觀形貌^[13]

Figure 5. Optical macrographs of the 5A33 Al alloy to the AZ31B Mg alloy CDFW joints at different friction time^[13]

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圖 6 不同摩擦時間的AISI 304L和WC?Co金屬陶瓷的CDFW接頭形態^[24]。（a）4 s；（b）6 s；（c）8 s；（d）10 s；（e）12 s

Figure 6. Photos of the AISI 304L to WC?Co cermet CDFW joints obtained using different friction times^[24]: (a) 4 s; (b) 6 s; (c) 8 s; (d) 10 s; (e) 12 s

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圖 7 AA5052與LCS的CDFW接頭形貌（a）及對應的摩擦扭矩曲線（b）^[26]

Figure 7. Joint morphology (a) and friction torque curve (b) during the CDFW of AA5052 to LCS^[26]

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圖 8 工藝參數對接頭形態的影響^[28]。（a）FT=4 s, UP=120 MPa；（b）FT=4 s, UP=220 MPa；（c）FT=6 s, UP=220 MPa

Figure 8. Influence of the process parameters on the joint morphology^[28]: (a) FT=4 s, UP=120 MPa; (b) FT=4 s, UP=220 MPa; (c) FT=6 s, UP=220 MPa

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圖 9 GH4169 CDFW有限元分析^[30]。（a）工件的二維軸對稱和網格模型；（b）溫度場；（c）接頭形貌

Figure 9. Finite element (FE) models of the GH4169 CDFW^[30]: (a) 2D axisymmetric model and meshing of the workpiece; (b) temperature contour; (c) joint morphology

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圖 10 AISI 1020和ASTM A536的CDFW及焊接工藝基本流程^[32]

Figure 10. Experimental setup for AISI 1020 to ASTM A536 CDFW with the basic steps in the welding process^[32]

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圖 11 聚氯乙烯與聚甲基丙烯酸甲酯CDFW焊縫拉伸試驗斷面微觀組織形態對比（Fud—中心區，Fpd—周邊區，Fpl—中間部分）。（a）未使用溶劑；（b）添加蒸餾水

Figure 11. Comparison of the microstructure morphologies of the CDFW joints after the tensile test (Fud—central zone, Fpd—middle section, Fpl—peripheral zone): (a) without solvent treatment; (b) treated with distilled water

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圖 12 中間層添加及CDFW示意圖^[35]。（a）為不銹鋼工件電沉積添加鎳中間層；（b）帶有鎳中間層的CDFW

Figure 12. Schematic of the interlayer insertion and the CDFW^[35]: (a) insertion of the Ni interlayer on the stainless-steel substrate through the electrodeposition process; (b) CDFW with the Ni interlayer

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圖 13 不同溫度條件下的高頻感應預加熱CDFW連接Al和Cu接頭斷面結構^[36]

Figure 13. Cross-section of the Al to Cu CDFW joints with different pre-heating temperatures by the high-frequency induction pre-heating method^[36]

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圖 14 45^#鋼CDFW接頭形貌^[37]

Figure 14. Macrographs of the 45^# steel CDFW joint^[37]

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圖 15 薄壁管件CDFW^[38]。（a）焊機結構；（b）接頭形貌

Figure 15. Thin-walled pipe CDFW^[38]: (a) welder structure; (b) joint morphology

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圖 16 皮質骨螺釘CDFW^[39]。（a）接頭形貌；（b）皮質骨螺釘設計結構

Figure 16. Cortical bone screw CDFW^[39]: (a) joint morphology; (b) schematic design of cortial bone screws

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