01 Kev Taw Qhia Nrog kev txhim kho sai ntawm cov tsheb tshiab lub zog thiab siab -kub superconducting technology, lub teeb yuag, siab conductivity thiab cov cuab yeej siv tau zoo heev tau dhau los ua cov teeb meem tseem ceeb hauv kev tsim khoom. Aluminium thiab tooj liab yog dav siv nyob rau hauv lub hwj chim roj teeb, hluav taws xob tsav systems, busbar kev twb kev txuas, thiab superconducting li vim hais tias ntawm lawv zoo heev hluav taws xob conductivity, tsawg ceev, thiab zoo corrosion kuj. Txawm li cas los xij, aluminium-aluminium, tooj liab-tooj liab, thiab txhuas-tooj liab pob qij txha feem ntau ntsib teeb meem xws li cov khoom siv hluav taws xob ntau dhau, tsim cov khoom sib txuas sib txuas, sib koom ua ke, thiab vuam deformation thaum lub sij hawm siv cov txheej txheem fusion vuam, txwv tsis pub lawv cov ntawv thov engineering. Ultrasonic welding, raws li cov khoom sib xws-lub xeev koom nrog thev naus laus zis, ua tiav kev sib txuas ntawm cov khoom siv hlau los ntawm siab- zaus tshuab vibrations thiab kev sib txhuam kev sib txhuam, muab cov txiaj ntsig zoo xws li cov khoom siv hluav taws xob tsawg, lub sijhawm vuam luv, thiab cov kev cuam tshuam cuam tshuam. Nyob rau hauv xyoo tas los no, nws tau txais kev saib xyuas dav hauv kev tsheb fais fab thiab kev tsim hluav taws xob superconducting. Tshwj xeeb tshaj yog nyob rau hauv cov roj teeb tab kev sib txuas, aluminium- tooj liab sib txawv hlau vuam, thiab siab -conductivity busbar manufacturing, ultrasonic welding qhia kev ua tau zoo tshaj rau cov txheej txheem vuam tsoos. Tawm tsam keeb kwm yav dhau los no, daim ntawv no tau tshuaj xyuas cov kev tshawb fawb ntawm txhuas thiab tooj liab ultrasonic vuam thev naus laus zis hauv kev siv hluav taws xob thiab kev siv hluav taws xob superconducting, suav nrog nws cov txheej txheem vuam, cov txheej txheem evolution, thiab daim ntawv thov engineering tam sim no, yog li muab cov kev siv theoretical rau cov txheej txheem txuas ntxiv thiab kev txhim kho thev naus laus zis.
02 Nta ntawm ultrasonic vuam
Ultrasonic welding feem ntau yog siv ob qho kev teeb tsa: lub npoo -siab system thiab lateral- tsav system (Daim duab 1). Ob qho tib si zoo sib xws hauv kev vibration mechanism tab sis txawv ntawm cov qauv qauv, qib amplitude, clamping quab yuam, thiab cov khoom siv. Lub npoo- lub zog siab yog tus cwj pwm los ntawm qhov tsis tshua muaj siab thiab siab clamping quab yuam, hloov ultrasonic zog ncaj qha mus rau qhov chaw ua haujlwm los ntawm kev sib xyaw ua ke ntawm longitudinal vibration thiab transverse vibration ntawm lub vuam taub, haum rau cov ntaub ntawv tuab lossis ntau dua. Lub lateral- tsav lub cev muaj qhov zoo ntawm qhov siab amplitude, tsis tshua muaj clamping quab yuam, thiab ntsuas qhov ntsuas tsis zoo, ua rau nws tsim nyog rau kev sib txuas cov xov hlau zoo, cov ntawv ci, thiab cov ntawv nyias nyias thiab yog li siv dav hauv thaj chaw xws li lithium- ion roj teeb thiab cov ntaub nplaum superconducting. Nyob rau hauv no lub hauv paus, ultrasonic welding tsis tau muab faib ua cov txheej txheem tsis thiab cov khoom tsis, nrog vuam zog, lub sij hawm, clamping quab yuam, thiab kev co amplitude yog cov tseem ceeb yam tseem ceeb txiav txim siab vuam zoo. Thaum lub sij hawm vuam, nws yog ib qho tsim nyog yuav tsum ua kom haum raws li lub zog clamping thiab kev vibration amplitude thaum ua kom muaj kev sib cuag txaus, kom tsis txhob ntog vim tsis txaus clamping quab yuam lossis ntau dhau ntawm cov khoom vim muaj zog ntau dhau.
