铝合金保护用富镁底漆的研制及其性能研究

开发了一种可以取代铬酸盐处理技术的环氧富镁底漆,对铝合金材料提供牺牲阳极保护。通过对镁粉的表面处理和配方优化,获得了贮存稳定、便于喷涂的富镁底漆;通过涂层基本性能测试、盐雾试验、金相显微镜观察确定了镁粉的合适用量,研究了镁粉细度对涂层性能的影响,考察了防沉剂的选择和用量对体系贮存稳定性的影响,以及涂层对2024-T3铝合金材料的保护效果。研究表明:镁粉在富镁底漆中合适的PVC为45%左右,粒径小有助于增加其在体系中的添加量;气相SiO2和有机膨润土配合使用可以获得更满意的贮存稳定性;富镁底漆对2024-T3铝合金表现出优越的耐盐雾保护性能。

铝合金阳极化保护涂料的研制

通过接枝共聚的方法合成了SBS改性丙烯酸树脂,并以此为基料制备了铝合金阳极化保护涂料。考察了SBS用量、不同单体用量和引发剂用量对树脂性能的影响。红外光谱分析表明SBS和丙烯酸成功进行了反应。通过改性丙烯酸涂料的冲击强度从原来的30kg·cm提高到50kg·cm,耐磨性提高了20%,拉伸强度提高了800%。

铝合金脉冲MIG焊参数对熔池视觉传感效果的影响

利用建立的铝合金脉冲MIG焊熔池CCD视觉传感系统,通过焊接工艺试验研究了脉冲电流模式、熔滴过渡形式、焊丝伸出长度、焊枪位置和焊接电压等焊接参数对熔池视觉传感效果的影响规律。结果表明,熔滴过渡形式对视觉传感效果影响最大,在合适的脉冲电流模式下,通过调整焊接工艺参数使熔滴过渡为小颗粒自由过渡,配合短弧焊接既可得到良好的焊缝质量和成形,又可保证视觉传感效果。

铝合金脉冲MIG焊过程双变量解耦控制

针对铝合金脉冲熔化极惰性气体保护焊(Metal inert-gas welding,MIG)过程中,焊接参数匹配范围窄、参数间耦合作用强、焊接过程不稳定、焊缝成形差等关键问题,提出双变量解耦的控制方案。利用视觉传感同时反馈熔宽和干伸长信号,一方面调整双脉冲占空因数进行可变双脉冲熔宽控制;另一方面,在熔宽控制的同时,改变送丝速度同步控制干伸长,在控制焊缝成形的同时保证焊接过程的稳定。设计模糊PID控制器,采用基于xPC的实时目标环境,建立铝合金脉冲MIG焊快速原型控制平台,在此基础上,利用图像视觉传感和相应的图像处理算法,采用补偿解耦的方法进行双变量解耦控制试验,获得了良好的解耦控制效果,得到熔宽均匀的焊缝。结果表明,采用双变量解耦的控制方案能够实现铝合金脉冲MIG焊过程的控制,在保证焊接过程稳定的基础上,实现了良好的焊缝成形。

Effect of pulsed current on temperature distribution,weld bead profiles and characteristics of gas tungsten arc welded aluminum alloy joints

Temperature distribution and weld bead profiles of constant current and pulsed current gas tungsten arc welded aluminium alloy joints were compared. The effects of pulsed current welding on tensile properties, hardness profiles, microstructural features and residual stress distribution of aluminium alloy joints were reported. The use of pulsed current technique is found to improve the tensile properties of the weld compared with continuous current welding due to grain refinement occurring in the fusion zone.

Fatigue life prediction of gas metal arc welded crucifrom joints of AA7075 aluminium alloy failing from root region

Empirical relationship was developed to predict the fatigue life of gas metal arc welded （GMAW） cruciform joints failing from root region. High strength, age hardenable aluminium alloy of AA7075-T6 grade was used as the base material. The design of experiments concept was used to optimize the required number of fatigue testing experiments. Fatigue experiment was conducted in a servo hydraulic controlled fatigue testing machine under constant amplitude loading. The empirical relationship was developed. By using the developed empirical relationship, the fatigue life of GMAW cruciform joints failing from root region was predicted at 95% confidence level. The effect of cruciform joint dimensions on fatigue life was discussed in detail.

