Study on the welding features of the weld joint between aluminum alloy to stainless steel and aluminum alloy to dual phase steel by using tig and friction stir welding

國立高雄科技大學 機械工程系博士班 博士論文 應用 TIG 與摩擦攪拌焊接法探討鋁合金與不銹鋼及鋁合 金與雙相鋼間銲接接頭之銲接特性 Study on the Welding Features of the Weld Joint between Aluminum Alloy to Stainless Steel and Aluminum Alloy to Dual Phase Steel by Using TIG and Friction Stir Welding 研究生：阮文一 指導教授 ：黃世疇 教授 中華民國 107 年 12 月 I 應用 TIG 與摩擦攪拌焊接法探討鋁合金與不銹鋼及鋁合 金與雙相鋼間焊接接頭之焊接特性 Study on the Welding Features of the Weld Joint between Aluminum Alloy to Stainless Steel and Aluminum Alloy to Dual Phase Steel by Using TIG and Friction Stir Welding 學生: 阮文一 Van Nhat Nguyen 指導教授 ：黃世疇 教授 Shyh-Chour Huang 國立高雄科技大學 機械工程系博士班 博士論文 Department of Mechanical Engineering National Kaohsiung University of Science and Technology In Partial Fulfillment of the Requirements for the Degree of Doctor of Philosophy in Mechanical Engineering December 2018 Kaohsiung, Taiwan, Republic of China 中華民國 107 年 12 月 II III 應用 TIG 與摩擦攪拌焊接法探討鋁合金與不銹鋼及鋁合 金與雙相鋼間焊接接頭之焊接特性 研究生：阮文一 指導教授：黃世疇 教授 國立高雄科技大學 機械工程系博士班 摘要 由於重量輕，耐腐蝕性和高抗氧化等優點，鋁合金與不銹鋼，鋁合金和雙相鋼 之間的焊接在工業上有廣泛的應用。然而，要將金屬焊接在一起，仍然存在許多挑 戰。 例如，鋼的熔點遠大於鋁的熔點，機械性能和化學成分的差異。 特別是在不銹 鋼與焊縫之間的界面處，容易形成金屬間化合物（IMC）層的脆性和裂縫。 這些問 題將對接頭的強度和焊接質量產生負面影響。 為了防止 IMC 層的形成和焊接接頭質 量缺陷的產生，必須發展合宜的焊接方法與焊接參數。 在本研究中，摩擦攪拌焊接（FSW）和鎢極惰性氣體（TIG）焊接分別用於焊接鋁 AA6351 / DP800 鋼和鋁 A6061-T6 / SUS304L 鋼。 鋁合金和不銹鋼，鋁合金和雙相鋼之間的銲件有許多優點，如重量輕，耐腐蝕 性和耐氧化性高，因而得到了更廣泛的工業應用 然而，要將金屬焊接在一起，仍 然存在許多挑戰 例如，鋼的熔點遠大於鋁的熔點，機械性能和化學成分的差異 特 別是在不銹鋼與焊縫之間的界面處，容易形成金屬間化合物（IMC）層的脆性和裂縫 這些問題將對接頭的強度和焊接質量產生負面影響 因此有必要有一個適當的焊接 IV 方法和設定的焊接參數來防止 IMC 層的形成和發展並形成缺陷，從而提高焊接接頭 的質量 在這項研究中，摩擦攪拌焊（FSW）和鎢惰性氣體（TIG）焊接分別用於焊 接鋁 AA6351 / DP800 鋼和鋁 A6061-T6 / SUS304L 鋼 通過攪拌摩擦焊方法成功地進行了 AA6351 與 DP800 鋼之間的搭接。利用掃描電 子顯微鏡（SEM）和 X 射線衍射（XRD）技術研究焊縫的顯微組織特徵。調查結果表 明，在鋼和鋁合金之間的界面出現的金屬間化合物層的厚度小於 微米，並進行相 存在於 IMC 層包括 Al3Fe 系，Fe3Al 金屬，和 Al2Fe 相 還檢查了熱循環以顯示溫度 分佈與金屬間化合物層的形成之間的關係 分析了採用 TI G 焊和 ER4047 填充金屬對鋁與鋼對接的特點 並使用光學顯微 鏡（OM），掃描電子顯微鏡（SEM），能量色散 X 射線衍射（EDS）來顯示微觀結構 試驗結果表明，焊縫外觀良好，無缺陷，且熱影響區非常小 此外，在鋼與焊縫之 間的界面處還發現了金屬間化合物層和裂縫，其厚度為 2μm。在包含 Fe4Al13，Fe2Al5 和 FeAl3 相的金屬間層中形成新相。通過維氏硬度試驗和拉伸試驗方法研究了焊接接 頭的機械性能。結果，不銹鋼，焊縫和金屬間層中的硬度的平均值分別為 218HV， 79HV 和 411HV。最大抗拉強度達到 226.5 Mpa，斷裂位置發生在焊接釬焊表面。 關鍵字：鎢極惰性氣體工藝，攪拌摩擦焊工藝，填充金屬，DP800 鋼金屬間化合物層， 微觀結構，機械性能，熱循環。 V Study on the Welding Features of the Weld Joint between Aluminum Alloy to Stainless Steel and Aluminum Alloy to Dual Phase Steel by Using TIG and Friction Stir Welding Student: Van Nhat Nguyen Advisor: Shyh-Chour Huang Department of Mechanical Engineering National Kaohsiung University of Science and Technology Abstract Due to the advantages such as light weight, corrosion resistance and high oxidation resistance, the connection between aluminum alloys and stainless steel, aluminum alloys and dual phase steel has used more widely in industrial applications However, to weld the metal together, there are still many challenges Such as, the melting point of steel is much larger than that of aluminum, the difference in mechanical properties and chemical composition Especially at the interface between the stainless steel and weld seam easily form an intermetallic compound (IMC) layer brittle and cracks These problems will have a negative impact on the strength of the joint and the quality of the weld To prevent the formation and development of the IMC layer and the formation of defects improving the quality of the welding joint, it is necessary to have a proper welding method and set of welding parameters In this study, Friction Stir Welding (FSW) and Tungsten Inert Gas (TIG) welding were used VI to weld Aluminum AA6351/DP800 steel and aluminum A6061-T6/SUS304L steel, respectively Lap joint between AA6351 to DP800 steel was carried out successfully by a friction stir welding method The scanning electron microscopy (SEM) and X-ray diffraction (XRD) technique was utilized to investigate the microstructural characteristics of the weld The survey results showed that at the interface between steel and aluminum alloy have appeared intermetallic compound layer with a thickness less than of 