CN105269137A - Intermediate frequency spot welding method for aluminum alloy and zinc-plated high-strength steel dissimilar material - Google Patents
Intermediate frequency spot welding method for aluminum alloy and zinc-plated high-strength steel dissimilar material Download PDFInfo
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- 239000010959 steel Substances 0.000 title claims abstract description 146
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- 238000000034 method Methods 0.000 title claims abstract description 70
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- 239000007769 metal material Substances 0.000 abstract description 2
- 150000001875 compounds Chemical class 0.000 abstract 1
- 229910052782 aluminium Inorganic materials 0.000 description 23
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 22
- 238000004519 manufacturing process Methods 0.000 description 8
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- 238000011160 research Methods 0.000 description 3
- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 2
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Abstract
本发明公开了一种铝合金与镀锌高强钢异种材料中频点焊的方法，属于金属材料焊接技术领域。该方法采用点焊电极对铝合金与镀锌高强钢施焊，其中铝合金侧为直径30-100mm的球面电极，镀锌高强钢侧为直径8-15mm的平端面电极。该方法可减小点焊过程中喷溅的产生，防止工件与电极的粘连及合金化反应；同时提高铝合金侧点焊熔核的尺寸，控制铝合金/镀锌高强钢界面金属间化合物的生长行为，减小脆性FexAly金属间化合物的产生。经过对电阻点焊工艺参数优化得到的铝合金与镀锌高强钢异种材料中频点焊接头性能得到显著提升，点焊接头的拉剪力最高可达5400N，铝合金/镀锌高强钢界面金属间化合物厚度控制在5.0μm以下。The invention discloses an intermediate frequency spot welding method for dissimilar materials of aluminum alloy and galvanized high-strength steel, belonging to the technical field of metal material welding. The method uses spot welding electrodes to weld aluminum alloy and galvanized high-strength steel, wherein the aluminum alloy side is a spherical electrode with a diameter of 30-100 mm, and the galvanized high-strength steel side is a flat end electrode with a diameter of 8-15 mm. This method can reduce the generation of spatter in the spot welding process, prevent the adhesion and alloying reaction between the workpiece and the electrode; at the same time increase the size of the spot welding nugget on the aluminum alloy side, and control the intermetallic compound at the aluminum alloy/galvanized high-strength steel interface growth behavior, reducing the generation of brittle FexAly intermetallic compounds. The performance of intermediate frequency spot welded joints of aluminum alloy and galvanized high-strength steel dissimilar materials obtained by optimizing the resistance spot welding process parameters has been significantly improved. The thickness of the compound is controlled below 5.0 μm.
Description
技术领域technical field
本发明涉及金属材料焊接技术领域，具体涉及一种铝合金与镀锌高强钢异种材料中频点焊的方法。The invention relates to the technical field of metal material welding, in particular to a method for intermediate frequency spot welding of dissimilar materials such as aluminum alloy and galvanized high-strength steel.
背景技术Background technique
在资源紧缺和环境污染的迫切形势下，汽车轻量化是汽车工业领域实现节能减排的对策之一。实现汽车轻量化的途径主要包括轻量化材料的使用、汽车结构的优化设计、先进制造技术的应用。增加汽车车身中铝合金与高强钢等轻质材料的使用比例是实现汽车轻量化最直接有效的方法。在高强钢结构车身中加入铝合金部件的钢/铝复合车身框架结构是当前汽车工业领域实现轻量化的主要设计思路和技术途径。因此，铝合金与高强钢异种材料的连接(焊接)是汽车制造过程中亟需解决的问题。Under the urgent situation of resource shortage and environmental pollution, automobile lightweight is one of the countermeasures to achieve energy saving and emission reduction in the field of automobile industry. The ways to achieve lightweight vehicles mainly include the use of lightweight materials, the optimal design of vehicle structures, and the application of advanced manufacturing technologies. Increasing the proportion of lightweight materials such as aluminum alloy and high-strength steel in the car body is the most direct and effective way to achieve lightweight cars. The steel/aluminum composite body frame structure in which aluminum alloy components are added to the high-strength steel structure body is the main design idea and technical approach to achieve lightweight in the current automotive industry. Therefore, the connection (welding) of aluminum alloy and high-strength steel dissimilar materials is an urgent problem to be solved in the automobile manufacturing process.
汽车工业中铝与钢的连接方法仍然采用传统机械连接方式，如胶接、铆接(包括自冲铆)、螺栓连接等。这些连接方法不仅工艺复杂、效率低、表面质量不美观，而且机械连接接头未能形成牢固的冶金结合，其腐蚀、疲劳等性能往往低于同质材料焊接接头，难以实现优质高效的连接。The connection method of aluminum and steel in the automobile industry still adopts traditional mechanical connection methods, such as adhesive bonding, riveting (including self-piercing riveting), bolting, etc. These connection methods are not only complicated in process, low in efficiency, and unattractive in surface quality, but also mechanically connected joints fail to form a firm metallurgical bond, and their corrosion and fatigue properties are often lower than those of welded joints made of homogeneous materials, making it difficult to achieve high-quality and efficient connections.
由于铝与钢异种材料之间的热物理性能如熔点、比热容、导热系数、电阻率和线膨胀系数等存在较大的差异，并且Fe在Al中的固溶度低，导致铝与钢异种材料之间的焊接性差。若采用传统熔化焊如TIG电弧焊、MIG/MAG电弧焊、CO2气体保护焊等，电阻焊诸如工频交流点焊等，接头中容易产生硬脆的金属间化合物、缩孔、裂纹等缺陷，严重恶化了焊接接头的性能，难以达到使役要求。因此，深入研究铝合金与高强钢异种材料焊接性特点，开发实用高效的焊接技术成为铝合金和高强钢在汽车制造工业中规模化应用的关键问题和技术难点之一。Due to the large differences in thermophysical properties between aluminum and steel dissimilar materials, such as melting point, specific heat capacity, thermal conductivity, resistivity and linear expansion coefficient, and the low solid solubility of Fe in Al, the dissimilar materials of aluminum and steel poor weldability. If traditional fusion welding such as TIG arc welding, MIG/MAG arc welding, CO2 gas shielded welding, etc., resistance welding such as power frequency AC spot welding, etc., defects such as hard and brittle intermetallic compounds, shrinkage cavities, and cracks are likely to occur in the joints , which seriously deteriorates the performance of welded joints, making it difficult to meet service requirements. Therefore, in-depth study of the weldability characteristics of aluminum alloy and high-strength steel dissimilar materials and the development of practical and efficient welding technology have become one of the key issues and technical difficulties in the large-scale application of aluminum alloy and high-strength steel in the automobile manufacturing industry.
