摘要:By optimizing the welding parameters of nonpenetration laser lap welding of stainless steel with two plate thickness combinations(2 mm +1.5 mm, 1.5 mm +2 mm), the laser welding quality control under the condition of multi-parameter coupling was realized, and their fatigue performances were studied. The welding process test is designed by orthogonal test method. According to the orthogonal test results, the relationship between three key welding parameters(power,welding speed, defocusing amount) and shear strength of welded joints of these two plate thicknesses combinations is ana lyzed. And the optimal welding parameters are obtained, namely1.5 mm+2 mm plate thickness combination(power of 3 700 W,welding speed of 4 330 mm/min, defocusing amount of +4 mm)and 2 mm+1.5 mm plate thickness combination(power of 3 700 W, welding speed of 4 580 mm/min, defocusing amount of0 mm). The fatigue properties of laser welded joints of these two plate thickness combinations under the optimal welding parameters are comparatively analyzed. The fatigue strength of welded joint of 2 mm+1.5 mm composite is higher than that of1.5 mm +2 mm composite, which provides a reference for further parameters optimization r and fatigue properties study of laser welding of stainless steel carbody.
关键词:laser lap welding;orthogonal design;variance analysis;welding parameter optimization;fatigue limit
摘要:In order to study the weld forming law of the 10 kW fiber laser self-fusion welding, and then realize the well formed weld under the condition of 30 kW laser power, the test taking30 mm and 40 mm thick Q235 low carbon steels as research object are carried out. On the basis of flat welding, the weld characteristics were analyzed under the conditions of different laser powers, defocusing amounts, welding speeds and side blow pressures. The welding parameters were optimized and the weld forming was controlled by self-made small side blow device.The results show that when the laser power reaches 30 k W, it is difficult to obtain a good weld formation only by changing the defocusing amount or welding speed, and the weld uniformity is poor and the welding spatter is large. Applying transverse side blow pressure of 0.3 ~0.4 MPa on the test plate can effectively improve the weld formation, reduce the welding spatter, and increase the weld penetration depth by more than 20%. Through the further optimization of the welding parameters, the weld surface forming control was realized during 30 kW laser welding with transverse side blow pressure of 0.4 MPa and welding speed of 0.6 m/min.
摘要:The TIG welding is used for surfacing to study the cladding layers of Ni3Al and Ni3Al+Cr3C2 intermetallic compoundbased metal powder-cored wires on different substrate materials.The results show that:(1) After cladding, the average dilution rate of Ni3Al+Cr3C2 wire(34.55%) is lower than that of Ni3Al wire(42.8%);(2) The microstructure of cladding layer after surfacing with pure Ni3Al metal powder-cored wire is mainly single γ’-Ni3Al phase, and when using Ni3Al+Cr3C2 wire, the cladding layer is mainly composed of γ’-Ni3Al phase and MC type and M23 C6 type carbides;(3)The microhardness of Ni3Al+Cr3C2 cladding layer is significantly higher than that of pure Ni3Al cladding layer;(4) Using Ni3Al,Ni3Al+Cr3C2 metal powder-cored wire for cladding on 4 kinds of experimental substrates, the bead has good metallurgy bonding and wetting, and few defects after surfacing, and the hardness of the surfacing layer is higher than that of the base metal, so it can be used for surfacing of related materials.
摘要:Flow passage components often fail due to surface wear in service. The traditional wear-resistant treatment method has limited effect on improving the service life of flow passage components, and there are some problems such as expensive equipment, complex process or high cost of raw materials. Researchers observed prepared Ni Cr BSi, Ni Cr BSi/WC,Ni Cr BSi/diamond wear-resistant braze coating, and found that the metallurgical bonding between the coating and the matrix was good. In Ni Cr BSi coating, chromium carbide, chromium boride, nickel boride and other strengthening phases are formed. In Ni Cr BSi/WC coating, the distribution density of WC particles gradually increases from the coating surface to the bottom, while in Ni Cr BSi/diamond coating, diamond particles are uniformly dispersed. Under the same wear test conditions,the mass loss of Ni Cr BSi/diamond coating is about 1/5 that of Ni Cr BSi coating and 1/3 that of Ni Cr BSi/WC coating, indicating that Ni Cr BSi/diamond coating has excellent wear resistance. The diamond brazecoating technology has been applied to rotating blades of soil-engaging components and screw conveyor blade of agricultural machinery touching the soil. The field test shows that the wear resistance and service life of the rotary tiller and screw blade coated with diamond brazing have been greatly improved. It provides theoretical reference and practical experience for the application of diamond brazing technology in other flow parts in the future.
