AA7075-T6铝合金电阻点焊工艺参数优化研究

轻量化结构设计在保证了结构强度的前提下降低了整车质量,减少了能量消耗,成为汽车工业和航空航天的研究重点。本工作通过建立正交实验获取AA7075-T6铝合金的最佳焊接工艺参数。对接头进行拉伸剪切实验、金相观察和显微硬度测试,并对最优参数组合进行数值模拟,以研究焊接工艺参数对接头质量的影响。结果表明:当焊接时间为60 ms、焊接电流为17 kA、电极压力为0.22 MPa时,点焊接头的综合力学性能最好;焊接参数对电阻点焊接头力学性能的影响顺序为焊接时间>焊接电流>电极压力。焊接过程数值模拟得到的熔核尺寸与实验结果一致。焊接过程发生飞溅和熔核存在缩孔缺陷,导致接头的力学性能较差,失效模式为界面断裂。由于焊接过程接头显微组织发生变化,接头显微硬度变化呈“W”形。

Microstructural characterization,tribological and corrosion behavior of AA7075-TiC composites

Aluminum alloys are the potential materials in the automobile and aerospace sectors due to their lower density,easy forming and excellent corrosion resistance.The demand of high strength-to-weight ratio materials in structural applications needs the engineering industries to seek aluminum alloy with new versions of hard and brittle ceramic particles.The microstructure,hardness,wear and corrosion behaviors of AA7075 composites with 2.5wt.%and 5wt.%TiC particles were studied.Microscopic analysis is evident that the transformation of the strong dendritic morphology to non-dendritic morphology on the incorporation of TiC into AA7075.Furthermore,the precipitation of the second-phase compounds such as Al_(2)CuMg,Al_(2)Cu andFe-rich Al_6(Cu,Fe)/Al_(7)Cu_(2)Fe)is promoted by TiC particles at inter-and intra-dendritic regions.Accordingly,the hardness of composites is improved by grain boundary strengthening and particulate strengthening mechanisms.Both coefficient of friction and wear rate have an inverse relation with TiC concentration.The base alloy without TiC shows adhesive-type wear-induced deformation due to the formation of an oxide film,while composite samples exhibit a mechanically mixed layer and abrasive-type wear behavior.Composite samples shows a higher corrosion rate due to the presence of numerous precipitates which promote pitting corrosion.

Selective Laser Melting of Novel SiC and TiC Strengthen 7075 Aluminum Powders for Anti-Cracks Application

The aerospace and military sectors have widely used AA7075, a type of 7075 aluminum alloy, due to its exceptional mechanical performance. Selective laser melting (SLM) is a highly effective method for producing intricate metallic components, particularly in the case of aluminum alloys like Al-Si-Mg. Nevertheless, the production of high-strength AA7075 by SLM is challenging because of its susceptibility to heat cracking and elemental vaporization. In this study, AA7075 powders were mechanically mixed with SiC and TiC particles. Subsequently, this new type of AA7075 powder was effectively utilized in green laser printing to create solid components with fine-grain strengthening microstructures consisting of equiaxial grains. These as-printed parts exhibit a tensile strength of up to 350 MPa and a ductility exceeding 2.1%. Hardness also increases with the increasing content of mixed powder, highlighting the essential role of SiC and TiC in SLM for improved hardness and tensile strength performance. .

Effect of deep cryogenic treatment on the microstructural,mechanical and ballistic properties of AA7075-T6 aluminum alloy

The study focused on investigating the effect of Deep Cryogenic Treatment(DCT)on the mechanical and ballistic properties of AA7075-T6 aluminum alloy.The microstructure,microhardness,tensile strength,and impact strength of the Base Material(BM)and DCT-treated 7075 samples were analyzed through metallographic analysis and mechanical tests.The microstructure of the DCT-treated 7075 samples revealed fine grains and a distribution of secondary phase particles.The tensile strength,impact strength,and microhardness of DCT-treated samples increased by 7.41%,4%,and 9.68%,respectively,compared to the BM samples.The fractography analysis of the tensile samples showed cleavage facets,microvoids,and dimples in both the samples.The ballistic behavior of the BM and DCT target plates were studied by impacting hard steel core projectiles at a velocity of 750±10 m/s.The target plates failed due to petaling and ductile hole enlargement,and the depth of penetration(DOP)of the DCT target was less than that of the BM target,indicating a higher ballistic resistance.The post-ballistic microstructure examination of the target plates showed the formation of an Adiabatic Shear Band(ASB)without any cracks.It was concluded that the DCT treatment improved the mechanical and ballistic properties of the aluminum alloy due to grain refinement and high dislocation density.

