Electron-Beam Welding Joint Strength of Dissimilar Materials

This paper provides an in-depth discussion of the joint strength of electron beam welding of dissimilar materials.The effect of welding parameters and material properties on the joint strength was analyzed,and an argument for the optimal parameter combination is presented.Electron-beam welding technology offers several advantages,including high energy density and the ability to create fine weld seams.However,it also presents certain challenges,such as the complexity of welding parameters and the potential generation of brittle phases.The analysis conducted in this paper holds significant importance in enhancing the quality and efficiency of dissimilar material welding processes.

SEMI-WEIGHT FUNCTION METHOD ON COMPUTATION OF STRESS INTENSITY FACTORS IN DISSIMILAR MATERIALS

Semi_weight function method is developed to solve the plane problem of two bonded dissimilar materials containing a crack along the bond. From equilibrium equation, stress and strain relationship, conditions of continuity across interface and free crack surface, the stress and displacement fields were obtained. The eigenvalue of these fields is lambda. Semi_weight functions were obtained as virtual displacement and stress fields with eigenvalue?_lambda. Integral expression of fracture parameters, K Ⅰ and K Ⅱ, were obtained from reciprocal work theorem with semi_weight functions and approximate displacement and stress values on any integral path around crack tip. The calculation results of applications show that the semi_weight function method is a simple, convenient and high precision calculation method.

Microstructure and mechanical properties of butt joints of QCr0.8/1Cr21Ni5Ti equal-thickness dissimilar materials by electron beam welding

Butt joints of QCr0.8/1Cr21Ni5Ti equal-thickness dissimilar materials were obtained by electron beam welding with fixed accelerating voltage 60 kV and focus current ~1.99 A , changed electron beam current and welding velocity. Microstructure and composition of the EBW joint were investigated by means of optical micrography and EDX analysis, mechanical properties of the joint were also tested. The results show that joint’s macrostructure was divided into three zones: top weld zone near QCr0.8 and bottom weld zone consisting of Cu(ss.Fe) with a certain amount of dispersedly distributed (α+ε) mixed microstructure, middle weld zone consisting of (α+ε) microstructure with a small amount of Cu(ss.Fe) particles. Morphological inhomogeneous macrostructure and uneven chemical compostion of QCr0.8/1Cr21Ni5Ti joint by EBW are the most important factor to result in decreasing joining strength.

Development of processing windows for friction stir spot welding of aluminium Al5052/copper C27200 dissimilar materials

Friction stir spot welding technique was used to join dissimilar combinations of aluminium alloy(Al5052)with copperalloy(C27200)and friction stir spot welding windows such as tool rotational speed–dwell time and tool rotational speed?plungedepth diagrams for effective joining of these materials were developed.Using a central composite design model,empirical relationswere developed to predict the changes in tensile shear failure load values and interface hardness of the joints with three processparameters such as tool rotational speed,plunge depth and dwell time.The adequacy of the developed model was verified usingANOVA analysis at95%confidence level.Response surface methodology was used to optimize the developed model to maximizetensile strength and minimize interface hardness.A high tensile shear failure load value of3850N and low interface hardness valueof HV81was observed for joints made under optimum conditions,and validation experiments confirmed the high predictability ofthe developed model with error less than2%.The operating windows developed shall act as reference maps for future designengineers in choosing appropriate friction stir spot welding process parameter values to obtain good joints.

WEIGHT FUNCTIONS FOR INTERFACE CRACKS IN DISSIMILAR ANISOTROPIC MATERIALS

Bueckner's work conjugate integral customarily adopted for linear elastic materials is established for an interface crack in dissimilar anisotropic materials.The difficulties in separating Stroh's six complex arguments involved in the integral for the dissimilar materials are overcome and thert the explicit function representations of the integral are given and studied in detail.It is found that the pseudo-orthogonal properties of the eigenfunction expansion form(EEF)for a crack presented previously in isotropic elastic cases,in isotopic bimaterial cases,and in orthotropic cases are also valid in the present dissimilar arbitrary anisotropic cases.The relation between Bueckner's work conjugate integral and the J-integral in these cases is obtained by introducing a complementary stress- displacement state.Finally,some useful path-independent integrals and weight functions are proposed for calculating the crack tip parameters such as the stress intensity factors.

Joining Technology of Dissimilar Materials for Automotive Components(Ⅱ)

Joining techniques of dissimilar materials for lightweight multi-material automotive body structure were discussed. The joining of 1 .4 mm thickness steel and 2 mm thickness of Al were performed by the new method that is hybrid laser welding system. After aluminum and steel were welded by laser hybrid welding process, the micro-structure investment and the micro-hardness test were carried out. Hybrid laser welding promises a bright future in joining technology of dissimilar materials for automotive components.

