铜铝异种有色金属钎焊的性能试验研究
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摘要
本文概述了铜、铝合金的性能特点及其在工业领域中的应用前景,分析了铜铝异种金属焊接过程中的主要问题,阐述了能够应用于铜、铝合金焊接的各种焊接方法、工艺要素及相关研究现状,其中包括冷压焊、摩擦焊、扩散焊、爆炸焊、电阻焊、激光焊、钎焊等,提出了有待进一步研究的相关问题。
本课题以铜铝异种金属构件潜在的工程应用为背景,试验选用钎焊方法将两者连接起来,并就相关的钎焊问题开展试验研究,内容包括对铜铝异种金属进行真空钎焊和火焰钎焊试验;选用Al-Si-Mg钎料去研究不同的工艺参数对真空钎焊接头性能的影响,并选用不同的钎料去研究钎料成分对火焰钎焊接头性能的影响;选用利用金相显微镜、显微硬度计、万能拉伸试验机、扫描电子显微镜、X射线衍射仪等试验测试手段,对焊接接头的微观组织结构、显微硬度、接头力学性能、接头区形貌特征及物相成份等进行分析;探讨铜铝及其合金焊接过程中产生宏观缺陷和微观缺陷的原因和预防措施。
研究结果表明:在工艺参数选择合适的情况下,钎焊可以得到表面成形良好的接头。钎焊温度,保温时间和钎料层厚度是影响真空钎焊接头质量的主要因素,而钎料成分和装配间隙是影响火焰钎焊接头质量的主要因素。火焰钎焊接头的钎缝中心区硬度明显高于两侧扩散区的硬度,进一步验证钎缝中有大量脆性相的生成。真空钎焊和扩散焊接头的强度相对偏低,而火焰钎焊的接头强度相对较高。接头拉伸断裂多发生在钎焊中心区,而且断裂面上有撕裂的痕迹,小部分呈现光亮带,可以推断断裂的方式可能是韧脆混合断裂形貌。钎缝中的物相主要有α-Al固溶体,CuAl2,Al4Cu9等脆性相,脆性相的存在会严重削弱接头的强度,并导致焊缝中产生微裂纹。接头中常见的缺陷有脆性相、气孔、裂纹等。钎料中加入少量的稀土元素不仅可以细化钎缝中晶粒,而且可以弥散分布焊缝中的脆性相。焊前彻底清除焊件表面的氧化膜和油垢,加强对焊缝的保护等工艺措施,可以有效地减少焊缝中气孔和裂纹。
The characteristics and industrial applications of copper and aluminium alloys were summerized in this paper, and the main problems in copper and aluminium welding were analyzed. Some welding methods that may be used on copper and aluminium alloys, and its procedure factors as well as its updated research results were reviewed, including cold welding, friction welding, diffusion welding, explosion welding, resistance pot welding, laser welding, brazing and so on, and the forwarding problems to be researched were pointed out as well.
Regarding potential engineering application of Cu-Al dissimilar metal components as the background, copper and aluminium was connected by means of brazing and problems associated with brazing were studied. It was studied that joint properties in vacuum brazing by different parameters when using Al-Si-Mg filler metal, and choosing different brazing filler composition to study joint properties in the flame brazing. It was contained that the vacuum brazing and flame brazing experiments on dissimilar metals copper and aluminum, analyzing the microstructure, microhardness, mechanical property, area morphology in brazing zones and phase compositions of joints by means of optical microscope, Vickers, universal tensile testing machine, scanning electron microscopy and X-ray diffraction, and discussing the reasons that caused macroscopical and microcosmic defects, and the preventive measure measures in the brazing process of joints.
The results show that good surface welded joints can be got under proper matching of brazing parameters. The main factors that affect the quality of the joints by the vacuum brazing are brazing temperature, holding time and the thickness of the brazing layer, while the factors that affect the quality of the joints by the flame brazing are the solder composition and assembling space. That the hardness of the central area on both sides of joints by the flame brazing is significantly higher than that of the proliferation zone further verify a large number of brittle phases coming in the brazing zones. The strength of joints by the vacuum brazing and diffusion welding is relatively low, while that of joints by the flame brazing is relatively high. The most tensile fracture of joints occurs in the central area of brazing, and that the fracture surface has the torn traces and a small part of the bright band can be inferred that the form of fracture can be the mixed ductile-brittle fracture morphology. The main phases in the brazing zones areα-Al solid solution, CuAl2, Al4Cu9 and so on, which will seriously undermine the strength of joints and lead to coming about micro-cracks in the weld. The common welded defects in the joints are brittle phases, porosity, cracks, etc. A small amount of rare earth elements in the filter metal can not only refine the grain, and disperse the brittle phase in the weld. The occurrence of weld porosity and cracks can be reduced by taking some measures, such as removing the oxide film, dirt and oil completely before welding, strengthening the protection for welding pool, etc.
