闪光对焊接头质量监控、判断的新方法

基于LabVIEW和Visual Bisic软件编制的高速采集和数据处理软件，把高速采集应用在闪光焊的焊接参数的采集中，得到了在50kHz采集频率下的焊接电流、焊接电压、烧化量等焊接质量参数的瞬时值；再根据在焊接过程中短路、断路、闪光时焊接电压、电流的特点，来判断焊接过程中的焊接状态，从而得到焊接过程加速阶段闪光率和低压Ⅱ阶段的闪光率；同时，通过数据处理，得到焊接总时间、焊接接头能量输入、烧化量。在此基础上，基于线性回归方法建立了焊接接头落锤质量和焊接过程特征量之间的关系方程，利用该方程．可以对接头的焊接质量进行预测和评判。     

细丝埋弧自动焊在吊车箱形梁焊接中的应用

针对手工电弧焊焊接吊车箱形梁时，存在生产率低，焊接质量差、焊材消耗大等问题，通过改用细丝埋弧自动焊焊接，大大提高了生产率和焊接质量，降低了生产成本。     

5号高炉stellite合金堆焊新技术

本文介绍了堆焊５号高炉（当时称新３高）ｓｔｅｌｌｉｔｅ合金阀前焊接参数的试验确定，选用及焊接试块的试制情况，探讨了ｓｔｅｌｌｉｔｅ合金的工艺性。试验表明，在堆焊象ｓｔｅｌｌｉｔｅ这样的对冷裂纹和热裂纹敏感性较大的合金时，只要选用适当的焊接方法和焊接规范，同查可获得得高质量的堆焊层；而且，在堆焊硬质合金这一领域，ＴＩＧ焊有很大的发展前途。     

水平固定管单面焊双面成形工艺的探讨

通过对管道焊接的研究，提出水平固定管单面焊时，采用小电流压低电弧的连弧焊接工艺，可达到双面成形的良好工艺性能。     

拼焊件的焊接方法及其成形性能

1前言 1967年，以TIG焊接的方式生产了一种汽车侧板，这一技术被看作重大事件。但是直到日本和欧洲汽车制造商于1985年将其用作制造汽车侧板和地面板时，这一技术才逐渐得到广泛的应用。介绍拼焊件的详细焊接方法和可成形性。     

马钢2 500m3高炉炉壳焊接工艺

通过对高炉炉壳采用的BBS03钢板进行焊接的工艺评定，确定了其焊接方法。焊后焊缝经超声波100％探伤检查，达到一级焊缝标准，外观检查为优，证明高炉炉壳的焊接工艺是可行的。     

不锈钢常用的焊接方法

对不锈钢最常用的焊接方法是手工焊(MMA)，其次是金属极气体保护焊(MIG／MAG)和钨极惰性气体保护焊(TIG)。虽然这些焊接方法对不锈钢工业的大多数人而言是熟悉的，但是我们认为这个领域值得深入探讨。     

STE355钢模拟焊接热影响区的组织与性能

采用模拟焊接热循环的方法，研究了单次热循环和多次热循环时，Ｔｍａｘ和ｔ８／５对ＳＴＥ３５５钢热影响区组织和性能的影响，为制定最佳焊接工艺参数提供依据。     

冶金电弧炉氧枪制作工艺研究

根据电炉氧枪具体的使用要求，通过对铜制枪头的锻压性能、切削性能分析，利用750kg空气锤、45^#钢模具制作毛坯，利用专用夹具、刀具车削“喉头出气孔”；通过对氧枪整体焊接性的分析，采用钨极氩弧焊(TIG)、涂抹活性剂法焊接枪头，攻克了枪头“喉口”过渡不圆滑、铜钢焊缝熔深浅，容易出气孔等难题，制定出了合理有效的加工工艺。     

日本采用激光法生产不锈钢及合金钢管材

随着世界石油、化工和汽车等行业的发展，对不锈钢管材的需求量也不断增加，而不锈钢无缝管已远远不能满足需求。随着激光焊接技术的发展，为不锈钢焊接钢管取代无缝管提供了条件，日本对不锈钢焊管特性进行试验分析，结果表明，不锈钢焊管采用不同的方法焊接可满足目标要求，逐步取代无缝钢管已势在必行。     

