Determining Mode-I Cohesive Parameters for Nugget Fracture in Ultrasonic Spot Welds

Ultrasonic spot welds have been used as a model system to investigate how to determine the mode-I cohesive parameters associated with interfacial fracture of a spot weld. Numerical analyses indicated that, while multiple combinations of the two cohesive parameters (characteristic strength, , and toughness, Γ _I) could result in virtually indistinguishable behaviors for individual geometries, only a single pair of parameters can provide a unique set of behaviors for different test geometries. This provides the basis for determining the cohesive parameters by comparing numerical predictions to experimental observations. In particular, a direct uniaxial tensile test was found to be particularly useful for measuring the characteristic strength of an ultrasonic weld. With the characteristic strength known, the toughness of the weld was determined by fitting numerical predictions to experimental observations of the load–displacement curves obtained from T-peel specimens bonded with the ultrasonic weld. These two parameters were then used without modification to predict the performance of welded U-peel specimens. The numerical predictions for this third configuration were in excellent agreement with the experimental results, verifying that it may be possible to use cohesive-zone parameters to predict the behavior of different geometries of spot welds formed under nominally similar conditions.     

焊缝超声检测缺陷类型的模糊C均值聚类识别

提出了一种采用模糊C均值聚类的方法来识别焊缝超声检测缺陷类型的方法.以夹渣、气孔、未焊透、未熔合4种焊缝常见缺陷为对象,对25个实际焊缝样本进行识别计算,并与射线检测结果进行比对.结果表明:该方法正确识别率达88%,具有较好的识别效果.     

超声冲击处理2A12铝合金焊缝表层微观组织结构变化

采用超声冲击工艺对母材为2A12铝合金焊接接头进行了焊后处理.利用扫描电镜、X射线衍射分析了超声冲击处理前后焊缝表面层的微观组织结构特征.结果表明,超声冲击处理可以在焊缝表面形成约为300μm的致密塑性变形层,晶粒明显细化.对X射线衍射峰的观察分析表明,处理后焊缝表层材料衍射峰明显宽化,这是超声冲击处理使焊缝表层材料粒子细化和晶格结构的微观应变引起的.利用谢乐方程和威尔逊公式对超声冲击处理后焊缝表层的晶粒度和微观应变进行了定量分析,结果表明,处理层的晶粒平均尺度为123nm,平均微观应变为0.134%.最后,对晶粒细化的机理进行了分析.     

Grain Size Measurement of Copper Spot Welding Caps Via Ultrasonic Attenuation and Scattering Experiments

During ultrasonic testing of resistance spot welds in real time, the probe sends the sound waves through the thickness of the copper electrode cap into the materials being welded. Characteristics of the reflected waves from the weld interfaces allow a reliable decision to be made on the quality of the joint. Transmission of high frequency sound waves through the relatively thick copper welding cap cause the signal to be greatly attenuated due to grain scattering. For this reason, close monitoring of the copper cap properties prior to installation is essential for adequate performance. Finding copper alloys with a small average grain size is essential in order to minimize the attenuating effects. The conducted backscatter and attenuation experiments indicate correlation between the ultrasonically measured parameters and the optically found copper grain size. This correlation suggests that the attenuation or backscatter technique could be used alone in order to validate the proper copper alloy to be used in spot weld probes. Using nondestructive testing techniques for this purpose greatly reduces the time and cost involved compared to optical techniques.     

Microstructure and Property Relationships in Resistance Spot Weld between 7114 Interstitial Free Steel and 304 Austenitic Stainless Steel

Due to the differences in physical, chemical and mechanical properties of the base metals, the resistance spot welding of dissimilar materials is generally more challenging than that of similar materials. The influence of the primary welding parameters affecting the heat input such as peak current on the morphology, microhardness, and tensile shear load bearing capacity of dissimilar welds between 304 grades austenitic and 7114 grade interstitial free steel has been investigated in this study. The optimum welding parameters producing maximum joint strength were established at a peak current of 9 kA, where the electrode force is kept 6×10-5 Pa and weld time is kept constant 17 cycles, respectively. The primary cause of weakening the weldment is identified as the excessive grain growing region of heat affected zone (HAZ) in case of 7114 grade interstitial free steel.     

电脉冲辅助超声冲击技术对焊缝残余应力及显微硬度的影响

焊接结构件中存在焊接残余应力,使得焊接构件在使用过程中容易发生断裂,缩短构件的使用寿命.以D36钢焊缝为研究对象,使用电脉冲辅助超声冲击技术处理D36钢焊接件,研究了电脉冲辅助超声冲击技术对焊缝残余应力和显微硬度的影响.研究结果表明:电脉冲辅助超声冲击技术在适当的电流密度和处理时间下消除焊接残余应力和表面强化的作用优于传统的单一超声冲击技术,不仅能够比单一超声冲击技术降低焊缝的残余应力最多达23 MPa,提高焊缝表层的最大硬度达109HV,同时增加强化层深度最多达250μm.     

