摘要:As a key technology in the manufacturing process of marine engineering equipment, ships, nuclear power pipelines and other fields, the thick plate welding quality determines the safety performance and service life of the equipment.Narrow gap submerged arc welding and narrow gap gas metal arc welding arewidely applied to the welding of plate with the thicknessof more than 20 mm,their higher heat input and high residual stress in the joints limit their application in welding of thick steel plate with high heat sensitivity.Laser welding has the advantages of high energy density, small heat-affected zone, small welding deformation, andsoon, whichis fit for welding of thick steel plate. Laser welding, laser welding with filler wire and laser-arc hybrid welding for narrow gap joint were introduced, their characteristics and problems were analyzed. Among them, laser-arc hybrid welding has the characteristics of higher welding efficiency, higher deposition rate and less thermal damage, which is one of the proper methods to weld thick plate.Atlast,the development prospect of laser welding technology in the weldingmanufacturing of thick plate were summarized and proposed.
关键词:narrow gap laser welding;thick plate;laser welding;laser-arc hybrid welding
摘要:The CuCrZr alloy possesses excellent thermal and electrical conductivity, as well as good mechanical properties, making it an important material for aerospace, nuclear reactor components, and other fields. This study analyzes the forming performance of CuCrZr alloy prepared by selective laser melting (SLM), focusing on the effects of three main process parameters—laser power, scanning speed, and scanning spacing—on the alloy’s density, microstructure, and microhardness. The research indicates that the pores in SLM-formed CuCrZr alloys are primarily caused by incomplete powder melting and gas pores. As the volumetric energy density increases, the pore type gradually transitions from powder melting incompleteness to gas pores. The alloy exhibits higher density when the scanning spacing is 0.12 mm compared to 0.09 mm. The optimal process parameters are 360 W laser power, 800 mm/s scanning speed, 0.12 mm scanning spacing, and 0.03 mm layer thickness, achieving a density of 99.30% with a volumetric energy density of 125 J/mm3. The microstructure of the alloy features large grains surrounding smaller grains, with irregular and randomly distributed grain shapes, reflecting the anisotropy of grain growth caused by the non-uniform temperature field during SLM forming. The microstructure morphology differs significantly in different building directions, with equiaxed grains dominating on the XY plane, while the XZ plane shows a large number of columnar grains growing along the building direction. Additionally, the process parameters have a minimal impact on the microhardness value of SLM-formed CuCrZr alloys, with density exerting a more significant influence on hardness. Higher hardness values are observed in areas with finer or elongated grain aggregation. SLM technology can be utilized to fabricate high-performance CuCrZr alloys, and optimizing process parameters can result in high density, fine and uniform microstructure, and high hardness.
摘要:Iron-chromium gradient coatings were prepared on 45 steel substrates using laser cladding technology to address the wear issue of screw drills. To tackle the common cracking problem during the cladding process, an optimization strategy was proposed to regulate the powder composition of the gradient coatings. Gradient hardness was achieved using cladding powders with different carbon contents, and the interface bonding was improved by introducing a JG-3 transition layer. The study revealed that the gradient coatings exhibited a gradual increase in hardness and enhanced wear resistance. The JG-3 transition layer effectively promoted the interfacial bonding between the substrate and the cladding layer, connecting different hardness layers and preventing cracking. Fracture morphology analysis indicated that the cladding layer exhibited typical “river pattern” cleavage fracture characteristics. Irregular metal oxides could tear the cladding layer matrix, significantly reducing its performance. Therefore, surface polishing of each layer after cladding is recommended to ensure complete removal of interfacial oxide layers. The prepared iron-chromium gradient coatings maintained a smooth and crack-free interface, providing an effective solution and basis for addressing cracking issues during the cladding process of gradient coatings.
摘要:For the large-scale welding equipment production site, due to the lack of data in the production process of welding equipment, complex business processes, and lack of information management and control in the welding process, the information transmission efficiency is low and errors are prone to occur. It is urgent to strengthen the information construction of the monorail frame welding in the production management link. This paper introduces an intelligent welding group control system for monorail frames based on industrial LAN, big data and cloud platform. The real-time monitoring and network management of manual and automatic welding machine state are carried out. At the same time, the problem that manual welding parameters can not be automatically matched is solved. It improves the automation and intelligence level of welding equipment, and realizes efficient and intelligent welding information management.
