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镀Zn钢-6016铝合金异种金属的激光熔钎焊及数值模拟
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更新时间：2015-10-17
熔钎焊是抑制或减少钢/铝异种金属激光焊接过程中FeAl脆性金属间化合物产生的有效工艺方法。采用光纤激光器，不添加任何钎料，对1.2 mm厚DC56D+ZF镀锌钢和6016铝合金平板试件进行激光搭接焊试验，利用MATLAB软件，针对焊接过程的实际情况，在一定的基本假设下建立准稳态下钢/铝异种金属激光焊接熔池形状的数学模型，基于准稳态形状控制方程数值计算获得的熔池几何形状分布，结合试验来调整焊接工艺参数，获得最佳焊接成形，利用卧式金相显微镜、扫描电镜和X射线衍射仪等手段研究焊接接头各区域的金相组织、主要元素分
镀Zn钢-6016铝合金异种金属的激光熔钎焊及数值模拟Laser welding-brazing and numerical simulation of zinc-coated steel and 6016 aluminum alloy
熔钎焊是抑制或减少钢/铝异种金属激光焊接过程中FeAl脆性金属间化合物产生的有效工艺方法。采用光纤激光器，不添加任何钎料，对1.2 mm厚DC56D+ZF镀锌钢和6016铝合金平板试件进行激光搭接焊试验，利用MATLAB软件，针对焊接过程的实际情况，在一定的基本假设下建立准稳态下钢/铝异种金属激光焊接熔池形状的数学模型，基于准稳态形状控制方程数值计算获得的熔池几何形状分布，结合试验来调整焊接工艺参数，获得最佳焊接成形，利用卧式金相显微镜、扫描电镜和X射线衍射仪等手段研究焊接接头各区域的金相组织、主要元素分布与物相组成。结果表明：焊接激光束照射搭接在钢板上的铝板对接焊缝时，焊接功率和焊接速度对熔池几何形状的影响较大，随着激光功率的增大，熔深增加；而随着焊接速度的增加，熔深却变浅。当焊接功率为1 600~1 800 W、焊接速度v=30 mm/s、离焦量D=0 mm时，焊缝成形性良好，无明显裂纹、气孔等缺陷，焊接接头区域存在一个台阶状结构，在平台区域，钢/铝两钟金属存在明显的界限，界面结合依靠液态的铝在钢母材表面上的润湿、填充和铺展等作用；下凹区域，钢/铝熔合较好，Fe和Al元素的混合区宽度较大，未形成明显的FeAl脆性金属间化合物，Fe和Al的热扩散是该区域界面结合的主要原因。
The laser welding-brazing is an effective process to inhibit or reduce FeAl brittle intermetallic compound produced during laser welding-brazing of steel and aluminum alloy. The laser lap welding test was carried out based on the DC56D+ZF galvanized steel with thickness of 1.2 mm and the 6016 aluminum alloy with the fiber laser. The Matlab software was used, according to the actual situation of welding process, the steel and aluminum dissimilar metal laser welding pool shapes of the mathematical model in the flight quasi-steady state was established under a certain basic assumption. Based on the quasi-steady numerical equations, the shape of molten pool geometry distribution was obtained. The welding process parameters were adjusted through the experiments to get the best welding forming. By optical microscopy, scanning electron microscopy and X-ray diffractometry, the microstructure, element distribution and phase composition of the steel/aluminum interface were studied. The results show that when the welding beam irradiates at the aluminum-seam interface, the welding power and welding speed have great influence on pool geometry. With the laser power increasing, the penetration increases; while with the welding speed increasing, the penetration depth becomes shallow. When the welding power is 1 600−1 800 W, the welding speed v is 30 mm/s and the defocus distance D is 0 mm, the best forming of welding is obtained, no cracks, holes and other defects are seen, and there is a bench-shape structure in the welding joint area. In the platform area, there is obvious boundary between the steel and aluminum. The interface bonding relies on the liquid aluminum on the wetting, filling and spreading of steel surface. In the concave region, the steel/aluminum fusion is better. The width is large for Fe and Al elements mixing zone, and FeAl brittle intermetallic compounds do not form, the thermal diffusion bonding between Fe and Al is the main reason for the region.
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