Daim duab 1 qhia txog lub tshuab vuam ultrasonic uas siv cov kev sib hloov kev co, suav nrog (a) lub caij nplooj ntoos hlav lub caij nplooj ntoos hlav thiab (b) ib qho kev tsav tsheb transverse [1] 2.
2 Hluav taws xob, thermal thiab mechanical yuav tsum tau ntawm ultrasonic vuam Raws li ib tug raug cov khoom- xeev koom txheej txheem, hlau ultrasonic vuam muaj qhov zoo hauv hluav taws xob, thermal thiab cov khoom siv sib xws, tshwj xeeb tshaj yog tsim rau kev koom nrog cov khoom siv thermal thiab hluav taws xob. Cov kev tshawb fawb tau pom tias piv nrog qhov chaw vuam, ultrasonic vuam txo lub zog noj hauv aluminium alloy kev npaj, thaum ua tiav cov hluav taws xob tsis tshua muaj hluav taws xob thiab thermal tiv thaiv, nrog rau vuam lub sij hawm tsuas yog nyob rau theem ib ntus, ua kom pom lub zog zoo thiab kev tswj xyuas thermal. Nyob rau hauv qis-kub hlau nplaum thiab cov ntawv thov superconducting (xws li REBCO CC tapes), kev sib koom ua ke yog nyob ntawm thermal conductivity, thermal expansion coefficient txuam thiab txhua yam ruaj khov. Raws li ultrasonic vuam tsis siv cov hlau muab tub lim, nws zoo tiv thaiv qhov seem seem, tawg lossis cuam tshuam cuam tshuam los ntawm thermal expansion mismatch, yog li txo qhov kev pheej hmoo ntawm quenching thiab ncua kev pab cuam lub neej. Nyob rau tib lub sijhawm, cov pob qij txha tsim los ntawm cov txheej txheem vuam ultrasonic muaj qhov zoo thermal stability, muaj txiaj ntsig zoo rau kev tswj xyuas cov qauv kev ncaj ncees thaum lub sijhawm tam sim no - nqa cov txheej txheem. Los ntawm cov ntaub ntawv thiab metallurgical foundations, ultrasonic vuam raws li ib tug khoom- lub xeev txheej txheem tuaj yeem ua tiav kev sib koom ua ke ntawm cov hlau sib txawv, muaj cov kev xav tau qis rau saum npoo, kev hloov pauv siab, tuaj yeem koom nrog cov khoom sib txawv loj hauv cov ntsiab lus melting, thiab txo qhov kev pheej hmoo corrosion. Cov pob qij txha uas tsim los ntawm cov txheej txheem no qhia tau hais tias tsawg kawg deformation thiab zoo vuam zoo, haum rau tuab daim hlau, nyias daim hlau thiab ultra{11}} nyias foils, ua tau zoo sustainability thiab engineering daim ntawv thov prospects nyob rau hauv precision koom teb xws li lithium{12}} ion roj teeb thiab superconducting tapes.
