Geometrical, microstructural and mechanical characterization of pulse laser welded thin sheet 5052-H32 aluminium alloy for aerospace applications

Pulse laser welding of 0.6 mm-thick AA5052-H32 was performed to determine the optimum set of parameters including laser pulse current,pulse frequency and pulse duration that meets the AWS D17.1 specifications for aerospace industry.The microstructure and mechanical properties of the weldments were also investigated.Relationships between the parameters and weld bead geometry were found.High quality weld joints without solidification crack that met AWS D17.1 requirements were obtained at(I)high pulse energy(25 J)and high average peak power(4.2 kW)and(II)low pulse energy(17.6 J)and low average peak power(2.8 kW).The weld joint formed at lower heat energy input exhibited finer dendritic grain structure.Mg vapourisation and hard phase compound(Al0.5Fe3Si0.5)formation decreased in the weld joint formed at lower heat energy input.Consequently,the tensile strength of the weldment formed at lower heat energy input(168 MPa)is by a factor of 1.15 higher but showed^29%decrease in hardness(111 HV0.1)at the joint when being compared with the weldment formed at higher heat energy input.Appropriate parameters selection is critical to obtaining 0.6 mm-thick AA5052-H32 pulse laser weld joints that meet AWS D17.1 requirements for aircraft structures.

Brazing diamond grits onto AA7075 aluminium alloy substrate with Ag–Cu–Ti filler alloy by laser heating

The brazing of diamond is a promising way to fabricate grinding wheels for efficient machining and precision grinding.This work investigated the feasibility of bonding diamond grits onto Aluminium Alloy 7075(AA7075)substrate with a Ag–Cu–Ti filler alloy via laser fusion brazing.The interfacial microstructures and the strength of the brazed diamond joints were studied.The cross-section of the brazed diamond joint consists of a molten filler alloy layer,a molten pool,a heat effect zone,a columnar crystal zone and an equiaxed crystal zone.Within the interface of the filler alloy/substrate metal,microstructures observed possibly were Ag(s.s),Al(s.s),Tix Al,Al2 Cu and Mg intermetallic compounds.A layer of Ti C with a thickness of about 30–50 nm was found at the bonding interface of the diamond/filler alloy.The averaged peak shear force of the brazed joints was found to be approximately 39.8 N.The abrasion grinding test indicated that the diamond/AA7075 brazed joint was adequate for grinding.However,the pulled-off of grit was found to be the primary failure of this type of brazed joint.This work broadened the brazing diamond technique and the range of applications of brazed diamond wheels for efficient grinding.

A Comparison of Laser Cladding Ni-based Coating on an Aluminium Alloy with CO_2 Laser and Nd: YAG Laser

In this paper, a plasma sprayed coating (Ni Cr B Si) on an Al Si alloy surface was melted by a CO 2 laser and a Nd:YAG laser respectively. The difference on the outline of the melted zone, chemical composition and hardness distribution of the laser melted zones were investigated. Experimental results showed that samples treated by the Nd:YAG laser have a better cladding tendency, more uniform chemical composition and microhardness distribution. Samples treated by the CO 2 laser have larger compositional segregation and poorer microhardness distribution.

Surface hardening of Fe-based alloy powders by Nd:YAG laser cladding followed by electrospark deposition with WC-Co cemented carbide

This paper presents the results of a study concerned with the surface hardening of Fe-based alloys and WC-8Co cemented carbide by inte- grating laser cladding and the electrospark deposition processes. Specimens of low carbon steel were processed firstly by laser cladding with Fe-based alloy powders and then by electrospark deposition with WC-SCo cemented carbide. It is shown that, for these two treatments, the electrospark coating possesses finer microstructure than the laser coating, and the thickness and surface hardness of the electrospark coating can be substantially increased.

Effect of Cu addition on microstructural evolution and hardening of mechanically alloyed Al-Ti-O in-situ composite

The microstructure formation and strengthening of an Al-5 wt.%TiO2 composites with additions of 5 wt.%Cu and 2 wt.% stearic acid(as a process control agent, PCA) during mechanical alloying and subsequent thermal exposure were studied. The powder composites were prepared by high-energy ball milling for up to 10 h. Single line tracks of the powders were laser melted. Optical and scanning electron microscopy, XRD analysis and differential scanning calorimetry were used to study microstructural evolution. The results showed that the Cu addition promotes an effective mechanical alloying of aluminum with Ti O2 from the start of milling, resulting in higher microhardness(up to HV 290), while the PCA, on the contrary, postpones this process. In both cases, the composite granules with uniform distribution of Ti O2 particles were formed. Subsequent heating of mechanically alloyed materials causes the activation of an exothermic reaction of Ti O2 reduction with aluminum, the start temperature of which, in the case of Cu addition,shifts to lower values, that is, the transformation begins in the solid state. Besides, the Cu-added material after laser melting demonstrates a more dispersed and uniform structure which positively affects its microhardness.

