AA6061-T6/QP980异种金属搅拌摩擦搭接焊工艺研究

Study on the Friction Stir Lap Welding Process of AA6061-T6/QP980 Dissimilar Metals

  • 摘要: 搅拌摩擦搭接焊(FRICTION STIR LAP WELDING, FSLW)作为一种固相连接技术,能有效避免材料在熔化焊接中因高温产生的气孔、热裂纹、成分偏析等问题,可实现铝/钢等异种材料的高效优质焊接。本文开展了6061-T6铝合金与QP980钢的FSLW工艺实验,研究了不同焊接速度(恒定搅拌头转速为600 RPM)对接头成形质量和焊接过程的影响。结果表明,在所研究的参数范围内,焊接速度越大,焊缝表面成形越光滑;受搅拌头搅拌作用和焊接热输入的影响,接头微观组织分为焊核区、热力影响区、热影响区和母材区,各区金相组织各异。接头力学性能测试结果发现,随着焊接速度增加,接头拉剪载荷先增后减,V=100 MM/MIN时达到最大;显微硬度分析显示,接头铝合金侧硬度分布呈“W”形,钢侧则呈倒“V”形。此外,随着焊速增加导致热输入减小,焊接过程中材料塑性流动变差,焊接时搅拌头承受的载荷有所增加。

     

    Abstract: Friction stir lap welding (FSLW) is a solid-state joining technique that effectively mitigates the formation of porosity, hot cracking, and compositional segregation associated with the high temperatures in fusion welding. It enables efficient and high-quality bonding of dissimilar materials such as aluminum and steel. In this study, FSLW experiments were performed on 6061-T6 aluminum alloy and QP980 steel to investigate the influence of varying welding speeds (at a constant tool rotational speed of 600 rpm) on joint formation and the welding process.The results indicate that, within the range of parameters examined, increasing the welding speed leads to improved surface smoothness of the weld. Due to the combined effects of tool stirring and heat input, the joint microstructure is characterized by four distinct zones: the weld nugget zone (WNZ), thermomechanical affected zone (TMAZ), heat-affected zone (HAZ), and base metal (BM), each exhibiting unique metallographic features.Mechanical testing reveals that the lap-shear strength of the joint initially increases and subsequently decreases with increasing welding speed, reaching a maximum at 100 mm/min. Microhardness profiles show a “W”-shaped distribution on the aluminum alloy side and an inverted “V”-shaped distribution on the steel side. Furthermore, as the welding speed increases, the corresponding reduction in heat input impairs the plastic flow of the material during welding, resulting in an increase in the load experienced by the tool.

     

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