基于侧碰抗撞性的AA7075 B柱轻量化设计

基于某车型的整体侧面碰撞有限元模型建立了车身侧面碰撞简化模型,并验证了二者的一致性。构建了AA7075 Johnson-Cook塑性阶段材料本构模型,将AA7075材料用于B柱内板和加强板,并与原模型进行了抗撞性对比分析。改进了加强板的结构,建立了近似模型并对其进行了厚度优化。结果表明,AA7075 B柱板件在有效降低侵入速度峰值和最大侵入位移的条件下质量减轻了60%,轻量化效果明显。

工艺参数对热冲压成形AA7075力学性能的影响

采用电磁感应辅助的热拉伸实验、红外热像仪和数字图像相关技术等手段模拟了热冲压成形AA7075汽车车身零件的制造流程,研究了变形温度、板料变形量、自然时效时间和烘烤时间对零件力学性能的影响。结果表明,提高变形温度可以提升热冲压成形AA7075的抗拉强度和屈服强度。当变形温度高于400℃时,变形温度对零件强度的提升较小;在成形过程中,变形量越大,热冲压成形AA7075的抗拉强度和屈服强度越低;自然时效20 d以内,热冲压成形AA7075的抗拉强度和屈服强度基本不变,自然时效时间大于20 d,抗拉强度和屈服强度均有一定下降;烘烤时间的波动对热冲压成形AA7075的抗拉强度和屈服强度无明显影响。

自然时效对AA7075板材锯齿形屈服行为的影响

基于高强铝合金低温形变热处理工艺,研究了自然时效对AA7075铝合金力学性能的影响并使用透射电镜(TEM)对热处理后的组织形貌进行了观察。将板材试样单向拉伸与三维数字图像相关(3D-DIC)技术相结合,研究了自然时效对板材拉伸变形锯齿形屈服行为(Portevin-Le Chatelier,PLC效应)的影响,对B型、C型PLC效应时域和空域行为的相关性进行了研究;应用轮廓扫描与3D-DIC等技术手段,研究了PLC效应为对变形试样表面质量的影响机制。研究表明:随自然时效时间延长,PLC效应产生的应力锯齿和PLC变形带特征均由C型向B型转变,直至消失;变形试样表面波纹度减弱。对于PLC变形带的带静态行为,变形带作用位置随机,产生周期短,对试件表面质量的影响最大;带动态行为,PLC变形带传播引发板材表面质点产生连续、均匀的厚向位移,对表面质量影响小。

Fatigue crack growth behaviour of friction stir welded AA7075-T651 aluminium alloy joints

The aim of the present work is to evaluate the fatigue crack growth behaviour of 12 mm thick AA 7075-T651 aluminium alloy plates joined by FSW. Fatigue crack growth test was carried out on center cracked tensile (CCT) specimens extracted from the FSW joints and unwelded parent metal. Transverse tensile properties of the unwelded parent metal and welded joints were evaluated. Microstructures of the welded joints were analyzed using optical microscopy and transmission electron microscopy. The scanning electron microscope was used to characterize the fracture surfaces. It was found that the ΔKcr of the welded joint is reduced by 10×10-3 MPa·m1/2 in comparison with the unwelded parent metal. Hence, the fatigue life of the friction stir welded AA 7075-T651aluminium alloy joints is appreciably lower than that of the unwelded parent metal, which is attributed to the dissolution of precipitates in the weld region during friction stir welding.

