Article(id=1149779603063005218, tenantId=1146029695717560320, journalId=1146120084050784272, issueId=1149779599254581563, articleNumber=null, orderNo=null, doi=10.19562/j.chinasae.qcgc.2025.02.017, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=null, receivedDate=1719763200000, receivedDateStr=2024-07-01, revisedDate=1724947200000, revisedDateStr=2024-08-30, acceptedDate=null, acceptedDateStr=null, onlineDate=1752058419241, onlineDateStr=2025-07-09, pubDate=1740412800000, pubDateStr=2025-02-25, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1752058419241, onlineIssueDateStr=2025-07-09, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1752058419241, creator=13701087609, updateTime=1752058419241, updator=13701087609, issue=Issue{id=1149779599254581563, tenantId=1146029695717560320, journalId=1146120084050784272, year='2025', volume='47', issue='2', pageStart='201', pageEnd='390', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=0, createTime=1752058418334, creator=13701087609, updateTime=1753780722751, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1157003467609956875, tenantId=1146029695717560320, journalId=1146120084050784272, issueId=1149779599254581563, language=EN, specialIssueTitle=, coverIllustrator=, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1157003467609956876, tenantId=1146029695717560320, journalId=1146120084050784272, issueId=1149779599254581563, language=CN, specialIssueTitle=, coverIllustrator=, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=367, endPage=375, ext={EN=ArticleExt(id=1149779603272720419, articleId=1149779603063005218, tenantId=1146029695717560320, journalId=1146120084050784272, language=EN, title=Study on Resistance Spot Welding Performance of Al-Si Coated Press Hardening Steels with High Toughness, columnId=null, journalTitle=Automotive Engineering, columnName=null, runingTitle=null, highlight=

Al-Si coated press hardening steels (PHS) with coating thicknesses ranging from 8 to 18 µm demonstrate enhanced toughness,drawing significant attention from the industry. However,there is limited evaluation of the resistance spot welding performance of Al-Si coated PHS with reduced coating thickness. This research compares the weldability of PHS with thin Al-Si coatings at strengths of 1 000,1 500,and 2 000 MPa. The results show that the weldability current range and mechanical properties of welds for all three grades of PHS meet industrial production requirements. Further analysis reveals that the mechanical properties of the welds are closely linked to the strength and toughness of the martensite in the nugget. As the matrix strength increases,the strength (hardness) of the martensite in the nugget also rises,while toughness decreases. Consequently,the tensile-shear ultimate load increases with rising weld strength,whereas the cross-tensile ultimate load decreases as weld toughness diminishes.

, articleAbstract=

Al-Si coated press hardening steels (PHS) with coating thicknesses ranging from 8 to 18 µm demonstrate enhanced toughness, drawing significant attention from the industry. However, there is limited evalua-tion of the resistance spot welding performance of Al-Si coated PHS with reduced coating thickness. This research compares the weldability of PHS with thin Al-Si coatings at strengths of 1 000, 1500, and 2 000 MPa. The results show that the weldability current range and mechanical properties of welds for all three grades of PHS meet industri-al production requirements. Further analysis reveals that the mechanical properties of the welds are closely linked to the strength and toughness of the martensite in the nugget. As the matrix strength increases, the strength (hardness) of the martensite in the nugget also rises, while toughness decreases. Consequently, the tensile-shear ultimate load increases with rising weld strength, whereas the cross-tensile ultimate load decreases as weld toughness diminishes.

, correspAuthors=Hongliang Yi, 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, authorCompany=null, fund=null, authors=null, authorsList=Zhengxian Li, Fei Cheng, Yilin Chen, Dapeng Yang, Hongliang Yi), CN=ArticleExt(id=1149779629289988587, articleId=1149779603063005218, tenantId=1146029695717560320, journalId=1146120084050784272, language=CN, title=高韧性铝硅镀层热成形钢电阻点焊性能研究*, columnId=null, journalTitle=汽车工程, columnName=null, runingTitle=null, highlight=

镀层厚度在8~18 μm的铝硅镀层热成形钢具有更高的韧性,已在汽车行业引起广泛关注。然而,对于减薄镀层后的铝硅镀层热成形钢的电阻点焊性能评价却较少。本文对比了强度级别分别为1 000、1 500和2 000 MPa的薄铝硅镀层热成形钢的焊接性能。研究发现,3种材料的可焊性电流范围及焊点的力学性能均能够满足生产需求。进一步分析发现,焊点力学性能和熔核区马氏体的强度和韧性有关。随着3种材料强度提高,熔核区马氏体的强度(硬度)增加,韧性降低,拉剪极限载荷随焊点强度提升而增大,而十字拉伸极限载荷随着焊点韧性降低而减小。

