Welding apparatus and welding method for temperature joints at interfaces such as metals and composite materials

Abstract

This invention discloses a welding device for metal-composite material interface temperature joints, comprising a base, a guide rail, a slider, and a fixture. The guide rail is connected to the base via a support column, the slider is nested within the guide rail, and the slider is connected to the fixture. A CNC resistance heater is installed on the base, and the CNC resistance heater is coaxially arranged with the fixture. This invention, by applying a CNC resistance heater, enables precise temperature control of the metal sample, ensuring that the metal sample reaches the predetermined target temperature before welding. Because the CNC resistance heater is coaxial with the fixture, it ensures a uniform temperature distribution at the interface between the metal and composite material samples upon contact, thereby achieving a stable connection between the dissimilar materials on both sides of the interface. A consistent interface temperature helps optimize joint strength, reduces stress concentration, and improves welding quality. This device enables accurate control of the interface temperature, providing a precise quantitative data basis for the relationship between joint strength and interface temperature.

Description

Technical Field

[0001] This invention relates to the field of welding technology, specifically to a welding apparatus and welding method for metal-composite material interface temperature joints. Background Technology

[0002] Metal-composite material joints are joint structures that firmly connect metal and composite materials through specific processes. Composite materials are typically composed of multiple materials to achieve specific properties, such as high strength, low density, and corrosion resistance. Metal-composite material joints play a vital role in modern industry, especially in aerospace, automotive manufacturing, and electronics. These joints allow for the full utilization of the advantages of different materials, achieving lightweighting, increased strength, and improved durability.

[0003] Metal-composite joints combine the advantages of both metals and composite materials, achieving optimized performance. For example, in the aerospace industry, aircraft structures require both lightweight and robustness, making the combination of composites and metals an ideal choice. Furthermore, in the automotive industry, such joints effectively reduce vehicle weight, improve fuel efficiency, and reduce emissions. Metal-composite joints are also widely used in electronic equipment to provide better heat dissipation and mechanical strength.

[0004] The bonding strength of metal-composite materials is closely related to the interface temperature. Generally, the higher the temperature, the more complete the chemical reaction between the resin matrix and the metal, resulting in higher bonding strength. However, when the temperature exceeds the decomposition temperature of the resin matrix, the burn-off of the composite material significantly reduces the bonding strength. Currently, the relationship between the bonding strength of metal-composite materials and the interface temperature can only be qualitatively analyzed, making quantitative evaluation difficult. This problem limits the performance optimization of metal-composite joints.

[0005] The temperature field distribution during traditional metal-composite welding is extremely uneven and highly nonlinear, which cannot meet the requirements for quantitative evaluation of joint strength. Therefore, designing joint types, controlling the welding process, achieving a uniformly distributed interface temperature field, and evaluating the mechanical properties of the joint have become key aspects of quantitative evaluation of the welding strength of metal-composite materials. Summary of the Invention

[0006] To address the aforementioned shortcomings of existing technologies, the present invention aims to provide a welding apparatus for metal-composite material interface temperature joints. This apparatus heats a metal sample to a target temperature using a CNC resistance heater, then brings the metal sample into contact with a composite material sample. The composite material on the contact surface melts under heat conduction and reacts with the metal surface, achieving a stable connection between the dissimilar materials on both sides of the interface. This results in a metal-composite material interface temperature joint with consistent and accurate interface temperature, providing a possibility for quantitatively evaluating the relationship between bond strength and interface temperature. This solves the technical problem that the relationship between bond strength and interface temperature in metal-composite material welded joints can only be qualitatively analyzed, making quantitative evaluation difficult. A second objective of the present invention is to provide a welding method for this metal-composite material interface temperature joint welding apparatus. Through standardized steps and precise control parameters, the welding operation process is simplified, welding time is reduced, and welding efficiency is improved. Simultaneously, the clear and easy-to-execute operation steps also reduce the risk of operational errors.

