银基钎料在制造业中的研究进展

钎料的性能很大程度上决定了钎焊接头的质量和钎料的应用范畴.银基钎料作为一类非常重要的硬钎焊材料,其填缝能力优异,强度与黄铜、低碳钢接近,可钎焊除铝、镁合金等轻金属之外的所有金属材料.因此,银基钎料广泛应用于航空航天、超硬工具等制造领域,并且受到国内外钎焊界学者们的高度关注.然而,银基钎料的发展及应用过程中仍存在以下问题:第一,钎料中贵金属银含量偏高(一般高于45%),导致钎料使用成本高;第二,银基钎料挤压、轧制、拉拔等加工过程中不可避免地存在夹杂物,影响钎料的使用性能和连接质量;第三,有益金属或合金调控钎料及其连接性能的机制较为复杂,尚未完全研究清楚;第四,传统制备银基钎料的方法产能低下;第五,银基钎料在制造业领域的应用研究尚未见系统报道.国内外对于银基钎料钎焊性能及工程应用方面的研究主要集中于:(1)开发多种节银降银钎料,主要是有益元素调控银基钎料连接性能方面的研究;(2)改进钎料的传统加工方法,提出新的制造方法,如粉末电磁压制成形、钎焊过程中原位合成、快速凝固、镀覆扩散组合等;(3)研究杂质元素(C、Ca、S、Al、Fe、Bi、Pb、O、N 等)的影响;(4)银基钎料形态创新研究,如三明治复合钎料(中间为铜合金、两边为银钎料)、箔带钎料、镀锡银钎料等;(5)工程应用研究,银基钎料在航空航天、汽车制造、电力能源等工业领域起着不可替代的作用,但目前国内外仍缺乏系统阐述该方面研究的报道.因此,本文对近20年国内外有关银基钎料的研究报道进行了评述,重点讨论了合金元素对银基钎料性能的影响.首先对银基钎料研究现状进行详述,总结了Cu、Zn、Sn、Ga、In、Ni、Mn、Cd、Li、Ce、La、P、Si、Pr在银基钎料中的优缺点,归纳了杂质元素C、S、O、N、Ca、Al、Fe、Pb、Bi的恶化作用.其次对银基钎料在航空航天、汽车制造、电力能源、超硬工具、家用电器、眼镜行业等制造业中的应用研究进行详细介绍.最后提出银基钎料研究和应用中的不足,为银基钎料的深入系统研究及相关技术发展提供理论指导.     

第十四讲:真空工程用焊接技术

银基钎料 银共熔点和流点均为960．5℃，室温强度高，塑性和加工性能好，导热、导电性能优良，有良好的抗腐蚀性能。 纯银焊料的纯度应≥99．99％。可焊镍、可伐合金等。但用纯银作钎料存在着钎焊温度高，高温强度低，对黑色金属润湿性能差等缺点，因此银基钎料是弥补纯银钎料的如上不足而研制的。     

真空技术及应用系列讲座 第十四讲:真空工程用焊接技术

6.5.2.2银基钎料(上接2006年第3期第63页)银共熔点和流点均为960.5℃,室温强度高,塑性和加工性能好,导热、导电性能优良,有良好的抗腐蚀性能。纯银焊料的纯度应≥99.99%。可焊镍、可伐合金等。但用纯银作钎料存在着钎焊温度高,高温强度低,对黑色金属润湿性能差等缺点,因此银基钎料是弥补纯银钎料的如上不足而研制的。由A g-Cu相图可知,铜能显著降低银的熔点,银铜合金的金相组织为固溶体和共晶体组成,所以银铜共晶型钎料在电子工业中钎焊铜及铜合金、钛及钛合金、可伐合金等得到广泛应用。最常用的银铜焊料有A gCu28和A gCu50两种。可用来…     

第十四讲:真空工程用焊接技术

7．2．2扩散钎焊用钎料 扩散钎焊时，钎料起着决定性的作用。与一般钎焊方法相比，扩散钎焊用钎料应满足两个特殊要求：一是应含有一定量能够降低钎料熔点的降熔元素，这些元素在扩散钎焊过程中又非常容易地扩散到基材中或被基材溶解；二是降熔元素扩散或被溶解后，钎料的强度和性能应能满足设计和使用要求。     

