AZ31B变形镁合金及其焊接件激光冲击处理研究
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摘要
镁合金作为最轻的金属结构材料,具有比强度和比刚度高、密度小、阻尼性能好、导热性好、电屏蔽性好、易回收等优点,被誉为21世纪的“绿色工程材料”,在航空航天及交通等领域有着广泛的应用前景。但镁合金强度低、抗磨损、抗应力腐蚀及抗疲劳性能差,限制了其优越性的发挥。随着我国各项节能减排法规的相继出台,构件的轻量化成为解决该问题的重要途径。因此,加大镁合金基础研究,可以充分发挥镁合金性能的优势,拓宽镁合金的应用范围,不仅符合我国科学发展的需要,而且经济和社会效益十分可观。为此本文开展了激光冲击AZ31B变形镁合金及其交流氩弧焊接件宏观性能、微观结构和强化机理的研究,丰富了超高应变率下材料塑性变形理论研究体系,为镁合金表面自纳米化和抗应力腐蚀提供了新的工艺方法,为镁合金零件疲劳损伤容限设计提供了理论依据,在激光诱导晶粒细化以及镁合金表面改性处理方面,具有重要的实用价值和理论意义。
通过理论计算,结合不同激光工艺参数对AZ31B变形镁合金表面微凹坑、表面粗糙度及表面微观结构的影响,得到优化的激光工艺参数；采用法国Thales公司研制的YAG激光器,根据优化的激光工艺参数：波长为1.054μm,脉冲宽度为15ns,激光脉冲能量为10J,光斑直径3mm,选用美国3M公司生产厚度为0.1mm的铝箔作为涂层,选用厚度为3mm水帘作为约束层,在AZ31B变形镁合金表面制得纳米晶,采用X射线衍射仪和透射电镜表征了AZ31B变形镁合金激光冲击处理后塑性变形层沿深度方向不同截面上的微观结构,分析了纳米晶粒内微孪晶的成因,探讨了激光冲击处理诱导AZ31B镁合金表面纳米化的机理；测定了残余应力、显微硬度、动电位极化曲线、拉伸性能、冲击韧性、耐磨性、抗应力腐蚀性能及抗疲劳性能。
根据优化的焊接工艺参数：焊接电流45-50A,钨极直径Φ2mm,焊丝直径Φ2mm,保护气体(氩气)流量8-10L/min,焊接速度以获得理想的焊接接头为准。利用自制的焊丝,采用单面焊接双面成型工艺手工焊接2.2mm厚AZ31B镁合金薄板,交流氩弧焊能够获得理想的焊接头。观测了焊接头宏观和微观结构,测定了焊接件热影响区残余应力和力学性能,分析了焊缝微观结构的变化和残余拉应力的成因。
采用法国Thales公司研制的YAG激光器,根据优化的激光工艺参数：波长为1.0541μm,脉冲宽度为15ns,脉冲能量4J,光斑直径3mm,选用美国3M公司生产厚度为0.1mm的铝箔作为涂层,选用厚度为3mm水帘作为约束层,在AZ31B镁合金交流氩弧焊接件热影响区表面制得纳米晶。测定了残余应力、动电位极化曲线、力学性能及抗应力腐蚀性能。
本文通过AZ31B变形镁合金及其TIG焊接件激光冲击处理研究,获得了以下创新性成果：
1、在机理研究方面,首次采用激光冲击处理技术,发现根据优化的激光工艺参数,能在AZ31B变形镁合金表层制得纳米晶。系统研究了激光冲击诱导AZ31B变形镁合金塑性变形层沿深度方向不同截面上的微观组织结构,首次揭示了激光冲击处理诱导AZ31B变形镁合金表层纳米化的机理：在变形初期,位错滑移导致位错缠结,应力集中诱发机械孪生；在已经细化的晶粒、亚晶粒内,继续形成网络状位错胞和位错缠结；位错缠结转变成小角度取向差的亚晶界,细分粗大晶粒为亚晶粒；亚晶界不断吸收新的位错而演变成大角度晶界,最终形成等轴状、取向随机分布的纳米晶。
2、在加工工艺方面,本文为AZ31B变形镁合金及其TIG焊接件表面自纳米化和抗应力腐蚀等性能的提高提供了新的工艺方法。根据激光冲击前后AZ31B镁合金及其TIG焊接件在酸性去离子水中应力腐蚀对比实验结果：AZ31B镁合金及其TIG焊接件分别经历了261小时和192小时后发生应力腐蚀断裂,而激光冲击试样在经历10个月后也未断裂,得出了激光冲击处理能显著提高AZ31B镁合金及其T1G焊接件抗应力腐蚀能力的结论；发现激光冲击处理之后,AZ3113变形镁合金的抗拉强度提高了16.9%左右,屈服强度提高了16.3%,延伸率下降了4%左布,夏比冲出功提高了70.3%,磨损率下降了384.5%,摩擦系数减小了60%,表面硬度提高了91.8%,塑性变形层深度达到700μmn左右,表面残余压应力达到-125MPa,AZ31B镁合金及其TIG焊接件热影响区表面纳米晶粒的大小分别为20hm和35nm左右。
3、在数据处理方面,提出了修正七点递增多项式拟合法,建立了原始试样和激光冲击试样在不同存活率下基于Paris公式的疲劳裂纹扩展速率方程,发现了不同存活率下,激光冲击试样的裂纹扩展速率明显小于原始试样的规律。首次运用数理统计的方法,对激光冲击前后AZ3113镁合金的疲劳寿命、断裂裂纹长度和裂纹扩展速率进行数字特征分析。发现二者断裂裂纹长度没有显著差异；而二者疲劳寿命和裂纹扩展速率存在显著差异,以95%的置信度,激光冲击处理试样的裂纹扩展寿命是原始试样裂纹扩展寿命的1.85-2.37倍,并从激光冲击抗疲劳的机理上解释了这一统计现象。
Magnesium alloys, as the lightest metal structural material, are regarded as the21st century green engineering material because of their excellent properties such as low density, superior strength-to-weight ratio, better thermal and electrical conductivity, good vibration and shock absorption ability, perfect electromagnetic interference shielding property and easy recycling. There are great application prospect for magnesium alloy in aerospace, transportation and other fields. However, a number of undesirable properties such as poor strength, wear resistance, stress corrosion cracking (SCC) resistance and fatigue resistance hinder the play of its advantages. With the various laws and regulations of energy conservation and emissions reduction, lightweight of the component becomes an important way to solve the problem. Therefore, to intensify the basic research of magnesium alloy could give full play to the advantages of magnesium alloy performance, broaden the application range of magnesium alloy, which not only meets the needs of scientific