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激光焊接是激光加工材料加工技术应用的重要方面之一。70年代主要用于焊接薄壁材料和低速焊接,焊接过程属于热传导型,即激光辐射加热工件表面,表面热量通过热传导向内部扩散,通过控制激光脉冲的宽度、能量、峰值功率和重复频率等参数,使工件熔化,形成特定的熔池。由于激光焊接作为一种高质量、高精度、低变形、高效率和高速度的焊接方法,随着高功率CO2和高功率的YAG激光器以及光纤传输技术的完善、金属钼焊接聚束物镜等的研制成功,使其在机械制造、航空航天、汽车工业、粉末冶金、生物医学微电子行业等领域的应用越来越广。
1.精密电阻点焊的应用
在继电器的触点、簧片、支架、推杆、外壳密封、安装板、隔磁片等部件中大量使用了电阻点焊工艺。
1.1电阻点焊的原理
焊件组合后通过电极施加压力,利用电流通过接头的接触面及邻近区域产生的电阻热进行焊接的方法称为电阻焊。电阻焊具有生产效率高、低成本、节省材料、易于自动化等特点,因此广泛应用于航空、航天、能源、电子、汽车、轻工等各工业部门,是重要的焊接工艺之一。
如图1所示,工件在上下电极间被加压、通电,利用焦耳热 Q=0.24I2RT使工件熔化,冷却结晶后产生熔焊核。
1.2电阻点焊的5大要素
从焦耳热的公式可看出 ,焊接电流、通电时间、接触电阻与发热有直接关系,而接触电阻与焊接时的压力密切相关,此外,电极端部的尺寸会影响电流密度从而影响发热,同时,电极材料对热平衡影响重大,从而影响焊接效果。所以,我们称焊接电流、通电时间、焊接压力、电流密度、电极材料为影响电阻点焊的5大要素。
1.2.1焊接电流、通电时间
电阻点焊中,焊接电流I、通电时间T非常重要,其波形、稳定性直接影响焊接效果,而I与T的特性是由焊接电源本身决定的,目前,焊接电源主要有单相交流式、电容储能式、逆变式和晶体管式等4种。几种焊接电流的波形见图2,各种电阻点焊电源特点见表1.
1.2.2焊接压力
焊接过程中压力过小会产生飞溅,焊接加压机构压力的追随性也很重要。此外,在自动点焊机中,通常采用气动加压方式,而在小批量试制中,采用脚踩式加压较为方便。
1.2.3电极
在电池中电极一般指与电解质溶液发生氧化还原反应的位置。电极有正负之分,一般正极为阴极,获得电子,发生还原反应,负极则为阳极,失去电子发生氧化反应。电极可以是金属或非金属,只要能够与电解质溶液交换电子,即成为电极。
电极的主要作用有导通电流,此外,在继电器的点焊中,它通常还是工装夹具的一部分。常用的电极材料有镉青铜、铬青铜、铬锆铜、钨铜合金、钼铜合金、铝表面分散强化合金等,电极无好坏之分,只有搭配是否合理之分。电极选择的一般原则是:
固有电阻大的工件选用固有电阻小的材料做电极,固有电阻小的工件,选用固有电阻大的材料做电极。如图所示,JQX-15F 的簧片与轭铁的点焊,簧片一侧采用WuCu电极,而轭铁一侧采用CrCu电极,这样,热量就会集中在工件结合面处,焊接效果较好。
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OMRON(欧姆龙)