摘要:With the increasing requirements of train running speed and carrying capacity,more stringent requirements have been put on the material and performance of the bogie welding framework.On the basis of MAG welding process,the welding technology research of bogie frame is already quite extensive and thorough.At present,although the bogie wire can meet the requirements for welding use,but there are large spatter,welding pores,welding slag and undercut etc.other defects in the process of welding,and the transient stability of small current need to be improved.There is an urgent need for new welding materials of cold-resistant and high toughness,which have excellent use of operational performance,long life,high reliability,and a wide range of environmental service consumables.In the future,new materials and new technology will be the hot spots and focuses for a long time.Light weight,environment friendliness,high reliability,long life and laser welding technology will lead to faster and better development of bogie welding manufacturing technology in the future.
关键词:bogie frame;MAG welding;wire;properties;fatigue life
摘要:In the process of the wire and plasma arc additive manufacturing,due to the accumulation of heat in the heating process,the difference between the height of the actual compress layer and the designed compress layer makes the arc length difficult to be constant;at the same time,the change of process parameters will also affect the stability of the additive manufacturing process.Therefore,the intelligent prediction for arc length and monitoring system based on LabVIEW is designed for wire and plasma arc additive manufacturing process.The system takes the USB4711 A acquisition card as the core,and uses sensors to collect signals such as current and voltage on the wire and plasma arc additive manufacturing process,and displays real-time process parameters,process information and data analysis.Meanwhile,an intelligent prediction model of arc length based on BP neural network is established to monitor the change of arc length in the process of additive manufacturing.The experiments show that the process monitoring system can monitor the process of additive manufacturing process in real time.By real-time invoking the BP neural network of 3-7-1 structure,it can predict the change of the arc length in real time,and the error range of the prediction is from-1.6 mm to 1.4 mm,reaching the expected requirement.
摘要:Laser welding with filler wire has made it possible to improve the economy of welding due to its properties.Therefore,it has broad application prospects in the additive manufacturing and repairing fields.However,the melting behaviors of filler wire seriously affects the stability of welding process and the quality of weld.Based on high-speed camera acquisition technology and welding process test system,this paper focuses on the systematic study of the internal connections between melting behaviors of filler wire and weld quality.The results show that position of wire feeding and the wire feeding speed have a great influence on the melting mechanisms and transfer behaviors of filler wire.According to the change of distance between laser spot and filler wire,transition behaviors of molten metal can be decomposed into globular transition behavior,liquid-bridge transition behavior and spreading transition behavior.The stable welding process and the well-formed deposition layer can be obtained when liquid metal was transferred into welding pool with liquid-bridge.
关键词:laser welding with filler wire;high-speed camera;melting mechanism;transition behaviors;weld quality
摘要:A weld pool image segmentation method based on FCM cooperative CV model is proposed for the weld pool image of GMA-AM.The algorithm uses the FCM segmentation theory to set the initial position,and then uses the CV active contour model to extract the weld pool profile.The results show that the FCM-CV algorithm eliminates the problem that the CV model is sensitive to the initial position and can effectively extract the contour of the weld pool under different process conditions.Compared with the traditional segmentation method,the weld pool profile of FCM-CV is accurate,smooth and closed.Also,the algorithm can accurately extract the contours of the arc,scum and the tail of the weld pool,and it has good adaptability and stability.
摘要:Research on the powder melting process is of crucial importance to the process optimization and formation control of laser processing and manufacturing technology.A high-speed camera system aiming at recording diode laser cladding process was established.With this system,the process of powder melting,gathering,fusing,spreading and forming was recorded,and five characteristic behaviors was concluded for a complete process.The characteristics of sufferance force,heat distribution and heat transfer during different periods for the melt was analyzed to explain the influence of different process parameters on forming process.The forming mechanism of some typical formation was also analyzed.
关键词:diode laser;melting of powder;forming process;high-speed camera
LI Yang,GUO Lijuan,LIU Dongjun,TIAN Hui,WANG Xijun
Vol. 48, Issue 6, Pages: 29-36(2018)
摘要:Based on carbon steel car body,the key structure of rail transit demand for laser wire filling welding technology,according to the different thickness plates butt joints of carbon steel for car body with the thickness of 2.5 mm and 4 mm,systematically research on laser wire filling welding process and welding procedure qualification,provide reliable technical guarantee for subsequent carbon steel car body structure of laser wire filling welding process production application.The results show that,the welding joint and bending specimens with no defects such as porosity crack,which shows that laser filling welding joint has excellent welding quality.The joint tensile strength at around 480 MPa and it meets the requirements of the base metal.From the point of fracture of the tensile samples,they are all broken in the base metal,indicating that the tensile test reflects the strength test results of the base metal,and that welding joint can meet the design requirements of the structure for strength.