, articleAbstract=

镀层厚度在8~18 µm的铝硅镀层热成形钢具有更高的韧性,已在汽车行业引起广泛关注。然而,对于减薄镀层后的铝硅镀层热成形钢的电阻点焊性能评价却较少。本文对比了强度级别分别为1000、1500和2 000 MPa的薄铝硅镀层热成形钢的焊接性能。研究发现,3种材料的可焊性电流范围及焊点的力学性能均能够满足生产需 求。进一步分析发现,焊点力学性能和熔核区马氏体的强度和韧性有关。随着3种材料强度提高,熔核区马氏体的强度(硬度)增加,韧性降低,拉剪极限载荷随焊点强度提升而增大,而十字拉伸极限载荷随着焊点韧性降低而减小。

, correspAuthors=易红亮, authorNote=null, correspAuthorsNote=
易红亮,教授,博士,E-mail:
, copyrightStatement=null, copyrightOwner=null, extLink=null, articleAbsUrl=null, sourceXml=O/5X4Evx6+AMJBQkGcSS2A==, magXml=jcy+pJ9Pi/MgwJUXpc6zrg==, pdfUrl=null, pdf=TTbezUPq9Zw2IfOctMtipg==, pdfFileSize=null, pdfExtLink=null, richHtmlUrl=null, mobilePdfUrl=null, reviewReport=null, pdfFirstPage=null, abstractGraph=null, abstractGraphContent=null, abstractVideo=null, citation=null, cebUrl=null, magXmlContent=wM2e2hosHuwl3i6NFAnUqg==, mapNumber=null, authorCompany=null, fund=null, authors=

易红亮 教授,博士

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(a)P10镀层;(b)P10基体;(c)P15镀层;(d)P15基体;(e)P20镀层;(f)P20基体

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(a)熔核区;(b)上临界热影响区;(c)焊点接头形貌;(d)临界热影响区;(e)亚临界热影响区

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(a)熔核区;(b)上临界热影响区;(c)焊点接头形貌;(d)临界热影响区;(e)亚临界热影响区

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(a)熔核区;(b)上临界热影响区;(c)焊点接头形貌;(d)临界热影响区;(e)亚临界热影响区

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(a)P10;(b)P15;(c)P20

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(a)P10;(b)P15;(c)P20

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检测后宏观照片

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钢号 成分/%
C Mn Si Ti Cr V B Al Fe
P10 0.06 1.2 0.21 0.03 0.20 0.003 Bal
P15 0.22 1.2 0.22 0.04 0.18 0.003 Bal
P20 0.33 1.1 0.25 0.20 0.15 0.003 0.4 Bal
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试验钢化学成分(质量分数)

, figureFileSmall=null, figureFileBig=null, tableContent=
钢号 成分/%
C Mn Si Ti Cr V B Al Fe
P10 0.06 1.2 0.21 0.03 0.20 0.003 Bal
P15 0.22 1.2 0.22 0.04 0.18 0.003 Bal
P20 0.33 1.1 0.25 0.20 0.15 0.003 0.4 Bal
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钢号 硬度/HV0.3
基材 上临界热影响区

临界热

影响区

亚临界热影响区域 熔核区
P10 372±10 365±8 305±33 389±10 370±11
P15 473±8 459±13 353±33 484±25 471±17
P20 570±6 556±8 425±35 584±17 571±8
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焊接接头各个区域硬度

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钢号 硬度/HV0.3
基材 上临界热影响区

临界热

影响区

亚临界热影响区域 熔核区
P10 372±10 365±8 305±33 389±10 370±11
P15 473±8 459±13 353±33 484±25 471±17
P20 570±6 556±8 425±35 584±17 571±8
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高韧性铝硅镀层热成形钢电阻点焊性能研究*
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李峥先 1 , 程菲 2 , 陈仪霖 2 , 杨达朋 1 , 易红亮 1, 2
汽车工程 | 2025,47(2): 367-375
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汽车工程 | 2025, 47(2): 367-375
高韧性铝硅镀层热成形钢电阻点焊性能研究*
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李峥先1, 程菲2, 陈仪霖2, 杨达朋1, 易红亮1, 2
作者信息
  • 1 东北大学,轧制技术及连轧自动化国家重点实验室,沈阳 110819
  • 2 育材堂(苏州)材料科技有限公司,苏州 215123

