摘要:The arc cavern behavior and its influence of submerged arc welding were reviewed. The results show that the arc cavern is a three-dimensional arc space with a top round and the bottom molten pool, consisting of a semi molten flux wall,and Internally filled with metal vapor and flux decomposition mixture. The arc shape in the cavern should belong to the continuous and inactive type,and the flux-wall guided transfer is the dominant transfer form in single wire submerged arc welding. The phenomenon of oxygen gaining occurs in the droplet and weld metal inside the arc cavern,and the content of oxygen gaining in the droplet is maximum,the polarity of the power supply and current changes affect the oxygen gaining content. The reaction of silicon reduction and oxygen gaining in the droplet reaction zone proves the fact of oxygen gaining in the cavern. The polarity of the power supply and the flux slag basicity may make the droplet oxygenation and fining droplet,but does not change the flux-wall guided transfer form of the droplet.
LIU Xiaoyun,WANG Baohua,ZHANG Junfen,ZHANG Chunlei,JIA Yunhai,WANG Jun,ZHANG Liang
Vol. 48, Issue 10, Pages: 8-12(2018)
摘要:The microstructure and mechanical properties of 0.6 mm thick LY12 aluminum alloy were studied by using the refill friction stir spot welding. According to the characteristics of welded joints,it is divided into the stir zone,thermo mechanically affected zone,heat affected zone and base metal. The results showed that there was no obvious deformation of the specimen after welding,the stir zone formed fine equiaxed grain,TMAZ formation of fibrous tissue,some grains during recovery and recrystallization,the stir zone of maximum hardness,the minimum value of the thermo mechanically affected zone,the rotational speed and welding time increased respectively,and the shear force increased first and then decreased,the shear fracture mode was brittle fracture,the crack started at the boundary and expanded along the thickness of the plate,the distribution of dimple tissue was uniform at the center of fracture,the optimum welding parameters for rotating speed 2 000 r/min,press amount 0.2 mm,the welding time of 3.5 s with the depth of 0.8 mm.
摘要:Using 8 mm length friction stir tool,7055-T6 aluminum alloy with the thickness of 12 mm was double-sided welded by friction stir welding(FSW),and the microstructure of the welded joint was observed,meanwhile,the mechanical properties were tested.The results show that the maco morphology of weld joint has no obvious plastic flow trace. When the AS on the same side,the tensile strength of the welded joint can reach 452 MPa,the joint coefficient of strength can reach 75%,which is better than the AS on the different side. The horizontal microhardness of weld is "W" distribution. The minimum of the microhardness is 101.7 HV on transition zone between TMAZ and BMZ of RS. The vertical microhardness of weld shows that the front side is lower than the back side. The morphology of tensile fracture surface appears dimples ductile fracture characteristice,which is ductile rupture.
摘要:As a new heat source,laminar plasmahas rarely been reported to be used in welding field. In this paper,laminar plasma welding and laminar plasma-MIG welding have been simultaneously implemented. The results show that fusion-type laminar plasma welding has a capability of forming weld. Fusion wall-type laminar plasma welding,in case of canceling the groove and retaining a2 mm gap,is qualified for the welding of Q235 A steel plate with a thick of 12 mm. The upper and lower pool widths in the as-formed weld are almost the same.
摘要:The process of welding manu facturing process is closely related to the quality of welding products,and determines the future service performance of products. The key process parameters in welding manufacturing,such as welding current,voltage,speed,gas flow,etc. have the characteristics of real-time and mass,which poses a great challenge to obtain the welding process parameters quickly and accurately. In addition,at present,most of the welding manufacturing process is still manual operation,so the welding manufacturing process is still in the process of welding manufacturing. Man,machine and material management is difficult,which is the key problem to restrict the development of digital and intelligent welding process control. With the advent of industry 4.0,the intelligent welding process acquisition terminal is developed,and the welding process data is transmitted remotely and real-time by network technology. By means of large data analysis,a cloud-based intelligent welding cluster management system is established to realize the quality and production management of the whole welding process and improve the precision of welding operation. Benefit management ability,ensure welding quality,track welding quality problems,promote the level of energy saving and consumption reduction in welding manufacturing,provide a strong support for efficient and intelligent manufacturing of welding equipment.