目前，国内外学者与工程技术人员尝试采用固相焊、电弧熔—钎焊、激光熔—钎焊和搅拌摩擦焊等方法实现铝与钢异种材料的焊接，具体方法及特点如下：At present, scholars and engineers at home and abroad are trying to achieve welding of dissimilar materials between aluminum and steel by means of solid phase welding, arc melting-brazing, laser melting-brazing and friction stir welding. The specific methods and characteristics are as follows:
(1)固相焊(1) solid phase welding
固相焊方法诸如爆炸焊、磁脉冲焊、超声波焊、摩擦焊等用于铝与钢异种材料焊接时，主要是利用外加强磁场力(磁脉冲焊)、机械振动导致的静压力(超声波焊)、摩擦力(摩擦焊)等诱发待焊的铝与钢异种材料工件在接触面处产生高速塑性流变，挤出接触面上的氧化膜，同时带来温度的骤升促进了界面反应行为，从而实现铝与钢异种材料的冶金结合。固相焊热输入较低，可有效减小铝与钢界面金属间化合物层的厚度，提高焊接接头的力学性能。但是固相焊焊接设备往往对待焊工件或结构的形状与尺寸要求较高，难以满足汽车工业批量化生产的需求。When solid-phase welding methods such as explosive welding, magnetic pulse welding, ultrasonic welding, friction welding, etc. are used for welding aluminum and steel dissimilar materials, they mainly use external magnetic field force (magnetic pulse welding) and static pressure caused by mechanical vibration (ultrasonic welding). ), friction (friction welding), etc. induce high-speed plastic rheology on the contact surface of aluminum and steel dissimilar material workpieces to be welded, extrude the oxide film on the contact surface, and bring about a sudden increase in temperature to promote the interface reaction behavior , so as to realize the metallurgical combination of aluminum and steel dissimilar materials. The solid phase welding heat input is low, which can effectively reduce the thickness of the intermetallic compound layer at the interface between aluminum and steel, and improve the mechanical properties of the welded joint. However, solid-phase welding equipment often has high requirements on the shape and size of the workpiece or structure to be welded, and it is difficult to meet the needs of mass production in the automotive industry.
(2)熔—钎焊(2) melting - brazing
熔—钎焊是采用TIG电弧、MIG电弧或激光作为热源，填加铝基或锌基焊丝对铝与钢异种材料工件进行焊接的方法。为抑制焊接接头中金属间化合物的生长，减小缩孔和裂纹等缺陷，需严格控制焊接工艺以保证钢母材不熔化，铝母材及焊丝熔化并铺展在钢的表面，从而形成熔—钎焊接头。熔—钎焊目前尚处于实验室研究阶段，并且熔—钎焊接头容易在铝/钢界面处断裂，限制了焊接质量的提升。Melting-brazing is a method of welding aluminum and steel dissimilar material workpieces by using TIG arc, MIG arc or laser as the heat source and adding aluminum-based or zinc-based welding wire. In order to inhibit the growth of intermetallic compounds in welded joints and reduce defects such as shrinkage cavities and cracks, it is necessary to strictly control the welding process to ensure that the steel base material does not melt, and the aluminum base material and welding wire melt and spread on the surface of the steel, thereby forming a molten- Brazed joints. Fusion-brazing is still in the stage of laboratory research, and the fusion-brazing joint is easy to break at the aluminum/steel interface, which limits the improvement of welding quality.
(3)搅拌摩擦焊(3) Friction stir welding
搅拌摩擦焊通过搅拌针高速旋转以及搅拌头肩部与待焊铝与钢工件摩擦产热作为热源，在铝与钢界面形成牢固冶金结合的方法。由于搅拌摩擦焊热输入较小，铝/钢界面的金属间化合物生长受到抑制，一定程度上改善了焊接质量。但是铝与钢搅拌摩擦焊尚处于研究探索中，且成本较高，尚未在汽车制造领域中得到应用。Friction stir welding is a method of forming a firm metallurgical bond at the aluminum-steel interface through the high-speed rotation of the stirring needle and the heat generated by the friction between the shoulder of the stirring head and the aluminum and steel workpieces to be welded as the heat source. Due to the small heat input of friction stir welding, the growth of intermetallic compounds at the aluminum/steel interface is inhibited, which improves the welding quality to a certain extent. However, the friction stir welding of aluminum and steel is still in research and exploration, and the cost is relatively high, so it has not been applied in the field of automobile manufacturing.
作为汽车制造过程中使用最广的焊接方法之一，若能通过电阻点焊方法实现铝合金与高强钢优质高效的连接，将极大提升铝合金和高强钢在汽车中的使用量，从而为实现汽车轻量化提供必要的技术基础。As one of the most widely used welding methods in the automobile manufacturing process, if the high-quality and efficient connection of aluminum alloy and high-strength steel can be realized through resistance spot welding, the usage of aluminum alloy and high-strength steel in automobiles will be greatly increased, thereby providing The realization of automobile lightweight provides the necessary technical foundation.
发明内容Contents of the invention
本发明的目的是提供一种铝合金与镀锌高强钢异种材料中频点焊的方法，该方法实现方式简单，可对汽车用铝合金与镀锌高强钢异种材料进行焊接。该方法可避免焊接过程中喷溅的产生，同时还可有效控制铝合金/镀锌高强钢界面金属间化合物的生长行为，减小脆性FexAly金属间化合物的产生，提升铝合金与镀锌高强钢异种材料中频点焊接头性能。The purpose of the present invention is to provide a method for intermediate frequency spot welding of dissimilar materials of aluminum alloy and galvanized high-strength steel. This method can avoid the generation of spatter during the welding process, and at the same time, it can effectively control the growth behavior of intermetallic compounds at the interface of aluminum alloy/galvanized high-strength steel, reduce the generation of brittle F x Al y intermetallic compounds, and improve the relationship between aluminum alloy and galvanized high-strength steel. Performance of intermediate frequency spot welded joints of zinc high strength steel dissimilar materials.