Performance Evaluation of Arc Welding Process Using Weld Data Analysis

Shielded metal arc welding (SMAW) and metal inert gas (GMAW) welding process are the two most widely used welding processes. These processes are widely used for the construction and fabrication purpose in almost all type of industries. Some of the important factors which govern the weld quality in these welding processes are welding power sources, role of shielding gas (for GMAW process), welding consumables and skill of the welders. Currently, effects of these factors are evaluated by examining the quality of the weld produced and not by monitoring how welding process is affected by change in these factors. This is an indirect method because actual contribution made by individual parameter in physical process is effectively ignored. Further, this is expensive and time-consuming as the assessment can be carried out only after the weld is completed. Hence, a procedure to assess the quality of welding process using the data acquired while welding is in progress is preferred to testing of the weld for this purpose. In both SMAW and GMAW processes, welding speed, voltage and current are important parameters that affect the quality of the welds. Among these, monitoring of welding speed is relatively easy; but monitoring voltage and current is not. This is because, welding is a stochastic process in which wide variation in voltage and current occurs and duration of these variations is so short that they are not observed in the voltage and current displayed in the power source. However, with the help of a high-speed data acquisition system, voltage and current variations during actual welding process can be recorded and subsequently analysed to reveal very useful information on the welding process, and subsequently quality analysis of individual welding parameters can also be done. In the present study, the voltage and current signals acquired using a digital storage oscilloscope have been used to study SMAW and GMAW processes. Data was acquired for duration of 20 s at a sampling rate of 100,000 samples/s while welding is in progress. In the case of SMAW process, welding data was acquired for welds made using different welding power sources, but with same welder and same type of electrode. In the case of GMAW process, welds were made using same wire and same welder but with different gases for shielding and at different set currents. Dynamic variation in the voltage and current signals were carefully studied using time domain and statistical analyses. Results showed that differences in the characteristics of the different power sources used for SMAW process and effect of shielding gases and arc current on GMAW process could be easily revealed by such analysis. For SMAW process, results obtained could also be correlated with the appearance of the weld beads. Hence, a procedure involving high-speed data acquisition of voltage and current signal while welding is in progress and the statistical analysis of the acquired data have been proposed for monitoring of these two arc welding processes.     

IDHB-GH型空压机转子的修复

对IDHB-GH型空压机转子推力盘与主轴的焊接性能进行了分析,采用快速、小电流、对称冷焊的焊接工艺,并在焊接全过程中采取振动时效处理,消除焊接应力,进行动平衡校验。实践证明,修复工艺可行,设备运行良好。     

Intelligent Modeling Combining Adaptive Neuro Fuzzy Inference System and Genetic Algorithm for Optimizing Welding Process Parameters

Modified 9Cr-1Mo ferritic steel is used as a structural material for steam generator components of power plants. Generally, tungsten inert gas (TIG) welding is preferred for welding of these steels in which the depth of penetration achievable during autogenous welding is limited. Therefore, activated flux TIG (A-TIG) welding, a novel welding technique, has been developed in-house to increase the depth of penetration. In modified 9Cr-1Mo steel joints produced by the A-TIG welding process, weld bead width, depth of penetration, and heat-affected zone (HAZ) width play an important role in determining the mechanical properties as well as the performance of the weld joints during service. To obtain the desired weld bead geometry and HAZ width, it becomes important to set the welding process parameters. In this work, adaptative neuro fuzzy inference system is used to develop independent models correlating the welding process parameters like current, voltage, and torch speed with weld bead shape parameters like depth of penetration, bead width, and HAZ width. Then a genetic algorithm is employed to determine the optimum A-TIG welding process parameters to obtain the desired weld bead shape parameters and HAZ width.     

K-TIG焊接中厚板的工艺窗口改进

针对穿孔深熔氩弧焊(K-TIG)工艺焊接8 mm厚Q235低碳钢板时焊接过程不稳定、焊接工艺窗口小等突出问题,首次提出在焊接工件背部铺加保护焊剂的方法改善焊接过程。采用对接焊的方式,在不开坡口、焊接过程不添加焊丝的情况下,达到单面焊双面成形的效果。最终成功的采用430～480 A范围内的直流电流对8 mm厚的Q235低碳钢进行了焊接,将焊接电流窗口扩大到50 A同时也显著的提高了焊接过程的稳定性。同时,在扩大焊接电流窗口之后,系统研究了不同焊接电流下焊接接头的组织性能。研究结果表明:在不同焊接电流下得到的焊接接头中,组织分布以及力学性能分布呈现出相同的状态。焊缝区的组织均由铁素体+珠光体+魏氏组织组成;熔合区由魏氏组织组成;热影响区由铁素体+少量的珠光体组成;此外随着焊接电流的增加,焊接接头背部的熔宽有略微增加;在焊接接头中,熔合区处硬度值最高,其次是焊缝区,之后是热影响区,母材的硬度值最低;焊接接头最终的拉伸断裂位置是在热影响区处。      

Comparative Study on Processing Property Between CWW CO2 Gas Shielded Welding and SAW

 Cable welding wire (CWW) CO2 gas shielded welding is an innovative process arc welding with high efficiency, high quality and low consumption, in which cable wire is used as consumable electrode. CWW CO2 gas shielded welding and submerged arc welding (SAW) are used for contrast studies on processing property of high strength steel A36 used in ship structure. The results show that the shapes of weld seam, using CWW CO2 gas shielded welding and SAW, are good and no weld defect such as air hole, flaw, slag inclusion, incomplete fusion, lack of penetration and so on are found in the weld seam. Because the rotating of arc during CWW CO2 gas shielded welding process has a strong stirring effect on molten pool, the grain in the heat affected zone (HAZ) of the joints, using CWW CO2 gas shielded welding, is small. Tensile failure positions of joints by CWW CO2 gas shielded welding and SAW are all in the base metal, but tensile strength of CWW CO2 gas shielded welding joint is higher than that of SAW joint by an average of 2. 3%. The average impact energy of HAZ, using CWW CO2 gas shielded welding and SAW, is almost equal, but the average impact energy of the weld seam using CWW CO2 gas shielded welding is increased by 6%, and the average impact energy of the fusion line is increased by 7%. The 180° bending tests for the joints of CWW CO2 gas shielded welding and SAW are all qualified, and the joints hardness is all less than HV 355, but hardness of CWW CO2 gas shielded welding wire welding joint near the fusion line is obviously lower. It can be concluded that the properties of CWW CO2 gas shielded welding are better than those of the SAW joint, and CWW CO2 gas shielded welding is suitable for welding high strength steel A36 used in ship structure.     

