蔡佳思,凌畅,孔英杰,等.基于RSM的6061-T6铝合金激光深熔焊工艺参数优化[J].精密成形工程,2025,17(5):1-11.
CAI Jiasi,LING Chang,KONG Yingjie,et al.Optimization of Laser Deep Penetration Welding Parameters of 6061-T6 Aluminum Alloy Based on RSM[J].Journal of Netshape Forming Engineering,2025,17(5):1-11. |
| 基于RSM的6061-T6铝合金激光深熔焊工艺参数优化 |
| Optimization of Laser Deep Penetration Welding Parameters of 6061-T6 Aluminum Alloy Based on RSM |
| 投稿时间：2024-10-11 |
| DOI：10.3969/j.issn.1674-6457.2025.05.001 |
| 中文关键词: 6061-T6铝合金 激光深熔焊 抗拉强度 气孔率 代理模型 响应面优化 |
| 英文关键词: 6061-T6 aluminum alloy laser deep penetration welding (LDPW) tensile strength porosity surrogate model response surface optimization |
| 基金项目:国家自然科学基金(52275341);南京航空航天大学博士研究生跨学科创新基金(KXKCXJJ202307) |
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| 中文摘要: |
| 目的 针对因铝合金焊后焊缝气孔率高及成形差而导致接头性能低的问题，探究焊接工艺参数对缺陷及力学性能的交叉影响，最终确定最佳工艺参数。方法 以激光功率PL、焊接速度vw、送丝速度fr为设计变量，接头抗拉强度σb、气孔率φ为响应，基于Box-Behnken方法设计三因素三水平实验矩阵;进行2 mm厚6061-T6铝合金激光深熔焊接实验，获得实验数据后建立σb和φ的二次多项式代理模型，分析加工变量的交互作用对接头抗拉强度和气孔率的影响规律;进一步，基于目标约束，计算得到最优工艺参数组合;最后，基于最优工艺参数组合进行激光焊接实验和性能表征实验，并通过实验对模型进行验证。结果 抗拉强度和气孔率代理模型ANOVA结果表明，代理模型拟合度精度高、适应性好，可以为工艺优化奠定良好的基础。等高线和三维响应面结果表明，激光功率对抗拉强度和气孔率的影响最显著;当激光功率保持固定时，通过调节焊接速度和送丝速度的配比能够抑制接头软化，提高接头性能。以接头抗拉强度望大和气孔率望小为目标，以抗拉强度数值不小于实验平均值且不超过母材抗拉强度为约束1，以气孔率不小于0且不大于实验平均值为约束2，得到优化焊接参数如下:PL=2 kW、vw=20.1 mm/s、fr=8 mm/s。抗拉强度的预测值和实验值分别为242.017 MPa和241.492 MPa，气孔率的预测值和实验值分别为0.23%和0.1%，二者误差仅为0.22%和56.5%。结论 采用优化后的工艺参数组合有效地改善了接头缺陷和力学性能，抗拉强度提高了18.5%，气孔率降低了91.7%，该代理模型可靠，可用于预测及优化焊缝接头质量。 |
| 英文摘要: |
| The work aims to address the high porosity rate and poor welding shape of aluminum alloy welds, leading to a decrease in joint performance, explore the cross-influence of welding process parameters on defects and mechanical properties, and ultimately determine the optimal process parameters.With laser power PL, welding speed vw, and wire feeding speed fr as design variables, and joint tensile strength σb and porosity φ as responses, a three factor three-level experimental matrix was designed based on the Box Behnken method; Laser deep penetration welding experiments were conducted on 2 mm thick 6061-T6 aluminum alloy. A quadratic polynomial surrogate model of σb and φ was established after obtaining experimental data, and the influence of the interaction of processing variables on the tensile strength and porosity of the joint was analyzed; Furthermore, based on the objective constraints, the optimal combination of process parameters was calculated; Finally, laser welding experiments and performance characterization experiments were conducted based on the optimal combination of process parameters to validate the model. The ANOVA results of the proxy model for tensile strength and porosity indicated that the proxy model had high fitting accuracy and good adaptability, which could lay a good foundation for process optimization. The contour lines and three-dimensional response surface results indicated that laser power had the most significant effect on tensile strength and porosity; When the laser power was kept constant, adjusting the ratio of welding speed and wire feeding speed could suppress joint softening and improve joint performance. With the goal of achieving high tensile strength and low porosity of the joint, and with the constraints 1 the tensile strength value was not less than the experimental average and did not exceed the tensile strength of the base material, and 2 the porosity value was not less than 0 and did not exceed the experimental average, the optimized welding parameters were obtained as follows:PL=2 kW, vw=20.1 mm/s, fr=8 mm/s. The predicted and experimental values of tensile strength and porosity were 242.017 MPa, 241.492 MPa, 0.23%, and 0.1%, respectively; The errors were only 0.22% and 56.5%. In conclusion, the optimized process parameter combination effectively improves joint defects and mechanical properties, with an increase and decrease of 18.5% and 91.7% in tensile strength and porosity, respectively. This combination method has a reliable surrogate model and can be used to predict and optimize the quality of weld joints. |
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