CN116278105A - Fiber wire preparation method and equipment for friction stir welding and welding method - Google Patents
Fiber wire preparation method and equipment for friction stir welding and welding method Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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Abstract
本发明公开了用于搅拌摩擦焊的纤维丝材制备方法和设备及焊接方法,制备方法包括以下步骤:S1、束状纤维材料经过宽展后并预浸定型胶形成单向薄层纤维带,将热塑性聚合物熔融塑化后涂覆在单向薄层纤维带上形成纤维涂覆带;S2、将纤维涂覆带轴向卷绕形成截面为圆形的单向多层纤维/聚合物预浸丝材;S3、将单向多层纤维/聚合物预浸丝材分切并保持半连状态后热熔处理并冷却得到切后再熔合的纤维丝材,本发明的纤维丝材焊接时能被均匀全方位分布在焊接部位,从而显著提高焊缝的强度,分切后的纤维可在高速旋转的搅拌头带动下呈现360度全方位的分布,焊缝处的各个角度均能得以纤维增强,避免了焊缝处力学性能因纤维增强所可能带来的各向异性。
The invention discloses a fiber filament material preparation method and equipment for friction stir welding and a welding method. The preparation method includes the following steps: S1. The bundled fiber material is stretched and pre-impregnated with a sizing glue to form a unidirectional thin-layer fiber belt. The thermoplastic polymer is melted and plasticized and coated on the unidirectional thin-layer fiber tape to form a fiber-coated tape; S2, the fiber-coated tape is wound axially to form a unidirectional multi-layer fiber/polymer preform with a circular cross section. Impregnated wire material; S3, cutting the unidirectional multi-layer fiber/polymer prepreg wire material and keeping it in a semi-continuous state, heat-melting treatment and cooling to obtain a fiber wire material that is fused after cutting, when the fiber wire material of the present invention is welded It can be evenly and omnidirectionally distributed in the welding part, thereby significantly improving the strength of the weld seam. The slit fibers can be distributed in a 360-degree direction under the drive of the high-speed rotating stirring head, and the fibers can be obtained from all angles of the weld seam. Reinforcement avoids the possible anisotropy of the mechanical properties of the weld due to fiber reinforcement.
Description
技术领域technical field
本发明涉及焊接技术领域,尤其是用于搅拌摩擦焊的纤维丝材制备方法和设备及焊接方法。The invention relates to the field of welding technology, in particular to a fiber wire material preparation method and equipment for friction stir welding and a welding method.
背景技术Background technique
材料焊接可以显著提高制品生产的可连续性,对于较多复杂金属制品来说,合理的焊接工艺可以明显缩短制造周期,减轻制品重量,提高制品外形及结构设计的灵活性,因而,焊接成为了一种重要的制品成型的工艺方法而广为关注,应用极其广泛。其中,搅拌摩擦焊(FSW)作为一种固态焊接过程,靠旋转工具和工件材料之间的摩擦产生热量,进而导致搅拌摩擦焊工具附近区域变软、混合并最终实现工件的结合。工件经过搅拌摩擦焊后往往具有较好的力学性能。目前,该工艺主要用于轻合金及低碳钢等的连接,也少量用于聚合物的焊接。Material welding can significantly improve the continuity of product production. For more complex metal products, a reasonable welding process can significantly shorten the manufacturing cycle, reduce product weight, and improve the flexibility of product shape and structural design. Therefore, welding has become It has attracted wide attention as an important product forming process and is widely used. Among them, friction stir welding (FSW), as a solid-state welding process, relies on the friction between the rotating tool and the workpiece material to generate heat, which in turn causes the area near the friction stir welding tool to soften, mix and finally achieve the bonding of the workpiece. Workpieces often have better mechanical properties after friction stir welding. At present, this process is mainly used for the connection of light alloy and low carbon steel, etc., and is also used for the welding of polymers in a small amount.
相对其它焊接方法来说,聚合物的搅拌摩擦焊具有温度低、塑性变形剧烈、接头质量高等优点,但也具有较多的限制及不足,比如,焊接质量受工艺的影响很大,因而施焊工艺窗口窄,在实际应用中施焊最优工艺不易稳定等,其实质性的原因则在于焊缝处的强度仍然远远低于母材,导致焊件在应用过程中的失效主要发生在焊接区域。Compared with other welding methods, polymer friction stir welding has the advantages of low temperature, severe plastic deformation, and high joint quality, but it also has many limitations and deficiencies. For example, the welding quality is greatly affected by the process, so welding The process window is narrow, and the optimal welding process is not easy to be stable in practical applications. area.
发明内容Contents of the invention
发明目的:本发明的目的在于提供一种用于搅拌摩擦焊的纤维丝材制备方法和设备及焊接方法,能够显著提升焊件的力学性能。Purpose of the invention: The purpose of the present invention is to provide a fiber filament preparation method and equipment for friction stir welding and a welding method, which can significantly improve the mechanical properties of the weldment.
