基于田口法的高硅铝合金超高旋转速度搅拌摩擦焊接工艺优化
Process optimization of ultra-high rotation speed friction stir welding for high silicon aluminum alloy based on Taguchi method
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摘要: 超高旋转速度搅拌摩擦焊借助超高旋转速度摩擦热量实现了薄板高硅铝合金的连接，这一方法大大降低了搅拌摩擦焊接的轴向力，减小了焊接变形，对焊接薄板铝合金具有独特的优势。文中以焊缝成形质量和焊接接头抗拉强度作为响应值，基于田口法对影响焊接质量的主要焊接工艺参数(旋转速度、焊接速度和下压量)进行试验设计，优化高硅铝合金超高旋转速度搅拌摩擦焊工艺。结果表明，焊接速度和下压量是显著影响因素，最优焊接工艺参数焊接速度为60 cm/min，旋转速度为14 000 r/min，下压量为1.8 mm。这一工艺条件下高硅铝合金超高旋转速度搅拌摩擦焊接接头的最大抗拉强度为129 MPa，达到母材高硅铝合金抗拉强度的97%。创新点： 采用田口法对超高旋转速度搅拌摩擦焊接工艺进行了优化，最后获得一套成熟、可复制的薄板铝合金的搅拌摩擦焊接工艺参数。Abstract: With the help of ultra-high rotation speed friction heat,the connection of thin plate high-silicon aluminum alloy was realized by ultra-high rotation speed friction stir welding (FSW).The axial force in the process of FSW was greatly reduced,thus the welding deformation was reduced.This method had unique advantages in welding thin aluminum alloy.Taking the formation quality of weld and tensile strength of welded joint as the response values in this paper,the experimental design of main welding parameters affecting welding quality such as rotation speed,welding speed and plunge length,was carried out based on Taguchi method in order to optimize the ultra-high rotation speed friction stir welding process of high silicon aluminum alloy.The results showed that the significant influencing factors were welding speed and press amount.The optimum welding parameters were welding speed of 60 cm/min,rotation speed of 14 000 r/min and plunge length of 1.8 mm.The maximum tensile strength of friction stir welded joint for high silicon aluminum alloy was 129 MPa,which reached 97% that of high silicon aluminum alloy under the optimum welding parameters.Highlights:The ultra-high speed FSW process was optimized by Taguchi method,and a set of mature and reproducible FSW parameters for thin aluminum alloy were obtained.
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