3.1 Kev Sib Tw hauv Vuam Optimization Hauv ultrasonic vuam daim ntawv thov ntawm txhuas, tooj liab, thiab cov ntaub ntawv sib txawv, ua tiav qib siab - zoo, cov pob qij txha zoo ib yam tseem ntsib ntau yam teeb meem. Txawm hais tias feem ntau cov txhuas alloys (xws li 5xxx thiab 6xxx series) tau raug pov thawj tias muaj qhov zoo ntawm ultrasonic weldability, qee cov hlau tseem raug kev txom nyem los ntawm cov teeb meem xws li vuam tip adhesion, deformation loj, thiab nqaim txheej txheem qhov rais, ua parameter optimization mas nyob ntawm cov khoom yam ntxwv. Vuam zoo yog qhov tsis tshua muaj siab rau cov txheej txheem, ntawm cov vuam zog, lub sijhawm, kev vibration amplitude, thiab clamping siab yog qhov tseem ceeb, thiab lawv cov kev sib cuam tshuam ntxiv ua rau cov txheej txheem nyuaj. Thaum ib txwm muaj tag nrho -factorial sim tsim tuaj yeem tau txais cov ntaub ntawv ntau, nws raug nqi thiab tsis muaj txiaj ntsig; Hauv qhov sib piv, kev txheeb xyuas qhov sib txawv (ANOVA) tau raug pov thawj los txheeb xyuas cov ntsiab lus tseem ceeb thiab lawv cov kev cuam tshuam nrog tsawg qhov kev sim, muab lub hauv paus txhim khu kev qha rau kev ua kom muaj zog vuam thiab tswj kev sib xws. Txawm li cas los xij, kev siv cov txheej txheem txheeb cais hauv kev lag luam tseem txwv los ntawm qhov nyuaj ntawm kev txhais cov ntaub ntawv.
Los ntawm kev xav txog kev siv tshuab, qhov kev ntxhov siab cuam tshuam cuam tshuam tsim tawm thaum lub sijhawm vuam ultrasonic tuaj yeem tsoo cov oxide zaj duab xis thiab txhawb kev sib txuas ntawm metallurgical. Tsis txaus los yog cov cua kub ntau dhau tuaj yeem ua rau hauv qab - vuam lossis dhau - vuam, uas ua rau cuam tshuam rau ntawm lub ntsej muag lossis kev ua haujlwm tsis zoo. Cov kev tshawb fawb tau pom tias qhov kev sib tw tsim nyog ntawm lub sijhawm vuam thiab kev vibration amplitude tuaj yeem tsim qhov zoo tshaj plaws weld core qauv, thaum cov tswv yim zoo xws li amplitude nkhaus tswj txhim kho vuam lub zog thiab ruaj khov ntawm qhov sib txawv ntawm Al-Cu pob qij txha los ntawm kev kho lub zog tawm tswv yim hauv theem. Tsis tas li ntawd, cov txheej txheem tsis xws li txoj hauj lwm ntawm nyias daim hlau nyob rau hauv ntau- txheej txheej, qhov zoo nkauj ntawm lub vuam taub thiab lub tog raj kheej, thiab qhov sib txawv ntawm qhov pib kuj tseem muaj feem cuam tshuam rau kev vuam zoo, tshwj xeeb tshaj yog nyob rau hauv cov ntaub ntawv rhiab heev xws li superconducting tapes, qhov parameter tsis sib haum yuav ua rau muaj kev tiv thaiv ntau ntxiv lossis kev puas tsuaj rau cov txheej txheem ua haujlwm. Zuag qhia tag nrho, cov kev sib tw tseem ceeb ntawm ultrasonic welding optimization yog nyob rau hauv kev ua kom muaj kev sib koom ua ke ntawm cov khoom siv adaptability, kev sib koom ua haujlwm, thiab cov txheej txheem ruaj khov nyob rau hauv kev sib koom ua ke ntawm ntau yam - parameter tej yam kev mob, uas yuav tsum tau ib tug systematic tsim combining mechanistic kev nkag siab thiab statistical optimization txoj kev nrog tsawg kawg nkaus sim nqi.