摘要:Some parts of aluminum alloy body of China Standardized EMU are welded by friction stir welding. The front bottom plate adopts bobbin friction stir welding process. During the production of the front bottom plate, the first pass rate of welding(phased array ultrasonic testing) is less than 50%, in view of the strict requirement on quality, it seriously affects the welding quality and delivery schedule. Aiming at the above problems, the welding defects were studied. ABAQUS was used to simulate the formation mechanism of cavity defects, cavity defects can be avoided with appropriate parameters. The normal and abnormal fracture zigzag lines were studied by OM and SEM, the origin and formation mechanism of the zigzage lines in the two kinds of defects were discussed. Through the improvement of the tool profile, the original triangular prism shaped agitator needle is changed into a positive and negative double helix shaped agitator needle, the research of welding technology has been improved systematically, the first pass rate of welding reaches 100%.
摘要:In view of the problems of low appearance level and low efficiency in resistance spot welding of stainless steel rail vehicles, a new product of stainless steel rail vehicles is first developed in China, which is made by partially replacing resistance spot welding with laser welding of thin plates. The laser lap welding process of stainless steel car body is developed and the welding parameters are optimized. Under the condition of 0.6 mm spot diameter, the welded joint with qualified shear strength and quality of outer surface of lower plate can be obtained when the?laser power is 1 200 W and welding speed is 30 mm/s. By defining weld quality standard(0.9 mm penetration depth) and developing weld quality monitoring device, the laser welding manufacturing system is built, and the mass application of the new laser welding technology in high standard stainless steel rail vehicle products is realized. The weight of the stainless steel car body with laser welding reduces by 1.8 t, the lateral impact resistance of the side wall significantly improves, and the life of the car body increases by over 15%.
关键词:high standard stainless steel vehicle car body;laser welding;quality detection;technology system
摘要:Stainless steel strip surfacing flux JWF304 D and JWF205 D for hydrogenation reactor have excellent welding process performance, which are suitable for 30 ~90 mm wide band welding. They can be adjusted according to different manufacturing process and are suitable for various of manufacturing process. They have the characteristics of small spatter during welding(for electroslag welding), excellent slag removal and good weld bead forming quality. Welding parameter adjustment range of submerged arc flux JWF304 D is large, not only suitable for high current with 90 mm wide band, but also suitable for small current, thin layer, rapid welding. The flux JWF205 D for electroslag welding can be welded at high welding speed, with suitable current and voltage, the surfacing speed can reach 27 cm/min, which improves the production efficiency. Both of the two fluxes can be welded by combining with a variety of welding strips,which can be used with EQ309 L, EQ308 L,EQ347 L and other types of stainless steel welding strips. The chemical composition and various performance of the surfacing layer meet the requirements of relevant standards and user’s technical agreements.
摘要:Aiming at the characteristics of stainless steel storage tanks and actual production conditions, a set of high-efficiency and high-quality DP-TIG welding technology solutions were proposed and corresponding research work was carried out. The results show that the DP-TIG welding technology increases the welding penetration through the arc perforation effect, realizes single-sided welding and double-sided forming, and the weld quality meets the requirements of industry standards. The ability to adapt to actual complex working conditions such as groove gap, angle and misalignment is strong. There is no groove required in welding process, less consumables and low production cost. The welding parameters are simple and easy to adjust, and the requirements of personnel operation skills are low. This technology has been successfully applied to stainless steel cryogenic storage tanks, medical equipment and other industries, changing the original production method with excellent weld quality and high welding efficiency, and meeting the production requirements of users.
关键词:stainless steel storage tank;DP-TIG;singlesided welding and double-sided forming
摘要:The hanging tube of coal-fired power station boiler is a small batch welding structure, which involves many kinds of materials and complex structure. The characteristics of hanging tube welding are: there is welding deformation, welding materials are heat-resistant steel and stainless steel, and it is dissimilar steel welding. The welding method of hanging tube is manual metal arc welding, which has low welding efficiency, poor stability of welding quality and high labor intensity of workers.The automatic welding production line for hanging tube realizes the automatic welding of hanging tube with symmetrical angle plates on both sides in the power plant boiler products. Based on the test, the uniform weld formation obtained in this production line can meet the standard requirements, and the welding qualification rate is more than 99%. At present, the equipment has been widely used in production practice.
