目的 研究不同焊接参数对5083/6061异种铝合金FSW接头组织和性能的影响。方法 选用焊接速度为100、200 mm/min,搅拌头转速为600、900、1 200 r/min的焊接参数对5083/6061异种铝合金板进行搅拌摩擦焊接,分析不同焊接工艺参数下焊接接头的显微组织及力学性能。采用ABAQUS软件,基于耦合欧拉-拉格朗日（CEL）方法,通过有限元模拟分析了焊接过程的温度和应变分布。结果 随着旋转速度的增加,接头处峰值温度和最大应变值均逐渐增加,锥形分布的高温、高应变区均处于前进侧（5083）。随着焊接速度从100 mm/min增加到200 mm/min,焊缝处金属流动性降低,焊核区（NZ）尺寸减小,接头性能显著提升。焊核区受热-力耦合和焊接热循环作用发生塑性变形和动态再结晶,形成致密的细小等轴晶粒。热机影响区（TMAZ）受机械搅拌和热循环作用,晶粒被拉长并细化,形成破碎组织到条状组织的晶粒变化梯度。热影响区（HAZ）仅受焊接热循环作用,区域等效塑性应变（PEEQ）较低,区域晶粒粗化。不同焊接参数下接头显微硬度均呈“W”形分布,接头处最低硬度及断裂位置均在后退侧（RS）6061的热影响区。结论 当焊接速度为200 mm/min、搅拌头转速为900 r/min时,接头性能最优,抗拉强度为211.6 MPa（相当于6061母材的75.6%）,延伸率为10.3%。
Abstract
The work aims to study the effect of different welding parameters on the microstructure and properties of 5083/6061 dissimilar aluminum alloy FSW joints. Friction stir welding was carried out on 5083/6061 dissimilar aluminum alloy plates under welding parameters of 100 and 200 mm/min and stirring head rotation speeds of 600, 900 and 1 200 r/min. The microstructure and mechanical properties of the welded joints under different welding process parameters were analyzed. With the ABAQUS software and based on the coupled Euler-Lagrange (CEL) method, the temperature and strain distribution of the welding process were analyzed by finite element simulation. With the increase of the rotation speed, both the peak temperature and the maximum strain value at the joint gradually increased. The high-temperature and high-strain zones with conical distribution were all on the advancing side (5083). As the welding speed increased from 100 mm/min to 200 mm/min, the fluidity of the metal at the weld seam decreased, the size of the nugget zone (NZ) reduced, and the joint performance was significantly improved. The nugget zone underwent plastic deformation and dynamic recrystallization under the action of heat-force coupling and welding thermal cycling, forming dense fine equiaxed grains. The thermo-mechanically affected zone (TMAZ) was subject to mechanical stirring and thermal cycling, during which grains were elongated and refined, forming a gradient of grain change from fragmented structure to strip-like structure. The heat affected zone (HAZ) was only affected by the welding thermal cycle, with a relatively low equivalent plastic strain (PEEQ) and grain coarsening in the region. Under different welding parameters, the microhardness of the joint showed a "W"-shaped distribution. The minimum hardness at the joint and the fracture position both occurred in the heat-affected zone of the recloser side (RS) 6061. When the welding speed is 200 mm/min and the stirring head rotation speed is 900 r/min, the joint performance is optimal, with a tensile strength of 211.6 MPa (equivalent to 75.6% of the 6061 base material) and an elongation of 10.3%.
关键词
搅拌摩擦焊 /
有限元模拟 /
异种铝合金 /
显微组织 /
力学性能
Key words
friction stir welding /
finite element modelling /
dissimilar aluminum alloys /
microstructure /
mechanical property
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基金
南宁科技开发项目（20231026）; 广西科技发展专项资金支持（AD25069078）; 国家自然科学基金（51661004）
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