材料成形原理焊接原理概述PPT課件

1、第一章 序論1.1 連接與人類歷史自石器時(shí)代至今天連接始終是人類制造業(yè)中最為重要的工藝過(guò)程之一材料成形原理-焊接原理（序論） 3第2頁(yè)/共34頁(yè)第1頁(yè)/共34頁(yè) 在通常意義上，連接是指將零、部件組合成一個(gè)（連續(xù)）整體的工藝過(guò)程，其所獲得的整體具備各被連接零、部件沒(méi)有的功能或復(fù)合功能。 連接所關(guān)心的核心問(wèn)題是那些具備固有微觀結(jié)構(gòu)與宏觀性能的被連接材料在連接過(guò)程中的演變，以及所構(gòu)建連接結(jié)構(gòu)的組織與力學(xué)特征。材料成形原理-焊接原理（序論） 41.2 連接的定義、目的及基本分類1.2.1 連接的定義第3頁(yè)/共34頁(yè)第2頁(yè)/共34頁(yè)Figure 1.1 Welding, using a variety

2、of fusion welding, predominantly consumable electrode processes, is used almost exclusively in ship construction. Roll product (e.g., plate and beams), forgings, and castings are all welded to provide structural integrity, structural efficiency, and leak tightness. In most shipyards parts are joined

3、 to create large pre-fabricated modules, which are then joined to produce the ship, here the aircraft carrier Reagan.大型結(jié)構(gòu)材料成形原理-焊接原理（序論） 5第4頁(yè)/共34頁(yè)第3頁(yè)/共34頁(yè)Figure 1.2 Modern manufacturing often benefits when labor-intensive, quality-critical assembly is automated, as exemplified in the automobile indu

4、stry by robotic welding. (Courtesy of DaimlerChrysler AG, Stuttgart, Germany, with permission.)中型結(jié)構(gòu)材料成形原理-焊接原理（序論） 6第5頁(yè)/共34頁(yè)第4頁(yè)/共34頁(yè)Figure 1.3 Welding is also used for microjoining for a variety of applications and industries. Here, very thin kovar sheets are spot-fillet welded by laser-beam welding

5、 to produce the minute lap joints shown. (Courtesy of Sandia National Laboratories, Albuquerque, NM, with permission.)微小結(jié)構(gòu)材料成形原理-焊接原理（序論） 7第6頁(yè)/共34頁(yè)第5頁(yè)/共34頁(yè)Figure 1.4 Typical large welded structures at a petrochemical plant. Note the bolted thick-section pipes, valves, and fittings at the left and ri

6、ght of the welded towers, as shown in a close-up in Figure 2.3. (Courtesy of Marathon Ashland Petroleum LLC, Findlay, OH, with permission.)金屬材料材料成形原理-焊接原理（序論） 8第7頁(yè)/共34頁(yè)第6頁(yè)/共34頁(yè)Figure 1.5 Typical use of manual iron soldering in industry. (Courtesy of the IBM Corporation, Poughkeepsie, NY, with permis

7、sion.)Figure 1.6 An example of a friction-welded ceramic assembly. (Courtesy of the Edison Welding Institute, Columbus, OH, with permission.)陶瓷+金屬材料成形原理-焊接原理（序論） 9第8頁(yè)/共34頁(yè)第7頁(yè)/共34頁(yè)Figure 1.7 The use of thermal bonding, as well as adhesive bonding, is commonplace in the assembly of thermoplastic monol

8、ithic and reinforced composites used in military aircraft. (Courtesy of Northrop Grumman Corporation, with permission.)復(fù)合材料材料成形原理-焊接原理（序論） 10第9頁(yè)/共34頁(yè)第8頁(yè)/共34頁(yè)Figure 1.8 In an analog to welding, a laser beam can be used to reattach a detached retina, with the heat of the laser causing joining by coagu

9、lating protein. (Courtesy of Julia A. Haller, M.D., The Johns Hopkins Hospital, Baltimore, MD, with permission.)生物材料材料成形原理-焊接原理（序論） 11第10頁(yè)/共34頁(yè)第9頁(yè)/共34頁(yè)Figure 1.9 Huge offshore drilling platforms, serving as self-sufficient cities at sea, use welding extensively in their land-based construction, on-s

10、ite erection, and above and below water repair. (Courtesy of Materials & Welding Technology, Houston, TX, with permission.) VA, with permission.)Figure 1.10 Underwater arc welding is necessary for both construction and repair. Here, a diver is shown arc-repair welding an obviously overgrown stee