关键词:monorail frame;welding;intelligent control system;parameter matching
摘要:In the welding crack detection of mechanical parts, because the welding boundary is interfered by reflection wave in the acquired image, there is fuzzy noise, which leads to inaccurate detection. In order to solve this problem, based on the principle of shape basis invariance in boundary morphology, a non-destructive image detection method for welding cracks of mechanical parts considering morphological characteristics was proposed. In this method, machine vision technology is used to collect the visual image of mechanical parts welding, and the fuzzy noise caused by optical interference is filtered by illumination reflection model and Fourier transform. The low frequency approximate component and high frequency detail component are constructed by the two-layer wavelet decomposition. By introducing morphological algorithm, taking structural elements as the core, through corrosion and expansion treatment, and optimization by optimizing corrosion frequency and homomorphic filtering, the morphological characteristics of welding cracks of mechanical parts are extracted, and the non-destructive detection of welding cracks of mechanical parts is realized. The experimental results show that the visual image collected by the proposed method is clearer, and the crack morphological characteristics and cracks can be effectively extracted. The detection location of welding cracks in mechanical parts is basically consistent with the actual location, and the error is only 0.01, indicating that the detection accuracy of the proposed method is high.
关键词:welding of machine parts;machine vision;homomorphic filtering;image correction;wavelet;morphological characteristics
摘要:In this paper, the surface quality, microstructure, internal texture and mechanical properties of three ERNiCrMo-3 welding wires at home and abroad were compared and studied. The results showed that the average relaxation diameter of the three welding wires was small, and the inclusion size of the 3# ERNiCrMo-3 welding wire was the smallest (0.047mm) among the three welding wires, and the inclusion area in 1# was 49.9% smaller than that of 2# (0.533%). Twin microstructure appeared in all three ERNiCrMo-3 wires, and the twin boundary accounted for the largest proportion (9.02%) in 1#, and the 3# (1.85%) with the fewest twin boundary was nearly 79.49% less than 1#. The three welding wires of 1#, 2#, and 3# all have obvious preferred orientation in the {111} and {110} crystal faces, and the texture density of the {111} crystal faces of 3# reaches a maximum of 23.75. The 3# with the largest tensile strength (1537MPa) is nearly 40.6% higher than the 1# (domestic) with the smallest tensile strength, and the grain boundary strengthening in 3# contributes 324.48MPa.
摘要:The high Mn content poses challenges for the welding of medium-Mn low-temperature steel, which to some extent limits its application in industrial production. Welding experiments were conducted on medium-Mn low-temperature steel using argon-rich mixed gas shielded welding to study the changes in microstructure and mechanical properties of welded joints under different heat input conditions. The results show that, except for the weld and base metal, all areas of the welded joint are localized hardening zones, and the degree of hardening increases with the increase of heat input; When the heat input increases from 12 kJ/cm to 22 kJ/cm, the yield strength of the welded joint decreases from 820 MPa to 775 MPa, and the tensile strength decreases from 983 MPa to 925 MPa; When the heat input is 12 kJ/cm and 16.8 kJ/cm, the welded joint has excellent impact toughness under -40 ℃ conditions, and the impact absorption energy in each area of the welded joint is relatively uniform, around 45 J; The small inclusions and acicular ferrite in the weld zone provide a large number of high-angle grain boundaries(HAGBs) slow down the crack propagation rate. The residual austenite with low stability in the heat-affected zone(HAZ) undergoes transformation-induced plasticity(TRIP) effect under impact load, which improves the low-temperature impact toughness of welded joints.
