Abstract: The existing distribution manifold is generally fixed by bolted connection, which has the problems of low cleanliness, low connection strength, poor durability and high production cost. The research group proposed the method of infrared welding PPS-GF40 4020T material to develop fluid distribution manifold to improve the connection mode: The infrared welding performance of the distribution manifold made of polyphenylene sulfide (PPS) is studied, and the connection strength of the new distribution manifold is analyzed. Using infrared welding test, by the automatic computer controlled blasting test bench to determine the connection blasting strength, according to the actual production of products to test, optimize the welding process parameters, to find the best welding effect. The results show that the optimal welding strength can be obtained when infrared power is 20 kW, welding heating time is 40 s, heating distance is 3 mm, welding curing time is 20 s, welding depth is 1.5mm and clamping force is 920 N. The pressure inside the distribution manifold can withstand 8 bar. When the infrared energy absorbed by the distributed manifold is different, the degree of fusion bonding and welding defects (cauterization, bubble and carbonization) of welded bars are the main factors affecting the mechanical properties and failure forms of joints.

Key words: Infrared welding; High strength; Lightweight; Hydrogen fuel cell; Distribution manifold

摘要： 现存分配歧管普遍采用螺栓连接固定，存在清洁度不高、连接强度低、耐久性较差以 及生产成本高的问题。课题组提出红外焊接 PPS-GF40 4020T 材料研制流体分配歧管的方法来 改进连接方式，对由聚苯硫醚（PPS）树脂制成的分配歧管的红外焊接性能进行研究，分析这 种新型分配歧管的连接强度；采用红外焊接进行试验，由全自动计算机控制爆破试验台测定 连接爆破强度，根据实际生产的产品进行测试，优化焊接工艺参数，寻找最优焊接效果。结 果表明，在红外功率 16 kW、焊接加热时间 40 s、加热距离 3 mm、焊接固化时间 20 s、焊接 深度 1.5 mm、夹紧力 920 N 时，获得最佳的焊接强度，分配歧管内部可以承受 8 bar 压强。 当分配歧管吸收的红外能量不同时，焊接筋的熔融结合作用程度和焊接缺陷（烧灼、气泡和 碳化）是影响接头力学性能和失效形式的主要因素。

关键词: 红外焊接；高强度；轻量化；氢燃料电池；分配歧管