摘要:The formation mechanism,influencing factors and control principles of cold lap defects in tandem GMAW welds were discussed. The results show that three types of cold lap are found at the weld toe of the tandem GMAW,their properties belong to the micro lack of fusion defects at the weld toe and may affect the fatigue life of the structure. Welding spatter and the overflow of molten metal are necessary conditions for forming cold lap,and the temperature of spatter,base metal and spilled metal are the sufficient condition for forming cold lap. The relationships between the welding behavior and the cold laps formation in tandem GMAW are established,the key points are that when the stability of arc and the balance of weld pool force are destroyed,the tendency of cold lap defect formation is increased. Four possible process routes to limit the number and size of defects are proposed.
关键词:cold lap;tandem GMAW;micro lack of fusion;spatter;overflow;oxides
摘要:In order to gain the basic data for the intelligent welding system,a laser grating vision system is built to measure digital contour of weld bore. Firstly,through the fringe images are analyzed under different working distances and grating projection angles,the preconditions are determined for obtaining grating fringe images representing the contour of weld bore. At the same time,it is discussed how to obtain the information of weld bore contour by means of fringe images when fringes continuous scan. And the established algorithm of laser grating scanning speed and camera exposure interval time provides a decision basis for the determination of system measurement speed and accuracy. Secondly,based on the algorithm of segmentation and refinement of the fringe image,the three-dimensional coordinates of discrete point is gained,the digital contour of weld bore is established by the means of three-dimensional reconstruction. Finally,the verification results show that the system can obtain the digital contour of the weld bore in real time,and the coincidence degree of width or depth values is up to 99.75% between the visual measurement system and the manual measuring.
WANG Fushan,WANG Xiyong,LI He,ZHAO Huimin,YANG Xinhua
Vol. 48, Issue 7, Pages: 13-18(2018)
摘要:A certain type main generator frame used in railway vehicles is taken as a research objective. The finite element simulation analysis of the frame is carried out by ABAQUS. The static strength is evaluated according to the actual working condition and design requirements;reference to the standards of IIW and EN15085,the fatigue strength and stress factor of the dangerous welds in the generator frame are calculated by the hot spot stress method and the equivalent structural stress method respectively and the results are compared.The results show that: under limited conditions,the maximum Mises stress of the generator frame is less than the yield strength of the base material,so the frame meets the static strength requirement;under the impact and stop conditions,the maximum stress change range of hot spot stress of the dangerous welds in the generator frame is less than the cut-off fatigue limit of the corresponding S-N curve,and the fatigue strength of the frame meets the design requirements. The structural stress at the dangerous weld toe is extracted by FE-SAFE,and the fatigue life of the dangerous weld obtained by the equivalent structural stress method can also meet the design requirements. By comparing the stress factors obtained by the two methods,it is concluded that the equivalent structural stress method can predict the fatigue life of welded structures more efficiently and accurately when the welding structure is complex.
摘要:Industrial pure titanium TA2 due to its excellent corrosion resistance is widely used in the water environment,in the actual production,pure titanium is mostly welded by TIG welding,but slow welding speed leads to low efficiency. The subject of the 0.9 mm TA2 laser welding research,first has carried on the orthogonal experiment of four factors and five levels. These four factors are laser power,welding speed,defocusing and laser incident angle,it is found that laser power and welding speed have the greatest influence on forming;then each factor is analyzed by single factor analysis,found that increasing laser power or decreasing welding speed can suppress the undercut,increasing the amount of positive defocus can reduce the back spatter,forward laser incident is easier to achieve penetration than backward incident.
关键词:industrial pure titanium;laser welding;undercut;spatter
摘要:Based on the characteristics of the technology and heat source of double-sided laser beam welding for T-joint,a new heat source consisting of a Gauss surface heat source and a self-adaptive body heat source is presented. The Gauss surface heat source represents the action of the heating effect of plasma cloud above the keyhole surface,and the self-adaptive body heat source represents the action of the Fresnel absorption and inverse bremsstrahlung absorption of the laser energy in the keyhole,and the effects of keyhole on the heat and mass transfer are also considered. Using the FLUENT software,a three-dimensional mathematical model for double-sided laser beam welding for T-joint is established,and the characteristics of the temperature field and keyhole are analyzed. The result shows that the molten pool temperature and keyhole shape distribute symmetrically along the stringer center. The molten pool temperature gradient on the cross section increases as the distance from the center of stinger center increases,especially on the skin side,and the maximum length of molten pool locates the keyhole interacting position rather than molten pool surface,the primary reason is the heat source coupling action of both sides. The simulated results agree well with the experimental results,which proves the accuracy and applicability of the model.
