A dual current ultrasonic hybrid welding method and system based on dissimilar metals

Abstract

The application discloses a kind of based on heterogeneous metal's double-current ultrasonic composite welding system and method, it is related to composite welding technical field.Inverse resistance welding power module according to current control signal to the heterogeneous metal plate to be welded output preset current amplitude two-way direct current;Two-way direct current flows through the heterogeneous metal plate to be welded and generates resistance heat ultrasonic welding power module according to ultrasonic control signal output preset amplitude and frequency ultrasonic vibration;Ultrasonic vibration acts on the heterogeneous metal plate to be welded;Controller is connected with inverse resistance welding power module and ultrasonic welding power module respectively, for: issue current control signal, and / or, ultrasonic control signal;Current control signal and ultrasonic control signal are sent according to set phase relationship;Heterogeneous metal plate to be welded occurs solid-phase connection under the action of resistance heat and the ultrasonic vibration, and forms the effective connection of heterogeneous metal.The application improves the mechanical properties of heterogeneous metal ultrasonic welding joint.

Description

Technical Field

[0001] The present invention relates to the technical field of composite welding, and in particular to a dual-current ultrasonic composite welding method and system based on heterogeneous metals. Background Art

[0002] In the field of new energy vehicles, the connection of dissimilar metals (such as Cu / Al and Fe / Al) has received widespread attention. As a high-quality solid-phase connection technology, ultrasonic metal welding has the advantages of short welding time, low interface temperature, and low energy consumption. To a certain extent, it has improved the current situation where there are large differences in the physical properties of dissimilar metals and the rapid formation of intermetallic compounds at the welding interface, resulting in deterioration of the mechanical properties of the joint. Therefore, it can be applied to the connection of dissimilar metals. However, under the action of temperature and high strain rate plastic deformation, the ultrasonic welding interface of metallurgical dissimilar metals is very likely to form thick intermetallic compounds, resulting in deterioration of the mechanical properties of the joint; and the short ultrasonic vibration time is not enough to generate the plastic strain and metallurgical bonding required for the connection at the interface, which greatly restricts the further application of ultrasonic welding in related fields of dissimilar metal welding.

[0003] To improve the welding process, current is introduced into the ultrasonic welding process of dissimilar metals. Chinese patent CN101966624A discloses a method and apparatus for ultrasonically welding non-ferrous metals using a combination of ultrasonic energy and resistance heat. During ultrasonic welding of non-ferrous metals, the resistance welder outputs current that flows through the metal being welded and generates resistance heat, promoting interfacial bonding and addressing issues such as insufficient ultrasonic welding energy and rapid thermal conductivity of non-ferrous metals. However, this method, in which the current flows through all the workpieces being welded, does not alleviate the significant differences in the physical properties of the dissimilar metals.

[0004] Chinese patent CN103639606A discloses a "Thin Metal Sheet Structure Resistance / Ultrasonic Composite Spot Welding Method." This method involves passing a current between two indenters on one side, achieving a weld interface through the combined action of resistance heat and ultrasonic energy. This method can lead to significant plastic deformation of the metal beneath the indenters, while minimizing the plastic deformation between the two indenters, potentially leading to stress concentration. Summary of the Invention

[0005] The purpose of the embodiments of the present invention is to provide a dual-current ultrasonic hybrid welding method and system based on heterogeneous metals, so as to improve the mechanical properties of heterogeneous metal ultrasonic welded joints.

[0006] To achieve the above objectives, the present invention provides the following solutions:

[0007] A dual-current ultrasonic hybrid welding system based on dissimilar metals, comprising:

[0008] An inverter resistance welding power supply module is used to output two DC currents of preset current amplitudes to the heterogeneous metal plates to be welded according to the current control signal; the two DC currents generate resistance heat when flowing through the heterogeneous metal plates to be welded;

[0009] An ultrasonic welding power supply module, configured to output ultrasonic vibrations of preset amplitude and frequency according to an ultrasonic control signal; the ultrasonic vibrations acting on the heterogeneous metal plates to be welded;

[0010] The controller is connected to the inverter resistance welding power module and the ultrasonic welding power module respectively, and is used to:

[0011] Sending the current control signal and / or the ultrasonic control signal;

[0012] The current control signal and the ultrasonic control signal are emitted according to a set phase relationship;

[0013] The heterogeneous metal plates to be welded are solid-phase connected under the action of the resistance heat and the ultrasonic vibration, forming an effective connection of the heterogeneous metals.

