多元气体大电流MAG焊试验系统

本文研制开发了一套多元气体大电流MAG焊试验系统 ,它包括一元化控制的IGBT逆变电源 ,电枢电压与速度反馈双闭环控制的双驱动送丝系统 ,双水冷焊枪以及质量流量闭环控制的精密气体配比供给系统。多元气体大电流MAG焊接试验证明 ,该系统具有焊接电源动态响应速度快 ;送丝速度稳定 ,调速范围宽 ,气体配比精密的特点 ,实现了1.2mm焊丝大电流MAG焊接高效的目标 ,其熔敷速率为普通MAG焊的2～ 3倍。     

S355J2W+N钢激光-MAG复合焊与MAG焊对比

利用激光-MAG复合焊和MAG焊进行了厚板S355J2W+N低碳钢的焊接实验,分析了两种焊接方法接头的微观组织和力学性能.结果表明:复合焊和MAG焊焊缝接头均由焊缝区、过热区、重结晶区和不完全重结晶区构成,复合焊接头截面呈“高脚杯”状特点,焊缝填充量和热影响区宽度较MAG焊明显减小.复合焊由于冷却速率快,过热区魏氏组织略有增多,硬度高于MAG焊,抗拉强度和弯曲性能与MAG焊相比,无显著差异,均能够满足生产标准的要求.     

内环槽复合测量尺的设计与使用

针对机械加工领域内环槽宽度尺寸无法直接测量难题,提出一种直接同时测量内环槽直径尺寸和宽度尺寸的一体式量具设计方案。运用齿轮传动及齿轮齿条传动原理,设计测量内环槽结构尺寸的机械式量具。对样品经过验证表明:该复合测量尺能够对内环槽直径尺寸和槽宽度尺寸同时进行精确测量,操作简单方便,可填补内环槽直接精确测量的空白。     

921A舰船钢激光–MAG复合焊接过程数值模拟分析

目的 对厚度为16 mm的921A舰船钢进行激光–MAG复合焊接,得到最佳工艺参数,从数值模拟的角度验证焊接工艺的可靠性。方法 利用SYSWELD+Visual–Environment软件对激光–MAG复合焊接过程进行数值模拟,选用3D高斯热源与双椭球热源相结合的复合热源模型对激光–MAG复合焊接过程进行仿真,绘制不同时刻及不同焊缝区域的时间–温度曲线,采用热弹塑性有限元法对应力变形场进行仿真计算。结果 双椭球热源模型与3D高斯热源模型相结合的复合热源模型能够获得较为理想、接近真实热源形貌的热源形态;焊缝区域的焊接热源在行进过程中温度稳定,模拟热源温度可达3 200 ℃,具有典型的焊接热循环曲线特征,且距离焊缝越远,升温速率和冷却速率越慢;焊接残余应力主要集中在焊缝处,约为440 MPa,且焊缝两端的结合部位具有较高的残余应力。结论 复合热源模型适用于16 mm厚的921A钢激光–MAG复合焊接数值模拟,焊后板材的残余应力低于材料的屈服强度,冷却后板材的变形程度较小,最大变形量为1.13 mm,表明激光–MAG复合焊接方法及工艺适用于16 mm厚921A钢的焊接。     

不锈钢半环零件工艺优化

该文以不锈钢半环零件为研究对象,零级静子内环组合件属于高压压气机单元体,位于前机匣内侧最前端,通过可调静子叶片与前机匣连接,材料为奥氏体不锈钢,最大直径Φ442mm,最小直径Φ401mm,为半环状态。零级静子内环的突出技术问题是零件加工过程中变形严重,变形控制困难,加工难度大,很难满足图纸要求,加工工艺不成熟,合格率低。     

小电流高频TIG焊电弧稳定性的研究

本文以大量的试验结果表明了电流频率、钨极尺寸和保护气体成分等对小电流 TIG 焊电弧稳定性的影响规律。并得出6～8A 小电流时的电弧稳定性条件是采用20KHz 以上的高频电流。(Ar+2%H_2)混合气体保护和直径为φ0.5mm 的细铈钨极。     

排钉的自动缝焊及其单片机控制系统

论述了排钉的自动缝焊方法焊机的机械系统与单片机控制的软件流程图。     

储油罐的现场机械化焊接

储油罐的现场焊接工作量大，质量要求高，储罐的机械化或自动化焊接一直是人们翘首以待的事情。文章介绍了国内引进的大型油罐的绝底埋弧焊、罐壁横缝埋弧焊及立缝气电焊的工艺、质量、效率、国产化及其存在的问题。     

基于多指标综合评分方差分析的镍铬合金储能缝焊工艺研究

以接头的拉剪力、重叠量和焊透率的加权综合评分值为检测质量指标,对0.5 mm厚的Cr20Ni80镍铬合金进行了储能缝焊(CDSEW)试验,采用多指标综合评分方差分析法(ANOVA)研究了焊接速度、放电频率和储能量对缝焊接头质量的影响,并对试样进行了金相观察.结果表明:焊接速度对镍铬合金储能缝焊接头质量影响显著,储能量对其影响比较显著,但影响程度低于焊接速度,而放电频率对接头质量无显著影响,焊接速度越大,失效能量越小,接头的塑性变形能力越差.最优工艺组合下三指标检测量的综合评分值为0.978,对应的拉剪力为4.971 kN,重叠量为45.8％,焊透率为63.7％.镍铬合金在缝焊过程中未发生相变,整个接头全为单相奥氏体固溶组织,焊缝熔核区组织均匀,晶粒以树枝状分布.     

