钛合金蒙皮-骨架结构激光焊接变形规律模拟研究

doi:10.12382/bgxb.2024.0017

摘要/Abstract

摘要：

钛合金常用于各类飞行器舵翼部件的蒙皮-骨架结构中,在兵器、航空航天行业受到广泛关注。以钛合金蒙皮-骨架结构激光焊接变形为研究对象,利用热循环曲线法模拟焊接顺序对焊接变形与应力的影响规律,通过在焊接生产过程中加入翻转工艺显著降低了焊接变形与残余应力。研究结果表明,优先焊接蒙皮中心区域焊缝,并在焊接过程中加入翻转,可以使峰值焊接应力从原始的1027.18MPa降低到745.30MPa,降低了27.4%;特征点P₁、P₂、P₃处变形由原始的0.168mm、0.178mm、0.198mm减小至0.066mm、0.028mm、0.021mm,分别减小60.7%、84.3%和89.4%。利用激光三维扫描仪测量了蒙皮-骨架结构激光焊接变形量,与实验测量结果相比,计算结果平均误差为9.98%,验证了有限元模型和优化焊接顺序的准确性。

关键词: 飞行器蒙皮-骨架结构, 激光焊接变形, 焊接顺序优化, 热循环曲线算法

Abstract:

Titanium alloy is commonly used in the skin-skeleton structure of various aircraft rudder and wing components,which has received widespread attention in the weapons,aviation and aerospace industries.In this work,the laser welding deformation of a titanium alloy skin-skeleton structure is taken as the research object.The influence of welding sequences on welding deformation and stress is simulated and investigated using the thermal cycling method,and the welding sequences are optimized.The welding deformation and stress are significantly reduced by adding the turnover process in the welding.The results show that the peak welding stress is reduced by 27.4% from the original 1027.18MPa to 745.30MPa by prioritizing welding in the center area of the skin and adding multiple overturns during welding.The deformations at the feature points P₁,P₂ and P₃ are decreased from the original 0.168mm,0.178mm and 0.198mm to 0.066mm,0.028mm and 0.021mm,respectively,by 60.7%,84.3% and 89.4%.The laser welding deformation of skin-skeleton structure is measured by a 3D laser scanner.Compared with the experimental results,the average error of the calculated results is 9.98%,which verifies the accuracy of the finite element model and the optimized welding sequence.

Key words: aircraft skin-skeleton structure, laser welding deformation, welding sequence optimization, thermal cycling curve algorithm

中图分类号:

TG456.7

王磊, 杜劭峰, 李红星, 刘港, 张磊, 彭勇. 钛合金蒙皮-骨架结构激光焊接变形规律模拟研究[J]. 兵工学报, 2025, 46(3): 240017-.

WANG Lei, DU Shaofeng, LI Hongxing, LIU Gang, ZHANG Lei, PENG Yong. Simulation Research on Deformation Laws of a Titanium Alloy Skin-skeleton Structure during Laser Beam Welding[J]. Acta Armamentarii, 2025, 46(3): 240017-.

图/表 19

图1 蒙皮-骨架结构

Fig.1 Skin-skeleton structure

图2 高斯面-圆柱体复合热源与热源校核结果

Fig.2 Gaussian surface-cylinder composite heat source model and comparison of welding joint results

表1 焊接工艺参数

Table 1 Welding parameters.

焊缝编号	接头类型	激光功率/W	焊接速度/ (m·s^-1)	离焦量/ mm	保护气流量/ (L·min^-1)
1~8	搭接	1200	0.025	+2	25
9~12	焊接	1100	0.025	+2	25

表2 热源模型参数

Table 2 Geometric parameters of heat source model

热源参数	对接焊接热源	搭接焊接热源
R_v/mm	0.25	0.30
H/mm	1.9	2
M_v	0	0
R_s/mm	0.8	1.2
M_s	3	3
面热源分配系数a	0.3	0.4
体热源分配系数b	0.7	0.6
热源效率η	0.85	0.8

表3 TA15钛合金部分热物理性能参数

Table 3 Thermal physical properties of TA15 titanium alloy

温度/ ℃	热导率/ (W·℃^-1·m^-1)	比热容/ (J·Kg^-1·℃^-1)	杨氏模量/ GPa	热膨胀系数/ (10^-6·℃^-1)
20	8.7	534	120	8.800
100	9.7	546	117	8.897
200	10.2	588	109	8.998
300	10.9	628	100	9.089
400	12.2	670	95	9.197
500	13.8	712	92	9.299
600	15.1	755	79	9.494
700	16.8	838	69	9.697
800	18	880	53.8	9.697
1000	21.4	967	39.5	9.697
1200	21.4	981	30	9.697
1680	21.4	981	5.1	9.697

图3 焊接热循环曲线

Fig.3 Thermal cycle curves

图4 瞬态热源法与热循环曲线法计算结果对比

Fig.4 Comparison of calculated results of transient heat source model and thermal cycle curve model

表4 焊接顺序

Table 4 Welding sequences

焊接顺序编号	焊接顺序
1	A1→A2→A3→A4→A5→A6→A7→A8→B1→B2→B3→B4→B5→B6→B7→B8→B9→B10→B11→B12→A9→A10→A11→A12
2	A6→A5→A3→A4→A1→A2→A7→A8→B6→B5→B3→B4→B1→B2→B7→B8→B9→B10→B11→B12→A9→A10→A11→A12
3	A6→A5→A3→A4(反向)→A1→A2(反向)→A7→A8→B6→B5→B3→B4(反向)→B1→B2(反向)→B7→B8→B9→B10→B11→B12→A9→A10→A11→A12

图5 焊接顺序1、2、3下计算的应力分布云图

Fig.5 Distribution maps of calculated stresses under welding sequences 1,2 and 3

图6 焊接顺序1、2和3下计算的焊接变形分布云图

Fig.6 Calculated deformations on Sides A and B under welding sequences 1,2 and 3

图7 焊接顺序4下计算的焊接应力分布云图

Fig.7 Calculated stress under welding sequence 4

图8 特征路径和点示意图

Fig.8 Feature lines and points on Sides A and B

图9 沿跟踪路径L1和L2的残余应力

Fig.9 Residual stresses along feature lines L1 and L2

图10 焊接顺序4的焊接变形计算结果

Fig.10 Calculated deformations under the welding sequence 4

图11 沿跟踪路径L1和L2的焊接变形

Fig.11 Welding deformations along L1 and L2

图12 焊接顺序1和4下特征点P1、P2、P3处焊接变形

Fig.12 Welding deformations at feature points P1,P2 and P3 under welding sequences 1 and 4

图13 不同焊接顺序条件下特征点处的变形量

Fig.13 Deformations at feature points under different welding sequences

图14 焊接变形测量示意图

Fig.14 Measurement diagram of welding deformation

表5 实验结果与计算结果对比

Table 5 Comparisons of experimental and calculated results

焊接顺序	特征点	实验变形/mm	计算变形/mm	误差/%
焊接顺序1	P₁	-0.188	-0.168	10.6
	P₂	0.196	0.178	9.2
	P₃	0.222	0.198	10.8
焊接顺序4	P₁	-0.063	-0.066	4.8
	P₂	-0.025	-0.028	12.0
	P₃	0.024	0.0210	12.5

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