复合轴向振动的旋转消耗极摩擦焊若干关键技术研究

Existing friction welding technology can not adopt welding process under complex spatial track, and it need very large upended force which make the device different to convert process. Those factors limit the technology promotion. Now an axial vibration combined spin consumable node friction welding was propose creatively. Based on consumable node friction welding, the node spin and vibrate to give energy which make the energy put into interface with high frequency and little displacement and low upended force, the bilateral stirring impact can thermodynamic make the interfacial metal flow, diffuse, recrystallize to merge the node and base metal. Fluid mechanics model was simulated with finite element method to built quasi-stable parameter which to guide process experiment. The experiment with typical material and structure were studied to find how the vibration and spin parameter influence node insert to stir the base metal at the beginning and integrate together lastly. Quasi-stable forming stage plastic strain zone have its own rule. The research findings will offer a new friction welding process with low upended force under vibration available to all forms of special track, which have important theoretically and engineering significance.

现有摩擦焊技术由于热源输入单一、空间成形轨迹适应性差、难以连续填充材料和大顶锻力等因素，极大地限制其推广应用。 申请者创新提出一种复合轴向振动的旋转消耗极摩擦焊新技术。该技术借用消耗极旋转及轴向振动摩擦生热，使摩擦界面能量以高频小位移方式输入，以小顶锻力实现界面附近材料双向搅拌作用，提供成形界面间塑变、流动、扩散与再结晶过程所需的热、力条件，最终形成消耗极与母材连续的冶金结合。课题在研究复合运动作用下摩擦焊过程消耗极和融合区全局耦合动力学模型的基础上，掌握其准稳态过程与消耗极扭振等动力学行为特征；并以典型材料和结构为对象进行仿真与实验研究，定量分析轴向振动参数等对连续填充过程影响，获得消耗极长压杆扭振规律和小顶锻力建立准则，并搭建该技术工艺系统原型。成果提供的振动摩擦复合、小顶锻力、适于各类空间轨迹成形与便捷实施的新材料连接技术和理论，将为摩擦焊技术应用提供新途径，具有重要理论与工程意义。

现有摩擦焊技术由于热源输入单一、空间成形轨迹适应性差、难以连续填充材料和大顶锻力等因素，极大地限制其推广应用。.课题创新提出了一种复合轴向振动的旋转消耗极摩擦焊新技术。该技术借用消耗极旋转及轴向振动摩擦生热，使摩擦界面能量以高频小位移方式输入，以小顶锻力实现界面附近材料双向搅拌作用，提供了成形界面间塑变、流动、扩散与再结晶过程所需的热、力条件，最终形成消耗极与母材连续的冶金结合。课题在研究复合运动作用下摩擦焊过程消耗极和融合区全局耦合动力学模型的基础上，掌握了其准稳态过程与消耗极扭振等动力学行为特征；并以典型材料和结构为对象进行仿真与实验研究，定量分析了轴向振动参数等对连续填充过程影响，获得了消耗极长压杆扭振规律和小顶锻力建立准则，并搭建了该技术工艺系统原型。成果提供的振动摩擦复合、小顶锻力、适于各类空间轨迹成形与便捷实施的新材料连接技术和理论，为摩擦焊技术应用提供新途径，具有重要理论与工程意义。