[0007] The present invention is achieved through the following technical solution: a welding device for interface temperature joints of metal-composite materials, including a base, a guide rail, a slider, and a fixture. The guide rail is connected to the base through a support column, the slider is nested in the guide rail, the slider is connected to the fixture, and the base is equipped with a CNC resistance heater, which is coaxially arranged with the fixture.

[0008] By employing the above technical solution and utilizing a CNC resistance heater, precise temperature control of the metal sample can be achieved, ensuring that the metal sample reaches the predetermined target temperature before welding, thus realizing quantitative control of the interface temperature. Because the CNC resistance heater is coaxially arranged with the fixture, misalignment is prevented when the metal sample and composite material sample are joined, ensuring that the prepared butt joint can be quantitatively characterized by tensile testing to assess its bond strength. This device enables accurate control of the interface temperature, providing a precise quantitative data basis for the relationship between bond strength and interface temperature.

[0009] In a further configuration, the slider includes a first slider and a second slider, and the clamp includes a first clamp and a second clamp, with the first clamp connected to the first slider and the second clamp connected to the second slider.

[0010] By adopting the above technical solution, the first and second sliders can be moved and adjusted independently, enabling precise alignment of metal and composite material samples of different sizes or shapes. This improves contact quality during welding and ensures consistency in the welding results. Independent control of each fixture ensures precise positioning during welding, avoiding misalignment caused by uneven materials or inaccurate fixture positioning. The first and second sliders enhance the equipment's adjustability, further improving welding precision.

[0011] In a further configuration, the second clamp holds the metal sample, with one side of the metal sample in contact with the CNC resistance heater and the other side of the metal sample in contact with the thermocouple.

[0012] By adopting the above technical solution, the actual temperature of the metal sample can be monitored in real time through direct contact between the thermocouple and the sample. This ensures that the sample reaches and is maintained at the required welding temperature, improving temperature accuracy during the welding process and thus ensuring the consistency of the welding results. Because the thermocouple is in direct contact with the metal sample, temperature measurement is more accurate, effectively avoiding temperature deviations caused by measurement errors.

[0013] Further, the first clamp holds the composite material sample.

[0014] Furthermore, the base is equipped with a propulsion mechanism, which includes a propulsion base and a push rod, with the push rod mounted on the propulsion base.

[0015] Furthermore, the guide rail is a linear guide rail. Furthermore, both the upper and lower surfaces of the base are flat.

[0016] Further, the CNC resistance heater includes a hot-press welding head with a flat end and a diameter of 15mm and a 936D CNC welding station.

[0017] Furthermore, the base, support column, guide rail, slider, and clamp are all made of stainless steel.

[0018] Furthermore, the fixture material is polyimide (PI) resin, which is used to fix the sample to be welded and reduce heat dissipation from contact with the sample.

[0019] Furthermore, the thermocouple is a contact thermocouple, which ensures the accuracy and controllability of the temperature at the interface of the prepared metal-composite material joint by monitoring the real-time temperature of the end of the metal sample near the composite material sample.

[0020] Furthermore, both the metal sample and the composite material sample are cylindrical samples with an end face size of 6.4 mm × 5 mm, in order to ensure the uniformity and consistency of temperature distribution at the metal-composite material interface.

[0021] A welding method for a metal-composite material interface temperature joint welding device includes the following steps:

[0022] Step 1: Fix the metal sample on the second fixture and the composite material sample on the first fixture, keeping the end faces of the metal sample and the composite material sample coaxially aligned.

[0023] Step 2: Set the target temperature of the CNC resistance heater, move the second slider to bring the metal sample into contact with the CNC resistance heater, and heat the metal sample;

[0024] Step 3: Monitor the real-time temperature of the metal sample using a thermocouple. Once the measured value reaches the target temperature and stabilizes, move the first slider to bring the composite material sample into contact with the metal sample.

