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Article(id=1321927737468638041, tenantId=1146029695717560320, journalId=1220038251117760515, issueId=1321927171292123557, articleNumber=null, orderNo=null, doi=10.11868/j.issn.1001-4381.2024.000126, pmid=null, cstr=32421.14.j.issn.1001-4381.2024.000126, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=research-article, receivedDate=1708358400000, receivedDateStr=2024-02-20, revisedDate=null, revisedDateStr=null, acceptedDate=1712505600000, acceptedDateStr=2024-04-08, onlineDate=1793101732841, onlineDateStr=2026-10-27, pubDate=1773936000000, pubDateStr=2026-03-20, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1793101732841, onlineIssueDateStr=2026-10-27, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1793101732841, creator=13701087609, updateTime=1793101732841, updator=13701087609, issue=Issue{id=1321927171292123557, tenantId=1146029695717560320, journalId=1220038251117760515, year='2026', volume='54', issue='3', pageStart='1', pageEnd='272', issueExtLink='null', onlineDate='null', pubDate='1773936000000', pubDateStr='2026-03-20', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1793101597855, creator='13701087609', updateTime=1793101597855, updator='13701087609', preIssue=null, nextIssue=null, articleTotal=null, ext=null, issueFiles=null, downloadFileDto=null}, startPage=144, endPage=160, ext={EN=ArticleExt(id=1321927739133776730, articleId=1321927737468638041, tenantId=1146029695717560320, journalId=1220038251117760515, language=EN, title=Microstructure and mechanical properties of aluminum alloy/steel tungsten inert gas fusion-brazed joints, columnId=1220689384450478826, journalTitle=Journal of Materials Engineering, columnName=RESEARCH ARTICLE, runingTitle=null, highlight=null, articleAbstract=

AA5052 aluminum alloy and 304 stainless steel with the thickness of 3 mm are welded with ZnAl22 flux-cored wire by tungsten inert gas （TIG） fusion-brazed welding. The effect of different welding currents and wire feeding speeds on the macro morphology of butt joints，microstructure of weld seam/steel interface，tensile properties and fracture behavior of the joints is studied. The results show that when the welding current is 110 A and the wire feeding speed is 24 mm/s，the maximum average tensile strength of the butt joints reaches 166 MPa. Fracture primarily occurs at the weld seam/steel interface， exhibiting typical brittle fracture characteristics. The weld seam/steel interface is composed of η-Fe2Al5Zn0.4，η-Zn（Al） and α-Al. With the increase of the welding current，the tensile strength of the joint first increases and then decreases. The white granular δ-FeZn10 appears in the η-Fe2Al5Zn0.4 interfacial layer，and Zn elements are segregated at the η-Fe2Al5Zn0.4/steel interface. The Zn-rich phases at the η-Fe2Al5Zn0.4/steel interface are determined to be Γ-Fe3Zn10 by transmission electron microscopy. It is found that excessively high welding current leads to cracking at the η-Fe2Al5Zn0.4/steel interface. With the increase of wire feeding speeds，the thickness of η-Fe2Al5Zn0.4 decreases gradually，and the phase composition at the weld seam/steel interface remains unchanged. Based on thermodynamic analysis，it is concluded that the formation sequence of intermetallic compounds （IMCs） at the weld seam/steel interface is η-Fe2Al5Zn0.4，δ-FeZn10，Γ-Fe3Zn10.

, authors=Yueting MA, Honggang DONG, Peng LI, authorsList=Yueting MA, Honggang DONG, Peng LI, authorCompany=null, correspAuthors=Honggang DONG, authorNote=null, correspAuthorsNote=null, copyrightStatement=null, copyrightOwner=null, extLink=null, articleAbsUrl=null, sourceXml=null, magXml=null, pdfUrl=null, pdf=null, pdfFileSize=null, pdfExtLink=null, richHtmlUrl=null, mobilePdfUrl=null, reviewReport=null, pdfFirstPage=null, abstractGraph=null, abstractGraphContent=null, abstractVideo=null, citation=null, cebUrl=null, magXmlContent=null, mapNumber=null, fund=null), CN=ArticleExt(id=1321927744519263105, articleId=1321927737468638041, tenantId=1146029695717560320, journalId=1220038251117760515, language=CN, title=铝合金/钢钨极氩弧熔-钎焊接头微观组织及力学性能, columnId=1220689384622445292, journalTitle=材料工程, columnName=研究论文, runingTitle=null, highlight=null, articleAbstract=

采用ZnAl22药芯焊丝对3 mm厚的AA5052铝合金和304不锈钢进行钨极氩弧（tungsten inert gas，TIG）熔-钎焊，研究不同焊接电流和送丝速度对对接接头宏观形貌、焊缝/钢界面微观组织以及接头抗拉性能和断裂行为的影响。结果表明：当焊接电流为110 A，送丝速度为24 mm/s时，对接接头平均抗拉强度达到最大值166 MPa，断裂位置主要为焊缝/钢界面，为典型的脆性断裂。焊缝/钢界面由η-Fe2Al5Zn0.4、η-Zn（Al）和α-Al构成。随着焊接电流的增加，接头抗拉强度先升高后降低。η-Fe2Al5Zn0.4界面层中出现白色颗粒状δ-FeZn10，Zn元素在η-Fe2Al5Zn0.4/钢界面偏聚，利用透射电镜确定η-Fe2Al5Zn0.4/钢界面处富Zn相为Γ-Fe3Zn10，过大的焊接电流导致η-Fe2Al5Zn0.4/钢界面产生开裂。随着送丝速度的增加，η-Fe2Al5Zn0.4厚度逐渐减小，焊缝/钢界面物相组成不发生改变。基于热力学分析得出焊缝/钢界面金属间化合物（intermetallic compounds，IMCs）形成先后顺序为η-Fe2Al5Zn0.4、δ-FeZn10、Γ-Fe3Zn10。