技术方案:在第一方面,本发明提供的用于搅拌摩擦焊的纤维丝材制备方法,包括以下步骤:Technical solution: In the first aspect, the fiber filament preparation method for friction stir welding provided by the present invention comprises the following steps:
步骤S1、束状纤维材料经过宽展后并预浸定型胶形成单向薄层纤维带,将热塑性聚合物熔融塑化后涂覆在单向薄层纤维带上形成纤维涂覆带;步骤S2、将纤维涂覆带轴向卷绕形成截面为圆形的单向多层纤维/聚合物预浸丝材;步骤S3、将单向多层纤维/聚合物预浸丝材分切并保持半连状态后热熔处理并冷却得到切后再熔合的纤维丝材。Step S1, the bundled fiber material is stretched and pre-impregnated with a sizing glue to form a unidirectional thin-layer fiber tape, and the thermoplastic polymer is melted and plasticized and coated on the unidirectional thin-layer fiber tape to form a fiber-coated tape; Step S2 1. Winding the fiber-coated tape axially to form a circular unidirectional multilayer fiber/polymer prepreg filament; step S3, cutting the unidirectional multilayer fiber/polymer prepreg filament and maintaining half After the continuous state, heat-melt treatment and cooling to obtain fiber filaments that are cut and fused.
进一步的,所述步骤S1中,所述热塑性聚合物与待焊接的母材材料相同。Further, in the step S1, the thermoplastic polymer is the same as the base material to be welded.
进一步的,所述步骤S1中,纤维涂覆带纤维含量为40%~60%。Further, in the step S1, the fiber content of the fiber-coated tape is 40%-60%.
进一步的,所述步骤S2中,单向多层纤维/聚合物预浸丝材的截面分层线为阿基米德螺旋线。Further, in the step S2, the cross-section delamination line of the unidirectional multilayer fiber/polymer prepreg is an Archimedes spiral.
进一步的,所述步骤S3中,切断比例占整个圆形截面的70~90%,分切长度为搅拌摩擦焊头直径的1.5~2.5倍。Further, in the step S3, the cutting ratio accounts for 70-90% of the entire circular section, and the cutting length is 1.5-2.5 times the diameter of the friction stir welding head.
进一步的,所述步骤S3中,分切后的单向多层纤维/聚合物预浸丝材在热熔处理时轴向受力挤压再熔。Further, in the step S3, the cut unidirectional multi-layer fiber/polymer prepreg filament is axially pressed and remelted during hot-melt treatment.
在另一方面,上述方法制备得到的纤维丝材,其应用于热塑性聚合物搅拌摩擦焊焊接工艺,具体的,焊接方法包括如下步骤:On the other hand, the fiber filament prepared by the above method is applied to a thermoplastic polymer friction stir welding welding process. Specifically, the welding method includes the following steps:
步骤1、将欲连接件的待焊部位修理平整后并将待焊部位中部去除材料;Step 1. After repairing and leveling the part to be welded of the parts to be connected, remove the material from the middle of the part to be welded;
步骤2、将所制备的纤维丝材嵌入或熔入已去除材料的待焊部位后将待焊部位压平;Step 2, embedding or melting the prepared fiber filament into the part to be welded where the material has been removed, and flattening the part to be welded;
步骤3、将两欲连接件的待焊部位对接后施以横向作用力,并压紧固定,经过搅拌头的高速旋转后,两件被连接。
进一步的,步骤1中待焊部位中部去除的材料与步骤2欲嵌入或熔入纤维丝材的体积量保持一致,步骤3的焊接过程中,下压量控制为压入焊丝后搅拌头轴肩端面超出焊丝上表面0.05~0.15mm,且下压量小于或等于焊件厚度与搅拌针长度之间的差值。Further, the material removed in the middle of the part to be welded in step 1 is consistent with the volume of the fiber filament material to be embedded or melted in step 2. During the welding process of
在另一方面,本发明提供一种用于搅拌摩擦焊的纤维丝材制备设备,包括:In another aspect, the present invention provides a fiber filament preparation equipment for friction stir welding, comprising:
挤出机,用于将热塑性聚合物熔融塑化后挤出;展纱辊,用于将束状纤维材料宽展后形成单向薄层纤维干带;纤维带黏合辊,用于将单向薄层纤维干带预浸定型胶形成整片的单向薄层纤维带;浸渍机头,用于将熔融塑化后的热塑性聚合物涂覆单向薄层纤维带形成纤维涂覆带;轴向卷绕器,用于对纤维涂覆带沿轴向卷绕形成单向多层纤维/聚合物预浸丝材;牵引对辊,用于将单向多层纤维/聚合物预浸丝材牵引至履带牵引机上;纵向切割器,用于对单向多层纤维/聚合物预浸丝材进行纵向分切;热熔烘箱,用于对单向多层纤维/聚合物预浸丝纵向切割后的断口再熔,再熔后冷却即得到纤维丝材。The extruder is used to extrude thermoplastic polymer after melting and plasticizing; the spreading roller is used to spread the bundled fiber material to form a unidirectional thin layer fiber dry tape; the fiber tape bonding roller is used to make the unidirectional The thin-layer fiber dry tape is pre-impregnated with sizing glue to form a whole piece of unidirectional thin-layer fiber tape; the dipping head is used to coat the melted and plasticized thermoplastic polymer on the unidirectional thin-layer fiber tape to form a fiber-coated tape; the shaft Direction winder, used to wind the fiber coating tape in the axial direction to form unidirectional multi-layer fiber/polymer prepreg; traction rollers, used to wind unidirectional multi-layer fiber/polymer prepreg Traction to crawler tractor; longitudinal cutter for longitudinal slitting of unidirectional multilayer fiber/polymer prepreg; hot melt oven for longitudinal slitting of unidirectional multilayer fiber/polymer prepreg The final fracture is remelted, and the fiber filament is obtained after remelting and cooling.
