LIU Lei,GENG Zheng,WANG Min,KONG Liang,HU Peiyuan,CHU Weidong,WANG Daming
Vol. 48, Issue 12, Pages: 1-5(2018)
摘要:Carbon fiber reinforced thermoplastic(CFRTP) are widely used in aerospace and automotive industries owing to its lightweight and high strength. The joining of CFRTP and aluminum alloy is still an urgent problem to be solved. The common joining are adhesive bonding and mechanical connection,but adhesive bonding procedure is complicated and the adhesive is easy to age,and the mechanical connection will cause stress concentration. Laser welding can realize the welding of CFRTP and aluminum alloy because of its high welding efficiency,energy concentration and easy industrial production. The strength of laser welding joints after different surface treatments and welding power range are studied,and the joining mechanism of laser welding between aluminum sheets and CFRTP is revealed by microscopic characterization.
LI Hong,LI Yunyue,LI Zhuoxin,JACEK Senkara,ZHUANG Hongshou,LU Qingsong
Vol. 48, Issue 12, Pages: 6-12(2018)
摘要:The cooled exhaust gas recirculation(EGR) system can effectively reduce the NOx emissions in the vehicle exhaust. The EGR cooler is the core component of the cold EGR system and is vacuum brazed. The research progress of high temperature brazing filler metal for vacuum brazing stainless steel EGR cooler is reviewed. The advantages and disadvantages of traditional nickel-based,copper-based brazing filler metals and new iron-based brazing filler metal are analyzed. The new iron-based brazing filler metal is mainly introduced. The effects of brazing filler metal alloy elements on melting temperature,microstructure and mechanical properties of brazing joint are analyzed. The influence rule of brazing technology on the corrosion of stainless steel base metal and the microstructure of brazing joints is introduced emphatically. And future research direction and development trend of high temperature brazing filler metal for stainless steel are prospected.
关键词:EGR cooler;high temperature brazing filler metal;melting temperature;joint strength;corrosion resistance
摘要:The microstructure and hardness of laser welding joint of CP-Ti are investigated with some technologies,and the corrosion resistance of joint in acid,neutral and alkaline solutions are also studied. The results show that the microstructure of joint consists of αphase,and the α grains in welds have three kinds of appearance,which are acicular,serrated and lath shaped and α grains in heat affected zone(HAZ)are serrated. The hardness test shows that the weld is the area with the maximum joint microhardness of 210 HV,and the microhardness of HAZ is about 165 HV,which is lower than that of weld. The corrosion resistance of joints in acid solution is the worst, the current density and corrosion rate in acid solution are higher than those in neutral and alkaline solutions.
摘要:The butt joining of 2 A14 aluminum alloy to 5 A06 aluminum alloy was conducted by TIG welding with BJ380 A,5 A06 and2325 aluminum alloy filler wires,and the microstructure and mechanical properties of the joints were analyzed. The results show that there are no cracks and pores in welds. The grain growth in the heat-affected zones(HAZ)near 2 A14 base metal is more obvious than that near 5 A06 base metal,and the grain is coarser in the weld made with BJ380 A filler wire than that in the weld made with 5 A06 or2325 filler wire. The tensile strength of joints is dissimilar by three filler wires,and the lowest value is about 83% of that of the 5 A06 aluminum alloy base metal. The tensile strength of the joint obtained by 2325 welding wire is the highest. Fracture analysis shows that the fracture of 2325 welding wire joint is ductile fracture,and the fracture is mainly dimple.
摘要:The high pace,high efficiency and high quality of automotive body have put forward challenge to the traditional welding process,however,it is difficult to meet requirement for high speed welding. This paper presents a novel welding process arcing-wire PAW welding process. With the new arc working mode,it is easier to achieved the new welding process which can relieved the inherent constraints in heat input and deposition,the advantages of the new welding process is the high efficiency and high welding speed and low heat input,increase the welding currents can get higher productivity and less distortion. The experimental system is established in lab,the waveforms of welding current and arc voltage are acquired through signal acquisition system,and the arc behavior and metal transfer process are monitored by high-speed camera synchronously. The results of experiments indicate that the metal transfer is stable without spatter,the droplet diameter decreased with the increase of the by-pass arc current,as the arc heat input and arc force changed accordingly. The metal transfer without spatter,the two arc have voltage fluctuation by the short between wire and work-piece. The weld formation is smooth without defects in high speed welding.
