镁合金薄板焊接工艺及弧长控制
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摘要
镁合金具有重量轻、比刚度比强度高、阻尼性好以及可回收利用等优点，被誉为21世纪绿色工程材料，在汽车、摩托车、航天航空等领域有广泛的应用前景。镁合金结构件的广泛应用，必将面临连结问题，焊接将是一种优选的连结方法。
为深入认识变形镁合金TIG焊接头组织与性能，探索提高镁合金熔焊接头性能的有效途径。在AZ31镁合金TIG焊工艺试验的基础上，使用拉伸试验机、光学显微镜、扫描电镜、X射线衍射仪、电子探针、显微硬度仪等现代分析测试手段，对AZ31镁合金TIG焊接头的力学性能、组织特征、断口形态、相组成、接头区的成分分布等进行了深入的研究分析。结果发现，与母材组织相比，焊缝区晶粒明显细小，为细小的等轴晶组成；热影响区的晶粒明显粗大，是接头断裂的危险区。进一步研究发现焊接热输入是决定焊接接头组织和性能的主要原因之一，在保证焊透的基础上，随焊接热输入的降低，接头组织晶粒变细，热影响区宽度变窄，接头组织明显改善，力学性能得到了提高。
为适应工件表面形状的变化，对镁合金薄壁件焊接过程进行有效的质量控制，在研究镁合金薄板TIG焊过程弧压-电流-弧长关系的基础上，提出了一种基于弧压、电流与弧长间的关系模型来准确控制弧长的技术，同时结合PID和Fuzzy控制的原理，设计了一种自适应ALC(Automatic Length Control)控制器，并建立了相应的弧长跟踪系统的软、硬件。焊接试验表明，设计的自适应ALC控制系统，突破了常规AVC(Automatic Voltage Control)系统不能在小电流和收弧期间工作的局限，成功实现了镁合金薄板和弓形件在TIG焊过程中的弧长跟踪控制问题，得到了成型较好的焊缝，且动态精度高、稳定性好。
本文还对镁合金交流TIG焊过程中高频干扰问题进行了分析，采用隔离、频蔽、接地等措施对高频干扰进行抑制，取得了较好的效果；同时设计了以正半波电弧电压作为弧长反馈信息的弧压采样电路，试验结果表明该采样电路能够很好地反映出镁合金焊接过程中的弧长变化。
Because of the characteristics of low density, high ratio rigidity and ratio strength, good damping and recycle, magnesium alloys are praised of the green engineering material, which have a widely applied prospect in the fields of automobile industry, motorcycle industry and aviation. With the extensive application to magnesium alloy structural components, the join of magnesium alloys will be developed, moreover, welding is a good methods of join.
To understand through the microstructure and properties in TIG welding joints of wrought alloys, the paper explored effective ways to improve the properties of fusion welding joints of magnesium alloy. Based on the experiments of AZ31 alloy by TIG, using tensile test machine, optical microscope, SEM, XRD, EPMA and micro-rigidity meter, the mechanical properties, microstructure, fracture morphology, phase composition, element distribution were investigated. The results showed the crystal grain was more fine in the fusion than that of the base metal, and the microstructure of heat affected zone became coarse obviously, which was the danger zone of crack. By Further analyzing, it was found the welding heat-input was the main cause effect on the microstructure and properties of joint. Under the condition of penetration, with the heat input decrease, the microstructure in fusion was improved, the width of HAZ becomes narrow, and the grains size in the weld zone become fine, and the mechanical properties were increased.
To adapt the change of workpiece figure, the quality of thin workpiece was controlled efficiently. Based on the investigation of the relation among the current, arc voltage and arc length in magnesium alloy sheets TIG welding, a new model based on the relationship among the current, arc voltage and arc length have been put forward, which was used to control arc length exactly. Refer to the principle of PID and Fuzzy, this article designed a kind of adaptive ALC (automatic length control) control system, and the software and hardware of arc length tracing system were established. The test showed that the new designed system broke through the limit of tradition AVC (automatic voltage control) that could not work during the low current and termination, and it solved the problem of arc length control for the magnesium alloy sheets and arc-shape workpiece. By this means, good weld bead could be get, moreover it had high dynamic response accuracy and good operation reliability.
In addition, the paper analyzes the problem of high-frequency interference in TIG welding, adopts the means of shield, insulate and connecting earth to prevent high-frequency interference and achieves the good results. The paper had designed the sampling circuit which take on the positive half-wave arc voltage to the feedback information of arc length, and the results showed the sampling circuit could response the change of arc length during the process of welding.
