摘要
摩擦搅拌焊（FSW）作为一种先进的固相连接技术，近年来在异种材料连接领域展现出显著优势。传统焊接方法难以克服异种材料间物理、化学和力学性能差异带来的问题，而摩擦搅拌焊通过机械能转化为热能的方式，在不熔化材料的前提下实现高质量连接，为航空航天、汽车制造及能源工业等领域提供了新的解决方案。本研究旨在探讨摩擦搅拌焊在异种材料连接中的应用潜力及其关键技术挑战，重点分析了工艺参数优化、工具设计改进以及微观组织演变对焊接性能的影响。通过实验研究与数值模拟相结合的方法，系统评估了不同材料组合（如铝-钢、镁-铝等）的焊接接头力学性能，并揭示了界面反应层的形成机制及其对连接强度的作用规律。研究发现，合理控制转速、进给速度和下压力等工艺参数能够有效抑制界面脆性相生成，同时改善接头区域的显微组织均匀性。此外，创新性地提出了一种多级搅拌工具设计方法，显著提升了复杂材料组合的焊接质量。研究表明，摩擦搅拌焊在异种材料连接中具有广阔的应用前景，其核心技术突破将为高性能轻量化结构的开发提供重要支持。
关键词：摩擦搅拌焊；异种材料连接；工艺参数优化；界面反应层；多级搅拌工具设计
Abstract
Friction stir welding (FSW), as an advanced solid-phase joining technology, has demonstrated significant advantages in the field of dissimilar material joining in recent years. Traditional welding methods struggle to overcome the challenges posed by differences in physical, chemical, and mechanical properties between dissimilar materials. In contrast, friction stir welding achieves high-quality joints by converting mechanical energy into thermal energy without melting the materials, offering new solutions for industries such as aerospace, automotive manufacturing, and energy. This study investigates the application potential of friction stir welding in dissimilar material joining and addresses its key technical challenges, with a focus on process parameter optimization, tool design improvement, and the influence of microstructural evolution on weld performance. By integrating experimental research with numerical simulation, the mechanical properties of welded joints for various material combinations, such as aluminum-steel and magnesium-aluminum, were systematically evaluated. The formation mechanism of interfacial reaction layers and their effects on joint strength were also revealed. It was found that appropriately controlling process parameters, including rotational speed, feed rate, and downward pressure, can effectively suppress the generation of brittle phases at the interface while enhancing the uniformity of the microstructure in the joint region. Additionally, an innovative multi-stage stirring tool design method was proposed, significantly improving the welding quality of complex material combinations. The findings indicate that friction stir welding holds broad application prospects in dissimilar material joining, and breakthroughs in its core technologies will provide critical support for the development of high-performance lightweight structures.
Keywords：Friction Stir Welding; Dissimilar Material Joining; Process Parameter Optimization; Interface Reaction Layer; Multi-Stage Stirring Tool Design
目 录
摘要 I
Abstract II
一、绪论 1
(一) 摩擦搅拌焊技术的发展背景与意义 1
(二) 异种材料连接的研究现状分析 1
(三) 本文研究方法与技术路线 2
二、摩擦搅拌焊的工艺原理与关键技术 2
(一) 摩擦搅拌焊的基本原理 2
(二) 关键工艺参数对焊接质量的影响 3
(三) 焊接过程中热力学行为分析 3
三、异种材料连接中的挑战与解决方案 4
(一) 异种材料连接的主要难点 4
(二) 材料兼容性与界面反应控制 4
(三) 工艺优化策略及其应用实例 5
四、摩擦搅拌焊在异种材料连接中的应用案例分析 5
(一) 航空航天领域的应用进展 5
(二) 汽车工业中的实践与创新 6
(三) 其他领域中的典型应用案例 7
结 论 8
参考文献 9