[0025] Step 4: The metal sample heats the composite material sample, and the composite material on the contact surface melts and reacts with the metal surface to form a stable chemical bond.

[0026] Step 5: After the metal sample and the composite material sample have been in contact for 3 seconds for heat transfer, the second slider is moved to separate the metal sample from the CNC resistance heater. After the welded sample is cooled to room temperature, a metal-composite material interface temperature joint with consistent and accurate interface temperature is obtained.

[0027] By adopting the above technical solution, in step 1, by fixing the metal sample and the composite material sample on their respective fixtures and keeping their end faces coaxially aligned, the consistency of the contact surface during the welding process is ensured, reducing the risk of misalignment of the butt joint and guaranteeing the consistency of the weld joint strength. In steps 2 and 3, the target temperature is set by a CNC resistance heater, and the temperature of the metal sample is monitored in real time using thermocouples to ensure that the metal sample reaches and maintains the ideal welding temperature, reducing the impact of temperature fluctuations. In steps 4 and 5, after the metal sample reaches the target temperature, the composite material sample is brought into contact with it, and the composite material is partially melted by heating, reacting with the metal surface to form a stable chemical bond. At the same time, the contact heat transfer time is strictly controlled to ensure that the composite material is fully melted and forms a good bond with the metal. Precise control and real-time monitoring throughout the welding process ensure the consistency of the interface temperature between the metal and the composite material during welding. This welding method simplifies the welding operation process, reduces welding time, and improves welding efficiency through standardized steps and precise control parameters. Furthermore, the clear and easy-to-execute operation steps also reduce the risk of operational errors.

[0028] Furthermore, when the metal sample and the composite material sample are fixed on the fixture, their end faces must be kept coaxially aligned.

[0029] By adopting the above technical solution, keeping the end faces of the metal sample and the composite material sample coaxially aligned can ensure that the two samples are precisely joined during the welding process, reducing strength fluctuations caused by sample misalignment.

[0030] Furthermore, the metal sample is made of aluminum alloy, and the surface of the aluminum alloy is treated with a silane coupling agent.

[0031] By employing the above technical solution, silane coupling agents can form a chemically active layer on the surface of aluminum alloys. This active layer can chemically react with organic or inorganic groups in the composite material, thereby forming a stronger chemical bond between the aluminum alloy and the composite material. The enhanced interfacial bonding helps improve the overall strength and durability of the welded joint, ensuring its reliability during use.

[0032] Furthermore, the material of the metal sample is high-strength steel or stainless steel.

[0033] In summary, the present invention has the following beneficial effects:

[0034] 1. This invention, through the application of a CNC resistance heater, enables precise temperature control of metal samples, ensuring the uniformity and controllability of the metal-composite material interface temperature. Because the CNC resistance heater is coaxially arranged with the fixture, it ensures precise alignment of the metal and composite material samples at the contact surface, reducing strength fluctuations caused by sample misalignment. This device achieves accurate control of the interface temperature, providing a precise quantitative data basis for the relationship between bonding strength and interface temperature.

[0035] 2. The welding method of the present invention, through precise temperature control, flexible adjustment design and standardized operation steps, can ensure the uniformity and controllability of the interface temperature between the metal and composite material samples, guarantee the consistency and stability of the welding results, shorten the operation time and reduce the risk of operation errors. Attached Figure Description

[0036] Figure 1 This is a schematic diagram of the structure of the preferred embodiment of the welding device for temperature joints at the interface of metal-composite materials, etc.

[0037] Figure 2 This is a front view of the preferred embodiment of the welding apparatus for temperature joints at the interface of metal-composite materials, etc.

[0038] Figure 3 This is a top view of a preferred embodiment of a welding apparatus for temperature joints at interfaces such as metal-composite materials.

