等离子弧焊接熔池和小孔形成过程数值分析

目的 研究等离子弧焊接穿孔过程中熔池内部的金属流动情况和小孔动态变化过程。方法 通过“传热-熔池流动-小孔”之间的相互耦合关系,建立了等离子弧焊接穿孔过程的数值分析模型,通过VOF方法追踪了小孔界面,采用FLOW-3D软件模拟了等离子弧焊接熔池和小孔的形成过程,定量计算了等离子弧焊接温度场、熔池流场及小孔形状;分析了等离子弧焊接熔池和小孔行为;并通过等离子弧焊接实验数据验证了模拟结果。结果 当焊接时间为0~1.0 s时,小孔深度曲线与熔深曲线几乎相同,小孔底部紧贴熔池底部;在2.8 s以后,小孔深度曲线与熔深曲线有一定距离,小孔深度曲线在一定范围内波动,等离子弧焊接电弧挖掘作用到达极限,电弧压力与其他力达到平衡状态。模拟的焊缝熔深为8.04 mm、熔宽为13.20 mm,实验测得的焊缝熔深为8.00 mm、熔宽为13.42 mm。结论 构建的随小孔动态变化的曲面热源模型和电弧压力模型可以描述等离子弧焊接过程中的电弧热-力分布;模拟出了等离子弧焊接熔池和小孔动态演变过程;模拟得到的等离子弧焊接焊缝形貌与实验测得的焊缝形貌基本吻合。     

2219高强铝合金活性TIG焊工艺

采用单组分活性剂(AlF_3和LiF)、3组分(AlF_3+30%LiF+10%KF-AlF_3)和4组分(AlF_3+30%LiF+10%KFAlF_3+10%K_2SiF_6)混合组分活性剂进行2219高强铝合金直流正极性活性TIG焊(DCSP A-TIG),研究4种类型活性剂对焊缝表面成型、焊缝内部质量(气孔)、焊缝熔深、电弧形态、接头组织与力学性能的影响。结果表明:涂覆活性剂有助于去除2219铝合金表面的氧化膜,提高焊缝表面成型质量,涂覆4组分活性剂的DCSP A-TIG焊缝表面成型质量最佳;与变极性TIG焊(VPTIG)焊缝内部质量相比,DCSP A-TIG焊接方法可显著降低2219铝合金焊缝内部气孔的产生;AlF_3单组分活性剂可显著增大焊缝熔深,其电弧形态具有明显的拖弧现象;DCSP A-TIG焊焊缝组织具有与母材相同的组织组成物,电流对A-TIG焊缝组织影响较大,增大焊接电流,会造成接头晶粒组织粗大;涂覆4组分活性剂的DCSP A-TIG接头强度和伸长率最高,与VPTIG焊接头力学性能具有相近的技术指标。2219高强铝合金的DCSP A-TIG焊接方法具有很大的工程应用价值。     

粉煤灰/二氧化硅活性剂在Q235钢A-TIG焊中的应用

为了探究粉煤灰作为A-TIG焊活性剂的可行性,以粉煤灰和不同含量的二氧化硅制备复合活性剂在Q235钢基体表面进行A-TIG焊,研究了复合活性剂成分含量对焊缝截面形貌、显微组织和元素分布的影响.结果表明:采用粉煤灰-40%SiO_2作为复合活性剂进行A-TIG焊时,可将6 mm厚Q235钢板一次性焊透,焊缝深宽比可达到0.85;焊缝出现明显的中间收缩倾向,呈"深口杯"状,可实现单道焊双面成型的效果;其焊缝柱状晶数目较多、组织排列规则且具有方向性,熔合区和热影响区组织均匀细小,可降低焊接母材的过热倾向;相对于100%SiO_2活性剂,Si元素的溶入量和溶入深度显著增加,这说明粉煤灰中其他成分的存在对Si元素溶入焊缝、进而增加焊缝熔深起到促进作用.采用粉煤灰-40%SiO_2为活性剂进行A-TIG焊时焊缝熔深的增加机理可能是以电弧收缩理论为主,但考虑到Al元素溶入较深且溶入量较多,粉煤灰中其他物相又十分复杂,在高温电弧作用下各物相之间相互反应放热致使电弧热输入增加、其他组分在熔池中改变了熔池表面张力温度梯度等均可能致使焊缝熔深增加.     