11、l structure. (Courtesy of Daves Diving & Offshore, in memory of Chris Mourtinson, Morgan City, LA, with permissionof David Gilbert.)海材料成形原理-焊接原理（序論） 12第11頁(yè)/共34頁(yè)第10頁(yè)/共34頁(yè)Figure 1.11 Welding is used to construct overland pipelines in all kinds of climates, including frozen tundra or scorching dese

12、rts, as shown here. (Courtesy of Bechtel Corporation, San Francisco, CA, with permission.)陸材料成形原理-焊接原理（序論） 13第12頁(yè)/共34頁(yè)第11頁(yè)/共34頁(yè)Figure 1.12 As humans venture farther and stay longer in outer space, joining by specially adapted conventional processes as well as yet-to-be-developed processes will be a

13、necessity. Here, an astronaut assembles new parts onto a portion of the InternationalOrbiting Space Station. (Courtesy of the National Aeronautics and Space Administration,Washington, DC, with permission.)天材料成形原理-焊接原理（序論） 14第13頁(yè)/共34頁(yè)第12頁(yè)/共34頁(yè)材料成形原理-焊接原理（序論） 151.2.2 連接的目的（1）功能： 獲得單一工藝方法（例鑄造、鍛壓、粉末冶金、機(jī)

14、加）無(wú)法獲得的大尺寸或復(fù)雜結(jié)構(gòu)構(gòu)件； 制備具有多功能耦合的多種材料復(fù)合體。（2）可制造性：利用已有構(gòu)件和材料達(dá)到整體結(jié)構(gòu)構(gòu)造的有效性；獲得單一工藝方法無(wú)法獲得的大尺寸或復(fù)雜結(jié)構(gòu)構(gòu)件將適合的材料用于適合的位置，優(yōu)化選擇；充分利用材料，盡量減少材料的消耗。（3）成本（4）美學(xué)重要性第14頁(yè)/共34頁(yè)第13頁(yè)/共34頁(yè)1.2.3 連接的基本分類連接（Joining）機(jī)械連接（Mechanical Fasteners, Riveting）粘接（Adhesive Bonding and Cementing）焊接（Welding, Braze, solder and diffusion bonding）機(jī)

15、械力（彈、塑性畸變）強(qiáng)度低、非密封范德華力 、氫鍵強(qiáng)度低、密封金屬鍵，共價(jià)鍵，離子鍵強(qiáng)度高、密封材料成形原理-焊接原理（序論） 16第15頁(yè)/共34頁(yè)第14頁(yè)/共34頁(yè)1.3 材料焊接成型的物理本質(zhì) 1.3.1 焊接基本方法材料成形原理-焊接原理（序論） 17第16頁(yè)/共34頁(yè)第15頁(yè)/共34頁(yè)焊接方法分類熔焊熔焊壓焊壓焊釬焊釬焊電弧焊電弧焊氣焊氣焊鋁熱焊鋁熱焊電渣焊電渣焊電子束焊電子束焊激光焊激光焊電阻點(diǎn)（縫）焊電阻點(diǎn)（縫）焊熔化極熔化極手工電弧焊手工電弧焊氬弧焊氬弧焊(MIG)埋弧焊埋弧焊(SAW)CO2焊焊螺柱焊螺柱焊非熔化極非熔化極鎢極氬弧焊鎢極氬弧焊(TIG)等離子弧焊等離子弧焊(P

16、AW)原子氫焊原子氫焊摩擦焊摩擦焊擴(kuò)散焊擴(kuò)散焊爆炸焊爆炸焊超聲波焊超聲波焊冷壓焊冷壓焊電阻焊、閃光對(duì)焊電阻焊、閃光對(duì)焊材料成形原理-焊接原理（序論） 18第17頁(yè)/共34頁(yè)第16頁(yè)/共34頁(yè)Figure 1.13 氣體保護(hù)鎢極電弧焊（ Gas-Tungsten Arc Welding; GTAW ）。示意圖 (Reprinted from Joining of Advanced Materials, Robert W. Messler, Jr., Fig. 6.9, page 202, Butterworth-Heinemann, Stoneham, MA, 1993)材料成形原理-焊接原理（

17、序論） 19第18頁(yè)/共34頁(yè)第17頁(yè)/共34頁(yè)Figure 1.14 氣體保護(hù)熔化極電弧焊（gas-metal arc welding; GMAW）示意圖 。(Reprinted from Joining of Advanced Materials, Robert W. Messler, Jr., Fig. 6.16, page 208, Butterworth-Heinemann, Stoneham, MA, 1993)材料成形原理-焊接原理（序論） 20第19頁(yè)/共34頁(yè)第18頁(yè)/共34頁(yè)Figure 1.15 手工電弧焊（shielded metal arc welding; SMAW

18、 ）示意圖 。(Reprinted from Joining of Advanced Materials, Robert W. Messler, Jr., Fig. 6.18, page 211, Butterworth-Heinemann, Stoneham, MA, 1993)材料成形原理-焊接原理（序論） 21第20頁(yè)/共34頁(yè)第19頁(yè)/共34頁(yè)Figure 1.16 藥芯焊絲電弧焊（flux-cored arc welding; FCAW）示意圖 。(Reprinted from Joining of Advanced Materials, Robert W. Messler, Jr.