Effect of post weld heat treatment on microstructure and mechanical properties of gas tungsten arc welded AA6061-T6 alloy

Double-V butt TIG welding process was performed on two plates of AA6061-T6 using ER5356 filler. The microstructure,mechanical and nanomechanical properties of the joint were evaluated in as-welded and after post weld heat treatment (PWHT) usingXRD, FESEM, EBSD, nanoindentation and tensile tests. The results show that PWHT led to microstructural recovery of the heataffected zone (HAZ) in addition to the appearance of β-phase (Al3Mg2) at the grain boundaries of weld zone. The hardness (Hnano) inall zones increased after PWHT while the elastic modulus (Enano) was improved from 69.93 GPa to 81 GPa in weld area. All resultsindicate that PWHT has created a homogenous microstructure in the weld zone in addition to outstanding improvement inmechanical properties for the weld zone which surpass the base metal.

Effect of welding processes on AA2219 aluminium alloy joint properties

AA2219 aluminium alloy square butt joints without filler metal addition were fabricated using gas tungsten arc welding （GTAW）, electron beam welding （EBW） and friction stir welding （FSW） processes. The effects of three welding processes on the tensile, fatigue and corrosion behaviour were studied. Microstructure analysis was carried out using optical and electron microscopes. The results show that the FSW joints exhibit superior tensile and fatigue properties compared to EBW and GTAW joints. It is also found that the friction stir welds show lower corrosion resistance than EB and GTA welds. This is mainly due to the presence of finer grains and uniform distribution of strengthening precipitates in the weld metal of FSW joints.

Microstructure analysis and mechanical characteristics of tungsten inert gas and metal inert gas welded AA6082-T6 tubular joint: A comparative study

The present study is aimed to compare the microstructure characteristics and mechanical properties of AA6082 in T6 condition of tubular joints fabricated by tungsten inert gas welding （TIG） and metal inert gas welding （MIG） processes. The effect of welding processes was analysed based on optical microscopy image, tensile testing, and Vickers micro-hardness measurements. The results showed that the tensile strengths of the TIG-welded joints were better than those of the MIG-welded joints, due to the contribution of fine equiaxed grains formation with narrower spacing arms. In terms of joint efficiency, the TIG process produced more reliable strength, which was about 25% higher compared to the MIG-joint. A significant decay of hardness was recorded in the adjacent of the weld bead zone, shown in both joints, related to phase transformation, induced by high temperatures experienced by material. A very low hardness, which was about 1.08 GPa, was recorded in the MIG-weldcd specimens. The extent of the heat-affected-zone （HAZ） in the MIG-welded joints was slightly wider than those of the TIG-welded specimens, which corresponded with a higher heat input per unit length.

Microstructural evolution and its effect on mechanical properties in different regions of 2219-C10S aluminum alloy TIG-welded joint

Microstructural evolution and its effect on mechanical properties in different regions of 2219-C10S aluminum alloy tungsten inert gas(TIG)welded joint were analyzed in detail.In weld zone(WZ),α+θeutectic structure formed at grain boundaries with no precipitates inside the grains.In partially melted zone(PMZ),symbiotic eutectic or divorced eutectic formed at grain boundaries and needle-likeθ′phases appeared in the secondary heated zone.In over aged zone(OAZ),the coarsening and dissolution ofθ′phases occurred and mostθ′phases transformed intoθphases.In general heat affected zone(HAZ),θ′phases coarsened.Factors such as the strengthening phases,the grain size,the Cu content in matrix and the dislocation density can affect the mechanical properties in different regions of the joint.Moreover,a model describing the relationship between mechanical properties of the material and the volume fraction of precipitates,the average diameter of precipitates and the concentration of soluble elements was proposed.

硅烷偶联剂(KH550)和羟基硅油共同改性环氧树脂及配制富镁底漆性能研究

通过两步反应法实现了硅烷偶联剂KH550和羟基硅油对环氧树脂E-20的共同改性,利用胺基加成反应引入KH550的乙氧基基团增加E-20的活性,从而提高与羟基硅油的接枝效率。通过红外光谱、GPC测试、稳定性分析以及DSC测试研究了分步反应过程和反应物配比对改性树脂性能的影响,优化改性工艺。研究表明,合适的反应物配比为E-20∶羟基硅油∶KH550=10∶1.5∶0.5 (质量比)。进一步利用改性树脂配制富镁涂层,通过涂层基本性能测试、盐雾试验和老化试验,研究了涂层对铝合金的保护性能。研究表明,涂层具有高的附着力,柔韧性好,耐盐雾和耐老化性能提高明显。