Realization of Al/High Strength Steel: Joints by Ultrasound Supported Friction Stir Welding - Process and Robustness, Mechanical Properties using Destructive and Non-Destructive Testing Methods, Microstructure, Corrosion, and Joining Area Integrated Corro

铝/高强度钢的实现：超声波支持的搅拌摩擦焊接头 - 工艺和稳健性、使用破坏性和非破坏性测试方法的机械性能、微观结构、腐蚀和连接区域综合腐蚀

• 批准号: 228911405
• 负责人: Professor Dr.-Ing. Wolfram Fuerbeth
• 金额: --
• 依托单位: Fraunhofer-Institut für Zerstörungsfreie Prüfverfahren (IZFP)
• 依托单位国家: 德国
• 项目类别: Priority Programmes
• 财政年份: 2012
• 资助国家: 德国
• 起止时间: 2011-12-31 至 2019-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/228911405?language=en
• 关键词: Realization; Al; Strength; Steel; Joints

The successful development and the construction of a completely new hybrid welding process, the Ultrasound Assisted Friction Stir Welding (UA-FSW), was in focus of the project, until now. It was found that the FSW process on the one hand is very suitable to produce material composites between dissimilar materials, even with very different melting points, and on the other hand that the parallel to the FSW process transmitted power ultrasound improves the monotonic and cyclic properties of the produced FSW-joints as expected. In recent years important developments in the FSW process technology as well as in the field of materials used in industrial application occur. New FSW tools with fixed shoulder and rotating pin make it possible to weld materials with very different melting points without an impermissibly wear of the FSW-tool. Furthermore, high-strength steels are increasingly being used in vehicle technology as elements of lightweight structures. However, attempts to produce Al / highstrength steel-joints by conventional FSW with sufficient strength were not successful. In this case, UA-FSW again is a pioneering joining process because the additional ultrasound can enable a more intensive joint between the materials without an increase of the temperature in the joining area or a higher wear of the FSW-tool. Therefore, Al / high-strength steel-joints should be produced in the third period by UA-FSW. Beside destructive testing methods, preprocess, in-line, and post-process non-destructive testing methods are provided. In addition, the microstructure of the produced joints will be analyzed and the corrosion behavior of the dissimilar joints will be investigated with a special focus on integrated corrosion protection concepts. The use of thermographic methods to optimize the joining process has proven itself and will be continued. The Al-lightweight materials EN-AW 6061 and EN-AC 48000 considered in the own project and other projects of the SPP1640 during the first two funding periods will be reused. As high strength steel joining partners boronalloyed tempered steel 22MnB5 in the martensitic condition, DP600 and MS-W 1200 should be considered, which are gaining more and more significance in industrial applications. Furthermore, the results will be compared with the joints between Al-alloys and the low strength steels C45 and DC04 of the second founding period.

到目前为止，一种全新的混合焊接工艺--超声波辅助搅拌摩擦焊(UA-FSW)的成功开发和施工一直是该项目的重点。研究发现，一方面，搅拌摩擦焊工艺非常适合于制备不同材料之间的复合材料，即使熔点相差很大；另一方面，与功率超声平行的搅拌摩擦焊工艺也如预期的那样改善了所制备的搅拌摩擦焊接头的单调和循环性能。近年来，搅拌摩擦焊工艺技术以及工业应用材料领域出现了重要的发展。具有固定肩部和旋转销的新型搅拌摩擦焊工具可以焊接熔点非常不同的材料，而不会对搅拌摩擦焊刀具造成不允许的磨损。此外，高强度钢正越来越多地作为轻量化结构的部件用于车辆技术。然而，用常规的搅拌摩擦焊方法生产具有足够强度的铝/高强度钢接头的尝试没有成功。在这种情况下，UA-FSW再次是一种开创性的连接工艺，因为额外的超声波可以实现材料之间更密集的连接，而不会增加连接区域的温度或FSW-Tool的磨损。因此，铝/高强度钢接头的生产应在UA-FSW的第三阶段进行。除无损检测方法外，还提供了前处理、在线和后处理无损检测方法。此外，还将分析生产的接头的微观结构，并研究不同接头的腐蚀行为，特别关注综合防腐概念。使用热像法来优化连接过程已经证明了自己，并将继续下去。在战略规划编制方案1640的前两个供资期间，自己的项目和其他项目中考虑的铝轻质材料EN-AW6061和EN-AC 48000将得到重复使用。DP600和MS-W1200作为高强度钢连接22MnB5调质钢，在工业应用中具有越来越重要的意义。并将计算结果与第二代低强度钢C45、DC04与铝合金的接头进行了比较。