本发明的技术方案是：Technical scheme of the present invention is:
一种铝合金与镀锌高强钢异种材料中频点焊的方法，该方法是采用点焊电极对铝合金与镀锌高强钢施焊，从而获得铝合金与镀锌高强钢异种材料的中频点焊接头。所述点焊电极具有经过优化的特殊端面形貌，铝合金侧为直径30-100mm的球面电极，镀锌高强钢侧为直径8-15mm的平端面电极。所述铝合金为6000系铝合金板，所述镀锌高强钢为热镀锌高强IF钢板。所述点焊电极材质为CuCr合金。所述球面电极和平端面电极表面粗糙度Ra值应低于0.8μm。A method for intermediate frequency spot welding of aluminum alloy and galvanized high-strength steel dissimilar materials, the method is to use spot welding electrodes to weld aluminum alloy and galvanized high-strength steel, thereby obtaining intermediate frequency spot welding of aluminum alloy and galvanized high-strength steel dissimilar materials head. The spot welding electrode has an optimized special end face shape, the aluminum alloy side is a spherical electrode with a diameter of 30-100 mm, and the galvanized high-strength steel side is a flat end face electrode with a diameter of 8-15 mm. The aluminum alloy is a 6000 series aluminum alloy plate, and the galvanized high-strength steel is a hot-dip galvanized high-strength IF steel plate. The material of the spot welding electrode is CuCr alloy. The surface roughness Ra value of the spherical electrode and the flat end electrode should be lower than 0.8 μm.
通过采用具有优化的特殊端面形貌的点焊电极以精确调整所述铝合金与所述高强钢结合面、所述电极与所述铝合金接触面、所述电极与所述镀锌高强钢接触面、所述铝合金板和所述高强钢板内的电流密度分布状态，从而减小中频电阻点焊过程中的喷溅的产生，防止工件与电极的粘连及合金化反应；同时还可提高所述铝合金侧点焊熔核的尺寸，有效控制所述铝合金/镀锌高强钢界面金属间化合物的生长行为，减小脆性FexAly金属间化合物的产生。Precisely adjust the joint surface between the aluminum alloy and the high-strength steel, the contact surface between the electrode and the aluminum alloy, and the contact between the electrode and the galvanized high-strength steel by using spot welding electrodes with optimized special end surface morphology Surface, the current density distribution state in the aluminum alloy plate and the high-strength steel plate, thereby reducing the generation of spatter during the intermediate frequency resistance spot welding process, preventing the adhesion and alloying reaction between the workpiece and the electrode; at the same time, it can also improve the The size of the spot welding nugget on the aluminum alloy side can effectively control the growth behavior of intermetallic compounds at the aluminum alloy/galvanized high-strength steel interface, and reduce the generation of brittle F x Al y intermetallic compounds.
所述中频点焊过程为：所述铝合金表面经过机械打磨以除去致密的Al2O3氧化膜，所述镀锌高强钢表面经过丙酮清洗以去除油污；所述优化的特殊端面形貌的点焊电极分别安装于中频直流电阻点焊设备的焊钳上，其中，所述平端面电极置于焊钳的固定端，所述球面电极置于焊钳的运动端；将所述6000系铝合金板与所述热镀锌高强IF钢板搭接在一起放置于所述平端面电极上，所述平端面电极位于所述热镀锌高强IF钢板表面搭接区域中心位置；按照设定的中频点焊参数进行施焊，得到铝合金与镀锌高强钢异种材料中频点焊接头。The intermediate frequency spot welding process is as follows: the surface of the aluminum alloy is mechanically polished to remove the dense Al 2 O 3 oxide film, the surface of the galvanized high-strength steel is cleaned with acetone to remove oil stains; the optimized special end surface morphology The spot welding electrodes are respectively installed on the welding tongs of the intermediate frequency DC resistance spot welding equipment, wherein the flat end electrode is placed on the fixed end of the welding tongs, and the spherical electrode is placed on the moving end of the welding tongs; the 6000 series aluminum The alloy plate and the hot-dip galvanized high-strength IF steel plate are lapped together and placed on the flat end electrode, and the flat end electrode is located at the center of the overlapping area on the surface of the hot-dip galvanized high-strength IF steel plate; according to the set intermediate frequency The spot welding parameters are used for welding to obtain intermediate frequency spot welding joints of aluminum alloy and galvanized high-strength steel dissimilar materials.
所述中频直流电阻点焊设备的初级电压为380V，初级频率为50Hz，次级频率为1kHz，次级短路电流最大为30kA，电极压力最大为9kN。所述中频点焊优化的工艺参数为：点焊电流为10-26kA，焊接时间为0.05-0.4s，电极压力为1.0-5.0kN，预压时间为0.2-0.4s，维持时间为0.3-0.4s。The primary voltage of the intermediate frequency DC resistance spot welding equipment is 380V, the primary frequency is 50Hz, the secondary frequency is 1kHz, the maximum secondary short-circuit current is 30kA, and the maximum electrode pressure is 9kN. The optimized process parameters of the intermediate frequency spot welding are: the spot welding current is 10-26kA, the welding time is 0.05-0.4s, the electrode pressure is 1.0-5.0kN, the preloading time is 0.2-0.4s, and the holding time is 0.3-0.4 s.