, authors=马月婷, 董红刚, 李鹏, authorsList=马月婷, 董红刚, 李鹏, authorCompany=null, correspAuthors=董红刚, authorNote=null, correspAuthorsNote=
董红刚（1975—），男，教授，博士，主要从事异种材料连接工艺与冶金机理、焊接材料成分设计、焊接热过程数值计算的研究工作，联系地址：辽宁省大连市甘井子区凌工路2号大连理工大学铸造中心304（116024），E-mail：
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articleTitle=铝/钢激光熔-钎焊的界面断裂行为及IMC层调控方法研究, refAbstract=null), Reference(id=1321928199764820390, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, doi=null, pmid=null, pmcid=null, year=2019, volume=null, issue=null, pageStart=null, pageEnd=null, url=null, language=null, rfNumber=[11], rfOrder=13, authorNames=XIA H B, journalName=null, refType=null, unstructuredReference=XIA H B.Research on interfacial fracturing behaviors and adjusted method of IMC layer for the laser welded-brazed Al/steel［D］.Harbin：Harbin Institute of Technology，2019., articleTitle=null, refAbstract=null), Reference(id=1321928199857095079, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, doi=null, pmid=null, pmcid=null, year=1991, volume=15, issue=4, pageStart=317, pageEnd=425, url=null, language=null, rfNumber=[12], rfOrder=14, authorNames=DINSDALE A T, journalName=Calphad, refType=null, unstructuredReference=DINSDALE A T.SGTE data for pure elements［J］.Calphad，1991，15（4）：317-425., articleTitle=SGTE data for pure elements, refAbstract=null), Reference(id=1321928199970341288, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, doi=null, pmid=null, pmcid=null, year=2015, volume=null, issue=null, pageStart=null, pageEnd=null, url=null, language=null, rfNumber=[13], rfOrder=15, authorNames=杨瑾, journalName=null, refType=null, unstructuredReference=杨瑾.铝钢异种材料激光焊接工艺与机理研究［D］.南昌：南昌大学，2015., articleTitle=铝钢异种材料激光焊接工艺与机理研究, refAbstract=null), Reference(id=1321928200075198889, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, doi=null, pmid=null, pmcid=null, year=2015, volume=null, issue=null, pageStart=null, pageEnd=null, url=null, language=null, rfNumber=[13], rfOrder=16, authorNames=YANG J, journalName=null, refType=null, unstructuredReference=YANG J.Research on technology and mechanism of laser welding of Al/steel dissimilar materials［D］.Nanchang：Nanchang University，2015., articleTitle=null, refAbstract=null), Reference(id=1321928200205222314, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, doi=null, pmid=null, pmcid=null, year=2023, volume=58, issue=6, pageStart=2647, pageEnd=2659, url=null, language=null, rfNumber=[14], rfOrder=17, authorNames=ZHANG S S, SONG R B, CAI C H, journalName=Journal of Materials Science, refType=null, unstructuredReference=ZHANG S S， SONG R B， CAI C H，et al.Diffusion and reaction mechanism in initial stage of Zn-Al-Mg hot-dip coating：molecular dynamics simulation［J］.Journal of Materials Science，2023，58（6）：2647-2659., articleTitle=Diffusion and reaction mechanism in initial stage of Zn-Al-Mg hot-dip coating：molecular dynamics simulation, refAbstract=null), Reference(id=1321928200297497003, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, doi=null, pmid=null, pmcid=null, year=1997, volume=32, issue=21, pageStart=5593, pageEnd=5602, url=null, language=null, rfNumber=[15], rfOrder=18, authorNames=JORDAN C E, MARDER A R, journalName=Journal of Materials Science, refType=null, unstructuredReference=JORDAN C E， MARDER A R.Fe-Zn phase formation in interstitial-free steels hot-dip galvanized at 450 ℃：part Ⅰ 0.00 wt% Al-Zn baths［J］.Journal of Materials Science，1997，32（21）：5593-5602., articleTitle=Fe-Zn phase formation in interstitial-free steels hot-dip galvanized at 450 ℃：part Ⅰ 0.00 wt% Al-Zn baths, refAbstract=null), Reference(id=1321928200393965996, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, doi=null, pmid=null, pmcid=null, year=2022, volume=218, issue=null, pageStart=114832, pageEnd=null, url=null, language=null, rfNumber=[16], rfOrder=19, authorNames=DONG W F, PAN H, LEI M, journalName=Scripta Materialia, refType=null, unstructuredReference=DONG W F， PAN H， LEI M，et al.Zn penetration and its coupled interaction with the grain boundary during the resistance spot welding of the QP980 steel［J］.Scripta Materialia，2022，218：114832., articleTitle=Zn penetration and its coupled interaction with the grain boundary during the resistance spot welding of the QP980 steel, refAbstract=null)], funds=[Fund(id=1321928198661718424, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, awardId=52275314, language=CN, fundingSource=国家自然科学基金面上项目(52275314), fundOrder=null, country=null)], companyList=[AuthorCompany(id=1321928189350363464, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, xref=null, ext=[AuthorCompanyExt(id=1321928189358752073, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, companyId=1321928189350363464, language=EN, country=null, province=null, city=null, postcode=null, companyName=null, departmentName=null, remark=School of Materials Science and Engineering，Dalian University of Technology，Dalian 116024，Liaoning，China), AuthorCompanyExt(id=1321928189371334986, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, companyId=1321928189350363464, language=CN, country=null, province=null, city=null, postcode=null, companyName=null, departmentName=null, remark=大连理工大学 材料科学与工程学院，辽宁 大连 116024)])], figs=[ArticleFig(id=1321928191338463587, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, language=EN, label=Fig.1, caption=Schematic diagram of TIG fusion-brazed welding, figureFileSmall=UuVInNLaxyLP8DcKdbJqmw==, figureFileBig=ik3tSxb+U/Yg4gtyBEl2LA==, tableContent=null), ArticleFig(id=1321928191401378148, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, language=CN, label=图1, caption=TIG熔-钎焊示意图, figureFileSmall=UuVInNLaxyLP8DcKdbJqmw==, figureFileBig=ik3tSxb+U/Yg4gtyBEl2LA==, tableContent=null), ArticleFig(id=1321928191493652837, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, language=EN, label=Fig.2, caption=Dimension of tensile specimen, figureFileSmall=iECHK+Te5N1B1bjzRJohZA==, figureFileBig=k8ruvs+ouOHhI1D+/Clrfw==, tableContent=null), ArticleFig(id=1321928191577538918, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, language=CN, label=图2, caption=拉伸试样尺寸, figureFileSmall=iECHK+Te5N1B1bjzRJohZA==, figureFileBig=k8ruvs+ouOHhI1D+/Clrfw==, tableContent=null), ArticleFig(id=1321928191711756647, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, language=EN, label=Fig.3, caption=Morphologies of the front side（1）， back side（2）， and cross-section（3） of the weld seam formed at a wire feed speed of 20 mm/s under different welding currents, figureFileSmall=POFa0B4QXLyj908I0fsYdg==, figureFileBig=AQ07fFfZAjDmBR9a283gjg==, tableContent=null), ArticleFig(id=1321928191804031336, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, language=CN, label=图3, caption=送丝速度为20 mm/s时不同焊接电流下焊缝成形正面（1）、背面（2）与横截面（3）形貌（a）I=90 A；（b）I=110 A；（c）I=130 A；（d）I=150 A

（a）I=90 A；（b）I=110 A；（c）I=130 A；（d）I=150 A

, figureFileSmall=POFa0B4QXLyj908I0fsYdg==, figureFileBig=AQ07fFfZAjDmBR9a283gjg==, tableContent=null), ArticleFig(id=1321928191866945897, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, language=EN, label=Fig.4, caption=Morphologies of the front side（1）， back side（2）， and cross-section（3） of the weld seam formed at a welding current of 110 A under different wire feed speeds, figureFileSmall=hqtAcaYQEz6LeLA5eHa5GA==, figureFileBig=Nb18tUj8tQQX+xpDmUhXkg==, tableContent=null), ArticleFig(id=1321928191942443370, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, language=CN, label=图4, caption=焊接电流为110 A时不同送丝速度下焊缝成形正面（1）、背面（2）与横截面（3）形貌（a）Vf=16 mm/s；（b）Vf=24 mm/s；（c）Vf=28 mm/s

（a）Vf=16 mm/s；（b）Vf=24 mm/s；（c）Vf=28 mm/s

, figureFileSmall=hqtAcaYQEz6LeLA5eHa5GA==, figureFileBig=Nb18tUj8tQQX+xpDmUhXkg==, tableContent=null), ArticleFig(id=1321928191996969323, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, language=EN, label=Fig.5, caption=Microstructures and element line scanning analysis results of weld seam/steel interface at a wire feed speed of 20 mm/s under different welding currents, figureFileSmall=fdTRkLjuv6T3GMq5NG2zlQ==, figureFileBig=vYVg6HnuDKiNcKKMlRoEwg==, tableContent=null), ArticleFig(id=1321928192072466796, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, language=CN, label=图5, caption=送丝速度为20 mm/s时不同焊接电流下焊缝/钢界面组织及元素线扫描分析结果

（a）I=90 A；（b）I=110 A；（c）I=130 A；（d）I=150 A

（a）I=90 A；（b）I=110 A；（c）I=130 A；（d）I=150 A

, figureFileSmall=fdTRkLjuv6T3GMq5NG2zlQ==, figureFileBig=vYVg6HnuDKiNcKKMlRoEwg==, tableContent=null), ArticleFig(id=1321928193754382702, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, language=EN, label=Fig.6, caption=Microstructures and element line scanning analysis results of weld seam/steel interface at a welding current of 110 A under different wire feed speeds, figureFileSmall=Zw1idLukIx6DffWNvLqsXQ==, figureFileBig=XuDvFbypR9hcEd5C7NBViw==, tableContent=null), ArticleFig(id=1321928193850851695, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, language=CN, label=图6, caption=焊接电流为110 A时不同送丝速度下焊缝/钢界面组织及元素线扫描分析结果

（a）Vf=16 mm/s；（b）Vf=24 mm/s；（c）Vf=28 mm/s

（a）Vf=16 mm/s；（b）Vf=24 mm/s；（c）Vf=28 mm/s

, figureFileSmall=Zw1idLukIx6DffWNvLqsXQ==, figureFileBig=XuDvFbypR9hcEd5C7NBViw==, tableContent=null), ArticleFig(id=1321928193926349168, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, language=EN, label=Fig.7, caption=TEM-EDS element mapping analysis of typical weld seam/steel interface, figureFileSmall=4TCBjA6YIfwH+gSl3xERSg==, figureFileBig=oZLgUV/K3PhkPv6eqRyjVQ==, tableContent=null), ArticleFig(id=1321928193997652337, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, language=CN, label=图7, caption=典型焊缝/钢界面TEM-EDS元素面扫描分析, figureFileSmall=4TCBjA6YIfwH+gSl3xERSg==, figureFileBig=oZLgUV/K3PhkPv6eqRyjVQ==, tableContent=null), ArticleFig(id=1321928194081538418, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, language=EN, label=Fig.8, caption=TEM analysis results of various phases at the weld seam/steel interface

（a）TEM bright-field image and SAED patterns；（b）HRTEM image and FFT patterns marked in Fig.（a）