7μm, and the phases exist in IMC layer includes Al3Fe, Fe3Al, and Al2Fe phases Thermal cycles were also examined to show the relationship between the distributions of temperature with the formation of the intermetallic layer The characteristics of Butt joint between aluminum and steel by using TIG welding with ER4047 filler metal were analyzed The optical microscopy (OM), scanning electron microscopy (SEM), energy dispersive X-Ray diffraction (EDS) have been done to demonstrate the microstructure of the weld Test results illustrated that the appearance of the weld good, no defects, and the heat-affected zone is very small Further, an intermetallic compound layer and cracks was also found at the interface between the steel and the welding seam, its thickness of µm The new phases formed in an intermetallic layer comprising Fe4Al13, Fe2Al5, and FeAl3 phases The mechanical properties of the welded joint have been explored by means of a Vickers hardness test and tensile test method As a result, the average value of hardness in the stainless steel, in the welding seam, and in the intermetallic layer is 218 HV, 79 HV, and 411 HV, respectively Maximum tensile strength reached 226.5 Mpa and the fracture location occurred at the welding-brazing surface Keywords: Tungsten Inert Gas (TIG) process, Friction Stir Welding (FSW) process, Filler metal, DP800 steel Intermetallic compound layer (IMC), Microstructure, Mechanical properties, Thermal Cycles VII Acknowledgments During my studies and research at the National Kaohsiung University of Science and Technology, I received great support from my teachers, my family, my friends, and my coworkers Through this opportunity, I want to present my deep sincere thanks to them First, I would like to express honest thanks and respect from my heart to my academic supervisor, Professor Shyh-Chour Huang, who pointed me to the direction of research, gave me motivation and support me throughout this study work Without his dedicated help, my research will not be as successful today Second, I am also extremely thanks to Mr Quoc Manh Nguyen, Mr Tien Dat Vu, for their support to experimental and data collection Third, I would like to thank the leadership of the mechanical engineering department of the Hung Yen University of Technology and Education for their help to my focuses to research In addition, I would like to choose this opportunity to indicate my sincere thanks to the members of the Computer Aided Engineering Application and Design LAB has helped me very enthusiastic during my time at National Kaohsiung University of Science and Technology Finally, I would also like to send my sincere thanks to I would like to send my sincere thanks to my younger brother Van Hai Nguyen and my younger sister Thi Lan Anh Nguyen They have replaced me with care, raised my mother, and help me to solve all the work in the family A very special thanks and respect for my wife, who has been with me overcome many difficulties, she has replaced me with care and education for my children VIII Contents 摘要 IV Acknowledgments VIII Contents VIII List of Tables XI List of Figures XII Chapter Introduction 1.1 Overview 1.2 Scope and Objectives of the Dissertation 1.3 Dissertation Outline Chapter Literature Reviews 2.1 Overview of Previous Research 2.2 Overview of Some Welding Methods 2.2.1 Tungsten Inert Gas Welding a Current Models Used in TIG Welding b The Shielding Gases and Gas Mixtures Used in TIG Welding 11 c Electrodes 13 2.2.2 Gas Metal Arc Welding 13 2.2.3 Friction Stir Welding 15 a Microstructural Characteristics 16 b Tools of Friction Stir Welding Process 17 2.2.4 Laser Welding 19 2.2.5 Ultrasonic Welding 22 VIII 2.2.6 Resistance Welding 24 2.2.7 Explosive Welding 26 2.3 Welding Defects 27 2.3.1 Cracks 28 2.3.2 Porosity 29 2.3.3 Undercutting 30 2.3.4 Lack of Fusion 32 2.4 Heat Transfer during Welding 32 2.5 Measurement Methods 33 2.5.1 Optical Microscope 33 2.5.2 Scanning Electron Microscopy 34 2.5.3 X-Ray Diffraction 35 2.5.4 Vickers Hardness Test 36 2.5.5 Tensile Testing 37 2.6 Summary 