本课题以铜铝异种金属构件潜在的工程应用为背景,试验选用钎焊方法将两者连接起来,并就相关的钎焊问题开展试验研究,内容包括对铜铝异种金属进行真空钎焊和火焰钎焊试验;选用Al-Si-Mg钎料去研究不同的工艺参数对真空钎焊接头性能的影响,并选用不同的钎料去研究钎料成分对火焰钎焊接头性能的影响;选用利用金相显微镜、显微硬度计、万能拉伸试验机、扫描电子显微镜、X射线衍射仪等试验测试手段,对焊接接头的微观组织结构、显微硬度、接头力学性能、接头区形貌特征及物相成份等进行分析;探讨铜铝及其合金焊接过程中产生宏观缺陷和微观缺陷的原因和预防措施。
研究结果表明:在工艺参数选择合适的情况下,钎焊可以得到表面成形良好的接头。钎焊温度,保温时间和钎料层厚度是影响真空钎焊接头质量的主要因素,而钎料成分和装配间隙是影响火焰钎焊接头质量的主要因素。火焰钎焊接头的钎缝中心区硬度明显高于两侧扩散区的硬度,进一步验证钎缝中有大量脆性相的生成。真空钎焊和扩散焊接头的强度相对偏低,而火焰钎焊的接头强度相对较高。接头拉伸断裂多发生在钎焊中心区,而且断裂面上有撕裂的痕迹,小部分呈现光亮带,可以推断断裂的方式可能是韧脆混合断裂形貌。钎缝中的物相主要有α-Al固溶体,CuAl2,Al4Cu9等脆性相,脆性相的存在会严重削弱接头的强度,并导致焊缝中产生微裂纹。接头中常见的缺陷有脆性相、气孔、裂纹等。钎料中加入少量的稀土元素不仅可以细化钎缝中晶粒,而且可以弥散分布焊缝中的脆性相。焊前彻底清除焊件表面的氧化膜和油垢,加强对焊缝的保护等工艺措施,可以有效地减少焊缝中气孔和裂纹。
The characteristics and industrial applications of copper and aluminium alloys were summerized in this paper, and the main problems in copper and aluminium welding were analyzed. Some welding methods that may be used on copper and aluminium alloys, and its procedure factors as well as its updated research results were reviewed, including cold welding, friction welding, diffusion welding, explosion welding, resistance pot welding, laser welding, brazing and so on, and the forwarding problems to be researched were pointed out as well.
Regarding potential engineering application of Cu-Al dissimilar metal components as the background, copper and aluminium was connected by means of brazing and problems associated with brazing were studied. It was studied that joint properties in vacuum brazing by different parameters when using Al-Si-Mg filler metal, and choosing different brazing filler composition to study joint properties in the flame brazing. It was contained that the vacuum brazing and flame brazing experiments on dissimilar metals copper and aluminum, analyzing the microstructure, microhardness, mechanical property, area morphology in brazing zones and phase compositions of joints by means of optical microscope, Vickers, universal tensile testing machine, scanning electron microscopy and X-ray diffraction, and discussing the reasons that caused macroscopical and microcosmic defects, and the preventive measure measures in the brazing process of joints.