摘要:3 mm thick AZ31B magnesium plates are butt welded by CMT technology. The welding parameters:1.6 mm diameter WE-33M feed wire,welding current of 76 A, wire feed rate of 6 m/min,welding speed of 0.8 m/min,weld interval of 1.5 mm. The welding process is stable without spatters and appearance of the weld is fine. The microstructure, microhardness,mechanical properties and tensile fracture appearance of welded joints are observed. The results show that grains in the weld microstructure are refined,the microhardness of the weld zone is the highest,and the average is 86 HV,the microhardness of HAZ is about 62 HV,the base metal about 65 HV. The maximum tensile strength and elongation of welded joint is 248.8 MPa and 7.16% respectively,which are 96.7%and 98.6% of the base metal respectively. The fracture is located in the base metal zone and belongs to ductile fracture.
摘要:Finishing is the most important process of improving the harshness of rail field welded joint. For the problem that the manual rail profiling refiner,nowadays used for the rail field welded joint grinding after welded in our country,has a low efficiency and an unstable grinding quality and the grinding process can’t be accurately controlled,a new shape finishing equipment for rail welded joint has been developed successfully and tested in field railway. The result shows that such an equipment can improve the harshness and surface quality of the welded joint effectively,and develop the joint’s passing rate of the joint harshness steadily. It has a high efficiency and is also applicable to the complex condition of the field grinding work.
摘要:Summarize a new type of friction stir welding method based on the stationary shoulder,and can gain no thinning surface after welding,by researching the split mixing tools,the implement of welding process,the microstructure and mechanical properties.Under the condition that the shoulder is stationary,the method can not only obtain the welded joint with excellent mechanical properties,but also achieve the intended purpose of no flashing,good surface finish after welding and no thinning,and may broaden the application field of friction stir welding to the welding of aluminum alloy structural parts with strict surface configuration.
ZHOU Yang,KONG Liang,WANG Min,HUA Xueming,MOU Gang
Vol. 48, Issue 7, Pages: 46-50(2018)
摘要:Titanium and titanium alloys have the advantages of both steel(high strength) and aluminum(light weight) as well as excellent corrosion resistance. They are widely used in the fields of aviation,aerospace, chemical engineering and metallurgy. The microstructure characteristics of TIG and LBW welded joints are introduced, and the method of evaluating the corrosion resistance of titanium and titanium alloy welded joints is summarized and compared with base material. The study finds that: titanium and titanium alloy welded joint microstructures change or more stable oxide film makes titanium and titanium alloy welded joints have improved corrosion resistance.
摘要:Wire arc additive manufacturing(WAAM) technology is a high-efficiency and low-cost metal manufacturing method.However,the travel speed of the torch cannot keep constant when fabricating complex parts,which is restricted by varied curvature of the path. Therefore,t is difficult to obtain consistent forming appearance. To deal with this problem,a speed planning algorithm under the technology constraint based on NURBS interpolation is proposed,which considers the allowable speed fluctuation of the WAAM technology. It aims at reducing the speed fluctuation during the manufacturing process and improving the consistency of the forming appearance. The maximum relative error does not exceed 5%,meeting the forming control requirements for arc additive manufacturing.
摘要:The 2A14 aluminum alloy is widely used in aerospace industry,especially for the manufacture of rocket fuel tanks,due to its good mechanical properties and resistance to stress corrosion from -250 ℃ to 250 ℃. In this paper,3-mm-thick 2A14 aluminum alloys were welded by the VPTIG arc welding,which were used to study the nonuniformity of microstructure and mechanical properties. The results show that grains in the weld are dendritic equiaxed grains,while the solid solution zone are coarse. The overaging zone and the base metal are flat. The content of alloying elements in the matrix of the weld zone is low,therefore the solid solution strengthening effect is weakened. At the same time,eutectic structures precipitate along the grain boundaries. The content of alloying elements in the heat-affected zone and the base metal matrix is relatively high. It can be seen from the microhardness measurements that the weld is almost the weakest zone in the joint. Moreover,base on the regression analysis,linear correlations among the yield strength and microhardness are established,σ0.2=2.94 HV-78.71.
LU Erjing,GUI Hongli,ZHANG Yanhui,HAO Xiaowei,YAO Zhenjiang,ZONG Huanxu
Vol. 48, Issue 7, Pages: 62-66(2018)
摘要:Through the analysis of the microstructure, hardness test,pulsating tensile fatigue test and the analysis of fatigue fracture morphology,this paper studied the microstructure and fatigue performance of resistance spot welding joint of 1.5 mm Q310 and 3 mm Q345. The results show that,the microstructure of Q310 and Q345 are similar,the base organization is pro-eutectoid ferrite and pearlite,the microstructure of HAZ is a few ferrite and pearlite. The microstructure of nugget area is lath martensite and bainite. From the nugget area to the base material,the hardness value distribution is in a step downward trend,the hardness value of nugget is the highest of the whole joint. The fatigue fracture is located in the nugget area. And the type of fatigue fracture is mixed with micropore and cleavage,the main cause of fatigue fracture is stress concentration.