development, but also can achieve considerable economy and society benefits. In the paper research on macro properties, microstructure and strengthening mechanism is carried out for AZ31B wrought magnesium alloy and its pulsed tungsten inert-gas (TIG) welding treated by Laser Shock Processing (LSP), which could enrich material plastic deformation theory under super high stain rate, provide new technology method for magnesium alloy surface nanocrystallization and stress corrosion cracking (SCC) resistance, and provide theoretical basis for fatigue damage tolerance design of magnesium alloy. In LSP induced grain refinement and magnesium alloy surface modification processing, there are important application value and theoretical significance.
Based on theoretical calculation and effect of different laser processing parameters on surface micro-dents, surface roughness and microstructure of AZ31B magnesium alloy, optimized laser processing parameters could be achieved. When AZ31B magnesium alloy plates are treated by using a YAG laser with a wavelength of1.054μm, a pulse width of15ns, a pulse energy of10J and a spot diameter of3mm.The water with a thickness of3mm was used as the transparent confining layer and the aluminum foil with a thickness of0.1mm was used as the opaque absorbing layer. Nano-sized grains are generated in the surface layer. The microstructure of the plastic deformation layer along the depth direction in different cross section is characterized by means of X-ray diffraction (XRD) and transmission electron microscope (TEM). The formation reasons of micro-twins and a possible LSP induced AZ31B magnesium alloy surface nanocrystallization mechanism are discussed. Residual stress, micro-hardness, potentiodynamic polarization curves, tensile property, impact toughness, wear resistance, stress corrosion cracking resistance and fatigue performance are examined.
According to the optimized welding technology parameters:welding current range from45to50A, tungsten electrode diameter of2mm, welding wire diameter of2mm, shield gas rate range from8to10liter per minute, welding speed based on accepting ideal welded joint. TIG welding was used to weld AZ31B Mg alloy plates with the thickness of2.2mm by using single-side welding double-side molding process, the ideal welded joints can be obtained. The macrostructure and microstructure of TIG welded joints are observed. The residual stress and mechanical properties of the welded joint are examined. The changes of microstructure for welded joint and reason for residual tensile stress formation are discussed.
According to optimized laser processing parameters, TIG welded AZ31B magnesium alloy sheets surface are processed using a YAG laser with a wavelength of1.054μm, a pulse width of15ns, a pulse energy of4J and a spot diameter of3mm. The water with a thickness of3mm was used as the transparent confining layer and the aluminum foil with a thickness of0.1mm was used as the opaque absorbing layer. A nano-structured surface layer can be produced on heat effect zone of welded AZ31B Mg alloys. Residual stress, potentiodynamic polarization curves, mechanical property and stress corrosion cracking performance are examined.
