材料成形原理焊接原理概述.pptx

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1、第一章 序论1.1 连接与人类历史自石器时代至今天连接始终是人类制造业中最为重要的工艺过程之一材料成形原理-焊接原理（序论）3第2页/共34页第1页/共34页在通常意义上，连接是指将零、部件组合成一个（连续）整体的工艺过程，其所获得的整体具备各被连接零、部件没有的功能或复合功能。连接所关心的核心问题是那些具备固有微观结构与宏观性能的被连接材料在连接过程中的演变，以及所构建连接结构的组织与力学特征。材料成形原理-焊接原理（序论）41.2 连接的定义、目的及基本分类1.2.1 连接的定义第3页/共34页第2页/共34页Figure 1.1 Welding,using a variety of fu

2、sion welding,predominantly consumable electrode processes,is used almost exclusively in ship construction.Roll product(e.g.,plate and beams),forgings,and castings are all welded to provide structural integrity,structural efficiency,and leak tightness.In most shipyards parts are joined to create larg

3、e pre-fabricated modules,which are then joined to produce the ship,here the aircraft carrier Reagan.大型结构材料成形原理-焊接原理（序论）5第4页/共34页第3页/共34页Figure 1.2 Modern manufacturing often benefits when labor-intensive,quality-critical assembly is automated,as exemplified in the automobile industry by robotic weld

4、ing.(Courtesy of DaimlerChrysler AG,Stuttgart,Germany,with permission.)中型结构材料成形原理-焊接原理（序论）6第5页/共34页第4页/共34页Figure 1.3 Welding is also used for microjoining for a variety of applications and industries.Here,very thin kovar sheets are spot-fillet welded by laser-beam welding to produce the minute lap

5、joints shown.(Courtesy of Sandia National Laboratories,Albuquerque,NM,with permission.)微小结构材料成形原理-焊接原理（序论）7第6页/共34页第5页/共34页Figure 1.4 Typical large welded structures at a petrochemical plant.Note the bolted thick-section pipes,valves,and fittings at the left and right of the welded towers,as shown i

6、n a close-up in Figure 2.3.(Courtesy of Marathon Ashland Petroleum LLC,Findlay,OH,with permission.)金属材料材料成形原理-焊接原理（序论）8第7页/共34页第6页/共34页Figure 1.5 Typical use of manual iron soldering in industry.(Courtesy of the IBM Corporation,Poughkeepsie,NY,with permission.)Figure 1.6 An example of a friction-wel

7、ded ceramic assembly.(Courtesy of the Edison Welding Institute,Columbus,OH,with permission.)陶瓷+金属材料成形原理-焊接原理（序论）9第8页/共34页第7页/共34页Figure 1.7 The use of thermal bonding,as well as adhesive bonding,is commonplace in the assembly of thermoplastic monolithic and reinforced composites used in military air

8、craft.(Courtesy of Northrop Grumman Corporation,with permission.)复合材料材料成形原理-焊接原理（序论）10第9页/共34页第8页/共34页Figure 1.8 In an analog to welding,a laser beam can be used to reattach a detached retina,with the heat of the laser causing joining by coagulating protein.(Courtesy of Julia A.Haller,M.D.,The Johns

9、 Hopkins Hospital,Baltimore,MD,with permission.)生物材料材料成形原理-焊接原理（序论）11第10页/共34页第9页/共34页Figure 1.9 Huge offshore drilling platforms,serving as self-sufficient cities at sea,use welding extensively in their land-based construction,on-site erection,and above and below water repair.(Courtesy of Materials

10、&Welding Technology,Houston,TX,with permission.)VA,with permission.)Figure 1.10 Underwater arc welding is necessary for both construction and repair.Here,a diver is shown arc-repair welding an obviously overgrown steel structure.(Courtesy of Daves Diving&Offshore,in memory of Chris Mourtinson,Morgan

11、 City,LA,with permissionof David Gilbert.)海材料成形原理-焊接原理（序论）12第11页/共34页第10页/共34页Figure 1.11 Welding is used to construct overland pipelines in all kinds of climates,including frozen tundra or scorching deserts,as shown here.(Courtesy of Bechtel Corporation,San Francisco,CA,with permission.)陆材料成形原理-焊接原