, figureFileSmall=/uRP1S+HWtsRI4rDS9wDzg==, figureFileBig=GcFsACH5Y5FmWIsfHYx3mg==, tableContent=null), ArticleFig(id=1321928194140258675, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, language=CN, label=图8, caption=焊缝/钢界面各物相TEM分析结果

（a）TEM亮场像及其SAED图案；（b）图（a）中标记的HRTEM成像和FFT图案

, figureFileSmall=/uRP1S+HWtsRI4rDS9wDzg==, figureFileBig=GcFsACH5Y5FmWIsfHYx3mg==, tableContent=null), ArticleFig(id=1321928194211561844, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, language=EN, label=Fig.9, caption=Tensile properties of welded joints at a wire feed speed of 20 mm/s under different welding currents

（a）force-displacement curves；（b）tensile strength

, figureFileSmall=xLSf6NPXUtJYnFeWxw1Emg==, figureFileBig=Q2GYWagdVEFWdx1ldHpQxg==, tableContent=null), ArticleFig(id=1321928194291253621, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, language=CN, label=图9, caption=送丝速度为20 mm/s时不同焊接电流下接头拉伸性能

（a）力-位移曲线；（b）抗拉强度

, figureFileSmall=xLSf6NPXUtJYnFeWxw1Emg==, figureFileBig=Q2GYWagdVEFWdx1ldHpQxg==, tableContent=null), ArticleFig(id=1321928194362556790, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, language=EN, label=Fig.10, caption=Fracture paths of welded joints at a wire feed speed of 20 mm/s under different welding currents, figureFileSmall=KBkvqYdWs7Panm3OrEoWxg==, figureFileBig=3frh/+LibCiYZ/GifLHwQg==, tableContent=null), ArticleFig(id=1321928194446442871, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, language=CN, label=图10, caption=送丝速度为20 mm/s时不同焊接电流下接头断裂路径

（a）I=90 A；（b）I=110 A；（c）I=130 A；（d）I=150 A

（a）I=90 A；（b）I=110 A；（c）I=130 A；（d）I=150 A

, figureFileSmall=KBkvqYdWs7Panm3OrEoWxg==, figureFileBig=3frh/+LibCiYZ/GifLHwQg==, tableContent=null), ArticleFig(id=1321928194505163128, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, language=EN, label=Fig.11, caption=Surface morphologies of the steel side fracture of welded joints at a wire feed speed of 20 mm/s under different welding currents, figureFileSmall=5gMOxBg64X9wbvIxuVVJHQ==, figureFileBig=/6h1qo3ASRXXVLF7MAe/ZQ==, tableContent=null), ArticleFig(id=1321928194568077689, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, language=CN, label=图11, caption=送丝速度为20 mm/s时不同焊接电流下接头钢侧断口表面形貌

（a）I=90 A；（b）I=110 A；（c）I=130 A；（d）I=150 A

（a）I=90 A；（b）I=110 A；（c）I=130 A；（d）I=150 A

, figureFileSmall=5gMOxBg64X9wbvIxuVVJHQ==, figureFileBig=/6h1qo3ASRXXVLF7MAe/ZQ==, tableContent=null), ArticleFig(id=1321928194660352378, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, language=EN, label=Fig.12, caption=Tensile properties of welded joints at a welding current of 110 A under different wire feed speeds

（a）force-displacement curves；（b）tensile strength

, figureFileSmall=5vOcaRg1pNju2j4ZO1DoNQ==, figureFileBig=QGIiqOUAzDu2vtmHOqa82g==, tableContent=null), ArticleFig(id=1321928194727461243, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, language=CN, label=图12, caption=焊接电流为110 A时不同送丝速度下接头拉伸性能

（a）力-位移曲线；（b）抗拉强度

, figureFileSmall=5vOcaRg1pNju2j4ZO1DoNQ==, figureFileBig=QGIiqOUAzDu2vtmHOqa82g==, tableContent=null), ArticleFig(id=1321928194794570108, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, language=EN, label=Fig.13, caption=Fracture paths of welded joints at a welding current of 110 A under different wire feed speeds, figureFileSmall=URTBRJcJ8TgxGRbVNH54vA==, figureFileBig=ehpY9BDvtj+JQLV4vrjTRg==, tableContent=null), ArticleFig(id=1321928194870067581, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, language=CN, label=图13, caption=焊接电流为110 A时不同送丝速度下接头断裂路径

（a）Vf=16 mm/s；（b）Vf=24 mm/s；（c）Vf=28 mm/s

（a）Vf=16 mm/s；（b）Vf=24 mm/s；（c）Vf=28 mm/s

, figureFileSmall=URTBRJcJ8TgxGRbVNH54vA==, figureFileBig=ehpY9BDvtj+JQLV4vrjTRg==, tableContent=null), ArticleFig(id=1321928194949759358, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, language=EN, label=Fig.14, caption=Surface morphologies of the steel side fracture of welded joints at a welding current of 110 A under different wire feed speeds, figureFileSmall=F1wPdSgkGxPggPSOceSxxg==, figureFileBig=SrWG4wlsHnTfUtRaQuW2jQ==, tableContent=null), ArticleFig(id=1321928195025256831, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, language=CN, label=图14, caption=焊接电流为110 A时不同送丝速度下接头钢侧断口表面形貌

（a）Vf=16 mm/s；（b）Vf=24 mm/s；（c）Vf=28 mm/s

（a）Vf=16 mm/s；（b）Vf=24 mm/s；（c）Vf=28 mm/s

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Chemical compositions of base materials（mass fraction/%）

, figureFileSmall=null, figureFileBig=null, tableContent=
MaterialCCrNiMnSiMoCuAlMgZnFe
304SS≤0.0119.138.211.090.390.017Bal.
AA50520.18<0.010.04<0.01Bal.2.630.010.16
), ArticleFig(id=1321928195889283467, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, language=CN, label=表1, caption=

母材的化学成分（质量分数/%）

, figureFileSmall=null, figureFileBig=null, tableContent=
MaterialCCrNiMnSiMoCuAlMgZnFe
304SS≤0.0119.138.211.090.390.017Bal.
AA50520.18<0.010.04<0.01Bal.2.630.010.16
), ArticleFig(id=1321928195964780940, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, language=EN, label=Table 2, caption=

Mechanical properties of base materials

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MaterialTensile strength/MPaYield strength/MPaElongation/%Hardness（HV）
304SS57725056204
AA50522231781370
), ArticleFig(id=1321928196031889805, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, language=CN, label=表2, caption=

母材的力学性能

, figureFileSmall=null, figureFileBig=null, tableContent=
MaterialTensile strength/MPaYield strength/MPaElongation/%Hardness（HV）
304SS57725056204
AA50522231781370
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Chemical compositions for ZnAl22 filler wire （mass fraction/%）

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NiFeCuAgAlZn
0.0030.0330.0020.00122Bal.
), ArticleFig(id=1321928196216439183, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, language=CN, label=表3, caption=

ZnAl22焊丝化学成分（质量分数/%）

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NiFeCuAgAlZn
0.0030.0330.0020.00122Bal.
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Process parameters of TIG welding

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Sample number

Welding current

I/A

Wire feed speed

Vf/（mm·s-1）

Welding speed

Vw/（mm·s-1）

190202
2110202
3130202
4150202
5110162
6110242
7110282
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TIG焊工艺参数

, figureFileSmall=null, figureFileBig=null, tableContent=
Sample number

Welding current

I/A

Wire feed speed

Vf/（mm·s-1）

Welding speed

Vw/（mm·s-1）

190202
2110202
3130202
4150202
5110162
6110242
7110282
), ArticleFig(id=1321928196476486034, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, language=EN, label=Table 5, caption=

EPMA quantitative points analysis of weld seam/steel interface at a wire feed speed of 20 mm/s under different welding currents （atomic fraction/%）

, figureFileSmall=null, figureFileBig=null, tableContent=
PositionZnAlFeCrNiPhase
A33.2466.76α-Al
B60.0539.95α-Al+η-Zn（Al）
C97.992.01η-Zn（Al）
D29.0135.7228.584.182.51η-Zn（Al）+η-Fe2Al5Zn0.4
E4.3173.6219.590.372.11η-Fe2Al5Zn0.4
F34.5952.5611.640.181.03Fe-Zn phase+η-Fe2Al5Zn0.4
G2.5975.7819.540.251.84η-Fe2Al5Zn0.4
H2.5276.0619.750.401.27η-Fe2Al5Zn0.4
I56.2430.7411.880.250.89Fe-Zn phase+η-Fe2Al5Zn0.4
), ArticleFig(id=1321928196556177811, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, language=CN, label=表5, caption=