关键词:welding management and control;cloud technology;big data;welding power source
摘要:The simulation of self piercing riveting process for 0.8 mm DX52 D+Z steel and 2.0 mm 6111 aluminum alloy is carried out by SORPAS software. Self piercing riveting process,distribution of stress and strain,and load stroke behavior are analyzed. The simulation results show that interlock distance and bottom thickness are 0.91 mm and 0.23 mm respectively. By self piercing riveting equipment,the experimental study of the above materials is carried out. Through the metallographic measurement of the section,the interlock distance and bottom thickness are 0.83 mm and 0.30 mm respectively,which verifies the effectiveness of the self piercing riveting process simulation.
摘要:The friction stir welding was carried out on T-joints of 4 mm+8 mm plate-thickness dissimilar aluminum alloy 5083-O/6082-T6 by using different rotation speed and welding speed,and the macrostructure and mechanical properties of the welded T-joints were compared and analyzed. The experimental results show the T-joints of dissimilar aluminum alloy with friction stir welding are completed,and formation of weld is well and the effective connection between the skin plate and the rib plate is realized. The advancing side area of weld is in a "sickl-shaped",and that lap interface of the skin plate and the rib plate in the retreating side area is offset toward the skin plate in a "wave shaped". The weld surface morphology and bending properties of the joints are well,and the joint tensile strength of T direction reached up to 256 MPa and the fracture occurs in heat affected zone of retreating side,and the joint tensile strength of L direction reached up to 105 MPa and the fracture occurs at the junction of the lap,at the rotational speed of 1 200 r/min for welding speed of 500 mm/min. T-joint skin plate area hardness value between 70~85 HV,and the hardness value of the rib plate area decreases first and then increases with the distance from the center of the skin plate,and the minimum value is 70 HV.
DENG Qinghong,LI Zhiming,JIANG Xijun,ZHOU Changxing,FU Ruidong
Vol. 48, Issue 10, Pages: 36-43(2018)
摘要:The 3 mm thickness industrial pure aluminum and AZ31 magnesium alloy dissimilar metals joints were successfully manufactured by friction stir welding(FSW). The influence of post-weld annealing treatment on microstructures and mechanical properties of dissimilar Al-Mg friction stir welded joint were investigated in detail. Using OM,EDS,IMCs deformability testing,tensile properties testing and SEM for fracture surface analysis. The results showed that the interface IMCs have obvious growth after annealing treatment. The interface IMCs layer cannot cooperate deformation with the both sides of the matrix metal,almost no deformation ability;the tensile strength of the as-welded FSW Al-Mg dissimilar joints was 106 MPa,92% of the base metal(BM)of aluminum.Meanwhile,the elongation was 3.2%,91% of BM of Al. The tensile strength and elongation of the Al-Mg joints decreased with the IMC grown up during the process of thermal of 300 ℃ with the holding time of 20 min,40 min and 60 min,which were 94 MPa/1.3%,70 MPa/0.7% and 28 MPa/0.4%,respectively. Accordingly,the fracture mode changed from ductile fracture to brittle fracture.
摘要:Currently,stainless steel railway vehicles body and structure are usually assembled by resistance spot welding process. The weak points of this process are the poor surface quality and bad airtight due to the pressure of electrodes. The partial penetration lap laser welding is investigated as a solution for the disadvantages of resistant spot welding stainless steel railway vehicles. In this paper the joint strength,appearance quality,microscopic structure and the working efficiency of a laser welding and resistance spot welding process are compared,and the results show that laser welding process can replace the resistance spot welding process to manufacture stainless steel car body,and can satisfy the demands of both the connection strength and the level of car body appearance. The application of lap laser welding process improves the production efficiency of stainless steel vehicle.