TLGA22无银中温钎料及其应用

研制的TLGA22钎料是一种不含银及不含镉等有毒元素的Cu-P-Si系新型钎料。钎料熔化温度为708～720℃,具有优良的钎焊工艺性能和对紫铜钎焊优良的自钎能力。而且,钎缝具有能承受强力旋压变形的特点。钎料抗拉强度达689N/mm~2,搭接接头剪切强度为215.4N/mm~2。它可代替银钎料用于钎焊铜及铜合金。本文还通过与磷含量相同的二元Cu-P合金性能的对比,探讨了该钎料中硅对钎料各方面性能的有益作用,并对其机理进行了分析。     

AgCuZnSn钎料制备方法及合金化的研究进展

AgCuZnSn钎料作为绿色环保型硬钎料,一直是国内外钎焊学术界和产业界关注的热点。主要对近20年国内外有关AgCuZnSn钎料的研究报道进行评述,首先对AgCuZnSn钎料体系进行概述,其次从制备方法角度对现有AgCuZnSn钎料的研究进行了归纳分析,然后详细综述了AgCuZnSn钎料合金化的研究进展,分析元素In、Ga、Ni、P、Mn、La及合金Ni-P、Ga-In、Ga-In-Ce的调控作用,最后提出AgCuZnSn钎料研究和应用过程中存在的不足,并对其未来发展的方向进行了展望,为新型AgCuZnSn钎料的进一步研究提供理论指导和参考信息。     

合金元素对Cu/Sn-/Cu回流焊焊点界面微观结构及剪切性能的影响

选用Sn64Bi35Ag1、Sn64.7Bi35Ag0.3和Sn99Ag0.3Cu0.7三种不同的钎料进行回流焊焊接试验,研究高Bi元素、低Ag元素钎料及低Ag钎料对Sn基钎料焊点微观组织及剪切性能的影响.结果表明:各焊点界面处均生成了 一层扇贝状的Cu6Sn5金属间化合物,在含Bi元素的钎料焊点中,Bi元素在焊点界面及内部聚集,导致界面处金属间化合物层的厚度增加,大量富Bi相呈脆性,降低钎料中的Ag含量对焊点中Bi元素的富集现象有减弱作用.Sn99Ag0.3Cu0.7钎料焊点界面处的金属间化合物层厚度最小,且焊点内部形成了细小的Ag3Sn相颗粒,共晶组织呈均匀分布,使得焊点剪切性能最优,其剪切强度达20.4 MPa.     

Bi(Pb)-2223在部分真空中的生成温度

高温超导Bi1 6Pb0.4Sr2Ca2Cu3O10+x/银(Bi(Pb)-2223/Ag)是大规模电力应用最有希望的候选者.制造这种带材的关键步骤是超导前驱物的合成、生坯带的制造和使生坯带获得传输性能的处理.生坯带采用如下两种方法制造:a)在纯银(99.99%)基带上涂复前驱物,例如电泳沉积(EPD);b)将前驱物嵌入银护套中,例如粉末装管法.生坯带的处理是将前驱物转变成Bi(Pb)-2223相和同时连接这些高Tc(～105K)晶粒.因此,Bi(Pb)-2223/Ag复合线中Bi(Pb)-2223的形成条件对于改善这些超导体的性能是最重要的.     

SnAgCuBi无铅钎料对不同体积比SiCP/6063Al复合材料真空软钎焊接头组织和性能的影响

在不同保温时间下,分别采用 Sn-3.0Ag-0.5Cu 和 Sn-3.0Ag-0.5Cu-3.0Bi 无铅软钎料,对表面镀镍的两种不同体积分数的 SiCP/6063Al 复合材料进行真空软钎焊。通过剪切强度测试、显微组织分析、能谱分析等手段研究了钎焊接头的组织和性能。结果表明：Bi 元素的加入改善了 Sn-3.0Ag-0.5Cu 钎料的铺展润湿性,降低了熔点,提高了焊缝的抗剪强度;在270℃保温35 min 时,Sn-3.0Ag-0.5Cu-3.0Bi 钎料钎焊接头抗剪强度达到最高值38.23 MPa;钎焊过程中只是两侧镀镍层间的焊接,钎料并未透过镍层与母材发生扩散反应。     