[0014] Optionally, the inverter resistance welding power supply module includes:

[0015] a first inverter resistance welding power supply, configured to output a first direct current according to the current control signal; the first inverter resistance welding power supply is connected to a first metal in the heterogeneous metal plates to be welded;

[0016] a second inverter resistance welding power supply, configured to output a second direct current according to the current control signal; the second inverter resistance welding power supply being connected to a second metal in the dissimilar metal plates to be welded;

[0017] The first direct current is greater than the second direct current; the two direct currents include the first direct current and the second direct current; the elastic modulus and melting point of the first metal are greater than the elastic modulus and melting point of the second metal.

[0018] Optionally, the ultrasonic welding power supply module includes:

[0019] an ultrasonic welding power supply, configured to generate a vibration signal of preset amplitude and frequency according to the ultrasonic control signal;

[0020] a transducer, connected to the ultrasonic welding power supply, for converting the vibration signal into ultrasonic vibration;

[0021] a horn connected to the transducer and used to conduct the ultrasonic vibration;

[0022] A tool head is connected to the horn and is used to apply the ultrasonic vibration to the heterogeneous metal plates to be welded.

[0023] Optionally,

[0024] The first inverter resistance welding power supply, the first metal and the tool head form a first current loop; a first direct current flows through the loop;

[0025] The second inverter resistance welding power supply, the second metal and the base form a second current loop; a second direct current flows through the loop;

[0026] The first direct current and the second direct current are in opposite directions, and the first metal and the second metal repel each other under the interaction of the current and the magnetic field.

[0027] Optionally,

[0028] The first inverter resistance welding power supply, the first metal and the tool head form a first current loop; a first direct current flows through the loop;

[0029] The second inverter resistance welding power supply, the second metal and the base form a second current loop; a second direct current flows through the loop;

[0030] The first direct current and the second direct current have the same direction, and the first metal and the second metal attract each other under the interaction of the current and the magnetic field.

[0031] A dual-current ultrasonic composite welding method based on dissimilar metals, comprising:

[0032] Sending a current control signal and / or an ultrasonic control signal;

[0033] The current control signal and the ultrasonic control signal are emitted according to a set phase relationship;

[0034] According to the current control signal, the inverter resistance welding power supply module outputs two DC currents with preset current amplitudes to the heterogeneous metal plates to be welded; the two DC currents generate resistance heat when flowing through the heterogeneous metal plates to be welded;

[0035] According to the ultrasonic control signal, the ultrasonic welding power supply module outputs ultrasonic vibrations of preset amplitude and frequency; the ultrasonic vibrations act on the heterogeneous metal plates to be welded;

[0036] The heterogeneous metal plates to be welded are solid-phase connected under the action of the resistance heat and the ultrasonic vibration, forming an effective connection of the heterogeneous metals.

[0037] Optionally, according to the current control signal, the inverter resistance welding power supply module outputs two DC currents of preset current amplitudes to the heterogeneous metal plates to be welded, specifically including:

[0038] According to the current control signal, the first inverter resistance welding power supply outputs a first direct current; the first inverter resistance welding power supply is connected to the first metal in the heterogeneous metal plates to be welded;

[0039] According to the current control signal, the second inverter resistance welding power supply outputs a second DC current; the second inverter resistance welding power supply is connected to the second metal in the dissimilar metal plates to be welded;

[0040] The first direct current is greater than the second direct current; the two direct currents include the first direct current and the second direct current; the elastic modulus and melting point of the first metal are greater than the elastic modulus and melting point of the second metal.

[0041] Optionally, according to the ultrasonic control signal, the ultrasonic welding power module outputs ultrasonic vibration of preset amplitude and frequency, specifically including:

[0042] generating a vibration signal of preset amplitude and frequency according to the ultrasonic control signal;

[0043] converting the vibration signal into ultrasonic vibration;

[0044] The ultrasonic vibration is conducted and acts on the dissimilar metal plates to be welded.