为深入认识变形镁合金TIG焊接头组织与性能，探索提高镁合金熔焊接头性能的有效途径。在AZ31镁合金TIG焊工艺试验的基础上，使用拉伸试验机、光学显微镜、扫描电镜、X射线衍射仪、电子探针、显微硬度仪等现代分析测试手段，对AZ31镁合金TIG焊接头的力学性能、组织特征、断口形态、相组成、接头区的成分分布等进行了深入的研究分析。结果发现，与母材组织相比，焊缝区晶粒明显细小，为细小的等轴晶组成；热影响区的晶粒明显粗大，是接头断裂的危险区。进一步研究发现焊接热输入是决定焊接接头组织和性能的主要原因之一，在保证焊透的基础上，随焊接热输入的降低，接头组织晶粒变细，热影响区宽度变窄，接头组织明显改善，力学性能得到了提高。
为适应工件表面形状的变化，对镁合金薄壁件焊接过程进行有效的质量控制，在研究镁合金薄板TIG焊过程弧压-电流-弧长关系的基础上，提出了一种基于弧压、电流与弧长间的关系模型来准确控制弧长的技术，同时结合PID和Fuzzy控制的原理，设计了一种自适应ALC(Automatic Length Control)控制器，并建立了相应的弧长跟踪系统的软、硬件。焊接试验表明，设计的自适应ALC控制系统，突破了常规AVC(Automatic Voltage Control)系统不能在小电流和收弧期间工作的局限，成功实现了镁合金薄板和弓形件在TIG焊过程中的弧长跟踪控制问题，得到了成型较好的焊缝，且动态精度高、稳定性好。
本文还对镁合金交流TIG焊过程中高频干扰问题进行了分析，采用隔离、频蔽、接地等措施对高频干扰进行抑制，取得了较好的效果；同时设计了以正半波电弧电压作为弧长反馈信息的弧压采样电路，试验结果表明该采样电路能够很好地反映出镁合金焊接过程中的弧长变化。
Because of the characteristics of low density, high ratio rigidity and ratio strength, good damping and recycle, magnesium alloys are praised of the green engineering material, which have a widely applied prospect in the fields of automobile industry, motorcycle industry and aviation. With the extensive application to magnesium alloy structural components, the join of magnesium alloys will be developed, moreover, welding is a good methods of join.
To understand through the microstructure and properties in TIG welding joints of wrought alloys, the paper explored effective ways to improve the properties of fusion welding joints of magnesium alloy. Based on the experiments of AZ31 alloy by TIG, using tensile test machine, optical microscope, SEM, XRD, EPMA and micro-rigidity meter, the mechanical properties, microstructure, fracture morphology, phase composition, element distribution were investigated. The results showed the crystal grain was more fine in the fusion than that of the base metal, and the microstructure of heat affected zone became coarse obviously, which was the danger zone of crack. By Further analyzing, it was found the welding heat-input was the main cause effect on the microstructure and properties of joint. Under the condition of penetration, with the heat input decrease, the microstructure in fusion was improved, the width of HAZ becomes narrow, and the grains size in the weld zone become fine, and the mechanical properties were increased.
To adapt the change of workpiece figure, the quality of thin workpiece was controlled efficiently. Based on the investigation of the relation among the current, arc voltage and arc length in magnesium alloy sheets TIG welding, a new model based on the relationship among the current, arc voltage and arc length have been put forward, which was used to control arc length exactly. Refer to the principle of PID and Fuzzy, this article designed a kind of adaptive ALC (automatic length control) control system, and the software and hardware of arc length tracing system were established. The test showed that the new designed system broke through the limit of tradition AVC (automatic voltage control) that could not work during the low current and termination, and it solved the problem of arc length control for the magnesium alloy sheets and arc-shape workpiece. By this means, good weld bead could be get, moreover it had high dynamic response accuracy and good operation reliability.
In addition, the paper analyzes the problem of high-frequency interference in TIG welding, adopts the means of shield, insulate and connecting earth to prevent high-frequency interference and achieves the good results. The paper had designed the sampling circuit which take on the positive half-wave arc voltage to the feedback information of arc length, and the results showed the sampling circuit could response the change of arc length during the process of welding.
引文
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[4] 黄晓峰，周宏，何镇明．镁合金的防燃研究及进展[J] ．中国有色金属学报，2000，10(S1)：797-801．
[5] S.F.SU, J.CHUANG, H.K.LIN, et al. Electron-beam welding behavior in Mg-Al-base alloys[J] . Metallurgical and Materials Transactions A, 2001, 33A(3): 1461-1473.
[6] Guenther Schubert, Armando Joaquin. Electron beam process delivers consistent welds[J] . Welding Journal, 2001, 80(6): 53-57.
[7] 刘静安．镁合金加工技术发展趋势与开发应用前景[J] ．轻合金加工技术，2001，29(11)：1-7．
[8] 顾钰熹．特种工程材料焊接[M] ．辽宁：辽宁科学技术出版社，1996．11．
[9] 美国焊接学会编，黄静文等译．金属及其焊接性[M] ，焊接手册第七版第四卷．北京：机械工业出版社，1991．1。
[10] 中国机械工程学会．材料的焊接[M] ，焊接手册，第2版第2卷．北京：机械工业出版社，2001，7．
[11] Toshikatsu Asahina,Hiroshi Tokisue. Electron beam weldability of pure magnesium and AZ31 magnesium alloy[J] . Journal of Japan Institute of Light Metals, 2000, 50(10): 512-517.
[12] Draugelates,Ulrich, et al. Welding of magnesium alloys by means non-vacuum electron-beam welding[J] . Welding and Cutting, 2000, 52(4): p62-67.
[13] HIRAGA Hitoshi, INOUE Takashi, et al. Effect of shielding gas and laser wavelength in laser welding of magnesium alloy sheet[J] . Yosetsu Gakkai Ronbunshu, 2001, 19(4): 591-599.
[14] M.Marya, G.R.Edwards. Factors controlling the magnesium weld morphology in deep penetration welding by a CO laser[J] . Journal of Materials Engineering and Performance, 2001, 10(4): 435-443.
[15] H.Zhao, T.DebRoy. Pore formation during laser beam welding of die-cast magnesium alloy AM60B-Mechanism and remedy[J] . Welding Journal, 2001, 80(8): 204-210.
[16] 张华，林三宝，吴林，冯吉才等．AZ31镁合金搅拌摩擦焊接头的力学性能[J] ．焊接学报，2003，24(6)：65-68．
[17] 邢丽，柯黎明，孙得超等．镁合金薄板的搅拌摩擦焊工艺[J] ．焊接学报，2001，22(6)：18-20。
[18] 銮国红，关桥。搅拌摩擦焊．革命性的宇航制造技术[J] ．航天制造技术，2003(4)：
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