Intelligent Modeling Using Adaptive Neuro Fuzzy Inference System (ANFIS) for Predicting Weld Bead Shape Parameters During A-TIG Welding of Reduced Activation Ferritic-Martensitic (RAFM) Steel

Reduced-activated ferritic-martensitic steels are considered to be the prime candidate for structural material of the fusion power plant reactor design. Tungsten inert gas (TIG) welding is preferred for welding of those structural materials. However, the depth of penetration achievable during autogenous TIG welding is very limited and hence productivity is poor. Therefore, activated-flux tungsten inert gas (A-TIG) welding, a new variant of TIG welding process has been developed in-house to increase the depth of penetration in single pass welding. In structural materials produced by A-TIG welding process, weld bead width, depth of penetration and HAZ width decide the mechanical properties and in turn the performance of the weld joints during service. To obtain the desired weld bead geometry, HAZ width and make a reliable quality weld, it becomes important to develop predictive tools using soft computing techniques. In this work, adaptive neuro fuzzy inference system is used to develop independent models correlating the welding parameters like current, voltage and torch speed with bead shape parameters like weld bead width, depth of penetration, and HAZ width. During ANFIS modeling, various membership functions were used. Triangular membership function provided the minimum RMS error for prediction and hence, ANFIS model with triangular membership functions were chosen for predicting for weld bead shape parameters as a function of welding process parameters.     

25t转炉托圈裂纹的焊修工艺

山东冶金机械厂在对２５ｔ转炉托圈裂纹的焊修中，采用手工电弧焊，焊接顺序为先修轴头再修盖板。焊前钻止裂孔，加拘束连接板，预热；焊接时采取多层多道、分段焊接的方法；焊后分别进行去应力退火和整体回火处理，使焊补焊缝及表面质量达到Ⅱ级。     

Formability and strength of friction-stir-welded aluminum sheets

Friction stir welding was investigated as a viable process for joining thin aluminum sheets in order to manufacture tailored blanks. In the present study three alloys were tested: 5182-O, 5754-O, and 6022-T4. All three of these alloys are being used to fabricate stamped automotive parts. The gas tungsten arc welding process has been used to make aluminum-tailored welded blanks industrially, so results using this process were compared to FSW results. Blanks of the same gage of all three alloys were welded and then evaluated using tensile and formability testing. The 5xxx series alloys had similar tensile ductility and formability regardless of the welding process. However, the 6022-T4 sheets joined using friction stir welding had better formability than those joined using gas tungsten arc welding because friction stir welding caused less softening in the heat-affected zone.     

Multi-objective Optimization of Welding Parameters in Submerged Arc Welding of API X65 Steel Plates

Submerged arc welding(SAW)is one of the main welding processes with high deposition rate and high welding quality.This welding method is extensively used in welding large-diameter gas transmission pipelines and high-pressure vessels.In welding of such structures,the selection process parameters has great influence on the weld bead geometry and consequently affects the weld quality.Based on Fuzzy logic and NSGA-II(Non-dominated Sorting Genetic Algorithm-II)algorithm,a new approach was proposed for weld bead geometry prediction and for process parameters optimization.First,different welding parameters including welding voltage,current and speed were set to perform SAW under different conditions on API X65 steel plates.Next,the designed Fuzzy model was used for predicting the weld bead geometry and modeling of the process.The obtained mean percentage error of penetration depth,weld bead width and height from the proposed Fuzzy model was 6.06%,6.40% and 5.82%,respectively.The process parameters were then optimized to achieve the desired values of convexity and penetration indexes simultaneously using NSGA-II algorithm.As a result,a set of optimum vectors(each vector contains current,voltage and speed within their selected experimental domains)was presented for desirable values of convexity and penetration indexes in the ranges of(0.106,0.168)and(0.354,0.561)respectively,which was more applicable in real conditions.     

LF21薄板搅拌摩擦焊工艺研究及微观组织分析

采用搅拌摩擦焊接方法对厚度为1．5mm的LF21薄板铝合金板在进行焊接试验,首次提出搅拌头旋转速度为5000r／min时的焊接工艺,实验结果表明：在焊接速度为70～105mm／min,压入量适中,并采用喷气冷却,可以获得较好的焊接接头,抗拉强度达到最大值111．530MPa。焊缝中存在3个组织变化区,其中焊核区内是细小均匀的等轴晶,焊缝两侧热机影响区组织存在较大差异,热影响区组织发生了回复、再结晶和粗化。