粉煤灰复合活性剂在A-TIG焊中增加熔深的机理研究

为实现对工业废弃物粉煤灰的剩余价值利用,尝试以粉煤灰作为主要原料制备焊接复合活性剂,并在AZ91镁合金板上进行A-TIG焊.利用焊缝的电特性实时采集、焊接温度场采集、电弧力测试等手段研究活性剂对电弧影响,通过熔池Bi粒子示踪实验探究活性剂对表面张力温度梯度影响.结果 表明:与常规TIG焊相比,粉煤灰复合活性剂可以使焊缝熔深增深1.4倍,熔宽减小,深宽比是常规TIG焊的1.43倍.粉煤灰复合活性剂中氟化物的解离和电离吸热过程、带电粒子的电子扩散和复合过程可以促进电弧收缩,使焊接电压升高,热输入量提高.而活性剂中的氧化物既可以通过对电弧的机械压缩作用强迫电弧收缩,又可以通过电离产生的氧元素实现对熔池液态金属表面张力温度梯度系数的改变,提高熔池中心热输入.A-TIG焊AZ91镁合金熔深增加是电弧收缩理论和表面张力温度梯度改变理论共同作用的结果.     

Research on the Mechanism of Penetration Increase by Flux in A-TIG Welding

The mechanism of penetration depth increased by activating flux in activating tungsten inert gas (A-TIG) weldingwas studied by measuring the distribution of trace element Bi in the weld and monitoring the change of arc voltageduring A-TIG welding of stain     

活性剂增加不锈钢A-TIG焊熔深机理研究

目的研究涂敷活性剂条件下1Cr18Ni9Ti奥氏体不锈钢的熔深增加机理。方法采用B1活性剂,涂敷在1Cr18Ni9Ti奥氏体不锈钢表面,进行A-TIG焊试验,分析活性剂对电弧形貌、阳极斑点、电弧电压和焊缝熔深的影响情况。结果涂敷活性剂后,电弧和阳极斑点都发生了收缩,电弧宽度由4.97 mm变为4.12mm,减小了17.1%,阳极斑点长轴长度由9.92 mm变为8.22 mm,短轴长度由4.75 mm变为4.35 mm,电弧电压提高了2.7 V,阳极区和弧柱区收缩,提高了弧柱电场强度;相同参数下,涂敷活性剂后熔宽缩小0.62mm,熔深增加了3.01 mm,显著增加熔深。结论阳极斑点收缩和电弧收缩是活性剂增加不锈钢A-TIG焊熔深的主要原因。     

粉末熔池耦合活性TIG焊接方法

提出了一种新型活性焊接方法——粉末熔池耦合活性TIG焊(Powder pool coupled activating TIG welding,PPCATIG)。该方法采用双层气体进行焊接,内层利用惰性气体保护钨极,外层通过自动送粉装置将活性剂粉末随保护气体送入电弧-熔池区域,增加熔深,提高焊接效率,实现机械化自动化焊接。针对SUS304不锈钢进行了直流正接PPCA-TIG表面熔深,通过与传统TIG焊对比,研究了SiO_2活性剂对电弧形态、焊缝成形、组织和力学性能的影响。结果表明:SiO_2能使电弧等离子体收缩、熔池金属流态改变,并且焊缝熔深能达到传统TIG焊的3倍以上,焊接效率明显提高。焊缝组织主要为奥氏体和铁素体,铁素体形态以骨架状为主。焊缝抗拉强度略低于母材,但相比传统TIG焊,焊缝屈服强度略有提高,其焊缝低温冲击韧性达到了传统TIG焊的96.8%,表现出了良好的力学性能。同时,采用该方法可有效避免活性剂粉末对钨极的污染。     

