Simulation Research on Deformation Laws of a Titanium Alloy Skin-skeleton Structure during Laser Beam Welding

doi:10.12382/bgxb.2024.0017

Abstract

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

CLC Number:

TG456.7

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-.

Figures/Tables 19

References 30

[1]	ZHAO Q Y, SUN Q Y, XIN S W, et al. High-strength titanium alloys for aerospace engineering applications:a review on melting-forging process[J]. Materials Science and Engineering A-Structural Materials Properties Microstructure and Processing, 2022, 845:143260.
[2]	吴崇周. 钛合金在飞行器中的作用[J]. 宇航材料工艺, 2016, 46(5):8-12.
	WU C Z. Effects of titanium alloy on flying equipments[J]. Aerospace Materials & Technology, 2016, 46(5):8-12. (in Chinese)
[3]	刘自刚, 代锋先, 陆刚, 等. 钛合金激光焊研究现状与展望[J]. 材料导报, 2023, 37(增刊1):354-359.
	LIU Z G, DAI F X, LU G, et al. Research status and prospect of laser welding of titanium alloy[J]. Materials Reports, 2023, 37(S1):354-359. (in Chinese)
[4]	武鹏博, 徐锴, 黄瑞生, 等. 薄壁钛合金T形接头摆动激光填丝焊组织与性能[J]. 兵工学报, 2023, 44(4):1015-1022.
	WU P B, XU K, HUANG R S, et al. Microstructure and properties of laser oscillating welding with filler wire of thin wall titanium alloy T-joints[J]. Acta Armamentarii, 2023, 44(4):1015-1022. (in Chinese) doi: 10.12382/bgxb.2021.0894
[5]	KUMAR R, GUPTA R, SARKAR A, et al. Vacuum diffusion bonding of α-titanium alloy to stainless steel for aerospace applications:interfacial microstructure and mechanical characteristics[J]. Materials Characterization, 2022, 183:111607.
[6]	LI Y L, LI Y Q, ZHANG C H, et al. Effect of structural restraint caused by the stiffener on welding residual stress and deformation in thick-plate T-joints[J]. Journal of Materials Research and Technology, 2022, 21:3397-3411.
[7]	李光祖, 王江涛, 谢利, 等. 航空铝合金激光焊接关键工艺参数与应力场关系[J]. 兵工学报, 2024, 45 (5):1692-1702. doi: 10.12382/bgxb.2023.0935
	LI G Z, WANG J T, XIE L, et al. Relationship between key process parameters and stress field of aviation aluminum alloy welded by laser beam[J]. Acta Armamentarii, 2024, 45 (5):1692-1702. (in Chinese) doi: 10.12382/bgxb.2023.0935
[8]	郦羽, 万正权, 唐文勇. 考虑固相变的钛合金焊接残余应力数值仿真方法[J]. 船舶力学, 2023, 27(1):109-120.
	LI Y, WAN Z Q, TANG W Y. Numerical simulation method of welding residual stress of titanium alloy considering solid-state phase transformation[J]. Journal of Ship Mechanics, 2023, 27(1):109-120. (in Chinese)
[9]	芦凤桂, 邓德安, 王亚琦, 等. 数值模拟技术在激光焊接过程中的应用及发展[J]. 焊接学报, 2022, 43(8):87-94. doi: 10.12073/j.hjxb.20220430001
	LU F G, DENG D A, WANG Y Q, et al. Application and development of numerical simulation technology in laser welding process[J]. Transactions of The China Welding Institution, 2022, 43(8):87-94. (in Chinese) doi: 10.12073/j.hjxb.20220430001
[10]	李小曼, 庄明祥, 段舒尧, 等. 焊接方向对钛合金H型桁条-蒙皮结构双激光束双侧同步焊接变形的影响[J]. 热加工工艺, 2021, 50(9):140-143.
	LI X M, ZHUANG M X, DUAN S Y, et al. Effect of welding direction on deformation of H-beam stringer-skin structure welded by double laser beam and bilateral simultaneous welding[J]. Hot Working Technology, 2021, 50(9):140-143. (in Chinese)
[11]	梁归慧, 谢锋, 韩世伟, 等. 1500 MPa级超高强钢复杂薄壁结构焊接变形预测[J]. 机械工程学报, 2023, 59(24):95-107.
	LIANG G H, XIE F, HAN S W, et al. Prediction of welding deformation of complex thin wall structure of 1500 MPa grade ultra-high strength steel[J]. Journal of Mechanical Engineering, 2023, 59(24):95-107. (in Chinese)
[12]	张月来, 何清和, 朱嘉翌, 等. 机车车辆大型长直弦梁焊接变形预测[J]. 焊接学报, 2023, 44(9):106-112.
	ZHANG Y L, HE Q H, ZHU J Y, et al. Prediction of welding deformation in large long straight beams for locomotive[J]. Transactions of The China Welding Institution, 2023, 44(9):106-112. (in Chinese)
[13]	HUANG H, WANG J D, LI L Q, et al. Prediction of laser welding induced deformation in thin sheets by efficient numerical modeling[J]. Journal of Materials Processing Technology, 2016, 227:117-128.
[14]	RENZI C, PANARI D, LEALI F. Predicting tolerance on the welding distortion in a thin aluminum welded T-joint[J]. International Journal of Advanced Manufacturing Technology, 2018, 96(5-8):2479-2494.