AA7075板材热处理的增塑机制及成形性能

结合生产工艺过程,研究了成形所需固溶处理、工序衔接所需自然时效、性能恢复所需人工时效对板材力学性能和成形性能的影响;通过金相显微镜、扫描电子显微镜和能谱分析等手段,探索热处理对板材显微组织与宏观力学性能的影响。结果表明:AA7075板材经固溶(480℃,0.5 h)水淬且自然时效处理后,最大力总伸长率提高85%、屈服强度降低60%,后经人工时效(120℃,12 h)处理,板材可完全恢复力学性能;固溶后,板材成形极限大幅提高,回弹比率显著减小;后继时效处理对弯曲角变化影响微弱。

AA7075合金搅拌摩擦焊接过程中力学性能变化

采用搅拌摩擦焊接技术进行了AA7075铝合金的焊接,针对搅拌摩擦焊接试样进行了拉压、弯曲和硬度测量实验,研究了AA7075铝合金在搅拌摩擦焊接过程中的组织演变和力学性能。实验及研究结果表明:焊接的强度高于母材15%,延展性为母材的50%,硬度相对于母材有所下降。在弯曲实验中,搅拌摩擦焊接之后的工件弯曲后更易产生裂缝。AA7075的微观组织演变主要体现在析出物尺寸和分布的变化。实验发现这些热影响区的析出物较为粗糙,而焊接区的析出物较为细小。

Comparative study on forming limit prediction of AA7075-T6 sheet with M−K model and Lou−Huh criterion

In order to effectively predict the fracture of AA7075-T6 sheet, the forming limit curves of AA7075-T6 high-strength sheet were drawn according to Morciniak Kuczyski (M K) model and Lou Huh criterion, respectively. The errors between the predicted values of the two theoretical prediction models and experimental values were calculated by error analysis. The forming limit curves were verified by the punch stretch test to evaluate the prediction accuracy of M K model and Lou Huh criterion. The error analysis results show that the mean error of Lou Huh criterion with the optimal parameters for all tensile specimens is 25.04%, while the mean error of M K model for all tensile specimens is 74.24%. The prediction accuracy of Lou Huh criterion in predicting the fracture of AA7075-T6 sheet is higher. The punch stretch test results show that the forming limit curve drawn by Lou Huh criterion can effectively predict the fracture of AA7075-T6 sheet, but the prediction accuracy of M K model is relatively poor.

Microstructure and mechanical properties of friction stir welded AA7075-T651 aluminum alloy thick plates

Friction stir butt welding of AA7075-T651 plates with thicknesses of 10 and 16 mm was investigated. Defect-free, full- penetration welds were obtained after careful process parameter selection. While the nuggets in both welds exhibited very fine reerystallized grains, and finer grains were observed in welds made on 10 mm thick plates. Microhardness surveys revealed that significant loss in hardness occurs in the heat-affected zone. The reduction in hardness due to the welding process is higher in the case of welds made on 16 mm thick plates. Welds made on 10 mm thick plates exhibited superior tensile properties compared with those made on 16 mm thick plates. Fracture during tensile test occurred in the heat-affected zone in both cases. TEM images of specimens revealed that the heat-affected zone consisted of widened precipitate-free zones along grain boundaries and partial dissolution of precipitates in the grain interiors. It is concluded that defect-free single pass welds can be made on AA7075-T651 thick plates using friction stir welding and the welds made on 10 mm thick plates exhibit high joint efficiency.

等离子体处理对AA7075铝合金表面特性及胶接性能的影响

目的改善AA7075铝合金的胶接性能及表面特性,提高胶接强度,研究等离子体处理对AA7075铝合金表面特性的影响。方法采用低温空气等离子体处理设备对AA7075铝合金进行表面处理,改变等离子体处理距离及处理速度,通过胶接及拉伸剪切试验对AA7075铝合金胶接强度进行测试,并利用SEM、AFM、接触角测量仪、FTIR、XPS等对铝合金表面的物化特性进行表征和分析,探究等离子体处理对铝合金胶接性能的影响及机理。结果当等离子体处理距离d为5 mm,速度v为2 mm/s时,AA7075铝合金胶接接头强度最大为14.56 MPa,与丙酮处理及未处理相比,分别提高约80%、200%。接头拉伸载荷位移曲线及破坏形貌表明,接头内聚破坏程度增大,胶粘剂呈内聚破坏形态分布在铝合金两侧。随着处理距离从10 mm降低至5 mm,铝合金表面部分污染物可以有效清除,表面最大高度差从221.8 nm降低至121.6 nm,表面微米级粗糙轮廓增加。同时,表面水接触角从46°降低至26°,表面自由能及极性分量增加,铝合金表面润湿性及表面吸附性能提高。表面FTIR、XPS测试表明,等离子体处理可以改变AA7075铝合金表面C1s、O1s、Al2p、N1s、Mg1s等元素含量占比,表面C—C、C—O和O—C=O基团含量减少,OH、Al—O等极性基团增多,铝合金表面活性明显增加。结论等离子体处理可以显著提高AA7075铝合金胶接强度,胶接接头失效模式由单一界面失效转变为胶粘剂内聚失效。等离子体处理通过改善AA7075铝合金表面润湿、黏附性能,增大粘结面积,同时提高表面极性基团及表面活性,使铝合金与胶粘剂胶接界面形成化学键合作用,从而提高其与胶粘剂界面的粘结强度。