所述中频点焊中未发生点焊喷溅，采用优化的工艺参数施焊后，所述铝合金与镀锌高强钢异种材料中频点焊接头表面未出现工件与电极的粘连及合金化反应，点焊接头中铝合金侧熔核的尺寸最大为10.1mm；所述铝合金与镀锌高强钢界面金属间化合物相组成为Fe2Al5和Fe4Al13，厚度小于4.0μm；铝合金侧表面压痕深度为铝合金板厚的17％，点焊接头的拉剪力最高可达5400N。In the intermediate frequency spot welding, spot welding spatter did not occur, and after welding with optimized process parameters, the surface of the intermediate frequency spot welding joint between the aluminum alloy and galvanized high-strength steel dissimilar materials did not appear adhesion and alloying reaction between the workpiece and the electrode, The size of the nugget on the aluminum alloy side in the spot welded joint is up to 10.1 mm; the phase composition of the intermetallic compound at the interface between the aluminum alloy and the galvanized high-strength steel is Fe 2 Al 5 and Fe 4 Al 13 , and the thickness is less than 4.0 μm; the aluminum alloy side The surface indentation depth is 17% of the thickness of the aluminum alloy plate, and the tensile shear force of the spot welded joint can reach up to 5400N.
铝合金与镀锌高强钢异种材料中频点焊接头在拉剪试验过程中的破坏方式为纽扣断裂，裂纹沿点焊接头周边铝合金母材处扩展，未出现结合面断裂方式。The failure mode of intermediate frequency spot welded joints between aluminum alloy and galvanized high-strength steel dissimilar materials during the tension-shear test is button fracture, and the cracks propagate along the aluminum alloy base metal around the spot welded joints, and no joint surface fracture mode occurs.
本发明方法主要用于汽车用6000系铝合金板与汽车覆盖件用热镀锌高强IF钢板的焊接。The method of the invention is mainly used for the welding of 6000 series aluminum alloy plates for automobiles and hot-dip galvanized high-strength IF steel plates for automobile covering parts.
本发明与现有的铝合金与高强钢异种材料电阻点焊的方法相比有以下优点：Compared with the existing method of resistance spot welding of aluminum alloy and high-strength steel dissimilar materials, the present invention has the following advantages:
1.实现形式简单，成本较低，便于操作，容易规模化生产应用。该中频点焊方法所选用的焊接设备为中频直流电阻点焊机，配套的焊钳为悬挂式，电极采用CuCr合金材质。利用普通数控车床或专用电极帽修整设备即可加工出经过优化的端面形状及尺寸的电极，并且电极端面在批量点焊过程中易于修整，有助于生产效率的提升。1. The implementation form is simple, the cost is low, the operation is convenient, and the large-scale production and application are easy. The welding equipment selected for this intermediate frequency spot welding method is an intermediate frequency DC resistance spot welder, and the matching welding tongs are suspended, and the electrodes are made of CuCr alloy. Electrodes with optimized end face shape and size can be processed by ordinary CNC lathe or special electrode cap trimming equipment, and the electrode end face is easy to trim during batch spot welding, which helps to improve production efficiency.
2.与传统工频交流点焊相比，本发明的铝合金与镀锌高强钢异种材料中频电阻点焊具有焊接电流输出精确稳定、功率因数高、对称电网负载、对网压冲击较小、节约电能等特点，因此工艺过程稳定性高，抑制了点焊喷溅的产生，减小了电极与工件的合金化反应，降低了电极的烧损，并提升了点焊的表面质量。2. Compared with the traditional power frequency AC spot welding, the intermediate frequency resistance spot welding of aluminum alloy and galvanized high-strength steel dissimilar materials of the present invention has the advantages of accurate and stable welding current output, high power factor, symmetrical grid load, and less impact on grid voltage. It saves electric energy and other characteristics, so the process stability is high, the generation of spot welding spatter is suppressed, the alloying reaction between the electrode and the workpiece is reduced, the burning loss of the electrode is reduced, and the surface quality of spot welding is improved.
3.通过采用优化的端面形貌的电极，可有效调整铝合金与高强钢结合面、电极与铝合金接触面、电极与镀锌高强钢接触面、铝合金板和高强钢板内的电流密度分布状态，从而减小中频电阻点焊过程中的喷溅的产生，防止工件与电极的粘连及合金化反应，减小铝合金侧焊点表面压痕深度；同时还可提高铝合金侧点焊熔核的尺寸，有效控制铝合金/镀锌高强钢界面金属间化合物的生长行为，减小脆性FexAly金属间化合物的产生。在此基础上，通过点焊工艺参数的优化可以进一步抑制点焊缺陷的产生，提高点焊接头的强度。因此，本发明获得的铝合金与镀锌高强钢点焊接头质量优于采用传统的F型电极电阻点焊得到的点焊接头。3. By adopting the electrode with optimized end surface morphology, the current density distribution in the joint surface of aluminum alloy and high-strength steel, the contact surface of electrode and aluminum alloy, the contact surface of electrode and galvanized high-strength steel, aluminum alloy plate and high-strength steel plate can be effectively adjusted state, thereby reducing the generation of spatter during the intermediate frequency resistance spot welding process, preventing the adhesion and alloying reaction between the workpiece and the electrode, and reducing the indentation depth of the aluminum alloy side solder joint surface; at the same time, it can also improve the aluminum alloy side spot welding melting The size of the nucleus can effectively control the growth behavior of intermetallic compounds at the interface of aluminum alloy/galvanized high-strength steel, and reduce the generation of brittle F x Al y intermetallic compounds. On this basis, through the optimization of spot welding process parameters, the occurrence of spot welding defects can be further suppressed and the strength of spot welding joints can be improved. Therefore, the quality of the aluminum alloy and galvanized high-strength steel spot welded joint obtained by the present invention is better than that obtained by traditional F-type electrode resistance spot welding.
4.本发明的焊接过程中既不需要额外加入电极板以防止电极与工件的粘连，又不必填加铝/钢包覆板作为中间层辅助铝合金与镀锌高强钢的点焊以降低铝/钢界面金属间化合物层的厚度，因此本发明与这些相关研究报道相比具有工艺简单、生产效率高、成本低且点焊接头质量高等优点。4. In the welding process of the present invention, there is no need to add additional electrode plates to prevent the adhesion of electrodes and workpieces, and it is not necessary to add aluminum/steel clad plates as an intermediate layer to assist spot welding of aluminum alloys and galvanized high-strength steels to reduce aluminum alloys. /thickness of the intermetallic compound layer at the steel interface, so the present invention has the advantages of simple process, high production efficiency, low cost and high quality of spot welded joints compared with these related research reports.