送丝速度为20 mm/s时不同焊接电流下焊缝/钢界面EPMA定量点分析（原子分数/%）

, figureFileSmall=null, figureFileBig=null, tableContent=
PositionZnAlFeCrNiPhase
A33.2466.76α-Al
B60.0539.95α-Al+η-Zn（Al）
C97.992.01η-Zn（Al）
D29.0135.7228.584.182.51η-Zn（Al）+η-Fe2Al5Zn0.4
E4.3173.6219.590.372.11η-Fe2Al5Zn0.4
F34.5952.5611.640.181.03Fe-Zn phase+η-Fe2Al5Zn0.4
G2.5975.7819.540.251.84η-Fe2Al5Zn0.4
H2.5276.0619.750.401.27η-Fe2Al5Zn0.4
I56.2430.7411.880.250.89Fe-Zn phase+η-Fe2Al5Zn0.4
), ArticleFig(id=1321928198233899412, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, language=EN, label=Table 6, caption=

EDS analysis of typical points at the fracture surface at a wire feed speed of 20 mm/s under different welding currents （atomic fraction/%）

, figureFileSmall=null, figureFileBig=null, tableContent=
PositionAlFeZnCrNiPhase
A30.8169.19η-Zn（Al）+α-Al
B23.2747.389.6414.624.39η-Fe2Al5Zn0.4
C40.6159.39η-Zn（Al）+α-Al
D66.0221.632.197.492.67η-Fe2Al5Zn0.4
E36.9663.04η-Zn（Al）+α-Al
F69.5417.424.425.353.27η-Fe2Al5Zn0.4
G4.6631.1351.3011.251.66α-Fe+Fe-Zn
H69.3918.764.456.021.38η-Fe2Al5Zn0.4
), ArticleFig(id=1321928198334562709, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, language=CN, label=表6, caption=

送丝速度为20 mm/s时不同焊接电流下断口表面特征点EDS分析（原子分数/%）

, figureFileSmall=null, figureFileBig=null, tableContent=
PositionAlFeZnCrNiPhase
A30.8169.19η-Zn（Al）+α-Al
B23.2747.389.6414.624.39η-Fe2Al5Zn0.4
C40.6159.39η-Zn（Al）+α-Al
D66.0221.632.197.492.67η-Fe2Al5Zn0.4
E36.9663.04η-Zn（Al）+α-Al
F69.5417.424.425.353.27η-Fe2Al5Zn0.4
G4.6631.1351.3011.251.66α-Fe+Fe-Zn
H69.3918.764.456.021.38η-Fe2Al5Zn0.4
), ArticleFig(id=1321928198401671574, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, language=EN, label=Table 7, caption=

EDS analysis of typical points at the fracture surface at a welding current of 110 A under different wire feed speeds （atomic fraction/%）

, figureFileSmall=null, figureFileBig=null, tableContent=
PositionAlFeZnCrNiPhase
A69.9419.053.125.681.98η-Fe2Al5Zn0.4
B71.7919.084.133.551.45η-Fe2Al5Zn0.4
C21.5814.4557.753.052.13η-Zn（Al）+α-Al
D8.026.3083.470.811.40η-Zn（Al）
E69.0620.916.431.830.77η-Fe2Al5Zn0.4
), ArticleFig(id=1321928198477169047, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321927737468638041, language=CN, label=表7, caption=

焊接电流为110 A时不同送丝速度下断口表面特征点EDS分析（原子分数/%）

, figureFileSmall=null, figureFileBig=null, tableContent=
PositionAlFeZnCrNiPhase
A69.9419.053.125.681.98η-Fe2Al5Zn0.4
B71.7919.084.133.551.45η-Fe2Al5Zn0.4
C21.5814.4557.753.052.13η-Zn（Al）+α-Al
D8.026.3083.470.811.40η-Zn（Al）
E69.0620.916.431.830.77η-Fe2Al5Zn0.4
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铝合金/钢钨极氩弧熔-钎焊接头微观组织及力学性能
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马月婷 , 董红刚 , 李鹏
材料工程 | 研究论文 2026,54(3): 144-160
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材料工程 |研究论文 2026 , 54 (3) : 144 -160
铝合金/钢钨极氩弧熔-钎焊接头微观组织及力学性能
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马月婷, 董红刚 , 李鹏
作者信息
  • 大连理工大学 材料科学与工程学院，辽宁 大连 116024
通讯作者:
董红刚（1975—），男，教授，博士，主要从事异种材料连接工艺与冶金机理、焊接材料成分设计、焊接热过程数值计算的研究工作，联系地址：辽宁省大连市甘井子区凌工路2号大连理工大学铸造中心304（116024），E-mail：
Microstructure and mechanical properties of aluminum alloy/steel tungsten inert gas fusion-brazed joints
Yueting MA, Honggang DONG , Peng LI
Affiliations
  • School of Materials Science and Engineering，Dalian University of Technology，Dalian 116024，Liaoning，China
出版时间: 2026-03-20 doi: 10.11868/j.issn.1001-4381.2024.000126
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摘要
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采用ZnAl22药芯焊丝对3 mm厚的AA5052铝合金和304不锈钢进行钨极氩弧（tungsten inert gas，TIG）熔-钎焊，研究不同焊接电流和送丝速度对对接接头宏观形貌、焊缝/钢界面微观组织以及接头抗拉性能和断裂行为的影响。结果表明：当焊接电流为110 A，送丝速度为24 mm/s时，对接接头平均抗拉强度达到最大值166 MPa，断裂位置主要为焊缝/钢界面，为典型的脆性断裂。焊缝/钢界面由η-Fe2Al5Zn0.4、η-Zn（Al）和α-Al构成。随着焊接电流的增加，接头抗拉强度先升高后降低。η-Fe2Al5Zn0.4界面层中出现白色颗粒状δ-FeZn10，Zn元素在η-Fe2Al5Zn0.4/钢界面偏聚，利用透射电镜确定η-Fe2Al5Zn0.4/钢界面处富Zn相为Γ-Fe3Zn10，过大的焊接电流导致η-Fe2Al5Zn0.4/钢界面产生开裂。随着送丝速度的增加，η-Fe2Al5Zn0.4厚度逐渐减小，焊缝/钢界面物相组成不发生改变。基于热力学分析得出焊缝/钢界面金属间化合物（intermetallic compounds，IMCs）形成先后顺序为η-Fe2Al5Zn0.4、δ-FeZn10、Γ-Fe3Zn10。

铝合金/钢异种金属  /  钨极氩弧熔-钎焊  /  金属间化合物  /  抗拉强度

AA5052 aluminum alloy and 304 stainless steel with the thickness of 3 mm are welded with ZnAl22 flux-cored wire by tungsten inert gas （TIG） fusion-brazed welding. The effect of different welding currents and wire feeding speeds on the macro morphology of butt joints，microstructure of weld seam/steel interface，tensile properties and fracture behavior of the joints is studied. The results show that when the welding current is 110 A and the wire feeding speed is 24 mm/s，the maximum average tensile strength of the butt joints reaches 166 MPa. Fracture primarily occurs at the weld seam/steel interface， exhibiting typical brittle fracture characteristics. The weld seam/steel interface is composed of η-Fe2Al5Zn0.4，η-Zn（Al） and α-Al. With the increase of the welding current，the tensile strength of the joint first increases and then decreases. The white granular δ-FeZn10 appears in the η-Fe2Al5Zn0.4 interfacial layer，and Zn elements are segregated at the η-Fe2Al5Zn0.4/steel interface. The Zn-rich phases at the η-Fe2Al5Zn0.4/steel interface are determined to be Γ-Fe3Zn10 by transmission electron microscopy. It is found that excessively high welding current leads to cracking at the η-Fe2Al5Zn0.4/steel interface. With the increase of wire feeding speeds，the thickness of η-Fe2Al5Zn0.4 decreases gradually，and the phase composition at the weld seam/steel interface remains unchanged. Based on thermodynamic analysis，it is concluded that the formation sequence of intermetallic compounds （IMCs） at the weld seam/steel interface is η-Fe2Al5Zn0.4，δ-FeZn10，Γ-Fe3Zn10.