制动管奥氏体不锈钢MAG焊与TIG焊试验研究

本文针对铁路货车制动管系用1Cr18Ni9Ti奥氏体不锈钢钢管与ZGOCr18Ni9接头体角焊缝的焊接方法进行工艺试验研究。根据全路货车用制动管系焊接生产的工艺现状,选取MAG焊方法和TIG焊方法进行焊接工艺试验,通过对焊接接头的金相组织和力学性能进行分析研究,进一步了解奥氏体不锈钢管与接头体角焊接头的性能及焊接工艺方法对接头性能的影响,为铁路货车用奥氏体不锈钢制动管的焊接生产提供工艺理论和实践支持,以确保制动管与接头体的焊接质量和使用性能。     

不同焊接参数下CT70连续钢管高频电阻焊残余应力分布的数值模拟

目的研究CT70连续油管高频电阻焊接后的残余应力值和分布规律,以及焊接速度和挤压量等焊接参数对残余应力的影响。方法通过有限元计算的方法施加移动面热源和移动挤压辊,来模拟高频电阻焊的加热和加压过程,并用小孔法测量了高频电阻焊后连续钢管的残余应力值。结果对比计算的和实际的焊缝尺寸,均是内壁处为0.2 mm,壁厚中间部位为0.1 mm,内壁凸起高度为1.0 mm,宽度为2.1 mm,验证了有限元模型的准确性。计算得到的高频电阻焊后在焊缝处的轴向残余应力较大,在400～500MPa之间;环向残余应力较小,在-100～200MPa之间,与小孔法测量的残余应力一致。结论焊缝附近的残余应力主要由不均匀加热引起,远离焊缝处的残余应力主要由挤压引起。热源与挤压辊间距离和焊接速度增加会导致焊缝附近的残余应力增加;挤压量增加和焊接功率增加会导致焊缝附近的残余应力降低。     

Residual stress reduction in the penetration nozzle weld joint by overlay welding

Stress corrosion cracking (SCC) in the penetration nozzle weld joint endangers the structural reliability of pressure vessels in nuclear and chemical industries. How to decrease the residual stress is very critical to ensure the structure integrity. In this paper, a new method, which uses overlay welding on the inner surface of nozzle, is proposed to decrease the residual stresses in the penetration joint. Finite element simulation is used to study the change of weld residual stresses before and after overlay welding. It reveals that this method can mainly decrease the residual stress in the weld root. Before overlay welding, large tensile residual stresses are generated in the weld root. After overlay weld, the tensile hoop stress in weld root has been decreased about 45%, and the radial stress has been decreased to compressive stress, which is helpful to decrease the susceptibility to SCC. With the increase of overlay welding length, the residual stress in weld root has been greatly decreased, and thus the long overlay welding is proposed in the actual welding. It also finds that this method is more suitable for thin nozzle rather than thick nozzle.     

Fatigue properties of combined friction stir and adhesively bonded AA6082‐T6 overlap joints

Even though friction stir welding (FSW) has been shown to produce high performing butt joints, stress concentration at the weld edges in overlap FSW significantly reduces the performance of these joints. By combining FSW and adhesive bonding into a friction stir (FS) weld bonding, joint mechanical performance is greatly improved. Quasistatic and fatigue strength of the proposed FS weld‐bonding joints was assessed and benchmarked against overlap FSW and adhesive bonding. The characterization of the structural adhesive is also presented, including differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA), as well as mechanical characterization with curing temperature. A small process parameter study was made to select proper FSW parameters for AA6082‐T6 overlap FSW and FS weld‐bonded joints. FS weld bonding achieved a significant increase in quasistatic and fatigue strength when compared with overlap FSW, with 79.9% of the fatigue strength of adhesive‐bonded joints at 10⁶ cycles, whereas FSW had 41.6%.     

Development of a New Electrode for Arc Wclding of Austempercd Ductile Iron(ADI)

The effect of Ca,Ba,Bi and Al on the amountof carbide in ductile iron weld metal,themicrostructural characteristics of ADI weld metaland the effect of heat treatment process on themicrostructure and mechanical properties of ADIweld metal have been studied.On this basis theoptimum composition of weld and the optimumheat treatment process of ADI weld metal were de-termined and a new electrode for arc cold-welding(i.e.,without preheat) of ADI was developed.Theductile iron welded joint free from eutectic carbidecan be produced by using this electrode beforeaustempering and the weld metal obtained afteraustempering has a microstructure and mechanicalproperties similar to those of ADI.The mechanicalproperties of welded joints can match the require-ment of ADI.     

