Theoretical and experimental studies on fabrication of two-layer aluminum−copper pipe by friction stir additive manufacturing  

搅拌摩擦增材制造制备双层铝铜管的理论与实验研究

作　　者：Mehdi FALAHATI NAQIBI Majid ELYASI Hamed JAMSHIDI AVAL Mohammad Javad MIRNIA Mehdi FALAHATI NAQIBI;Majid ELYASI;Hamed JAMSHIDI AVAL;Mohammad Javad MIRNIA(Department of Mechanical Engineering,Babol Noshirvani University of Technology,Shariati Avenue,Babol 47148-71167,Iran;Department of Materials Engineering,Babol Noshirvani University of Technology,Shariati Avenue,Babol 47148-71167,Iran)

机构地区：[1]Department of Mechanical Engineering,Babol Noshirvani University of Technology,Shariati Avenue,Babol 47148-71167,Iran [2]Department of Materials Engineering,Babol Noshirvani University of Technology,Shariati Avenue,Babol 47148-71167,Iran

出　　处：《Transactions of Nonferrous Metals Society of China》2021年第12期3643-3658,共16页中国有色金属学报（英文版）

摘　　要：Using a friction stir additive manufacturing(FSAM)process,the fabrication of a two-layer aluminum−copper pipe was studied experimentally and numerically.For this purpose,by presenting a 3D thermo-mechanical model in ABAQUS software,the temperature and strain distributions during the process were studied.The simulation results show that,although the rotational-to-traverse speed ratio with a good approximation can predict the heat input during welding,it is not a precise measure to predict the occurrence of defects in the weld cross-section.There is a good agreement between the predicted and experimental thermal results,and the maximum relative error is 4.1%in estimating the maximum temperature during welding.Due to heat and severe plastic deformation in the stir zone,the aluminum−copper intermetallic compounds(CuAl_(2) and Cu_(9)Al_(4))are formed.The maximum hardness in the stir zone is 301.4 HV_(0.1) in sample welded with an overlap of−0.5 mm.The ultimate tensile strength and elongation of the two-layer pipe fabricated by friction stir additive manufacturing are(319.52±2.31)MPa and 19.47%,respectively.对采用搅拌摩擦增材制造(FSAM)工艺制备的双层铝铜管进行实验和数值研究。用ABAQUS软件建立三维热力学模型,研究制备过程中的温度和应变分布。模拟结果表明,虽然采用转动速度与移动速度比可以较好地预测焊接过程中的热输入,但是不能准确地预测焊缝截面缺陷的形成。预测结果与实验结果吻合较好,对焊接过程最高温度估计的最大误差为4.1%。由于热和大塑性变形,搅拌区形成铝铜金属间化合物(CuAl_(2)和Cu_(9)Al_(4))。焊接重叠区为−0.5 mm的样品搅拌区具有最大硬度301.4 HV_(0.1)。搅拌摩擦增材制造的双层管的极限抗拉强度和伸长率分别为(319.52±2.31)MPa和19.47%。

关 键 词：friction stir welding thermo-mechanical simulation two-layer Al−Cu pipes microstructure mechanical properties 

分 类 号：TG453.9[金属学及工艺—焊接]