[0045] Optionally, according to the current control signal, the first inverter resistance welding power supply outputs a first direct current; according to the current control signal, the second inverter resistance welding power supply outputs a second direct current, including:

[0046] The first inverter resistance welding power supply, the first metal and the tool head form a first current loop; a first direct current flows through the loop;

[0047] The second inverter resistance welding power supply, the second metal and the base form a second current loop; a second direct current flows through the loop;

[0048] The first direct current and the second direct current are in opposite directions, and the first metal and the second metal repel each other under the interaction of the current and the magnetic field.

[0049] Optionally, according to the current control signal, the first inverter resistance welding power supply outputs a first direct current; according to the current control signal, the second inverter resistance welding power supply outputs a second direct current further comprises:

[0050] The first inverter resistance welding power supply, the first metal and the tool head form a first current loop; a first direct current flows through the loop;

[0051] The second inverter resistance welding power supply, the second metal and the base form a second current loop; a second direct current flows through the loop;

[0052] The first direct current and the second direct current have the same direction, and the first metal and the second metal attract each other under the interaction of the current and the magnetic field.

[0053] In an embodiment of the present invention, a controller controls an inverter resistance welding power module to output two DC currents of preset current amplitudes to the dissimilar metal plates to be welded. The two DC currents generate resistance heat when flowing through the dissimilar metal plates, enabling targeted adjustment of the heat distribution during dissimilar metal welding. The controller also controls an ultrasonic welding power module to output ultrasonic vibrations within a set amplitude and frequency range. The interaction of the two DC currents and the ultrasonic vibrations connects the dissimilar metal plates. This effectively utilizes the electroplastic effect generated by current flowing through the metals being welded and the principle of mutual attraction between currents flowing in the same direction to improve the microstructure of the dissimilar metal weld interface and the mechanical properties of the joint. BRIEF DESCRIPTION OF THE DRAWINGS

[0054] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0055] Figure 1 A schematic structural diagram of a dual-current ultrasonic hybrid welding system based on heterogeneous metals provided by an embodiment of the present invention;

[0056] Figure 2 A detailed structural diagram of a dual-current ultrasonic hybrid welding system based on dissimilar metals provided in an embodiment of the present invention;

[0057] Figure 3 A schematic diagram of a first current loop provided by an embodiment of the present invention;

[0058] Figure 4 A schematic diagram of a second current loop provided by an embodiment of the present invention;

[0059] Figure 5 A schematic diagram of a first dual current-ultrasound composite waveform provided by an embodiment of the present invention;

[0060] Figure 6 A schematic diagram of a second dual current-ultrasound composite waveform provided by an embodiment of the present invention;

[0061] Figure 7 A schematic diagram of a third dual current-ultrasound composite waveform provided by an embodiment of the present invention;

[0062] Figure 8 A schematic flow chart of a dual-current ultrasonic hybrid welding method for heterogeneous metals provided in an embodiment of the present invention.

[0063] Explanation of symbols:

[0064] Inverter resistance welding power module-1, controller-2, ultrasonic welding power module-3. DETAILED DESCRIPTION

[0065] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0066] The purpose of the present invention is to provide a dual-current ultrasonic composite welding method and system based on heterogeneous metals to solve the problem of poor mechanical properties of existing heterogeneous metal ultrasonic welding joints.

[0067] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the present invention is further described in detail below with reference to the accompanying drawings and specific embodiments.

[0068] Figure 1 and Figure 2 An exemplary structure of the above-mentioned dual-current ultrasonic hybrid welding system based on heterogeneous metals is shown. The following is a detailed introduction to each module.

[0069] The inverter resistance welding power supply module 1 is used to output two DC currents of preset current amplitudes to the heterogeneous metal plates to be welded according to the current control signal; when the two DC currents flow through the heterogeneous metal plates to be welded, resistance heat is generated;

[0070] The inverter resistance welding power supply module 1 includes: a first inverter resistance welding power supply and a second inverter resistance welding power supply, namely, a resistance spot welding power supply 1 and a resistance spot welding power supply 2 .

[0071] The first inverter resistance welding power supply is used to output a first direct current according to a current control signal; the first inverter resistance welding power supply is connected to a first metal in the heterogeneous metal plates to be welded;

[0072] The second inverter resistance welding power supply is used to output a second direct current according to the current control signal; the second inverter resistance welding power supply is connected to the second metal in the dissimilar metal plates to be welded;

[0073] The first direct current is greater than the second direct current; the two direct currents include the first direct current and the second direct current; the elastic modulus and melting point of the first metal are greater than the elastic modulus and melting point of the second metal.