进一步的,还包括调速对辊,其速度与牵引对辊的速度相同,且小于履带牵引机的速度。Further, it also includes a speed-regulating pair of rollers, the speed of which is the same as that of the traction pair of rollers, and is lower than the speed of the crawler tractor.
有益效果:本发明能够显著提高焊缝的强度;本发明避免了焊缝处力学性能因纤维增强所可能带来的各向异性;本发明可以有效避免普通聚合物搅拌摩擦焊容易产生的焊缝孔隙或间隙存在的机率;本发明使用方便,丝材分切后的再熔合可显著提高使用的便利性,焊接易实施;丝材制备及焊接过程均绿色无污染。Beneficial effects: the invention can significantly improve the strength of the weld; the invention avoids the possible anisotropy of the mechanical properties of the weld due to fiber reinforcement; the invention can effectively avoid the weld that is easily produced by ordinary polymer friction stir welding The probability of the existence of pores or gaps; the invention is convenient to use, and the refusion after the wire material is cut can significantly improve the convenience of use, and the welding is easy to implement; the wire material preparation and welding process are green and pollution-free.
附图说明Description of drawings
图1为本发明的纤维丝材的制备设备结构示意图;Fig. 1 is the schematic diagram of the preparation equipment structure of fiber silk material of the present invention;
图2为本发明的纤维丝材切后再熔合实物图;Fig. 2 is the physical figure of fusion after cutting the fiber filament material of the present invention;
图3为本发明的焊接实物图;Fig. 3 is the physical figure of welding of the present invention;
图4为本发明实施例1的纤维丝材在工件焊缝处的SEM表征图;Fig. 4 is the SEM characterization figure of the fiber wire material of the embodiment 1 of the present invention at the workpiece weld;
图5为本发明实施例2的以聚碳酸酯为原料无纤维材料焊接后的SEM表征图;Fig. 5 is the SEM characterization figure of the embodiment of the present invention 2 using polycarbonate as a raw material without fiber material after welding;
图6为本发明实施例1和实施例2焊接测试样片的测试前后的样品外形图;Fig. 6 is the sample outline drawing before and after the test of the welding test sample of embodiment 1 of the present invention and embodiment 2;
图7为本发明实施例3中所连接的工件焊缝处SEM表征图。Fig. 7 is a SEM characterization diagram of the welding seam of the workpiece connected in Example 3 of the present invention.
具体实施方式Detailed ways
下面结合附图和具体实施例对本发明技术方案作进一步说明。The technical solution of the present invention will be further described below in conjunction with the accompanying drawings and specific embodiments.
如图1所示的是本发明的用于制备搅拌摩擦焊所使用的纤维丝材的设备,该图1也同样显示了纤维丝材的制备工艺,设备主要包括挤出机1,纱架2,展纱辊4,纤维带黏合辊5,浸渍机头7,轴向卷绕器8、牵引对辊9、履带牵引机10、纵向切割器11、热熔烘箱12和调速对辊13。As shown in Figure 1 is the equipment for preparing the used fiber silk material of friction stir welding of the present invention, and this Figure 1 also shows the preparation process of fiber silk material, and equipment mainly comprises extruder 1, creel 2 , Spreading roller 4, fiber
挤出机1连接浸渍机头7,挤出机1一侧设置依次纱架2,展纱辊4,纤维带黏合辊5,挤出机1的另一侧依次设置有轴向卷绕器8、牵引对辊9、热熔烘箱12和调速对辊13,此外在牵引对辊9和热熔烘箱12之间设置有履带牵引机10和纵向切割器11,纵向切割器11设置在履带牵引机10的正上方。The extruder 1 is connected with the
通过上述的设备制备纤维丝材的步骤如下:The steps of preparing fiber filaments by the above-mentioned equipment are as follows:
步骤(1),将热塑性聚合物通过挤出机1熔融塑化后进入到浸渍机头7中;In step (1), the thermoplastic polymer is melted and plasticized by the extruder 1 and then entered into the dipping
步骤(2),将特定的纤维材料置于纱架2中,此时纤维材料为束状,纤维束3经过展纱辊4的宽展作用后形成单向薄层纤维干带;纱架2的数量可以为一个或一个之上,展纱辊4的数量与纱架2应保持一致;In step (2), the specific fiber material is placed in the creel 2. At this time, the fiber material is in the form of a bundle, and the
步骤(3),若干展平后的纤维干带经过纤维带黏合辊5时被预浸微量定型胶形成整片的单向薄层纤维带6,该纤维带6也进入到浸渍机头7中,纤维带6被均匀的涂上聚合物高温熔体,形成纤维涂覆带;控制纤维涂覆带的涂覆量可控制纤维含量并保证纤维在该涂覆带中的均匀分布,本实施例中,纤维含量保持在40%~60%之间;In step (3), several flattened fiber strips are pre-impregnated with a small amount of sizing glue to form a whole piece of unidirectional thin-
步骤(4),纤维涂覆带被随后的轴向卷绕器8沿轴向卷绕,形成截面为圆形的单向多层纤维/聚合物预浸丝材;In step (4), the fiber-coated tape is wound axially by the subsequent
步骤(5),丝材在牵引对辊9的作用下进入到履带牵引机10上,并被纵向切割器11分切并保持半连状态;Step (5), the wire enters the
步骤(6),半连状态的丝材在通过热熔烘箱12时,断口处的聚合物少量熔融,同时,受到后面的调速对辊13的轻微阻滞力量,使熔融的聚合物受压并相互黏结,从而形成了切后再熔合的纤维丝材14,该丝材后续被缠绕或卷取后备用,调速对辊13的速度可与牵引对辊9的速度保持一致,它们的速度均比履带牵引的速度低2~5%。Step (6), when the wire in the semi-continuous state passes through the hot-