The innovative results are obtained through the above study as followings.
Firstly, in the aspect of mechanism research, LSP technology is used to produce nanocrystalline in AZ31B magnesium surface layer according to optimized laser processing parameters. Microstructures of LSP induced plastic deformation layer along the depth in different cross section is studied systematically. For the first time the mechanism of surface nanocrystallization for AZ31B wrought magnesium with LSP is proposed as followings:In original grains, dislocation slipping leads to the formation of dislocation tanglings and stress concentration leads to deformation twinning; in the subgrains and refined grains, dislocation tanglings and dislocation cells are formed continuously; dislocation tanglings are transformed into subgrains boundary with low angle, which divides coarse grains into subgrains; subboundaries are gradually developed into grains boundary with high angle, finally, nano-scale grains with equiaxed shape and random orientations are formed.
Secondly, in the aspect of processing technology, the paper has provided a new technology method for AZ31B wrought magnesium alloy and its TIG weldment surface nanocrystallization and the improvement of performance of stress corrosion cracking resistance, etc. Stress corrosion cracking contrast experiment results in acid deionized water for AZ31B wrought magnesium alloy and its TIG weldment before and after LSP show that the time of stress corrosion fracture for AZ31B wrought magnesium alloy and its TIG weldment without LSP is261hours and192hours, respectively, however, no cracks are observed on samples with LSP after ten months. So it is concluded that LSP can significantly improve stress corrosion cracking resistance of AZ31B magnesium alloy and its TIG weldment. Comparing with the as-received sample, the tensile strength and the yield strength are improved by16.9%and16.3%for samples treated by LSP, respectively, however, the elongation is decreased by4%, the mean impact energy of samples with LSP is increased by70.3%, the wear rate of the treated specimen is decreased by384.5%and the value of steady-state friction coefficient decreased by60%, surface micro-hardness is improved by91.8%, the depth of plastic layer is about700μm, the surface residual compressive stress is as high as-125MPa. The surface nano grain size of AZ31B magnesium alloy and its TIG weldment by LSP is about20nm and35nm, respectively.
Thirdly, in the aspect of data processing, modified fitting method of seven data is put forward to obtain fatigue crack growth rate equations in different probability of AZ31B Mg alloy with and without LSP. It is found that crack growth rate of samples by LSP is obviously smaller than as-received samples. For the first time mathematical statistics method is used to analyze the value of fatigue life, crack length and crack growth rate. It is found that the standard deviation of crack length between sample with and without LSP has no obvious difference, however, the standard deviation of crack growth rate and fatigue life between sample with and without LSP has obvious difference. Fatigue life of sample by LSP is1.85-2.37times longer than sample without LSP under95%reliability, and the statistical phenomenon is explained by the mechanism of LSP leading to improvement of fatigue resistance.
