Page 21 - 《应用声学》2023年第4期

第 42 卷 第 4 期 Vol. 42, No. 4
2023 年 7 月 Journal of Applied Acoustics July, 2023

⋄ 研究报告 ⋄

超声辅助搅拌摩擦焊仿真分析及实验 ∗

张 轩 1,2 刘小振 1,2 吴思楠 1 傅 波 1,2†

(1 四川大学机械工程学院 成都 610065)
(2 四川大学宜宾产业技术研究院 宜宾 644000)

摘要：为解决传统的搅拌摩擦焊工艺存在的轴向压力过大、搅拌头易磨损、焊接表面存在缺陷等问题，设计了
一种集搅拌头与夹心式纵扭超声振动换能器为一体的超声辅助搅拌摩擦焊工具头。对超声辅助搅拌摩擦焊工
具头进行了模态分析与谐响应分析，确保换能器结构满足要求。应用仿真软件对超声辅助搅拌摩擦焊进行了
流体场、温度场和声场仿真分析，验证了在搅拌摩擦焊过程中加入纵扭超声振动能够增强材料的软化率，提高
焊接材料的塑性流动。搭建实验平台，进行了 6061 铝合金的超声辅助搅拌摩擦焊焊接实验。结果表明，纵扭超
声的引入能够提高焊接过程中材料流动性，减小搅拌头的前进阻力和轴向压力，改善焊接表面质量。在焊头
转速 900 r/min、焊接速度 1.4 mm/s、轴向压力 2.6 kN、超声功率 100 W 时，焊接效果最好，能较好地应在铝合
金、镁合金等焊接熔点比较低的轻金属焊接之中。
关键词：超声辅助搅拌摩擦焊；纵扭超声振动换能器；仿真分析；焊接参数
中图法分类号: TG456 文献标识码: A 文章编号: 1000-310X(2023)04-0683-10
DOI: 10.11684/j.issn.1000-310X.2023.04.003

Simulation analysis and experimental study of ultrasonic assisted friction stir welding

ZHANG Xuan 1,2 LIU Xiaozhen 1,2 WU Sinan 1 FU Bo 1,2

(1 School of Mechanical Engineering, Sichuan University, Chengdu 610065, China)
(2 Yibin Institute of Industrial Technology, Sichuan University, Yibin 644000, China)
Abstract: In order to solve the problems of the traditional friction stir welding (FSW) process, such as
excessive axial pressure, easy wear of the mixing head, and the welding quality of the surface to be improved,
an ultrasonic assisted friction stir welding (UAFSW) tool head integrating the mixing head and ultrasonic
transducer is designed. The modal analysis and harmonic response analysis of the longitudinal torsion ultrasonic
transducer are carried out to ensure that the transducer structure can meet the experimental requirements.
The fluid field, temperature field and sound field of UAFSW are simulated. It is verified that ultrasonic can
enhance the softening rate of materials and improve the plastic flow of welding materials in FSW process. The
experimental platform was built and the UAFSW welding experiment of 6061 aluminum alloy was completed.
Results show that ultrasonic vibration can improve the fluidity of materials in the welding process, reduce
the forward resistance and axial pressure of the mixing head, and improve the welding surface quality. The
welding effect is the best when the head rotation speed is 900 r/min, welding speed is 1.4 mm/s, axial pressure
is 2.6 kN, and ultrasonic power is 100 W. The technology can be better used in the welding of light metals
with low melting point, such as aluminum alloy and magnesium alloy.
Keywords: Ultrasonic assisted friction stir welding; Longitudinal torsion ultrasonic transducer; Simulation
analysis; Welding parameters

2022-04-10 收稿; 2022-06-29 定稿
四川省科技计划资助项目 (2020YFG0117), 川大 -自贡校地科技合作专项资金项目 (2020CDZG-1), 川大 -宜宾战略合作专项资金项目
∗
(2019CDYB-1)
作者简介: 张轩 (1998– ), 男, 重庆人, 硕士研究生, 研究方向: 机械制造及其自动化。
通信作者 E-mail: bofu@scu.edu.cn
†