A CRACK EMANATING FROM THE TIP OF BONDED DISSIMILAR MATERIALS

A crack is assumed to emanate from the tip of bonded dissimilar materials with the crack on the bisector of one of the bonded wedges. The problem is firstly divided into symmetric and anti-symmetric modes according to the characteristics of the local geometry. By eigenexpansion method, the eigenequations for the two modes are derived, respectively, and the corresponding eigenvalues are obtained with different ratios of dissimilar material constants and angles of the wedges. The singularity of the crack is then analyzed by the eigenvalues that are less than one. The fields of displacement and stress in the vicinity of the tip of the crack are finally derived in an explicit form.

Materials flow and phase transformation in friction stir welding of Al 6013/Mg

Material flow and phase transformation were studied at the interface of dissimilar joint between Al 6013 and Mg, produced by stir friction welding （FSW） experiments. Defect-free weld was obtained when aluminum and magnesium were placed in the advancing side and retreating side respectively and the tool was placed 1 mm off the weld centerline into the aluminum side. In order to understand the material flow during FSW, steel shots were implanted as indexes into the welding path. After welding, using X-ray images, secondary positions of the steel shots were evaluated. It was revealed that steel shots implanted in advancing side were penetrated from the advancing side into the retreating side, whereas the shots implanted in the retreating side remained in the retreating side, without penetrating into the advancing side. The welded specimens were also heat treated. The effects of heat treatment on the mechanical properties of the welds and the formation of new intermetallic layers were investigated. Two intermetallic compounds, Al3Mg2 and Al12Mg17, were formed sequentially at Al6013/Mg interface.

Ultrasonic echo signal fetures of dissimilar material bonding joints

An ultrasonic evaluation method of echo feature of diffusion bond joint between two dissimilar materials is presented. The echo signal was acquired by an automatic ultrasonic C-scan test system. It is found that the intensity of echo and its phase can be used to evaluate the joint quality, and interface products of dissimilar materials bonding can be evaluated by ultrasonic method.

Review on friction stir welding of dissimilar magnesium and aluminum alloys: Scientometric analysis and strategies for achieving high-quality joints

Magnesium and aluminum alloys continually attract interest as lightweight structural materials for transport applications. However, joining these dissimilar alloys is very challenging. The main obstacle that hinders progress in dissimilar Mg-Al joining is the formation of brittle intermetallic compounds(IMCs). As a solid-state joining technique, FSW is an excellent candidate to attenuate the deleterious IMC effects in dissimilar Al-Mg joining due to the inherent low heat inputs involved in the process. However, the IMCs, namely Al_(3)Mg_(2) and Al_(12)Mg_(17) phases, have also been reported to form during Al-Mg dissimilar FSW;their amount and thickness depend on the heat input involved;thus,the weld parameters used. Since the heat dissipated in the material during the welding process significantly affects the amount of IMCs,the heat input during FSW should be kept as low as possible to control and reduce the amount of IMCs. This review aims to critically discuss and evaluate the studies conducted in the dissimilar Al/Mg FSW through a scientometric analysis and also with a focus on the strategies recently applied to enhance joint quality. The scientometric analysis showed that the main research directions in Mg/Al FSW are the technological weldability of aluminum and magnesium during FSW, structural morphology, and mechanical properties of dissimilar welded joints. Considering the scope of application of the aforementioned joints, the low share of articles dealing with environmental degradation and operational cracking is surprising. This might be attributed to the need for well-developed strategies for obtaining high-quality and sustainable joints for applications. Thus, the second part of this review is conventional, focusing mainly on the new strategies for obtaining high-quality Mg/Al joints. It can be concluded that in addition to the necessity to optimum welding parameters to suppress the excessive heat to limit the amount and thickness of IMC formed and improve the overall joint quality, strategies such as using Zn interlayer, electric current assisted FSW(EAFSW), ultrasonic vibration FSW(UVa FSW), are considered effective in the elimination, reduction, and fragmentation of the brittle IMCs.