上述方法制备得到的纤维丝材,其应用于热塑性聚合物搅拌摩擦焊的焊接工艺,具体的,包括如下步骤:The fiber filament material prepared by the above method is applied to the welding process of thermoplastic polymer friction stir welding, specifically, including the following steps:
1)将欲连接件的待焊部位修理平整后并将待焊部位中部去除适量材料;1) After repairing and leveling the part to be welded of the parts to be connected, remove an appropriate amount of material from the middle of the part to be welded;
2)将所制备的丝材嵌入或熔入待焊部位后将待焊部位压平;2) After embedding or melting the prepared wire into the part to be welded, flatten the part to be welded;
3)将两欲连接件的待焊部位对接后施以适量横向作用力,并随后压紧固定在工作台上,在确定的焊接工艺条件下,经过搅拌头的高速旋转后,两件被连接。3) Apply an appropriate amount of lateral force after docking the parts to be welded of the two parts to be connected, and then press and fix them on the workbench. Under the determined welding process conditions, after the high-speed rotation of the stirring head, the two parts are connected .
其中,在步骤1)中每一个待焊部位中部去除的材料与步骤2)欲嵌入或熔入丝材的体积量保持一致。Wherein, the material removed in the middle of each part to be welded in step 1) is consistent with the volume of the wire to be embedded or melted in step 2).
在步骤3)中的焊接工艺条件主要包括下压量及焊接速度,一般的,下压量控制为压入焊丝后搅拌头轴肩端面超出焊丝上表面0.05~0.15mm为宜,且下压量小于或等于焊件厚度与搅拌针长度之间的差值。The welding process conditions in step 3) mainly include the amount of pressing force and welding speed. Generally, the amount of pressing force is controlled so that the end surface of the shoulder of the stirring head exceeds the upper surface of the welding wire by 0.05-0.15mm after the welding wire is pressed in, and the amount of pressing force Less than or equal to the difference between weldment thickness and pin length.
实施例1Example 1
为更容易展示实施效果,本实施例针对透明聚碳酸酯焊件开展搅拌摩擦焊,使用的主要原料包括聚碳酸酯(PC,熔融体积速率为24cm3/10min,(300℃/1.2kg))及碳纤维(12K,T700),均为市售。In order to demonstrate the implementation effect more easily, this example conducts friction stir welding for transparent polycarbonate weldments, and the main raw materials used include polycarbonate (PC, melting volume rate is 24cm 3 /10min, (300°C/1.2kg)) And carbon fiber (12K, T700), are commercially available.
整个过程主要包括丝材制备及施焊两步,其中丝材制备过程如下:The whole process mainly includes two steps of wire preparation and welding. The wire preparation process is as follows:
首先,将聚碳酸酯通过挤出机1熔融塑化后进入到浸渍机头7中,同时,将1束碳纤维置于纱架2中,经过展纱辊4的宽展作用后形成单向薄层纤维干带,再经过纤维带黏合辊5时被预浸微量定型胶形成整片的单向薄层纤维带6,纤维含量保持在50%,该纤维带6也进入到浸渍机头7中,纤维带6被均匀的涂上聚碳酸酯高温熔体,形成纤维涂覆带;Firstly, the polycarbonate is melted and plasticized by the extruder 1 and then enters the
其次,纤维涂覆带被随后的轴向卷绕器8沿轴向卷绕,截面逐渐形成阿基米德螺旋线,形成截面为圆形的单向多层纤维/聚合物预浸丝材,丝材在牵引对辊9的作用下进入到履带牵引机10上,并被纵向切割器11分切并保持半连状态;切断比例占整个圆形纤维/聚合物预浸物截面的80%,分切长度为12mm(搅拌摩擦焊头直径为6mm),半连状态的丝材在通过热熔烘箱12时,断口处的聚合物少量熔融,同时,由于调速对辊13的速度与牵引对辊9的速度一致,它们的速度均比履带牵引的速度低3%,因而,半连状态的丝材会受到后面调速对辊13的轻微阻滞作用,熔融的聚合物受压并相互黏结,从而形成了切后再熔合的纤维丝材14,该丝材后续被缠绕或卷取后备用。切后再熔合的纤维丝材的外形如图2所示。熔合指的是本发明中,断口处的纤维丝材的聚合物熔融,熔融的聚合物受压并相互黏结,冷却后断口处的聚合物以粘合的方式连接,其中,在断口处,粘合后受到切割的纤维仍然保持切断状态。Secondly, the fiber-coated tape is wound in the axial direction by the subsequent
制备的丝材继而被用于搅拌摩擦焊,主要包括:The prepared wire is then used for friction stir welding, mainly including:
1)通过热压或其它工艺获得以聚碳酸酯为原料的将欲连接件,将其待焊部位修理平整后并将待焊部位中部去除与丝材截面相当的材料;1) Obtain the joints to be connected with polycarbonate as raw material by hot pressing or other processes, repair and flatten the parts to be welded, and remove the material equivalent to the cross section of the wire in the middle of the parts to be welded;
2)将所制备的丝材嵌入到待焊部位后将待焊部位再次压平;2) After embedding the prepared wire into the part to be welded, flatten the part to be welded again;
3)将两欲连接件的待焊部位对接后施以适量横向作用力,并随后压紧固定在工作台上,在确定的焊接工艺条件下,经过搅拌头的高速旋转后,两件被连接为一体。3) Apply an appropriate amount of lateral force after docking the parts to be welded of the two parts to be connected, and then press and fix them on the workbench. Under the determined welding process conditions, after the high-speed rotation of the stirring head, the two parts are connected as one.
