ABS塑料及其与铝合金的感应焊接工艺研究

发布时间：2019-04-11 19:24

【摘要】：当今社会塑料材料已经广泛用于经济生活的各个领域,从生活用品到尖端科学领域都有塑料的身影,而塑料被制成各种形状零件与其他材料配合使用,由于塑料本身加工工艺、零件设计、工作环境限制等方面的原因,很多具有复杂结构的产品,不能一次加工成型,而通过焊接方法可以把多个零部件无缝连接到一起,形成一个完整的零件,所以塑料与塑料,塑料与其他材料的连接技术有十分重要的价值对于热塑性的塑料焊接工艺得到了越来越广泛的应用,塑料焊接是永久性连接塑料部件的有效方法。感应焊接的可焊性范围之广涵盖了全系列工程塑料及难以用其它方法焊接的高分子或高填充复合物。随着高强度塑料使用量在各个行业的显著增长,比如汽车制造业、包装行业、医疗设备制造业等。感应焊接正成为塑料连接方法至关重要的一环。本文主要采用ABS塑料和6082铝合金进行实验,在塑料与塑料的焊接中制成尺寸150mm×40mm×2mm的板件,在塑料与铝合金的焊接中制成尺寸150mm×30mm×2mm的板件,在型号为LK-25的感应焊机上进行塑料与塑料、塑料与铝板搭接方式的焊接。整个感应焊接过程用时少,加热速度快,在压力作用下熔融态塑料可以在连接界面上得到良好铺展形成接头。搭接接头处光滑均匀,没有沟槽,飞边极少,上下板材连接紧密,没有气孔、焊穿、感应物滑移等缺陷。采用正交优化设计,以搭接接头抗拉剪强度为主要标准研究焊接参数对其力学性能的影响,主要的影响因素有加热温度、加热时间、保温电流、保温时间以及压力。并得出了最优组合参数:在压力相同的情况下塑料与塑料焊接的最优参数为加热电流800A,加热时间10s,保温电流300A,最大抗拉剪力载荷为2.70k N。塑料与铝的最优参数热电流900A,加热时间7s,保温时间2s,最大抗拉剪力载荷为1.02k N。利用扫描电子显微镜分析搭接接头,在塑料与塑料的焊接过程中,在感应热、传导热以及压力的共同作用下,塑料板与感应物之间除了机械连接外,还在连接界面上发生了浸润现象,形成了再固化层。充当感应物的铝合金板边缘被塑料粘附。在塑料和铝的焊接过程中塑料板与铝合金板的连接界面上除了机械连接外,还在连接界面上发生了浸润现象,形成了再固化层,碳元素与铝元素在再固化层中有少部分的扩散现象。对搭接接头处的塑料利用红外光谱分析发现在连接界面处,生成了新的化学基团。塑料与塑料的搭接接头的断裂方式有三种,在热影响区断裂的情况较多,接头强度高于塑料板的强度。远离焊缝处断裂的情况较少。第三种断开方式直接在搭接位置,这是参数选择问题,应当避免这种形式出现。塑料与铝的搭接接头的断裂方式有两种,在热影响区断裂的情况,说明接头强度高于塑料板的强度。第二种断开方式直接在搭接位置。
[Abstract]:Plastic materials have been widely used in various fields of economic life in today's society, from household supplies to cutting-edge science, and plastics are made into parts of various shapes and used in conjunction with other materials, due to the processing technology of the plastics itself. For reasons such as part design, work environment restriction and so on, many products with complex structure can not be machined and formed at a time, but by welding method, many parts can be seamlessly connected together to form a complete part. Therefore, plastics and plastics, plastic and other materials connection technology has a very important value for thermoplastic plastic welding technology has been more and more widely used, plastic welding is an effective way to permanently connect plastic parts. The wide range of weldability of induction welding covers a full range of engineering plastics and polymer or high filling compounds that are difficult to weld by other methods. With the use of high-strength plastics in various industries, such as automotive, packaging, medical equipment manufacturing and so on. Induction welding is becoming a crucial part of plastic bonding methods. In this paper, ABS plastic and 6082 aluminum alloy are used to experiment, and the plate of size 150mm 脳 40mm 脳 2mm is made in the welding of plastic and plastic, and the plate of size 150mm 脳 30mm 脳 2mm is made in the welding of plastic and aluminum alloy. Type LK-25 induction welding machine for plastic and plastic, plastic and aluminum plate lap welding. The whole induction welding process takes less time and the heating speed is fast. The melt plastic can be well spread to form the joint on the interface under the action of pressure. Lap joints are smooth and uniform, there are no grooves, few flying edges, tight connections between the upper and lower plates, no holes, weld penetration, inductor slip and other defects. Orthogonal optimization design was used to study the influence of welding parameters on the mechanical properties of lap joints with tensile shear strength as the main criterion. The main influencing factors were heating temperature, heating time, holding current, holding time and pressure. At the same pressure, the optimal parameters for welding of plastics and plastics are: heating current 800A, heating time 10s, holding current 300A, maximum tensile shear load 2.70kN, and the optimal combination parameters are as follows: heating current 800A, heating time 10s, holding current 300A, maximum tensile shear load 2.70kN. The optimum parameters of plastics and aluminum are 900A, heating time 7s, holding time 2s, maximum tensile shear load 1.02kN. A scanning electron microscope is used to analyze the lap joints. In the process of welding between plastics and plastics, under the combined action of induced heat, conduction heat and pressure, the connection between the plastic plate and the inductor is in addition to the mechanical connection. There is also a phenomenon of infiltration on the interface, forming a resolidified layer. The edge of the aluminum alloy plate acting as an inductor is attached to the plastic. In the process of welding between plastic and aluminum, the interface between plastic plate and aluminum alloy plate is not only mechanically connected, but also infiltrated on the joint interface, forming a resolidified layer. There are a few diffusion phenomena between carbon and aluminum in resolidified layer. A new chemical group was found at the interface by infrared spectrum analysis of the plastics at the lap joint. There are three kinds of fracture modes of the lap joint between plastics and plastics, and the strength of the joint is higher than that of the plastic plate. The fracture away from the weld seam is less common. The third way of disconnecting is directly in the lap position, which is a parameter selection problem and should be avoided. There are two kinds of fracture modes for the lap joint of plastic and aluminum. The strength of the joint is higher than that of the plastic plate when the joint is broken in the hot sound region. The second way to disconnect is directly in the lap position.
【学位授予单位】：兰州理工大学
【学位级别】：硕士
【学位授予年份】：2016
【分类号】：TG44;TQ325.2

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