[0039] The attached figures are labeled as follows: 1. Base; 1-1. Support column; 2. Guide rail; 3. Slider; 3-1. First slider; 3-2. Second slider; 4. Fixture; 4-1. First fixture; 4-2. Second fixture; 5. CNC resistance heater; 6. Metal sample; 7. Composite material sample; 8. Propulsion mechanism; 8-1. Propulsion base; 8-2. Push rod. Detailed Implementation

[0040] The preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0041] like Figure 1-3 As shown, the preferred embodiment of the metal-composite material interface temperature joint welding device includes a base 1, a guide rail 2, a slider 3, and a clamp 4. The guide rail 2 is connected to the base 1 through a support column 1-1. The slider 3 is nested in the guide rail 2 and connected to the clamp 4. The base 1 is provided with a CNC resistance heater 5, which is coaxially arranged with the clamp 4.

[0042] The slider 3 includes a first slider 3-1 and a second slider 3-2, and the clamp 4 includes a first clamp 4-1 and a second clamp 4-2. The first clamp 4-1 is connected to the first slider 3-1, and the second clamp 4-2 is connected to the second slider 3-2.

[0043] The second clamp 4-2 holds the metal sample 6. One side of the metal sample 6 is in contact with the CNC resistance heater 5, and the other side is in contact with the thermocouple. When the metal sample 6 is not clamped in the clamp, the thermocouple is not connected to the device.

[0044] The first clamp 4-1 holds the composite material sample 7.

[0045] The base 1 is equipped with a propulsion mechanism 8, which includes a propulsion base 8-1 and a push rod 8-2, with the push rod 8-2 mounted on the propulsion base 8-1. The propulsion mechanism is driven by a motor.

[0046] Guide rail 2 is a linear guide rail. The upper and lower surfaces of base 1 are both flat. The CNC resistance heater 5 includes a hot-press welding head with a flat end and a diameter of 15mm and a 936D CNC welding station. Base 1, support column 1-1, guide rail 2, slider 3, and clamp 4 are all made of stainless steel. Clamp 4 is made of polyimide (PI) resin and is used to fix the sample to be welded and reduce heat dissipation from contact with the sample. The thermocouple is a contact thermocouple, which monitors the real-time temperature of the metal sample 6 near the end of the composite material sample 7 to ensure the accuracy and controllability of the temperature at the metal-composite material joint interface. Both metal sample 6 and composite material sample 7 are cylindrical samples with an end face size of 6.4mm × 5mm to ensure the uniformity and consistency of temperature distribution at the metal-composite material joint interface.

[0047] Metal sample 6 is an Al5052-O aluminum alloy; composite sample 7 is a carbon fiber reinforced composite material containing 80% PA6 resin matrix and 20% short carbon fibers. The sample size is 6.4 mm × 5 mm × 45 mm.

[0048] The base 1, support column 1-1, and guide rail 2 are fixed together with bolts. The slider 3 and clamp 4 are fixed together with bolts. The CNC resistance heater 5 is fixed together with the base 1 with bolts.

[0049] A welding method for a metal-composite material interface temperature joint welding device includes the following steps:

[0050] Step 1: Fix the metal sample 6 on the second clamp 4-2 and the composite material sample 7 on the first clamp 4-1, keeping the end faces of the metal sample 6 and the composite material sample 7 coaxially aligned.

[0051] Step 2: Set the target temperature of the CNC resistance heater 5, move the second slider 3-2 to bring the metal sample 6 into contact with the CNC resistance heater 5, and heat the metal sample 6.

[0052] Step 3: Monitor the real-time temperature of the metal sample 6 using a thermocouple. Once the measured value reaches the target temperature and stabilizes, move the first slider 3-1 to bring the composite material sample 7 into contact with the metal sample 6.

[0053] Step 4: The metal sample 6 heats the composite material sample 7. The composite material on the contact surface melts upon heating and reacts with the metal surface to form a stable chemical bond.

[0054] Step 5: After the metal sample 6 and the composite material sample 7 come into contact and transfer heat for 3 seconds, the second slider 3-2 is moved to separate the metal sample 6 from the CNC resistance heater 5. After the welded sample is cooled to room temperature, a metal-composite material interface temperature joint with consistent and accurate interface temperature is obtained.

