基于响应曲面法的涡轮增压器废气阀门激光焊接工艺优化研究

激光焊接技术凭借其高效、高精度的特点已广泛应用在汽车制造产业,在涡轮增压器的生产中,激光焊接也逐步被应用于实现废气阀门与阀杆的连接。虽然当前对于激光焊接的工艺研究很多,但对工艺参数的优化也一直缺少一个科学有效的方法。本文以熔接深度、熔接宽度和内部缺陷作为响应变量,选取焊接功率、焊接速度作为因子,运用响应曲面法(RSM)设计实验方案,通过对响应结果进行分析,研究焊接参数对焊接质量的影响,拟合能够预测最优参数的数学模型,最终将获得的最优参数运用到生产中进行验证。     

Impact of gas formation on the transfer of Ti and O from TiO2-bearing basic-fluoride fluxes to submerged arc welded metals: A thermodynamic approach

Gas-slag-metal equilibrium calculations are performed to investigate the transfer of Ti and O to submerged arc welded metals with increasing TiO₂ addition in basic-fluoride fluxes. The results indicate that activities of TiO₂ and Ti₂O₃ considering slag-metal reactions alone do not account for Ti transfer behaviors since TiF₃ gas tends to form and reduce Ti-oxide activities. Thermodynamic simulation indicates that consideration of gases is essential to improve the prediction accuracy of Ti and O concentrations.     

硅对304不锈钢GMAW高速焊接头组织性能的影响

以不锈钢焊丝中Si元素含量不同对高速焊焊后焊缝成形以及接头组织性能为研究目的，采用GMAW焊接工艺方法，借助扫描电镜、XRD衍射图谱、拉伸以及微观硬度等力学性能测试作为分析手段，深入研究Si元素在焊缝内部空间分布规律，及其对焊后成形焊缝组织和力学性能的影响规律. 结果表明，焊丝中存在特定含量的Si元素，不仅能够增加熔池金属流动性，提高焊接过程稳定性，改善焊后焊缝成形；同时焊接速度可以大幅提高至120 cm/min；由于Si元素的存在，GMAW高速焊焊后接头组织主要为奥氏体+δ铁素体，焊缝组织得到优化. XRD衍射图谱中发现焊后接头组织中存在马氏体和渗碳体，焊后接头微观硬度有所增加，拉伸性能基本持平，且在拉伸断裂前有明显的颈缩，塑性及抗拉强度良好.     

Fatigue performance of friction stir welded Al2024 alloy in a different corrosive environment

The study examines the corrosion fatigue behavior of friction stir welded Al2024 alloy in the corrosive medium. The fatigue tests are conducted at a stress ratio of -1 in the different corrosive medium. The decrease in the fatigue life of welded joints in the corrosive environment is attributed to an increase in the crack initiation susceptibility in the presence of corrosive media. The fractured surfaces are investigated using the scanning electron microscopy (SEM). The formation of the corrosive compounds was studied using x-ray diffractometry.     

Effect of multi pulse current treatment on microstructure and microhardness of resistance spot welded dual phase steel DP590

In this paper, microhardness and microstructural characteristics of dual phase DP590 steel resistance spot weld joint under two different welding conditions (i. e. single pulse and multi pulse) were studied. It was observed that applying multi pulse currents resulted in quasi-equiaxed grains of tempered martensite in fusion zone (FZ) of the weldment. The refinement of microstructure in fusion zone using multi pulse current treatment resulted in reduced hardness of the weld joint.     