[0074] In one example, during the dual-current ultrasonic hybrid welding process, two direct currents flow through the heterogeneous metal plates to be welded, including: a first direct current (larger current) flows through the first metal (such as Cu, Fe, Ti, etc.) with a larger elastic modulus and a higher melting point in the heterogeneous metal plates to be welded, and a second direct current (smaller current) flows through the second metal (such as aluminum plate) with a smaller elastic modulus and a lower melting point.

[0075] The ultrasonic welding power supply module 3 (ultrasonic welding equipment) is used to output ultrasonic vibrations of preset amplitude and frequency according to the ultrasonic control signal; the ultrasonic vibrations act on the heterogeneous metal plates to be welded;

[0076] See Figure 2 The ultrasonic welding power supply module 3 includes: an ultrasonic welding power supply, a transducer, a horn and a tool head.

[0077] The ultrasonic welding power supply is used to generate a vibration signal of preset amplitude and frequency according to the ultrasonic control signal;

[0078] The transducer is connected to the ultrasonic welding power supply, and the transducer is used to convert the vibration signal into ultrasonic vibration;

[0079] The horn is connected to the transducer, and the horn is used to conduct the ultrasonic vibration;

[0080] The tool head is connected to the horn, and the tool head is used to apply ultrasonic vibration to the heterogeneous metal plates to be welded.

[0081] In one example, a tool head is used to generate ultrasonic vibrations on the dissimilar metal plates to be welded according to the vibration signal and the welding pressure; the tool head is placed above the dissimilar metal plates to be welded;

[0082] Under the action of resistance heat and ultrasonic vibration, the dissimilar metal plates to be welded undergo solid phase connection, forming an effective connection of the dissimilar metals.

[0083] A laser displacement sensor is used to measure the vibration process of the tool head, and a Hall current sensor is used to measure the first DC current output by the first inverter resistance welding power supply and the second DC current output by the second inverter resistance welding power supply. The first DC current and the second DC current enter the signal acquisition system through the data acquisition channel and are displayed and saved by Labview.

[0084] The controller 2 (composite control box) is connected to the inverter resistance welding power module 1 and the ultrasonic welding power module 3 respectively. The controller 2 is used to:

[0085] Sending a current control signal and / or an ultrasonic control signal;

[0086] The current control signal and the ultrasonic control signal are sent out according to the set phase relationship;

[0087] The heterogeneous metal plates to be welded are solid-phase connected under the action of resistance heat and the ultrasonic vibration, forming an effective connection of the heterogeneous metals.

[0088] In one example, the controller 2 is used to control the first inverter resistance welding power supply and the second inverter resistance welding power supply to apply DC currents with the same or different directions to the heterogeneous metal plates to be welded; the DC current is used to generate resistance heat in the heterogeneous metals.

[0089] The controller 2 is also used to control the ultrasonic welding power module 3 to output a vibration signal with an amplitude of 10um to 50um and a frequency of 10kHZ to 60kHZ.

[0090] In summary, in an embodiment of the present invention, a controller controls an inverter resistance welding power module to output two DC currents of preset current amplitudes to the dissimilar metal plates to be welded. When the two DC currents flow through the dissimilar metal plates, they generate resistance heat, enabling targeted adjustment of the heat distribution during dissimilar metal welding. The controller also controls the ultrasonic welding power module to output ultrasonic vibrations within a set amplitude and frequency range. The interaction between the two DC currents and the ultrasonic vibrations connects the dissimilar metal plates. This effectively utilizes the electroplastic effect generated by current flowing through the metals being welded, as well as the principle of mutual attraction between currents flowing in the same direction, to improve the microstructure of the dissimilar metal weld interface and the mechanical properties of the joint.

[0091] The first inverter resistance welding power source forms a first current loop with the first metal assembly and the tool head; a first direct current flows through the first current loop;

[0092] The second inverter resistance welding power supply, the second metal and the base form a second current loop; a second DC current flows through the second current loop;

[0093] The first direct current and the second direct current are in opposite directions, and the first metal and the second metal repel each other under the interaction of the current and the magnetic field.