焊接方法对铝合金焊接接头微弧氧化色差的影响

目的分析铝合金焊接接头微弧氧化过程中色差产生的原因。方法采用单激光和激光-MIG复合焊2种焊接方法焊接2A12铝合金,利用RGB值定性描述不同焊接试样的色差差异大小,采用金相、SEM和微区XRD观察2A12铝合金单激光和激光-MIG复合焊接头微弧氧化前后的组织、微观形貌和表面物相组成。结果经微弧氧化处理后,2A12铝合单激光焊焊件的焊缝和母材之间无明显色差,2A12铝合金激光-MIG复合焊焊件的焊缝和母材之间存在明显色差,结合金相组织、表面和截面的SEM形貌以及表面EDS和XRD测试分析结果可知,成分和表面熔融物颗粒的大小不同是铝合金焊接接头微弧氧化色差形成的主要原因,焊接接头的组织对铝合金焊接接头微弧氧化色差的产生没有影响。结论单激光焊接接头微弧氧化后的氧化色差较激光-MIG复合焊接头的小;铝合金(2A12)焊接接头产生氧化色差主要是因为焊接接头的成分和表面熔融物颗粒大小不同,而组织对色差无影响。

激光清洗时氟碳铝粉漆层表面粗糙度的分析及其对激光吸收的影响

激光清洗2024铝合金飞机蒙皮表面漆层过程中,粗糙表面的形成与演化会对漆层与激光的热交互作用及漆层去除机理产生较大的影响.1 064 nm脉冲激光逐层除漆过程中,分析了漆层表面形貌与粗糙程度的变化,研究了粗糙表面的产生机理及其演化规律,并通过建立漆层粗糙表面等效分析模型计算分析了漆层粗糙表面对激光吸收率的影响规律.结果表明,激光除漆过程中不同的去除机理作用后漆层均会出现粗糙表面,且粗糙表面的演化存在一定的规律;逐层除漆时,漆层粗糙表面对激光吸收率有明显增加作用,在激光作用7次后漆层粗糙表面对激光的吸收率增加了32.8%,如果采用固定的初始激光清洗工艺,会因吸收率增大导致铝合金基材产生损伤行为.

激光冲击强化7075铝合金数值模拟与试验分析

针对激光冲击强化7075铝合金的问题,利用有限元技术和试验方法进行研究。首先利用光学显微镜、电子背散射衍射、显微硬度试验分析激光冲击前后试样上表面和横截面上微观组织和力学性能。其次采用有限元软件对7075铝合金进行数值模拟,得到应力变化云图和残余应力云图。试验结果表明,激光冲击细化表面和横截面晶粒组织,表面和横截面上再结晶晶粒占比分别从激光冲击前6.5%和8.3%提升到33.0%和80.1%;激光冲击后表面平均显微硬度提升幅度超过15%;随着深度增加,横截面上显微硬度提升幅度逐渐衰减。数值模拟结果表明,激光冲击过程中应力从447 MPa提升到581 MPa,在稳定时降到550 MPa;激光冲击提高了表面残余应力,而横截面上应力随着厚度增加而衰减。

Microstructural origins of high strength of Al-Si alloy manufactured by laser powder bed fusion:In-situ synchrotron radiation X-ray diffraction approach

The microstructural factors contributing to the high strength of additive-manufactured Al-Si alloys us-ing laser-beam powder bed fusion(PBF-LB)were identified by in-situ synchrotron X-ray diffraction in tensile deformation and transmission electron microscopy.PBF-LB and heat treatment were employed to manufacture Al-12%Si binary alloy specimens with different microstructures.At an early stage of de-formation prior to macroscopic yielding,stress was dominantly partitioned into the α-Al matrix,rather than the Si phase in all specimens.Highly concentrated Si solute(~3%)in the α-Al matrix promoted the dynamic precipitation of nanoscale Si phase during loading,thereby increasing the yield strength.After macroscopic yielding,the partitioned stress in the Si phase monotonically increased in the strain-hardening regime with an increase in the dislocation density in the α-Al matrix.At a later stage of strain hardening,the flow curves of the partitioned stress in the Si phase yielded stress relaxation owing to plastic deformation.Therefore,Si-phase particles localized along the cell walls in the cellular-solidified microstructure play a significant role in dislocation obstacles for strain hardening.Compared with the results of the heat-treated specimens with different microstructural factors,the dominant strengthening factors of PBF-LB manufactured Al-Si alloys were discussed.