摘要:Through the analysis of the microstructure,hardness test and pulsating tensile fatigue test,study the microstructure and properties of the plug welding joint of Q310NQL2 and Q345NQR2 corrosion resistant steels. The results show that,when the ER50-G mild steel welding wire is used for plug welding process,the structure of plug weld nugget zone is pearlite,ferrite and Widmanstatten structure. In the heat affected zone the pearlite become larger because of overheating. The hardness of nugget zone is the highest in the whole joint,and the hardness of heat affected zone relatively decreased,but the softening phenomenon is not obvious. The fracture of pulsating tensile fatigue specimen is located at the root of the side nugget zone of thin plate. The brittle structure and stress concentration here are the main causes of fatigue fracture.
SUN Yan,GAO Xiangdong,XIAO Zhenlin,CHEN Xiaohui,LI Xiuzhong
Vol. 48, Issue 7, Pages: 72-75(2018)
摘要:During disk laser welding bead-on-plate welding of type 304 austenitic stainless steel plates,a near infrared band highspeed camera,an ultraviolet band high-speed camera and a visible light band high-speed camera are used to capture the dynamic images of the keyhole,plume and spatters in the laser welding at the same time. The keyhole,plume and spatters are defined as the characteristic parameters of welding process,and the dynamic characteristics are considered as the output parameters of the neural network,and the weld width is considered as a parameter reflecting the welding status and the input parameter of the neural network. A technique that uses multifeature information fusion of keyhole,plume and spatters to obtain the welding status of high-power disk laser welding based on neural network technology is presented. The defined keyhole,plume and spatters characteristic parameters are considered as inputs to calculate theoretical weld width. The proposed BP neural network has been successfully tested in a real time disk laser welding process.
关键词:high-power disk laser welding;multi-feature parameters;welding status;synchronous detection
摘要:The application of weathering steel sheet is the core technology to solve the lightweight of high speed heavy load truck. In order to solve the problems of large heat input,burn through and large deformation during the welding process of weathering steel sheet,the CMT welding method is used to optimize the welding parameters of 1.5 mm weathering steel sheet,and the optimal parameters are used to simulate and compare the deformation of CMT welding with that of traditional welding(MAG welding)for weathering steel. The results show that the properties of the full penetration joints are good,and increasing welding speed can reduce joint misalignment and improve the joint property,the tensile strength of joint peaks at 669.6 MPa;the simulation results show that the deformation trend of CMT welding is similar to that of MAG welding,the deformation of weld center and edge plate are large,the maximum CMT welding deformation is +3.8 mm,the maximum MAG welding deformation is +4.8 mm,the CMT welding deformation is obviously smaller than MAG welding deformation.
摘要:In order to study the effect of wire feed speed and welding speed on the forming of Q345E low-alloy steel narrow gap laser wire-bonding welding,the experiment were designed by changing the wire feeding speed and welding speed. According to the test results,the macro-metallurgical status of the welded joint at the welding speed and wire feed speed,the penetration depth and the weld width were analyzed. Through the analysis and comparison,the suitable wire feeding speed of Q345E narrow-gap laser wire-bonding backing welding were obtained,the welding speed was 5 m/min and the welding speed was 0.36 m/min.
关键词:Q345E low alloy steel;narrow gap laser filler wire welding;penetration and melting width
摘要:Dissimilar metals of 1060 aluminum and galvanized steel were joined with lap joint by pulsed double electrode gas metal arc welding-brazing with ER4043 aluminum filler metals. The welding joints of aluminum and steel were heat-treated at 270 ℃ and 350 ℃. The microstructure of the welded joint was observed by scanning electron microscopy,the diffusion and hardness distribution of alloying elements in different areas of the welded joint before and after heat treatment were tested by energy spectrometer and microhardness tester. The results show that the homogenization diffusion of alloy elements in welding joint occurs after heat treatment.After heat treatment at 350 ℃,a layer of Fe2Al5Zn0.4 intermetallic compound was formed in the weld toe area of the welding joint. The microhardness distribution of weld metal is uniform and the change of microhardness of weld toe area is smaller after heat treatment at 270 ℃,it is beneficial to avoid the stress concentration and improve the mechanical properties of the welding joint.