摘要:This article mainly introduces the application and controlling of Clinchen technology in auto production,and the process of principle for Clinch,analyzes the reasons why it has been gradually applied to the automotive industry.Explains the structural features of riveting equipment used in body manufacturing,a description is given of the standard of test,the quality inspection method,destructive and non-destructive inspection process,inspection items,evaluation criteria and the causes of the defects.Examples of common defects are explained through examples.Finally,the future development of Clinch technology in automobile industry is prospected.
关键词:Clinchen;metallographic;force plug;former block;undercut value
摘要:In order to plan the welding path of the spot welding robot work station for the rear side of the car reasonably,a mathematical model of three-dimensional TSP is established to find shortest moving distance between the welding spots.The ant colony algorithm is used to solve the problem.Aiming at the shortcomings that the ant colony algorithm is apt to fall into the local optimal solution because of improper setting of parameters,this paper proposes that the parameters of ant colony algorithm are optimized by orthogonal test and regression analysis.The optimal parameters are obtained by orthogonal experiment,through regression analysis,the relationship between the key parameters and the optimal solution is clarified,and the hypothesis test verifies that it meets the quadratic function and finally obtains the optimal or approximate optimal solution.The results show that the improved ant colony algorithm can get the best or approximate optimal path of the welding robot work station.
摘要:Multiple panel sheet like three,four even five sheets spot welding process is usually exist in white car body frame,when we use regular parameter to weld,it is hard to achieve the good spot welded joints and defects such as splash,spur and through holes comes out during welding,thus lead to wasting cost and time in production.While the hot forming sheets is widely used by the motor factory,non-splash,well forming joint is hardly achieved by the single pulse parameter process.For such spot welded joints of multilayer plates containing thermoformed plates,spot welding controllers based on BOS6000 software are used for multi-pulse spot welding process parameter tests.By metallographical,BOS6000 UIR Curve,production line feedback,the welding joints with reliable welding spots and low splash rate can be obtained by using the multi-pulse spot welding process.
摘要:Nowadays the steel rails gas-pressure welding machine of GPW-1200,which is widely used in the rail exchange by each domestic railway administrations,has the control functions of flexible gas control,flexible oscillation of the heater,oil pressure control,welding process control,cooling process control and normalizing process control with PLC and its corresponding modules as the control core.According to the welding requirements of the high speed rail,the control system realizes the control of the gas-press welding machine and avoids the influence of human factors.The field application shows that it can apply to working condition of the rail off-line welding,rail on-line welding and rail welding repair with the good and stable rail welding quality.
摘要:According to the orthogonal test of the axial pressure in the 6 mm thick 5 A06-H112 aluminum alloy friction stir welding process,the influence of the process parameters on the axial pressure in the welding process was obtained by using the self-made friction stir welding axial pressure measuring platform.The results show that under the condition of other parameters constant the axial force decreases with the increase of FSW tool rotation speed,increases with the increase of welding speed and pressure.The rotational speed of the stirring tool has the greatest influence on the axial pressure,followed by the welding speed and the pressure is the least.When the axial force is more than 4.8 k N,the mechanical performance is good.
摘要:The key process of explosive clad steel plate is explosion compounding,heat treatment,splicing and uncombined area repair welding.Introduce the explosion welding technology of 2205+Q345 C duplex stainless steel,obtaining the ideal bonding quality by controlling the plate spacing,explosive formulation,explosive density,thickness,foundation and so on.Selecting a reasonable heat treatment process to eliminate the explosion welding stress,and also obtain good mechanical properties of the substrate and ensure excellent corrosion resistance of the coating.Meanwhile,in order to meet the requirements of the standard,through the quality control of the splicing of the coating and the repair of the uncombined area,excellent weld performance is also obtained.Thus,the mechanical properties,corrosion resistance and comparison of the 2205 duplex stainless steel composite plate meet the technical requirements.