附图说明Description of drawings
图1铝合金与镀锌高强钢异种材料中频点焊过程示意图；其中：图(b)为图(a)中工件搭接结构的俯视图。Fig. 1 Schematic diagram of the intermediate frequency spot welding process of aluminum alloy and galvanized high-strength steel dissimilar materials; where: Fig. (b) is a top view of the overlapping structure of the workpiece in Fig. (a).
图中：1-镀锌高强钢板；2-铝合金板；3-铝合金熔核；4-铝合金侧球面电极；5-镀锌高强钢侧平端面电极；6-搭接区域。In the figure: 1- galvanized high-strength steel plate; 2- aluminum alloy plate; 3- aluminum alloy nugget; 4- aluminum alloy side spherical electrode; 5- galvanized high-strength steel side flat end electrode; 6- overlapping area.
图2铝合金/镀锌高强钢异种材料中频点焊接头表面成形照片；其中：(a)铝合金侧；(b)镀锌高强钢侧。Fig. 2 Photos of surface formation of aluminum alloy/galvanized high-strength steel dissimilar material intermediate frequency spot welding joint; among them: (a) aluminum alloy side; (b) galvanized high-strength steel side.
图3铝合金/镀锌高强钢异种材料中频点焊接头横断面宏观组织照片。Figure 3 Macrostructure photo of the cross-section of the intermediate frequency spot welded joint of aluminum alloy/galvanized high-strength steel dissimilar materials.
图4铝合金/镀锌高强钢异种材料中频点焊接头中部Al/Fe界面金属间化合物的扫描电镜照片。Fig. 4 SEM photo of the intermetallic compound at the Al/Fe interface in the middle of the intermediate frequency spot welded joint of aluminum alloy/galvanized high-strength steel dissimilar materials.
图5铝合金/镀锌高强钢异种材料中频点焊接头中部Al/Fe界面区域微区X射线衍射分析结果。Figure 5 X-ray diffraction analysis results of the micro-area of the Al/Fe interface area in the middle of the intermediate frequency spot welded joint of aluminum alloy/galvanized high-strength steel dissimilar materials.
图6铝合金/镀锌高强钢异种材料中频点焊接头的拉伸曲线。Fig. 6 Tensile curves of intermediate frequency spot welded joints of aluminum alloy/galvanized high-strength steel dissimilar materials.
图7铝合金/镀锌高强钢异种材料中频点焊接头的纽扣断裂后的形貌。Fig. 7 The morphology of the broken button of the aluminum alloy/galvanized high-strength steel dissimilar material intermediate frequency spot welding joint.
图8铝合金/镀锌高强钢异种材料中频点焊接头表面成形照片；其中：(a)铝合金侧；(b)镀锌高强钢侧。Fig. 8 Photos of surface forming of aluminum alloy/galvanized high-strength steel dissimilar material intermediate frequency spot welding joints; among them: (a) aluminum alloy side; (b) galvanized high-strength steel side.
图9铝合金/镀锌高强钢异种材料中频点焊接头横断面宏观组织照片。Figure 9 Macrostructure photos of the cross-section of the intermediate frequency spot welded joint of aluminum alloy/galvanized high-strength steel dissimilar materials.
图10铝合金/镀锌高强钢异种材料中频点焊接头中部Al/Fe界面金属间化合物的扫描电镜照片。Fig. 10 Scanning electron micrographs of intermetallic compounds at the Al/Fe interface in the middle of the intermediate frequency spot welded joint of aluminum alloy/galvanized high-strength steel dissimilar materials.
图11铝合金/镀锌高强钢异种材料中频点焊接头表面成形照片；其中：(a)铝合金侧；(b)镀锌高强钢侧。Fig. 11 Photos of surface formation of aluminum alloy/galvanized high-strength steel dissimilar material intermediate frequency spot welding joints; where: (a) aluminum alloy side; (b) galvanized high-strength steel side.
图12铝合金/镀锌高强钢异种材料中频点焊接头横断面宏观组织照片。Figure 12 Macrostructure photos of the cross-section of the intermediate frequency spot welded joint of aluminum alloy/galvanized high-strength steel dissimilar materials.
图13铝合金/镀锌高强钢异种材料传统F型电极中频点焊接头表面成形照片；其中：(a)铝合金侧；(b)镀锌高强钢侧。Fig. 13 Photos of surface forming of aluminum alloy/galvanized high-strength steel dissimilar materials traditional F-type electrode intermediate frequency spot welding joint; where: (a) aluminum alloy side; (b) galvanized high-strength steel side.
图14铝合金/镀锌高强钢异种材料传统F型电极中频点焊接头横断面宏观组织照片。Fig. 14 Macrostructure photo of cross-section of aluminum alloy/galvanized high-strength steel dissimilar material traditional F-type electrode intermediate frequency spot welding joint.
图15铝合金/镀锌高强钢异种材料传统F型电极中频点焊接头中部Al/Fe界面金属间化合物的扫描电镜照片。Fig. 15 SEM photo of the Al/Fe interface intermetallic compound in the middle of the intermediate frequency spot welding joint of traditional F-type electrode of aluminum alloy/galvanized high-strength steel dissimilar materials.
图16铝合金/镀锌高强钢异种材料传统F型电极中频点焊接头中部Al/Fe界面区域微区X射线衍射分析结果。Figure 16 X-ray diffraction analysis results of the micro-area of the Al/Fe interface area in the middle of the intermediate frequency spot welding joint of the traditional F-type electrode of aluminum alloy/galvanized high-strength steel dissimilar materials.
图17铝合金/镀锌高强钢异种材料传统F型电极中频点焊接头的结合面断裂后的形貌。Fig. 17 Morphology of fractured joint surface of aluminum alloy/galvanized high-strength steel dissimilar materials traditional F-type electrode intermediate frequency spot welding joint.