关键词:lap laser welding;stainless steel railway vehicle car body;welding parameters
摘要:Impact toughness and electrochemical corrosion resistance of simulated coarse-grained HAZ of weathering steel Q420 qNH are studied in the paper. The coarse-grained HAZ is simulated by Gleeble2000 D thermal simulation tester upon different heat input energy. The results show that the impact energy decreases with the increase of heat input energy,because the microstructure changes gradually into granular bainite(GB) from lathlike bainite(LB),and the high-angle grain boundary density of coarse-grained HAZ reduces gradually. In addition, the electrochemical corrosion resistance of coarse-grained HAZ is influenced by the heat input energy.As the heat input energy increases,the corrosion current density gradually increases and the AC impedance value gradually decreases.It is determined that the heat input energy should not exceed 36 kJ/cm for the weathering steel Q420 qNH.
关键词:weathering steel plate for bridge;simulated coarse-grained HAZ;impact toughness;electrochemical corrosion
摘要:As the sandwich panel structure is simple and relatively lighter with considerable strength,it has great application prospect in the shipbuilding industry. Using the laser welding to fabricate the steel sandwich panel is the preferred manufacturing technology.As the T-joint structure is the base welding unit of the sandwich structure,this paper has set up a T-joint welding platform based on laser welding. On the basis of the experimental results,a new mixed heat source model was proposed. The heat flux distribution during laser welding could be accurately described by the mixed heat source model. Through laser welding experiment and FEM calculation,the welding deformation and residual stresses of the sandwich structure were analyzed. Besides,the influence factors on the welding deformation and residual stresses were also discussed,finding that the welding deformation was significantly decreased by using laser welding,but the residual stress was still at high level.
摘要:The fatigue crack in bridge deck is one of the most important defects of steel box girder,which endangers the safety and service life of bridge. The cracks are classified according to their locations and propagation directions. The main causes of fatigue crack in bridge deck of steel box girders includes structure stress state,stress concentration effect,vehicle overload,manufacturing defects,etc. This paper puts forward several reparation methods by welding,such as gauging and repair welding directly,welding with backing,and welding after replacement of partial members. The applicability of different methods by considering the types of cracks,development degree of cracks,and the construction conditions of bridge site is discussed as well. And supplementary measures should be taken if necessary. The key points of detecting and locating of cracks,selection of welding procedures according to specific situations,and detail treatment are summarized. This paper can be the reference for the establishment of crack reparation methods in different situations.
摘要:In order to fulfill the construction task of the second-line oil pipeline project of China and Russia on time with high quality and quantity,the project Department of the second-line oil pipeline of China and Russia has organized and held many process evaluation seminars and put forward a scheme to guarantee the construction task of the second-line oil pipeline of China and Russia. Efficient and fast CRC automatic welding process is adopted as a feasible solution for the main line welding process in a feasible location. According to CRC automatic welding process and construction site characteristics,the project department carried out CRC pipeline automatic welding process assessment before the start of construction,optimized the configuration of CRC automatic welding machine personnel and equipment,CRC automatic welding process after the start of the project site inspection and field application showed that CRC automatic welding process square. The case is completely feasible and applicable in the second-line project of Sino-Russian crude oil pipeline. Its successful application improves the construction efficiency and progress of the project,and verifies the characteristics of rapid and efficient construction technology,which accumulates experience for future pipeline construction.
关键词:automatic welding;internal welding machine;cold season construction;welding quality
摘要:Laser filled wire welding and MAG welding of SUS301 L sheets with the lap joint form 1 mm +2 mm were carried out,and comparative researched the effect of the two welding method on welding appearance,microstructure and properties. The result showed that the laser filled wire welding had a better weld formation than MAG welding,the reinforcement and weld width of weld significantly reduced. Microstructure of laser filled wire welding joint consisted of fine columnar austenitic dendritic crystals,microstructure of MAG welding joint consisted of coarse columnar austenite and isometric crystal. Laser filled wire welding had a higher weld hardness than MAG welding,and the tensile shear force was 727.3 MPa,up to 73% of base metal. Both of them break at the weld,in a classical ductile way.
