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Ġstanbul Teknġk Ünġversġtesġ Fen ĠSTANBUL TEKNĠK ÜNĠVERSĠTESĠ FEN BĠLĠMLERĠ ENSTĠTÜSÜ 5754 ALÜMĠNYUM ALAġIMININ KAYNAK DAVRANIġININ ĠNCELENMESĠ YÜKSEK LĠSANS TEZĠ SavaĢ AKINCI Metalurji ve Malzeme Mühendisliği Anabilim Dalı Malzeme Mühendisliği Programı Malzeme Mühendisliği Programı Anabilim DalıEYLÜL : Herhangi 2008 Mühendislik, Bilim Programı : Herhangi Program ĠSTANBUL TEKNĠK ÜNĠVERSĠTESĠ FEN BĠLĠMLERĠ ENSTĠTÜSÜ 5754 ALÜMĠNYUM ALAġIMININ KAYNAK DAVRANIġININ ĠNCELENMESĠ YÜKSEK LĠSANS TEZĠ SavaĢ AKINCI (506051416) Metalurji ve Malzeme Mühendisliği Anabilim Dalı Malzeme Mühendisliği Malzeme Mühendisliği Programı Tez DanıĢmanı: Prof. Dr. Yılmaz TAPTIK Anabilim DalıEYLÜL : Herhangi 2008 Mühendislik, Bilim Programı : Herhangi Program iv İTÜ, Fen Bilimleri Enstitüsü’nün 506051416 numaralı Yüksek Lisans / Doktora Öğrencisi SavaĢ AKINCI, ilgili yönetmeliklerin belirlediği gerekli tüm şartları yerine getirdikten sonra hazırladığı “5754 ALÜMĠNYUM ALAġIMININ KAYNAK DAVRANIġININ ĠNCELENMESĠ” başlıklı tezini aşağıda imzaları olan jüri önünde başarı ile sunmuştur. Tez DanıĢmanı : Prof. Dr. Yılmaz TAPTIK ............................ .............................. İstanbul Teknik Üniversitesi Jüri Üyeleri : Prof. Dr. Mehmet KOZ ............................ ............................. İstanbul Teknik Üniversitesi Doç. Dr. Özgül KELEġ ............................ .............................. Marmara Üniversitesi Teslim Tarihi : 04.09.2008 Savunma Tarihi : 04.09.2008 iii iv ÖNSÖZ Bu çalışmada 5754 alüminyum alaşımının kaynak davranışları incelenmiştir.Farklı akım değerlerinde TIG kaynak yöntemi ile kaynaklanmış alüminyum levhaların dayanım , sertlik , kaynak dikişi porozite miktarı,kırılma yüzey analizleri yapılmıştır. Çalışmamda bana hiçbir yardımı esirgemeyen sayın hocam, Prof.Dr. Yılmaz TAPTIK’a, değerli arkadaşım Met.Y.Müh. Alper DOMBAYCI ve Çev.Y.Müh. Tolga TEZGEL’e ve deneyde kullanılan kaynak malzemelerini tedarik eden Askaynak firmasına en içten teşekkürlerimi sunarım. Savaş Akıncı Mart 2012 (Metalurji ve Malzeme Mühendisi) v vi ĠÇĠNDEKĠLER Sayfa ÖNSÖZ…...……………………………………………………………...….............. v ĠÇĠNDEKĠLER……………………………………………………..……………... vii KISALTMALAR………………………………………………………………….. ix ÇĠZELGE LĠSTESĠ…………………………………………………..…………… xi ġEKĠL LĠSTESĠ ………………………………...……………….…….…..….…..xiii ÖZET……………………………………………………………………………… xv SUMMARY………………………………………………...………………..…….xvii 1. GĠRĠġ .................................................................................................................. 1 2. ALÜMĠNYUM ALAġIMLARI ........................................................................ 3 2.1 Alüminyumun Keşfi ..................................................................................... 3 2.2 Alüminyum Alaşımlarının Karakteristik Özellikleri ................................... 3 2.3 Alüminyum Alaşımlarının Sınıflandırılması................................................ 5 2.4 Alaşım Elementlerinin Etkisi ....................................................................... 5 2.5 Alüminyumun Isıl İşlem İşaretleri ............................................................... 7 2.5.1 Ana menevişleme işaretleri ...................................................................... 7 2.5.2 Gerinme sertleşmesi alt bölümleri ........................................................... 7 2.5.3 Isıl işlem alt bölümleri ............................................................................. 7 2.6 Direk Döküm ve Çift Merdaneli Döküm Yöntemleri İle Alüminyum Levha Üretimi ..................................................................................................................... 8 2.6.1 DC döküm yöntemi .................................................................................. 8 2.6.2 İkiz merdaneli döküm [TCR] ................................................................ 10 2.6.3 DC ve TCR yöntemlerinin kıyaslaması ................................................. 10 3. ALÜMĠNYUM ALAġIMLARININ KAYNAĞI ........................................... 13 3.1 Alüminyum Alaşımlarına Uygulanan Kaynak Yöntemleri........................ 13 3.2 Alüminyum Kaynak Yönteminin Seçimi ................................................... 14 3.3 Koruyucu Gazlar ........................................................................................ 20 3.4 Kaynak Dikişi ve Ana Metal Arasındaki Renk Uyumu ............................. 22 3.5 Alüminyumun TIG Kaynağında Kullanılan Elektrotlar ............................ 22 3.5.1 Elektrot sınıflandırması ve uygun elektrot seçimi ................................. 23 3.6 Tungsten İnert Gaz Kaynak Yöntemi (TIG) .............................................. 25 3.6.1 Prosesin avantajları ................................................................................ 