2219薄板铝合金浮动式双轴肩搅拌摩擦焊接及组织性能分析

以运载火箭助推器贮箱广泛应用的4 mm厚2219薄板铝合金为焊接对象,研制了浮动式双轴肩搅拌头,分析了内部塑性金属流动模式及特点,并推测出需匹配较低焊接热输入才能获得优质焊缝。工艺探索及优化试验结果直接验证了焊缝内部塑性金属流动模式及推测。接头宏观组织形貌分析结果显示:不同焊接速度下的焊缝横截面宏观形貌都可以观察洋葱环特征,且随着焊接速度提高,洋葱环特征越发增多,并从靠近前进侧的焊核区逐渐向后退侧孕育发展,这也有效验证了薄板铝合金双轴肩搅拌头的设计思路。薄板铝合金双轴肩搅拌摩擦焊接头横截面显微硬度分布均呈"U"型,接头显微硬度最低点位于焊核区与后退侧热机影响区的交界处。接头力学性能测试结果显示:随着焊接速度逐渐升高,接头抗拉强度逐渐升高,且当焊接速度达到350 mm/min时,接头抗拉强度达到最高值。铝合金浮动式双轴肩搅拌摩擦焊接头延伸率整体较高,焊接速度对其影响不大。铝合金双轴肩搅拌摩擦焊接头正、背弯均可以达到180°无裂纹。基于立式纵缝搅拌摩擦焊系统成功实现了2 m长试片的浮动式双轴肩搅拌摩擦焊,累计焊接长度达到60 m,且双轴肩搅拌头完整,未发现裂纹、扭曲或其他损伤。     

Oscillatory thermocapillary flows in simulated floating-zones with time-dependent temperature boundary conditions

This study deals with numerical simulations of the Maxus sounding rocket experiment on oscillatory Marangoni convection in liquid bridges. The problem is investigated through direct numerical solution of the non-linear, time-dependent, three-dimensional Navier-Stokes equations. In particular, a liquid bridge of silicon oil 2[cs] with a length L = 20 [mm] and a diameter D = 20 (mm) is considered. A temperature difference ΔT = 30 [K] is imposed between the supporting disks, by heating the top disk and cooling the bottom one with different rates of ramping. The results show that the oscillatory flow starts as an ‘axially running wave’, but after a transient time the instability is described by the dynamic model of a ‘standing wave’, with an azimuthal spatial distribution corresponding to m = 1 (where m is the critical wave number). After the transition, the disturbances become larger and the azimuthal velocity plays a more important role and the oscillatory field is characterized by a travelling wave. The characteristic times for the onset of the different flow regimes are computed for different rates of ramping.