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首页> 外文期刊>Proceedings of the Institution of Mechanical Engineers. Part L, Journal of Materials: Design and Application >Computational analysis of the intermetallic formation during the dissimilar metal aluminum-to-steel friction stir welding process
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Computational analysis of the intermetallic formation during the dissimilar metal aluminum-to-steel friction stir welding process

机译：不同金属铝对摩擦搅拌焊接工艺中金属间形成的计算分析

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摘要

The extent of inter-material mixing and the formation of intermetallic compounds play a critical role in the structural integrity and mechanical properties of the joints in the case of dissimilar metal friction stir welding. In general, there is a critical volume fraction of the intermetallic compounds in the mix zone of the friction stir welding-joint at which the mechanical properties of the joint are maximized. That is, insufficient inter-material mixing and the accompanying sub-critical volume fraction of the intermetallic compounds results in insufficient inter-material bonding and inferior joint strength. Conversely, super-critical volume fraction of the intermetallic compounds typically gives rise to the joint embrittlement. To address the problem of the effect of the friction stir welding process parameters on the extent of intermetallic compound formation, a multi-physics computational framework has been developed and applied to the case of dissimilar metal friction stir welding involving commercially pure (CP) aluminum and AISI 1005 low-carbon steel. The multi-physics framework comprises the following main modules: (a) finite-element-based friction stir welding-process modeling; (b) quantum-mechanics, atomistic and CALPHAD-type continuum material thermodynamics analyses of the intermetallic compound-nucleation process; (c) a continuum-type analysis of multi-component diffusion-controlled growth of the intermetallic compounds; and (d) Kolmogorov-Johnson-Mehl-Avrami type analysis of the evolution of the intermetallic compound volume fraction within the friction stir welding joint as a function of the friction stir welding process parameters. The results obtained revealed that: (i) the extent and the spatial distribution of the intermetallic compounds is a sensitive function of the friction stir welding-process parameters; and (ii) among the six potential Al-Fe intermetallic compounds, FeAl and Fe3Al are associated with the largest volume fractions and, hence, play a key role in both attaining the required joint strength and in the potential loss of the joint fracture toughness.
机译：在不同的金属摩擦搅拌焊接焊接的情况下，材料间聚混合和金属间化合物的形成在关节的结构完整性和机械性能下起着关键作用。通常，在摩擦搅拌焊接接头的混合区中存在金属间化合物的临界体积分数，在此接头的机械性能最大化。也就是说，金属间化合物的伴随亚临界体积分数不足，伴有金属间化合物的间质粘合不足和较差的关节强度。相反，金属间化合物的超级临界体积分数通常会产生关节脆化。为了解决摩擦搅拌焊接过程参数对金属间化合物形成程度的影响，已经开发了一种多物理计算框架，并应用于涉及商业纯（CP）铝的不同金属摩擦搅拌焊接的情况。 AISI 1005低碳钢。多物理框架包括以下主要模块：（a）基于有限元的摩擦搅拌焊接工艺造型; （b）量子 - 力学，原子和鱿鱼型连续体材料热动力学分析金属间化合物 - 成核过程; （c）金属间化合物的多组分扩散控制生长的连续型分析; （d）Kolmogorov-Johnson-Mehl-Avrami型分析摩擦搅拌焊接接头内金属间化合物体积分数的演变作为摩擦搅拌焊接工艺参数的函数。得到的结果显示：（i）金属间化合物的程度和空间分布是摩擦搅拌焊接工艺参数的敏感功能; （ii）在六种潜在的Al-Fe金属间化合物中，FEAL和Fe3Al与最大体积分数相关，因此，在达到所需的关节强度和关节断裂韧性的潜在损失中起着关键作用。

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