汽车用双相钢／铝合金异种材料电阻点焊过程数值模拟研究

Numerical Simulation on Resistance Spot Welding process of Aluminum Alloy and Duplex Steel Dissimilar Materials Used for Vehicle

基于SORPAS软件,对1.8 mm的DP590双相钢板和1.2 mm的6061-T6铝合金板材点焊过程进行了模拟,并将模拟熔核形貌与试验结果进行对比。结果表明,随着焊接过程的进行,工件与电极接触界面处温度迅速升高,而上下电极附近温度并没有迅速升高,接头在铝合金侧和双相钢侧形成双熔核;在整个焊接过程中,铝合金侧的应变明显比双相钢侧大,变形主要集中在熔核附近,熔核边缘应变大于心部;模拟的熔核直径为4.3 mm,实测值为4.6 mm,模拟结果与实测结果较为吻合,所建立的模型可以用于DP590钢及6061-T6铝合金板异种材料电阻点焊过程模拟。

Based on SORPAS software, the spot welding process of 1.2mm thickness 6061-T6 aluminum alloy and 1.8mm thickness DP590 duplex steel plate was simulated, and the modeling nugget morphology was compared with the measured results. The results show that the temperature at the contact interface between work-piece and electrode increases rapidly in the welding process, while the temperature at the tips of upper and lower electrodes did not rise rapidly, and double nugget forms at the aluminum alloy side and the dual phase steel side; the strain in the aluminum alloy side is much larger than that of the dual phase steel side during the whole welding process, and the deformation mainly concentrates at the areas near the nugget; the strain at the edge of nugget is larger than that of in the core; the modeling nugget diameter is 4.3mm, and the measured value is 4.6 ram; the simulation results are in good agreement with the measured results, which indicates that the model established in the research could be used for the simulation of resistance spot welding process for DP590 steel and 606 l-T6 aluminum alloy plate dissimilar materials.