3.2 Kev Sib Tw hauv Cov Khoom Siv thiab Metallurgy Nyob rau hauv ultrasonic vuam txheej txheem ntawm txhuas, tooj liab, thiab cov ntaub ntawv sib txawv, cov khoom siv thiab metallurgical yam ntawm kev sib koom ua ke yog qhov nyuaj tshwj xeeb. Corrosion cwj pwm yog ib qho ntawm cov teeb meem tseem ceeb uas txwv tsis pub muaj kev ntseeg siab ntawm kev sib koom ua ke. Atmospheric corrosion, fretting corrosion, thiab galvanic corrosion tag nrho degrade cov hlau - mus rau -hlau kev sib cuag interface, ua rau muaj kev tiv thaiv thiab txo qhov ntev - lub sij hawm stability ntawm roj teeb thiab REBCO CC pob qij txha. Kev coj tus cwj pwm oxidation ntawm cov khoom sib txawv sib txawv: cov oxide txheej ntawm cov ntaub ntawv txhuas ua tau sai heev thiab nyias nyias, thaum tooj liab oxide txheej muaj cov qauv nyuaj, muaj ob qho tib si conductive thiab insulating zog, ua rau metallurgical tswj ntawm cov khoom sib txawv ntawm cov khoom sib txawv. Nyob rau hauv Al-Cu ultrasonic vuam, cov txheej txheem kev sib tshuam feem ntau muaj cov nanocrystalline, amorphous theem, thiab siab - ntom dislocations. Cov qauv no yog los ntawm cov yas deformation hnyav thiab atomic interdiffusion induced los ntawm ultrasonic kev co, uas yog zoo rau cov neeg kho tshuab interlocking thiab metallurgical bonding, tab sis kuj yuav txhawb kev tsim ntawm brittle intermetallic compounds (IMCs). Vim tias muaj tshuaj lom neeg muaj txiaj ntsig zoo ntawm Al thiab Cu, thaum qhov kub thiab txias deformation tshaj qhov tseem ceeb, IMCs xws li Al₂Cu tau tsim tau yooj yim, ua rau txo qis hauv cov khoom sib koom ua ke thiab kev ua kom muaj zog, tshwj xeeb tshaj yog thaum IMC txheej thickness ntau tshaj li ntawm 2 µm, nws cov teebmeem tsis zoo yuav ua rau muaj kev cuam tshuam ntau dua.
Raws li pom hauv daim duab 2, nrog rau lub sijhawm vuam thiab lub zog nce zuj zus, qhov cuam tshuam ntawm qhov vuam lub taub hau thiab lub taub hau nce ntxiv, thiab qhov sib txawv ntawm qhov chaw thiab tus ntoo khaub lig-sectional thinning nta tshwm sim hauv thaj chaw vuam, qhia txog cov yas ntws thiab cov khoom siv rov qab thaum lub sij hawm vuam. Lub waviness ntawm lub interface nce nrog nce vuam lub sij hawm, uas tsis tsuas yog shortens lub tawg propagation txoj kev tab sis kuj hloov lub puas hom, maj hloov los ntawm interfacial puas mus rub - tawm los yog sib tov puas, yog li cuam tshuam rau lub load tsis ua hauj lwm. Rau qhov sib txawv ntawm cov khoom siv vuam, qhov sib txawv ntawm cov khoom hardness amplifies no deformation asymmetry; Cov khoom siv softer yog qhov yooj yim rau dynamic recrystallization thiab grain refinement, ua rau tsis sib xws hardness faib nyob rau hauv weld cheeb tsam.