12、理（序论）13第12页/共34页第11页/共34页Figure 1.12 As humans venture farther and stay longer in outer space,joining by specially adapted conventional processes as well as yet-to-be-developed processes will be a necessity.Here,an astronaut assembles new parts onto a portion of the InternationalOrbiting Space Stati

13、on.(Courtesy of the National Aeronautics and Space Administration,Washington,DC,with permission.)天材料成形原理-焊接原理（序论）14第13页/共34页第12页/共34页材料成形原理-焊接原理（序论）151.2.2 连接的目的（1）功能：获得单一工艺方法（例铸造、锻压、粉末冶金、机加）无法获得的大尺寸或复杂结构构件；制备具有多功能耦合的多种材料复合体。（2）可制造性：利用已有构件和材料达到整体结构构造的有效性；获得单一工艺方法无法获得的大尺寸或复杂结构构件将适合的材料用于适合的位置，优化选择；充分利

14、用材料，尽量减少材料的消耗。（3）成本（4）美学重要性第14页/共34页第13页/共34页1.2.3 连接的基本分类连接（Joining）机械连接（Mechanical Fasteners,Riveting）粘接（Adhesive Bonding and Cementing）焊接（Welding,Braze,solder and diffusion bonding）机械力（弹、塑性畸变）强度低、非密封范德华力、氢键强度低、密封金属键，共价键，离子键强度高、密封材料成形原理-焊接原理（序论）16第15页/共34页第14页/共34页1.3 材料焊接成型的物理本质 1.3.1 焊接基本方法材料成形原

15、理-焊接原理（序论）17第16页/共34页第15页/共34页焊接方法分类熔焊熔焊压焊压焊钎焊钎焊电弧焊电弧焊气焊气焊铝热焊铝热焊电渣焊电渣焊电子束焊电子束焊激光焊激光焊电阻点（缝）焊电阻点（缝）焊熔化极熔化极手工电弧焊手工电弧焊氩弧焊氩弧焊(MIG)埋弧焊埋弧焊(SAW)CO2焊焊螺柱焊螺柱焊非熔化极非熔化极钨极氩弧焊钨极氩弧焊(TIG)等离子弧焊等离子弧焊(PAW)原子氢焊原子氢焊摩擦焊摩擦焊扩散焊扩散焊爆炸焊爆炸焊超声波焊超声波焊冷压焊冷压焊电阻焊、闪光对焊电阻焊、闪光对焊材料成形原理-焊接原理（序论）18第17页/共34页第16页/共34页Figure 1.13 气体保护钨极电弧焊（Ga

16、s-Tungsten Arc Welding;GTAW）。示意图(Reprinted from Joining of Advanced Materials,Robert W.Messler,Jr.,Fig.6.9,page 202,Butterworth-Heinemann,Stoneham,MA,1993)材料成形原理-焊接原理（序论）19第18页/共34页第17页/共34页Figure 1.14 气体保护熔化极电弧焊（gas-metal arc welding;GMAW）示意图。(Reprinted from Joining of Advanced Materials,Robert W.M

17、essler,Jr.,Fig.6.16,page 208,Butterworth-Heinemann,Stoneham,MA,1993)材料成形原理-焊接原理（序论）20第19页/共34页第18页/共34页Figure 1.15 手工电弧焊（shielded metal arc welding;SMAW）示意图。(Reprinted from Joining of Advanced Materials,Robert W.Messler,Jr.,Fig.6.18,page 211,Butterworth-Heinemann,Stoneham,MA,1993)材料成形原理-焊接原理（序论）21第2

18、0页/共34页第19页/共34页Figure 1.16 药芯焊丝电弧焊（flux-cored arc welding;FCAW）示意图。(Reprinted from Joining of Advanced Materials,Robert W.Messler,Jr.,Fig.6.19,page 213,Butterworth-Heinemann,Stoneham,MA,1993)材料成形原理-焊接原理（序论）22第21页/共34页第20页/共34页Figure 1.17 埋弧焊（submerged arc welding;SAW）示意图。(Reprinted from Joining of

19、Advanced Materials,Robert W.Messler,Jr.,Fig.6.20,page 213,Butterworth-Heinemann,Stoneham,MA,1993)材料成形原理-焊接原理（序论）23第22页/共34页第21页/共34页Figure 1.18 电渣焊（electroslag welding;ESW）示意图。(Reprinted from Joining of Advanced Materials,Robert W.Messler,Jr.,Figs.6.21 and 6.22,page 215,Butterworth-Heinemann,Stoneha

