WO2024183111A1 - Procédé et dispositif de préparation de fil de fibre pour soudage par friction-malaxage, et procédé de soudage pour fil de fibre - Google Patents

Procédé et dispositif de préparation de fil de fibre pour soudage par friction-malaxage, et procédé de soudage pour fil de fibre Download PDF

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Publication number
WO2024183111A1
WO2024183111A1 PCT/CN2023/084343 CN2023084343W WO2024183111A1 WO 2024183111 A1 WO2024183111 A1 WO 2024183111A1 CN 2023084343 W CN2023084343 W CN 2023084343W WO 2024183111 A1 WO2024183111 A1 WO 2024183111A1
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Prior art keywords
fiber
wire
welding
unidirectional
tape
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Ceased
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PCT/CN2023/084343
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English (en)
Chinese (zh)
Inventor
周应国
蒋振国
杨金强
陈书锦
邹俊
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Jiangsu University of Science and Technology
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Jiangsu University of Science and Technology
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Publication of WO2024183111A1 publication Critical patent/WO2024183111A1/fr
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/06Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using friction, e.g. spin welding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29DPRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00Subject matter not provided for in other groups of this subclass

Definitions

  • the invention relates to the technical field of welding, in particular to a method and equipment for preparing fiber wires used for friction stir welding and a welding method.
  • FSW friction stir welding
  • This process is mainly used for the connection of light alloys and low-carbon steel, and is also used in a small amount for the welding of polymers.
  • the friction stir welding of polymers has the advantages of low temperature, intense plastic deformation and high joint quality, but it also has many limitations and shortcomings.
  • the welding quality is greatly affected by the process, so the welding process window is narrow, and the optimal welding process is not easy to stabilize in practical applications.
  • the substantial reason is that the strength of the weld is still far lower than that of the parent material, resulting in the failure of the weld during application mainly occurring in the welding area.
  • the purpose of the present invention is to provide a method and equipment for preparing fiber wires for stir friction welding and a welding method, which can significantly improve the mechanical properties of the weldment.
  • the present invention provides a method for preparing a fiber wire for friction stir welding, comprising the following steps:
  • Step S1 after the bundled fiber material is widened and pre-impregnated with a shaping glue to form a unidirectional thin fiber tape, a thermoplastic polymer is melted and plasticized and then coated on the unidirectional thin fiber tape to form a fiber coated tape;
  • Step S2 the fiber coated tape is axially wound to form a unidirectional multi-layer fiber/polymer prepreg wire material with a circular cross-section;
  • Step S3 the unidirectional multi-layer fiber/polymer prepreg wire material is cut and kept in a semi-connected state, and then hot-melt treated and cooled to obtain a fiber wire material that is cut and then fused.
  • thermoplastic polymer is the same as the base material to be welded.
  • step S1 the fiber content of the fiber coating tape is 40% to 60%.
  • the cross-sectional layering lines of the unidirectional multi-layer fiber/polymer prepreg wire material are Archimedean spiral lines.
  • step S3 the cutting ratio accounts for 70-90% of the entire circular cross section, and the cutting length is 1.5-2.5 times the diameter of the friction stir welding head.
  • step S3 the slit unidirectional multi-layer fiber/polymer prepreg wire material is subjected to axial force extrusion and remelting during the hot melt treatment.
  • the fiber filament prepared by the above method is applied to a thermoplastic polymer friction stir welding process.
  • the welding method comprises the following steps:
  • Step 1 Repair and level the welded part of the connecting piece and remove the material from the middle of the welded part;
  • Step 2 embedding or melting the prepared fiber filament into the part to be welded where the material has been removed, and then flattening the part to be welded;
  • Step 3 After the welding parts of the two parts to be connected are butt-jointed, a lateral force is applied and they are pressed and fixed. After the stirring head rotates at a high speed, the two parts are connected.
  • the material removed from the middle of the part to be welded in step 1 is consistent with the volume of the fiber wire to be embedded or melted in step 2.
  • the downward pressure is controlled so that the end face of the stirring head shoulder exceeds the upper surface of the welding wire by 0.05 to 0.15 mm after the welding wire is pressed in, and the downward pressure is less than or equal to the difference between the thickness of the weldment and the length of the stirring needle.
  • the present invention provides a fiber wire preparation device for friction stir welding, comprising:
  • the extruder is used to extrude the thermoplastic polymer after melting and plasticizing; the yarn spreading roller is used to widen the bundled fiber material to form a unidirectional thin-layer fiber dry tape; the fiber tape bonding roller is used to pre-impregnate the unidirectional thin-layer fiber dry tape with a shaping glue to form a whole piece of unidirectional thin-layer fiber tape; the impregnation head is used to coat the unidirectional thin-layer fiber tape with the melted and plasticized thermoplastic polymer to form a fiber coated tape; the axial winder is used to axially wind the fiber coated tape to form a unidirectional multi-layer fiber/polymer prepreg wire material; the traction roller pair is used to pull the unidirectional multi-layer fiber/polymer prepreg wire material onto the crawler traction machine; the longitudinal cutter is used to longitudinally cut the unidirectional multi-layer fiber/polymer prepreg wire material; the hot melt oven is used to re-melt the fracture of the unidirectional multi-
  • it also includes a speed-adjustable pair of rollers, whose speed is the same as the speed of the traction pair of rollers and is less than the speed of the crawler traction machine.
  • the present invention can significantly improve the strength of the weld; the present invention avoids the anisotropy of the mechanical properties at the weld due to fiber reinforcement; the present invention can effectively avoid the probability of weld pores or gaps that are easily generated by ordinary polymer stir friction welding; the present invention is easy to use, and the re-fusion of the wire after slitting can significantly improve the convenience of use, and welding is easy to implement; the wire preparation and welding process are both green and pollution-free.
  • FIG1 is a schematic diagram of the structure of a fiber filament preparation device of the present invention.
  • FIG2 is a physical picture of the fiber filaments of the present invention after cutting and then fusing
  • FIG3 is a welding physical diagram of the present invention.
  • FIG4 is a SEM characterization image of the fiber wire material at the weld of the workpiece according to Example 1 of the present invention.
  • FIG5 is a SEM characterization image of the fiber-free material after welding using polycarbonate as raw material according to Example 2 of the present invention.
  • FIG6 is a sample appearance diagram of welding test pieces of Example 1 and Example 2 of the present invention before and after the test;
  • FIG. 7 is a SEM characterization image of the weld of the workpieces connected in Example 3 of the present invention.
  • the device for preparing fiber filaments used for stir friction welding of the present invention is shown.
  • Figure 1 also shows the preparation process of the fiber filaments.
  • the device mainly includes an extruder 1, a yarn frame 2, a yarn spreading roller 4, a fiber tape bonding roller 5, an impregnation head 7, an axial winder 8, a traction roller pair 9, a crawler traction machine 10, a longitudinal cutter 11, a hot melt oven 12 and a speed-adjustable roller pair 13.
  • the extruder 1 is connected to the impregnation head 7.
  • a yarn frame 2, a yarn spreading roller 4, and a fiber tape bonding roller 5 are arranged on one side of the extruder 1 in sequence.
  • An axial winder 8, a traction roller pair 9, a hot melt oven 12, and a speed regulating roller pair 13 are arranged on the other side of the extruder 1 in sequence.
  • a crawler traction machine 10 and a longitudinal cutter 11 are arranged between the traction roller pair 9 and the hot melt oven 12. The longitudinal cutter 11 is arranged directly above the crawler traction machine 10.
  • Step (1) the thermoplastic polymer is melted and plasticized through an extruder 1 and then enters an impregnation head 7;
  • Step (2) placing a specific fiber material in a creel 2, at which time the fiber material is in a bundle shape, and the fiber bundle 3 is formed into a unidirectional thin fiber dry belt after being widened by a yarn spreading roller 4;
  • the number of creels 2 can be one or more, and the number of yarn spreading rollers 4 should be consistent with that of creels 2;
  • Step (3) when a plurality of flattened dry fiber tapes pass through a fiber tape bonding roller 5, they are pre-impregnated with a trace amount of shaping glue to form a whole piece of unidirectional thin layer fiber tape 6, and the fiber tape 6 also enters an impregnation head 7, where the fiber tape 6 is evenly coated with a polymer high-temperature melt to form a fiber coated tape; controlling the coating amount of the fiber coated tape can control the fiber content and ensure uniform distribution of the fibers in the coated tape.
  • the fiber content is maintained between 40% and 60%;
  • Step (4) the fiber coating tape is subsequently wound axially by an axial winder 8 to form a unidirectional multi-layer fiber/polymer prepreg wire material with a circular cross section;
  • Step (5) the wire material enters the crawler traction machine 10 under the action of the traction roller 9, and is cut by the longitudinal cutter 11 and maintained in a semi-connected state;
  • Step (6) when the semi-connected wire passes through the hot melt oven 12, a small amount of polymer at the fracture is melted. At the same time, it is slightly blocked by the speed-adjustable roller 13 behind it, so that the molten polymer is compressed and adheres to each other, thereby forming a fiber wire 14 that is cut and then fused. The wire is subsequently wound or coiled for standby use.