aluminum alloy/steel dissimilar metal  /  TIG fusion-brazed welding  /  intermetallic compounds  /  tensile strength
马月婷, 董红刚, 李鹏. 铝合金/钢钨极氩弧熔-钎焊接头微观组织及力学性能. 材料工程, 2026 , 54 (3) : 144 -160 . DOI: 10.11868/j.issn.1001-4381.2024.000126
Yueting MA, Honggang DONG, Peng LI. Microstructure and mechanical properties of aluminum alloy/steel tungsten inert gas fusion-brazed joints[J]. Journal of Materials Engineering, 2026 , 54 (3) : 144 -160 . DOI: 10.11868/j.issn.1001-4381.2024.000126
正文
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轻量化是目前工程发展的重要方向。铝合金具有质量轻、强度高和耐腐蚀性好等优点，常被用于车辆、船舶和航空航天等领域［1］，例如汽车制造过程中，将铝合金作为车身主要材料，同时在碰撞安全区采用热成型钢等制成安全的笼式结构，既减轻了车身质量又满足了强度方面的需求。但是铝合金和钢的热导率和电阻率差别较大，焊接过程中温度场呈非均匀分布；铝合金线膨胀系数约为钢的两倍，焊后接头产生较大的残余应力，导致接头开裂倾向增加。根据Fe-Al二元相图，常温下，Fe不溶于Al，当温度升高至225~600 ℃，Fe在Al中的固溶度仅为0.01%~0.022%（质量分数，下同）；当温度达到649 ℃时，Al与Fe发生反应生成一系列的脆硬金属间化合物（intermetallic compounds，IMCs）（FeAl2、FeAl3和Fe2Al5等），恶化接头力学性能，降低其服役寿命。
焊接铝合金和钢的主要方法有爆炸焊、搅拌摩擦焊、感应钎焊和电弧熔-钎焊等［2-5］。电弧熔-钎焊相比于上述焊接方法，具有操作灵活、工序简单等优点，在焊接复杂结构件时该方法具有较高的可达性。Cao等［6］研究焊丝成分和焊接工艺参数对铝/钢冷金属过渡（cold metal transfer，CMT）熔-钎焊接头力学性能的影响，对结果进行方差统计分析可知，焊丝种类对接头抗拉强度影响最大，其次是送丝速度和焊接速度，优化工艺参数后接头拉剪强度约为8.8 kN。Dong等［7］通过填充ZnAl15药芯焊丝实现5A02-H34铝合金与304不锈钢（stainless steel，SS）的钨极氩弧（tungsten inert gas，TIG）熔-钎焊。当铝合金板厚为2 mm，不锈钢板厚为1 mm时，焊态下搭接接头拉剪强度约为80 MPa。焊接接头经280 ℃保温30 min的热处理后，界面处粗大的富Zn相颗粒溶解，接头强度提升至180 MPa，断裂位置由钢侧IMCs层转移至铝合金侧热影响区。Ye等［8］对3 mm厚的铝合金和钢进行了MIG-TIG双面焊，研究发现MIG-TIG双面焊的铝合金/钢接头背面成形优于金属惰性气体保护（metal inert gas，MIG）单面焊接头，并且双面焊的焊缝组织更加均匀，FeAl3 IMCs层厚度减小，接头抗拉强度可达146 MPa，远高于MIG单面焊的56 MPa。在承受拉伸载荷作用时，铝/钢熔-钎焊接头的失效位置大多为焊缝/钢界面，因此研究焊缝/钢界面各物相对接头断裂行为的作用机制是十分必要的。
本工作采用ZnAl22药芯焊丝以及TIG熔-钎焊的方法焊接3 mm厚的AA5052铝合金和304不锈钢，探究不同焊接电流和送丝速度对接头成形、焊缝/钢界面微观组织以及拉伸性能的影响，揭示适合铝/钢TIG熔-钎焊接头的焊缝/钢界面物相组合，为制备高强度铝/钢异种金属TIG熔-钎焊接头提供理论指导。
1 实验材料与方法
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1.1 实验材料
实验采用3 mm厚的304SS和AA5052铝合金作为母材，母材的化学成分及力学性能分别如表1和表2所示，304SS主要由奥氏体构成，AA5052铝合金处于轧制状态。填充焊丝采用直径为2 mm的ZnAl22药芯焊丝，焊丝成分见表3，药芯成分为65%KAlF4与35%K3AlF6。
1.2 实验方法
实验采用钨极氩弧焊方法完成304SS和AA5052的对接熔-钎焊，保护气体为99.9%的氩气，保护气体流量为15 L/min，焊接电源为YC-500WX4N型TIG焊机，最大额定电流为500 A，实验具体的焊接工艺参数如表4所示。焊接前，将100 mm×80 mm×3 mm的304SS和AA5052板材通过电火花线切割和铣床加工成如图1所示的V型坡口，钢侧坡口角度为40°，铝合金侧坡口角度为30°，焊接间隙1.5 mm。焊接试板坡口边缘的高熔点氧化物容易导致焊缝产生夹杂缺陷，在焊接前采用角磨机和400#水砂纸对坡口两侧20 mm范围进行打磨，随后用无水乙醇清洗表面油污和残余砂粒。
焊后通过电火花线切割切取垂直于焊缝的试样，用800#~2000#的SiC砂纸对试样进行逐级打磨，最后用1.5 μm金刚石抛光膏进行抛光处理。采用JXA-8350F Plus型电子探针（electron probe micro-analyzer，EPMA）对接头焊缝/钢界面微观组织进行观察分析。采用EOL JEM-2100F型高分辨扫描透射电子显微镜（scanning transmission electron microscopy，STEM）对界面各物相的晶格结构和元素分布等进行表征。为了更精确地获取特定区域实验样品，采用Helios G4 UX型聚焦离子束（focused ion beam，FIB）在高倍电镜视场下制备透射电镜试样。
拉伸实验根据 GB/T 228.1—2010以及GB/T 2651—2008对铝/钢对接接头进行拉伸实验，焊接接头未去除余高的试样尺寸如图2所示。拉伸实验在DNS-100电子伺服万能试验机上进行，拉伸速率为0.5 mm/min，为保证拉伸测试数据的准确性和可靠性，每组试样均进行3次重复实验。拉伸实验完成后，采用Zeiss SUPRA55型场发射扫描电镜（scanning electron microscopy，SEM）对断口表面形貌进行观察。
2 结果与分析
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2.1 接头成形及宏观形貌
不同焊接电流下焊缝成形及横截面形貌如图3所示。焊接过程中焊丝填充方式是将焊丝置于坡口底部，紧贴成形槽，液态钎料优先填充坡口根部完成背面成形，再由下向上沿着坡口表面润湿铺展实现正面成形。当I=90 A时，焊缝正面成形不良有明显的咬边，焊缝背面成形连续且饱满。接头横截面见图3（a-3），钎料在钢母材上表面未实现润湿铺展。当I=110 A时，焊缝正面和背面成形均匀且连续。图3（b-3）表明相较于I=90 A时，钎料在钢母材上表面的润湿能力明显增强，接头余高下降，焊缝无宏观气孔、宏观裂纹和未熔透缺陷。进一步增加焊接电流至130 A时，焊缝正面和背面成形良好。接头余高与I=110 A时接近，在钢母材坡口根部出现宏观气孔，如图3（c-3）所示。当I=150 A时，焊缝正面宽度明显增加，如图3（d-3）所示，铝合金熔化量显著增加，钎料在钢母材上表面的润湿距离增大，接头余高进一步降低，在铝合金和钢母材坡口根部均存在宏观气孔。接头中气孔的形成是在焊接过程中，焊接热输入过大导致液态熔池停留的时间过长，在熔池冷却凝固过程中H、O未能逸出所致。