通过理论计算,结合不同激光工艺参数对AZ31B变形镁合金表面微凹坑、表面粗糙度及表面微观结构的影响,得到优化的激光工艺参数；采用法国Thales公司研制的YAG激光器,根据优化的激光工艺参数：波长为1.054μm,脉冲宽度为15ns,激光脉冲能量为10J,光斑直径3mm,选用美国3M公司生产厚度为0.1mm的铝箔作为涂层,选用厚度为3mm水帘作为约束层,在AZ31B变形镁合金表面制得纳米晶,采用X射线衍射仪和透射电镜表征了AZ31B变形镁合金激光冲击处理后塑性变形层沿深度方向不同截面上的微观结构,分析了纳米晶粒内微孪晶的成因,探讨了激光冲击处理诱导AZ31B镁合金表面纳米化的机理；测定了残余应力、显微硬度、动电位极化曲线、拉伸性能、冲击韧性、耐磨性、抗应力腐蚀性能及抗疲劳性能。
根据优化的焊接工艺参数：焊接电流45-50A,钨极直径Φ2mm,焊丝直径Φ2mm,保护气体(氩气)流量8-10L/min,焊接速度以获得理想的焊接接头为准。利用自制的焊丝,采用单面焊接双面成型工艺手工焊接2.2mm厚AZ31B镁合金薄板,交流氩弧焊能够获得理想的焊接头。观测了焊接头宏观和微观结构,测定了焊接件热影响区残余应力和力学性能,分析了焊缝微观结构的变化和残余拉应力的成因。
采用法国Thales公司研制的YAG激光器,根据优化的激光工艺参数：波长为1.0541μm,脉冲宽度为15ns,脉冲能量4J,光斑直径3mm,选用美国3M公司生产厚度为0.1mm的铝箔作为涂层,选用厚度为3mm水帘作为约束层,在AZ31B镁合金交流氩弧焊接件热影响区表面制得纳米晶。测定了残余应力、动电位极化曲线、力学性能及抗应力腐蚀性能。
本文通过AZ31B变形镁合金及其TIG焊接件激光冲击处理研究,获得了以下创新性成果：
1、在机理研究方面,首次采用激光冲击处理技术,发现根据优化的激光工艺参数,能在AZ31B变形镁合金表层制得纳米晶。系统研究了激光冲击诱导AZ31B变形镁合金塑性变形层沿深度方向不同截面上的微观组织结构,首次揭示了激光冲击处理诱导AZ31B变形镁合金表层纳米化的机理：在变形初期,位错滑移导致位错缠结,应力集中诱发机械孪生；在已经细化的晶粒、亚晶粒内,继续形成网络状位错胞和位错缠结；位错缠结转变成小角度取向差的亚晶界,细分粗大晶粒为亚晶粒；亚晶界不断吸收新的位错而演变成大角度晶界,最终形成等轴状、取向随机分布的纳米晶。
2、在加工工艺方面,本文为AZ31B变形镁合金及其TIG焊接件表面自纳米化和抗应力腐蚀等性能的提高提供了新的工艺方法。根据激光冲击前后AZ31B镁合金及其TIG焊接件在酸性去离子水中应力腐蚀对比实验结果：AZ31B镁合金及其TIG焊接件分别经历了261小时和192小时后发生应力腐蚀断裂,而激光冲击试样在经历10个月后也未断裂,得出了激光冲击处理能显著提高AZ31B镁合金及其T1G焊接件抗应力腐蚀能力的结论；发现激光冲击处理之后,AZ3113变形镁合金的抗拉强度提高了16.9%左右,屈服强度提高了16.3%,延伸率下降了4%左布,夏比冲出功提高了70.3%,磨损率下降了384.5%,摩擦系数减小了60%,表面硬度提高了91.8%,塑性变形层深度达到700μmn左右,表面残余压应力达到-125MPa,AZ31B镁合金及其TIG焊接件热影响区表面纳米晶粒的大小分别为20hm和35nm左右。
3、在数据处理方面,提出了修正七点递增多项式拟合法,建立了原始试样和激光冲击试样在不同存活率下基于Paris公式的疲劳裂纹扩展速率方程,发现了不同存活率下,激光冲击试样的裂纹扩展速率明显小于原始试样的规律。首次运用数理统计的方法,对激光冲击前后AZ3113镁合金的疲劳寿命、断裂裂纹长度和裂纹扩展速率进行数字特征分析。发现二者断裂裂纹长度没有显著差异；而二者疲劳寿命和裂纹扩展速率存在显著差异,以95%的置信度,激光冲击处理试样的裂纹扩展寿命是原始试样裂纹扩展寿命的1.85-2.37倍,并从激光冲击抗疲劳的机理上解释了这一统计现象。
Magnesium alloys, as the lightest metal structural material, are regarded as the21st century green engineering material because of their excellent properties such as low density, superior strength-to-weight ratio, better thermal and electrical conductivity, good vibration and shock absorption ability, perfect electromagnetic interference shielding property and easy recycling. There are great application prospect for magnesium alloy in aerospace, transportation and other fields. However, a number of undesirable properties such as poor strength, wear resistance, stress corrosion cracking (SCC) resistance and fatigue resistance hinder the play of its advantages. With the various laws and regulations of energy conservation and emissions reduction, lightweight of the component becomes an important way to solve the problem. Therefore, to intensify the basic research of magnesium alloy could give full play to the advantages of magnesium alloy performance, broaden the application range of magnesium alloy, which not only meets the needs of scientific development, but also can achieve considerable economy and society benefits. In the paper research on macro properties, microstructure and strengthening mechanism is carried out for AZ31B wrought magnesium alloy and its pulsed tungsten inert-gas (TIG) welding treated by Laser Shock Processing (LSP), which could enrich material plastic deformation theory under super high stain rate, provide new technology method for magnesium alloy surface nanocrystallization and stress corrosion cracking (SCC) resistance, and provide theoretical basis for fatigue damage tolerance design of magnesium alloy. In LSP induced grain refinement and magnesium alloy surface modification processing, there are important application value and theoretical significance.