38 Chapter Experimental Procedure 39 3.1 The Influence of Welding Parameters on the Quality of TIG Weld 39 3.1.1 Welding Current 39 3.1.2 Welding Voltage 39 3.1.3 Filler Metals 40 3.1.4 Shielding Gas 40 3.2 The Influence of Welding Parameters on the Quality of Friction Stir Weld 41 3.2.1 Rotational Speed and Travel Speed 41 IX Chapter Conclusions and Future Works 6.1 Conclusions The main research activity of this dissertation is to study the microstructure and mechanical properties of welding joints with dissimilar materials (A6061-T6 / SUS304L and DP800 / AA6351) produced by TIG welding process and friction stir welding method The necessity of examining the microstructure and mechanical properties of the welded joints is because they are the most important characteristic of the weld joints and they have a great influence on the quality of welded joints In the TIG welding process, selecting a set of welding parameters and filler metal suitable for basic materials and welding joints contributes to creating a highquality welding connection with the appearance of a welding seam is good and no defects In particular, the formation and development of the IMC layer along the interface of the SUS304L steel and the welding seam was controlled; with the IMC layer thickness obtained about µm The tensile strength of the welded joint was lower than the tensile strength of the A6061-T6 aluminum alloy at about 79% and it was higher than the tensile strength of the filler metal ER4047 Hardness values are distributed unequally from the steel side through the interlayer to the fusion zone and to the base aluminum alloy The maximum hardness value determined at the IMC layer is 469 HV and it tends to decrease gradually towards the A6061-T6 alloy Welding defects such as cracking, porosity, lack of fusion have a direct effect on the tensile strength of the weld joint This is because the starting position of the fault process occurs at the location where the defects occur All tensile test samples indicated that the fracture was seen from the IMC region, which is the weakest point in the weld joint due to the presence of brittle phases and defects 76 With the friction welding process, the combination of different welding parameters generates different heat input and thermal cycles in the weld joints The welding bond is formed from a rotational speed of 800 rpm, a transverse speed of 25 mm / with a maximum heat input of 325 degree C and maximum failure load of KN The combination of welding parameters has an important role in the creation of heat input and decide on the thickness of the IMC layer formed in the welding joint All of the fracture surfaces of the tensile test samples has been investigated and it indicates that the fault mechanism is a combination of a brittle fracture and a cleavage fracture 6.2 Suggestion for Future Works Although this study has achieved certain results in examining the microstructure and mechanical properties of welding joints between dissimilar materials However, still some other studies need to be done to better understand this topic Residual stress and distortion factors generated by the welding process itself They have a great impact on the productivity and quality of the product Therefore, studies on the residual stress and deformation generated in the welding bond between these materials should be another are for further research Optimization techniques such as Taguchi, Response Surface, Gray Relation Analysis, and Artificial Neural Networks need to be further investigated in order to better understand the influence of welding parameters on the microstructure and mechanical properties of the welded joints The influence of elements such as types of filler metals, shielding gas, welding torch angle and bevel on the formation and quality of welding joint is another area of interest 77 The microstructural examination and mechanical properties of the welded joint between dissimilar materials produced by hybrid Friction stir 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