具体实施方式detailed description
本发明采用经过优化的特殊端面形貌的点焊电极进行中频点焊，从而获得铝合金与镀锌高强钢异种材料的高质量中频点焊接头。所述铝合金与镀锌高强钢异种材料中频点焊过程如图1所示。本发明的具体实施过程如下：The invention adopts an optimized spot welding electrode with a special end face shape to carry out intermediate frequency spot welding, thereby obtaining a high-quality intermediate frequency spot welding joint of dissimilar materials of aluminum alloy and galvanized high-strength steel. The intermediate frequency spot welding process of the aluminum alloy and galvanized high-strength steel dissimilar materials is shown in FIG. 1 . Concrete implementation process of the present invention is as follows:
首先将待焊镀锌高强钢板1表面经过丙酮清洗以去除油污，然后风干；然后利用机械打磨的方式(采用800号SiC砂纸手动研磨或利用附有砂轮磨头的打磨机打磨)以去除待焊铝合金板2表面致密的Al2O3氧化膜。电极材质选用CuCr合金，利用数控车床或专用电极帽修整机加工出优化的端面形状及尺寸的电极，即直径D2为30-100mm的球面电极4以及直径D1为8-15mm的平端面电极5，电极端面的粗糙度Ra值应低于0.8μm。焊接设备选用中频直流电阻点焊设备，其技术指标如下：初级电压为380V，初级频率为50Hz，次级频率为1kHz，次级短路电流最大为30kA，电极压力最大为9kN。将球面电极4和平端面电极5安装固定于中频直流电阻点焊设备的焊钳上，其中，平端面电极置于焊钳的固定端，球面电极置于焊钳的运动端，这种布置方式可保证待焊工件与电极作用时搭接结构的平稳性。将镀锌高强钢板1与铝合金板2搭接在一起放置于平端面电极上，平端面电极5位于所述镀锌高强钢板1表面搭接区域6的中心位置。根据所设定的中频点焊优化的工艺参数(点焊电流为10-26kA，焊接时间为0.05-0.4s，电极压力为1.0-5.0kN，预压时间为0.2-0.4s，维持时间为0.3-0.4s)在中频点焊设备的人机交互界面上进行相应的程序编程。对镀锌高强钢板1与铝合金板2搭接接头进行中频点焊，焊接过程参数通过预先编好的程序指令自动控制，即先后经过预压、焊接、维持三个阶段。焊接过程中，镀锌高强钢板1/铝合金板2界面处的铝合金熔化形成点焊熔核3，而镀锌高强钢侧未发生熔化；熔融的铝合金在镀锌高强钢表面快速铺展及润湿，在原子互扩散及界面反应的作用下形成冶金结合，最终得到镀锌高强钢板1与铝合金板2异种材料中频点焊接头。First, the surface of the galvanized high-strength steel plate 1 to be welded is cleaned with acetone to remove oil stains, and then air-dried; then mechanically polished (manually with 800 SiC sandpaper or with a grinder with a grinding wheel) to remove the surface to be welded. A dense Al 2 O 3 oxide film on the surface of the aluminum alloy plate 2. The electrode material is CuCr alloy, and the electrode with the optimized end shape and size is processed by a CNC lathe or a special electrode cap trimming machine, that is, the spherical electrode 4 with a diameter D2 of 30-100mm and the flat end electrode 5 with a diameter D1 of 8-15mm , the roughness Ra value of the electrode end surface should be lower than 0.8μm. Welding equipment adopts intermediate frequency DC resistance spot welding equipment, and its technical indicators are as follows: primary voltage is 380V, primary frequency is 50Hz, secondary frequency is 1kHz, secondary short-circuit current is up to 30kA, and electrode pressure is up to 9kN. The spherical electrode 4 and the flat end electrode 5 are installed and fixed on the welding tongs of the intermediate frequency DC resistance spot welding equipment, wherein the flat end electrode is placed on the fixed end of the welding tongs, and the spherical electrode is placed on the moving end of the welding tongs. This arrangement can be To ensure the stability of the overlapping structure when the workpiece to be welded interacts with the electrode. The galvanized high-strength steel plate 1 and the aluminum alloy plate 2 are overlapped and placed on the flat end electrode, and the flat end electrode 5 is located at the center of the overlapping area 6 on the surface of the galvanized high-strength steel plate 1 . Process parameters optimized according to the set intermediate frequency spot welding (spot welding current is 10-26kA, welding time is 0.05-0.4s, electrode pressure is 1.0-5.0kN, pre-pressing time is 0.2-0.4s, holding time is 0.3 -0.4s) Perform corresponding program programming on the human-computer interaction interface of the intermediate frequency spot welding equipment. Intermediate frequency spot welding is performed on the lap joint of galvanized high-strength steel plate 1 and aluminum alloy plate 2. The parameters of the welding process are automatically controlled by pre-programmed instructions, that is, three stages of preloading, welding, and maintenance. During the welding process, the aluminum alloy at the interface of the galvanized high-strength steel plate 1/aluminum alloy plate 2 melts to form a spot welding nugget 3, while the galvanized high-strength steel side does not melt; the molten aluminum alloy spreads rapidly on the surface of the galvanized high-strength steel and Wetting, metallurgical bonding is formed under the action of atomic interdiffusion and interfacial reaction, and finally an intermediate frequency spot welded joint of dissimilar materials of galvanized high-strength steel plate 1 and aluminum alloy plate 2 is obtained.
下面结合具体实施例及对比例详细说明本发明。The present invention will be described in detail below in conjunction with specific examples and comparative examples.