等离子+缆式焊丝脉冲GMAW复合焊熔池流体行为研究

目的 研究等离子+缆式焊丝脉冲GMAW复合焊过程的熔池流体行为.方法 综合考虑传热学以及流体动力学,建立Fluent数值分析模型.使用双椭球–锥体热源模型代表等离子弧焊传热模型,用双椭球热源表征GMAW电弧传热并考虑熔滴传热,同时考虑熔池受到的电磁力、浮力、表面张力、等离子流力等作用力.基于Fluent软件,对复合焊过...     

Numerical simulation of fluid flow and temperature field in keyhole double‐sided arc welding process on stainless steel

Double‐sided arc welding process powered by a single supply is a type of novel high‐production process. In comparison with the conventional single‐sided arc welding, this process has remarkable advantages in enhancing penetration, minimizing distortion and improving welding production. In this paper, a three‐dimensional steady numerical model is developed for the heat transfer and fluid flow in plasma arc (PA)–gas tungsten arc (GTA) double‐sided keyhole welding process. The model considers the surface tension gradient, electromagnetic force and buoyancy force. A CCD camera is used to observe the size and shape of the keyhole and weld pool. The acquired images are analysed through image processing to obtain the surface diameters of the keyhole on the two sides. A double‐V‐shaped keyhole geometry is then proposed and its characteristic parameters are derived from the images and cross‐section of weld bead. In the numerical model, the keyhole cavum within the weld pool is treated as a whole quality, whose temperature is fixed at the boiling point of the workpiece material. The heat exchange between the keyhole and weld pool is treated as an interior boundary of the workpiece. Based on the numerical model, the distributions of the fluid flow and temperature field are calculated. A comparison of cross‐section of the weld bead with the experimental result shows that the numerical model's accuracy is reasonable. Copyright © 2005 John Wiley & Sons, Ltd.     

Numerical investigation of droplet impact on the welding pool in gas metal arc welding

A transient three‐dimensional model that describes physical phenomena inside a welding pool during gas–metal arc welding process is presented. The model considers such phenomena as heat‐mass transfer, electromagnetics, hydrodynamic processes and deformation of the weld pool free surface. The fluid flow in the weld pool is induced due to the presence of the mechanical impact of the droplets, thermo‐capillary surface tension, thermal buoyancy and electromagnetic forces. The weld pool surface deformation is calculated by considering arc pressure and droplet impact force. A comparative analysis of the impact of the electric current of the welding arc and different force factors causing the motion of liquid metal in the weld pool on the shape of the welded seam was carried out and discussed.     

Genetic-Algorithm-Based Computational Models for Optimizing the Process Parameters of A-TIG Welding to Achieve Target Bead Geometry in Type 304 L(N) and 316 L(N) Stainless Steels

The weld-bead geometry in 304LN and 316LN stainless steels produced by A-TIG welding plays an important role in determining the mechanical properties of the weld and its quality. Its shape parameters such as bead width, depth of penetration, and reinforcement height are decided according to the A-TIG welding process parameters such as current, voltage, torch speed, and arc gap. Identification of a suitable combination of A-TIG process parameters to produce the desired weld-bead geometry required many experiments, and the experimental optimization of the A-TIG process was indeed time consuming and costly. Therefore it becomes necessary to develop a methodology for optimizing the A-TIG process parameters to achieve the target weld-bead geometry. In the present work, genetic algorithm (GA)-based computational models have been developed to determine the optimum/near optimum process parameters to achieve the target weld-bead geometry in 304LN and 316LN stainless steel welds produced by A-TIG welding.     

