正交试验法优化铜铝超声波焊接工艺研究

熊志林; 张义福; 陈朵云; 张云

doi:10.13433/j.cnki.1003-8728.20200523

正交试验法优化铜铝超声波焊接工艺研究

doi: 10.13433/j.cnki.1003-8728.20200523

1.
湖南工业职业技术学院机械工程学院，长沙　410208
2.
九江学院材料科学与工程学院，江西九江　332005

基金项目: 湖南省自然科学基金项目（2021JJ60035）

详细信息

作者简介:
熊志林（1986−），副教授，硕士研究生，研究方向为异质金属焊接工艺，xzhilin123@163.com

通讯作者:
张义福，讲师，博士研究生， zhangyifulj@163.com

中图分类号: TG453⁺.9
计量
- 文章访问数: 102
- HTML全文浏览量: 30
- PDF下载量: 16
- 被引次数: 0
出版历程
- 收稿日期: 2020-11-24
- 录用日期: 2021-12-17
- 刊出日期: 2022-04-05

Study on Optimal process in Ultrasonic Welding of Copper and Aluminum via Orthogonal Test Method

1.
School of Mechanics Engineering, Hunan Industry Polytechnic, Changsha 410208, China
2.
School of Material Science and Engineering, Jiujiang University, Jiujiang 332005, Jiangxi, China

摘要

摘要: 为提高铜（Cu）和铝(Al)异种材料超声波焊接接头性能，采用正交试验法对0.3 mm厚的Cu/Al箔片进行超声波焊接试验设计，采用扫描电镜（SEM）、能谱仪（EDS）和X射线衍射仪（XRD）等方法对最优参数下获得接头的界面组织成分和断口形貌进行研究，并进行拉伸力测试，探讨了界面连接机理及断口机制。结果表明：最优焊接参数组合为焊接时间（T）900 ms、焊接功率（P）600 W、焊接压力（F）0.5 MPa、振幅（L）45 μm，在该参数下的接头拉伸力达到527.49 N，铜铝界面结合紧密并发生互扩散，生成了约4.5 μm厚的金属间化合物层（IMCs），接头界面连接强度主要是由界面原子扩散和机械互锁决定，接头断裂形式为韧-脆混合断裂模式。
- 铜/铝箔片 /
- 正交试验法 /
- 超声波焊接 /
- 连接强度 /
- 断口机制
Abstract: To improve the properties of the ultrasonic welded joints of copper (Cu) and aluminum(Al), the orthogonal test method was used to design the ultrasonic welding experiment of 0.3 mm thick Cu/Al foil. The interface microstructure, composition, and fracture morphology of the welded joints were obtained under the optimal parameters were studied with the scanning electron microscope (SEM), energy dispersive spectrometer (EDS) and X-ray diffractometer (XRD), and the tensile force test of welded joints were carried out, and the interface junction mechanism and fracture mechanism were discussed. The results show that the optimal process parameters were obtained as welding time (T) was 900 ms, welding power (P) was 600 W, welding pressure (F) was 0.5 MPa, and amplitude (T) was 45 μm. Under the process parameters, the tensile force of welded joint reaches 527.49 N, the Cu/Al joint interface is tightly bonded and interdiffusion has occurred, resulting in about 4.5 μm thick intermetallic compound layer (IMCs). The strength of the joint interface junction is mainly determined by the diffusion of interface atoms and mechanical interlocking. The fracture mode of the welded joints is a ductile-brittle mixed fracture.
- Cu/Al foil /
- orthogonal test method /
- ultrasonic welding /
- junction strength /
- fracture mechanism

HTML全文

图 1 超声波焊接设备与焊极形状图

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图 2 拉伸测试试验装配图

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图 3 试验因素水平与拉伸力的分析趋势图

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图 4 最优参数下接头微观组织及EDS线扫描图

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图 5 最优参数下接头剪切断口形貌

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图 6 最优参数下接头断口X射线衍射分析

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表 1 纯铝和T2紫铜的热物理性能参数

母材	热导率/ (W·(m·K)⁻¹)	热膨胀系数/ 10⁻⁶K⁻¹	比热容/ (J·(kg·K)⁻¹)	弹性模量/ GPa
纯铝	376.69	25.6	964.7	70
T2紫铜	690.39	16.9	611	119

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表 2 正交试验因素和水平参数表

水平	因素
水平	焊接时间 T/ms	焊接功率 P/W	焊接压力 F/MPa	振幅 L/μm
1	500	500	0.3	35
2	600	600	0.4	40
3	700	700	0.5	45
4	800	−	−	−
5	900	−	−	−
6	1000	−	−	−

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表 3 L₁₈(6×4⁶)试验设计与结果

试验号	水平组合	因素				拉伸力平均值/N	接头强度平均值/MPa
试验号	水平组合	焊接时间/ms	焊接功率/W	焊接压力/MPa	振幅 /μm	拉伸力平均值/N	接头强度平均值/MPa
1	1111	500	500	0.3	35	247.90	4.13
2	1222	500	600	0.4	45	360.78	6.01
3	1333	500	700	0.5	55	342.40	5.71
4	2112	600	500	0.3	45	303.82	5.47
5	2223	600	600	0.4	55	328.44	5.47
6	2331	600	700	0.5	35	305.06	5.08
7	3121	700	500	0.4	35	400.21	6.67
8	3232	700	600	0.5	45	449.77	7.50
9	3313	700	700	0.3	55	478.55	7.98
10	4133	800	500	0.5	55	401.20	6.69
11	4211	800	600	0.3	35	403.24	6.72
12	4322	800	700	0.4	45	366.77	6.11
13	5123	900	500	0.4	55	421.15	7.02
14	5231	900	600	0.5	35	513.61	8.56
15	5312	900	700	0.3	45	500.87	8.35
16	6132	1000	500	0.5	45	436.64	7.28
17	6213	1000	600	0.3	55	403.32	6.72
18	6321	1000	700	0.4	35	433.53	7.23

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表 4 L₁₈(6×4⁶)试验设计与结果

水平	因素
水平	焊接时间/ms	焊接功率/W	焊接压力/MPa	振幅/μm
1	317.0	368.5	389.6	383.9
2	312.4	409.9	385.1	403.1
3	442.8	404.5	408.1	395.8
4	390.4	−	−	−
5	478.5	−	−	−
6	424.5	−	−	−
R_i极差	166.1	41.4	23.0	19.2
影响程度	1	2	3	4

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表 5 正交试验方差分析结果

项目	自由度 DF	各因素的离差平方和 Adj SS	各因素对应的均方值 Adj MS	各因素的统计量值F	各因素的显著性概率P
焊接时间/ms	5	69157	13831	9.86	0.007
焊接功率/W	2	6078	3039	2.17	0.196
焊接压力/MPa	2	1779	890	0.63	0.563
振幅/μm	2	1126	563	0.40	0.686
误差	6	8418	1403	－	－
总计	17	86558	－	－	－

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表 6 接头区的EDS 结果

位置	ω（Cu）	ω（Al）	可能相
1	92.34%	7.66%	Cu
2	70.11%	29.89%	Cu₉Al₄
3	33.74%	66.26%	CuAl₂
4	20.15%	79.85%	Al+CuAl₂
5	6.35%	93.65%	Al

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表 7 图5所示EDS结果

位置	ω（Cu）	ω（Al）
1	7.73%	92.27%
2	19.32%	80.68%
3	68.51%	31.49%
4	91.67%	8.33%
5	35.43%	64.57%

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