[0094] In the dual-current ultrasonic hybrid welding system based on dissimilar metals, an insulating rubber pad is placed under the base, the screws are wrapped with electrical insulating tape, and the base is fixed to the steel plate with an insulating gasket to ensure that there is no conductivity between the base and the tool head.

[0095] In one example, if Figure 3As shown, controller 2 controls the vibration signal (electrical signal) output by ultrasonic welding power module 3, which is applied to the tool head through the transducer and horn. Controller 2 also controls the first DC current output by the first inverter resistance welding power supply to flow back to the first inverter resistance welding power supply through the base, the metal with a higher elastic modulus and melting point, and the tool head, forming a first current loop. Controller 2 controls the second DC current output by the second inverter resistance welding power supply to flow back to the second inverter resistance welding power supply through the welding head, the metal with a lower elastic modulus and melting point, and the base, forming a second current loop. The currents in the first and second current loops flow in opposite directions.

[0096] The first direct current and the second direct current flow through the first metal and the second metal in opposite directions, and the first metal and the second metal repel each other under the interaction of the current and the magnetic field.

[0097] The first inverter resistance welding power source, the first metal and the tool head form a first current loop; a first direct current flows through the first current loop;

[0098] The second inverter resistance welding power supply, the second metal and the base form a second current loop; a second DC current flows through the second current loop;

[0099] The first direct current and the second direct current have the same direction, and the first metal and the second metal attract each other under the interaction of the current and the magnetic field.

[0100] In one example, if Figure 4 As shown, controller 2 controls the vibration signal (electrical signal) output by ultrasonic welding power module 3, which is applied to the tool head through the transducer and horn. Controller 2 also controls the first DC current output by the first inverter resistance welding power supply to flow back to the first inverter resistance welding power supply through the base, the metal with a higher elastic modulus and melting point, and the tool head, forming a first current loop. Controller 2 controls the second DC current output by the second inverter resistance welding power supply to flow back to the second inverter resistance welding power supply through the welding head, the metal with a lower elastic modulus and melting point, and the base, forming a second current loop. The currents in the first and second current loops are in the same direction.

[0101] In other embodiments of the present invention, the operation process of the dual-current ultrasonic hybrid welding system based on dissimilar metals can also be as follows:

[0102] An M5000 side-drive ultrasonic welding power module 3 (the ultrasonic welding power supply) outputs ultrasonic vibrations, and two JYD-04LB precision inverter spot welding power supplies serve as the first and second inverter resistance welding power supplies. Controller 2, using the DSPIC33FJ64GS610 chip, coordinates the on / off triggering timing of the ultrasonic welding power supply, the first and second inverter resistance welding power supplies, enabling welding with ultrasonic vibration and dual current in various timing matching modes. The ultrasonic vibration of the tool head is measured in real time using an LG5100 laser displacement sensor. Hall effect current sensors 1 and 2 measure the DC return currents from the first and second inverter resistance welding power supplies, respectively. The tool head vibration signal and the current signals from the first and second inverter resistance welding power supplies are collected by a computer via a PCI-6133 data acquisition card. The data is then displayed and stored using Labview (the monitoring and display module). Based on the dual current signals and ultrasonic vibration signals displayed by Labview, it can be determined whether the control method of the chip DSPIC33FJ64GS610 meets expectations.

[0103] For heterogeneous metal plates of different thicknesses and materials to be welded, the method of adjusting the size and duration of the two DC currents, and the size and duration of the ultrasonic amplitude is adopted to obtain different current-ultrasonic composite waveforms, improve the microstructure of the welding interface, and enhance the mechanical properties of the welded joint.

[0104] In one example, during the welding process of a 0.8 mm Al plate and a 0.8 mm Cu plate, the two DC currents were set to I1 (500 A) and I2 (2700 A), the ultrasonic amplitude was 25 μm, and the initial duration was 0.2 s. The actual dual current-ultrasonic composite waveform measured was as follows: Figure 5 shown. Figure 5 The horizontal axis of (A) represents time t, and the vertical axis represents amplitude. Figure 5 The horizontal axis of (I) is time t, and the vertical axis is current. The ultrasonic vibration and current duration increase by 0.1s, and the measured composite waveform is as follows Figure 6 and Figure 7 shown.