  • the speed of the speed-adjustable roller 13 can be consistent with the speed of the traction roller 9, and their speeds are 2 to 5% lower than the speed of the crawler traction.
  • thermoplastic polymer stir friction welding which specifically comprises the following steps:
  • step 1) The material removed from the middle of each part to be welded in step 1) is consistent with the volume of the wire to be embedded or melted in step 2).
  • the welding process conditions in step 3) mainly include the downward pressure and the welding speed.
  • the downward pressure is controlled so that the end face of the stirring head shoulder exceeds the upper surface of the welding wire by 0.05 to 0.15 mm after the welding wire is pressed in, and the downward pressure is less than or equal to the difference between the thickness of the weldment and the length of the stirring needle.
  • this embodiment carries out friction stir welding on a transparent polycarbonate weldment.
  • the main raw materials used include polycarbonate (PC, melting volume rate of 24 cm 3 /10min, (300°C/1.2kg)) and carbon fiber (12K, T700), both of which are commercially available.
  • the whole process mainly includes two steps: wire preparation and welding.
  • the wire preparation process is as follows:
  • the polycarbonate is melted and plasticized by the extruder 1 and then enters the impregnation head 7.
  • a bundle of carbon fibers is placed in the creel 2.
  • a unidirectional thin fiber dry tape is formed.
  • the fiber tape 6 also enters the impregnation head 7, and the fiber tape 6 is evenly coated with the polycarbonate high-temperature melt to form a fiber coating tape;
  • the fiber coating tape is axially wound by the subsequent axial winder 8, and the cross section gradually forms an Archimedean spiral, forming a unidirectional multi-layer fiber/polymer prepreg wire material with a circular cross section.
  • the wire material enters the crawler traction machine 10 under the action of the traction roller 9, and is cut by the longitudinal cutter 11 and kept in a semi-connected state; the cutting ratio accounts for 80% of the entire circular fiber/polymer prepreg cross section, and the cutting length is 12mm (the diameter of the friction stir welding head is 6mm).
  • the semi-connected wire material passes through the hot melt oven 12, a small amount of polymer at the fracture is melted.
  • Fusion means in the present invention that the polymer of the fiber filament at the fracture is melted, the molten polymer is compressed and adheres to each other, and after cooling, the polymer at the fracture is connected in an adhesive manner, wherein at the fracture, the cut fiber remains in a cut state after bonding.
  • the prepared wire is then used for friction stir welding, mainly including:
  • the downward pressure of the welding head is controlled to be 0.30mm
  • the thickness of the weldment is 2mm
  • the selected stirring needle length is 1.5mm.
  • the weld of the connected workpieces was characterized by SEM, and the results are shown in Figure 4.
  • fibers of almost equal length are evenly distributed in an arc shape, and the reinforcing effect of the fibers can be foreseen from its structure.
  • the cut fibers can be distributed 360 degrees in all directions under the drive of the high-speed rotating stirring head.
  • all angles of the weld can be reinforced by fibers, avoiding the anisotropy of the mechanical properties of the weld due to fiber reinforcement.
  • the use of wire can also effectively avoid the probability of weld pores or gaps that are easily generated by ordinary polymer stir friction welding.
  • the wire-reinforced weldment of the present invention has a fiber distribution structure of a specific form, exhibits excellent mechanical properties, and has excellent application prospects.
  • Example 2 For comparison with Example 1, similar to Example 1, this comparative example also uses commercially available polycarbonate (melting volume rate of 24 cm 3 /10min) as the base material, but Example 2 does not use fiber filaments.
  • the welding process is mainly as follows: obtain the parts to be connected using polycarbonate as the raw material through hot pressing or other processes, then butt the parts to be welded of the two parts to be connected, apply a proper lateral force, and then press and fix them on the workbench. Under certain welding process conditions, the two parts are connected as one after the high-speed rotation of the stirring head.
  • the welds of the connected workpieces were characterized by SEM, and the results are shown in FIG5 . As can be seen in FIG5 , there are many voids and gaps at the joint of the welds, so it is foreseeable that the strength of the welds will not be very good.
  • FIG6 A rectangular test specimen was cut out of the connected workpiece and subjected to a tensile mechanical property test. The appearance results are also shown in FIG6 , wherein FIG6c and FIG6d respectively show the appearance of the sample before and after the test. As can be seen from FIG6d , the tensile fracture occurred at the weld without any suspense at this time, which is sufficient to indicate that the mechanical properties at the weld need to be improved.