关键词:arcing-wire PAW;high speed welding;arc behavior;metal transfer
摘要:Most kinds of welding positioners at present are aim at welding position-change of one workment. Therefore,two or more positioners are required to coordinate and perform the displacement operation if welding and position-change are related to more than one workments. And this leads to low welding efficiency and high cost. In order to solve this problem,this paper designed and analyzed a new type of welding positioner,which can realize rotational position-change,assembling and welding,independent and synchronous positi on-chan ge of two workments by coordination among two abreast welding clamping mechanisms,revolute joint and driving mechanism. SolidWorks analysis results show that its structure meets the requirements. And it is proved by tests that it can effectively improve production efficiency and productivity.
摘要:The effect of different connection modes of inductor polarity,namely,the start point of inductor winding on the stability of the current mode power supply is discussed. The main reason of the system instability is that the system operates in the critical state of current mode and voltage mode at low duty cycle. The inductor will cause the space magnetic field,which will cause the inducted current in the system feedback loop. Connecting the start point of the inductor winding to LX of Buck IC can strengthen the current feedback signal according to the inducted current,so the system can consistently operate in current mode without the oscillation. Conversely,connecting the start point to Vo will cause oscillation in Buck converter from 12 V to 1.1 V. The simulation waveforms and actual test results are obtained through the couple inductor model.
摘要:Ring welds are a kind of welds commonly used in the production of pipes,containers,chemical equipment,etc. Due to their many welding positions,poor accessibility of manual welding and difficulty in welding,various forms of automatic ring seams are often used in actual production. The welder replaces manual welding. However,the current automatic seam welder still has problems such as low production efficiency and narrow adaptability. According to the actual production needs,this paper uses ordinary positioner and the most common gas shielded welder to transform. Through the powerful automatic control function of PLC,multiple torches are controlled at the same time,which realizes automatic and efficient ring weld welding. The system is simple in structure. High production efficiency and powerful function,especially suitable for the welding of coaxial multi-channel annular welds.
摘要:In order to improve the welding quality and efficiency of wind tower and other steel structure projects,the basic research on the actual application of waveform control double wire submerged arc welding technology is carried out. The application purpose and principle of waveform control technology and the control target and control process of waveform-controlled power are introduced in detail. The impact toughness,welding efficiency,groove design and other welding parameters of the joints and their applications are analyzed,which can provide a reference for technicians.
摘要:Among all failure modes of high-power electromagnetic relays,the one caused by splashing of welding take a relatively high portion. The splashing may cause short circuit and electrical breakdown between contactor. In actual situation,the yoke iron assembly tend to lack of spot welding strength and severely splash metal remains. To solve this problem, simulation of the yoke iron assembly spot welding process is used in this work. Welding structure improvement and processing parameter optimization are used to solve problem of splashing. In general,the reliability and stability of high-power electromagnetic relays are enhanced.
关键词:high power electromagnetic relay;welding spatter;computer simulation
BAO Yefeng,WU Chen,YAO Ziling,CHEN Hui,JIANG Yongfeng
Vol. 48, Issue 12, Pages: 50-54(2018)
摘要:Integration algorithm is used to calculate dynamic resistance of resistance spot welding. A model of "nugget diameter-dynamic resistance" is established according to the change rules of body resistance and contact resistance of sopt welding of dual-phase steel.DP600 dual-phase steel is selected as the test material, a self-developed spot welding quality prediction system is used to measure the dynamic resistance in spot welding process,and nugget diameter is measured by metallographic method,the values of dynamic resistances and nugget diameters in different current conditions are acquired,the model parameters of "nugget diameter-dynamic resistance" of spot welding of DP600 steel are obtained by the least square method. The test results show that the mean absolute error and relative error of nugget diameter predicted by this model is 0.13 mm and 2.28% respectively. This model has higher accuracy.
