等离子弧焊自动控制器的研究

本文介绍了一种小孔法等离子弧焊双参数微机控制器。它以小孔电压作为检测对象，以焊接电流和焊接速度作为被控对象，采用微机进行实时控制，具有灵敏度高、灵活性好、结构简单、与焊机控制部分联机自动化程度高、操作方便等优点。工艺考核表明：控制系统允许焊接规范参数有较大的波动范围，并能降低对工件装配质量的要求。     

Laser–arc hybrid welding of high-strength steel and aluminum alloy joints with brass filler

The laser–tungsten inert gas hybrid welding method was adopted to realize the welding process between Q460 high-strength steel and 6061 aluminum alloy. The influence of the dual heat source on the mechanical properties and microstructure of the welded joints are discussed. In addition, the effects of including a copper–zinc interlayer on the microstructure, elemental distribution, and mechanical properties of welded joints are also studied. The results show that the mechanical properties of the welded joints are influenced by the relative heat inputs of the two heat sources and the Cu-Zn interlayer. The braze welded joint fabricated without a Cu-Zn interlayer fractured at an Al-Fe intermetallic compound (IMC) layer formed at the interface, whereas the braze welded joint fabricated with a Cu-Zn interlayer fractured at an Al-Cu IMC layer formed at the interface. Comparisons show that the maximum tensile shear load of the brazed welded joint with the Cu-Zn interlayer was increased by about 20% relative to that formed without the interlayer. The formation of Al-Fe IMC layer in the deep penetration joint was inhibited by the combined effect of the dual heating sources and the Cu-Zn interlayer.     

低功率脉冲激光-电弧复合热源高效焊接过程中的“匙孔”行为研究

激光-电弧复合热源焊接技术由于具有焊接熔深大、效率高、质量好等优点而受到广泛关注。采用低功率脉冲激光-钨极惰性气体保护(Tungsten inert gas,TIG)焊电弧复合热源技术进行镁合金板材的焊接,研究激光脉冲作用消失之后的等离子体行为和激光"匙孔"行为。在上述试验结果的指导下优化工艺参数,对比研究采用单独激光焊、TIG电弧焊和复合热源焊这三种方法实现镁合金板材对接焊相同效果时焊接效率的差异。研究结果表明,激光"匙孔"和"匙孔"等离子体的形成是实现复合热源高效焊接的前提条件,恰当的工艺参数可以使得激光"匙孔"维持稳定的开口状态,这种状态提高了电弧的稳定性和能量密度,延长了镁等离子体的恢复时间,因此能够提高复合热源的焊接效率。达到相同焊接效果时复合热源的焊接效率分别达到单独激光焊接效率的7.14倍和单独TIG电弧焊接效率的4.29倍。     

匙孔效应对激光熔覆层横截面几何形貌的影响研究

目的 研究匙孔效应在不同激光功率、扫描速度和送粉速率工艺参数下,对熔覆层横截面形貌的影响规律,并揭示匙孔对基体的作用机制。方法 利用光束模式为高斯光束分布的YLS-3000光纤激光器进行熔覆镍基高温合金Ni35实验。利用光学显微镜（OM）采集熔覆层横截面宏观形貌,并用金相分析软件以及计算机辅助绘图软件对熔覆横截面参数进行测量。结果 随激光功率的增加,匙孔深度增加;随送粉速率和激光扫描速度的增加,匙孔深度减小。随送粉速率的增加和激光功率的减小,熔覆层横截面左右垂直段高度值（H2和H4）减小;随扫描速度的增加,H2和H4先增加再减小。在激光熔覆过程中,当基体没有形成匙孔时,H2和H4的值为零,熔覆层与基体混合区域的横截面形貌为月牙形;当在基体中形成匙孔时,H2和H4的值大于零,熔覆层与基体混合区域的横截面形貌为蘑菇形。结论 在激光熔覆过程中,不同激光功率、扫描速度和送粉速率工艺参数对匙孔的影响机制不同。匙孔效应的强弱显著影响熔覆层横截面参数H2和H4的大小,进而影响熔覆层形貌。     

Dynamic keyhole profile during high-power deep-penetration laser welding

Based on a butt-joint configuration assembled from transparent glass and stainless steel, the dynamic keyhole profile was observed during 10-kW fiber laser welding. The “gauffers” and vapor flow on the front keyhole wall moved downwards to the bottom of the keyhole. The downward-flowing vapor met the upward-flowing vapor at the bottom of the keyhole, which resulted in a whirlpool of vapor. The suspended droplets were drove to move in a random fashion by the whirlpool. The fluctuating vapor flow and pressure were the key factors causing the fluctuating keyhole wall and resulting in a vapor-generated wave (VGW) on the rear keyhole wall. The dynamic VGW was a very important factor affecting the dynamic welding process. When the VGW broke at the keyhole outlet, it was accompanied by swellings, spatter, columns, a decrease of the diameter of keyhole inlet, and a change in the direction of plume.     

Determining the keyhole geometry based on double-elliptic distribution of plasma arc pressure

The plasma arc pressure plays an important role in determining the keyhole formation and size. So it is of great significance to choose adaptive distribution mode of the plasma arc pressure for determining keyhole shape and size. In this study, through employing a double-elliptic distribution mode of plasma arc pressure, three-dimensional keyhole was numerically simulated. The unsymmetric feature of the keyhole inside the weld pool was described. The development of keyhole was demonstrated under different levels of welding current. The critical current required to form an open keyhole was obtained for the study cases.     

保护气流对CO2激光焊接铝合金的影响

利用3 kW高功率CO2激光器,通过改变保护气体流量和流动方向,对2 mm厚的A5083铝合金薄板进行了焊接实验研究.研究发现,小孔的稳定存在取决于保护气体对等离子体云的抑制效果,而侧吹保护气体对等离子体云的抑制效果主要取决于所形成的气流方向,从而影响焊接熔化特性.利用有限元法对激光焊接时保护气体在小孔内部和表面气流状况进行了数值模拟,通过对不同焊接条件下模拟形成的小孔气动扰流的气流场和压力分布云图的分析,解释了采用逆向侧吹保护气体吹除等离子体的方法,可以更有效地抑制等离子体云的产生,防止小孔塌陷,有利于维持小孔的稳定性.     

脉冲CO2激光焊接30CrMnSiA气孔控制及机理分析

为了研究激光深熔焊气孔的产生规律及抑制气孔的措施,采用脉冲CO2激光焊接的方法,得到了未焊透时焊缝气孔率和脉冲参数的关系。结果表明,在脉冲频率低于50Hz时,焊缝气孔随着脉冲频率的增加显著减少,当频率在50Hz~200Hz范围时,可以稳定地抑制焊缝气孔的产生。适当提高占空比有利于减少气孔数量。