[15]	FAHLSTRÖM K, ANDERSSON O, MELANDER A, et al. Correlation between laser welding sequence and distortions for thin sheet structures[J]. Science and Technology of Welding and Joining, 2017, 22(2):150-156.
[16]	JIN H X, CHEN Z L, LIU X B, et al. Numerical simulation research on welded residual stress and distortion of aero-engine afterburner lobe mixer with different welding sequences[J]. International Journal of Advanced Manufacturing Technology, 2023, 126(3/4):1329-1346.
[17]	WU R L, HUANG Y, XU J J, et al. Stress and distortion of the 10mm thick plate EH40 and 316L different butt joints in 10 kW laser welding[J]. Optics & Laser Technology, 2022, 152:108179.
[18]	MA N S, HUANG H. Efficient simulation of welding distortion in large structures and its reduction by jig constraints[J]. Journal of Materials Engineering and Performance, 2017, 26(11):5206-5216.
[19]	BAI R X, GUO Z F, TIAN C G, et al. Study on welding sequence of butt-welded structures based on equivalent heat source parameter[J]. International Journal of Pressure Vessels and Piping, 2018, 163:15-22.
[20]	WANG Y F, FENG G J, PU X W, et al. Influence of welding sequence on residual stress distribution and deformation in Q345 steel H-section butt-welded joint[J]. Journal of Materials Research and Technology, 2021, 13:144-153.
[21]	MOSLEMI N, ABDI B, GOHARI S, et al. Influence of welding sequences on induced residual stress and distortion in pipes[J]. Construction and Building Materials, 2022, 342:127995.
[22]	RONG Y M, XU J J, HUANG Y, et al. Review on finite element analysis of welding deformation and residual stress[J]. Science and Technology of Welding and Joining, 2018, 23(3):198-208.
[23]	王秋实. 转向架构架侧梁的焊接变形数值模拟研究[D]. 成都: 西南交通大学, 2017.
	WANG Q S. Research of welding deformation of bogie side frame based on numerical simulation method[D]. Chengdu: Southwest Jiaotong University, 2017. (in Chinese)
[24]	ZHAO W Y, LI S D, DING J Q, et al. Building framework for selecting finite element models of complex large welded structure of railway vehicles[J]. Simulation Modelling Practice and Theory, 2019, 97:101950.
[25]	ZHANG K Z, LIU D, CAI J M, et al. Influence of laser offsets on microstructure and tensile properties of laser welded Ti-3Al-6Mo-2Fe-2Zr and TA15 dissimilar joints[J]. Materials Characterization, 2021, 180:111441.
[26]	杨光, 丁林林, 钦兰云, 等. TA15钛合金激光沉积温度场数值模拟与检测[J]. 强激光与粒子束, 2014, 26(11):293-299.
	YANG G, DING L L, QIN L Y, et al. Measurement and numerical simulation of temperature field of laser deposition 0f TAl5 titanium alloy[J]. High Power Laser and Particle Beams, 2014, 26(11):293-299.
[27]	王君俊. TA15钛合金薄壁锥筒件焊后热处理校形数值模拟研究[D]. 哈尔滨: 哈尔滨工业大学, 2015.
	WANG J J. Simulation on post-welded hot sizing of ta15 titanium alloy thin-walled cone piece[D]. Harbin: Harbin Institute of Technology, 2015. (in Chinese)
[28]	廖娟, 程鹏, 冯芳, 等. 基于热循环曲线法的低合金高强钢对接接头焊接残余应力数值模拟[J]. 机械工程材料, 2023, 47(7):85-90.
	LIAO J, CHENG P, FENG F, et al. Numerical simulation of welding residual stress in butt joint of low alloy high strength steel based on thermal cycle curve method[J]. Materials for Mechanical Engineering, 2023, 47(7):85-90. (in Chinese)
[29]	吴振, 王发展, 安高灵, 等. 基于热循环曲线的分段移动组合型焊接热源研究[J]. 热加工工艺, 2015, 44(11):211-216.
	WU Z, WANG F Z, AN G L, et al. Research of segmented moving combined welding heat source using thermal cycle curve as control variables[J]. Hot Working Technology, 2015, 44(11):211-216. (in Chinese)
[30]	于金超. TA15钛合金结构件焊接变形分析与优化[D]. 成都: 电子科技大学, 2021.
	YU J C. Analysis and optimization of welding deformation of TA15 titanium alloy structure[D]. Chengdu: University of Electronic Science and Technology of China, 2021. (in Chinese)

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

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

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

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

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