电子封装用Sn‒Ag‒Cu低银无铅钎料研究进展及发展趋势

目的 为了适应高银钎料向低银钎料转变的发展趋势,综述近年来对低银SnAgCu钎料的最新研究,展示其在电子封装材料领域中宽广的应用前景。方法 通过分析国内外有关低银钎料的研究成果,详细介绍合金化和颗粒强化等方法对低银钎料熔化特性、润湿性、显微结构、界面组织、力学性能的影响,重点总结元素掺杂的最佳添加量以及改性机理。结论 通过添加金属元素、稀土元素、纳米颗粒,采用新型搅拌技术能有效提升钎料性能,部分改性后的低银复合钎料性能达到了高银钎料性能水平。     

The green element method

This paper discusses an element-by-element approach of implementing the Boundary Element Method (BEM) which offers substantial savings in computing resource, enables handling of a wider range of problems including non-linear ones, and at the same time preserves the second-order accuracy associated with the method. Essentially, by this approach, herein called the Green Element Method (GEM), the singular integral theory of BEM is retained except that its implementation is carried out in a fashion similar to that of the Finite Element Method (FEM). Whereas the solution procedure of BEM couples the information of all nodes in the computational domain so that the global coefficient matrix is dense and full and as such difficult to invert, that of GEM, on the other hand, involves only nodes that share common elements so that the global coefficient matrix is sparse and banded and as such easy to invert. Thus, GEM has the advantage of being more computationally efficient than BEM. In addition, GEM makes the singular integral theory more flexible and versatile in the sense that GEM readily accommodates spatial variability of medium and flow parameters (e.g., flow in heterogeneous media), while other known numerical features of BEM—its second-order accuracy and ability to readily handle problems with singularities are retained by GEM. A number of schemes is incorporated into the basic Green element formulation and these schemes are examined with the goal of identifying optimum schemes of the formulation. These schemes include the use of linear and quadratic interpolation functions on triangular and rectangular elements. We found that linear elements offer acceptable accuracy and computational effort. Comparison of the modified fully implicit scheme against the generalized two-level scheme shows that the modified fully implicit scheme with weight of about 1·25 offers a marginally better approximation of the temporal derivative. The Newton–Raphson scheme is easily incoporated into GEM and provides excellent results for the time-dependent non-linear Boussinesq problem. Comparison of GEM with conventional BEM is done on various numerical examples, and it is observed that, for comparable accuracy, GEM uses less computing time. In fact, from the numerical simulations carried out, GEM uses between 15 and 45 per cent of the simulation time of BEM.     

采用广义协调条件构造具有旋转自由度的四边形膜元

本文根据广义协调的概念,通过引进单元结点刚体转角,提出两种具有平面内旋转自由度的四边形膜元。单元列式简单,是能通过任意四边形分片检验的收敛单元。数值计算表明这两种单元无论是位移还是应力都有很高的计算精度。     

广义协调平板型三角形壳元

本文构造了一种具有三个角点十八个自由度的平板三角形壳元GST18。其拉伸与弯曲部分分别由含旋转自由度的三角形膜元和薄板弯曲三角形元组成。广义协调方法的采用,使得该单元的收敛性得到保证。在结点上引入了平面内旋转自由度,从根本上克服了单元共面刚度矩阵出现奇异这一困难。对平面膜元采用了缩减积分方案,使该单元不会产生薄膜闭锁现象。数值算例表明,本文提出的GST18薄壳元是计算精度优于同类单元的可靠、实用的单元。     

具有旋转自由度的广义协调矩形膜元

本文根据广义协调的思想,在平面应力矩形单元双线性协调位移场中,引入附加广义泡状位移场,构造出一种具有平面内旋转自由度的矩形膜单元,它满足广义协调条件。数值计算结果表明,这种单元有很高的计算精度,而且计算量少,是一种能收敛于精确解的单元。     

带转角自由度的四边形六面体单元

本文提出了三个带转角自由度单元，其中一个平面四边形单元，两个空间六面体单元。对平面单元每个结点有两个线位移自由度、一个转角自由度；对空间单元，每个结点有三个线位移自由度、三个转角自由度。这些单元列式简单，其中两个无多余零能模式，数值计算表明，它们的计算精度高。     