Based on theoretical calculation and effect of different laser processing parameters on surface micro-dents, surface roughness and microstructure of AZ31B magnesium alloy, optimized laser processing parameters could be achieved. When AZ31B magnesium alloy plates are treated by using a YAG laser with a wavelength of1.054μm, a pulse width of15ns, a pulse energy of10J and a spot diameter of3mm.The water with a thickness of3mm was used as the transparent confining layer and the aluminum foil with a thickness of0.1mm was used as the opaque absorbing layer. Nano-sized grains are generated in the surface layer. The microstructure of the plastic deformation layer along the depth direction in different cross section is characterized by means of X-ray diffraction (XRD) and transmission electron microscope (TEM). The formation reasons of micro-twins and a possible LSP induced AZ31B magnesium alloy surface nanocrystallization mechanism are discussed. Residual stress, micro-hardness, potentiodynamic polarization curves, tensile property, impact toughness, wear resistance, stress corrosion cracking resistance and fatigue performance are examined.
According to the optimized welding technology parameters:welding current range from45to50A, tungsten electrode diameter of2mm, welding wire diameter of2mm, shield gas rate range from8to10liter per minute, welding speed based on accepting ideal welded joint. TIG welding was used to weld AZ31B Mg alloy plates with the thickness of2.2mm by using single-side welding double-side molding process, the ideal welded joints can be obtained. The macrostructure and microstructure of TIG welded joints are observed. The residual stress and mechanical properties of the welded joint are examined. The changes of microstructure for welded joint and reason for residual tensile stress formation are discussed.
According to optimized laser processing parameters, TIG welded AZ31B magnesium alloy sheets surface are processed using a YAG laser with a wavelength of1.054μm, a pulse width of15ns, a pulse energy of4J and a spot diameter of3mm. The water with a thickness of3mm was used as the transparent confining layer and the aluminum foil with a thickness of0.1mm was used as the opaque absorbing layer. A nano-structured surface layer can be produced on heat effect zone of welded AZ31B Mg alloys. Residual stress, potentiodynamic polarization curves, mechanical property and stress corrosion cracking performance are examined.
The innovative results are obtained through the above study as followings.
Firstly, in the aspect of mechanism research, LSP technology is used to produce nanocrystalline in AZ31B magnesium surface layer according to optimized laser processing parameters. Microstructures of LSP induced plastic deformation layer along the depth in different cross section is studied systematically. For the first time the mechanism of surface nanocrystallization for AZ31B wrought magnesium with LSP is proposed as followings:In original grains, dislocation slipping leads to the formation of dislocation tanglings and stress concentration leads to deformation twinning; in the subgrains and refined grains, dislocation tanglings and dislocation cells are formed continuously; dislocation tanglings are transformed into subgrains boundary with low angle, which divides coarse grains into subgrains; subboundaries are gradually developed into grains boundary with high angle, finally, nano-scale grains with equiaxed shape and random orientations are formed.
Secondly, in the aspect of processing technology, the paper has provided a new technology method for AZ31B wrought magnesium alloy and its TIG weldment surface nanocrystallization and the improvement of performance of stress corrosion cracking resistance, etc. Stress corrosion cracking contrast experiment results in acid deionized water for AZ31B wrought magnesium alloy and its TIG weldment before and after LSP show that the time of stress corrosion fracture for AZ31B wrought magnesium alloy and its TIG weldment without LSP is261hours and192hours, respectively, however, no cracks are observed on samples with LSP after ten months. So it is concluded that LSP can significantly improve stress corrosion cracking resistance of AZ31B magnesium alloy and its TIG weldment. Comparing with the as-received sample, the tensile strength and the yield strength are improved by16.9%and16.3%for samples treated by LSP, respectively, however, the elongation is decreased by4%, the mean impact energy of samples with LSP is increased by70.3%, the wear rate of the treated specimen is decreased by384.5%and the value of steady-state friction coefficient decreased by60%, surface micro-hardness is improved by91.8%, the depth of plastic layer is about700μm, the surface residual compressive stress is as high as-125MPa. The surface nano grain size of AZ31B magnesium alloy and its TIG weldment by LSP is about20nm and35nm, respectively.
Thirdly, in the aspect of data processing, modified fitting method of seven data is put forward to obtain fatigue crack growth rate equations in different probability of AZ31B Mg alloy with and without LSP. It is found that crack growth rate of samples by LSP is obviously smaller than as-received samples. For the first time mathematical statistics method is used to analyze the value of fatigue life, crack length and crack growth rate. It is found that the standard deviation of crack length between sample with and without LSP has no obvious difference, however, the standard deviation of crack growth rate and fatigue life between sample with and without LSP has obvious difference. Fatigue life of sample by LSP is1.85-2.37times longer than sample without LSP under95%reliability, and the statistical phenomenon is explained by the mechanism of LSP leading to improvement of fatigue resistance.
引文
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