20、m,MA,1993)材料成形原理-焊接原理（序论）24第23页/共34页第22页/共34页Figure 1.19 电阻点焊（resistance spot welding;RSW）示意图。(Reprinted from Joining of Advanced Materials,Robert W.Messler,Jr.,Fig.6.24,page 218,Butterworth-Heinemann,Stoneham,MA,1993)材料成形原理-焊接原理（序论）25第24页/共34页第23页/共34页Figure 1.20 (a)爆炸焊示意图（explosion welding;EXW）；(b

21、)爆炸焊典型形貌。（Reprinted from Joining of Advanced Materials,Robert W.Messler,Jr.,Fig.6.28,page 224,Butterworth-Heinemann,Stoneham,MA,1993）材料成形原理-焊接原理（序论）26第25页/共34页第24页/共34页Figure 1.21 (a)摩擦焊（friction welding;FRW）示意图；(b)典型摩擦焊接头。(Reprinted from Joining of Advanced Materials,Robert W.Messler,Jr.,Fig.6.29,p

22、age 225,Butterworth-Heinemann,Stoneham,MA,1993)材料成形原理-焊接原理（序论）27第26页/共34页第25页/共34页1.3 材料焊接成型的物理本质 1.3.2 焊接的定义两种或两种以上的材料，在添加或不添加填充材料的条件下，通过加热、加压，或二者并用的外场形式，并借助物质迁移过程，消除接触表面、形成永久性、致密、高强接头的物理化学过程。材料成形原理-焊接原理（序论）28第27页/共34页第26页/共34页1.3.3 不同焊接方法所需外场（温度、压力）s2s3s4sTmTb激光电子束电弧电渣气焊扩散接触超声冷压磁脉冲爆炸磨擦0.1110100100

23、00.111010010000.010t/sP图1-22 不同焊接方法作用温度、压力及过程持续时间的对比材料成形原理-焊接原理（序论）29第28页/共34页第27页/共34页1.3.4 焊接的物理本质 图1-24 固-固硬球结构模型 图1-23 固-液硬球结构模型 材料成形原理-焊接原理（序论）30第29页/共34页第28页/共34页则两原子间的相吸力为图1-2 原子间作用力与距离关系1斥力；2引力；3合力材料成形原理-焊接原理（序论）31莱纳德-琼斯势Lennard-Jones按求极限法则可得到与最大净作用力对应的原子间距为标准的莱纳德-琼斯势，m=6，n=12，An、Am的数据可以根据点阵

24、参数和升华能的数据导出第30页/共34页第29页/共34页作用本质加热形成L/L、L/S界面对接触接头进行局部加热，借助熔化、液相融合过程消除L/L界面；借助凝固过程消除L/S界面加热/加压形成S/S界面借助热激活、畸变能激活，促进S/S接触界面的塑性变形、原子互扩散与成键消除S/S界面材料成形原理-焊接原理（序论）32第31页/共34页第30页/共34页形成体积意义上的具有力学不均匀的焊接接头 图1-25 焊接接头示意图：1.焊缝；2.熔合区；3.热影响区；4.未变化的母材3124材料成形原理-焊接原理（序论）33第32页/共34页第31页/共34页Ti at.%Al at.%Cr at.%

25、Nb at.%Cu at.%Ni at.%A167.129.11.20.41.40.8B163282.40.73.62.4C173.724.60.30.10.80.4D17013.40.90.287.5E1626.30.5-625.5F157.811.90.2-13.916.3G150.85.40.7-18.624.6图1-26 钎焊接头示意图:1扩散区；2界面区；3钎缝中心区-TiAl钎焊接头微观结构及成份分布（Ti5 wt.%Cu15 wt.%Ni钎料）材料成形原理-焊接原理（序论）34第33页/共34页第32页/共34页局部加热的超高温度场组织的不均匀性力学性能不均匀性残余热应力分布连接材料的氧化倾向特有缺陷的产生材料成形原理-焊接原理（序论）35以熔焊为代表整体加热的高温度场接头组织的特殊性以钎焊、扩散焊(也有局部加热的情况)为代表残余热应力分布连接材料的氧化倾向特有缺陷的产生1.3.5 不同焊接方法所涉及的基本原理第34页/共34页第33页/共34页感谢您的观看！第34页/共34页