通讯作者:

易红亮,教授,博士,E-mail:
Study on Resistance Spot Welding Performance of Al-Si Coated Press Hardening Steels with High Toughness
Zhengxian Li1, Fei Cheng2, Yilin Chen2, Dapeng Yang1, Hongliang Yi1, 2
Affiliations
  • 1 Northeastern University,State Key Laboratory of Rolling and Automation,Shenyang 110819
  • 2 Easyforming Materials Technology Co.,Ltd.,Suzhou 215123
出版时间: 2025-02-25 doi: 10.19562/j.chinasae.qcgc.2025.02.017
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镀层厚度在8~18 µm的铝硅镀层热成形钢具有更高的韧性,已在汽车行业引起广泛关注。然而,对于减薄镀层后的铝硅镀层热成形钢的电阻点焊性能评价却较少。本文对比了强度级别分别为1000、1500和2 000 MPa的薄铝硅镀层热成形钢的焊接性能。研究发现,3种材料的可焊性电流范围及焊点的力学性能均能够满足生产需 求。进一步分析发现,焊点力学性能和熔核区马氏体的强度和韧性有关。随着3种材料强度提高,熔核区马氏体的强度(硬度)增加,韧性降低,拉剪极限载荷随焊点强度提升而增大,而十字拉伸极限载荷随着焊点韧性降低而减小。

Al-Si镀层  /  热成形钢  /  电阻点焊  /  可焊窗口  /  组织和性能

Al-Si coated press hardening steels (PHS) with coating thicknesses ranging from 8 to 18 µm demonstrate enhanced toughness, drawing significant attention from the industry. However, there is limited evalua-tion of the resistance spot welding performance of Al-Si coated PHS with reduced coating thickness. This research compares the weldability of PHS with thin Al-Si coatings at strengths of 1 000, 1500, and 2 000 MPa. The results show that the weldability current range and mechanical properties of welds for all three grades of PHS meet industri-al production requirements. Further analysis reveals that the mechanical properties of the welds are closely linked to the strength and toughness of the martensite in the nugget. As the matrix strength increases, the strength (hardness) of the martensite in the nugget also rises, while toughness decreases. Consequently, the tensile-shear ultimate load increases with rising weld strength, whereas the cross-tensile ultimate load decreases as weld toughness diminishes.

