Zhang Yu, Pang Qiu
Hubei Longzhong Laboratory, Wuhan University of Technology, Xiangyang 441000, China.
Hubei Key Laboratory of Advanced Technology for Automotive Components, Wuhan University of Technology, Wuhan 430070, China.
Materials (Basel). 2024 Oct 11;17(20):4981. doi: 10.3390/ma17204981.
In recent years, high-performance lightweight and multifunctional aluminum foam sandwiches (AFSs) can be successfully applied to spacecraft, automobiles, and high-speed trains. Friction stir welding (FSW) has been proposed as a new method for the preparation of AFS precursors in order to improve the cost-effectiveness and productivity of the preparation of AFS. In this study, the AFS precursors were prepared using the FSW process. The distribution of foaming agents in the AFS precursors and the structure and morphology of AFS were observed using optical microscopy (OM), scanning electron microscopy (SEM), and X-ray energy dispersive spectroscopy (EDS). The effects of the temperature and material flow on the distribution of the foaming agent during the FSW process were analyzed through experimental study and numerical simulation using ANSYS Fluent 19.0 software. The results show that the uniform distribution of the foaming agent in the matrix and excellent densification of AFS precursor can be prepared when the rotation speed is 1500 r/min, the travel speed is 25 mm/min, the tool plunge depth is 0.2 mm, and the tool moves along the retreating side (RS). In addition, the experimental and numerical simulations show that increasing the welding temperature improves the uniformity of foaming agent distribution and the area of AFS precursor prepared by single welding, shortening the thread length inhibits the foaming agent from reaching the upper sandwich plate and moving along the RS leads to a more uniform distribution of the foaming agent. Finally, the AFS with porosity of 74.55%, roundness of 0.97, and average pore diameter of 1.192 mm is prepared.
近年来，高性能轻质多功能泡沫铝夹层板（AFS）已成功应用于航天器、汽车和高速列车。搅拌摩擦焊（FSW）被提议作为制备AFS预制件的一种新方法，以提高AFS制备的成本效益和生产率。在本研究中，采用FSW工艺制备了AFS预制件。利用光学显微镜（OM）、扫描电子显微镜（SEM）和X射线能谱仪（EDS）观察了AFS预制件中发泡剂的分布以及AFS的结构和形貌。通过实验研究和使用ANSYS Fluent 19.0软件的数值模拟，分析了FSW过程中温度和材料流动对发泡剂分布的影响。结果表明，当转速为1500 r/min、行进速度为25 mm/min、工具插入深度为0.2 mm且工具沿后退侧（RS）移动时，可以使发泡剂在基体中均匀分布，并制备出致密性良好的AFS预制件。此外，实验和数值模拟表明，提高焊接温度可改善发泡剂分布的均匀性以及单次焊接制备的AFS预制件的面积，缩短螺纹长度会抑制发泡剂到达上夹层板，而沿RS移动会使发泡剂分布更均匀。最后，制备出了孔隙率为74.55%、圆度为0.97且平均孔径为1.192 mm的AFS。