  • this comparative example also carried out friction stir welding on a transparent polycarbonate weldment, and the main raw materials used included polycarbonate (melting volume rate of 24 cm 3 /10 min) and carbon fiber (12K, T700), both of which are commercially available.
  • the whole process mainly includes two steps: wire preparation and welding.
  • the wire preparation process is similar to the existing conventional long fiber reinforced polymer granular materials except that no cutting is performed: the polycarbonate is melted and plasticized through an extruder and then enters the impregnation head. At the same time, the carbon fiber tow placed in the creel is also introduced into the impregnation head. The fiber is impregnated with the high-temperature melt of polycarbonate in the impregnation head to form a fiber/polymer prepreg wire with an irregular cross-section. The wire is subsequently pulled, wound or coiled for use to form a continuous wire.
  • the prepared wire was then used for friction stir welding as follows:
  • the weld of the connected workpieces was characterized by SEM, and the result is shown in FIG7 .
  • the fiber distribution at the weld is very disordered, the fiber length difference is also large, and the distribution of the fibers in all directions is also relatively disordered.
  • friction stir welding is performed on nylon weldments.
  • the main raw materials used include nylon (PA66, melting volume rate is 23 cm 3 /10min) and glass fiber (12K, T700), both of which are commercially available.
  • the whole process mainly includes two steps: wire preparation and welding.
  • the wire preparation process is as follows:
  • the PA66 is melted and plasticized by the extruder 1 and then enters the impregnation head 7.
  • two bundles of carbon fibers are placed in two creels 2 respectively, and are respectively spread by two yarn spreading rollers 4 to form unidirectional thin-layer fiber dry tapes.
  • the two unidirectional thin-layer fiber dry tapes are then pre-impregnated with a trace amount of shaping glue when passing through the fiber tape bonding roller 5 to form a whole piece of unidirectional thin-layer fiber tape 6, and the fiber content is maintained at 60%.
  • the fiber tape 6 also enters the impregnation head 7, and the fiber tape 6 is evenly coated with the PA66 high-temperature melt to form a fiber coating tape;
  • the fiber coated tape is axially wound by the subsequent axial winder 8, and the cross section gradually forms an Archimedean spiral to form a unidirectional multi-layer fiber/polymer prepreg wire with a circular cross section.
  • the wire enters the crawler traction machine 10 under the action of the traction roller 9, and is cut by the longitudinal cutter 11 and kept in a semi-connected state; the cutting ratio accounts for 1.3% of the entire circular fiber.
  • the slitting length is 9cm (the diameter of the friction stir welding head is 6mm)
  • the speed of the speed regulating roller 13 is consistent with the speed of the traction roller 9, their speeds are 5% lower than the speed of the crawler traction, so the semi-connected wire will be slightly blocked by the speed regulating roller 13 behind, and the molten polymers are pressed and bonded to each other, thereby forming a fiber wire 14 that is cut and then fused, and the wire is subsequently wound or coiled for standby use.
  • the appearance of the fiber wire that is cut and then fused is also similar to Figure 2.
  • the prepared wire was then used for friction stir welding as follows:
  • the downward pressure of the welding head is controlled to be 0.35mm
  • the thickness of the weldment is 2mm
  • the selected stirring needle length is 1.5mm.
  • this comparative example also carried out friction stir welding of fiber wires without cutting for nylon weldment, and the main raw materials used included nylon (melting volume rate of 23 cm 3 /10min) and carbon fiber (12K, T700), both of which are commercially available.
  • the whole process mainly includes two steps: wire preparation and welding.
  • the wire preparation process is similar to the existing conventional long fiber reinforced polymer granular materials except that no cutting is performed: the nylon is melted and plasticized through an extruder and then enters the impregnation head. At the same time, the carbon fiber bundle placed in the creel is also introduced into the impregnation head. The fiber is impregnated with the high-temperature melt of nylon in the impregnation head to form a fiber/polymer prepreg wire with an irregular cross-section. The wire is subsequently pulled, wound or coiled for use to form a continuous wire.
  • the prepared wire was then used for friction stir welding as follows:
  • the welds of the connected workpieces were characterized by SEM, and the results were similar to those in Example 3.
  • the fiber distribution at the welds was very chaotic, the fiber lengths varied greatly, and the distribution of the fibers in all directions was also relatively chaotic.
  • the fiber content of the fiber-coated tape is 40%; the cutting ratio accounts for 70% of the entire circular cross-section, the cutting length is 15 mm, and the downward pressure of the welding head is controlled to be 0.25 mm.
  • the fiber content of the fiber-coated tape is 60%; the cutting ratio accounts for 90% of the entire circular cross-section, the cutting length is 15 mm, and the downward pressure of the welding head is controlled to be 0.32 mm.

