基于田口方法的铸铝A356焊接工艺参数优化研究

Study on Optimization of Welding Process Parameters for A356 Cast Aluminum Alloy Based on Taguchi Method

铝合金在汽车副车架得到了广泛应用。本文采用脉冲焊方法,以ER5554焊丝作为填充材料,对铸造铝合金A356进行了焊接试验研究,为汽车铸造铝合金副车架设计和焊接提供理论指导。采用田口正交试验的方法,针对焊接电流、焊接速度、间隙、焊枪倾角及干伸长5个焊接参数,设计了5因素3水平的正交试验方案。利用光学显微镜与拉伸试验机对焊缝的成形及接头的力学性能进行了研究。结果表明,焊接电流、焊接速度与间隙对焊缝熔宽、余高与根部侧壁熔合有显著影响;间隙对焊缝根部侧壁熔合影响最大,过小的间隙容易造成焊缝根部未熔合,会极大地降低接头抗拉强度。

Aluminum alloy is widely used in the automotive auxiliary frame. Taking ER5554 solder wires as filling materials, GMAW-P method was used to research welding test of cast aluminum alloy A356, which could provide theory guidance for design and welding of cast aluminum auxiliary frame. During the research, aiming at five welding parameters such as welding current, welding speed, gap, welding torch inclination angle and tip-to-work distance, orthogonal experiment scheme of five factors with three levels was designed with Taguchi orthogonal experiment method. Optical microscope and tensile testing machine were used to study weld formation and joint mechanical properties. The result shows that welding current, welding speed and gap have a great influence on melt width, residual height of the weld seam and fusion of weld root sidewall, and the influence of gap is the most significant to the fusion of weld root sidewall. Too small gap can easily cause weld root sidewall incomplete fusion, and the joint tensile strength will be greatly reduced.