上述过程及焊接制品形状效果如图3所示。The above process and the shape effect of the welded product are shown in Figure 3.
其中,由于丝材在嵌入待焊部位后,丝材距离焊件外上壁有0.2mm,则焊接头的下压量控制为0.30mm,焊件厚度为2mm,选择的搅拌针长度为1.5mm。Among them, since the wire material is 0.2mm away from the outer upper wall of the weldment after it is embedded in the part to be welded, the downward pressure of the welding head is controlled to 0.30mm, the thickness of the weldment is 2mm, and the length of the selected stirring needle is 1.5mm .
对所连接的工件焊缝处用SEM表征,其结果如图4所示,在图4中可以看出,几乎同等长度的纤维呈圆弧状均匀分布,从其结构可以预见纤维的增强作用。分切后的纤维可在高速旋转的搅拌头带动下呈现360度全方位的分布,此时焊缝处的各个角度均能得以纤维增强,避免了焊缝处力学性能因纤维增强所可能带来的各向异性,丝材的应用也可以有效避免普通聚合物搅拌摩擦焊容易产生的焊缝孔隙或间隙存在的机率。SEM was used to characterize the welds of the connected workpieces, and the results are shown in Figure 4. In Figure 4, it can be seen that the fibers of almost the same length are evenly distributed in an arc shape, and the reinforcement of the fibers can be predicted from its structure. The slit fibers can be distributed in 360 degrees under the drive of the high-speed rotating stirring head. At this time, all angles of the weld can be reinforced by fibers, avoiding the mechanical properties of the weld that may be caused by fiber reinforcement. Anisotropy, the application of wire can also effectively avoid the probability of weld pores or gaps that are easily produced by ordinary polymer friction stir welding.
对所连接工件截取出矩形测试样片,进行拉伸力学性能测试,其外形结果如图6所示,其中图6a与6b分别显示的是测试前后的样品外形,从图6b可知,此时拉伸断裂并不发生在焊缝处,而是离焊接稍近的影响区域,这足以表明焊缝处的力学性能较好,已经超过母材的影响区域。测试结果列于表1之中。Cut out a rectangular test sample from the connected workpiece and perform a tensile mechanical performance test. The shape results are shown in Figure 6, where Figures 6a and 6b show the shape of the sample before and after the test, respectively. From Figure 6b, it can be seen that the tensile The fracture does not occur at the weld, but in the affected area a little closer to the weld, which is enough to indicate that the mechanical properties of the weld are better than the affected area of the base metal. The test results are listed in Table 1.
从表1结果可知,该实施例所得焊缝的拉伸强度接近母材,因而,本发明的丝材增强焊件具有特定形态的纤维分布结构,表现出力学性能优异的特点,具有优异的应用前景。From the results in Table 1, it can be seen that the tensile strength of the weld seam obtained in this embodiment is close to that of the base metal. Therefore, the wire reinforced weldment of the present invention has a fiber distribution structure of a specific form, exhibits the characteristics of excellent mechanical properties, and has excellent application prospect.
实施例2Example 2
为了与实施例1对比,与实施例1类似的,本对比实施例也使用市售聚碳酸酯(熔融体积速率为24cm3/10min)作为母材原料,不同的是实施例2没有使用纤维丝材,其焊接工艺主要为:通过热压或其它工艺获得以聚碳酸酯为原料的将欲连接件,然后将两欲连接件的待焊部位对接后施以适量横向作用力,并随后压紧固定在工作台上,在确定的焊接工艺条件下,经过搅拌头的高速旋转后,两件被连接为一体。In order to compare with Example 1, similar to Example 1, this comparative example also uses commercially available polycarbonate (melting volume rate is 24cm 3 /10min) as the base material raw material, and the difference is that Example 2 does not use fiber filaments material, the welding process is mainly as follows: through hot pressing or other processes to obtain the joints to be connected with polycarbonate as raw material, and then apply an appropriate amount of lateral force after the parts to be welded of the two joints to be welded, and then compress Fixed on the workbench, under the determined welding process conditions, after the high-speed rotation of the stirring head, the two pieces are connected as one.
