镁合金与铝合金超声辅助连接技术的研究进展及发展趋势

杜文玉; 王延; 周弋凇; 谢旭峰; 钟韬; 胡红军

doi:10.3969/j.issn.1674-6457.2025.09.004

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精密成形工程 ›› 2025, Vol. 17 ›› Issue (9) : 45-59. DOI: 10.3969/j.issn.1674-6457.2025.09.004

轻合金成形

镁合金与铝合金超声辅助连接技术的研究进展及发展趋势

杜文玉¹, 王延¹, 周弋凇¹, 谢旭峰¹, 钟韬^2,*, 胡红军^1,*

作者信息 +

Research Progress and Development Trends of Ultrasonic-assisted Joining Technology for Magnesium and Aluminum Alloys

DU Wenyu¹, WANG Yan¹, ZHOU Yisong¹, XIE Xufeng¹, ZHONG Tao^2,*, HU Hongjun^1,*

Author information +

文章历史 +

摘要

聚焦于7类代表性技术：超声波点焊（USW）、超声辅助瞬态液相连接（U-TLP）、超声辅助摩擦搅拌焊接（UAFSW）、超声振动辅助电弧焊（UAW）、超声辅助钎焊、超声辅助铆接及超声黏接,系统综述了超声辅助连接技术在镁/铝（Mg/Al）异质材料连接领域的研究进展与发展趋势。深入分析结果表明,超声振动通过多重核心机制显著提升了接头质量,包括改善材料塑性流动、抑制脆性金属间化合物（IMCs）的形成、增强界面机械互锁效应、细化晶粒组织以及破碎表面氧化膜。研究明确指出,关键工艺参数对界面特性具有决定性影响：焊接能量（如USW中约1 000 J达到强度峰值）、中间层设计（如采用Zn/Ag箔可有效抑制Al₁₂Mg₁₇等有害IMCs）以及超声参数（振幅、频率、时间）共同调控着界面IMCs层的厚度与均匀性。得益于超声振动对塑性变形和元素扩散的促进作用,接头力学性能得到显著优化,例如U-TLP接头剪切强度可达95.3 MPa,并有效延长了疲劳寿命。然而,当前该技术仍面临若干挑战：焊接参数适配性与优化不足、界面稳定性受限、在动态服役环境（如腐蚀、高温）下的性能研究薄弱以及工业化应用存在瓶颈。未来研究需着力于：深化超声场-热力场等多物理场的耦合作用机制研究,开发智能化的工艺参数调控系统,并积极拓展其在航空航天、汽车轻量化等领域的工程应用。

Abstract

The work systematically reviews research advances and development trends in ultrasonic-assisted joining of magnesium/aluminum (Mg/Al) dissimilar materials through analysis of seven key techniques: Ultrasonic Spot Welding (USW), Ultrasonic-assisted Transient Liquid Phase bonding (U-TLP), Ultrasonic-assisted Friction Stir Welding (UAFSW), Ultrasonic Vibration-assisted Arc Welding (UAW), Ultrasonic-assisted Brazing, Ultrasonic-assisted Riveting, and Ultrasonic Adhesive Bonding: demonstrates that ultrasonic vibration enhances joint quality through multiple mechanisms: including improved material plasticity, suppressed formation of brittle intermetallic compounds (IMCs), enhanced interfacial mechanical interlocking, refined grain structure, and disrupted surface oxides. Critical parameters decisively govern interfacial IMC characteristics: welding energy (e.g., about 1 000 J for peak strength in USW), interlayer design (e.g., Zn/Ag foils inhibiting Al₁₂Mg₁₇), and ultrasonic parameters (amplitude, frequency, duration). Ultrasonic promotion of plastic deformation and elemental diffusion markedly optimizes mechanical properties; U-TLP joints achieve shear strengths up to 95.3 MPa with extended fatigue life. Persistent challenges include inadequate parameter optimization, limited interfacial stability, insufficient dynamic performance data (e.g., corrosion, high temperature), and industrial-scale bottlenecks. Future priorities should involve elucidating ultrasonic-thermal-stress coupling mechanisms, developing intelligent process control systems, and expanding aerospace/automotive lightweight applications.

导出引用

杜文玉, 王延, 周弋凇, 谢旭峰, 钟韬, 胡红军. 镁合金与铝合金超声辅助连接技术的研究进展及发展趋势[J]. 精密成形工程. 2025, 17(9): 45-59 https://doi.org/10.3969/j.issn.1674-6457.2025.09.004

DU Wenyu, WANG Yan, ZHOU Yisong, XIE Xufeng, ZHONG Tao, HU Hongjun. Research Progress and Development Trends of Ultrasonic-assisted Joining Technology for Magnesium and Aluminum Alloys[J]. Journal of Netshape Forming Engineering. 2025, 17(9): 45-59 https://doi.org/10.3969/j.issn.1674-6457.2025.09.004

中图分类号： TG456.9

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