电子封装超声互连研究新进展

超声振动摩擦和局部高温高压可实现同材或异材的低温、快速、可靠的互连,超声技术在电子封装中显示出无与伦比的技术优势。综述了超声引线键合、块体母材直接超声键合、母材/焊料/母材三体超声固相键合等超声固相键合技术,超声钎焊、超声瞬态液相扩散焊等超声液相键合技术,超声纳米烧结、混合(复合)焊料超声互连等超声固液混合键合技术。无论是高频低功率的高速超声键合,还是中频高功率超声常速键合,超声的作用规律和效果相似,其互连质量和互连机理与接触材料及其状态有着最为密切的关系;考虑由于超声互连过程快、时间短、互连界面窄、接头不透明,可以采用焊接实时高速摄像技术和同步辐射X射线成像技术相结合,实时观察液态焊料润湿流动、焊料颗粒运动轨迹、母材的剥离过程及界面形成规律;考虑由于微焊点尺寸放大,可以借助温度传感器和压力传感器进行超声的温度效应和瞬态压强实时测量;基于双超/多超声诸多影响因素,多超声的数值模拟分析将成为微焊点超声互连机理研究的有效手段。

Microstructure and mechanical properties of dissimilar Al-Cu joints by friction stir welding

Dissimilar friction stir welding between 1060 aluminum alloy and annealed pure copper sheet with a thickness of 3 mm was investigated. Sound weld was obtained at a rotational speed of 1050 r/min and a welding speed of 30 mm/min. Intercalation structure formed at the crown and Cu/weld nugget （WN） area promotes interracial diffusion and metallurgical bonding of aluminum and copper. However, corrosion morphology reveals the weak bonding mechanism of internal interface, which causes the joint failing across the interface with a brittle-ductile mixed fracture mode. The tensile strength of the joint is 148 MPa, which is higher than that of the aluminum matrix. Crystal defects and grain refinement by severely plastic deformation during friction stir welding facilitate short circuit diffusion and thus accelerate the formation of A14Cu9 and A12Cu intermetallic compounds （IMCs）. XRD results show that A14Cu9 is mainly in Cu/WN transition zone. The high dislocation density and formation of dislocation loops are the major reasons of hardness increase in the WN.

SA508-3/690异种金属焊接接头显微组织及裂纹形成机理

镍基焊材52M因具有优异的抗晶间腐蚀性和耐蚀性,被广泛应用在核电站关键部位的焊接。通过焊条电弧焊用焊材52M焊接低合金钢SA508Gr.3Cl.2和镍基Inconel690合金。结合光学显微镜和扫描电子显微镜分析熔合边界附近的微观组织、成分分布及析出相,探究其对熔敷金属内裂纹形成及硬度变化的影响。结果表明:隔离层熔合边界附近形成Ⅰ型边界、Ⅱ型边界、半岛状组织及岛状组织;S、Nb、Mo元素在局部晶界偏析发生共晶反应引起液化,进而导致在熔敷金属中形成少量结晶裂纹;由于Nb、Mo、Cr等元素的固溶强化作用,熔敷金属的显微硬度略高于两侧母材。

外加能场辅助搅拌摩擦焊研究现状

搅拌摩擦焊作为先进固相连接技术,广泛应用于航空航天等领域,轻质高强材料及异种材料连接对常规搅拌摩擦焊的发展提出了新的挑战.近年来,外加能场辅助搅拌摩擦焊技术的兴起有效地解决了异种材料连接中塑化程度不匹配和界面金属间化合物导致接头脆化的问题.同时,这一技术也为解决高熔点材料流变应力大、塑性变形能力差以及焊具磨损严重、焊接效率低等问题提供了新的思路.文中综述了外加能场辅助搅拌摩擦焊的研究现状,包括感应加热、激光加热、电流加热、电弧加热和超声辅助等,从过程产热、材料流动、组织性能调控和耦合作用机制等方面分析了热能和机械能对接头微观组织和性能的影响规律,同时对未来的研究方向进行展望.

FeCrNiAlCu中间层铝/铜电阻点焊接头的组织性能

采用FeCrNiAlCu高熵合金粉末作为中间层,对2A16铝合金/T2紫铜进行电阻点焊,研究高熵合金粉末对接头显微组织和力学性能的影响。结果表明:高熵合金粉末与液态铝合金存在元素相互扩散现象,并且反应生成富Al的固溶体过渡层。铜侧界面存在两层相结构组织,分别为富Al的固溶体层以及由Al_(2)Cu化合物组成的金属间化合物层(Intermetallic compound,IMC),部分固溶体颗粒与母材形成机械咬合。在焊接电流大小为20~32 kA时,接头的拉伸强度随焊接电流的增加先增加后减小;电流大小为25 kA时,接头的拉伸强度最高,达到1.64 kN,较无中间层的接头提升了30%;接头的断裂发生在铜侧界面处。