对所连接的工件焊缝处用SEM表征,其结果如图5所示,在图5中可以看出,焊缝的结合处有较多的空隙及间隙,因而该焊缝强度可以预见不会太好。SEM is used to characterize the welding seam of the connected workpiece, and the result is shown in Figure 5. It can be seen from Figure 5 that there are many gaps and gaps at the joint of the weld seam, so the strength of the weld seam can be predicted to be low. great.
对所连接工件截取出矩形测试样片,进行拉伸力学性能测试,其外形结果也如图6所示,其中图6c与6d分别显示的是测试前后的样品外形,从图6d可知,此时拉伸断裂毫无悬念的出现在焊缝处,这足以表明焊缝处的力学性能有待提高。A rectangular test piece was cut out from the connected workpiece, and the tensile mechanical performance test was carried out. The shape results are also shown in Figure 6. Figures 6c and 6d show the shape of the sample before and after the test, respectively. From Figure 6d, it can be seen that the tension The tensile fracture appeared in the weld without suspense, which is enough to indicate that the mechanical properties of the weld need to be improved.
拉伸力学性能测试,其结果也列于表1之中,此时拉伸断裂均发生在焊缝处,表明焊缝处的力学性能仍然较低。从表1结果可知,该对比例所得焊缝的拉伸强度与实施例1差距很大,表明使用纤维丝材与否对焊接质量的影响较大。The results of the tensile mechanical properties test are also listed in Table 1. At this time, the tensile fractures all occurred at the welds, indicating that the mechanical properties of the welds are still low. As can be seen from the results in Table 1, the tensile strength of the weld seam obtained in this comparative example is very different from that of Example 1, indicating that the use of fiber filaments has a greater impact on the welding quality.
实施例3Example 3
为了和实施例1对比,本对比例也针对透明聚碳酸酯焊件开展搅拌摩擦焊,使用的主要原料包括聚碳酸酯(熔融体积速率为24cm3/10min)及碳纤维(12K,T700),均为市售。In order to compare with Example 1, this comparative example also carries out friction stir welding for transparent polycarbonate weldments, and the main raw materials used include polycarbonate (melting volume rate is 24cm 3 /10min) and carbon fiber (12K, T700), both is commercially available.
整个过程主要包括丝材制备及施焊两步,其中丝材制备过程中除不进行切割以外,和现有常规长纤维增强聚合物颗粒料类似:将聚碳酸酯通过挤出机熔融塑化后进入到浸渍机头中,同时,将置于纱架中的碳纤维丝束也引入到浸渍机头中,纤维在浸渍机头中被浸上聚碳酸酯高温熔体,形成截面不太规则的纤维/聚合物预浸丝材,该丝材后续被牵引、缠绕或卷取后备用,形成连续的丝材。The whole process mainly includes two steps of wire material preparation and welding. The wire material preparation process is similar to the existing conventional long fiber reinforced polymer pellets except that no cutting is performed: after the polycarbonate is melted and plasticized through the extruder Entering the dipping head, at the same time, the carbon fiber tow placed in the creel is also introduced into the dipping head, and the fibers are dipped in polycarbonate high-temperature melt in the dipping head to form fibers with irregular cross-sections / Polymer prepreg filaments that are subsequently drawn, wound or coiled for use as continuous filaments.
制备的丝材继而被用于搅拌摩擦焊,步骤如下:The prepared wire was then used for friction stir welding as follows:
1)通过热压或其它工艺获得以聚碳酸酯为原料的将欲连接件,将其待焊部位修理平整后并将待焊部位中部去除与丝材截面相当的材料;1) Obtain the joints to be connected with polycarbonate as raw material by hot pressing or other processes, repair and flatten the parts to be welded, and remove the material equivalent to the cross section of the wire in the middle of the parts to be welded;
2)将所制备的丝材嵌入到待焊部位后,按需切断,再将待焊部位再次压平;2) After embedding the prepared wire into the part to be welded, cut off as needed, and flatten the part to be welded again;
3)将两欲连接件的待焊部位对接后施以适量横向作用力,并随后压紧固定在工作台上,在确定的焊接工艺条件下,经过搅拌头的高速旋转后,两件被连接为一体。3) Apply an appropriate amount of lateral force after docking the parts to be welded of the two parts to be connected, and then press and fix them on the workbench. Under the determined welding process conditions, after the high-speed rotation of the stirring head, the two parts are connected as one.
对所连接的工件焊缝处用SEM表征,其结果如图7所示,在图7中可以看出,焊缝处的纤维分布很乱,纤维长度差距也较大,纤维在各方向的分布也比较混乱。SEM is used to characterize the welding seam of the connected workpiece, and the result is shown in Figure 7. It can be seen from Figure 7 that the fiber distribution at the welding seam is very chaotic, and the fiber length difference is also large. The distribution of fibers in each direction It's also confusing.