27 3.6.2 Prosesin sınırları ..................................................................................... 27 3.6.3 Proses değişkenleri ................................................................................. 28 3.6.4 Ark akımı ............................................................................................... 28 3.6.5 Ark Voltajı ............................................................................................. 28 3.6.6 Kaynakta ilerleme hızı ........................................................................... 29 3.6.7 Tel besleme ............................................................................................ 29 vii Sayfa 3.6.8 Alternatif akım ....................................................................................... 29 3.6.9 Doğru akım ............................................................................................. 30 3.7 Kaynaklı Alüminyum Alaşımların Özellikleri ........................................... 33 3.7.1 Metalurjik etki ........................................................................................ 33 3.7.2 Kaynak metali ........................................................................................ 33 3.7.3 Isı tesiri altındaki bölge .......................................................................... 33 3.8 Oksit Film Tabakasının Kaldırılması ......................................................... 35 4. KAYNAK HATALARI.................................................................................... 37 4.1 Nüfuziyet Azlığı ......................................................................................... 37 4.2 Birleştirme Azlığı (Yetersiz Erime) ........................................................... 37 4.3 Yanma Olukları veya Çentikleri ................................................................ 38 4.4 Kalıntılar ..................................................................................................... 39 4.5 Kaynak Metalinde ve Ana Metalde Oluşan Çatlaklar ................................ 40 4.6 Gözenekler ................................................................................................. 41 4.6.1 Azot nedeni ile gözenek oluşumu .......................................................... 41 4.6.2 Hidrojen nedeni ile gözenek oluşumu .................................................... 42 4.6.3 Karbon monoksit nedeni ile gözenek oluşumu ...................................... 42 4.7 Sıçramalar ................................................................................................... 43 5. KAYNAK DĠKĠġĠ HASARSIZ MUAYENE YÖNTEMLERĠ .................... 47 6. DENEYSEL ÇALIġMALAR .......................................................................... 50 6.1 Deney Malzemeleri .................................................................................... 50 7. DENEY SONUÇLARI VE ĠRDELENMESĠ ................................................. 55 7.1 Sertlik Ölçümü ........................................................................................... 55 7.2 Çekme Testi ................................................................................................ 56 7.3 Mikroyapı Karakterizasyonu ...................................................................... 59 7.4 Kırılma Yüzeyleri SEM Görüntüleri .......................................................... 61 8. Sonuç ................................................................................................................. 65 KAYNAKLAR……………………………………………………………………. 67 ÖZGEÇMĠġ…………………………………………………………...…………… 69 viii KISALTMALAR AC : Alternative Current DC : Direct Current DCEP : Direct Current Electrode Positive DCEN : Direct Current Electrode Negative TRC : Twin Roll Casting DC : Direct Casting TIG : Tungsten Inert Gas MIG : Metal Inert Gas MAG : Metal Active Gas SEM : Scanning Electrone Microscope EDS : Energy Dispersive Spectrometry ITAB : Isı Tesiri Altındaki Bölge HAZ : Heat Affected Zone ix x ÇĠZELGE LĠSTESĠ Sayfa Çizelge 2.1. Çeşitli alüminyum alaşımları ve çeliklerin mekanik özellikleri [1] ....... 4 Çizelge 2.2. Al alaşımları ve % 0,15 C’ lu çeliğin bazı fiziksel özellikleri [2]........... 5 Çizelge 2.3. Alüminyum alaşımları için tanımlama sistemi [3].................................. 6 Çizelge 3.1. Al alaşımlarında kullanılan kaynak yönteminin özellikleri[4].............. 13 Çizelge 3.2. Isıl işlem uygulanamayan dövme alüminyum alaşımlarının kaynak yöntemlerine uygunluğu [2]................................................................... 15 Çizelge 3.3. Isıl işlem uygulanabilen dövme alüminyum alaşımlarının kaynak yöntemlerine uygunluğu [2]................................................................... 16 Çizelge 3.4. Isıl işlem uygulanamayan döküm alüminyum alaşımlarının kaynak yöntemlerine uygunluğu
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