IWJC-Korea2017 laser Roll Welding of dissimilar...
Transcript of IWJC-Korea2017 laser Roll Welding of dissimilar...
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IWJC-Korea 2017 April 12th , 2017, Gyeongju
Laser Roll Welding of Dissimilar Metal Joints
Muneharu KUTSUNA(Advanced Laser Tehnology Research Center)
Hitoshi OZAKI( Mie University)
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1. IntroductionNeeds for multi material structures
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Fe - Al equilibrium phase diagram
Ductile IMC
Brittle IMC
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Mechanical Properties of Intermetalic Compounds in Fe-Al series
Flow curves under compressive loading *
Hardness and fracture toughness *
Therefore, if amount of Fe-rich ductile IMC in interfacelayer is increased at the expense of Al-rich brittle IMC, thejoint strength may improve.
* M.Yasuyama and K.Ogawa, JJWS,1996
Fe-rich IMC are ductileAl-rich IMC are brittle
(Yasuyama et al
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Mutual Diffusion Coefficient
DFe in Al = 1.2 10-5 m2/s EFe in Al = 135,000 J/mol for 20oC-642oC
Temperature, oC
Diff
usio
n C
oeff
icie
nt, 1
0-9cm
2 /s
-1.0
0.0
1.0
2.0
3.0
0 200 400 600 800 1000
DFe in Al
DAl in Fe
DAl in Fe = 5.2 10-4 m2/s EAl in Fe = 246,000 J/mol for 900oC-1100oC
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Growth of Intermetallic Compound
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Time-Temperature-Phase (TTP) Diagram
Pressure: 31.5 MPa
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2.Laser Roll Welding for Fe-Al joint
Direction of table travel
Reflecting Mirror Angle : 57.5o
Distance between Beam Spot center and Roller : 17 mmBeam Diameter : 2.5 mm minor
3.5 mm majorShielding Method : Argon Gas shieldInsert material used : Aluminium brazing flux,
K AlF4:K2AlF6.H2O
Details of Sheet Clamping
2.4kW CO2 laser with TEM 01* mode
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Classification of Welding Processes
1.Fusion welding 融接
3.Brazing ろう付
2.Solid-state welding 固相接合
4. One side Melting Fusion Welding
=Laser roll welding
AorB
Pressure
Pressure
Fusion Zone
Brazing / Soldering materials
Self-melting Zone
AAorB
A A
AAorB
A
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Process Features of LRW
1) formations of ductile intermetallic compounds such as FeAl and Fe3Al oreutectic phase after self-melting in the interface layer;
2) keeping the intermetallic compound layer thickness less than 10 µm; 3) the idea of using a sharp intensified fast moving heat source to just cause
wetting and diffusion for a very short period to form a metallic bond. 4) Heating is only one metal sheet by laser
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3.Laser Roll Welding of SPCC steel and Aluminum Alloys
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Research BackgroundAutomobile industry aims at • Improving fuel efficiency of vehicle• Minimizing environmental pollution (CO2
Gas)
One of the ways is to reduce vehicle weight by
• Use of high strength steels• Amount of steel in the vehicle should be reduced
by using aluminum alloys which have highstrength-to-weight ratio
For example, use of steel-aluminum hybrid structures.
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Set up of SPCC steel and A5052 Alloy
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Tensile test specimen
SPCC base metal was broken
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Erichsen Test Specimen
Aluminum
SPCC Steel
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Welding Condition of LRW Laser Power 1.0 kW〜 2.0kWTravel Speed 1.0 〜 3.2 m/minBeam spot dia. 3mm 〜 5mmRoll Pressure 100 〜 202 MPaShielding Method Argon Gas shielding Insert Material used Aluminium brazing flux,
KAlF4:K2AlF6.H2O
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3.1 Experiment
1) Materials usedSPCC steel for car body ; Thickness 0.7 and 1.0 mm
Size : 23mm x 200mm and 40mm x 200mmPreparation: Polishing with Emery paper #120Coating : Graphite coating
A6022 and A6K21 : Thickness 1.2 mm Size : 23mm x 200mm and 40mm x 200mmPreparation: Polishing with Emery paper #400Coating : FL-7 flux for Al brazing
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2) Laser Facility used3kW Single mode Fiber laser (IPG)
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Laser Roll Welding Machine
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Specimen No.
Laser Power ( W)
DefocusingDistance Df(mm)
Travel speed mm/sec
Loading (N)
Shielding Gas and flow rate
Remarks
AT-1 2200 165 15 100 Ar15+15 No Flux, Copper Backing AT-2 2200 165 20 100 Ar15+15 No Flux, Copper Backing At-8 2100 165 13 800 Ar15+15 With Flux, Copper Backing
AT-9 2100 165 14 800 Ar15+15 With Flux, Copper Backing AT-10 2100 165 15 800 Ar15+15 With Flux, Copper Backing AT-11 2100 165 16 800 Ar15+15 With Flux, Copper Backing AT-12 2100 165 17 800 Ar15+15 With Flux, Copper Backing AT-25 2200 167 8 100 Ar15+15 With Flux, Copper Backing AT-26 2200 167 10 100 Ar15+15 With Flux, Copper Backing AT-27 2200 167 12 100 Ar15+15 With Flux, Copper Backing AT-28 2200 167 14 100 Ar15+15 With Flux, Copper Backing FA-2 2200 167 15 100 Ar15+15 With Flux, Copper Backing FA-4 2200 167 12 100 Ar15+15 With Flux, Steel Backing FA-5 2200 167 12 100 Ar15+15 With Flux, SUS Backing FA-6 2200 167 12 100 Ar15+15 With Flux, Alumi. Backing AK-25 2200 167 8 100 Ar15+15 With Flux, Alumi. Backing AK-26 2200 167 10 100 Ar15+15 With Flux, Alumi. Backing AK-27 2200 167 12 100 Ar15+15 With Flux, Alumi. Backing
3) Welding condition
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Cross section of Fe-Al joint
FA-6 : Aluminium Backing
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FA-2: Copper Backing
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Cross section of Fe-Al Joint
FA-5: Stainless Steel Backing
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Interface of joint FA-6
SPCC steel
A6022 Alloy
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Result of EPMA
Fe Al
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Re-zaSpecimenNo.
Laser Power( W)
DefocusingDistanceDf(mm)
Travelspeedmm/sec
Loading(N)
Tensilestrength(MPa)
Remark
AT-25 2200 167 8 100 169 With Flux, Copper Backing
AT-26 2200 167 10 100 153 With Flux, Copper Backing
AT-27 2200 167 12 100 119 With Flux, Copper Backing
AT-28 2200 167 14 100 179 With Flux, Copper Backing
AK-25 2200 167 8 100 102 With Flux, Al Backing
AK-26 2200 167 10 100 168 With Flux, Al Backing
AK-27 2200 167 12 100 215 With Flux, Al Backing
FA-2 2200 167 15 100 330 With Flux, Copper Backing
FA-4 2200 167 12 100 126 With Flux, steel Backing
FA-5 2200 167 12 100 153 With Flux, SUS Backing
FA-6 2200 167 12 100 294 With Flux, Al Backing
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Tensile test specimen
Copper Backing
Stainless Steel Backing
Aluminium Backing
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Conclusion1) It is suggested that intermetallic compound
layer that is formed mainly is ductile FeAl . As the Backing material are Copper plate or Aluminum alloy.
2) The tensile strength of laser roll welded joint using copper backing is 330 Mpa. It was broken at Base metal of SPCC steel