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研究生： 納賽爾
Nasser, Ali
論文名稱： 夾層材料對異種材料激光焊接影響分析
Analysis of Laser Welding on Dissimilar Materials with the Influence of Adding Interlayer Material
指導教授： 羅裕龍
Lo, Yu-Lung
學位類別： 碩士
Master
系所名稱： 工學院 - 機械工程學系
Department of Mechanical Engineering
論文出版年： 2022
畢業學年度： 111
語文別： 英文
論文頁數： 50
中文關鍵詞： 激光焊接 、夾層材料 、異種焊接 、金屬間化合物（IMC）
外文關鍵詞： Laser welding, Interlayer material, Dissimilar welding, Intermetallic compound (IMC)
相關次數： 點閱：174  下載：0 
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    • Table of Contents Abstract I 中文摘要 II Table of Contents VI List of Tables VII List of Figures VIII Chapter 1 Introduction 1 1.1 Preface 1 1.1.1 A Brief description of laser beam welding 2 1.1.2 Laser beam welding modes 2 1.2 Brief description and a literature review 3 1.2.1 Influence of a Ni-foil interlayer on SS/Al dissimilar joint by laser penetration welding 3 1.2.2 Effect of nickel interlayer thickness on lap joint laser welding for aluminum-steel dissimilar materials 9 1.3 Research motivation and objective 10 Chapter 2 The Basic Theory and Methodology 12 2.1 Numerical simulation 12 2.1.1 Thermomechanical boundary condition 15 2.1.2 Heat source modeling 16 2.1.3 Discrete finite element model 17 2.1.4 Deformations and residual stresses of the weld 18 Chapter 3 Experimentation and testing procedures 20 3.1 Experiment Material 20 3.2 Microstructural analysis and mechanical testing 22 3.3 Mechanical characteristics of Lap Joint Tensile test 22 Chapter 4 Results of melting pool’s shape and residual stress 24 4.1 Weld joint characteristics and nickel addition effect 24 4.2 Validation of the simulation model 26 4.3 Residual stress analysis of weld joints 30 Chapter 5 Results of mechanical properties of lap joint 33 5.1 Mechanical characteristics of lap joint tensile shear test 33 5.2 Fracture shape of weld lap joint with Ni-foil 36 5.3 Simulation in tensile shear test of weld lap joint with Ni-foil 38 Chapter 6 Results of electron dispersive spectroscopy (EDS) analysis 41 6.1 Experimental results 41 Chapter 7 Conclusions and Future works 46 7.1 Conclusions 46 7.2 Future Works 47 References 48   List of Tables Table 1 EDS data for the A to E regions [10] 8 Table 2 Properties of the SS 304 alloy [15] 13 Table 3 Aluminum alloy 6061 Properties [16] 13 Table 4 Nickel foil alloy Properties [17] 13 Table 5. Welding experiment parameters 21   List of Figures Fig.1 shows representative power density profiles for laser, electron beam, plasma, and arc together with a schematic representation of the appropriate weld bead shapes [1] 2 Fig.2 Continuous wave and modulated pulsed wave modes are distinguished from one another [3] 2 Fig. 3 visualization of the laser welding modes 3 Fig. 4 shows the microstructures of the stainless steel/aluminum alloy junction 7 Figure 5 shows the joint's tensile properties (a) and microhardness (b) [10] 8 Figure 6 shows two different fracture morphologies: one without Ni foil and the other with Ni foil [10] 8 Figure 7 shows the weld penetration depth at various nickel foil thicknesses (0,10,20,30,40, and 50) [11] 10 Fig.8 Diagram of Finite Element (FE) analysis procedure 14 Fig. 9 Boundary conditions, and the finite element mesh 18 Fig. 10 Formation of residual stresses due to welding [28] 19 Fig.11 Schematic illustration of lap joint welding dimensions 20 Fig.12 Schematic illustration of clamping setup for weld samples 21 Fig.13 laser welding for each lap joint setup 21 Fig.14: Mechanical lap shear tests: (a) experimental configuration and specimen size, and (b) laser welding for each lap joint setup 23 Fig.15 Penetration vs. linear energy for SS304-on-Al6061 with 0.1 mm and 0.2 mm of nickel foil and without interlayer 25 Fig.16: Penetration and interface at P = 2100 W and V = 1.5m/min. (a) OM image of melt pool cross-section for joint without Ni foil, (b) OM image of melt pool cross-section for joint with 0.1 mm Ni foil, and (c) OM image of melt pool cross-section for joint with 0.2 mm Ni foil 25 Fig. 17 shows the temperature distribution and melt pool profile for the simulation and experimental data for (a) a joint cross-section without Ni foil, (b) a joint cross-section with 0.1 mm Ni foil, and (c) a joint cross-section with 0.2 mm Ni foil 28 Fig.18 Demonstrates how the joint's physical model was created: (a) laser beam was focused on the SS plate; (b) formation of welding pool; (c) heat was transferred from welding pool to the SS-Ni alloy interface; (d) atomic (Ni) interdiffusion at SS-Al alloy interface led to formation of fusion and diffusion to create intermetallic layer 29 Fig.19 Temperature distribution on the surfaces of joints without/with Ni foil surface of lap welding joint 29 Fig.20: Comparison of experimental and simulation results for: (a) Penetration depth, and (b) Interface width at P = 2100 w and V = 1.5m/min 30 Fig.21 Residual stress of lap welding joints 32 Fig.22 Numerically-predicted 3D residual-stress distributions for a laser power of 2100W and a welding speed of 1.5 m/min 32 Fig.23: Mechanical lap shear tests: (a) Experimental configuration and specimen size, and (b) Laser welding for each lap joint sample 34 Fig.24 Effect of various laser powers on lap tensile shear force for: (a) Samples without Ni-foil, (b) Samples without Ni-foil for average value, (c) Samples with 0.1mm Ni-foil, (d) Samples with 0.1mm Ni-foil for average value, (e) Samples with 0.2mm Ni-foil, and (f) Samples with 0.2mm Ni-foil for average value 35 Figure 25. Fracture mode I: (a) Tensile fracture sample; (b) Fracture scheme 37 Figure 26. Fracture mode II: (a) Tensile fracture sample; (b) Fracture scheme 37 Fig.27 Finite element model 39 Figure 28. Stress distribution results after tensile load 39 Figure 29. Equivalent plastic strain: (a) Before Loading; (b) After Loading 39 Figure 30. Load-displacement of the experimental and numerical tensile test sample 40

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