Microstructure and mechanical properties of Fe-doped NiAl-28Cr-6Mo eutectic alloys

Room temperature and high temperature microstructural and mechanical properties of arc melted Ni Al-28Cr-6Mo eutectic alloys doped with 0.1% Fe, 0.2% Fe and 0.5% Fe(mole fraction) were investigated. The homogenization heat treatment of the alloys was conducted at 1300℃ in Ar atmosphere. Microscopic analyses, hardness measurements, XRD measurements and compression tests were used to characterize the alloys. As-cast and homogenized alloys exhibit fine cellular eutectic structures with coarse intercellular eutectic structure. The increase in the content of Fe results in coarsening eutectic layers and the decrease in eutectic cells. All alloys have very high compressive stress and strain at room temperature. The addition of Fe has small negative impact on the strength and ductility of the alloys at room temperature. However, the addition of Fe increases the high temperature strength of the alloy. High temperature XRD patterns show that peaks shift to lower Bragg angles. This indicates that the lattice parameter of the alloys increases.

扫描速率对激光重熔微弧氧化层组织性能影响研究

为了提高汽车车身用铝合金的表面力学性能,设计了复合工艺的加工处理,通过微弧氧化(MAO)和激光重熔(LR)技术对6061铝合金表面进行复合处理。通过调节激光扫描速度,制备具有良好力学性能的6061合金表面陶瓷(α-Al_(2)O_(3))层。研究结果表明,经LR、MAO复合处理后,致密层主要为比较稳定的α-Al_(2)O_(3)相,疏松层为亚稳态的Mg_(3)Al_(2)(SiO_(4))_(3)和Mg_(2)Si相构成,复合处理有效改善了材料组织结构。此次使用MAO与LR复合工艺制备的表面陶瓷层显微硬度显著提高,平均硬度最高可达220 HV,陶瓷层结合强度随扫描速度增加先上升后降低并且材料表面亲水性降低。

5083铝合金激光-MIG复合单面焊双面成形打底焊工艺优化

采用激光-熔化极惰性气体保护电弧(MIG)复合焊对5083铝合金板进行打底焊,以模拟铝合金罐体单面成形对接焊缝,研究了激光束摆动方式(不摆动、直线摆动、圆形摆动、方形摆动)、激光功率(2.5~4.0 kW)、组对间隙(0,1 mm)和错边(0,1 mm)对焊缝成形质量的影响,并分析了优化工艺下接头的力学性能。结果表明:在3.0 kW激光功率下,当激光束不摆动时,焊缝背面不连续并伴有凹坑,当激光束直线摆动时,焊缝内部存在大量气孔;在圆形激光束摆动模式下,当激光功率为2.5 kW时,焊缝背面未形成连续的全熔透焊缝,当激光功率为4.0 kW时,焊缝出现严重的下塌现象。3.0~3.5 kW激光功率以及圆形或方形激光束摆动模式能够实现单面焊背面自由成形,且焊缝成形良好,在不同组对间隙和错边条件下表现出较强的适应性;在激光功率为3.0 kW、激光束摆动模式为圆形摆动的优化工艺下,焊接接头抗拉强度达到母材的90%,正弯和背弯后接头中均未出现裂纹和其他开口缺陷,满足工程应用要求。

Cavitation-erosion mechanism of laser cladded SiC particle reinforced metal matrix composite

With 2 kW continuous wave Nd-YAG laser, SiC ceramic powder was laser-cladded on the AA6061 aluminium alloy surface. Within the range of process parameters investigated, the parameters were optimized to produce the SiC_p reinforced metal matrix composites(MMC) modified layer on AA6061 alloy surface. After being treated, the modified layer is crack-free, porosity-free, and has good metallurgical bond with the substrate. The microstructure and chemical composition of the modified layer were analyzed by such detection devices as scanning electronic microscope(SEM-EDX) and X-ray diffractometer(XRD). The performance of electrochemical corrosion and cavitation erosion and their mechanism were estimated by the microhardness tester, potentiostat and (ultrasonic-)(induced) cavitation device.