TIG焊接熔池表面变形对流场与热场的影响

利用流体力学理论和变分法原理,根据熔池本身重力、电弧压力和表面张力之间的动态平衡,推导出了 TIG 焊接熔池表面变形的计算公式。建立了熔池表面存在变形的流场与热场的数学模型。采用 SIMPLER 方法对不锈钢试件焊接熔池内的流场与热场进行了数值分析。焊接工艺试验表明,该模型计算的熔池成形与实验值吻合良好。     

Numerical Analysis of Two-Way Interaction between Weld-Pool and Arc for GTA Welding Process

［1］H.G.Fan, S.J.Na and Y.W.Shi: J. Phys. D: Appl. Phys., 1997, 30, 94. ［2］Y.P.Lei and Y.W.Shi: Numerical Heat Transfer B,1994, 26, 455. ［3］R.T.C.Choo, J.Szekely and R.C.Westhoff: Metall. Trans. B, 1992, 23B, 357.     

Modelling of arc welding: The importance of including the arc plasma in the computational domain

We present results of computational simulations of tungsten-inert-gas and metal-inert-gas welding. The arc plasma and the electrodes (including the molten weld pool when necessary) are included self-consistently in the computational domain. It is shown, using three examples, that it would be impossible to accurately estimate the boundary conditions on the weld-pool surface without including the arc plasma in the computational domain. First, we show that the shielding gas composition strongly affects the properties of the arc that influence the weld pool: heat flux density, current density, shear stress and arc pressure at the weld-pool surface. Demixing is found to be important in some cases. Second, the vaporization of the weld-pool metal and the diffusion of the metal vapour into the arc plasma are found to decrease the heat flux density and current density to the weld pool. Finally, we show that the shape of the wire electrode in metal-inert-gas welding has a strong influence on flow velocities in the arc and the pressure and shear stress at the weld-pool surface. In each case, we present evidence that the geometry and depth of the weld pool depend strongly on the properties of the arc.     

Marangoni convection and weld shape variations in He–CO<Subscript>2</Subscript> shielded gas tungsten arc welding on SUS304 stainless steel

Bead-on-plate GTA welding (gas tungsten arc welding) on a SUS304 substrate is carried out to investigate the effect of carbon dioxide gas in the helium base shielding on the oxygen content in the weld pool and the weld shape variations. Experimental results show that small addition of carbon dioxide to the shielding gas can precisely adjust the weld metal oxygen content and change the weld shape from wide shallow type to narrow deep one when the weld pool oxygen content is over the critical value, which is from 68 to 82 ppm, due to the Marangoni convection reversal from the outward to inward mode on the pool surface. The weld depth/width ratio increases two times suddenly when the carbon dioxide content in the torch gas is over 0.4 or 0.2% for 1 mm or 3 mm arc length, respectively. The GTA weld shape depends to a large extent on the pattern and magnitude of the Marangoni convection on the pool surface, which is influenced by the active element oxygen content in the SUS304 pool, temperature coefficient of the surface tension (dσ/dT), and the temperature gradient on the pool surface (dT/dr, r is the radius of the weld pool surface). Changing the welding parameters will alter the temperature distribution and gradient on the pool surface, and thus, affect the magnitude of the Marangoni convection and the final weld shape.     

Activated flux TIG welding of Inconel 718 super alloy in presence of tri-component flux

In this study, we have explored the influence of newly developed tri-component oxide flux (Cr₂O₃, FeO, and MoO₃) on weldability, bead geometry, weld pool temperature variation, and mechanical strength of Inconel 718 welded joints. Moreover, the influence of used flux on weld pool, the surface morphology of electrode and penetration capability of tungsten inert gas (TIG) welding on Inconel 718 plates have been well elucidated. Results indicate that the flux mixture significantly increases the penetration depth as well as aspect ratio almost 200% as compared to conventional TIG welding. The arc constriction caused by newly developed oxide flux upsurges the heat density and the weld pool temperature of joints. The alloying effect caused by entrapped oxide particles greatly improves the hardness as well as the tensile strength of joints. The reported reinforcement in the welding performance may increase potential utility of the developed methods for real-world applications.     