摘要:Welding robot has the advantages of high production efficiency, stable welding quality and sustainable operation, and has been widely used in manufacturing industry.The welding of nuclear reactor pressure vessel(RPV) closure head are analyzed, a welding robot system for weld in closure head is designed, and its welding process is studied and confirmed, and the actual welding implementation of welding robot is introduced. According to the characteristics of J-groove weld in RPV closure head, the key technology and difficulties of welding robot are analyzed. Focusing on the welding trajectory, welding positioning, welding deformation and other key technical difficulties of the welding robot as well as the quality control of the welding process, the solutions are proposed, which provides experience for the application of welding robot in the welding of J-groove weld in RPV closure head.
摘要:Based on dimension acquisition of structured light 3 D-Scanning technology, data processing and reverse reconstruction of Geomagic, and slicing and path planning of AMSlicer Pro, the lacking part of thin-wall aluminum alloy ZL114 A was modeled in reverse. Through arc additive manufacturing and repair with welding wire ER4043, the lacking part was repaired perfectly. The means of nondestructive testing, microhardness tester, electronic universal testing machine and scanning electron microscopy were used to study and analyze the microstructure and performance of the repaired part in arc additive manufacturing and repair. The results show that the surface of repaired sample has no surface-breaking defect, and the internal microstructure is dense without visible defects. The microhardness at the top of repaired sample is a bit higher than that at the bottom, and the microhardness in the middle part is stable. The mechanical properties of the sample parallel to the direction of arc cladding are superior to those perpendicular to the direction of arc cladding. Therefore, the mechanical properties of repaired sample are anisotropy. The Al-Si eutectic structure of repaired sample showing fine strips distributes in α solid solution, and extends from bottom to top. The Al-Si eutectic structure at the top of repaired sample disperses and has small cutting effect onα matrix, which makes the properties of Al-Si eutectic at the top better than those at the bottom.
摘要:Aiming at the brazing problem of the new valve structure, a set of brazing solutions for the valve of precision thinwalled parts has been developed. The project content includes the research and development of composite coating brazing filler materials for the process and reliability requirements of the brazing connection of the screw and cap weldment; the design and manufacture of the automatic high frequency brazing equipment and induction coil for the base material with low melting point and easy to burn; the brazing parameters such as brazing current,brazing time, brazing position are adjusted, and a set of mature automatic high-frequency brazing process are explored. The overall brazing solution has the advantages of high efficiency, low cost and greenness, and successfully solves the technical problems of automatic brazing for the screw of the valve nozzle assembly and the base of the sensor, and passes the tensile test and air tight test after brazing, meeting the brazing quality demands and improving the production efficiency and the qualified rate of the finished product. At present, this project has been applied in practical production.
关键词:precision thin-walled parts;valve;high frequency induction brazing;brazing material;brazing process
摘要:A series of refractory solid welding wire with different alloy composition were designed and the contrast experiment was conducted. By means of various test methods including chemical composition test, tensile test, optical microscope and scanning electron microscope, combining the experimental results of mechanical properties and microstructure, the effect of V and Nb on the microstructure and mechanical properties of deposited metal of refractory solid welding wire was analyzed, and the relationship between the microstructure and mechanical properties was analyzed. The results show that at high temperatures the addition of V and Nb can promote dispersed precipitation of carbide, enhance the precipitation strengthening effect and the stability of microstructure, thus effectively increases the high-temperature yield strength of deposited at 600 ℃, but the addition of Nb obviously reduces the low-temperature impact toughness of deposited metal. Solid welding wire containing Mo and V can guarantee good high-temperature yield strength and favorable low-temperature impact toughness.
摘要:In this experiment, ABAQUS was used to simulate and analyze the welding temperature field, post welding residual stress and out of plane deformation of 6 mm thick T-joint double wire MAG welding. There are two kinds of constraint conditions: scheme 1 does not fix the bottom plate and the welding is free from deformation; scheme 2 fixes the bottom plate during welding and releases the fixation after cooling. The results show that the welding temperature fields of the two schemes are consistent under the same heat source; the angular deformation of scheme 1 is large, the maximum deformation is about 1 mm, the deformation of the bottom plate in the weld heat affected zone is about 0.2 mm, and the maximum residual stress is located in the weld center, about 235 MPa; the maximum deformation in scheme 2 is located in the weld center, but the area is small, the maximum deformation is located near the weld heat affected zone, about 0.3 mm, and the maximum residual stress in the weld center is about 180 MPa;The analysis shows that the welding residual stress and out of plane deformation can be reduced by fixing the base plate and releasing it after cooling.