摘要:In the past,argon arc welding was used for 100% carbon steel road passenger cars,φ(Ar)80%+φ(CO2)80% gas shielded arc welding,using ER44-8 filler material. The operator’s skill requirements were high,and the heat generated during welding was large. It is easy to cause deformation of the workpiece and poor appearance quality,so it is more and more difficult to meet the user’s requirements for welding quality. The application of the spot welding technology in the carbon steel EMU reduces the output of the welding heat and the deformation of the welding process,especially its successful application in the side wall steel structure,which greatly improves the flatness requirements and surface quality of the side wall.
AN Bo,CHEN Liyuan,HAO Xiaowei,HU Wenhao,CUI Yan,JIA Zhanjun,HE Yuxiang,GONG Baoqiang
Vol. 48, Issue 10, Pages: 77-81(2018)
摘要:The MAG welding of S355 J2 W +N steel, which is commonly used for bogie frame, was carried out by using binary and ternary shielding gas respectively. The influence of ternary shielding gas and binary shielding gas MAG welding on the microstructure and properties of S355 J2 W+N steel was studied by contrast analysis. The result shows that,the weld of S355 J2 W+N steel with ternary gas mixture has better tensile strength,all bending tests of 180° are qualified,has good ductility and toughness. The hardness distribution of each characteristic zone is uniform,the hardness of the ternary gas mixture is slightly higher,and the width of the heat affected zone is 1 mm narrower than that of the binary gas mixture. Whether the weld or the heat affected zone,the impact energy of the welded joint of both gas is higher impact toughness at low temperature. The central weld microstructure of S355 J2 W+N steel is distributed on the columnar grain boundary with binary and ternary protective gas,and the HAZ is composed of ferrite and pearlite with different grain size and strip distribution along the rolling direction. This provides a basis for the use of ternary shielding gas MAG welding for the railway train steering frame.
摘要:Taking 316 stainless steel as the base material,and the diameter of M6 and M8 stainless steel studs was used for welding.The influence of the diameter of the stud on the welding process of 316 stainless steel draw-arc stud and the microstructure of the joint was studied. The results show that the optimum welding time was extended and the adjustable range of optimum welding time narrowed with the increase of the diameter of the stud. The optimum welding time of M8 stud was 68 ms compared with M6 which was only 60 ms.The optimization welding time of M6 stud could be adjusted in the range of 52~60 ms while the M8 one was in the range of 64~68 ms.At the case of the corresponding optimum parameters,the columnar crystals significantly grew and ratio of width to length become small.Besides,the maximum bending angle of M6 could reach up to 75° before the crack appeared while M8 one was only 66°.
WAN Jun,SONG Wei,SUN Yaohua,HOU Chunjie,HAN Bangqing,ZHANG Jing
Vol. 48, Issue 10, Pages: 86-88(2018)
摘要:φ(Ar)78%+φ(He)20%+φ(CO2)2% shielded MAG automatic welding was proposed to study the effects of welding parameters by using 16 mm thickness 304 L stainless steels. The results showed that short circuiting transfer can lead to the unstable electric arc and excessive spatter. Besides, porosities were observed in the weld. The stable electric arc can be obtained by using spray transfer, but the helium arc could cause undercut. Finally, the weld quality was satisfactory by using the average current of 240 A.
摘要:The frame of battery box used in high-speed train is mainly composed of square tube steel profile and welded structure of bending steel plate. Aiming at the further lightening requirement of 400 km/h high-speed train,this paper designs a battery box with aluminum alloy profiles and bending plates as the main structural parts,realizes the lightening of the whole box structure,which is beneficial to train speed-up and energy consumption reduction. Based on Solidworks,three-dimensional model of the battery box is built,and Ansys Workbench is used to analyze its structural strength under ultimate load. At the same time,the natural frequency and mode shapes of battery box in the free state are studied. Through modal analysis and static strength analysis,the safety and reliability of this new structure are verified.
摘要:Keyhole tungsten inert gas welding(K-TIG) is a new welding technology that can form a keyhole during welding and achieve a large penetration depth. The forming of K-TIG weld is well and the welding quality is high. The K-TIG weld can be obtained with single-sided welding and double-sided shaping,so it has great application prospects in the welding of medium plates. In this paper,the acoustic signal data acquisition software for robot K-TIG welding process was written and the acoustic signal acquisition system was established in order to study the penetration state of K-TIG welding. Real-time acquisition of the acoustic signals in the 304 stainless steel K-TIG welding process enables real-time storage of acoustic signals during K-TIG welding. Finally,the characterization and extraction of time domain signal features are carried out from the aspects of energy,variance,root mean square and kurtosis coefficient.It lays a solid foundation for online melt penetration prediction during K-TIG welding.