[0105] During Cu / Al ultrasonic welding, the second inverter resistance welding power supply outputs a current of 500A, which flows through the aluminum plate and the base and then back to the second inverter resistance welding power supply; the first inverter resistance welding power supply outputs a current of 2700A, which flows through the welding head and the copper plate and then back to the first inverter resistance welding power supply. The current flowing through the copper plate has the same direction as the current flowing through the aluminum plate, such as Figure 3As shown. A Cu / Al metal plate is placed below the tool head, and the vibration signal output by an ultrasonic welding power supply acts on the Cu / Al heterogeneous metal plates, generating ultrasonic vibrations. The ultrasonic vibrations are transmitted from the tool head and copper plate to the aluminum plate. Simultaneously, the corresponding first and second inverter resistance welding power supplies output first and second DC currents according to preset waveforms. The first DC current flows through the tool head and the copper plate to be welded, generating resistance heat. The second DC current passes through the aluminum plate and the base, also generating resistance heat. The first DC current is 2700A, and the second DC current is 500A. The resistance heat generated by the dual DC currents coupled with the ultrasonic vibrations creates a solid-phase connection between the copper and aluminum plates.

[0106] In addition, in actual applications, the system can also design a human-computer interaction device and select the communication interface of two resistance welding power supplies and ultrasonic welding power supplies, set the timing relationship between ultrasonic vibration and dual current output through the keypad, import and save it in the DSPIC microcontroller. When the composite welding switch is pressed, the human-computer interaction device can output pulses to the communication interfaces of the first inverter resistance welding power supply, the second inverter resistance welding power supply and the ultrasonic welding power supply, prompting the first inverter resistance welding power supply, the second inverter resistance welding power supply and the ultrasonic welding power supply to start according to the set timing relationship. The set timing relationship can be as follows: Figure 5 、 Figure 6 and Figure 7 As shown, it can also be different. It is required that the metal plate to be welded is pressed tightly by the tool head before current output can be generated to avoid the occurrence of power generation.

[0107] In addition, the embodiment of the present invention is applicable to the welding of dissimilar metals. After combining a large number of welding tests, the system determines its optimal welding parameters. Through the dual current-ultrasonic composite welding process, it can obtain a heterogeneous metal component with sound functions, few defects and excellent performance, that is, a composite plate of heterogeneous metals.

[0108] To achieve the above objectives, the present invention further provides the following solutions:

[0109] A dual current ultrasonic hybrid welding method based on dissimilar metals, see Figure 8 ,include:

[0110] Step 1: Sending a current control signal and / or an ultrasonic control signal;

[0111] The current control signal and the ultrasonic control signal are sent out according to the set phase relationship;

[0112] Step 2: Based on the current control signal, the inverter resistance welding power module outputs two DC currents of preset current amplitudes to the heterogeneous metal plates to be welded; when the two DC currents flow through the heterogeneous metal plates to be welded, resistance heat is generated; specifically, the steps include:

[0113] Step 21: According to the current control signal, the first inverter resistance welding power supply outputs a first direct current; the first inverter resistance welding power supply is connected to the first metal in the dissimilar metal plates to be welded;

[0114] Step 22: According to the current control signal, the second inverter resistance welding power supply outputs a second DC current; the second inverter resistance welding power supply is connected to the second metal in the dissimilar metal plates to be welded;

[0115] The first DC current is greater than the second DC current; the two DC currents include the first DC current and the second DC current;

[0116] The elastic modulus and melting point of the first metal are greater than the elastic modulus and melting point of the second metal.

[0117] According to the current control signal, the first inverter resistance welding power supply outputs a first DC current; according to the current control signal, the second inverter resistance welding power supply outputs a second DC current, including:

[0118] The first inverter resistance welding power source, the first metal and the tool head form a first current loop; a first direct current flows through the first current loop;

[0119] The second inverter resistance welding power supply, the second metal and the base form a second current loop; a second DC current flows through the second current loop;

[0120] The first direct current and the second direct current are in opposite directions, and the first metal and the second metal repel each other under the interaction of the current and the magnetic field.

