Research status of dissimilar welding-brazing of aluminum to copper
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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.Abstract: Due to the great difference in physical and chemical properties between aluminum alloy and copper dissimilar metals, the strong oxidation property of aluminum alloy and other factors, it has become a difficult point in the welding field of dissimilar metals joining. The research status of aluminum/copper dissimilar metal welding-brazing in recent years and weldability of aluminum and copper dissimilar metal were reviewed, common problems of the aluminum/copper dissimilar metal welding-brazing were discussed. Appropriate welding process with adjustment of alloy elements is the key to solve the problem of aluminum/steel dissimilar metal welding and brazing, and the research and development in this field are prospected and reviewed.
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材料 铝 铜 点阵类型 面心立方 面心立方 熔点Tm/ ℃ 660 1084 密度ρ / (g·cm−3) 2.70 8.96 比热容c / (W·m−1·K−1) 917 386 热导率λ / (W·m−1·K−1) 238 397 热膨胀系数q / K−1 2.38×10−6 1.20 电阻率ρ / (Ω·m) 2.65×10−8 1.68 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 mmTIG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 / minIMCs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 mmCMT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,CuAl2,α-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 mmCMT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 / minIMCs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 mmCMT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 mmDE-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 / minIMCs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 mmDE-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 / minIIMCs层:CuAl2,α-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 mmDE-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 / minIMCs层:CuAl2,α-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 mmDE-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] 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 mmTIG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 / minIMCs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 mmTIG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 / minIMCs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 mmTIG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 / minIMCs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 / minIMCs层:CuAl,CuZn4, α-Al,β-Zn
拉剪强度:274 MPa
断裂形式:解理断裂[66] 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)无 激光功率:3500 W
焊接速度:2000 mm / min
光斑向铝侧偏移0.4 mmIMCs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)无 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 HzIMCs层:CuAl2,Cu9Al4
拉剪强度:121 MPa[63-65] 1060铝合金
T2紫铜铜:2 mm
铝:2 mmDE-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:CuAl2,α-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 mmDE-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 mmCMT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 mmCMT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 mmIMCs层:CuAl,Cu9Al4,CuAl2
拉剪强度:0.78 kN
断裂形式:解理断裂[68] -
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