Corrosion behavior and mechanical properties of cold metal transfer welded dissimilar AA7075-AA5754 alloys

Cold metal transfer(CMT) welding is a brand-new arc welding technique which shows adequate results for welding of thin sheets and dissimilar materials. Corrosion behavior of dissimilar aluminum joints should be determined in terms of predicting the effect of welding process on the possible failures in their constructions caused by corrosive agents. The present study investigates the effect of heat input on mechanical properties and corrosion rate of AA5754-AA7075 joints welded by CMT using ER5356 filler wire. Pore formation was observed not only in the weld metal but also in the partially melted zone of AA7075 base metal due to the vaporization of zinc. Increased heat input caused over aging and zinc vaporization in AA7075 base metal, and grain coarsening in AA5754 base metal consequently decreased the tensile strength. The average tensile strength of AA7075-AA5754 joints varies between 235 and 240 MPa. The ductile fracture occurred at the AA5754 base metal side in all samples. Pitting was observed as the dominant corrosion mechanism. Corrosion resistance tended to increase with increasing heat input. Heat input values between 95 and 110 J/mm are recommended for the optimization of corrosion resistance and strength.

Cooling slope casting of AA7075 alloy combined with reheating and thixoforging

Cooling slope casting has been applied to aluminium casting alloys for producing ingots with non-dendritic microstructure.Semi-solid forming of the AA7075 was studied via cooling slope casting,reheating and thixoforging processes in order to determine the effect of semi-solid casting on the microstructure of the alloy.AA7075 ingots with non-dendritic microstructure were produced with cooling slope pouring.Castings were characterized by light microscopy,image analysis,scanning electron microscopy and EDS analysis.The resulting structures are promising in terms of grain size and sphericity.It was realized that grain coarsening may occur very suddenly in the reheating process.Cooling slope castings were obtained with 30°and 60°inclination angles,and in comparison,60°castings showed better results.Moreover,by using short reheating periods,semi-solid forging causes trace formation in the solid grains.

Effect of reverse dual rotation process on properties of friction stir welding of AA7075 to AISI304

The friction stir lap welding of AISI304 stainless steel to AA7075 aluminium alloy was investigated using the conventional friction stir welding (C-FSW) and the reverse dual rotation friction stir welding (DR-FSW) processes. In order to reduce the heat input, a dual rotation tool with a lower shoulder rotating speed was used. The results showed that both processes provide welds with excellent appearance and free of internal defects. The use of the DR-FSW process with the tool shoulder rotating reversely at low speed results in larger grain refinement in the nugget and less change in the microstructure of the aluminium alloy than using the C-FSW. The use of DR-FSW process at low speed of rotation allows to reduce the amount of intermetallic compounds in the welding interface, but does not prevent their formation. Although DR-FSW welding exhibits tensile strength superior to that achieved with the conventional process (C-FSW), both exhibit brittle behaviour with fracture at the weld interface.