Al-Si coating  /  PHS  /  resistance spot welding  /  welding lobe  /  microstructure and properties
李峥先, 程菲, 陈仪霖, 杨达朋, 易红亮. 高韧性铝硅镀层热成形钢电阻点焊性能研究*. 汽车工程, 2025 , 47 (2) : 367 -375 . DOI: 10.19562/j.chinasae.qcgc.2025.02.017
Zhengxian Li, Fei Cheng, Yilin Chen, Dapeng Yang, Hongliang Yi. Study on Resistance Spot Welding Performance of Al-Si Coated Press Hardening Steels with High Toughness[J]. Automotive Engineering, 2025 , 47 (2) : 367 -375 . DOI: 10.19562/j.chinasae.qcgc.2025.02.017
先进高强钢的大量应用可以在保证安全的前提下实现零件的轻量,是实现车身轻量化并切实推进我国“双碳”战略的重要途径之一[1-2]。目前,抗拉强度达到1 500 MPa及以上的零件只能通过热冲压成形的方式制造。热成形构件除了具备超高强度外,还能解决冷成形钢在成形过程时构件回弹大、尺寸精度差的问题,但热成形钢在加热过程中会出现钢板表面氧化与脱碳问题[3]。为解决这一问题,通常在钢板表面预涂一层金属或合金,主要为Al-Si镀层。Al-Si镀层热成形技术是由安赛乐米塔尔公司发明,并围绕该项技术进行了大量专利布局[4]。研究人员对Al-Si镀层的高温组织演变[5-7]、焊接特性[8-10]及耐腐蚀性[11-12]等相关领域进行了广泛而深入的研究。经过20年多年的发展,该技术显然已经在汽车工业中日益成熟。Al-Si镀层热成形钢在热冲压过程中,Fe与镀层中的Al、Si会发生相互扩散。易红亮等[13-14]提出,在扩散过程中,C倾向于在基体界面富集,形成的高碳马氏体会严重影响Al-Si镀层热成形钢的弯曲韧性。为此,研究者建议将镀层减薄至8~18 μm,以降低镀层与基体界面的C富集,从而提高热成形钢的弯曲韧性[13-14]。该技术不仅提高了热成形钢的韧性,还大幅减少了涂镀过程中Al的用量,在降低碳排放的同时还能节约成本[15]
热成形一体式激光拼焊门环设计可以进一步提升车身安全性并实现轻量化[16]。热成形一体式激光门环的选材具有多样性,所选材料包括强度级别为1 000、1 500及2 000 MPa的钢材,其中相当一部分是铝硅镀层热成形钢。在车身总成中,热成形一体式激光拼焊门环还须与其他零部件通过电阻点焊进行连接,因此材料的电阻点焊可焊性显得尤为重要。常规镀层厚度的热成形钢的电阻点焊可焊性已有较多研究[17-19],但对于薄铝硅镀层技术下的高强度热成形钢,其可焊性研究较少。为此,本文以薄铝硅镀层技术下强度为1 000、1 500及2 000 MPa级的热成形钢为研究对象,对其焊接工艺窗口、焊点力学性能及失效形式进行了详细分析。
本研究使用的材料为国内某钢厂生产的厚度规格为1.4 mm、热冲压后强度分别为1 000、1 500和2 000 MPa级的铝硅镀层热成形钢,分别用P10、P15和P20代指,3种不同强度级别的热成形钢的基体成分见表1
图1显示了3种材料的工程应力应变曲线,可以明显观察到3种热成形钢在力学性能上的差异。具体而言:P10的抗拉强度约1 145 MPa,屈服强度约972 MPa,总延伸率达7.8%;P15的抗拉强度约1 510 MPa,屈服强度约1 221 MPa,总延伸率达7.4%;P20的抗拉强度约1 925 MPa,屈服强度约1 303 MPa,总延伸率达6.6%。
3种热成形钢的表面均具有铝硅镀层。由图2可见,3种材料的镀层厚度在13~15 µm之间,且镀层结构相同,从基材界面向镀层表面依次为相互扩散层(α-Fe层和FeAl层)、Fe2Al5层、FeAl层和Fe2Al5层。图2还显示了3种材料的基体组织均为马氏体(α′)。
电阻点焊的评价标准依据GWS-5A-2007。每种材料分别在170、200及230 ms的焊接时间下获得工艺窗口。试样使用DTBZ-80BT中频直流点焊机(PSI6000控制器)进行焊接。图3示意性展示了焊点进行拉剪试验和十字拉伸试验的试样形式和尺寸。拉剪试样和十字拉伸试样使用专用夹具在UTM5000系列万能拉伸机上以2 mm/min的拉伸速率进行拉伸测试。