摘要:Copper(T2) and aluminium alloy(5 A06) were welded by friction stir welding(FSW).The microstructure,mechanical properties and fracture characterization of FSW joints were studied by metallography,tensile testing machine and scanning electron microscope(SEM).The results indicated that the high quality weld joint could be obtained when tool rotational speed was 950 r/min,and travel speed was 150 mm/min.The maximum value of tensile strength was about 296 MPa.The metal Cu and Al close to copper side in the weld nugget(WN) zone showed a lamellar alternating structure characteristic.However,a mixed structure characteristic of Cu and Al existed in the aluminium side of weld nugget(WN) zone.Macroscopic fracture surfaces of the weld section showed obvious layered characteristic,and there were a lot of dimple structures of ductile fracture character in the middle layer of the fracture.The brittle Al-Cu-Mg intermetallic compounds of brittleness were found in the dimple.
PI Dongdong,YAN Zhihong,LU Zhenyang,LIU Zixiao,LUO Mingrui
Vol. 48, Issue 6, Pages: 73-78(2018)
摘要:In recent years,robot welding has replaced artificial welding in more and more fields,and robotic welding has been gradually moving towards the intelligent direction with perception.Welding of standardized workpieces of uniform shape and size,such as tendons,fittings,stampings,castings,etc.,is a type of welding problem frequently encountered in welding constructions.This type of workpiece is characterized by its small size,uniform shape and some geometric features.This paper develops a set of robotic welding positioning system based on two-color light source vision for this kind of workpieces.The image processing algorithm uses two steps of the initial positioning of the welding workpiece and the precise positioning of the welding seam.The two-color light source effectively improves the discrimination between the target and the background,step-by-step image processing algorithm improves the reliability of positioning algorithm.
摘要:Considering different deformation conditions including various specifications,mechanical properties(such as yield ratio,uniform elongation,etc.) and internal pressure of X75 submarine steel pipeline,ultimate stress and strain was analyzed during the tensile deformation process by using ANSYS software.The results showed that,the ultimate stress overall increased gradually but the ultimate strain showed an overall decreasing trend with the increase of strain rate when the pressure was constant;the ultimate stress and limit strain overall showed a gradually increasing trend with the increase of internal pressure when the strain rate was constant;the ultimate stress and strain decreased firstly and then increased with the increase of yield ratio,while they showed a different trend with the change of stiffness.This change was in accordance with the practical condition.The simulation results were reliably and could provide a reference for the industrial production.
关键词:X75 submarine pipeline steel;tensile deformation;ultimate stress and strain;ANSYS;numerical simulation
摘要:Surfacing weld was carried out by using martensitic wear-resistant flux cored wire.The welding form,microstructure and mechanical properties were analyzed.The results show that the weld characterized by martensite and retained austenite and the average hardness is 50 HRC.The average of surfacing weld wear loss is 1.7 mg,which is better than that of 42 Cr Mo steel.The average bending strength of layer surfacing weld is 1 182 MPa,which is similar to 42 Cr Mo steel.
HAI Minna,WANG Wen,HUANG Fan,LI Xianjun,YUAN Xiaogang,ZHANG Yongqiang,LIU Jixiong,XIONG Fuchang,WANG Kuaishe
Vol. 48, Issue 6, Pages: 87-91(2018)
摘要:Zirconium and zirconium alloys are a kind of structural materials with excellent corrosion resistance and have broad application prospects in chemical industry and nuclear industry.Welding techniques for zirconium and zirconium alloy materials and the performance of welded joints are critical to the service life and reliability of equipment.On the basis of analyzing the welding technical characteristics of zirconium and zirconium alloy,the latest research status of welding technology,mechanical properties and corrosion properties of zirconium and zirconium alloy are reviewed.The application prospect of zirconium and zirconium alloy welding technology in chemical industry is also viewed.
关键词:Zirconium and zirconium alloy;welding technique;corrosion resistance;development prospects
摘要:In order to study the process of high-frequency electromagnetic copper and steel re-melt welding,better understand the distribution and change of electromagnetic field and heat field in the process of high frequency electromagnetic induction welding.Using Ansys to model the object by 2 D,and divide the model into a suitable mesh,assign the material to the grid,and set its boundary conditions.The solver with its own solver is circulated.The electromagnetic field and thermal field are analyzed.The parameters such as current and coil radius are changed to check the effect of these parameters on the field,so as to improve the use of the parameters in the welding process,and to understand the temperature change of the welding more completely.