摘要:IN625 alloy was prepared by plasma jet welding machine,and the effect of surfacing current and post heat treatment on microstructure and mechanical properties of the surfaced IN625 alloy was investigated. The results showed that the microstructure of the surfaced IN625 alloy consisted of the orientational dendrite Laves phase and austenite. The content of dendrite Laves was increased and its morphology was coarsened with the increase of surfacing current,the microhardness of the surfaced IN625 alloy was decreased from 230 HV to about 190 HV. The partial Laves in the surfaced IN625 alloy was dissolved and refined after solution treatment at 1 180 ℃,and the microhardness and the tensile strength were increased to 310 HV and 872 MPa,respectively. While the microstructure of the surfaced IN625 alloy was coarsened and the microhardness was decreased after solution treatment at 1 200 ℃.The microhardness and the tensile strength of the solution-aging treated IN625 alloy were lower than that of the solution treated alloy.The content of dendrite Laves in the solution-aging treated IN625 alloy was increased and its microhardness was decreased with the increase of welding current. The fracture mechanism of the surfaced IN625 alloy before and after heat treatment was ductile fracture,and the dimple in the fracture surface of heat treated IN625 alloy was presented as small size,showing good toughness.
摘要:Based on the linear growth law of heating power during non-steady-state friction plug welding,the linearization of heat generation is carried out,and the heating model of friction plug welding under non-steady state is established. The finite element analysis software ABAQUS was used to establish a three-dimensional finite element model of friction plug welding in the unsteady state of 2 mm thick 7075-T6 aluminum alloy plate,and the accuracy was verified by the test results. The simulation results are in good agreement with the experimental measurements,and the error is within the allowable range,which verifies the correctness of the heat generation model and the numerical simulation results. The numerical simulation results show that the temperature and stress at any point close to the welding area are only related to the distance from the center of the plug hole.
摘要:Dissimilar materials hybrid structures are widely used in lightweight of automobile, and the Al-steel resistance spot welding(RSW) is the core technique in the lightweight of automobile. However, the Al-steel RSW technique is not mature because of the huge differences of the metallurgical properties and thermodynamic properties between Al and steel. The theory and difficulties of Al-steel RSW are described, the research hotspot and status of Al-steel RSW are summarized and the future research directions is discussed.
关键词:steel;aluminum;resistance spot welding;research status
LIU Dongya,JI Yaoyao,LI Zitao,WANG Weifeng,CHENG Changjing,SUN Chenyang,ZHANG Wu,LIU Yonggang
Vol. 48, Issue 12, Pages: 71-73(2018)
摘要:The chromium-zirconium-copper electrode(Cr Zr Cu electrode)and the Al2O3 dispersion strengthened copper electrode(Al2O3 electrode)are used to study the resistance spot welding of 800 MPa high-strength galvanized steel. The weldability of automobile sheets with different electrode materials are investigated. The failure mechanisms of different electrode materials are analyzed by scanning electron microscopy(SEM)and energy disperse spectroscopy(EDS). The results show that the weldability windows when using Al2O3 electrode is twice as large as that when using Cr Zr Cu electrode under the same conditions,and the tensile-shear load of the welded joint is a little higher than that of Cr Zr Cu electrode. The life of Al2O3 electrode is much longer than that of Cr Zr Cu electrode under the same conditions. The internal cause of the electrode failure is the alloying reaction between the element Cu in the electrode and the zinc layer on the surface of automobile sheet. As the Al2O3 electrode has good heat-resistant property,it can reduce the upsetting on the electrode end face under the action of thermal cycle,and the Al2O3 phase dispersed in the Al2O3 electrode can suppress the alloying of atom Cu and Zn to extend the electrode life.