焊接后的焊接接头经切割制取金相试样,热镶后进行打磨、抛光。采用体积分数为4%的硝酸酒精溶液进行腐蚀,利用OLYMPUS BX53MRF-S光学显微镜进行焊点形貌及熔核尺寸检测,采用ZEISS GEMINI 300场发射扫描电子显微镜(SEM)进行焊接接头组织分析。此外,使用FALCON 501FAP自动维氏硬度计在300 g力下对焊接接头进行硬度测试。
焊接过程中,电极压力设定为4 kN,焊接电流从5 kA起始,以0.2 kA间隔递增,分别在170、200和230 ms的焊接时间下,获得每种材料的二维焊接工艺窗口,如图4所示。从图中可以看出,二维焊接工艺窗口由7个关键临界点构成。其中,A、B和C点为焊接工艺窗口的下边界临界点,下边界临界点代表在不同时间下熔核尺寸达到临界尺寸4tt为板厚)的电流值。D、E和F点分别代表在不同焊接时间下发生飞溅的电流值。飞溅时的熔池液态金属流失会导致焊点尺寸减小,进而最终导致焊点的力学性能下降。E点表示的是在中值时间下最先产生飞溅的电流值,把E点参数的电流减去0.2 kA获得G点参数,那么G点参数下可以获得该时间下最大热输入下的不发生飞溅的焊点,因此,G点参数即为该工艺窗口下最佳焊接参数。
进一步分析发现,P10在3组不同的焊接时间下,A~D、B~E和C~F之间的可焊性电流范围均为1.6 kA。P15在焊接时间为230和170 ms时,可焊性电流范围均为1.4 kA,而200 ms焊接时间下可焊性电流范围为1.2 kA。P20在所有焊接时间下的可焊性电流范围均为1.2 kA。P10在3组材料中表现出最大的焊接工艺窗口,而P15和P20的焊接工艺窗口略有下降。
对于同种强度的热成形钢,随着电极压力的增加,可焊性窗口变大[20],这是因为更大的压力能够保证板料之间更好的接触。因此,在本研究中,在相同电极压力下,基体硬度更高的P20的焊接工艺窗口相对较小。然而,3种材料均满足工程应用对焊接材料可焊性工艺窗口大于1.0 kA的要求。
在电阻点焊过程中,由于热输入和冷却速率在接头各个区域不均匀,导致焊接接头中各个区域的温度呈现梯度分布,焊点中间温度最高,周边温度不断降低,最终使接头各区域呈现不同的组织状态[20]图5(c)图6(c)图7(c)是选取G点的工艺下获得的3种材料的焊接接头形貌,点焊焊接接头可以分为3个区域:熔核区、热影响区和基材。其中热影响区又根据受热情况不同分为3个区域:热影响区中温度介于Ac 3和熔点之间的区域称之为上临界热影响区,峰值温度介于Ac 1Ac 3之间的区域称为临界热影响区,受热温度低于Ac 1的热影响区部分称为亚临界热影响区[20]
在P10焊接接头中,熔核区为马氏体组织,这一区域是在基体材料熔化后重新凝固形成的。在冷却过程中,水冷电极通过内循环冷却水并保持压力在熔核区,因此沿电极方向的温度梯度最大,冷却速率远远超过了该材料的马氏体相变的临界冷速,因此导致了全马氏体组织的形成,如图5(a)所示。在液态金属凝固过程中,晶粒沿着电极方向迅速生长,因此熔核区域的组织呈现出柱状晶形态,详见图5(c)
靠近熔核区的上临界热影响区,温度介于Ac 3和熔点之间。在这一区域内,P10基材中马氏体组织完全转变为奥氏体。在焊接结束后的冷却过程中,热量迅速向四周传递,这种快速冷却使得奥氏体全部转变为马氏体组织,具体可参考图5(b)
在温度保持在Ac 1~Ac 3之间时,基体中的马氏体组织开始向奥氏体转变。由于在这个区域内每个位置的温度不同,奥氏体相变程度也会有所不同。焊接结束后,临界热影响区获得了马氏体和铁素体(α)的双相组织,具体可见图5(d)
最后,在亚临界热影响区受到热影响且温度低于Ac 1时,基体中的马氏体组织将经过回火处理。通常情况下,回火过程会导致少量碳化物析出,最终形成马氏体和少量析出碳化物的组织结构,具体可见图5(e)
相应地,P15和P20的焊接接头的组织演变规律与上述描述的P10相似,具体参见图6图7
P15和P20的各个区域组织结构如下:它们的熔核区均为板条状马氏体,上临界热影响区呈现细小的马氏体组织,临界热影响区则是马氏体与铁素体的双相组织。由于P15和P20的基体都是马氏体组织,因此经过回火处理后,在亚临界热影响区的组织包括马氏体和析出的碳化物。
进一步地,焊接接头不同区域的组织差异直接影响其硬度分布,这是影响焊点力学性能和失效形式的关键因素。3种材料的焊接接头硬度分布曲线如图8所示,它们展现了相似的规律。以下以P20为例进行详细分析。