Effects of CO2 shielding gas additions and welding speed on GTA weld shape

Gas tungsten arc (GTA) welding with deep penetration for high efficiency has long been of concern in industry. Experimental results showed that the small addition of carbon dioxide to the argon shielding gas produces an increase in the weld metal oxygen content, which is one of the compositional variables that strongly influence the Marangoni convection on the pool surface and ultimately change the weld pool shape. An inward Marangoni convection on the weld pool occurs, and hence a narrow and deep weld pool forms when the weld metal oxygen content is over the critical value of 100 ppm. When lower than this value, the weld shape becomes wide and shallow. A heavy oxide layer forms in the periphery area on the pool surface when the CO₂ concentration in the shielding gas is over 0.6%. This continuous heavy oxide layer becomes a barrier for oxygen absorption into the molten pool, and also changes the convection mode on the pool surface. A higher welding speed decreases the heat input and temperature gradient on the pool surface, which weakens the Marangoni convection on the liquid surface.     

活性剂对铁素体不锈钢A-TIG接头熔深及组织性能研究

目的 选用430铁素体不锈钢作为研究对象,对比研究添加SiO2、TiO2、Cr2O3和未添加活性剂对A-TIG焊接接头显微组织和力学性能的影响。方法 采用3种活性剂涂覆在430铁素体不锈钢上进行A-TIG试验,分析活性剂对接头熔深、组织、性能、元素含量的影响情况。结果 同一焊接工艺参数下,活性剂的加入均能提高焊缝的熔深和深宽比,减少熔宽;其中,SiO2为活性剂时获得了最佳的焊缝几何形貌。同时,对比常规TIG焊接(未添加活性剂)接头的显微组织及力学性能可知,活性剂的加入并未改变焊接接头的显微组织且无新相的生成;活性剂的添加能够细化接头组织,从而使得接头硬度有所提高。结论 活性剂的加入能够显著增加铁素体不锈钢TIG焊缝熔深,改善接头组织,提高接头硬度。     

TC4合金等离子–MIG复合焊过程温度场的数值模拟

目的 研究TC4合金在等离子-MIG复合焊(Plasma–MIG Hybrid Welding)过程中的温度场特性,探究不同电弧功率对熔池形貌的影响。方法 进行了2组4 mm TC4合金板堆焊试验,根据实验结果提出了一种改进的复合热源模型并进行了相应的仿真分析。结果 仿真与实验获得的焊缝截面相吻合;等离子电流的增大使熔池尺寸增大且余高减小,等离子电弧功率的变化对熔池宽度的影响相对较小。结论 等离子–MIG复合电弧对工件的热作用非常集中,更易实现深熔焊、焊接效率更高;所提出的热源模型适用于TC4合金等离子–MIG复合焊温度场模拟。     

Optimization of A-TIG process parameters using response surface methodology

In the present work, the influence of process parameters such as welding current (I), welding speed (S), and flux coating density (F) on different aspects of weld bead geometry for example depth of penetration (DOP), bead width (BW), depth to width ratio (D/W), and weld fusion zone area (WA) were investigated by using the central composite design (CCD). 9–12% Cr ferritic stainless steel (FSS) plates were welded using A-TIG welding. It was observed that all input variables have a direct influence on the DOP, BW, and D/W. However, flux coating density has no significant effect on WA. Mathematical models were generated from the obtained responses to predict the weld bead geometry. An optimized DOP, BW, D/W, and WA of 6.95?mm, 8.76?mm, 0.80, and 41.99?mm², respectively, were predicted at the welding current of 213.78 A, the welding speed of 96.22?mm/min, and the flux coating density of 1.99?mg/cm². Conformity test was done to check the practicability of the developed models. The conformity test results were in good agreement with the predicted values. Arc constriction and reversal in Marangoni convection were considered as major mechanisms for the deep and narrow weld bead during A-TIG welding.