实施例1Example 1
待焊镀锌高强钢板的化学成分为(wt.％)：C0.01％，Si0.09％，Mn0.51％，S0.01％，P0.05％，Nb0.02％，Ti0.01％，Fe余量；镀锌工艺采用双面热镀锌，镀锌层厚度为8μm；主要相结构为α-Fe，屈服强度为260MPa，抗拉强度为410MPa，延伸率为32％；镀锌高强钢板利用线切割加工成100mm×25mm×1mm。待焊铝合金板的化学成分为(wt.％)：Mg0.45％，Si0.56％，Cu0.15％，Mn0.45％，Zn0.01％，Fe0.19％，V0.08％，Ti0.02％，Al余量；初始供货态为T6态；主要相结构为α-Al，屈服强度为270MPa，抗拉强度为310MPa，延伸率为15％；铝合金板利用线切割加工成100mm×25mm×1.5mm。采用本发明的中频点焊方法进行焊接，其中，点焊电极材质为CuCr合金，铝合金侧电极为直径70mm的球面电极，镀锌高强钢侧电极为直径10mm的平端面电极，两种电极表面粗糙度Ra值均为0.8μm。中频点焊工艺参数选择如下：点焊电流为22kA，焊接时间为0.3s，电极压力为3.5kN，预压时间为0.4s，维持时间为0.4s。The chemical composition of the galvanized high-strength steel plate to be welded is (wt.%): C0.01%, Si0.09%, Mn0.51%, S0.01%, P0.05%, Nb0.02%, Ti0.01% , Fe balance; the galvanizing process adopts double-sided hot-dip galvanizing, and the thickness of the galvanized layer is 8 μm; the main phase structure is α-Fe, the yield strength is 260MPa, the tensile strength is 410MPa, and the elongation is 32%; galvanized high-strength The steel plate is processed into 100mm×25mm×1mm by wire cutting. The chemical composition of the aluminum alloy plate to be welded is (wt.%): Mg0.45%, Si0.56%, Cu0.15%, Mn0.45%, Zn0.01%, Fe0.19%, V0.08%, Ti0.02%, Al balance; the initial supply state is T6 state; the main phase structure is α-Al, the yield strength is 270MPa, the tensile strength is 310MPa, and the elongation is 15%; the aluminum alloy plate is processed by wire cutting 100mm×25mm×1.5mm. The intermediate frequency spot welding method of the present invention is used for welding, wherein the spot welding electrode is made of CuCr alloy, the aluminum alloy side electrode is a spherical electrode with a diameter of 70 mm, and the galvanized high-strength steel side electrode is a flat end electrode with a diameter of 10 mm. The roughness Ra values are all 0.8 μm. The medium frequency spot welding process parameters are selected as follows: the spot welding current is 22kA, the welding time is 0.3s, the electrode pressure is 3.5kN, the preloading time is 0.4s, and the holding time is 0.4s.
试验结果表明，铝合金/镀锌高强钢异种材料中频点焊接头表面成形良好(如图2所示)，镀锌高强钢侧表面未发生与平端面电极的合金化反应，同时，铝合金侧表面出现圆形压痕，焊点中心未出现与球面电极的粘连。铝合金/镀锌高强钢异种材料中频点焊接头是通过熔化的铝合金在固态高强钢表面润湿铺展作用并伴随着原子的互扩散及界面反应而形成的，因此它属于熔—钎焊接头(图3)。如图3所示，点焊接头铝/钢界面处未出现缩孔、裂纹等缺陷，点焊接头铝合金熔核直径为10.1mm，铝合金侧表面压痕深度为铝合金板厚的17％。点焊接头中铝合金/镀锌高强钢界面产生了金属间化合物层，其厚度在接头中心处最高(4.0μm)(图4)。微区X射线衍射分析结果表明，金属间化合物由Fe2Al5和Fe4Al13组成(图5)。点焊接头拉剪力达到5400N(图6)，拉剪过程中接头以纽扣断裂形式破坏(图7)。The test results show that the surface of the medium-frequency spot welding joint of aluminum alloy/galvanized high-strength steel dissimilar materials is well formed (as shown in Figure 2), and the alloying reaction between the surface of the galvanized high-strength steel side and the flat end electrode does not occur. At the same time, the aluminum alloy side There is a circular indentation on the surface, and there is no adhesion to the spherical electrode in the center of the solder joint. The intermediate frequency spot welding joint of aluminum alloy/galvanized high-strength steel dissimilar materials is formed by the wetting and spreading of molten aluminum alloy on the surface of solid high-strength steel accompanied by interdiffusion of atoms and interfacial reaction, so it belongs to fusion-brazing joints (image 3). As shown in Figure 3, there are no shrinkage cavities, cracks and other defects at the aluminum/steel interface of the spot welded joint. The diameter of the aluminum alloy nugget of the spot welded joint is 10.1mm, and the indentation depth on the aluminum alloy side surface is 17% of the thickness of the aluminum alloy plate . The aluminum alloy/galvanized high-strength steel interface in the spot welded joint produced an intermetallic compound layer whose thickness was the highest (4.0 μm) at the center of the joint (Fig. 4). Micro-area X-ray diffraction analysis results show that the intermetallic compound is composed of Fe 2 Al 5 and Fe 4 Al 13 (Fig. 5). The tensile shear force of the spot welded joint reaches 5400N (Figure 6), and the joint is broken in the form of button fracture during the tensile shear process (Figure 7).
实施例2Example 2
待焊镀锌高强钢板及铝合金板的材质及工件尺寸均与实施例1相同。采用本发明的中频点焊方法进行焊接，其中，点焊电极材质为CuCr合金，铝合金侧电极为直径70mm的球面电极，镀锌高强钢侧电极为直径12mm的平端面电极，两种电极表面粗糙度Ra值均为0.8μm。中频点焊工艺参数选择如下：点焊电流为24kA，焊接时间为0.35s，电极压力为3.5kN，预压时间为0.4s，维持时间为0.4s。The material and workpiece size of the galvanized high-strength steel plate and the aluminum alloy plate to be welded are the same as those in Example 1. The intermediate frequency spot welding method of the present invention is used for welding, wherein the spot welding electrode material is CuCr alloy, the aluminum alloy side electrode is a spherical electrode with a diameter of 70 mm, and the galvanized high-strength steel side electrode is a flat end electrode with a diameter of 12 mm. The roughness Ra values are all 0.8 μm. The medium frequency spot welding process parameters are selected as follows: the spot welding current is 24kA, the welding time is 0.35s, the electrode pressure is 3.5kN, the preloading time is 0.4s, and the holding time is 0.4s.