不同选择激光熔化工艺参数下Al-4.77Mn-1.37Mg-0.67Sc-0.25Zr合金的拉伸性能及显微组织

采用选择激光熔化(SLM)技术在不同工艺参数下制备Al-4.77Mn-1.37Mg-0.67Sc-0.25Zr合金(质量分数,%),通过拉伸试验和显微观察研究合金的组织和力学性能。结果表明:当能量密度为104~143 J/mm^(3)时,力学性能保持相对稳定;屈服强度为335~338 MPa,抗拉强度为397~400 MPa,伸长率均在11%以上。在此能量密度区间内,SLM合金缺陷和粗大金属间化合物较少,与此同时,有大量细小的Al Fe Mn Sc Zr相析出。当能量密度超过152 J/mm^(3)时,可以观察到一些孔洞和裂纹,且伸长率急剧下降。定量计算结果表明,该合金固溶强化、晶界强化和析出强化占比分别为44%、41%和15%。

激光-仅线圈式EMAT的金属检测系统优化设计

在铝合金铸造和高温轧制过程中,采用非接触式无损检测技术实现在线监测与检测,对减小生产成本、保证生产线连续、提高产品成品率具有重要意义。首先,建立了以脉冲激光束激励和仅线圈式电磁超声换能器(EMAT)接收的铝合金Laser-EMAT检测过程有限元模型,分析了水膜表面约束机制以及硅钢聚磁结构对所激励的多模式超声波幅值的影响规律,研究了仅线圈式EMAT的励磁线圈和接收线圈的外径、内径、线径、层数等对超声波接收效率的影响;其次,开展了铝合金Laser-EMAT检测实验,验证了水膜表面约束机制、仅线圈式EMAT设计参数和硅钢聚磁结构对检测回波幅值的影响规律。研究结果表明,水膜表面约束下,采用硅钢材料作为励磁线圈的聚磁背板后,超声回波信号幅值增强了37.76%,信噪比增加了17.3 dB。在激光能量一定、光斑大小不变、励磁线圈外径为12.3 mm、内径为1.6 mm、线径为0.4 mm、层数为2层时,线圈阻抗与电路内阻一致,线圈获得的能量最多,其提供的径向偏置磁场最强。当接收线圈外径为14.1 mm、内径为1.7 mm、线径为0.26 mm时,超声波接收效率最佳。

6005A铝合金摆动激光焊接组织及力学性能研究

目的优化铝合金摆动激光焊焊接接头组织结构,减少焊接缺陷,提高接头机械性能。方法采用无摆动、三角摆动和无穷摆动3种模式对6005A铝合金进行焊接。采用金相显微镜、扫描电子显微镜、能谱仪对焊接接头的组织结构和元素分布进行表征;使用显微硬度计及拉伸试验机对接头进行力学性能测试;利用扫描电子显微镜分析拉伸断口的形貌特征。结果与无摆动和三角摆动两种模式相比,无穷摆动模式下焊缝成形最佳,晶粒尺寸最小,元素分布最均匀,这得益于复杂的双向循环摆动设计对熔池产生的强烈搅动效果。无摆动、三角摆动、无穷摆动模式下焊核平均显微硬度分别为66HV、72HV、77HV;3种模式下接头平均抗拉强度分别为183.21、205.52、215.80 MPa;断裂模式分别为解理断裂、解理断裂+韧窝断裂及韧窝断裂模式。无穷摆动模式同样显示出最佳的力学性能。结论铝合金摆动激光焊接采用无穷摆动模式可以获得组织均匀细小、无焊接缺陷且综合性能优良的焊接接头,该模式十分适合铝合金材料的焊接。

6061铝合金焊后氧化物的激光清洗机理和工艺研究

采用纳秒脉冲激光器对6061铝合金焊后氧化物进行激光清洗实验。首先分析焊斑清洗前和清洗后的表面形貌和元素组成,探明焊后氧化物组成成分。其次再利用前期实验所获得不同工艺参数对清洗质量的影响规律,设计正交实验,划定各因素区间范围,分析参数对清洗质量的影响权重。利用正交实验法分析得到:影响表面轮廓线峰谷值的参数主次顺序为激光功率>脉冲频率>扫描速度>脉冲宽度;影响氧元素质量百分比的参数主次顺序为脉冲宽度>扫描速度>激光功率>脉冲频率。通过综合平衡法最终获得优化工艺参数组:扫描速度、激光功率、脉冲频率、脉冲宽度分别为2950 mm/s、141 W、29 kHz、330 ns。优化后可确保铝合金焊后氧化物清洗彻底、无基材损伤、清洗效率高。