对不同送丝速度对接接头成形及横截面形貌进行分析见图4，当Vf=16 mm/s时，焊缝正面和背面成形连续且均匀，接头横截面如图4（a-3）所示，相较于Vf=20 mm/s时，分散至铝合金和钢母材的电弧热增加，铝合金母材大量熔化。送丝速度过小，填充金属量不足导致接头余高下降。随着送丝速度增加至24 mm/s，焊缝正面和背面仍保持良好的成形。图4（b-3）表明，焊接过程中铝合金母材仅上表面发生熔化，增加送丝速度，增大了填充金属量，液态钎料填满背面成形槽后沿着钢侧坡口根部向上润湿铺展，钎料在钢母材上表面的润湿距离增加。当Vf=28 mm/s时，焊缝正面存在焊丝未熔化造成的夹杂，焊缝背面有明显的未熔合缺陷。此时，电弧热主要用于熔化焊丝，送丝速度过大，液态钎料的峰值温度降低，冷却凝固时间减少，液态钎料尚未到达坡口根部即发生凝固，大量填充金属堆积在坡口上部，接头余高增加，钎料在钢母材上表面润湿距离增大，如图4（c-3）所示。
2.2 焊缝/钢界面微观组织演变
采用EPMA对不同焊接电流下铝/钢对接接头焊缝/钢界面的微观组织及主要元素分布情况进行分析如图5所示。同时，特征相的定量点分析结果列于表5。当I=90 A时，焊缝/钢界面主要由靠近钢侧深灰色的η-Fe2Al5Zn0.4（层Ⅰ）、白色的η-Zn（Al）和浅灰色的α-Al和η-Zn（Al）混合物（层Ⅱ）、波浪状浅灰色α-Al和η-Zn（Al）混合物（层Ⅲ）构成。浅灰色混合物中的η-Zn（Al）是从过饱和α-Al中脱溶沉淀形成的。根据图5（a）中Al元素的变化趋势可知，在焊接过程中Al元素不仅由焊缝向钢界面迁移，并且在焊缝/钢界面处发生偏聚。当I=110 A时，层Ⅰ和层Ⅱ的厚度明显增加，细小的白色颗粒相分布于η-Fe2Al5Zn0.4，并且靠近焊缝侧的η-Fe2Al5Zn0.4呈现锯齿状，不同于I=90 A时，层Ⅱ仅由η-Zn（Al）构成，见图5（b）。根据图5（b）的元素线扫描结果可知，随着焊接电流增加，与Al元素类似，Zn元素也出现明显的由焊缝向钢母材的迁移现象。层Ⅰ处Zn元素含量明显低于焊缝，但是距离钢母材越近，Zn元素含量反而升高。如图5（c）所示，焊接电流进一步增加至130 A，层Ⅰ的厚度增加，白色颗粒数量增多、尺寸增大，但层Ⅱ的厚度略有减小。层Ⅰ中存在微裂纹，微裂纹的位置更加靠近钢母材，与图5（c）的元素线扫描结果中Zn元素偏聚的趋势一致。当I=150 A时，层Ⅰ的厚度接近10 μm，此时，仅有少量的η-Zn（Al）形成于锯齿状η-Fe2Al5Zn0.4与焊缝的界面处，白色颗粒相尺寸和数量均明显增长，根据EPMA点分析结果推测其为Fe-Zn相。主裂纹贯穿钢母材和η-Fe2Al5Zn0.4层之间的界面，垂直于主裂纹方向的微裂纹仅存在于靠近钢侧的η-Fe2Al5Zn0.4中，靠近焊缝侧的η-Fe2Al5Zn0.4没有观察到微裂纹，如图5（d）所示。图5（d）的元素线扫描结果表明主裂纹靠近钢侧的断面存在Zn元素的偏聚。当I=130 A和I=150 A时，层Ⅰ产生裂纹的原因，一方面与层Ⅰ复杂的物相构成、数量及分布有关，另一方面，焊接电流增加导致焊接热输入增大，相较于I=90 A和I=110 A，层Ⅰ处焊后残余应力超出其承受极限进而发生断裂。
在焊接过程中，电弧热主要用于加热焊丝和母材，送丝速度的增加或减少主要影响液态钎料的峰值温度，进而改变焊缝/钢界面的温度场，决定层Ⅰ和层Ⅱ的厚度与构成。图6为不同送丝速度下焊缝/钢界面的微观组织与元素线扫描结果。当送丝速度减小至16 mm/s时，焊缝/钢界面的峰值温度提升，促进了液态钎料中的Al、Zn与钢母材中的Fe发生反应，形成的η-Fe2Al5Zn0.4相对较厚并且出现微裂纹，同时Fe-Zn相发生长大，但其数量无明显变化，如图6（a）所示。反之，当送丝速度增加至24 mm/s和28 mm/s时，η-Fe2Al5Zn0.4厚度和Fe-Zn相尺寸均减小。当Vf=28 mm/s时，根据EPMA定量点分析结果可知，层Ⅱ的部分区域由η-Zn（Al）、α-Al和η-Zn（Al）混合物共同构成，如图6（c）所示。根据元素线扫描结果可知，当I=110 A，Vf=16、24、26 mm/s时，η-Fe2Al5Zn0.4/钢界面均出现了Zn元素的偏聚现象。对层Ⅱ的厚度及构成进行分析可知，送丝速度相对较小时，液态钎料的峰值温度升高，其冷却凝固过程中液相大多转变为α-Al，并且将大量的Zn排入剩余液相中，最后在η-Fe2Al5Zn0.4与焊缝的界面以及α-Al枝晶间形成η-Zn（Al）。当Vf=20 mm/s时，液态钎料峰值温度下降，液相至α-Al的转变不能充分进行，更多的剩余液相转变为η-Zn（Al），层Ⅱ的厚度增加。当Vf=24 mm/s和Vf=28 mm/s时，液态钎料的峰值温度进一步下降，α-Al的生成量减少，但是，相较于Vf=16 mm/s和Vf=24 mm/s时，不断输入的液态钎料降低了剩余液相中的Zn含量，导致层Ⅱ的厚度减小，并且在送丝速度达到28 mm/s时，层Ⅱ的部分区域形成了α-Al和η-Zn（Al）混合物。
为了确定对接接头焊缝/钢界面的特征物相，对焊接电流为110 A，送丝速度为20 mm/s的典型焊缝/钢界面进行FIB取样以及TEM分析。图7所示为焊缝/钢界面TEM-EDS面扫描元素分布情况，结果表明，界面IMCs层富集Al元素，Fe-Zn相主要分布于钢基体附近和界面IMCs层中。
为确定Fe-Zn相以及IMCs层的类型，对图8中各标记点进行选区电子衍射（selected area electron diffraction，SAED）、高分辨透射（high-resolution transmission electron microscopy，HR-TEM）成像以及快速傅里叶转变（fast Fourier transformation，FFT）。根据SAED以及HR-TEM成像结果可知，靠近焊缝的Fe-Zn相（点SAED1）呈现扁平菱形状为六方结构的δ-FeZn10，晶带轴为［100］，IMCs层（点SAED2）是具有正交结构的η-Fe2Al5Zn0.4，晶带轴为［011］，与η -Fe2Al5Zn0.4接触的富Fe区域（点SAED3）为Zn固溶于Fe后生成的体心立方α-Fe，晶带轴为［100］。此外，在钢基体的晶界上也出现了富Zn颗粒，如图7所示。该富Zn相的HR-TEM和FFT结果如图8（b）所示，对衍射花样进行标定确定其为晶带轴［100］的Γ-Fe3Zn10。Tan等［9］在研究不同Al含量的Zn-Al焊丝对铝/钢熔-钎焊接头抗拉性能的影响时，发现焊缝/钢界面是由η-Fe2Al5Zn0.4以及分布其中的δ-FeZn10构成。Adachi等［10］在探究镀锌钢镀层过程中钢表面物相生长机制时，指出在含Al镀锌液中η-Fe2Al5Zn0.4与钢基体之间形成了Γ-Fe3Zn10。
2.3 拉伸性能及断口分析
不同焊接电流下铝/钢对接接头的抗拉强度结果如图9所示，随着焊接电流的增加，接头拉伸承载能力总体上呈现先增加后下降的趋势。小电流90 A时，由于液态钎料润湿铺展性能差，接头正面出现咬边缺陷，平均抗拉强度较低为131 MPa。当焊接电流为110 A和130 A时，接头横截面形貌相似，焊缝表面均无明显成形缺陷，平均抗拉强度分别为161 MPa和153 MPa。当焊接电流增加至130 A时，接头抗拉强度略有下降，这主要是因为在焊缝/钢界面处η-Fe2Al5Zn0.4中存在微裂纹，承受拉伸载荷作用时微裂纹易扩展为宏观裂纹，造成接头断裂。大电流150 A时，焊缝表面可观察到大量气孔，焊缝/钢界面处有明显的宏观裂纹，接头抗拉强度仅为73 MPa。由图9（a）分析可知，焊接电流由90 A增加至150 A，接头的断裂位移与抗拉强度变化趋势一致，表现为先上升后下降。此外，焊接电流为110 A和130 A时，力-位移曲线出现锯齿状波动，表明铝/钢对接接头在塑性变形过程中发生动态应变时效，加工硬化速率增大，从而导致接头极限强度有所提升。这主要是由于接头中铝合金的溶质原子向位错扩散，捕捉位错并阻碍位错滑移，而位错克服阻碍继续运动并重复经历被溶质原子的捕捉和释放过程所致。