[0055] like Figure 1-3 As shown, when the metal sample 6 and the composite material sample 7 are fixed on the fixture, their end faces must be kept coaxially aligned. The metal sample 6 is made of aluminum alloy, and the surface of the aluminum alloy is treated with a silane coupling agent.

[0056] The material of metal sample 6 is high-strength steel or stainless steel.

[0057] The metal-composite interface temperature joint prepared in this case can be used for subsequent mechanical testing, providing data support for quantitatively evaluating the relationship between the bonding strength of metal-composite materials and the interface temperature. By controlling the contact heat transfer time and contact pressure between metal sample 6 and composite sample 7, the effects of heating time and pressure on the bonding strength of the metal-composite welded joint can be quantitatively evaluated.

[0058] The above-described specific implementations can be partially adjusted by those skilled in the art in different ways without departing from the principles and purpose of the present invention. The scope of protection of the present invention is defined by the claims and is not limited to the above-described specific implementations. All implementation schemes within the scope of the claims are bound by the present invention.

Claims

1. A welding method using a metal-composite interface temperature joint welding apparatus, characterized by, The welding device includes a base (1), a guide rail (2), a slider (3), and a clamp (4). The guide rail (2) is connected to the base (1) through a support column (1-1). The slider (3) is nested in the guide rail (2) and connected to the clamp (4). The base (1) is provided with a CNC resistance heater (5). The CNC resistance heater (5) is coaxially arranged with the clamp (4). The CNC resistance heater (5) includes a hot press welding head with a flat end and a diameter of 15mm and a 936D CNC welding station. The slider (3) includes a first slider (3-1) and a second slider (3-2), and the clamp (4) includes a first clamp (4-1) and a second clamp (4-2). The first clamp (4-1) is connected to the first slider (3-1), and the second clamp (4-2) is connected to the second slider (3-2). The second clamp (4-2) clamps the metal sample (6), with one side of the metal sample (6) in contact with the CNC resistance heater (5) and the other side of the metal sample (6) in contact with the thermocouple; The first clamp (4-1) holds the composite material sample (7); The base (1) is provided with a propulsion mechanism (8), which includes a propulsion base (8-1) and a push rod (8-2), with the push rod (8-2) mounted on the propulsion base (8-1). The welding method includes the following steps: Step 1: Fix the metal sample (6) on the second clamp (4-2) and the composite material sample (7) on the first clamp (4-1), keeping the end faces of the metal sample (6) and the composite material sample (7) coaxially aligned. Step 2: Set the target temperature of the CNC resistance heater (5), move the second slider (3-2) to make the metal sample (6) contact the CNC resistance heater (5) and heat the metal sample (6). Step 3: Monitor the real-time temperature of the metal sample (6) using a thermocouple. Once the measured value reaches the target temperature and stabilizes, move the first slider (3-1) to bring the composite material sample (7) into contact with the metal sample (6). Step 4: The metal sample (6) heats the composite material sample (7), and the composite material on the contact surface melts and reacts with the metal surface to form a solid chemical bond; Step 5: After the metal sample (6) and the composite material sample (7) have been in contact for 3 seconds, the second slider (3-2) is moved to separate the metal sample (6) from the CNC resistance heater (5). After the welded sample is cooled to room temperature, a metal-composite material interface temperature joint with consistent and accurate interface temperature is obtained.

2. The welding method according to claim 1, characterized in that, When the metal sample (6) and the composite material sample (7) are fixed on the fixture, their end faces must be kept coaxially aligned.

3. The welding method of claim 2, wherein, The metal sample (6) is made of aluminum alloy, and the surface of the aluminum alloy is treated with a silane coupling agent.

4. The welding method according to claim 3, characterized in that, The metal sample (6) is made of high-strength steel or stainless steel.

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