关键词:high frequency electromagnetic induction welding;simulation;electromagnetic-thermal-structural coupling;copper and steel
MA Zhen,ZHUANG Minghui,YUAN Shidan,LIAN Jun,LI Muqin
Vol. 48, Issue 6, Pages: 97-100(2018)
摘要:With the increasing application of wind power generation,higher quality requirements for motor manufacturing enterprises are put forward.According to the quality control situation and existing problems of 42 Cr Mo rotor and Q235 web welding of large wind power generator,through the use of reasonable welding tooling,assembly and welding processes,the welding quality and welding deformation are effectively controlled to ensure the performance of the motor rotor,providing reference and reference for the welding of similar motor rotor.
关键词:wind motor;rotor;welding technology;quality control
摘要:SAW is one way of welding with the high efficiency of metal deposited.SAW is applied in medium and thick steel plates welding with deep penetration,high productivity,and high degree of mechanization operation.It is necessary to improve the welding productivity with the consideration of many welding work for tank bottom plates at crude oil tank farm in limited working time.Combined with the construction of 100 000 m3 tank,SAW welding productivity has been effectively improved by increasing the welding line energy,narrow gap welding,and adding alloy powders,resulting in good results.
关键词:SAW;oil tank bottom plates;weld productivity;application
摘要:The hot-wire TIG welding equipment was built based on the heat-conduction method.The temperature-controlling model was developed and verified within a certain temperature range.The results showed that the wire temperature could be maintained at(220 ±5)℃.The comparing experiments between the hot-wire TIG at temperature of 220 ℃ and ordinary TIG were conducted.The results showed that the hot-wire TIG based on the heat-conduction method could improve the appearance and the feeding speed.When the appearance was similar,due to the chilling effect of hot wire TIG welding wire on arc is small,the efficiency of hot-wire TIG in bottom welding was doubled compared with that of the ordinary TIG.The efficiency of hot-wire TIG in cover welding was tripled compared with that of the ordinary TIG.Moreover,the microstructure of welding seam of the hot-wire TIG welding was finer than that of the ordinary TIG welding.The hardness of welding seam of the hot-wire TIG welding was harder than that of the ordinary TIG welding slightly.The mechanical property of the two joints was well.The fracture was located in the ASTM A106 base metal.
摘要:According to the optimized welding parameters,weld test plates are welded and related mechanical properties are tested.Finally,three aspects of the welding process properties,mechanical properties,production efficiency and energy consumptions are analyzed reasonably.This article provides a technical reference for the application of double wire submerge arc welding on longitudinal and circumferential seam welding of pressure-bearing equipment through the welding test.Compared with conventional single wire submerged arc welding,the technology of double wire submerge arc welding without back chipping can improve the working environment and reduce the manufacturing cost,which has positive social benefits at the same time.
摘要:Taking the solenoid valve and the thruster as an example,the vacuum electron beam welding process of the typical structure of the annular joint is described.The main factor affecting weld quality is porosity defect during welding.The main causes of welding porosity are unreasonable use of silicone oil,vacuum in the chamber,unreasonable position of the cutter slot and cavity after root cleaning.After adopting reasonable welding process measures,the blowhole in the joint can be well controlled,which ensures the mechanical properties of the weld and meets the requirements of the design.
摘要:In this paper,the velocity field and pressure field numerical simulation of the special cutting nozzle are carried out by Mixture model,the flow state of gas-liquid two phase flow in cutting nozzle is analyzed,and the change of velocity and pressure at different positions are analyzed.To study the effect of oxygen flow at different pressures on the speed change of ethanol fuel and the effect of oxygen flow under certain pressure on the atomization of ethanol gasoline at different speeds.By analyzing the underexpansion of static pressure on both sides of the fluid,it is concluded that the under-expansion jet is conducive to the mixing of air and liquid fuel.The simulation results show that increasing the speed difference of gas-liquid mixture can improve the atomization degree of ethanolgasoline at the outlet of the nozzle,which is beneficial to the full combustion.
关键词:flame cutting;gas-liquid two phase flow;Mixture model;numerical simulation
摘要:Through the change of welding heat input,the effect of welding heat input on the mechanical properties and microstructure of weld metal of low alloy high-strength steel CHE607 QR for spherical vessel was investigated by metallographic microscope.The result shows that,the low temperature impact performance of the weld increases first and then decreases with the increase of the welding heat input.When the welding heat input is up to 49 k J/cm,the low temperature impact of weld seam occurs;the heat input of welding is less than 42 k J/cm,the low temperature impact performance of the welding seam is better.
关键词:weld metal;welding heat input;low temperature impact value;CHE607QR welding rod