The results show that good surface welded joints can be got under proper matching of brazing parameters. The main factors that affect the quality of the joints by the vacuum brazing are brazing temperature, holding time and the thickness of the brazing layer, while the factors that affect the quality of the joints by the flame brazing are the solder composition and assembling space. That the hardness of the central area on both sides of joints by the flame brazing is significantly higher than that of the proliferation zone further verify a large number of brittle phases coming in the brazing zones. The strength of joints by the vacuum brazing and diffusion welding is relatively low, while that of joints by the flame brazing is relatively high. The most tensile fracture of joints occurs in the central area of brazing, and that the fracture surface has the torn traces and a small part of the bright band can be inferred that the form of fracture can be the mixed ductile-brittle fracture morphology. The main phases in the brazing zones areα-Al solid solution, CuAl2, Al4Cu9 and so on, which will seriously undermine the strength of joints and lead to coming about micro-cracks in the weld. The common welded defects in the joints are brittle phases, porosity, cracks, etc. A small amount of rare earth elements in the filter metal can not only refine the grain, and disperse the brittle phase in the weld. The occurrence of weld porosity and cracks can be reduced by taking some measures, such as removing the oxide film, dirt and oil completely before welding, strengthening the protection for welding pool, etc.
引文
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[7] Lacaze J, Tierce S, Lafont M C,et al. Study of the microstructure resulting from brazed aluminium materials used in heat exchangers[J] . Materials Science and Engineering A ,2005,413-414:317-321.
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[15] V A Sidyakin,A I Danilov. Low- pressure butt welding of steel and nickel alloy pipes in power engineering. Welding International , 2004 ,18(4):324-329.
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[2]周振丰主编.焊接冶金学(金属焊接性).北京:机械工业出版社,1993,142-143.
[3]刘中青,刘凯.异种金属焊接技术指南[M].北京:机械工业出版社,1997.
[4]崔忠圻.金属学与热处理[M].机械工业出版社,2006,408-432.
[5]里亚博夫BP.铝及铝合金与其他金属的焊接[M];北京:宇航出版社,1990.
[6] Mai T A, Spowage A C. Characterisation of dissimilar joints in laser welding of steel-kovar, copper-steel and copper-aluminium[J] . Materials Science and Engineering A ,2004,374(1-2):224-233.
[7] Lacaze J, Tierce S, Lafont M C,et al. Study of the microstructure resulting from brazed aluminium materials used in heat exchangers[J] . Materials Science and Engineering A ,2005,413-414:317-321.
[8]黄伯云.我国有色金属材料现状及发展战略[J].中国有色金属学报,2004,14 SI(5);122-127.
[9]何康生,曹雄夫.异种金属焊接[M].北京:机械工业出版社,1986.
[10]杨瑞鹏,蔡殉,李培祖等.铝铜直接钎焊的研究.焊接技术,1999,28(5):4-5.
[11]孙德超,胡伟.Al-Cu接头钎焊研究.焊接技术,2002,31(2):18-19.
[12] E Tasak,M Stankiewicz,R Gierlicki et al. Properties of joints welded in dissimilar materials. Welding International,2003,17(4):293-297.
[13] Long S.S.,Ellis F.V.. The Thermal stress analysis of dissimilar metal weld. Properties of steel weldments for elevated temperature containent applications,ASME,1978:77-90.
[14] M.V.Shakhmatov,D.M. Shakhmatov. Features of resistance butt,welding of cast iron. Welding International,2004,18(9):737-741.
[15] V A Sidyakin,A I Danilov. Low- pressure butt welding of steel and nickel alloy pipes in power engineering. Welding International , 2004 ,18(4):324-329.
[16] Veselov V A et al. Butt welding with the heating by the low pressure arc of steel-aluminium pipe transition pieces for cryogenic systems and equipment. Avtsvarka.1990,(4):50-55.
[17]中国机械工程学会.焊接学会.焊接手册.材料的焊接.第2册[M].北京:机械工业出版社,1992:609
[18]郝长岭,亢世江,陈学广.不断发展的固体焊接技术[J].焊接技术,2000年10月.第31卷第5期:18-19.
[19]郑远谋.爆炸焊接和金属复合材料及其工程应用[M].长沙:中南大学出版社,2004:7 -16.
[20]赵熹华.压力焊.北京:机械工业出版社,1988.
[21]孙启政,王凯.接触焊机理的探索.航空精密制造技术,2001,37(4):20-25.
[22] Sidyakin V A. Flash welding with the low pressure arc. In: New developments in the technology of resistance welding. Mashinostroenie:Moscow, 1981:25-44.
[23]重庆焊接研究所.铝铜焊接专专集,1980
[24]邹家生主编.材料连接原理与工艺[M].哈尔滨工业大学出版社,2005,315-316.
[25]孙德超,胡伟.Al - Cu接头钎焊研究[J].焊接技术,2002,31(2):18-19.
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