Ballistic behavior of boron carbide reinforced AA7075 aluminium alloy using friction stir processing-An experimental study and analytical approach

High strength-to-weight ratio of non-ferrous alloys, such as aluminium, magnesium and titanium alloys, are considered to be possible replacement of widely accepted steels in transportation and automobile sectors. Among these alloys, magnesium is self explosive and titanium is costlier, and aluminium is most likely to replace steels. Application of aluminium or its alloys is also thought of as an appropriate replacement in defence field, especially to enhance the easiness in mobility of combat vehicles while maintaining the same standard as that of conventional armour grade steels. Hence most of the investigations have been confined to aluminium or its alloys as base material and open an era of developing the newer composite materials to address the major limitation, i.e. tribological properties. The surface composites can be fabricated by incorporating the ceramic carbides like silicon carbide, carbides of transition metals and oxides of aluminium using surface modification techniques, such as high energy laser melt treatment, high energy electron beam irradiation and thermal spray process which are based on fusion route. These techniques yield the fusion related problems, such as interfacial reaction, pin holes, shrinkage cavities or voids and other casting related defects, and pave the way to need of an efficient technique which must be based on solid state. Recently developed friction stir processing technique was used in the present investigation for surface modification of AA7075 aluminum alloy, which is an alternative to steels. In the present investigation, 160 μm sized boron carbide powder was procured and was reduced to 60 μm and 30 μm using high energy ball mill. Subsequently these powders were used to fabricate the surface composites using friction stir processing.Ballistic performance testing as per the military standard(JIS.0108.01) was carried out. In the present work, an analytical method of predicting the ballistic behavior of surface composites was developed. This method was based on energy balance, i.e., the initial energy of impact is same as that of energy absorbed by multi layers. An attempt also has been made to validate the analytical results with the experimental findings. Variation between the analytical and experimental results may be accounted due to the assumptions considering such as isotropic behavior of target and shearing area of contact as cylindrical instead of conical interface As the analytical model yields the ballistic performance in the closer proximity of experimentally obtained, it can be considered to be an approximation to evaluate the ballistic performance of targets.

Tensile fracture behavior of AA7075 alloy produced by thixocasting

Tensile fracture behaviors of thixocast, artificially aged thixocast （thixocast＋T6） and as-extruded AA7075 alloys were investigated. The microstructural and fractographic observations were carried out using optical microscope （OM） and scanning electron microscope （SEM）. Experimental studies showed that as-extruded and thixocast＋T6 specimens exhibited considerably more excellent mechanical properties than as-thixocast AA7075 specimen. T6 artificial heat treatment with prolonged solution treatment significantly improved the tensile properties of the thixocast AA7075 alloy. The tensile properties of as-extruded and thixocast＋T6 specimens were close to each other. In as-thixocast specimen having remarkable micro-cracks, fracture was intergranular brittle type. The ductile fracture surfaces were observed in as-extruded and thixocast＋T6 specimens. In as-thixocast specimens, decohesion started between the eutectic-matrix interfaces and propagated through grains. Micro-void coalescence was the dominant form of fracture in thixocast＋T6 heat treated specimens. The micro-voids nucleation was initiated at the interface between the matrix and multinary eutectic structure.

应力控制模式下疲劳损伤对AA7075-T651铝合金腐蚀行为影响的研究

通过AA7075-T651铝合金中断疲劳实验、含疲劳损伤试样的拉伸实验、电化学实验及微观结构观察等系统地探究了应力控制模式下疲劳损伤对其力学性能及腐蚀行为的影响。实验结果表明:应力控制模式下的疲劳损伤不仅可以提升AA7075铝合金的综合力学性能,还可以增加其耐腐蚀性,而疲劳损伤前后的微观结构变化(位错密度增加及二次相析出)是影响AA7075铝合金力学性能及腐蚀行为变化的根本原因。

基于激光喷丸技术的7075铝合金耐腐蚀性能研究

针对7xxx系铝合金耐腐蚀性能较差,长期服役在盐雾大气环境下存在点蚀、剥落腐蚀等问题,采用激光喷丸表面强化技术应用优势,对航空铝合金的耐腐蚀性性能的影响进行试验分析。研究发现,通过激光喷丸表面强化可以提高材料的耐腐性,从而进一步提高其疲劳性能和服役寿命,经过激光喷丸表面处理,材料表层的微结构改变,晶粒细化和表面压应力的存在使得材料的耐腐蚀性能大幅提高。其它合金在激光喷丸处理后腐蚀性能也有明显提高。