YANG Gaoyang,ZHANG Shaojun,YAO Huancheng,KANG Ning,YANG Hongwei
Vol. 48, Issue 7, Pages: 91-94(2018)
摘要:For the thick plate box K-joint component of Malaysian signature tower project,the welded joint form and welding groove sequence are optimized. Considering the local cushioning effect of welded joints,the first weld in each layer starts from the side of the flange. In order to control the welding heat input,a combined welding method of flux-cored wire gas shielded welding and submerged arc welding filling cover is adopted for the welds of main part. The welding sequences of the main weld and K joint are well-designed. Preheating, post-heat and interpass temperatures are strictly controlled to prevent lamellar tearing and guarantee the delivery quality of project components.
JIN Mingfeng,LUO Yongfei,GAO Hongming,LIU Hongwei,LIU Zhiyong
Vol. 48, Issue 7, Pages: 95-101(2018)
摘要:Pressure vessel of gasifier is usually made of ASME specification material SA-387GR11CL2 plate. Due to the specific requirements of working conditions and service performance, the medium temperature mechanical properties of the pressure vessel are generally specified. In a gasifier project of DBC,the tensile strength of material and welding joints SA-387GR11CL2 plate at 427 ℃ should be not less than 450 MPa. Whether the material and welding joints could meet the relevant technical requirements after series of welding and heat treatment is the main manufacturing difficulty of this product. The effect of welding process and heat treatment specification on the properties of SA-387GR11CL2 materials and welding joints was studied by series of welding and heat treatment process tests analyzed with larson-miller parameters,and the heat treatment process test of the head was especially carried out. Reasonable welding process and heat treatment specification of pressure vessel of gasifier reactor,quench room and head were worked out.
关键词:gasifier;SA-387GR11CL2 plate;welding and heat treatment process;larson-miller parameters;performance effect
摘要:Economizer tube leakage occurs after 34 days of use,and the leakage point is at the butt weld of the steel tube. In order to find out the leakage reasons,the base material composition test,microstructure observation and hardness test of the weld section are carried out,and the test results are compared with the specified requirements in the standard <GB 5310-2008 seamless steel tubes and pipes for high pressure boiler>,the material composition and hardness test results meet the requirements of relative standards. By observing the microstructure,it is found that the pores and internal cracks in weld fusion zone cause the decrease of the weld strength.In use process,the extension of internal cracks in work environment is the main reason for steel tube leakage at weld.
摘要:The submerged arc surfacing with band-electrode technology is used to surfacing Inconel 625 on the 16 Mn tube sheet. And then the macroscopic testing, permeation testing,metallographic structure analysis,HV-hardness testing and corrosion resistance testing are used to test the quality of welded joints. By welding procedure qualification,suitable welding parameters are chose and formulated to ensure the welding quality to meet the requirements of design and use.
摘要:By using a C type induction heater with variable radius and three dimensional tooling car,an electromagnetic induction heating device which is suitable for the preheating of the inner wall surfacing of the nuclear pressurizer and the hydrogen baking is designed in this article. The C induction heater with adjustable radius can heat the large area in a certain range,and the tooling car can adjust the position of the C induction heater in the three-dimensional space. The device is featured by high automation and good heating effect,and is of high engineering application value.
摘要:The principle of hydrodynamics is applied to the design of automatic welding cover for underwater pipeline repair by using FLUENT software. The structure and size of the drain cover are determined,and the MIG automatic welding experiment is carried out for underwater pipeline repair. Argon is used as protective gas and the pressure of the experimental environment is 0.15 MPa. The velocity and pressure cloud images obtained through the calculation and simulation of the FLUENT software can directly show the influence of different intake modes on the airflow stability in the gas phase space. The underwater MIG automatic welding experiment by this method shows that the drainage hood has good drainage effect,the arc combustion is stable and the underwater weld quality is good,which lays the foundation for the underwater welding equipment and technology research.
关键词:drainage hood;automatic welding for underwater pipeline repair;FLUENT software
摘要:Based on the analysis of the development of welding technology and characteristics of welding discipline,this paper points out that in the field of patent examination,books retrieval has an important meaning,and Duxiu Knowledge Search Database shows as one of the most important database,and is the necessary searching database in welding field,and combined with case analysis elaborated to point out Duxiu Knowledge Search Database is of importance in acquiring closest prior art,proofing common general knowledge,auxiliary reasoning,understanding and responding to comments stated by the applicant.
摘要:During the structure construction of offshore engineering,there is a large number of welding and inspection work accompanied,as each weld joint is combination with an independent inspection report,there are many different kinds of welding inspection reports,and the format is not identical,thus it takes a lot time to manage the inspection reports. The low efficiency and high error rate bring great trouble to the construction management. A welding inspection report management system is developed,which SQL Server database and client/Server mode are used,and the system had been well applied in BZ34-9 etc. project. Many users online simultaneously, data sharing,intelligent query operation,intelligent error correction,automatic statistics etc. functions are realized in this system,so the accuracy and efficiency of the inspection report management is improved significantly,and a lot of time is saved for the subsequent work.