关键词:medium-Mn low-temperature steel;argon-rich mixed gas shielded welding;heat input;residual austenite
摘要:PPCA-TIG welding as a high-efficiency welding method improves the utilisation of active elements on the surface of the molten pool, but there is still a gap in the understanding of the physical behaviour of this arc. In order to elucidate the distribution characteristics of active elements in the arc and the influence law on the physical behaviour of the arc in PPCA-TIG welding, this paper intends to adopt the spectroscopic method, design the arc airspace point-by-point scanning synchronous acquisition system, and use two active agents, CaF2 and MnCl2, to calculate the electron density of the arc by using the Stark spectral line method, and the distribution characteristics of the Ca and Mn elements are discussed. The results show that under the same parameters, the addition of MnCl2 and CaF2 active agents can significantly increase the overall arc ionisation, and can significantly increase the electron density of the arc. Under the condition that the heat input is kept unchanged, the increase in electron density leads to an increase in current density, and the heat on the surface of the molten pool is more concentrated, thus increasing the weld depth.
关键词:PPCA-TIG welding;electron density;arc spectroscopy;arc temperature
摘要:The brazing joint of quartz glass/TC4 titanium alloy was brittle. to solve this problem, The vacuum brazing of quartz glass /AgCuTi/TC4 titanium alloy was carried out by adding Cu buffer layer in the weld. The effects of Cu buffer layer and different brazing processes on the microstructure and mechanical properties of SiO2/TC4 joint were analyzed. The results shows that: At the right brazing temperature, The addition of Cu buffer layer can form TiSi2+Ti4O7/Cu2Ti4O at the interface of SiO2/AgCuTi, and form a large amount of Cu solid solution in the weld, which can reduce the residual stress of the joints, and then improve the mechanical properties of the brazed joint. When the brazing temperature is 900 ℃ and the holding time is 10 min, the shear strength of the brazed joint with Cu buffer layer is the highest, reaching 38 MPa.
摘要:To solve the poor accessibility of narrow hole inner wall surfacing and enhance the wear resistance of 304L stainless steel, a layer of stellite 6 wear-resistant coating with a thickness of approximately 2.5 mm, density of 99.9981%, and free of cracks and unfused defects was deposited on the inner wall of a 304L narrow hole with a depth of 30 mm and diameter of 14 mm using laser metal deposition. The microstructure, phase composition, hardness distribution, and wear resistance of the wear-resistant layer were systematically investigated through micro-nano CT, XRD, metallographic examination, hardness testing, and friction wear testing. The results revealed that the stellite 6 wear-resistant layer was dense and defect-free, with its microstructure transitioning from planar crystals at the bottom to cellular crystals, dendrites, and equiaxed crystals at the top. The phase composition mainly consists of γ-Co, M23C6, CoCx, and (Cr,Fe)7C3, etc. Various elements are evenly distributed near the fusion line, with no significant aggregation. The average microhardness of the wear-resistant layer is 2.38 times that of the 304L matrix, and the microhardness values at different heights of the narrow hole are relatively stable. The wear rate of the wear-resistant layer is 29.3% lower than that of the 304L matrix, indicating excellent wear resistance. This study provides a basis for the application of laser metal deposition wear-resistant coatings on large depth-width ratio inner hole walls in industries such as nuclear power and energy.
关键词:laser metal deposition;narrow hole inner wall;Stellite6 alloy;microstructure and properties;wear-resistant layer
摘要:Aluminum alloy E600 and galvanized steel DP590D+Z for automotive body were tested by laser wire welding at different welding speeds. ER4047 wire was selected as welding material. The weld morphology, intermetallic compound layer thickness and mechanical properties were analyzed at different welding speeds. The test results show that the brazing joint with defects free and certain tensile strength can be obtained by laser wirefusion brazing with appropriate welding parameters. In order to ensure the performance of the weld joint, it was necessary to control the intermetallic compound thickness of FeAl2 and FeAl3 at the interface. With the increase of welding speed, the line energy and the intermetallic compound thickness decreased.On the basis of meeting the requirements of aluminum and steel dissimilar metal welding forming, the welding speed can be selected as far as possible to control the thickness and ensure the performance of the joint. Considering the linear load of the joint and production efficiency,the optimal welding speed was 1.5 m/min. The linear load was about 197 N/mm,and the converted strength of aluminum alloy was 219 MPa,which was equivalent to 81% of the strength of the base metal.