[0121] According to the current control signal, the first inverter resistance welding power supply outputs a first DC current; according to the current control signal, the second inverter resistance welding power supply outputs a second DC current further comprising:

[0122] The first inverter resistance welding power source, the first metal and the tool head form a first current loop; a first direct current flows through the first current loop;

[0123] The second inverter resistance welding power supply, the second metal and the base form a second current loop; a second DC current flows through the second current loop;

[0124] The first direct current and the second direct current have the same direction, and the first metal and the second metal attract each other under the interaction of the current and the magnetic field.

[0125] Step 3: According to the ultrasonic control signal, the ultrasonic welding power module outputs ultrasonic vibration of preset amplitude and frequency; the ultrasonic vibration acts on the heterogeneous metal plates to be welded; specifically including:

[0126] Step 31: Generate a vibration signal of preset amplitude and frequency according to the ultrasonic control signal;

[0127] Step 32: Convert the vibration signal into ultrasonic vibration;

[0128] Step 33: Conducting ultrasonic vibration and applying the ultrasonic vibration to the dissimilar metal plates to be welded.

[0129] Step 4: The heterogeneous metal plates to be welded are solid-phase connected under the action of resistance heat and the ultrasonic vibration, forming an effective connection of the heterogeneous metals.

[0130] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. Reference can be made to the common and similar parts between the various embodiments. For the systems disclosed in the embodiments, since they correspond to the methods disclosed in the embodiments, the description is relatively simple, and the relevant parts can be referred to the method description.

[0131] This document uses specific examples to illustrate the principles and implementation methods of the embodiments of the present invention. The description of the above embodiments is only intended to help understand the methods and core concepts of the embodiments of the present invention. At the same time, for those skilled in the art, based on the concepts of the embodiments of the present invention, there may be changes in the specific implementation methods and application scope. In summary, the content of this specification should not be understood as limiting the embodiments of the present invention.

Claims

1. A dual current ultrasonic hybrid welding system based on heterogeneous metals, characterized in that: include: An inverter resistance welding power supply module is used to output two DC currents of preset current amplitudes to the heterogeneous metal plates to be welded according to the current control signal; When the two DC currents flow through the heterogeneous metal plates to be welded, resistance heat is generated; The inverter resistance welding power supply module includes: a first inverter resistance welding power supply, configured to output a first direct current according to the current control signal; the first inverter resistance welding power supply is connected to a first metal in the heterogeneous metal plates to be welded; a second inverter resistance welding power supply, configured to output a second direct current according to the current control signal; the second inverter resistance welding power supply being connected to a second metal in the dissimilar metal plates to be welded; the first direct current being greater than the second direct current; the two direct currents comprising the first direct current and the second direct current; and the elastic modulus and melting point of the first metal being greater than the elastic modulus and melting point of the second metal; An ultrasonic welding power supply module, configured to output ultrasonic vibrations of preset amplitude and frequency according to an ultrasonic control signal; the ultrasonic vibrations acting on the heterogeneous metal plates to be welded; A controller is connected to the inverter resistance welding power module and the ultrasonic welding power module, respectively, and is used to: emit the current control signal and / or the ultrasonic control signal; the current control signal and the ultrasonic control signal are emitted according to a set phase relationship; the controller is also used to control the ultrasonic welding power module to output a vibration signal with an amplitude of 10μm to 50μm and a frequency of 10kHz to 60kHz; the controller can adjust the magnitude and duration of the two direct currents and the magnitude and duration of the ultrasonic amplitude for different thicknesses and materials to be welded, thereby obtaining different current-ultrasonic composite waveforms, improving the microstructure of the welding interface, and enhancing the mechanical properties of the welded joint; The dissimilar metal plates to be welded are solid-phase connected under the action of the resistance heat and the ultrasonic vibration, forming an effective connection of the dissimilar metals; The first inverter resistance welding power supply, the first metal and the tool head form a first current loop; a first direct current flows through it; the second inverter resistance welding power supply, the second metal and the base form a second current loop; a second direct current flows through it; when the first direct current and the second direct current are in opposite directions, the first metal and the second metal repel each other under the interaction of the current and the magnetic field; when the first direct current and the second direct current are in the same direction, the first metal and the second metal attract each other under the interaction of the current and the magnetic field; under the interaction of the two direct currents and ultrasonic vibrations, the heterogeneous metal plates are connected to each other, and the electroplastic effect generated when the current flows through the metal to be welded and the principle of mutual attraction of currents in the same direction can be utilized to improve the microstructure of the heterogeneous metal welding interface and the mechanical properties of the joint.

