弧焊及搅拌摩擦焊工艺对高速铁路动车组铝合金车体侧墙焊接变形的影响
刘松王亚男耿明张欣盟郭春成严格格
Effect of Arc Welding and Friction Stir Welding Processes on Sidewall Welding Deformation of Aluminum Alloy Carbody in High-speed Railway EMU
LIU SongWANG Ya’nanGENG MingZHANG XinmengGUO ChunchengYAN Gege
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作者信息:中车长春轨道客车股份有限公司工程技术中心，130062，长春
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Affiliation:Engineering Technology Center, CRRC Changchun Railway Vehicles Co., Ltd., 130062, Changchun, China
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关键词:
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Key words:
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DOI:10.16037/j.1007-869x.2025.02.030
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中图分类号/CLCN:U270.6
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栏目/Col:应用技术
摘要:
［目的］受铝合金材质热导率与线膨胀特性的影响，高速铁路动车组铝合金车体在焊接过程中极易产生焊接变形。有必要对目前较为成熟的弧焊工艺、新一代的搅拌摩擦焊工艺进行研究，对这2种工艺引起的焊接变形进行对比分析。［方法］介绍了试验的材料及试验方法，选取车体侧墙的弧度、高度、挠度3个指标作为焊接变形对比的参数。针对反装组焊试验、正装组焊试验完成后的结果，分别对弧焊、搅拌摩擦焊2种工艺下车体侧墙的弧度变形量、高度变形量、挠度变形量进行了对比，分析了2种工艺下焊接变形的变化趋势。［结果及结论］采用搅拌摩擦焊工艺制造的铝合金车体侧墙可以有效降低焊接变形。搅拌摩擦焊的焊后弧度变形量是弧焊焊后弧度变形量的20%。搅拌摩擦焊不会引起侧墙型材在高度方向上的收缩变形。与弧焊的侧墙焊后挠度回弹量相比，搅拌摩擦焊的焊后挠度回弹量更大。
Abstracts:
［Objective］ Due to the influence of thermal conductivity and linear expansion characteristics of aluminum alloy materials, welding deformation is prone to occur during the welding process of aluminum alloy carbodies in high-speed railway EMU (electric multiple units). It is necessary to study the currently mature arc welding process and the next-generation friction stir welding process, so as to compare and analyze the welding deformations caused by these two methods. ［Method］ The experimental materials and methods are introduced, and three parameters of curvature, height, and deflection for carbody sidewalls are selected as indicators for comparing welding deformation. Based on results from reverse-assembly welding and forward-assembly welding experiments, the curvature, height, and deflection deformation values of carbody sidewalls are compared in terms of the arc welding and friction stir welding processes. The welding deformation changing trends under the two processes are analyzed. ［Result & Conclusion］ The aluminum alloy carbody sidewalls manufactured using friction stir welding process can effectively reduce welding deformation. The post-weld curvature deformation of friction stir welding is 20% of that of arc welding. Friction stir welding will not cause shrinkage deformation of sidewall profiles in the height direction. However, compared with arc welding, the deflection rebound of the sidewalls after welding is greater with friction stir welding.
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