摘要:The microstructure and mechanical properties of friction stir welded butt joints of aluminum-copper dissimilar metal sheets at different rotational speeds (1600~2000 r/min) were studied, which provided a reference for the development of copper-aluminum thinner composite components. Under the condition of 1600~2000 r/min, the friction stir welding ( FSW ) method was used to weld the copper-aluminum sheet. After the welding was completed, the macroscopic morphology of the welded joint was observed by metallographic microscope. The microstructure of the welded joint was observed by scanning electron microscope ( SEM ). The element change of the welded joint was studied by X-ray energy dispersive spectrometer ( EDS ). The phase of the intermetallic compounds ( IMCs ) was studied by X-ray diffractometer ( XRD ). The microhardness of the welded joint was studied by micro Vickers hardness tester. The tensile properties of welded joints were studied by tensile testing machine. It is found that the welded joints with good surface quality can be obtained at different rotational speeds (1600~1800 r/min). When the rotational speed is further increased, the surface quality is further improved. Complex microstructure was produced at the interface of aluminum matrix and copper matrix, and two intermetallic compounds, Al2Cu and Al4Cu9, were produced. With the increase of rotational speed, the thickness of IMCs also increased. The peak value of microhardness appears in the weld nugget zone, and the average microhardness is higher than that of the copper side and the aluminum side. The fracture modes of the joints at different rotational speeds are all in the form of ductile-brittle mixed fracture, and the fracture positions are all broken at the copper-aluminum butt joints. When the welding speed is 30 mm/min and the rotation speed is 1 800 r/min, the surface quality of the joint is the best and the interface structure is the best. The thickness of the IMCs is 2.65 μm, and the tensile strength of the joint can reach the maximum, which is suitable for the development of thin copper-aluminum composite components.
摘要:With regard to the fatigue life and solder joint arrangement of flanged end-face flanges, if the solder joint arrangement scheme of the workpiece is designed according to the welding standard, the performance of the workpiece material may not be fully developed, if there are too few solder joints in some dangerous areas, it will lead to welding failure, too many solder joints will lead to the destruction of material properties, welding costs increase. Therefore, according to the relationship between the fatigue life and the number of flanged solder joints, the layout of flanged solder joints was optimized to improve the fatigue life of flanged solder joints. Firstly, the layout of flanged end-face anti-looseness solder joint is designed. Secondly, a finite element model of anti-looseness welding was established based on Ansys. Gauss heat source model was used as the heat source of anti-looseness welding model by analyzing the heat flux distribution during the welding process. Based on the analysis of the solder joint model of flanged flanges, the maximum strain of different solder joint arrangement of flanged ends is obtained. Finally, the fatigue life prediction model of solder joint is established, and the fatigue life of solder joint is predicted and solved according to the strain, the data were fitted with Gauss curve to establish an optimization function. The fitting optimization results show that when 24 inner ring solder joints and 30 outer ring solder joints simultaneously act on the anti loosening sheet, the fatigue life of the solder joints can be well maintained.
关键词:resistance spot welding;fatigue life;optimization of solder joint distribution
摘要:With the continuous advancement of new energy technology, the production efficiency of new energy storage module equipment has become particularly important. A solution based on scanning laser flight welding technology is proposed. This solution involves the design of coherent production equipment and the introduction of scanning laser flight welding technology. Scanning laser flight welding technology offers advantages such as non-contact operation, high precision, and dynamic running, which can effectively reduce processing time, improve product quality, lower labor costs, and promote the development of the new energy industry. This paper mainly discusses the production equipment, process route, and advantages of scanning laser flight welding for new energy storage modules. Through on-site debugging and process testing, the core technology of scanning laser flight welding has been mastered, enabling the stable and efficient application of new energy storage modules. The feasibility of this technology in the production process of new energy storage modules has been verified.