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  • Mechanical Engineering (AREA)
  • Reinforced Plastic Materials (AREA)

Abstract

L'invention concerne un procédé et un dispositif de préparation d'un fil de fibre pour le soudage par friction-malaxage, ainsi qu'un procédé de soudage pour un fil de fibre. Le procédé de préparation comprend les étapes suivantes : S1, étalement d'un matériau fibreux en forme de faisceau et pré-imprégnation dans un adhésif de mise en forme pour former une bande fibreuse unidirectionnelle à couche mince, et fusion et plastification d'un polymère thermoplastique puis application de celui-ci sur la bande fibreuse unidirectionnelle à couche mince pour former une bande de revêtement de fibres ; S2, enroulement axial de la bande de revêtement de fibres pour former un fil préimprégné unidirectionnel multicouche en fibre/polymère ayant une section circulaire ; et S3, fendage du fil préimprégné unidirectionnel multicouche en fibre/polymère, en le maintenant dans un état semi-connecté, et en effectuant un traitement de fusion à chaud et un refroidissement pour obtenir un fil de fibre qui est fusionné après le fendage. Le fil de fibre de la présente invention peut être distribué uniformément et de manière omnidirectionnelle sur une pièce à souder pendant le soudage, ce qui améliore considérablement la résistance d'un cordon de soudure ; les fibres fendues peuvent être entraînées par une tête d'agitation tournant à grande vitesse, de manière à être distribuées de manière omnidirectionnelle à 360 degrés, et le cordon de soudure à tous les angles peut être renforcé par les fibres, ce qui permet d'éviter l'anisotropie des propriétés mécaniques, qui peut être causée par le renforcement de la fibre, au niveau du cordon de soudure.
PCT/CN2023/084343 2023-03-03 2023-03-28 Procédé et dispositif de préparation de fil de fibre pour soudage par friction-malaxage, et procédé de soudage pour fil de fibre Ceased WO2024183111A1 (fr)

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CN202310197774.7A CN116278105B (zh) 2023-03-03 2023-03-03 用于搅拌摩擦焊的纤维丝材制备方法和设备及焊接方法
CN202310197774.7 2023-03-03

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