P20的基体碳含量约为0.33%,基体中的马氏体组织硬度约为570 HV。在亚临界热影响区进行了回火处理,导致了马氏体中的碳化物析出,从而略微降低了硬度。临界热影响区的硬度显著降低,因为该区域是马氏体与铁素体的双相组织,硬度降至约400 HV左右,与其他区域的硬度相比有显著差异,因此该区域通常称为“软化区”。研究表明,软化区的存在会导致焊点容易从该区域失效断裂[21]。接着,硬度值会显著增加,因为临近上临界热影响区是全马氏体组织,其晶粒尺寸甚至比熔核区更小,这导致硬度略高于熔核区[22]。最后,熔核区是全马氏体组织,其硬度与基体几乎相同。
P10和P15的焊接接头硬度分布展现了与P20相似的规律,但由于基体成分差异,导致硬度值存在一定差异。详细的数据可以参见表2
电阻点焊中,热量的产生由焦耳定律决定,公式为 H=I 2 RT。随着焊接电流的不断增加,被焊接材料界面处产生的电阻热越多,焊接结束后得到的熔核尺寸越大[20]。如图9所示,3种材料A、B和C的下边界临界点参数下焊点的熔核尺寸均小于D、E和F的上边界临界点参数下焊点的熔核尺寸。对于厚度为1.4 mm的材料,满足焊接工艺窗口的最小临界熔核尺寸约4.73 mm。然而,实际焊接过程中无法精确获得满足该熔核尺寸的焊接电流,因此下边界临界点参数所对应的熔核尺寸在4.7~4.9 mm之间,数据波动不大。
上边界临界点参数所对应的熔核尺寸略有差异。具体而言,P10在飞溅电流下焊点的熔核尺寸在5.5~5.8 mm之间,而P15和P20在飞溅电流下的熔核尺寸分别在5.2~5.4 mm和5.2~5.5 mm之间。3种材料在上边界临界点的熔核尺寸相较于下边界临界点的熔核尺寸波动较大。例如,P20在F点参数下的熔核尺寸为5.5±0.25 mm,而在C点参数下的熔核尺寸为4.8±0.05 mm。这主要是因为D、E和F点的熔核尺寸是在飞溅电流下产生的,此时熔化的基体会从熔池中喷溅出来,导致熔核尺寸较小,多组平行试样下的熔核尺寸波动也较大。3种材料在G点最佳工艺参数下获得熔核尺寸分别为:6.1±0.08 mm(P10)、5.8±0.09 mm(P15)和5.7±0.08 mm(P20),均大于其他参数点下的熔核尺寸。
研究表明,熔核尺寸的大小直接影响焊点的力学性能,熔核尺寸越大,焊点的拉剪载荷和十字拉伸载荷越大[21]。在3种材料的焊点力学性能测试中也能明显观察到这一趋势,如图10所示。具体来说,在焊接工艺窗口内,P10的拉剪载荷在11.8~17.0 kN之间,十字拉伸载荷在6.5~8.3 kN之间;P15的拉剪载荷在15.5~20.2 kN之间,十字拉伸载荷在4.7~6.3 kN之间;P20的拉剪载荷在16.5~20.5 kN之间,十字拉伸载荷在4.4~5.1 kN之间。由于焊点的力学性能与熔核尺寸大小直接相关,当熔核尺寸在D、E和F点的数值波动性较大时,拉剪载荷和十字拉伸载荷也会表现出相似的波动性。这说明熔核尺寸的变化对焊点力学性能有显著影响。
对于在G点下获得的焊点进行力学性能测试显示,P10的拉剪载荷为18.9±0.48 kN,十字拉伸载荷为8.8±0.48 kN;P15的拉剪载荷为22.6±0.49 kN,十字拉伸载荷为6.5±0.42 kN;而P20的拉剪载荷为23.5±0.41 kN,十字拉伸载荷为5.3±0.23 kN。进一步地,3种材料在G点参数下获得的焊点较E点参数下获得的焊点的拉剪载荷均提升10%以上,十字拉伸载荷也均有提高5%以上。
图11所示,对3种材料在G点工艺下获得的焊点的力学性能进一步分析可以发现,在拉剪载荷上表现出随着基体强度增加而增加的趋势,而十字拉伸载荷则随着基体强度的增加而逐渐降低。
这种趋势与焊点在不同受力模式下以及材料本身的强韧性密切相关。如图12(a)所示,在拉剪试验中,焊点承受水平方向的剪切力,而周围的基材则在竖直方向上承受一定的剪切力,但是相应的剪切应力较小。当焊点承受的剪切应力达到其极限时,裂纹会从焊点缺口处开始并沿着熔核的水平界面扩展,最终导致焊点以界面撕裂或者熔核拔出形式失效。
由于这种受力模式以及3种热成形钢的高强度特性,试样在受力时往往表现出较小的塑性变形。3种材料拉剪载荷的大小主要取决于焊点本身能够承受的极限载荷,而这一极限载荷则与焊点的强度、熔核尺寸及其材料本身的特性密切相关。在拉剪过程中,基材很难发生变形,焊点不会因为基材变形而产生扭转,焊点几乎只承受剪切力,最终3种焊点均以界面撕裂的形式失效,如图13所示。但是,较高的焊点强度通常会使焊点能够承受更大的极限载荷,因此,随着当基体强度从1 000提升至2 000 MPa,最佳工艺下获得的焊点的拉剪载荷从约18.9增长至23.5 kN。