采用EPMA的背散射电子成像对接头焊缝/钢界面断裂路径进行分析，如图10所示。当焊接电流为90 A时，η-Fe2Al5Zn0.4层厚度较小，裂纹贯穿η-Fe2Al5Zn0.4。焊接电流为110 A时，焊缝/钢界面主要在η-Fe2Al5Zn0.4内部断裂，部分区域沿着η-Fe2Al5Zn0.4/钢界面处断裂。从图10（c）中可以看出，主裂纹存在向焊缝挠曲的趋势，并且靠近焊缝的锯齿状η-Fe2Al5Zn0.4中萌生出二次裂纹。当焊接电流增加至130 A时，主裂纹出现在靠近钢母材η-Fe2Al5Zn0.4中，并且仍有向焊缝延伸的趋势，但被白色颗粒状的δ-FeZn10阻碍，部分区域主裂纹沿着η-Fe2Al5Zn0.4/钢界面扩展，大量的二次裂纹分布于靠近焊缝的η-Fe2Al5Zn0.4中，见图10（c）。夏鸿博［11］认为主裂纹向焊缝的挠曲行为有效增加了焊缝/钢界面对拉伸载荷的抗力，有利于抗拉强度和塑性变形能力的提升。当焊接电流进一步增加至150 A时，断裂位置为η-Fe2Al5Zn0.4/钢界面红色十字标记处成分为67.3%Zn+16.6%Fe+5.0%Cr+11.1%Ni（原子分数），表明Zn元素已扩散进入钢基体。
对不同焊接电流下铝/钢对接接头断口表面形貌进行扫描电镜观察，如图11所示。小电流90 A时，断口形貌主要表现为大面积的光滑解理平面，根据EDS点分析结果（表6）可知，该断面主要由η-Fe2Al5Zn0.4组成（点B）。局部区域存在颗粒状η-Zn（Al）和α-Al混合物（点A）。这说明断裂发生在η-Fe2Al5Zn0.4中，但是仍有小部分区域主裂纹向η-Zn（Al）和α-Al混合物的混合层扩展。当焊接电流为110 A时，断口表面相对粗糙，为层状分布的解理平面，部分解理面上分布有颗粒状η-Zn（Al）和α-Al混合物，如图11（b）所示。这表明断裂过程中主裂纹贯穿η-Fe2Al5Zn0.4并存在向焊缝的挠曲现象。当焊接电流增加至130 A时，断口表面的解理平面仍呈现层状分布，但是颗粒状η-Zn（Al）和α-Al混合物的断面占比减小，以光滑的河流状解理平面为主，见图11（c）。这说明断裂过程中主裂纹仍然贯穿η-Fe2Al5Zn0.4，但向焊缝挠曲的区域减少，与断裂路径观察到的结果保持一致。大电流150 A时，断口形貌平整，对其进行EDS点分析可知，光滑断裂面存在大量的Fe、Zn元素，主要由Γ-Fe3Zn10和α-Fe构成（点G），部分区域分布有η-Fe2Al5Zn0.4。这说明焊接热输入过大时，Zn元素导致钢基体晶界弱化，断裂发生在η-Fe2Al5Zn0.4与钢之间，主裂纹扩展过程中未出现向焊缝的挠曲。
图12（a）和图12（b）分别为不同送丝速度下铝/钢对接接头的典型力-位移曲线和平均抗拉强度。随着送丝速度的增加，接头抗拉强度呈现先上升后下降的趋势。当送丝速度为16 mm/s时，尽管接头无明显宏观缺陷，但是焊缝/钢界面处存在微裂纹，焊缝余高较小，接头有效承载面积减少，平均抗拉强度仅为107 MPa。送丝速度增加至24 mm/s时，接头平均抗拉强度可达166 MPa，这表明该焊接参数下接头形貌和焊缝/钢界面结构的组合具有相对优异的抗拉强度。送丝速度进一步增加至28 mm/s，较大的焊缝余高增加了接头有效承载面积，但是焊缝正面存在未熔化焊丝形成的夹杂，接头背面有明显的未熔合缺陷，焊接质量较差，导致其平均抗拉强度降低至158 MPa。如图12（a）所示，类似的，在拉伸载荷作用下，送丝速度为24 mm/s和28 mm/s时，力-位移曲线均出现了锯齿状波动，接头发生动态应变时效。
为进一步分析焊缝/钢界面结构对接头断裂行为的影响，对不同送丝速度下焊缝/钢界面的断裂路径进行了EPMA背散射电子成像，如图13所示。当送丝速度为16 mm/s时，断裂主要发生在η-Fe2Al5Zn0.4/钢界面处，部分区域经过钢母材附近的η-Fe2Al5Zn0.4内部，这与焊后焊缝/钢界面处微裂纹的产生位置保持一致。图13（a）为经过η-Fe2Al5Zn0.4内部的断裂路径背散射成像，可观察到该区域二次裂纹主要出现于η-Fe2Al5Zn0.4/钢界面以及部分钢母材中，少量二次裂纹分布于主裂纹附近的η-Fe2Al5Zn0.4。如图13（b）所示，当送丝速度增加至24 mm/s时，主裂纹贯穿η-Fe2Al5Zn0.4内部并且部分区域经过η-Fe2Al5Zn0.4/钢界面。相较于送丝速度为16 mm/s时，断裂位置向焊缝方向略有偏移，部分区域存在向焊缝的挠曲，见图13（b）。当送丝速度为28 mm/s时，焊缝/钢界面在η-Fe2Al5Zn0.4内部断裂，无明显的二次裂纹，见图13（c）。
采用扫描电镜对不同送丝速度下铝/钢对接接头断口表面形貌进行观察，如图14所示。低送丝速度16 mm/s时，断口形貌为光滑的解理平面，对其进行EDS点分析（表7）可知，该断面主要为η-Fe2Al5Zn0.4（点A）。当送丝速度为24 mm/s时，断口表面呈现层状分布的解理平面，其中光滑解理平面主要由η-Fe2Al5Zn0.4构成（点B），部分解理平面上存在颗粒状的η-Zn（Al）和α-Al混合物（点C和点D）。相较于送丝速度20 mm/s时，层状的解理平面被剥离得更加明显，这是因为主裂纹在形成过程中受到更大的阻力，导致二次裂纹的萌生和进一步延伸，说明该焊接参数下焊缝/钢界面的抗拉能力有所提升。高送丝速度28 mm/s时，断口表面相对光滑，仍由层状分布的解理平面构成，其主要为η-Fe2Al5Zn0.4（点E），解理平面无颗粒状η-Zn（Al）和α-Al混合物，此时，主裂纹沿着η-Fe2Al5Zn0.4内部扩展，没有出现裂纹扩展方向的偏转或者二次裂纹的萌生。
图15为焊接电流110 A、送丝速度24 mm/s时接头显微硬度分布图，结果表明，由铝合金到不锈钢，显微硬度逐渐增加，并在焊缝/钢界面达到峰值，随后降低至不锈钢母材的硬度。由于焊缝中α-Al、Zn-Al共晶物以及η-Zn（Al）具有不同的硬度，导致焊缝区域的显微硬度出现波动，并且ZnAl22药芯焊丝制备的铝/钢对接接头并未在焊缝处形成软化区。
2.4 焊缝/钢界面IMCs热力学特性及形成机制
焊缝/钢界面微观组织的分析结果表明，典型的焊缝/钢界面IMCs是由η-Fe2Al5Zn0.4、δ-FeZn10和Γ-Fe3Zn10构成。通过计算焊缝/钢界面IMCs的反应吉布斯自由能ΔG，判断三者的形成顺序，进而揭示界面IMCs的形成机制。当ΔG<0时，表明该物相能够形成，并且随着ΔG的减小，物相形成趋势增加。纯物质标准状态下经典热力学理论描述的ΔG计算公式为：
ΔG0=ΔH2980-TΔS2980
式中：ΔG为物质的自由能；ΔH2980为物相标准状态下的生成焓；ΔS2980为物相标准状态下的过剩熵；T为绝对温度。
其中，标准状态下纯物质的生成焓和熵变值均可从热力学手册中查得。对于以下反应：
xA+yB→zC+wD
其中ΔG可表达为：
ΔG=(zΔGC+wΔGD)-(xΔGA+yΔGB)
式中：ΔGA、ΔGB、ΔGC和ΔGD分别对应物质A、B、C和D；x、y、z和w为物质A、B、C和D的摩尔分数。
参考SGTE DATA数据库［12］，Fe、Al和Zn的ΔG0可描述为：
ΔGFe0=1225.7+124.134T-23.5143Tln(T)-0.00439752T2
ΔGAl0=-11278.378+188.684153T-31.748192Tln(T)
ΔGZn0=-11070.546+172.345644T-31.38Tln(T)
杨瑾［13］认为由于Zn在η-Fe2Al5Zn0.4中的原子分数较小，在计算过程中可将η-Fe2Al5Zn0.4简化为η-Fe2Al5。此时，η-Fe2Al5Zn0.4、FeZn10和Fe3Zn10的吉布斯自由能ΔG0为：
ΔGFe2Al50=-40312.8+177.240T-29.395Tln(T)-0.001256T2
ΔGFeZn100=-13429.363+170.443T-30.924Tln(T)-0.002551T2
ΔGFe3Zn100=-7437.113+165.991T-29.561Tln(T)-0.0010158T2