对所连接工件截取出矩形测试样片,进行拉伸力学性能测试,其结果也列于表1之中,此时拉伸断裂均发生在焊缝处,表明焊缝处的力学性能仍然较低。从表1结果可知,该对比例所得焊缝的拉伸强度与实施例差距较大,表明纤维丝材的制备方法对焊接质量的影响较大。The rectangular test specimens were cut out from the connected workpieces, and the tensile mechanical properties were tested. The results are also listed in Table 1. At this time, the tensile fractures all occurred at the welds, indicating that the mechanical properties of the welds are still low. It can be seen from the results in Table 1 that the tensile strength of the weld seam obtained in this comparative example is far from that of the examples, indicating that the preparation method of the fiber filament has a great influence on the welding quality.
实施例4Example 4
本实施例针对尼龙焊件开展搅拌摩擦焊,使用的主要原料包括尼龙(PA66,熔融体积速率为23cm3/10min)及玻璃纤维(12K,T700),均为市售。In this example, friction stir welding is carried out for nylon weldments. The main raw materials used include nylon (PA66, melting volume rate: 23cm 3 /10min) and glass fiber (12K, T700), both of which are commercially available.
整个过程主要包括丝材制备及施焊两步,其中丝材制备过程如下:The whole process mainly includes two steps of wire preparation and welding. The wire preparation process is as follows:
首先,将PA66通过挤出机1熔融塑化后进入到浸渍机头7中,同时,将2束碳纤维分别置于两个纱架2中,分别经过两个展纱辊4的宽展作用后形成单向薄层纤维干带,两条单向薄层纤维干带再经过纤维带黏合辊5时被预浸微量定型胶形成整片的单向薄层纤维带6,纤维含量保持在60%,该纤维带6也进入到浸渍机头7中,纤维带6被均匀的涂上PA66高温熔体,形成纤维涂覆带;First, the PA66 is melted and plasticized by the extruder 1 and then enters the
其次,纤维涂覆带被随后的轴向卷绕器8沿轴向卷绕,截面逐渐形成阿基米德螺旋线,形成截面为圆形的单向多层纤维/聚合物预浸丝材,丝材在牵引对辊9的作用下进入到履带牵引机10上,并被纵向切割器11分切并保持半连状态;切断比例占整个圆形纤维/聚合物预浸物截面的90%,分切长度为9cm(搅拌摩擦焊头直径为6mm),半连状态的丝材在通过热熔烘箱12时,断口处的聚合物少量熔融,同时,由于调速对辊13的速度与牵引对辊9的速度一致,它们的速度均比履带牵引的速度低5%,因而,半连状态的丝材会受到后面调速对辊13的轻微阻滞作用,熔融的聚合物受压并相互黏结,从而形成了切后再熔合的纤维丝材14,该丝材后续被缠绕或卷取后备用。切后再熔合的纤维丝材的外形也与图2类似。Secondly, the fiber-coated tape is wound in the axial direction by the subsequent
制备的丝材继而被用于搅拌摩擦焊,步骤如下:The prepared wire was then used for friction stir welding as follows:
1)通过热压或其它工艺获得以聚碳酸酯为原料的将欲连接件,将其待焊部位修理平整后并将待焊部位中部去除与丝材截面相当的材料;1) Obtain the joints to be connected with polycarbonate as raw material by hot pressing or other processes, repair and flatten the parts to be welded, and remove the material equivalent to the cross section of the wire in the middle of the parts to be welded;
2)将所制备的丝材嵌入到待焊部位后将待焊部位再次压平;2) After embedding the prepared wire into the part to be welded, flatten the part to be welded again;
3)将两欲连接件的待焊部位对接后施以适量横向作用力,并随后压紧固定在工作台上,在确定的焊接工艺条件下,经过搅拌头的高速旋转后,两件被连接为一体。3) Apply an appropriate amount of lateral force after docking the parts to be welded of the two parts to be connected, and then press and fix them on the workbench. Under the determined welding process conditions, after the high-speed rotation of the stirring head, the two parts are connected as one.
其中,由于丝材在嵌入待焊部位后,丝材距离焊件外上壁有0.2mm,则焊接头的下压量控制为0.35mm,焊件厚度为2mm,选择的搅拌针长度为1.5mm。Among them, since the wire material is 0.2mm away from the outer upper wall of the weldment after it is embedded in the part to be welded, the downward pressure of the welding head is controlled to 0.35mm, the thickness of the weldment is 2mm, and the length of the selected stirring needle is 1.5mm .
对所连接工件截取出矩形测试样片,进行拉伸力学性能测试,其测试结果列于表1。从表1结果可知,该实施例所得焊缝的拉伸强度接近母材,因而,本发明的丝材增强焊件具有特定形态的纤维分布结构,表现出力学性能优异的特点,具有优异的应用前景。The rectangular test specimens were cut out from the connected workpieces, and the tensile mechanical properties were tested. The test results are listed in Table 1. From the results in Table 1, it can be seen that the tensile strength of the weld seam obtained in this embodiment is close to that of the base metal. Therefore, the wire reinforced weldment of the present invention has a fiber distribution structure of a specific form, exhibits the characteristics of excellent mechanical properties, and has excellent application prospect.