铝合金激光-MIG复合焊研究现状与展望

铝合金具有良好的导电性、导热性、耐腐蚀性及较高的比强度,在航空航天、轨道客车、汽车工业、船舶制造等领域都得到了广泛应用。激光焊具有能量密度高、焊接熔深大、焊接速度快、焊接变形小等优点,但同时也存在对装配精度要求高、易产生焊接气孔、激光能量利用率低、设备使用及维护成本高的问题。激光焊用于铝合金焊接时焊接气孔问题尤其严重,还存在接头软化等问题。为了解决铝合金激光焊接存在的问题,国内外焊接工作者针对铝合金激光-MIG复合焊技术开展了大量研究。通过对近几年最新的研究成果进行总结,可以进一步加强对该焊接技术的研究,促进该焊接方法在工业生产中的应用。本文针对铝合金激光-MIG复合焊,从薄板焊接、厚板焊接、异种金属焊接、辅助焊接、焊接气孔等几方面总结了铝合金激光-MIG复合焊的最新研究进展和研究成果,并基于当前的研究现状提出存在的问题和展望未来的发展方向。

基于ReliefF特征权重融合的激光冲击强化保护层烧损实时检测

激光冲击强化(LSP)作为一种新型的激光表面处理技术已应用于航空发动机、机匣等关键部件的强化延寿处理,确保LSP加工质量的一致性及稳定性对上述航空装备的长寿命服役具有重要意义。然而,在高能瞬态LSP过程中,保护层容易发生烧蚀破损,极大地限制了LSP的工业应用。因此,通过分析激光诱导等离子体光谱信号,提出了一种基于ReliefF特征权重融合的LSP保护层烧损实时检测方法。以4 mm厚的7075铝合金为LSP靶材,以黑胶带为LSP保护层。首先,利用长波段范围的Ocean Optics-HR4000光谱仪和高分辨率的Princeton SP2750光谱仪同步采集LSP瞬态过程中产生的等离子体光谱信息;其次,根据Princeton SP2750光谱仪采集的高精度光谱信号,分别选取波长为394.40和396.15 nm的AlⅠ谱线以及波长为393.36和396.80 nm的FeⅠ谱线,提取其峰值强度与Stark展宽特征,然后结合ReliefF特征重要度筛选出对保护层烧损状态更加敏感的两条AlⅠ谱线,并且定性分析了AlⅠ谱线的峰值强度和Stark展宽对保护层烧损状态的敏感程度和瞬态变化规律;再次,基于ReliefF算法构造了一种融合多谱线特征信息的特征参数I-FWHM(Intensity-FWHM),然后基于特征类间距离,定量评估了各特征对三类烧损状态的区分能力;最后,结合阈值分割法实现了LSP保护层烧损实时检测。实验结果表明,峰值强度对于区分正常状态与轻微破损状态的能力很差,而对于区分轻微破损与完全破损的能力很强;Stark展宽对于区分正常状态与轻微破损状态的能力远优于强度,而对于区分轻微破损与完全破损的能力相对较弱。I-FWHM融合了上述单一特征的优点,能同时较好地区分三类烧损状态,因此对于LSP过程中保护层烧损状态的实时检测具有更强的抗干扰能力和更高的鲁棒性。

轨道交通铝合金型材激光−电弧复合焊工艺适应性

针对轨道交通3 mm铝合金型材,采用激光−电弧复合焊工艺方法,对生产过程中常出现的错边、装配间隙对焊缝质量的影响规律开展试验研究。结果表明,激光−电弧复合焊对轨道交通铝合金型材焊接的工况适应性较强;在试验条件下,装配间隙主要影响焊缝余高及接头抗拉强度;随着装配间隙的增大,焊缝余高降低直至出现下凹,接头抗拉强度有所降低;错边量增大,会导致焊缝表面飞溅变多,装配错边对焊缝气孔及接头抗拉强度等影响不明显;在试验条件下,0.5 mm装配间隙及错边以内,激光−电弧复合焊焊缝成形、气孔、接头金相组织和抗拉强度均满足生产需求。