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铝/铜异种金属熔钎焊研究现状

徐文虎 杨瑾 肖明 彭铭建 赵一璇 刘红兵 陆汉龙

徐文虎, 杨瑾, 肖明, 彭铭建, 赵一璇, 刘红兵, 陆汉龙. 铝/铜异种金属熔钎焊研究现状[J]. 上海工程技术大学学报, 2021, 35(3): 215-228.
引用本文: 徐文虎, 杨瑾, 肖明, 彭铭建, 赵一璇, 刘红兵, 陆汉龙. 铝/铜异种金属熔钎焊研究现状[J]. 上海工程技术大学学报, 2021, 35(3): 215-228.
XU Wenhu, YANG Jin, XIAO Ming, PENG Mingjian, ZHAO Yixuan, LIU Hongbing, LU Hanlong. Research status of dissimilar welding-brazing of aluminum to copper[J]. Journal of Shanghai University of Engineering Science, 2021, 35(3): 215-228.
Citation: XU Wenhu, YANG Jin, XIAO Ming, PENG Mingjian, ZHAO Yixuan, LIU Hongbing, LU Hanlong. Research status of dissimilar welding-brazing of aluminum to copper[J]. Journal of Shanghai University of Engineering Science, 2021, 35(3): 215-228.

铝/铜异种金属熔钎焊研究现状

基金项目: 国家自然科学基金资助项目(51805315);上海工程技术大学人才行动计划资助项目(2018RC45)
详细信息
    作者简介:

    徐文虎(1998−),男,在读硕士,研究方向为异种材料连接. E-mail:1130194286@qq.com

    通讯作者:

    杨 瑾(1987−),男,副教授,博士,研究方向为异种材料连接、激光焊接和超快激光微纳制造等. E-mail:jyang@sues.edu.cn

  • 中图分类号: TG457

Research status of dissimilar welding-brazing of aluminum to copper

  • 摘要: 由于铝合金和铜异种金属之间的物化性能差异较大,铝合金具有强氧化性等因素,铝/铜异种金属连接是焊接领域的研究难点. 综述近年来铝/铜异种金属熔钎焊的研究现状,介绍了铝合金和铜异种金属的焊接性,评述了铝/铜异种金属电弧和激光熔钎焊的研究进展,讨论了铝/铜异种金属熔钎焊仍然存在的共性问题;通过采用合适的焊接工艺配合合金元素调控是解决铝/钢异种金属熔钎焊问题的关键,并对该领域的研究发展进行展望和评述.
  • 图  1  Al-Cu二元相图

    Figure  1.  Al-Cu binary phase diagram

    图  2  激光−冷金属过渡焊接复合熔钎焊示意图[32]

    Figure  2.  Schematic diagram of laser-gold metal transfer welding composite welding-brazing[32]

    图  3  TIG电流对钎料与母材润湿角的影响[49]

    Figure  3.  Influence of TIG current on wetting angle between filler metal and base metal[49]

    图  4  CMT示意图

    Figure  4.  Schematic diagram of CMT

    图  5  焊接区的组织[52]

    Figure  5.  Structure of welding zone[52]

    图  6  镀镍层的截面厚度、镀层的形态和焊接接头的显微组织[53]

    Figure  6.  Cross section thickness of nickel plating layer, morphology of coating and microstructure of welded joint[53]

    图  7  焊缝结合区硬度分布图[54]

    Figure  7.  Hardness distribution diagram of weld bonding zone[54]

    图  8  MIG熔钎焊基本原理及实物[56]

    Figure  8.  Basic principle and real object of MIC welding brazing[56]

    图  9  脉冲旁路耦合电弧熔钎焊不同填充焊丝下接头焊缝中心区微观组织[59]

    Figure  9.  Microstructure of center area of joint weld under different filler wires in pulsed bypass coupled arc welding-brazing[59]

    图  10  脉冲旁路耦合电弧熔钎焊不同填充焊丝下接头电导率随焊接电流变化情况[59]

    Figure  10.  Variation of joint conductivity with welding current under different filler wires in pulsed bypass coupled arc welding-brazing[59]

    图  11  经过400 ℃热处理的接头SEM图像[61]

    Figure  11.  SEM images of joint after 400 ℃ heat treatment[61]

    图  12  焊缝横截面[62]

    Figure  12.  Cross section of weld seam[62]

    图  13  焊缝横截面[64]

    Figure  13.  Cross section of weld seam[64]

    图  14  铜侧焊缝区组织形貌[66]

    Figure  14.  Microstructure morphology of copper side weld area[66]

    图  15  填充材料的Cu-Al焊缝断口区域的SEM显微图[67]

    Figure  15.  SEM micrograph of Cu-Al weld fracture area without filler material[67]

    表  1  Al和Cu的物理性能参数[6]

    Table  1.   Physical property parameters of Al and Cu[6]

    材料
    点阵类型面心立方面心立方
    熔点Tm/ ℃ 6601084
    密度ρ / (g·cm−3)2.708.96
    比热容c / (W·m−1·K−1)917386
    热导率λ / (W·m−1·K−1)238397
    热膨胀系数q / K−12.38×10−61.20
    电阻率ρ / (Ω·m)2.65×10−81.68
    下载: 导出CSV