陶瓷的激光连接技术研究进展

随着材料加工的快速化、智能化、数字化的发展趋势,材料连接技术越来越受到广泛的重视,其中激光连接陶瓷技术是引人关注的重要技术之一。论述了近年来激光连接陶瓷技术的研究现状与进展,首先阐述了激光连接技术的原理和分类;其次对适合陶瓷激光连接的激光器类型和特点进行了介绍,并分析了影响激光连接陶瓷质量的关键因素;然后对基于激光连接技术的陶瓷与陶瓷之间的连接以及陶瓷与异质材料之间的连接的研究进展进行了详细的介绍,阐述了各种激光连接陶瓷方法的特点、机理和连接性能;最后对激光连接陶瓷技术进行总结,并展望其发展趋势。

铝/铜蓝-红激光复合焊接头组织及性能

为实现动力电池的高效可靠焊接,文中采用蓝-红复合激光进行了1050 Al/T2 Cu搭接焊,分析了激光功率对接头显微组织、相分布、力学性能及导电性能的影响规律.结果表明,铝/铜搭接接头焊缝表面平整,截面呈现T形,PB(蓝光功率)保持300 W,PR(红光功率)在700~1400 W区间内增加,铜侧熔深由60μm增大到1000μm,在PR=800 W时实现良好的冶金结合.焊缝组织由Al固溶体、Al-Cu共晶相和Al_(2)Cu金属间化合物组成,随激光功率增大,焊缝局部出现Al_(4)Cu_(9)相,边缘出现AlCu,Al_(4)Cu_(9)和AlCu_(3)相.在PR=800 W下抗剪强度达到最高108.6 MPa,接触电阻达到最小94μΩ,裂纹由两极交界处Al_(2)Cu区域萌生,沿焊缝边缘由外层Al_(2)Cu区扩展到底部Al固溶体和Al-Cu共晶区交界处,断裂形式为解理断裂.

铝/镁异种材料搅拌摩擦焊工艺参数优化及组织特征分析

利用光学显微镜和电子背散射衍射仪研究1060铝/AZ31B镁异种材料搅拌摩擦焊接头的组织特征,并采用Box-Behnken方法建立响应面模型,对焊接工艺参数偏置量ρ、转速ω、焊速v进行优化。结果表明:热输入过高或过低时,接头焊核区的铝、镁两种材料混合不充分,甚至会产生孔洞;搅拌针偏置量会影响受搅拌的铝和镁材料的体积,当搅拌针偏置时铝和镁材料体积不均匀,也会导致焊核区的铝和镁混合不充分。通过分析响应面模型,结果显示焊速对接头抗拉强度影响最大,优化的工艺参数为ρ=0 mm、ω=1200 r/min、v=150 mm/min,此时接头的抗拉强度较高,其预测值为95.7 MPa。在该焊接工艺参数下,接头焊核区无缺陷且材料混合充分,组织呈现出良好的机械互锁特征,且焊核区因发生动态再结晶,得到均匀细小的组织,接头的实测抗拉强度为96.1 MPa,与响应面模型预测值基本吻合。

铝-钢异种材料回填式搅拌摩擦点焊接头界面连接机制与力学性能研究

以5754铝合金与DC04钢为研究对象,进行了铝板在上的回填式搅拌摩擦点焊试验,研究了搅拌套下扎深度对铝-钢界面微观组织特征与接头力学性能的影响。结果表明,当搅拌套未扎入下层钢板时,冶金结合为铝-钢界面的主要连接机制。当搅拌套扎入下层钢板时,铝-钢界面同时发生机械咬合与冶金结合,其中,机械咬合主要发生在搅拌套作用区。通过工艺优化得出最优工艺参数为:转速2000 r/min、焊速0.5 mm/s,搅拌套下扎深度1.45 mm,此时接头最大拉剪失效载荷达5105 N。

制氢转化炉上尾管加强接头频繁开裂原因分析及对策

某炼化企业制氢转化炉2010年升级改造后,不同炉管的加强接头与上尾管焊口位置先后出现了5次开裂,造成制氢装置非计划停工。通过对运行环境、高温氢腐蚀、热膨胀应力、结构应力、异种钢焊接、弹簧支吊架等多方面开展深入分析,发现泄漏的原因主要是加强接头与上尾管连接焊缝局部高应力区发生了应力松弛开裂,同时,工艺参数控制不严格加遽了开裂速度。2021年通过实施炉管材质升级、稳定工艺运行环境、严控施工质量等措施,没有再出现过开裂的情况,彻底消除了炉管运行过程中的安全隐患,保障了设备的本质安全和装置的长周期运行。