AlN对铁基合金等离子喷焊层组织和摩擦磨损性能的影响

目的 加入AlN提高铁基合金的摩擦磨损性能。方法 采用PTA-400E3-HB等离子喷焊设备在Q235钢表面制备添加AlN的铁基合金喷焊层。通过光学显微镜、扫描电镜（SEM）和X射线衍射仪（XRD）研究喷焊层的组织和相结构。利用显微硬度计、摩擦磨损试验机和台阶仪对喷焊层的硬度和摩擦磨损性能进行测试。结果 添加AlN的喷焊层主要物相为α-Fe、γ-Fe和(Fe,Cr)7C3。未添加AlN的喷焊层由等轴晶组成，添加AlN的喷焊层呈现柱状树枝晶，且随AlN量增加，树枝晶组织愈加粗大。添加1%AlN喷焊层的平均显微硬度最高，为(890.1±46.8)HV0.3，比铁基喷焊层的显微硬度高131.6HV0.3；当AlN含量增加，未转变奥氏体量增加，导致喷焊层的硬度降低。加入AlN的喷焊层的摩擦系数均降低，摩擦系数稳定在0.40~0.57之间。当AlN添加量为3%时，喷焊层的磨损形貌最光滑，磨损率为1.15×10-14 m3/(N?m)。添加AlN后，喷焊层的磨损机理从之前的粘着磨损变为磨粒磨损。结论 添加AlN能提高铁基喷焊层的摩擦磨损性能。     

焊接线能量对高强钢焊接接头组织性能的影响

采用1.3、1.6、1.9 kJ/mm 3种不同线能量对960QT钢进行焊接，研究了线能量对960QT钢焊接接头组织和性能的影响。研究表明，随着线能量的增加，焊接接头强度下降，但塑性提高，焊缝冲击韧性变化不大，热影响区冲击韧性先降低后增大，热影响区冲击韧性均高于焊缝。对3种线能量下960QT高强钢的焊接接头进行金相分析，发现焊缝组织主要为针状铁素体和粒状贝氏体。随着线能量的增加，针状铁素体发生粗化，数量相对减少，粒状贝氏体数量增多。焊接接头热影响区的金相组织主要为板条M/B和粒状贝氏体。随着焊接线能量的增大，冷却速率减小，粒状贝氏体组织数量相对增加，而板条贝氏体组织的数量逐渐减少。     

Effect of microstructure inhomogeneity on mechanical properties of different zones in TA15 electron beam welded joints

The effects of microstructure inhomogeneity on the mechanical properties of different zones in TA15 electron beam welded joints were investigated using a micromechanics-based finite element method. Considering the indentation size effect, the mechanical properties for constituent phases of the base metal (BM) and heat affected zone (HAZ) were determined by the instrumented nano-indentation test. The macroscopic mechanical properties of BM and HAZ obtained from the tensile test agree well with the numerical results. The incompatible deformation between the constituent phases tends to localize along the softer primary phase α where failure usually initiates in form of localized plastic strain. Compared with the BM, the mechanical properties of constituent phases in the HAZ differ substantially, leading to more serious strain localization behavior.     

辅助电流对Cu/Al大功率超声波焊接的影响

为获得更高质量的Cu/Al异质金属接头，开展了Cu/Al电流辅助大功率超声波焊接工艺试验，研究了辅助电流对Cu/Al超声波焊接的界面温度、材料塑性流动、界面中间相分布及接头力学性能的影响。结果表明，复合焊件成型良好，其接头抗拉剪力为3030 N，接头的断裂模式为韧性-脆性复合断裂。在同样的焊接时间0.2 s内，随着电流的增大，Cu/Al界面温度增加，金属塑性流动以及界面扩散也随之增强，这说明辅助电流能明显促进界面冶金；相比长时间0.4 s的超声波焊接，辅助电流能在保证界面温度、材料塑性变形的前提下，能明显减薄了界面IMC层的厚度，这是电流增强Cu/Al接头的主要物理机制。研究结果为优化Cu/Al复合焊接头强度提供了参考。     

2219铝合金搅拌摩擦焊和钨极保护焊焊接件残余应力的中子衍射研究

利用中子衍射法对2219铝合金搅拌摩擦焊（FSW）和钨极保护焊（TIG）焊接件开展了三维残余应力测量，并对残余应力分布规律进行了分析。结果表明：焊接件的纵向残余应力数值较大；FSW焊接件残余应力整体较TIG焊接件的小；FSW和TIG焊接件的残余拉应力最大值分别为101 MPa和174 MPa，FSW焊接件残余拉应力最大值较TIG焊接件的小；FSW残余拉应力最大值处于轴肩边缘，且前进侧峰值大于后退侧峰值；TIG焊接件残余拉应力最大值处于焊缝边缘。通过中子衍射实验获得的焊接件残余应力分布，将可用于焊接工艺的优化与焊接件的寿命预测。