关键词:galvanometer laser welding technology;new energy storage module;process route;flight welding
摘要:The bimetal bandsaw blade is welded with M42 high-speed steel tooth material and B2000 high-strength steel back material. The tooth material has high red hardness and strength, while the back material has good toughness. However, welding can easily generate thermal stress, affecting the performance of the weld. This study investigates the microstructure evolution and element distribution of the welded joint of the bimetal bandsaw blade after annealing at 820℃ (in a annealing furnace) and then cooling with the furnace. The results show that the microstructure of the weld evolves from columnar grains to spheroidized carbides after annealing. Alloying elements such as Mo, Cr, V, and W form carbides with C and gradually spheroidize, leading to the agglomeration of alloying elements at the joint. Moreover, the increased element diffusion coefficient during annealing causes the elements in the base metal of the bimetal bandsaw blade to diffuse into the weld, forming M6C, M23C6, and MC type carbides, which reduce the hardness of the weld. This research provides a theoretical basis for the optimization of the annealing process of the welded joint of bimetal bandsaw blades, which can help improve the quality and service life of bimetal bandsaw blades.
关键词:bimetal bandsaw blade;annealing;welded joint;carbide spheroidization;element distribution
摘要:Stainless Steel Electron Beam Welding is often considered the optimal upgrade for manual GTAW welding. However, in some welding structures with shear strength requirements, the narrow characteristics of electron beam welds may affect their load-bearing performance. Since the welds of nuclear fuel cylinder components need to withstand long-term high temperature and pressure, radiation creep stress, and chemical corrosion in the reactor core, the shear load-bearing performance of electron beam welds has been questioned by experts. To ensure the reliability of the core product welding structure, the geometric dimensions and load-bearing area of electron beam (EB) welds and manual GTAW welds were first compared and analyzed, and it was found that the width of EB welds is only 53.5% of GTAW welds, and the load-bearing area is only 48.8% of GTAW welds. Then, through theoretical calculation and working condition analysis, it was concluded that the maximum load-bearing capacity of the cylinder component weld is 134,765 N, and the theoretical load-bearing capacity of both EB and GTAW welds is much greater than this value. Finally, through physical testing, it was found that the load-bearing performance of EB and GTAW welds is equivalent and both are greater than the load-bearing capacity of the cylinder component itself. It was ultimately proven that the EB welds can meet the design requirements for product load-bearing performance under normal and accident conditions, providing support for the smooth advancement of research on the localization of nuclear fuel.
摘要:With the intensification of global market competition, the tower crane manufacturing sector is facing challenges such as low cost, short cycle, and high quality. Herein, an automated welding production line for tower crane piece standard sections is introduced. This production line integrates robotic technology, welding technology, automation technology, simulation technology, and fixture design technology, effectively enhancing the quality and stability of welding, reducing labor requirements, improving production efficiency, and reducing costs. The composition, layout, process division, and rhythm calculation of the production line are detailed, along with key technologies such as simulation technology, robot body technical parameters, starting point detection, and seam tracking functions. Practical production verification has shown that the production line meets the needs of efficient production and demonstrates the applicability of robots in the automated production of heavy workpieces. Finally, the direction for optimizing this automated welding production line is pointed out, including reducing investment costs, improving production flexibility, and enhancing the overall equipment effectiveness (OEE) of the production line, which can provide guidance and reference for the automated production of tower crane standard sections.
关键词:welding automation;arc welding robots;production line planning;simulation;tower crane standard sections
摘要:The failure analysis of the sealing face and shaft hole of the three-eccentric butterfly valve serviced in a coal mine gas extraction system was systematically investigated and the main failure mechanical was homogeneous corrosion. This failed three-eccentric butterfly valve is serviced in the high temperature gas rich in liquid and highly corrosive gas (H2S, CO2, SO2). Based on this, the sealing face and shaft hole is suggested to plasma cladding with stellite 12 alloy. Microstructure observation, chemical composition and microhardness tests were performed to evaluate the cladding layer. The results show that the stellate cladding layer is consisted of cellular dendrites. The cladding layer is free from cracks and pores, showing good bonding with the base metal. The cellular structure is Co-based solid solution. The net structures rich in Cr element (Cr-based solid solution and chromium carbides) present continuous distribution among these cellular structures. Some W rich structures composed by W2C and Co-based solid solution are distributed in the net structure. The microhardness of the stellite cladding layer is 375~450 HV0.3, which is higher than the base metal (100~150 HV0.3) and the original stainless steel sleeve (200~250 HV0.3). The repaired butterfly valve has been in service for 4 months in the coal mine without failure, while the new butterfly valve failed after only 1 month of service. It is proved that the plasma cladding of stellite 12 alloy on the sealing face and shaft hole has well protected the substrate.