摘要:According to the characteristics of multifunctional flame cutting equipment, considering the pipe and plate cutting features in the process,based on the analysis of structure of the linear and profiling flame cutting device,the design and production of multifunctional flame cutting equipment were finished. The power output was changed by adjusting the motor through the worm,gear and clutch group,by adjusting the movement of double gear in the main drive shaft and the transmission shaft respectively mesh with the driven gear,the conversion function from cutting tube to cutting plate is completed,different groove processing on the same equipment is realized. The equipment has been successfully applied in actual production and teaching.
KONG Meng,ZHANG Jie,ZHANG Lunzhao,HOU Zhen,CHEN Huabin,CHEN Shanben
Vol. 48, Issue 10, Pages: 101-104(2018)
摘要:Aimed at seam tracking of fillet weld for robotic welding,we developed laser vision sensor and filter system in this paper. Based on measuring principle of matrix transformation,it simplified calibration of vision system. Steger method based on Hessian matrix is used to extract sub-pixel level linear feature and its orientation information. The random sample consensus algorithm is used to fitting lines as profile model and center of weld seam is extracted furtherly. Tracking test results shows that mean tracking error is 0.52 along welding direction,which meets the actual welding production requirements of the robot.
摘要:Aiming at real-time monitoring of resistance spot welding process,analysis of welding process parameters,real-time display of welding current and electrode voltage curve,resistance spot welding monitor that uses PIC32MZ0512EFF100 as control core and XG070YMN11R touch screen for the parameter setting and display device is designed. The control system software and human-machine interactive system of resistance spot welding monitor are developed. Online monitoring for resistance and real-time display welding current waveform,electrode voltage waveform,dynamic resistance waveform and welding power waveform have been realized in different measuring parameters. The test results show that the monitor have precise output,friendly interface and flexible operability. It can meet the requirement of online monitoring for resistance spot welding and analysis of welding process.
摘要:A composite forming system of adding/reducing materials,which is integrated with arc welding and reducing materials,has been developed. The system is composed of the main control part,the additive part,the reducing part,the changing tool mechanism,the equipment foundation part and the auxiliary mechanism. The motion mechanism and the numerical control system are integrated to perform the movement track of the additive and reducing material processing. The welding torch is set as a tool. The tool changing system can replace either the tool in the tool bank or the welding torch. The power supply equipment with CMT function and the wire feeding mechanism with a variety of wire diameter are selected. The main control system based on industrial control computer is developed. Through the actual sample processing and the scrap part repairing,the developed equipment has the capability of adding/reducing material compound processing,low cost and rapid manufacturing speed,and can meet the demands of various parts.
摘要:The nuclear island components of a new nuclear power project was designed in accordance with the ASME standard and AWS standard. This article summarized the NDE standards and regulations followed by the new nuclear islands construction and the descriptive approach of NDE design requirements. Especially,the requirements of the NDE personnel certification were also summarized. At last,some suggestions for improvement for follow-up improved projects were given according to experience feedbacks.
摘要:For nuclear equipment,there are rigorous regulatory requirements to equipment welding in nuclear codes and standards,whereas,the requirement to post welding heat treatment of base metal and welding joints-an important part of equipment manufa-cturing cannot have the same rigidity as compared to welding. In this thesis,contents such as treatment requirement,operator,device and file documentation in post welding heat treatment regulations of AP1000,ACP1000 and China manufactured RPV will be compared,analyzed and proposal will be given intending to optimize the regulation related to post welding heat treatment. In addition to that,the author will summarize some focal points of qualification control in nuclear equipment post welding heat treatment based on his years of experience as nuclear equipment welding designer.
关键词:heat treatment;heat treatment standard;heat treatment procedure;heat treatment process