3.3 Electromechanical Coupling Challenges Nyob rau hauv daim ntawv thov xws li hluav taws xob lub tsheb roj teeb packs thiab superconducting REBCO CC tapes, ultrasonic welded pob qij txha tsis tsuas yog yuav tsum tau raws li cov neeg kho tshuab kev twb kev txuas tab sis kuj yuav tsum muaj tsawg thiab ruaj khov hluav taws xob tiv thaiv kom tsis txhob Joule cua sov tsub zuj zuj, hluav taws xob imbalance, thiab ua rau muaj kev ruaj ntseg teeb meem xws li overcharging, overcharging. Kev tshawb fawb qhia tau hais tias cov qauv kev sib koom ua ke thiab cov khoom siv teeb tsa cuam tshuam rau kev ua haujlwm thiab kev coj tus cwj pwm: nyob rau hauv multilayer Cu-Al pob qij txha, cov ntaub ntawv softer ntawm lub vuam taub hau sab yog ntau dua rau deformation thiab thinning, yog li degrading hluav taws xob kev ua tau zoo ntawm kev sib koom tes; Nyob rau hauv sib piv, muab ib tug thicker los yog nyuaj Cu txheej nyob rau hauv anvil sab yuav txo tau interfacial tsis xws luag thiab txo kev sib koom ua ke. Tam sim no pulse loading thwmsim ntxiv qhia tau tias Al-Cu pob qij txha, vim muaj kev cuam tshuam ntau dua, muaj kev kub ntxhov ntau dua nyob rau hauv tib lub sijhawm tam sim no piv rau Cu-Cu pob qij txha, qhia txog kev txwv tsis pub electro-thermal- qauv kev sib txuas ntawm kev sib koom ua ke. Raws li pom nyob rau hauv daim duab 3, piv rau cov tsoos brazed pob qij txha, ultrasonic welded pob qij txha txo tus naj npawb ntawm cov ntaub ntawv txheej thiab interfaces nyob rau hauv txoj kev tam sim no los ntawm kev tsim cov khoom ncaj qha- xeev kev sib txuas ntawm cov txheej tooj liab, yog li txo qis qhov kev tiv thaiv tag nrho; Txawm li cas los xij, lawv qhov kev sib txuas feem ntau yog ob qho tib si sib txuas (P1) thiab tsis sib koom (P2) thaj tsam, thiab cov hluav taws xob ua haujlwm tau zoo heev rau thaj tsam kev sib raug zoo. Txhawm rau txhim kho qhov ruaj khov ntawm kev sib koom ua ke hauv cov hlau nplaum muaj zog thiab qhov chaw nyob ib puag ncig cryogenic, brazing{12}}ultrasonic composite vuam txoj kev tau raug npaj. Txoj kev no txhim kho kev sib cuag hluav taws xob txuas ntxiv, txo kev sib koom ua ke, thiab txhim kho kev ruaj ntseg thiab khoov tsis kam los ntawm kev tso cai rau solder nkag mus rau thaj tsam tsis muaj kev sib koom tes. Zuag qhia tag nrho, cov txiaj ntsig tau pom nyob rau hauv daim duab intuitively ua kom pom kev sib raug zoo ntawm kev sib koom ua ke ntawm cov qauv sib txuas, thaj chaw ua haujlwm zoo, thiab tus cwj pwm electromechanical coupling. Kev tsim qauv tsim ntawm ultrasonic welded kev sib koom ua ke thiab nws cov txheej txheem hybrid yog qhov tseem ceeb rau kev ua tiav kev sib txuas hluav taws xob zoo heev.
04 Kev xaus Zuag qhia tag nrho, kev vuam ultrasonic ua kom pom qhov zoo tshaj plaws hauv kev sib koom ua ke ntawm txhuas thiab tooj liab, ua rau nws tshwj xeeb tshaj yog tsim rau lub tsheb hluav taws xob thiab kev siv hluav taws xob superconducting uas xav tau hluav taws xob tsis tshua muaj hluav taws xob thiab kev ua haujlwm zoo. Cov kev tshawb fawb uas twb muaj lawm tau qhia tawm nws txoj kev sib txuas lus sib txuas thiab ua tiav qhov tseem ceeb hauv cov txheej txheem parameter optimization thiab kev siv engineering. Txawm li cas los xij, kev tshawb fawb ntawm cov txheej txheem ntau txheej txheej, kev siv sijhawm ntev - kev ntseeg siab ntawm cov khoom sib txawv, thiab cov qauv ntawm cov txheej txheem vuam tseem txwv. Cov kev tshawb fawb yav tom ntej yuav tsum tau tsom mus rau ntau- ntsuas kev ntsuas ntsuas, kev tswj xyuas kom zoo ntawm lub qhov rais txheej txheem, thiab kev sib koom ua ke ntawm ultrasonic vuam nrog rau lwm yam kev koom ua ke siab heev los txhawb rau hauv - kev txhim kho tob thiab kev siv tshuab ntawm cov cuab yeej no hauv high-kev tsim khoom.