非协调元性能分析的两个定理

在构造非协调元的过程中,必须遵守一定的构造规律。本文从基本力学观点出发,提出并证明了两个定理。定理一、如果某种类型的有限单元共有n个独立参与整体刚度运算的自由度,则该单元最多只能精确模拟n种弹性力学基本解。该定理说明了单元的精度从根本上受自身自由度限制的,并指出了现有的四边形四结点单元发展空间不大,而四边形八结点Q8单元以及三维八结点H8单元仍然具有较大的发展余地。定理二则认为四边形四结点内参型非协调元如果能够通过小片试验,则不可能在任意畸变状态下精确表示纯弯场。该定理表明了畸变问题的尝试是有限制的。以上的结论虽然是针对非协调元的构造来提出的,但从论证过程看,应对其它类型的有限单元也适用。定理一和定理二对于今后新型有限元的发展可以起到一定的指导作用。     

A 3‐node flat triangular shell element with corner drilling freedoms and transverse shear correction

The formulation, implementation and testing of simple, efficient and robust shell finite elements have challenged investigators over the past four decades. A new 3‐node flat triangular shell element is developed by combination of a membrane component and a plate bending component. The ANDES‐based membrane component includes rotational degrees of freedom, and the refined nonconforming element method‐based bending component involves a transverse shear correction. Numerical examples are carried out for benchmark tests. The results show that compared with some popular shell elements, the present one is simple but exhibits excellent all‐around properties (for both membrane‐and bending‐dominated situations), such as free of aspect ratio locking, passing the patch test, free of shear locking, good convergence and high suitability for thin to moderately thick plates. The developed element has already been adopted in a warpage simulation package for injection molding. Copyright © 2011 John Wiley & Sons, Ltd.     

Genetic algorithm based deformation control and clamping force optimisation of workpiece fixture system

In re-engineering mass production industry, design and production of components are frequently changed according to the customer needs within a very short span of time. This leads to rising difficulty in maintaining the accuracy of every finished component. It also induces the long setup time of the cutting tools and machine tools affecting the production rate of the components. To reduce the production time and to improve the accuracy of the finished product, proper fixture element is essential. The accuracy of the finished work-piece strongly depends on the position of the locators and clamps in the work-piece fixture system. The finite element analysis tool is well suited to predict the active and passive forces on the work piece-fixture system. The accuracy of the workpiece not only depends on the clamping force but also depends upon the locator force (reaction force). This paper presents the optimisation of the locations of active (clamp) and passive (locator/support) elements in the workpiece-fixture system using genetic algorithm (GA) with ANSYS parametric design language (APDL) of finite element analysis. Three case studies are given to illustrate the application of the proposed approach. Finally the case study results have been compared with the Li and Melkote (1999a Li, B and Melkote, SN. 1999a. An elastic contact model for the prediction of workpiece-fixture contact forces in clamping. ASME Journal of Manufacturing Science and Engineering, 121(3): 485–493.  [Google Scholar]) [Li, B. and Melkote, S.N., 1999a. An elastic contact model for the prediction of workpiece-fixture contact forces in clamping. ASME Journal of Manufacturing Science and Engineering, 121(3), 485–493] study. This presented prediction method is conceptually simple and computationally efficient.     

带转角自由度的三角形三棱柱单元

本文提出了一个带转角自由度平面三角形单元、两个带转角自由度空间三棱柱单元。对平面单元每个结点有两个线位移自由度、一个转角自由度；对空间单元每个结点有三个线位移自由度、三个转角自由度。这些单元列式简单，其中两个无多余零能模式，数值计算表明，它们的计算精度高。     

A higher-order facet quadrilateral composite shell element

A C⁰ finite element formulation of flat faceted element based on a higher-order displacement model is presented for the analysis of general, thin-to-thick, fibre reinforced composite laminated plates and shells. This theory incorporates a realistic non-linear variation of displacements through the shell thickness, and eliminates the use of shear correction coefficients. The discrete element chosen is a nine-noded quadrilateral with five and nine degrees of freedom per node. A comparison of results is also made with the 2-D thin classical and 3-D exact analytical results, and finite element solutions with 9-noded first-order element. © 1997 John Wiley & Sons, Ltd.