    表  2  铝/铜异种金属熔钎焊研究(铝硅焊丝)

    Table  2.   Study on welding-brazing of aluminum and copper dissimilar metals (Al-Si filler metal)

    母材厚度/mm焊接工艺填充金属焊接参数接头性能参考文献
    5052铝合金
    H62黄铜
    铜:1 mm
    铝:2 mm
    TIG搭接
    (铝上)
    1.6 mm Al-12%Si
    药芯焊丝
    焊接电流:90~130 A
    焊接速度:120 mm / min
    送丝速度:80 mm / min
    IMCs层:CuAl2,Cu9Al4,CuZn
    硬度(HV):<100
    拉剪强度:0.920 kN
    断裂形式:解理断裂
    [48]
    6061铝合金
    T2紫铜
    铜:1 mm
    铝:1 mm
    CMT对接/搭接
    (铝上、铜上)
    1.2 mm ER4043焊丝 焊接速度:6 mm / min
    送丝速度:520~590 mm / min(对接)
    650~740 mm / min(铜上)
    480~600 mm / min(铝上)
    IMCs层:CuAl,CuAl2α-Al
    拉剪强度:0.88 kN (对接)
    154 N / mm (铜上)
    195 N / mm(铝上)
    断裂形式:解理断裂
    [52]
    1060铝合金
    镀镍T2紫铜
    铜:2 mm
    铝:2 mm
    CMT搭接
    (铝上)
    1.2 mm ER4043焊丝 焊接电流:110 A
    焊接电压:13.5 V
    焊接速度:750 mm / min
    IMCs层:Cu3.8Ni,Al3Ni2
    拉剪强度:70.77 MPa
    断裂形式:解理断裂
    [53]
    1060铝合金
    T2紫铜
    铜:2 mm
    铝:2 mm
    CMT搭接
    (铝上)
    1.2 mm ER4043焊丝
    1.2 mm ER4047焊丝
    焊接电流:110 A
    焊接速度:750 mm / min
    纯氩保护气流量:20 L / min
    焊枪倾角:45°
    IMCs层:α-Al,CuAl2
    硬度(HV):470 (ER4043)
    170~180 (ER4047)
    [54]
    5A06铝合金
    T2紫铜
    铜:1.5 mm
    铝:1.5 mm
    DE-MPAW搭接
    (铝上)
    1.2 mm ER4047焊丝 焊接电流:45 A
    旁路电流:0 A
    焊接速度:90 mm / min
    送丝速度:32 mm / min
    离子气流量:0.6 L / min
    IMCs层:CuAl,CuAl2,Cu9Al4
    硬度(HV):436
    拉剪强度:0.69 kN
    断裂形式:脆性断裂
    [56]
    5052铝合金
    T2紫铜
    铜:2 mm
    铝:1 mm
    DE-GMAW 搭接
    (铝上)
    1.2 mm ER4047焊丝 焊接电流:15~65 A
    旁路电流:25 A
    脉冲频率:80 Hz
    焊接速度:30 mm / min
    IIMCs层:CuAl2α-Al
    拉剪强度:168 MPa
    断裂形式:解理断裂
    [57]
    1060铝合金
    T2紫铜
    铜:2 mm
    铝:2 mm
    DE-GMAW 搭接
    (铝上)
    1.2 mm ER4043焊丝
    1.2 mm ER4047焊丝
    焊接电流:35 A
    旁路电流:25 A
    脉冲频率:80 Hz
    焊接速度:30 mm / min
    IMCs层:CuAl2α-Al,Si相
    拉剪强度:
    158 MPa (ER4043)
    161 MPa (ER4047)
    硬度(HV):444
    [58-60]
    1060铝合金
    T2紫铜
    铜:2 mm
    铝:2 mm
    DE-GMAW 搭接
    (铝上)
    1.2 mm ER4043焊丝
    1.2 mm ER4047焊丝
    焊接电流:35 A
    旁路电流:25 A
    脉冲频率:80 Hz
    焊接速度:30 mm / min

    IMCs
    层:CuAl, Cu4Al3, CuAl2
    Cu3Al2,Cu9Al4
    [61]
    下载: 导出CSV

    表  3  铝/铜异种金属熔钎焊研究(锌铝焊丝)

    Table  3.   Study on welding-brazing of aluminum and copper dissimilar metals (Zn-Al filler metal)

