焊头形状对Cu/Al大功率超声焊接温度场及塑性变形的影响  

Effects of Sonotrode Geometry on Welding Temperature Field and Plastic Deformation in Cu/Al High-power Ultrasonic Welding

作　　者：李欢 张健[1] 伍世英 刘千喜 LI Huan;ZHANG Jian;WU Shiying;LIU Qianxi(School of Mechanical Engineering,Yangtze University,Jingzhou 434023,Hubei,China;School of Mechanical and Electronics,Guangzhou Railway Polytechnic,Guangzhou 510430,China)

机构地区：[1]长江大学机械工程学院,湖北荆州434023 [2]广州铁路职业技术学院机电工程学院,广州510430

出　　处：《材料导报》2025年第6期195-200,共6页Materials Reports

基　　金：湖北省教育厅重点项目(D20221306);2022年度广东省普通高校青年创新人才类项目-异种材料超声波辅助扩散连接关键性问题研究(2022KQNCX224);湖北省重点研发计划项目(2020BAB055)。

摘　　要：焊头形状是超声焊接的重要参数,但目前关于焊头形状对焊接过程的影响认识不足。利用有限元方法建立了一个三维声-热-结构场耦合模型,针对Cu/Al大功率超声焊接过程,主要研究了焊头的齿间距及角度对界面温度、材料塑性变形、焊头下压位移及微观组织的影响。结果表明,当焊头齿间距为0.9 mm时,接头成型良好,无明显缺陷,且较高的界面温度促进了中间相的生长;在齿间距为0.8 mm、1.0 mm时,焊头边缘下方材料的塑性应变较高,导致裂纹产生并扩展。随着焊头齿角度从108°增大到135°,界面温度从471.9℃逐渐降低至456.3℃,焊头下压位移从0.344 mm降低至0.304 mm,工件最大塑性应变从0.94大幅降低至0.63。研究结果可为优化焊头形状提供了理论参考。The geometry of the sonotrode tip is an important parameter of ultrasonic welding,but the influence of the welding head geometry on the wel-ding process is insufficient currently.A three-dimensional sound-thermal-mechanical field coupling model was established using the finite ele-ment method.The influence of tooth spacing and angle on interface temperature,interface plastic deformation and microstructures,and sonotrode downward displacement during Cu/Al high power ultrasonic welding was mainly investigated.The results showed that when the spacing of the sonotrode tooth was 0.9 mm,the joint was well formed without obvious defects,and the higher interface temperature promoted the growth of the intermetallic compound.When the spacing of the tooth was 0.8 mm or 1.0 mm,the plastic strain of the material below the edge of the sonotrode was significantly higher,resulting in the production and expansion of the crack.As the sonotrode teeth angle increased from 108°to 135°,the interface temperature decreased from 471.9℃to 456.3℃,the sonotrode displacement decreased from 0.344 mm to 0.304 mm,and the maximum plastic strain of specimens sharply decreased from 0.94 to 0.63.This research should provide a theoretical reference of optimizing the welding geometry.

关 键 词：超声焊接 焊头形状 铝合金 异质接头 塑性变形 

分 类 号：TG456.9[金属学及工艺—焊接]