Weld Shape Variation and Electrode Oxidation Behavior under Ar-(Ar-CO_2) Double Shielded GTA Welding

Double shielded gas tungsten arc welding (GTAW, also known as tungsten inert gas (TIG) welding) of an SUS304 stainless steel with pure inert argon as the inner layer shielding and the Ar-CO₂ or CO₂ active gas as the out layer shielding was proposed in this study to investigate its effect on the tungsten electrode protection and the weld shape variation. The experimental results showed that the inner inert argon gas can successfully prevent the outer layer active gas from contacting and oxidizing the tungsten electrode during the welding process. Active gas, carbon dioxide, in the outer layer shielding is decomposed in the arc and dissolves in the liquid pool, which effectively adjusts the active element, oxygen, content in the weld metal. When the weld metal oxygen content is over 70×10^-6, the surface-tension induced Marangoni convection changes from outward into inward, and the weld shape varies from a wide shallow one to a narrow deep one. The effect of the inner layer gas flow rate on the weld bead morphology and the weld shape was investigated systematically. The results show that when the flow rate of the inner argon shielding gas is too low, the weld bead is easily oxidized and the weld shape is wide and shallow. A heavy continuous oxide layer on the liquid pool is a barrier to the liquid pool movement.     

铌在堆焊金属中的应用

利用X射线衍射、TEM、EPMA、SEM等研究了含Nb堆焊金属中的碳化物分布形态及基体组织,分析了碳化物形成过程.结果表明,Nb的加入有利于形成大量碳化物硬质相,但Nb含量过多时,会形成铁素体基体及大量共晶碳化物,导致堆焊金属硬度过低;适量Ti、Nb、V共同作用时,能获得大量均匀分布的颗粒碳化物及马氏体或贝氏体基体,颗粒碳化物是以氧化物为核心的复合碳化物,内层Ti含量高于Nb,外层Nb含量高于Ti.     

薄板TIG焊熔池谐振法熔透自适应控制

在直流电流上附加正弦波焊接电流,诱发熔池金属振荡,通过电弧电压检测熔池谐振信号,此谐振信号与熔池尺寸有良好对应关系。实验研究了影响熔池谐振信号产生的电弧因素,通过建立以直流变动电流电源、步进电弧、微计算机数据采集和反馈控制为主体的焊接熔透控制系统,实现了薄板对接焊缝熔宽的实时控制,获得良好焊缝成形。在有意识地改变外部影响因素条件下,取得了满意的自适应控制效果。     

Finite Element Analysis of Modeling Residual Stress Distribution in All-position Duplex Stainless Steel Welded Pipe

On the basis of the thermal-elastic-plastic theory, a three-dimensional finite element numerical simulation is performed on the girth welded residual stresses of the duplex stainless steel pipe with ANSYS nonlinear finite element program for the first time. Three-dimensional FEM using mobile heat source for analysis transient temperature field and welding stress field in circumferential joint of pipes is founded. Distributions of axial and hoop residual stresses of the joint are investigated. The axial and the hoop residual stresses at the weld and weld vicinity on inner surface of pipes are tensile, and they are gradually transferred into compressive with the increase of the departure from the weld. The axial residual stresses at the weld and weld vicinity on outer surface of pipes is compressive while the hoop one is tensile. The distributions of residual stresses compared positive-circle with negative-circle show distinct symmetry. These results provide theoretical knowledge for the optimization of p     

Ti2AlNb合金电子束焊接头残余应力及变形的数值模拟

目的 研究平板对接电子束焊接过程中Ti2AlNb合金接头的残余应力及变形规律。方法 采用高斯圆柱体和高斯面组合热源模型模拟了6.6 mm厚的Ti2AlNb合金平板对接电子束焊过程,对比研究了高焊速高束流和低焊速低束流2种工艺参数下焊接接头的残余应力和变形分布规律,并用小孔法测量了焊缝中心及距焊缝中心10 mm位置的残余应力值。结果 在高焊速高束流参数下,获得了熔池体积小、熔池宽度窄(为3.62 mm)、深宽比高的焊缝;在该参数下焊缝横截面上的高应力集中区(应力在900 MPa以上)尺寸较小,其宽度仅为低焊速低束流参数下的89%;同时,在高焊速高束流参数下,焊缝法向变形最大值为0.79 mm,低于低焊速低束流参数下的0.82 mm;模拟计算所得残余应力与实测值的误差在5.64%以内。结论 高束流高焊速工艺具有热输入小、热量集中、加工效率高的特点,有助于获得高应力集中区域小、深宽比高、变形小的焊缝,比低束流低焊速工艺更具优势。     

初始几何缺陷对仓壁柱承钢筒仓稳定性能的影响

仓筒壁直接支承于支柱是小型钢筒仓的一种简单、经济的支承方式。薄壳结构通常对初始几何缺陷十分敏感。引入周向轴对称焊缝凹陷和特征值屈曲模态两种缺陷形式,通过几何非线性分析,研究初始缺陷对轴压下仓壁柱承筒仓稳定性能的影响。研究表明,周向焊缝凹陷会显著降低结构的屈曲荷载,且与焊缝位置密切相关,而特征值模态缺陷只有在支柱接近仓顶时才会显著影响其屈曲强度。