实施例5Example 5
为了和实施例4对比,本对比例也针对尼龙焊件开展无切割处理的纤维丝材搅拌摩擦焊,使用的主要原料包括尼龙(熔融体积速率为23cm3/10min)及碳纤维(12K,T700),均为市售。In order to compare with Example 4, this comparative example also carries out non-cut fiber filament friction stir welding for nylon weldments, and the main raw materials used include nylon (melting volume rate is 23cm 3 /10min) and carbon fiber (12K, T700) , are commercially available.
整个过程主要包括丝材制备及施焊两步,其中丝材制备过程中除不进行切割以外,和现有常规长纤维增强聚合物颗粒料类似:将尼龙通过挤出机熔融塑化后进入到浸渍机头中,同时,将置于纱架中的碳纤维丝束也引入到浸渍机头中,纤维在浸渍机头中被浸上尼龙高温熔体,形成截面不太规则的纤维/聚合物预浸丝材,该丝材后续被牵引、缠绕或卷取后备用,形成连续的丝材。The whole process mainly includes two steps of wire material preparation and welding. The wire material preparation process is similar to the existing conventional long fiber reinforced polymer pellets except that no cutting is performed: the nylon is melted and plasticized by the extruder and then enters the In the impregnation head, at the same time, the carbon fiber tow placed in the creel is also introduced into the impregnation head, and the fiber is impregnated with nylon high-temperature melt in the impregnation head to form a fiber/polymer preform with irregular cross-section. Impregnated wire, which is subsequently pulled, wound or coiled for use as continuous wire.
制备的丝材继而被用于搅拌摩擦焊,步骤如下:The prepared wire was then used for friction stir welding as follows:
1)通过热压或其它工艺获得以尼龙为原料的将欲连接件,将其待焊部位修理平整后并将待焊部位中部去除与丝材截面相当的材料;1) Obtain the connector to be connected with nylon as raw material by hot pressing or other processes, repair and flatten the part to be welded, and remove the material equivalent to the cross section of the wire in the middle of the part to be welded;
2)将所制备的丝材嵌入到待焊部位后,按需切断,再将待焊部位再次压平;2) After embedding the prepared wire into the part to be welded, cut off as needed, and flatten the part to be welded again;
3)将两欲连接件的待焊部位对接后施以适量横向作用力,并随后压紧固定在工作台上,在确定的焊接工艺条件下,经过搅拌头的高速旋转后,两件被连接为一体。3) Apply an appropriate amount of lateral force after docking the parts to be welded of the two parts to be connected, and then press and fix them on the workbench. Under the determined welding process conditions, after the high-speed rotation of the stirring head, the two parts are connected as one.
对所连接的工件焊缝处用SEM表征,其结果也与实施例3类似,焊缝处的纤维分布很乱,纤维长度差距也较大,纤维在各方向的分布也比较混乱。The welded joints of the connected workpieces were characterized by SEM, and the results were similar to those in Example 3. The distribution of fibers at the welded joints was chaotic, the difference in fiber length was also large, and the distribution of fibers in various directions was also chaotic.
对所连接工件截取出矩形测试样片,进行拉伸力学性能测试,其结果也列于表1之中,此时拉伸断裂均发生在焊缝处,表明焊缝处的力学性能仍然较低。从表1结果可知,该对比例所得焊缝的拉伸强度与实施例差距较大,表明纤维丝材的制备方法对焊接质量的影响较大。The rectangular test specimens were cut out from the connected workpieces, and the tensile mechanical properties were tested. The results are also listed in Table 1. At this time, the tensile fractures all occurred at the welds, indicating that the mechanical properties of the welds are still low. It can be seen from the results in Table 1 that the tensile strength of the weld seam obtained in this comparative example is far from that of the examples, indicating that the preparation method of the fiber filament has a great influence on the welding quality.
实施例6Example 6
与实施例1不同的是,本实施例中,纤维涂覆带纤维含量40%;切断比例占整个圆形截面的70%,分切长度为15mm,焊接头的下压量控制为0.25mm。The difference from Example 1 is that in this example, the fiber content of the fiber-coated tape is 40%; the cutting ratio accounts for 70% of the entire circular section, the cutting length is 15mm, and the pressing amount of the welding head is controlled to 0.25mm.
实施例7Example 7
与实施例1不同的是,本实施例中,纤维涂覆带纤维含量60%;切断比例占整个圆形截面的90%,分切长度为15mm,焊接头的下压量控制为0.32mm。The difference from Example 1 is that in this example, the fiber content of the fiber-coated tape is 60%; the cutting ratio accounts for 90% of the entire circular section, the cutting length is 15mm, and the pressing amount of the welding head is controlled to 0.32mm.
表1几种焊件的拉伸性能比较Table 1 Comparison of tensile properties of several weldments
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US6543671B2 (en) * | 2001-09-05 | 2003-04-08 | Lockheed Martin Corporation | Apparatus and method for friction stir welding using filler material |
JP2007245200A (en) * | 2006-03-16 | 2007-09-27 | Nissan Motor Co Ltd | Friction stir welding method, and welded member |
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US7507310B2 (en) * | 2006-12-29 | 2009-03-24 | General Electric Company | Friction stir welding of fiber reinforced thermoplastics |
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