关键词:ABAQUS;temperature field;welding residual stress;out of plane deformation
摘要:Aiming at the laser arc hybrid welding process of 20 mm thick wall S355 J2 H beam tube commonly used in rail vehicle bogie frame, the groove form, backing welding process window, cosmetic welding process window, welding gas pore suppression and other aspects are optimized. The results show that the main factors controlling the weld formation are the weld groove, distance between filaments and defocusing amount of laser beam. Using Y-groove with 8 mm blunt edge height and20 ° ~ 25 ° single side, DLA = 2 ~ 4 mm, defocusing amount of0 ~ 2 mm, continuous backing welding joints are obtained;Using cosmetic welding parameters of laser power of 500 ~1000 W, arc current of 200 ~ 250 A, defocusing amount of-2 ~0 mm, continuous, uniform and beautiful welds without cracks,gas pores and other welding defects are obtained. The laser-MAG arc hybrid welding of 20 mm thick beam tube is realized,and the feasibility of laser-MAG arc hybrid welding of beam tube is verified.
摘要:In this research, single-mode fiber laser welding process of 2 mm 6013 aluminum alloy are carried out based on response surface method. The relationship between the process parameters such as laser power, welding speed, and defocused position of the laser beam with the output responses such as top melt width, back melt width, back-to-top width ratio and fusion zone area are established in terms of 3 D response surface models. The models are significant and fit well. The influence of process parameter on the geometric characteristics of welded joints and the microstructure properties of typical welds are analyzed. The results show that the laser power is positively correlated with back melt width, back-to-top width ratio and fusion zone area; welding speed is negatively correlated with all output variables; the defocused position is positively correlated with top melt width and fusion zone area, while negatively correlated with back-to-top width ratio. There is an obvious interaction between laser power and defocused position in the regression model of back-to-top width ratio. The single-mode fiber laser can realize the full penetration of 2 mm 6013 aluminum alloy under the process matching of low power and high welding speed, and the section melting width of the welded joint is narrower and the micro grain size is small. Its tensile strength and section elongation are 315.5 MPa and 12.3%respectively, which can reach 90% and 42% of the base metal.
摘要:Through the welding process test, the welding process characteristics of Tri-Arc and Tandem dual wire welding were compared. The results show that Tri-Arc dual wire welding not only has the same welding efficiency as Tandem dual wire welding, but also has a lower welding heat input than Tandem dual wire welding under the same wire deposition rate(wire feed speed) and welding speed conditions. The results are reflected in lower weld penetration ratio and less welding deformation. Therefore, Tri-Arc can replace Tandem in all efficient welding applications and achieve the same or even higher wire deposition rate, as well as providing superior welding performance and a wider range of applications.
摘要:Welding is a key link in the manufacturing process of pressure equipment. The performance and stability of welding materials play a key role in the manufacturing quality of pressure equipment and determine the final performance of pressure equipment. R307 L electrode and H08 Cr Mo(H)/JWF201(H) submerged-arc welding materials for 15 Cr Mo R(H)steel are developed. The welding process and properties of deposited metal are studied. Taking the properties of welded joint as the main evaluation index, after adopting various heat treatments including simulated head thermal forming, the test data still maintain excellent level. The microstructure of welded joint is analyzed, and the microstructure of weld is mainly ferrite with a little bainite and pearlite.
摘要:Metal cutting plays an important role in the fields of infrastructure and intelligent manufacturing in China.However, traditional metal cutting techniques can no longer satisfy the user’s new demands, which are caused by labor shortages, a sharp increase in labor costs, and the harsh requirements for energy conservation and environmental protection. In order to increase production efficiency and alleviate labor intensity, this paper proposes a remote operation and maintenance system for the metal cutting machines. This system makes full use of Internet of Things, cloud services, big data, industrial bus, and digital control technique. It can reduce the technical requirements for operators and improve the dirty working environment, which is valuable for the development of the metal cutting unmanned factory.
关键词:metal cutting;remote operation and maintenance;one-click cutting;IDCS
摘要:The solidification processes of twin-roll strip casting Cu-3.2 Ni-0.75 Si alloy at different cooling rates were observed in situ by confocal laser scanning microscope(CLSM),and the functional relationship between the crystallization temperature and the secondary dendrite spacing of the solidified structure depending on cooling rate was quantitatively analyzed.The results show that the increase of cooling rate can significantly reduce the crystallization temperature and the secondary dendrite spacing of the solidified structure. When the cooling rate increases from 0.1 ℃/s to 100 ℃/s, the crystallization temperature decreases from 1 096 ℃ to 890 ℃,and the secondary dendrite spacing increases from 77.5 μm to23.5 μm, the function relations of crystallization temperature and secondary dendrite spacing depending on cooling rate are TL→ S=194×(-v/14)+895 and λ2=60×v-0.11, respectively. The subrapid solidification characteristics of twin roll strip casting can significantly refine the solidification structure of the alloy and inhibit the microsegregation of Ni and Si elements. The reason is that the increase of cooling rate enhances the initial undercooling of the alloy melt during crystallization.