19、, Fig. 6.19, page 213, Butterworth-Heinemann, Stoneham, MA, 1993)材料成形原理-焊接原理（序論） 22第21頁(yè)/共34頁(yè)第20頁(yè)/共34頁(yè)Figure 1.17 埋弧焊（submerged arc welding; SAW）示意圖。 (Reprinted from Joining of Advanced Materials, Robert W. Messler, Jr., Fig. 6.20, page 213, Butterworth-Heinemann, Stoneham, MA, 1993)材料成形原理-焊接原理（序論） 2

20、3第22頁(yè)/共34頁(yè)第21頁(yè)/共34頁(yè)Figure 1.18 電渣焊（electroslag welding; ESW）示意圖 。(Reprinted from Joining of Advanced Materials, Robert W. Messler, Jr., Figs. 6.21 and 6.22, page 215, Butterworth-Heinemann, Stoneham, MA, 1993)材料成形原理-焊接原理（序論） 24第23頁(yè)/共34頁(yè)第22頁(yè)/共34頁(yè)Figure 1.19 電阻點(diǎn)焊（resistance spot welding; RSW）示意圖。(Repr

21、inted from Joining of Advanced Materials, Robert W. Messler, Jr., Fig. 6.24, page 218, Butterworth-Heinemann, Stoneham, MA, 1993)材料成形原理-焊接原理（序論） 25第24頁(yè)/共34頁(yè)第23頁(yè)/共34頁(yè)Figure 1.20 (a) 爆炸焊示意圖（explosion welding; EXW）； (b)爆炸焊典型形貌。 （Reprinted from Joining of Advanced Materials, Robert W. Messler, Jr., Fig.

22、 6.28, page 224, Butterworth-Heinemann, Stoneham, MA, 1993）材料成形原理-焊接原理（序論） 26第25頁(yè)/共34頁(yè)第24頁(yè)/共34頁(yè)Figure 1.21 (a) 摩擦焊（friction welding; FRW）示意圖； (b) 典型摩擦焊接頭。 (Reprinted from Joining of Advanced Materials, Robert W. Messler, Jr., Fig. 6.29, page 225, Butterworth-Heinemann, Stoneham, MA, 1993)材料成形原理-焊接原理

23、（序論） 27第26頁(yè)/共34頁(yè)第25頁(yè)/共34頁(yè)1.3 材料焊接成型的物理本質(zhì) 1.3.2 焊接的定義 兩種或兩種以上的材料，在添加或不添加填充材料的條件下，通過(guò)加熱、加壓，或二者并用的外場(chǎng)形式，并借助物質(zhì)遷移過(guò)程，消除接觸表面、形成永久性、致密、高強(qiáng)接頭的物理化學(xué)過(guò)程。材料成形原理-焊接原理（序論） 28第27頁(yè)/共34頁(yè)第26頁(yè)/共34頁(yè)1.3.3 不同焊接方法所需外場(chǎng)（溫度、壓力）s2s3s4sTmTb激光電子束電弧電渣氣焊擴(kuò)散接觸超聲冷壓磁脈沖爆炸磨擦0.111010010000.111010010000.010t/sP圖1-22 不同焊接方法作用溫度、壓力及過(guò)程持續(xù)時(shí)間的對(duì)比材料成形原理-焊接原理（序論） 29第28頁(yè)/共34頁(yè)第27頁(yè)/共34頁(yè) 1.3.4 焊接的物理本質(zhì) 圖1-24 固-固硬球結(jié)構(gòu)模型 圖1-23 固-液硬球結(jié)構(gòu)模型 材料成形原理-焊接原理（序論） 30第29頁(yè)/共34頁(yè)第28頁(yè)/共34頁(yè)則兩原子間的相吸力為nmrarbrafffnmrA)5 . 03 . 0(圖1-2 原子間作用力與距離關(guān)系1斥力；2引力；3合力材料成形原理-焊接原理（序論） 31萊納德-瓊斯勢(shì)nnmmrArArV)(Lennard-Jones按求極限法則可得到與最大凈作用力對(duì)應(yīng)的原子間距為標(biāo)準(zhǔn)