2. The dual current ultrasonic hybrid welding system based on heterogeneous metals according to claim 1, characterized in that: The ultrasonic welding power supply module includes: an ultrasonic welding power supply, configured to generate a vibration signal of preset amplitude and frequency according to the ultrasonic control signal; a transducer, connected to the ultrasonic welding power supply, for converting the vibration signal into ultrasonic vibration; a horn connected to the transducer and used to conduct the ultrasonic vibration; A tool head is connected to the horn and is used to apply the ultrasonic vibration to the heterogeneous metal plates to be welded.

3. A dual current ultrasonic composite welding method based on heterogeneous metals, characterized in that: The dual-current ultrasonic hybrid welding method based on heterogeneous metals is applied to the dual-current ultrasonic hybrid welding system based on heterogeneous metals according to any one of claims 1-2, and the dual-current ultrasonic hybrid welding method based on heterogeneous metals includes: Sending a current control signal and / or an ultrasonic control signal; The current control signal and the ultrasonic control signal are emitted according to a set phase relationship; According to the current control signal, the inverter resistance welding power supply module outputs two DC currents with preset current amplitudes to the heterogeneous metal plates to be welded; the two DC currents generate resistance heat when flowing through the heterogeneous metal plates to be welded; According to the ultrasonic control signal, the ultrasonic welding power supply module outputs ultrasonic vibrations of preset amplitude and frequency; the ultrasonic vibrations act on the heterogeneous metal plates to be welded; The heterogeneous metal plates to be welded are solid-phase connected under the action of the resistance heat and the ultrasonic vibration, forming an effective connection of the heterogeneous metals.

4. The dual current ultrasonic hybrid welding method based on heterogeneous metals according to claim 3, characterized in that: According to the current control signal, the inverter resistance welding power supply module outputs two DC currents with preset current amplitudes to the heterogeneous metal plates to be welded, specifically including: According to the current control signal, the first inverter resistance welding power supply outputs a first direct current; the first inverter resistance welding power supply is connected to the first metal in the heterogeneous metal plates to be welded; According to the current control signal, the second inverter resistance welding power supply outputs a second DC current; the second inverter resistance welding power supply is connected to the second metal in the dissimilar metal plates to be welded; The first direct current is greater than the second direct current; the two direct currents include the first direct current and the second direct current; the elastic modulus and melting point of the first metal are greater than the elastic modulus and melting point of the second metal.

5. The dual current ultrasonic hybrid welding method based on heterogeneous metals according to claim 3, characterized in that: According to the ultrasonic control signal, the ultrasonic welding power module outputs ultrasonic vibrations of preset amplitude and frequency, specifically including: generating a vibration signal of preset amplitude and frequency according to the ultrasonic control signal; converting the vibration signal into ultrasonic vibration; The ultrasonic vibration is conducted and acts on the dissimilar metal plates to be welded.

6. The dual current ultrasonic hybrid welding method based on heterogeneous metals according to claim 4, characterized in that: According to the current control signal, the first inverter resistance welding power supply outputs a first DC current; according to the current control signal, the second inverter resistance welding power supply outputs a second DC current, including: The first inverter resistance welding power supply, the first metal and the tool head form a first current loop; a first direct current flows through the loop; The second inverter resistance welding power supply, the second metal and the base form a second current loop; a second direct current flows through the loop; The first direct current and the second direct current are in opposite directions, and the first metal and the second metal repel each other under the interaction of the current and the magnetic field.

7. The dual current ultrasonic hybrid welding method based on heterogeneous metals according to claim 4, characterized in that: According to the current control signal, the first inverter resistance welding power supply outputs a first direct current; according to the current control signal, the second inverter resistance welding power supply outputs a second direct current further comprising: The first inverter resistance welding power supply, the first metal and the tool head form a first current loop; a first direct current flows through the loop; The second inverter resistance welding power supply, the second metal and the base form a second current loop; 4 a second DC current flows; The first direct current and the second direct current have the same direction, and the first metal and the second metal attract each other under the interaction of the current and the magnetic field.

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