另一方面,在进行十字拉伸试验时,焊点在竖直方向上承受正向拉力,而周围的基材同时承受竖直方向上的剪切力,如图12(b)所示。剪切力与施加的拉力方向一致,因此周围基材所承受的剪切应力较高。由于3种基材的含碳量不同,虽然基材均为马氏体组织,但是马氏体的硬度有所区别。如表2所示,P10的基体硬度约372 HV,P15的基体硬度约473 HV,P20的基体硬度约570 HV。马氏体的硬度越高,强度越高,相应的韧性越差。同理,P20的焊点强度在这三者中最高,韧性最差。在进行十字拉伸试验时,在焊点缺口处形成的裂纹更倾向于沿着硬脆的熔核区马氏体扩展。如图14(c)所示,P20焊点拉断后仅剩部分熔核,相应的十字拉伸载荷最低,仅5.3 kN左右。而P10焊点在进行十字拉伸试验时,裂纹沿着热影响区扩展,整个熔核区承受正拉力,相应的十字拉伸极限载荷最高能达到8.8 kN左右,如图14(a)所示。P15焊点韧性处于中等水平,裂纹沿着熔合线边缘扩展,断口保留了大部分的熔核区,因此,其十字拉伸载荷介于P10和P20之间。
另一方面,在十字拉伸过程中,如果焊点能够承受的正向载荷大于周围基材发生塑性变形的载荷,那么基材往往会首先发生塑性变形。随着载荷的增加,基材的塑性变形达到一定程度后,焊点才会沿着热影响区或熔核区发生断裂。如果焊点能够承受的正向拉力载荷低于周围基材发生塑性变形的载荷,那么基材通常不会发生塑性变形,焊点会直接沿着熔核区开裂。因此,在本研究中,P10基材韧性最好,在焊点的十字拉伸试验中基材的塑性变形较为显著,焊点在断裂前产生了较大的位移。P20基材的韧性最差,所以在拉伸过程中基材产生的塑性变形最小,焊点失效位移量不足10 mm,如图15(b)图16(b)所示。
而拉剪试验时,施加在试样上的正拉力在基材上的分力不足以使得基材产生塑性变形。因此3种材料的焊点在拉剪试验时产生的塑性变形很小,焊点失效位移量不足1 mm,如图15(a)图16(a)所示。
(1)3种不同强度的Al-Si镀层热冲压钢(P10、P15和P20)在GWS-5A-2007评价标准下获得的二维焊接工艺窗口中,可焊性电流范围均大于1.0 kA,满足工业实际生产需求。其中,P10的可焊电流范围达1.6 kA;P15的可焊电流范围达1.4 kA;P20的可焊电流达1.2 kA。随着材料强度的增加,焊接工艺窗口中的可焊性电流范围逐渐降低。
(2)3种材料的焊接接头组织分布及硬度表现出相似的分布规律。基体为马氏体,亚临界热影响区包含马氏体和碳化物,临界热影响区为马氏体和铁素体,上临界热影响区为马氏体,熔核区为板条马氏体。基体中的碳含量有差异,导致硬度值略有差异,但是硬度分布曲线表现出相同的趋势。
(3)对可焊区间内的焊点力学性能进行了评价,结果显示3种材料的焊点力学性能均能满足要求。由于焊点成分和组织与基材一致,随着3种材料强度提升,焊点强度(硬度)增加,但其韧性降低。焊点的承受极限载荷大小与焊点强度及韧性有关,3种材料的拉剪极限载荷随焊点强度提升而增加,而十字拉伸极限载荷则随焊点韧性降低而降低。
  • *国家自然科学基金(52101128)
  • 中国博士后科学基金(2022M710021)
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2025年第47卷第2期
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doi: 10.19562/j.chinasae.qcgc.2025.02.017
  • 接收时间:2024-07-01
  • 首发时间:2025-07-09
  • 出版时间:2025-02-25
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  • 收稿日期:2024-07-01
  • 修回日期:2024-08-30
基金
*国家自然科学基金(52101128)
中国博士后科学基金(2022M710021)
作者信息
    1 东北大学,轧制技术及连轧自动化国家重点实验室,沈阳 110819
    2 育材堂(苏州)材料科技有限公司,苏州 215123

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易红亮,教授,博士,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
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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