摘要:This paper conducts an in-depth analysis of the transverse crack issues in the R337 butt weld of the high-pressure main steam valve and high-pressure regulating valve after the through-flow transformation of a certain unit. By observing on-site cracks, analyzing samples, and evaluating material performance, the main causes of crack formation were determined. Firstly, the improper selection of the R337 welding material led to an increase in the brittleness of the weld. Secondly, the superimposed effects of structural stress and alternating stress accelerated the expansion of the cracks; the high carbon equivalent of ZG15Cr1Mo1V steel makes it prone to cold cracking, and the addition of Nb elements increases the sensitivity to reheat cracking. Based on the causes of crack formation, treatment suggestions were put forward, which include the thorough removal of the original R337 weld and the repair with a lower-matched R317 welding rod; during the welding process, strict control of preheating temperature, interlayer temperature, and welding line energy is required to reduce welding stress; post-weld heat treatment by induction heating is carried out to evenly distribute the temperature field and fully relieve stress; considering the reheat cracking tendency of ZG15Cr1Mo1V steel, appropriate preventive measures are recommended during the repair process. This study not only provides technical basis for the repair of high-pressure main steam valve welds but also offers references for similar material and structural welding repair work.
摘要:During the operation of a supercritical boiler in a certain power plant, it was found that the T91/TP347H dissimilar steel welded joint at the outlet of the high-temperature reheater had fractured, causing a boiler leak. A series of tests were conducted on the failed welded joint, including macroscopic morphology observation, chemical composition analysis, metallographic examination, and hardness testing. Combined with the operating conditions and historical fault history of the boiler, a comprehensive analysis was made of the failure causes of the dissimilar steel welded joint. The results showed that poor weld formation and unqualified welding quality were the direct causes of the joint cracking; the large chemical composition difference and uneven performance of the dissimilar steel joint itself, under long-term high temperature and stress, led to element migration, resulting in a decline in interface performance, which is the fundamental reason for the cracking of the welded joint; the deep peak shaving and frequent start-stop peak shaving of the unit further accelerated the generation of cracks. Based on the failure cause analysis, and drawing on the management standards and practical experience of dissimilar steel welded joints, subsequent maintenance inspection and metal supervision strategy optimization suggestions were put forward, which can provide a reference for the management of dissimilar steel welded joints in similar power plants.
摘要:This article takes the course of 《Welding Robot Skills Training》in the intelligent welding technology major as an example to realize the close integration of knowledge transmission, ideological and political education, quality education and ability cultivation through innovation design of teaching projects. In the process of teaching implementation, we can explore the ideological and political points contained in the curriculum, integrate ideological and political themes of “ Reflection on the spirit of craftsmanship, Defending quality and safety, Aspiration skills for serving the country”. We can put professional concepts “Patriotic sentiment, Professionalism, Professional spirit, Outlook on life, Values, Rigorous and meticulous, Striving for perfection” into the class in a subtle and silent way of moistening things. We can standardize student behavior through regulations, stimulate students’ potential through activities, set some role models in the process of students’ growth, then use role models to guide their growth,and achieve teaching objectives of “ Solid foundation, Mastery skills, Skilled in innovation” effectively.
关键词:welding robot;ideological and political education in the course;spirit of craftsmanship;striving for perfection
摘要:In order to further improve the professional literacy and innovation ability of welding major students, this paper analyzes the three current situations in welding teaching: "unclear learning objectives", "difficult interdisciplinary studies", and "unplanned career paths". The three intelligent welding ideological and political education approaches of "tracing the past", "grasping the present" and "exploring the future" are proposed. Aim to inherit the fighting spirit of the older generation of welding workers, integrate existing resource reform education methods, and cultivate students' innovative spirit. To achieve the organic integration of specialized education in intelligent welding and ideological and political education, explore effective ways of talent cultivation under the background of new engineering disciplines, and contribute to the strategy of strong marine country.
关键词:new engineering;intelligent welding;ideological and political education