摘要:When laser welding is directly used for steel/aluminum joints, brittle Fe-Al intermetallic compounds are easily produced. For the issue, the effects of silver interlayer on microstructure and mechanical properties of 304 stainless steel/6061 aluminum alloy welded joint were investigated by utilizing double laser weldi ng in the paper. The results of the research showed that the interlayer was the prefabricated by silver, and the joint was formed well by dual laser welding process. Organizational analysis showed that the weld area was obviously divided into area A near the aluminum side and area B near the steel side. Area A was a silver-rich phase mixed with aluminum-rich phase, and area B was made from pure silver zone(B1) and austenitic zone(B2). In addition, Fe-Al brittle intermetallic compounds didn’t appear in the weld seam. The results of mechanical properties showed that the fracture occurred in the pure silver zone of the joint, and the tensile strength was175.59 MPa, and the elongation after fracture was about 3%.
关键词:silver interlayer;304 stainless steel;6061 aluminum alloy;laser welding;brittle metal intermetallic compound
摘要:The composition, welding application value,welding process test and practical welding application of a single power source twin-wire system(Deepen Twin) are introduced and analyzed. Deepen Twin is composed of welding power source, twin-wire feeder and twin-wire welding gun,which is simple and easy to be operated. Deepen Twin can be used for manual welding and automatic welding of the special machine and robot. And it can realize the free switch between single wire and twin wires, and can be used for backing welding with single wire and welding with twin wires, high current and high cladding rate, and the maximum cladding efficiency can be increased by 50%. The twin wires form a single wide arc, thus the arc heat distribution is more uniform, undercut is not easy to occur in weld, and there are low spatter, good weld forming and no arc interference, the quality of weld obtained by twin-wire welding is higher than that by single wire welding, which is a new high-speed and efficient welding solution.
关键词:Deepen Twin;application value;welding process;high-speed and efficient
摘要:The side wall unit is the skeleton of the vehicle body, which needs to be welded with the top cover and underframe respectively to support the whole vehicle body. The welding method of side wall unit is MIG welding, which is easy to produce welding deformation in the welding process;secondly, the welding process requirements of the side wall are relatively high and there are many welding processes. A series of processes such as upper door corner assembly welding, lower door corner assembly welding and side wall unit assembly welding need to be carried out respectively. Each process needs to be strictly controlled in order to ensure the overall dimen-sional accuracy. Through the analysis of the welding difficulties of the side wall unit, through the optimization of process parameters, the use of appropriate assembly tooling and reasonable welding sequence, the welding deformation of the side wall unit in the assembly welding process is effectively controlled, so that the process size and welding quality of the side wall unit are well guaranteed, which provides a reference for the subsequent assembly welding of similar side wall units.
摘要:Plasma-MIG hybrid welding was carried out on 5 mm thick 5083 aluminum alloy. The influence of wire feed speed on the weld appearance and properties of welded joints were studied. The microstructure of the joint was analyzed and the mechanical properties of the joint were tested. The results show that both wire feed speeds can obtain welded joints without obvious defects, and the reinforcement increases slightly when the wire feed speed improves. The dendrites in the weld zone of welded joints with wire feed speed of 9 m/min are smaller than those with wire feed speed of 7 m/min. The microhardness distribution of the welded joint is "W" shaped. The average hardness of weld zone and bond are lower than that of the base metal. The minimum hardness occurs in the bond that is 3 ~4 mm distant from the weld center. When the wire feed speed is 7 m/min, the joint softening is more obvious. Both tensile fractures of the joints at these two wire feed speeds occur near the bond. The tensile strength and elongation of welded joints at wire feed speed of 9 m/min are higher than those at 7 m/min.The fracture form is a typical toughness fracture.
摘要:A remote monitoring system of welding quality based on 5G communication is analyzed. This system can realize the remote real-time monitoring of the working status and location information of various welding equipment in multiple locations, obtain welding current, welding voltage, wire feed speed, gas flow and other information, and monitor the real-time data of welding process and realize the postweld traceability analysis, production quality control, production resources management and so on.