关键词:electrode material;galvanized high strength steel;resistance spot welding;failure analysis
摘要:T-type welding is a widely used form of welding. The welding deformation and residual stress in the welding process will affect the integrity and reliability of the structure. In order to offset and compensate the welding deformation,the workpiece is artificially deformed in the direction opposite to the welding deformation. This method is called reverse deformation method,which is one of the most commonly used methods in production. In order to study the effect of reverse deformation on post-weld deformation and residual stress,the multi-layer multi-pass welding deformation and residual stress field of T-joint of S355 steel were numerically simulated based on thermo-elastic-plastic method. The results show that the maximum deformation of T-joint of S355 steel occurs at the web far from the weld,and the Von-Mises equivalent stress is concentrated in the weld zone and heat-affected zone. By applying proper reverse deformation to the web,the welding deformation can be effectively reduced without affecting the peak value of the overall residual stress,thus taking into account the flatness and bearing capacity of the T-joint. The research results in this paper have certain guiding significance for actual welding production.
关键词:T-joint;reverse deformation;finite element method;welding deformation;residual stress
摘要:In order to improve our country’s rapid manufacturing quality of railway truck bogie frame type,the welding residual stresses of butt and T-corner joints of Q345 E low alloy steel welded in free and pressure state and treated by stress relief are measured by Xray method. The result shows that,no matter the test plate is under a free state or pressure condition,the stress after heat treatment,the elimination of the parallel and vertical direction of weld on the longitudinal residual stress are decreased,the decrease of transverse residual stress is not obvious,but its distribution tends to be homogeneous. According to the overall law,the longitudinal residual stress and transverse residual stress of the weld in the direction of the weld under compaction are significantly reduced,while the ultrasonic impact treatment can significantly reduce the residual stress of all the welds,which has a good effect of stress removal.
XU Ye,HAN Xiaohui,LI Yongbing,ZHANG Zhiyi,HUANG Shiming,WANG Bin
Vol. 48, Issue 12, Pages: 85-88(2018)
摘要:In this paper,stainless steel of railway vehicles(1.5 mm-EN1.4318+2 G and 1.5 mm-SUS301 L-HT)were welded by conventional spot welding and spot weld bonding with precoated structural adhesive on intermediate frequency inverter resistance spot welding machine.Visual testing,macroscopic examination,shear tensile testing,and metallographic examination were carried on according to the product standard after welding. Results show that the spot weld bonding joints have good appearance quality and shallow surface indentation under lower welding current and electrode force. Moreover,penetration rates and nugget diameter of bonding joints meet the product requirements,and the spot weld bonding joints have better tensile shear property than the conventional spot welded joints.
摘要:Buffer rod is an important part for connecting buffer system of locomotive and rolling stock. Its material is generally 45 steel. Under suitable welding current,welding voltage,welding speed and wire feed rate,the structure,hardness,tensile property,impact property and metallographic structure of surfacing layer and HAZ of 45 steel by cold metal transition were studied. The results show that the mechanical property of the surfacing repair zone improves obviously comparing with that of buffer rod 45 steel base metal when the current is 150~160 A,voltage is 15~16 V,wire feed rate is 5 m/min,welding speed is 12 mm/s and the mixed gas flow is 20~25 L/min. The repaired buffer rod has no welding defects after magnetic powder and ultrasonic flaw detection. The repair process improves the service life of the buffer rod.
摘要:Submerged arc welding and gas shielded welding butt joint tests were carried out on domestic Q345 qE weatherproof steel.Mechanical properties and metallographic structure were observed and analyzed after welding. The results show that the weldability of Q345 qE weatherproof steel is good,without preheating welding,and the toughness of heat affected zone is good,but the heat input has an effect on the impact performance. In practical application,the heat input should be controlled to be less than or equal to 35 kJ/cm;the metallographic structure of weld seam is B+F+P,and the mechanical properties are good;the tensile and bending properties of welded steel sheet are qualified at room temperature. The weldability of Q345 qE weathering steel and the toughness of heat affected zone can be improved indirectly by using low carbon composition.
