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I H C QU C GIA TP.HCM TR NG I H C BÁCH KHOA VÕ MINH LUÂN NGHIÊN C U HÀN K T C U D NG T M PH NG GI A NG VÀ H P KIM NHÔM 6061 B NG PH NG PHÁP HÀN MA SÁT KHU Y Chuyên ngành : K Thu t C Khí Mã s : 8520103 LU N V N TH C S TP H CHÍ MINH, tháng n m 2021 Cơng trình đ Cán b h c hoàn thành t i: Tr ng ng d n khoa h c: TS L u Ph i h c Bách Khoa – HQG-HCM ng Minh Cán b ch m nh n xét 1: TS Nguy n Thanh H i Cán b ch m nh n xét 2: PGS.TS Ph m S n Minh Lu n v n th c s đ c b o v t i Tr ng i h c Bách Khoa, HQG Tp.HCM ngày 20 tháng 08 n m 2021 (Tr c n) Thành ph n h i đ ng đánh giá lu n v n th c s g m: PGS.TS Nguy n H u L c - Ch t ch TS Ph m Quang Trung - Th ký TS Nguy n Thanh H i - Ph n bi n PGS.TS Ph m S n Minh - Ph n bi n TS Nguy n Vinh D - y viên Xác nh n c a Ch t ch H i đ ng đánh giá LV Tr ngành sau lu n v n đ CH T CH H I NG ng Khoa qu n lý chuyên c s a ch a (n u có) TR NG KHOA C KHÍ TR C NG HÒA XÃ H I CH NGH A VI T NAM c l p - T - H nh phúc I H C QU C GIA TP.HCM NG I H C BÁCH KHOA NHI M V LU N V N TH C S H tên h c viên: VÕ MINH LUÂN MSHV: 2070259 Ngày, tháng, n m sinh: 26/08/1993 N i sinh: TP H Chí Minh Chuyên ngành: I TÊN K Thu t C Khí Mã s : 8520103 TÀI: Nghiên c u hàn k t c u d ng t m ph ng gi a đ ng h p kim nhôm 6061 b ng ph ng pháp hàn ma sát khu y II NHI M V VÀ N I DUNG: Nghiên c u lý thuy t hàn ma sát khu y hai v t li u khác nhau, q trình hàn có sinh nhi t nên ph i th c hi n mô ph ng nhi t b ng ph n m m máy tính, ti n hành th c nghi m hàn ma sát khu y hai v t li u khác dùng ph ng pháp phân tích th ng kê đ đ a nh n xét cho th c nghi m III NGÀY GIAO NHI M V : 22/02/2021 IV NGÀY HOÀN THÀNH NHI M V : 13/06/2021 V CÁN B H NG D N: TS L u Ph ng Minh……………………… Tp H Chí Minh, ngày tháng n m 2021 CÁN B H NG D N (H tên ch ký) TR CH NHI M B MÔN ÀO T O (H tên ch ký) NG KHOA C KHÍ (H tên ch ký) LU L IC L u tiên xin c d n th c hi nh cs ng tài lu i gian th c hi n lu ng d n, l i khuyên s c v n t Th y, nh ng ki n th c mà Th y cung c tơi có th tháo g nh ng khu t m t v v tơi có th hồn thành lu k thu t liên quan i h n t tr v ki n th ng tr thi t b d ng c thí nghi m C m y/ Cơ c a b t b công ngh v t li tơi thí nghi m ng th il ic n Th y/ Cô c ng d y môn h c Cao h c, cung c p ki n th Cu i xin g i l i c ng h , chia s n anh, ch th c hi n lu n ng nghi p, b n bè, gia ng viên su t trình h c t p t Bách Khoa TPHCM giúp tơi có nh i u ki n t t nh hoàn thành vi c h c t p nghiên c u t Tôi xin trân tr ng c TP H Chí Minh H c viên Võ Minh Luân HVTH : VÕ MINH LUÂN LU TÓM T T Th m hi n t i có r b o v mô i, nhiên v m t ng, hi u qu ng hàn ma sát khu y (FSW) nhi t công ngh V ch c ti n k thu ng m i hàn c l n im tm b n m i, gi m ng su b n tt cịn có th d dàng hàn k t n i hai lo i v t li u khác Trong nghiên c u s c n vi c th c nghi m mô ph ng hàn hai t m v t li u khác gi a ng nhôm 6061 S d ng ph n m mơ ph ng l i nhi q trình hàn Thơng qua mơ ph ng ta có th d c nhi trình hàn ng thái r n c a kim lo i Trong trình th c nghi m s s d h ki m tra l i q trình mơ ph ng V ph d ng s th kéo, ch p SEM ng m i hàn, m có th theo dõi dịng v t li u l ch th c nghi m Box- cs d nh gi a thông s ng ti ng d ch chuy b n kéo l n nh Các thơng s t ng u ki n thí nghi m 65% so v i kim lo b n kéo T c ch ng m i hàn t t nh t ng n n tài: Hàn ma sát khu y, H p ch t liên kim, Mô ph ng comsol, hàn liên k t hai kim lo i khác HVTH : VÕ MINH LUÂN ng c ), nhi c so v i kim lo i n n nhôm m c thông s a thông s T ng c a thông s hàn (t c LU ABSTRACT Currently, there are many metal welding methods, but in terms of environmental protection and energy efficiency, friction stir welding (FSW) has been a "green technology" for many years, and it is also a great technological advance in this period In terms of weld quality, this method results in a weld with greater strength, increased fatigue strength, reduced residual stress, less defects In addition, this method can also easily weld two connections different types of materials In this study, we will talk about experimenting and simulating the welding of two different materials between copper and aluminum 6061 Using COMSOL software to simulate the temperature in the welding process Through simulation, we can predict the welding process temperature as well as the solid state of the metal During the experiment, a heat meter will be used to check the simulation process As for the evaluation of weld quality, the methods used will be tensile testing, nanoscale SEM to be able to monitor the material flow and intermetallic layer (IMC) The Boxbehnken experimental planning method is used to determine between the impact parameters of the welding parameters (rotational speed, feed rate and tool tip displacement), temperature, and tensile strength From there, the maximum tensile strength achieved compared to the base metal is aluminum at any parameter level The optimal parameters of welding parameters to achieve the best weld quality under test conditions are 65% compared to the base metal Keywords for the topic: Friction stir welding, Intermetallic compound, Comsol simulation, bonding two different metals HVTH : VÕ MINH LUÂN LU L u hàn k t c u d ng t m ph ng hai v t li u khác gi hàn ma sát khu ng h p kim nhôm 6061 b u c a riêng Các s li u tài li u s d ng lu khoa h c T t c nh ng tham kh o k th c công b nghiên c u c trích d H c viên Võ Minh Luân HVTH : VÕ MINH LUÂN LU M CL C M C L C i DANH SÁCH HÌNH V ii DANH SÁCH B NG BI U iii T VI T T T iv TÓM T T NGHIÊN C U 1.1 Gi i thi u 1.2 ng d ng hàn ma sát khu y hai v t li u 1.3 M c tiêu nhi m v c a nghiên c u 1.4 L tài LÝ LU N VÀ GI THUY T KHOA H C b n m i hàn thông s ng 2.2 D ng c hàn ma sát khu y 14 2.3 C u trúc hàn 19 2.4 Dòng v t li u 21 2.5 Các vùng trình hàn 22 2.6 Các h p ch t liên kim 25 2.7 L c trình hàn 29 2.8 Qúa trình sinh nhi t hàn 29 2.9 Khuy t t t hàn 36 U 39 3.1 Ch n b thơng s thí nghi m mơ hình toán 39 HVTH : VÕ MINH LN LU 3.2 Mơ hình thí nghi m 49 t qu 53 3.4 K t qu th o lu n 67 K T LU NG PHÁT TRI 86 4.1 K t lu n 86 4.2 ng phát tri 88 TÀI LI U THAM KH O 89 HVTH : VÕ MINH LUÂN LU DANH SÁCH HÌNH V Hình 1.1 mơ t q trình hàn ma sát khu Hình 1.2 ng d nc cc Hình 1.3 Chi ti t máy k t h p gi Hinh 2.1 T hàn t ng ng nhôm quay khác c a FSW v t li u Al Hình 2.2 B m t m i hàn b m t b c chi c chi Hình 2.3 Hình d ng c Hình 2.4 Mơ t v trí l ch c Hình 2.5 : Mơ t ch u khu ng m i hàn khác d d u khu y hình d ng Hình 2.6 Hình dáng vai d ng c Hình 2.7 H u d ng c Hình 2.8 Hình th c xen k Hình 2.9 H n h .19 ng nh t Hình 2.10 K t c u g n gi ng h n h p Hình 2.12 Gi Hình 2.13 pha Al Cu thơng s Hình 2.14 V u khu y Hình 2.15 a/ Cùng kim lo i b/ Hai kim lo ns n kh HVTH : VÕ MINH LUÂN 20 LU K T LU NG NGHIÊN C 4.1 K t lu n Lu - i quy t v sau: Trình bày nh ng n i dung t ng quan v hai v t li u khác - y (FSW) ng nhôm, nh Trình bày nh c m cơng ngh nghiên c u khoa h c c hàn ma sát khu y c a kim lo i ho c kim lo i khác nhau: + Các y u t c n m i hàn + D ng c hàn + V t li u hàn + L c tác d ng + T ch c m i hàn + Nhi - trình hàn D lý thuy t ti n hành mơ ph ng q trình sinh nhi t lúc hàn S d ng ph n m qu cho th y nhi C, nhi nhi t vùng nhi ti n hành q trình Sau mơ ph ng, k t t u khu y m i hàn có nhi giao ng t xung quanh m i hàn t n ng i x ng qua m ng khu v u ch ng minh nhi i x ng qua tâm m i hàn tính ch t c a nh ng kim lo i n n khác Nhi t i vai d ng c t hàn ph thu c r t l n vào thông s hàn (t ng d ch chuy n ch vòng quay, v n t c hàn, vòng quay thông s ng m i hàn Bên c c a d ng c a t m Nhi t c th c nghi m cho nhi th nhi t g n gi ng v HVTH : VÕ MINH LUÂN 86 ng t i vai th nhi t c a vi c mô ph ng b ng LU ph n m y cho ta th thuy t ba c nh u vào theo lý u xác, nh ng hàm có th mơ ph ng cho q trình hàn ma sát khu y hai v t li u khác - Sau th c nghi m, ta có k t qu kéo c a m u hàn, giá tr th p nh t mà ta m u có giá tr cl n kéo c a nh ng nghiên c khu y gi c hàn ma sát ng nhơm (B y ta có th th nghi u c a lu c vi c th c i phù h p v i tình hình nghiên c u th gi i - ng th i ti n hành phân tích th c nghi m b - Behnken u ki n thí nghi m hồn tồn phù h mô t th c nghi m Các thơng s máy có vi c hình thành m i hàn ch t t ct cho k t qu b n m i hàn m ng h n ng m i hàn Ti n hành phân tích nhân u ki n thí nghi m này, có th c 65% so v i kim lo B thông s t ng n n vòng quay n = 677.77 vòng/ phút, t ng d ch chuy n x = 0.8mm V i vi b n c a kim lo i n n m b n kéo b n kéo kho ng t s r t kinh ng t giá tr r t t t so v i nh ng nghiên c u khác th gi i - Trong q trình hàn ta có th nh n th y m t s khuy t t t m t, thi u v t hàn - có th ch ng m i hàn c n ph i có nh ng th c nghi m b n kéo c a m i hàn, hình ch p t ch c t vi, thí nghi m u n m u trình th c hi n lu vi c ch p hình t ch c t vi thí nghi m u v i vi c thí nghi ch Covid-19 bùng phát nên c th c hi ng m i hàn HVTH : VÕ MINH LUÂN 87 LU Vì lúc làm vi c m i hàn có b phá h y hay khơng m i v n quan tr ng nh t ng phát tri n nh ng h n ch trình th c nghi m ta có th ng ng phát tri - L a ch n l i b thông s m i g n v i vùng t cho k t qu th c nghi m t - Nghiên c u rõ thêm nh ng c a t ng d ch chuy n b n m i hàn - Nghiên c u phát tri n d ng c - Nghiên c b h p ch u su t hàn t t b n m i hàn T m ki c b dày liên kim nh b nm i hàn - Nghiên c u d ng c , b thơng s có th c nh ng t m v t li ng nghiên c u có th áp d lai, nghiên c u sâu ng h n ch v nh ng ki n th c, kinh nghi m, th i gian, d ch b nh kinh phí, nên r c xin ý c a c a Qúy Th y/Cô cho vi c c n b ng nghiên c u c n khai thác thêm nh m giúp v phù h p v i vi c ng d ng th c t HVTH : VÕ MINH LUÂN 88 nghiên c LU TÀI LI U THAM KH O [1] G Kerrar, N Merah, A N Shuaib, F AL-Badour and A Bazoune, Experimental and Numerical Investigations of Friction Stir Welding of Aluminum to Copper, Applied Mechanics, Behavior of Materials, and Engineering Systems,pp 119-138, 2017 [2] A Esmaeili, G M Besharati, R H Zareie, Experimental investigation of material flow and welding defects in friction stir welding of aluminum to brass Materials and Manufacturing Processes, vol 27, no 12, pp 1402-1408, 2012 [3] A Esmaeili, M B Givi and H Z Rajani, A metallurgical and mechanical study on dissimilar Friction Stir welding of aluminum 1050 to brass 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