    母材厚度/mm焊接工艺填充金属焊接参数接头性能参考文献
    5052铝合金
    H62黄铜
    铜:1 mm
    铝:2 mm
    TIG搭接
    (铝上)
    1.6 mm Zn-2%Al
    药芯焊丝
    焊接电流:90~130 A
    焊接速度:120 mm / min
    送丝速度:80 mm / min
    IMCs层: CuAl2,CuAl,Cu9Al4,CuZn
    硬度(HV):270
    拉剪强度:1.917 kN
    断裂形式:解理断裂
    [47-48]
    纯铜
    纯铝
    铜:2 mm
    铝:2 mm
    TIG搭接
    (铝上)
    2 mm Zn-5%Al
    药芯焊丝
    焊接电流:60~80 A
    焊接电压:30 V
    焊接速度:150 mm / min
    送丝速度:240 mm / min
    IMCs层:CuAl2
    拉剪强度:90 MPa
    断裂形式:解理断裂
    [49]
    2A16铝合金
    T2紫铜
    铜:1 mm
    铝:1 mm
    TIG搭接
    (铝上)
    2 mm Zn-5%Al
    药芯焊丝
    焊接电流:60~105 A
    焊接速度:35,62,85 mm / min
    IMCs层:CuZn4,Zn基固溶体,Al基固溶体
    拉剪强度:240 MPa
    断裂形式:解理断裂
    [51]
    LY16铝合金
    T2紫铜
    铜:2 mm
    铝:2 mm
    激光对接 2 mm Zn-5%Al
    药芯焊丝
    激光功率:1800~2600 W
    焊接速度:500~1300 mm / min
    IMCs层:CuAl,CuZn4, α-Al,β-Zn
    拉剪强度:274 MPa
    断裂形式:解理断裂
    [66]
    下载: 导出CSV

    表  4  铝/铜异种金属熔钎焊研究(其他填充金属)

    Table  4.   Study on welding-brazing of aluminum and copper dissimilar metals (other filler metal)

    母材厚度/mm焊接工艺填充金属焊接参数接头性能参考文献
    1060铝合金
    T2紫铜
    铜:3 mm
    铝:3 mm
    激光搭接
    (铝上)
    激光功率:3500 W
    焊接速度:2000 mm / min
    光斑向铝侧偏移0.4 mm
    IMCs层: CuAl2,Cu3Al2
    拉剪强度:101 MPa
    断裂形式:解理断裂
    [62]
    1050A铝合金
    SF-Cu紫铜
    铜:200 μm
    铝:210 μm
    激光搭接
    (铝上)
    激光功率:400 W
    焊接速度:3 mm / min
    焦点直径:31 μm
    波长:1070 nm
    脉冲时间:32 μs
    扫描频率:500 Hz
    IMCs层:CuAl2,Cu9Al4
    拉剪强度:121 MPa
    [63-65]
    1060铝合金
    T2紫铜
    铜:2 mm
    铝:2 mm
    DE-GMAW 搭接
    (铝上)
    1.2 mm ER1100焊丝
    1.2 mm ER5356焊丝
    焊接电流:35 A
    旁路电流:25 A
    脉冲频率:80 Hz
    焊接速度:30 mm / min
    纯氩保护气流量:20 L / min
    旁路纯氩保护气流量:5 L / min
    焊枪倾角:45°
    IMCs层:CuAl2α-Al
    拉剪强度:112 MPa (ER5356)
    硬度(HV):444
    [59-60]
    1060铝合金
    T2紫铜
    铜:2 mm
    铝:2 mm
    DE-GMAW 搭接
    (铝上)
    1.2 mm ER1100焊丝 焊接电流:35 A
    旁路电流:25 A
    脉冲频率:80 Hz
    焊接速度:30 mm / min
    纯氩保护气流量:20 L / min
    旁路纯氩保护气流量:5 L / min
    焊枪倾角:45°
    IMCs层:CuAl,Cu4Al3
    CuAl2,Cu3Al2,Cu9Al4
    [61]
    1060铝合金
    T2紫铜
    铜:1 mm
    铝:1 mm
    CMT搭接(铝上) 1.2 mm ER2319焊丝
    1.2 mm AlCu5焊丝
    焊接电流:80~102 A
    焊接速度:900-1500 mm / min
    纯氩保护气流量:15 L / min
    焊枪倾角:90°
    IMCs层:α-Al,CuAl,CuAl2
    Cu3Al2,Cu9Al4
    [55]
    1060铝合金
    T2紫铜
    铜:2 mm
    铝:2 mm
    CMT搭接(铝上) 1.2 mm S301焊丝 焊接电流:110 A
    焊接速度:750 mm / min
    纯氩保护气流量:20 L / min
    焊枪倾角:45°
    IMCs层:α-Al,CuAl2
    硬度(HV):470
    [54]
    纯铜
    纯铝
    铜:1 mm
    铝:1 mm
    激光对接 1.6 mm CuSi3焊丝 纯氩保护气流量:5 L / min
    波长:1064 nm
    硬度(HV):800 (0.5 N )
    弯曲变形:0.28±0.06 mm
    [67]
    3003铝合金
    110紫铜
    铜:0.54 mm
    铝:0.49 mm
    激光搭接
    (铝上)
    100 μm Sn–Ag–Ti 激光功率:500 W
    焦点直径:10 μm
    焦距:100 mm
    IMCs层:CuAl,Cu9Al4,CuAl2
    拉剪强度:0.78 kN
    断裂形式:解理断裂
    [68]
    下载: 导出CSV
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  • 收稿日期:  2021-05-26
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