FeCrAl 金属 /SCFR-PA6 复合材料超声波焊接接头界面结合特性及性能调控机制

Interface bonding characteristics and performance regulation mechanism of ultrasonic welded FeCrAl Alloy/SCFR-PA6 joint

  • 摘要: FeCrAl 合金与碳纤维增强热塑性复合材料(CFRTP)的结合,为航空航天部件的轻量化发展提供了一种有前景的策略。本文采用超声波焊接技术设计FeCrAl 合金表面刻蚀处理与短碳纤维增强聚酰胺6 (SCFR-PA6)板材的搭接接头试样,对比与拉伸加载性能平行与垂直两个方向超声波加载工艺下接头横截面形貌特征和接头结合强度,探讨了超声振动方向和金属表面激光刻蚀非对称纹理特征对接头形成过程及界面结合机制的影响规律。通过评估熔融短碳纤维增强聚酰胺6 (SCFR-PA6)在激光刻蚀纹理表面不同方向上的润湿性,结合微观表征分析及界面力学性能测试技术,综合分析了接头横截面形貌和拉剪断口形貌特征。结果表明:连续的凹槽结构有利于树脂流动,当超声振动方向垂直于试样拉伸方向时,界面结合紧密,而当超声振动方向平行于试样拉伸方向时,熔融SCFR-PA6润湿性好易铺展,导致大量熔融树脂流失,凹槽内出现不完全填充和树脂疏松组织特征,接头强度下降;同时通过EDS、XRD分析证实了界面的局部冶金结合。揭示了“纹理结构与超声振动方向”协同调控规律,阐明了超声波焊接过程中熔融树脂在金属刻蚀表面结构中润湿铺展行为和异质界面结合的强化机制。

     

    Abstract: The joining of FeCrAl alloy and carbon fiber reinforced thermoplastic composites (CFRTP) presents a promising strategy for lightweight aerospace component development. In this study, ultrasonic welding technology was employed to lap weld laser textured FeCrAl alloy and short carbon fiber reinforced polyamide 6 (SCFR-PA6). The cross-sectional morphology characteristics and joint bonding strength of the joint under ultrasonic loading processes in parallel and vertical directions were compared. The influence of ultrasonic vibration direction and laser etching asymmetric texture characteristics on the joint formation process and interface bonding mechanism is discussed. By evaluating the wettability of molten short carbon fiber reinforced polyamide 6 (SCFR-PA6) on laser-textured surfaces in different orientations, and combining microscopic characterization with interfacial mechanical property testing techniques, a comprehensive analysis was conducted on the cross-sectional morphology of joints and the characteristics of tensile-shear fracture surfaces. The results show that continuous groove structures promote resin flow. When the ultrasonic vibration direction is vertical to the tensile direction, a tightly bonded interface is formed. In contrast, when the vibration direction is parallel to the tensile direction, the molten SCFR-PA6 demonstrates good wettability and spreads readily, leading to significant resin loss, incomplete filling, and a loosely packed resin structure in the grooves, ultimately reducing joint strength. Furthermore, local metallurgical bonding at the interface was confirmed by EDS and XRD analyses. The synergistic regulation of "texture structure and ultrasonic vibration direction" is revealed, and the strengthening mechanism of the wetting and spreading behavior of molten resin and the enhancing bonding of heterogeneous interfaces during ultrasonic welding is elucidated.

     

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