试验结果表明，铝合金/镀锌高强钢异种材料中频点焊接头表面成形良好(如图8所示)，镀锌高强钢侧表面与铝合金侧表面均未出现与球面电极的粘连。点焊接头铝/钢界面处未出现缩孔与裂纹等缺陷，铝合金熔核直径为9.5mm，铝合金侧表面压痕深度为铝合金板厚的16％(图9)。点焊接头中铝合金/镀锌高强钢界面产生了金属间化合物层(Fe2Al5和Fe4Al13)，其厚度在接头中心处最高(3.8μm)(图10)。点焊接头拉剪力达到5000N，拉剪过程中接头以纽扣断裂形式破坏。The test results show that the surface of the intermediate frequency spot welding joint of aluminum alloy/galvanized high-strength steel dissimilar materials is well formed (as shown in Figure 8), and neither the side surface of the galvanized high-strength steel nor the side surface of the aluminum alloy appears to adhere to the spherical electrode. There are no defects such as shrinkage cavities and cracks at the aluminum/steel interface of the spot welded joint. The diameter of the aluminum alloy nugget is 9.5mm, and the indentation depth on the aluminum alloy side surface is 16% of the thickness of the aluminum alloy plate (Figure 9). Intermetallic compound layers (Fe 2 Al 5 and Fe 4 Al 13 ) were produced at the aluminum alloy/galvanized high-strength steel interface in the spot welded joint, and the thickness was the highest (3.8 μm) at the center of the joint (Fig. 10). The tensile shear force of the spot welded joint reaches 5000N, and the joint is broken in the form of button fracture during the tensile shear process.
实施例3Example 3
待焊镀锌高强钢板及铝合金板的材质及工件尺寸均与实施例1相同。采用本发明的中频点焊方法进行焊接，其中，点焊电极材质为CuCr合金，铝合金侧电极为直径100mm的球面电极，镀锌高强钢侧电极为直径10mm的平端面电极，两种电极表面粗糙度Ra值均为0.8μm。中频点焊工艺参数选择如下：点焊电流为25kA，焊接时间为0.4s，电极压力为4kN，预压时间为0.4s，维持时间为0.4s。The material and workpiece size of the galvanized high-strength steel plate and the aluminum alloy plate to be welded are the same as those in Example 1. The intermediate frequency spot welding method of the present invention is used for welding, wherein the spot welding electrode material is CuCr alloy, the aluminum alloy side electrode is a spherical electrode with a diameter of 100 mm, and the galvanized high-strength steel side electrode is a flat end electrode with a diameter of 10 mm. The roughness Ra values are all 0.8 μm. The medium frequency spot welding process parameters are selected as follows: the spot welding current is 25kA, the welding time is 0.4s, the electrode pressure is 4kN, the preloading time is 0.4s, and the holding time is 0.4s.
试验结果表明，铝合金/镀锌高强钢异种材料中频点焊接头表面成形良好(如图11所示)，镀锌高强钢侧表面与铝合金侧表面均未出现与球面电极的粘连。点焊接头铝/钢界面处未出现缺陷，铝合金熔核直径为9.2mm，铝合金侧表面压痕深度为铝合金板厚的13.6％(图12)。点焊接头拉剪力达到5100N，拉剪过程中接头以纽扣断裂形式破坏。The test results show that the surface of the intermediate frequency spot welding joint of aluminum alloy/galvanized high-strength steel dissimilar materials is well formed (as shown in Figure 11), and neither the side surface of the galvanized high-strength steel nor the side surface of the aluminum alloy appears to adhere to the spherical electrode. There is no defect at the aluminum/steel interface of the spot welded joint, the diameter of the aluminum alloy nugget is 9.2mm, and the indentation depth on the aluminum alloy side surface is 13.6% of the thickness of the aluminum alloy plate (Figure 12). The tensile shear force of the spot welded joint reaches 5100N, and the joint is broken in the form of button fracture during the tensile shear process.
对比例comparative example
待焊镀锌高强钢板及铝合金板的材质及工件尺寸均与实施例1相同。采用传统F型电极中频点焊方法进行焊接。优化的点焊工艺参数选择如下：点焊电流为9kA，焊接时间为0.3s，电极压力为3kN，预压时间为0.4s，维持时间为0.4s。The material and workpiece size of the galvanized high-strength steel plate and the aluminum alloy plate to be welded are the same as those in Example 1. The traditional F-type electrode intermediate frequency spot welding method is used for welding. The optimized spot welding process parameters are selected as follows: the spot welding current is 9kA, the welding time is 0.3s, the electrode pressure is 3kN, the preloading time is 0.4s, and the holding time is 0.4s.
试验结果表明，铝合金/镀锌高强钢异种材料中频点焊接头表面成形较差(如图13所示)，镀锌高强钢侧表面出现与电极的合金化反应，铝合金侧表面出现与电极的粘连。点焊接头中铝合金熔核的直径为5.8mm(图14)，点焊接头铝/钢界面处产生厚度达13μm的金属间化合物层(如图15所示)。微区X射线衍射分析结果表明，金属间化合物由Fe2Al5和Fe4Al13组成(图16)。点焊接头拉剪力为3200N，拉剪过程中接头以结合面断裂形式破坏(图17)。因此采用本发明的中频点焊方法进行铝合金与镀锌高强钢板的焊接质量显著优于采用传统F型电极中频点焊方法。The test results show that the surface of the intermediate frequency spot welding joint of aluminum alloy/galvanized high-strength steel dissimilar materials is poorly formed (as shown in Figure 13), the side surface of the galvanized high-strength steel has an alloying reaction with the electrode, and the side surface of the aluminum alloy has an alloying reaction with the electrode. of adhesion. The diameter of the aluminum alloy nugget in the spot welded joint is 5.8 mm (Figure 14), and an intermetallic compound layer with a thickness of 13 μm is produced at the aluminum/steel interface of the spot welded joint (as shown in Figure 15). Micro-area X-ray diffraction analysis results show that the intermetallic compound is composed of Fe 2 Al 5 and Fe 4 Al 13 (Fig. 16). The tensile shear force of the spot welded joint is 3200N, and the joint is broken in the form of joint surface fracture during the tensile shear process (Fig. 17). Therefore, the welding quality of the aluminum alloy and the galvanized high-strength steel plate using the intermediate frequency spot welding method of the present invention is significantly better than that of the traditional F-type electrode intermediate frequency spot welding method.
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