LI Tao,ZHU Zhongyin,XING Yanshuang,LI Junmin,ZHANG Haoru
Vol. 48, Issue 12, Pages: 98-103(2018)
摘要:Taking S355 J2 N steel as the research object, the ultra-narrow gap laser welding is used for welding technology test to study the tensile strength, bending property, impact strength, microhardness and microstructure of welded joints. The results show that the all these properties of welded joints meet standard requirements. The microstructure of the base metal is composed of ferrite and pearlite. The microstructure of the weld zone is composed of first eutectoid ferrite which distributes along columnar crystals, the carbon-free bainite grows into the crystal parallel to the boundary and the acicular ferrite,granular bainite and pearlite distribute in the crystal. The reticular crystal boundary of the HAZ is obvious and its microstructure is lath martensite and M-A microstructure.The microstructure of the interlayer of multilayer are observed to find that white ferrite is precipitated along the grain boundary of primary austenite and the acicular ferrite, granular bainite and pearlite distribute in the crystal. So the ultra-narrow gap wire filler welding has good application value for the S355 J2 N steel welding.
关键词:ultra-narrow gap laser wire filler welding;S355J2N welded joints;ferrite;pearlite;granular bainite
摘要:The shape of the claws of the control rod drive mechanism(CRDM) is complex and precise,the claws are the motion actuator in primary circuit of the pressurized water reactor,the surfacing layer of the pin hole and claws tooth is welded by the cobalt-base alloys,so the microstructure and properties of the surfacing layer have a great influence on the CRDM. The appropriate technological parameters that meet the design requirements are obtained by the oxyacetylene welding technology and laser welding technology tests.In addition, the microstructure characterization and analysis of the surfacing deposition layers of the cobalt-base alloys obtained by theses two welding technologies are carried out, the differences of the macrostructures and microstructures of the deposition layers of these two technologies are compared, and the micro hardness of the deposition layer is tested are contrastively analyzed. The elements Co, Cr and Fe of the deposition layer are tested by the line scanning. The relations between the dilution rate and hardness difference of these two different deposition layers are analyzed through the distribution of element Fe. No micro crack,inclusion,air hole,lack of fusionand other defects are observed in these two different surfacing layers. Because of the fine grain strengthening effect,the grain in the surfacing layer of cobalt-base alloys by laser welding is the most fine, and the micro hardness is also the highest in the surfacing layer.
摘要:According to the technological characteristics of all-position automatic welding of superalloy conduit,the causes of common welding defects such as non-fusion,non-penetration and weld depression were analyzed,the corresponding welding process plan and the measures to avoid welding defects were formulated,the process test was carried out to verify and the product was welded in kind,all welds were subjected to non-destructive tests(appearance inspection,endoscopy inspection,X-ray inspection,hydraulic airtight test)and destructive test(mechanical performance test and metallographic analysis),and the quality of welds met the corresponding standard requirements,guaranteed product quality and improved workshop production efficiency. It is an inevitable trend to replace the traditional manual argon arc welding process for all-position automatic welding of superalloy conduits.
关键词:high temperature alloy;catheter;all position welding;welding defects
摘要:Friction stir welding(FSW) is a new solid phase joining technology and is widely used in the fields of aviation,spaceflight,shipbuilding and so on. The flow of material in the weld zone has an important influence on the welding quality of FSW. In general,it is hard to study the material flow directly,while the flow field simulation provides an important means to study it. The application status of flow field simulation in FSW is reviewed,including plastic material flow mechanism,stir tools structure optimization and auxiliary energy impact analysis. The research progress and achievements of flow field simulation are summarized,which provides a reference and basis for the flow field simulation in FSW from the theoretical analysis to engineering application.
摘要:The thermocouple plugs used in spacecraft thermal test are manually welded. With the increase of model development tasks in China,the problems of low efficiency of manual welding process and insufficient welding quality have been exposed. In order to ensure the production progress,improve the efficiency of plug welding and the quality of welding joints,a welding robot is introduced to realize the automatic welding process of thermocouple plugs. In order to solve the problem that different batches of copper wire butt welding and thermocouple have more than one welding joint under automatic welding process,the comparative tests of tension resistance test,temperature measurement performance test under normal working conditions and temperature measurement performance test under extreme tension deviation are carried out by using comparative method. The reliability of automatic welding process for thermocouple plug is verified through comparative analysis of test data.
关键词:thermocouple plug;automatic welding;process test