ΔGFe2Al50、ΔGFeZn100和ΔGFe3Zn100随温度的变化趋势如图16所示。铝/钢TIG熔-钎焊界面温度在900~2000 K之间，在该温度范围内，ΔGFe2Al50、ΔGFeZn100和ΔGFe3Zn100均小于0，表明TIG熔-钎焊过程中三种IMCs均可自发生成，这与接头微观组织观察结果一致。三者的ΔG0由高到低排列为ΔGFe3Zn100>ΔGFeZn100>ΔGFe2Al50，说明在焊缝/钢界面处倾向于形成η-Fe2Al5Zn0.4，再者是δ-FeZn10，最后是Γ-Fe3Zn10。
当焊接电流为90 A时，焊缝/钢界面仅由单一的η-Fe2Al5Zn0.4构成，其反应示意图如图17所示。Zhang等［14］通过分子动力学模拟计算得出在1 ns内Fe、Zn和Al的扩散速率由高到低排列为：Zn>Fe>Al。焊接过程中，在焊缝/钢界面发生Fe、Zn和Al的相互扩散，由于Fe在Al基体中的扩散系数远大于Al在Fe基体中的扩散系数，大量的Fe原子在焊缝/钢界面处富集，直至超过Fe在Al基体和Zn基体中的固溶度时，开始形成IMCs。当焊接温度足够高，高温停留时间充足时，焊缝/钢界面IMCs的形成顺序主要与其对应的ΔG0有关，此时，反应体系中η-Fe2Al5Zn0.4的ΔG0相对较低，η-Fe2Al5Zn0.4优先在界面形成，并且η-Fe2Al5Zn0.4的出现阻碍了Fe、Zn原子的相互扩散，延迟了Fe-Zn IMCs的形成。该参数下焊接热输入较低，高温停留时间较短，焊缝/钢界面处没有充分的时间形成δ-FeZn10和Γ-Fe3Zn10。此时，η-Fe2Al5Zn0.4只能通过结晶反应形成，当界面处Fe原子被完全消耗，η-Fe2Al5Zn0.4的形成即停止，因此，η-Fe2Al5Zn0.4的厚度相对较小。
当焊接电流为110 A或130 A时，焊缝/钢界面峰值温度均超过δ-FeZn10和Γ-Fe3Zn10的形成温度，根据透射电镜分析结果可知，δ-FeZn10主要分布于η-Fe2Al5Zn0.4内部，Γ-Fe3Zn10集中在钢基体的晶界或η-Fe2Al5Zn0.4/钢界面处，其反应示意图见图18。该参数下焊接热输入较大，在焊缝/钢界面处存在更多游离的Fe原子，其与Al原子结合形成较厚的η-Fe2Al5Zn0.4。研究表明，η-Fe2Al5Zn0.4的形成仅延迟了Fe、Zn之间的反应，并没有完全抑制［15］。随着高温停留时间的延长，Zn原子通过η-Fe2Al5Zn0.4的快速扩散路径（如：晶界或表面颗粒与层结构之间的界面）向钢基体扩散，迁移过程中与Fe原子结合形成Fe-Zn相。由于ΔGFeZn100<ΔGFe3Zn100，焊缝/钢界面倾向于形成δ-FeZn10。Jordan等［15］研究发现相较于Fe3Zn10，δ-FeZn10优先在靠近液相的η-Fe2Al5Zn0.4中产生。当Zn原子扩散至钢基体附近时，被大量的游离Fe原子包围形成Γ-Fe3Zn10。在后续的降温过程中，Γ-Fe3Zn10发生包晶反应转变为δ-FeZn10，因此，部分δ-FeZn10在η-Fe2Al5Zn0.4中的分布位置更靠近钢基体。此外，Zn原子倾向于在晶界富集，导致Γ-Fe3Zn10还形成于钢基体的晶界上［16］。
当焊接电流为150 A时，焊缝/钢界面处η-Fe2Al5Zn0.4与钢之间产生裂纹，钢基体中出现富Zn相，其反应示意图如图19所示。焊接热输入过大，大量的Zn原子扩散至钢基体附近，导致钢基体的晶界上存在Zn的富集并且形成更多的Γ-Fe3Zn10。Zn的沉积拓宽了晶界，弱化晶界结合强度，而Γ-Fe3Zn10的硬度远大于Fe，增大了晶界的脆硬性，当受到较大的焊后残余应力时，焊缝/钢界面处钢基体晶界易发生开裂。该参数下，η-Fe2Al5Zn0.4的厚度进一步增加，焊后冷却过程中其生长应力（如：钢基体与η-Fe2Al5Zn0.4的错配引起的外延约束）会导致η-Fe2Al5Zn0.4破裂，此时，相较于Zn原子向晶界的扩散，熔池中液态Zn袭击晶界的速度更快，使得钢基体中产生由Zn和Γ-Fe3Zn10构成的富Zn相。
层Ⅱ的构成与层Ⅰ中η-Fe2Al5Zn0.4的形成量有关。η-Fe2Al5Zn0.4具有较低的ΔG0，因此优先在焊缝/钢界面形成。当焊接电流较小时，η-Fe2Al5Zn0.4的形成量较少，形成过程中消耗较少的Al原子，此时层Ⅱ的Al含量较高，由α-Al和η-Zn（Al）共同构成。当焊接电流较大时，大量的Al原子参与η-Fe2Al5Zn0.4的形成反应，η-Fe2Al5Zn0.4的厚度增加，导致层Ⅱ中Al含量降低，浅灰色的α-Al和η-Zn（Al）混合物的数量减少、尺寸减小，直至层Ⅱ中灰色的α-Al和η-Zn（Al）混合物消失。当焊接电流进一步增加，Zn原子有足够的时间和能量向钢基体扩散，并且界面温度达到Fe-Zn相的形成温度，Zn原子参与Fe-Zn相的形成反应，此时层Ⅱ中不仅Al含量降低，Zn含量也随之减少，层Ⅱ主要由η-Zn（Al）构成，并且层Ⅱ厚度逐渐减小直至转变为块状分布的η-Zn（Al）。
3 结论
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（1）根据钎料在钢侧的润湿铺展行为及拉伸测试结果，确定优化后焊接工艺参数为：焊接电流110 A、送丝速度24 mm/s，接头最大平均抗拉强度166 MPa。
（2）焊缝/钢界面各物相分析表明，随着焊接电流的增加，界面η-Fe2Al5Zn0.4厚度增加，在焊接电流超过130 A时η-Fe2Al5Zn0.4/钢基体界面开裂；增加送丝速度，界面η-Fe2Al5Zn0.4厚度呈现逐渐减小趋势。对接接头的η-Fe2Al5Zn0.4中分布的白色颗粒相为δ-FeZn10，随着焊接电流的增加δ-FeZn10由颗粒状转变为块状，Zn在η-Fe2Al5Zn0.4/钢基体界面处偏聚，靠近η-Fe2Al5Zn0.4的不锈钢晶界上分布有Γ-Fe3Zn10相。
（3）吉布斯自由能分析计算结果表明，界面处η-Fe2Al5Zn0.4最易形成，其次是δ-FeZn10，再者是Γ-Fe3Zn10。焊缝形貌和焊缝/钢界面IMCs共同决定了铝/钢TIG熔-钎焊接头拉伸性能。接头断裂位置均为焊缝/钢界面和部分焊缝余高处，避免Γ-Fe3Zn10在钢基体晶界上的形成，抑制晶界弱化，有利于提高接头力学性能。
基金
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  • 国家自然科学基金面上项目(52275314)
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2026年第54卷第3期
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doi: 10.11868/j.issn.1001-4381.2024.000126
  • 接收时间：2024-02-20
  • 首发时间：2026-10-27
  • 出版时间：2026-03-20
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  • 收稿日期：2024-02-20
  • 录用日期：2024-04-08
基金
国家自然科学基金面上项目(52275314)
作者信息
    大连理工大学 材料科学与工程学院，辽宁 大连 116024

通讯作者:

董红刚（1975—），男，教授，博士，主要从事异种材料连接工艺与冶金机理、焊接材料成分设计、焊接热过程数值计算的研究工作，联系地址：辽宁省大连市甘井子区凌工路2号大连理工大学铸造中心304（116024），E-mail：
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2种不同金属材料的力学参数
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鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
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