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Volume 55 期 12，2025 2025年第55卷第12期

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    LI Chunkai, XIE Ruoyu, SHI Yu, WANG Wenkai, WANG Cheng

    DOI：10.7512/j.issn.1001-2303.2025.12.01
    摘要：Gas Metal Arc Welding (GMAW) has found extensive application in engineering fields due to its advantages of low cost, high efficiency, and ease of automation. However, variations in fit-up factors such as mismatch and gap during actual welding processes readily cause instability in the weld poo, rendering real-time monitoring and control of the penetration state in GMAW backing welding challenging. To address this, a dynamic sensing system for groove and weld pool, based on a structured light laser and a High Dynamic Range (HDR) camera, is proposed. This system is used for pre-welding scanning to acquire mismatch and gap groove information, as well as for dynamic measurement of the front dimensions of the GMAW weld pool during real-time welding. A dataset of front weld poo images and geometric characteristics of the back bead width under different welding process parameters and fit-up parameters (mismatch and gap) is collected through orthogonal experiments. Furthermore, a Deep Neural Network (DNN) model based on process factors, weld poo images, and fit-up factors is constructed to predict back-side penetration. The SHapley Additive exPlanations (SHAP) interpretable algorithm is employed to analyze the key factors influencing the penetration state and optimize the DNN model. The results indicate that the performance of the neural network model considering fit-up factors is significantly superior to that of a model solely considering weld poo geometric characteristics. Gap is identified as a crucial factor influencing the size and stability of back-side penetration, as variations in gap can alter the force distribution at the bottom of the weld poo and the internal metal flow pattern. Larger gaps lead to increased liquid metal flowing to the bottom, reducing the stability of back-side penetration. The optimized DNN model meets the requirements of practical welding in terms of prediction accuracy and real-time performance.  
    关键词：artificial neural network;GMAW;deep learning;gap   
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    更新时间：2025-12-22

    XU Shaofeng, LU Lili, LIN Tengfei, HAN Zheng, FENG Guocai, GONG Ya, REN Liping

    DOI：10.7512/j.issn.1001-2303.2025.12.02
    摘要：To investigate the residual stress distribution characteristics and fatigue life of titanium alloy tube butt welds, a numerical simulation model for welding processes was established based on ABAQUS. The double ellipsoid heat source model was employed to characterize the heat flux distribution of tungsten inert gas (TIG) welding. The temperature field and residual stress during welding were solved using a sequentially coupled thermo-elastoplastic method, and experimental validation was conducted through the full strain release technique. Based on the FE-SAFE platform, the Brown-Miller model was applied to predict the fatigue life of the tube butt weld.Resultsindicate that the simulation results exhibit high consistency with experimental measurements. Significant axial compressive stress exists at the weld surface center, reaching a maximum value of -240 MPa. The residual stress gradually transitions from compressive to tensile stress when moving from the weld center toward the base metal. Under service conditions, the maximum residual stress occurs in the weld heat-affected zone, with a predicted service life of 104.2 cycles, meeting the required service life specifications. The multi-field coupling simulation methodology and life prediction model developed in this study provide theoretical support and technical reference for optimizing titanium alloy welding processes, controlling weld quality, and enhancing equipment reliability.  
    关键词：Titanium alloy tube butt welds;residual stress;fatigue life;finite element simulation;welding process   
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    更新时间：2025-12-22

    TAN Bo, CHEN Wenjing, LIU Chuihua, YANG Chen, LUO Qingsong

    DOI：10.7512/j.issn.1001-2303.2025.12.03
    摘要：Ultra-high-speed laser cladding technology was employed to fabricate Fe-Cr-Ni and Fe-Cr-Ni+0.8wt.% CeO2 composite coatings on the surface of LZ50 axles. The microstructure and phase composition of the coatings were characterized using scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS), and X-ray diffraction (XRD). The mechanical properties of the cladding layers were evaluated through microhardness tests, Charpy impact tests, and tensile tests. Results indicate that both coatings formed excellent metallurgical bonding with the substrate, primarily consisting of austenite, (Fe,Ni) solid solution, and (Cr,Fe)7C3 carbides. The addition of CeO2 reduced porosity and refined grain structure within the coating. Mechanical property testing revealed that the Fe-Cr-Ni+CeO2 coating achieved an average microhardness of 456.38 HV0.2, representing a 33% improvement compared to the CeO2-free coating. The tensile strength and yield strength increased by 23.51% and 14.1%, reaching 912 MPa and 597 MPa, respectively, while the elongation and reduction in cross-sectional area improved synchronously to 9.3% and 18.9%. The average impact toughness increased by 8.05%, attaining 34.9 J, which approaches the level of the LZ50 substrate. This study confirms that rare earth CeO2 modification effectively optimizes the microstructure and mechanical properties of ultra-high-speed laser-clad Fe-Cr-Ni coatings, providing theoretical foundations and technical support for high-performance remanufacturing of damaged LZ50 axles.  
    关键词：ultra-high-speed laser cladding;LZ50 axle steel;CeO2;microstructure;mechanical properties   
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    更新时间：2025-12-22

    GUO Zhe, LIU Fei, PANG Lihui, WANG Peifeng

    DOI：10.7512/j.issn.1001-2303.2025.12.04
    摘要：To address the issue of performance degradation in Al/Cu dissimilar ultrasonic welding joints caused by the formation of brittle intermetallic compounds, silver (Ag) powder was employed as an interlayer to join 1.5 mm thick 1060 aluminum alloy and 0.5 mm thick T2 copper via ultrasonic lap welding (welding time: 0.4 s). The effect of the Ag interlayer on the microstructure and mechanical properties of the joint was systematically investigated. The results indicate that without the interlayer, an intermetallic compound layer (primarily AlCu and Al4Cu9) approximately 0.5 μm thick forms at the interface, and the joint exhibits an average tensile shear strength of 43.0 MPa. After introducing the Ag powder interlayer (particle size: 20 μm), material flow at the interface intensifies, promoting the formation of Ag-based solid solutions (e.g., Ag0.803Al0.197) and Al-based solid solutions, while effectively suppressing the generation of brittle intermetallic compounds. Consequently, the average tensile shear strength of the joint increases to 46.0 MPa, representing an improvement of 5.7%. Fracture analysis reveals that the addition of the Ag interlayer changes the fracture mode from a quasi-cleavage and dimple composite type to a dimple-dominated ductile fracture. This study confirms that the Ag interlayer significantly enhances the mechanical properties of Al/Cu ultrasonic welding joints by promoting solid solution formation and optimizing the interfacial structure.  
    关键词：aluminum/copper dissimilar metals;ultrasonic welding;interlayer;microstructure;solid solution   
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    更新时间：2025-12-22
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