T91／P91钢管焊接接头的超声波探伤

通过对T91／P91钢中声速的理论计算和实际测试,利用声波的反射规律和运用几何关系,计算了常用不同K值探头在对T91／P91钢进行超声波探伤中的K值变化、深度和水平距离的差异。用常用探头和普通试块即可完成T91／P91钢管焊接接头以及与T91／P91钢对接的普通低合金钢焊接接头的超声波探伤。     

焊接微缺陷磁光成像检测有限元分析

目的 研究铁磁材料焊接微缺陷的磁光成像规律.方法 运用漏磁检测原理和法拉第磁致旋光效应,建立微缺陷三维有限元模型,分析微缺陷磁光成像过程与磁场之间的关联,研究不同提离值、励磁电流、缺陷宽度、缺陷深度下的磁光成像,以及探索这些因素对磁光图像特征的影响.在此基础上,对最小宽度为0.05 mm的微缺陷进行磁光成像检测实验,并...     

高频焊接钢管焊缝的超声波自动检测工艺

在高频焊接钢管焊缝自动超声波检测的实际工作中,精确的焊缝跟踪较难实现,易影响检测的可靠性.通过对超声波检测技术进行分析,利用6 dB声束全壁厚覆盖区进行检测,提出了一套超声波检测新工艺.实践证明:该工艺可以在焊缝跟踪不精确的情况下实现可靠的超声波检测,为高频焊接钢管焊缝自动超声波检测提供了一套有效的检测方法.     

电容式微加工超声传感器(cMUT)的结构设计及仿真

与传统的压电传感器相比,电容式微加工超声传感器(cMUT)性能优良,有着广泛的应用前景．为此．介绍了cMUT的基本结构和工作原理,并提出了一种新型结构．利用有限元分析软件ANSYS对这种结构进行模态分析．得到其共振频率和一阶振动图;利用ANSYS的耦合场分析模块和参数化设计语言(APDL),对结构进行力电耦合仿真,获得其直流偏压和作为发射器时所需的交流电压值．分析结果表明,所设计的结构符合设计要求．     

GH169合金制件中黑斑和白斑偏析的超声检验

通过对所搜集到自然缺陷试样的超声检验，研究ＧＨ１６９合金中黑斑和白斑偏析的可探性。     

基于卷积神经网络的超声金属材料辨识

传统的金属材料辨识方法会给被检测样品带来一定程度的损伤。文章通过采集金属材料的超声回波时域信号,采用短时傅里叶变换对其进行时频分析,得到包含金属材料微观组织信息的超声时频谱。将目标样品的超声时频谱预处理后作为训练样本,输入到构建好的卷积神经网络中进行训练。然后采集目标样品以及干扰样品的超声频谱图,分别将其输入网络进行辨识。结果表明,神经网络在训练时收敛较快,损失函数在迭代200次后收敛,在经过100次迭代后训练集准确率趋于100%。训练完成的网络模型记录着对应训练样本的特征信息,利用该训练好的网络对待测样本进行辨识,最终可实现超声金属材料辨识。     

SUS304不锈钢板点焊接头超声成像及力学性能EI北大核心CSCD

利用超声波水浸聚焦入射法,对1mm厚的SUS304奥氏体不锈钢板点焊接头进行超声C扫描成像检测,研究不同焊接工艺参数下接头的C扫描图像特征,检测分析点焊的熔核直径,并对点焊接头进行拉伸-剪切实验。结果表明：超声波水浸聚焦C扫描成像法能够有效检测点焊熔核直径,为4．76～5．25mm,比金相实测值大2．6％～5．3％;随着焊接电流的增加（4-8kA）,接头的失效载荷均值从7116．8N增加到9707．1N,能量吸收均值从66．3J增加到196J,同时反映在C扫描图像上的熔核直径也从4．76mm增加到5．11mm;当焊接电流增加至9kA时,接头的失效载荷均值下降至6799．5N,能量吸收均值下降至41．3J,此时在C扫描图像上反映出飞溅、焊穿等典型的焊接缺陷。     

SUS304不锈钢点焊与胶焊接头的疲劳强度分析

通过拉剪实验测定1.5mm厚SUS304不锈钢点焊接头、胶焊接头的抗拉强度,并开展疲劳实验,获得不同应力水平下两种接头的疲劳寿命,得到两种接头的载荷-寿命曲线;借助扫描电镜分析接头疲劳失效过程。结果表明:当焊接电流为10.0kA、焊接时间为80ms、电极压力为0.5 MPa时,能获得较好的胶焊接头。在此焊接参数下,点焊接头、未固化胶焊接头和固化胶焊接头的平均失效载荷分别为12 825.5N、10 345.6N、10 022.9N;在疲劳实验载荷-寿命曲线的有限寿命区内,SUS304不锈钢胶焊接头的疲劳强度均大于点焊接头;点焊接头和胶焊接头的疲劳失效形式主要由母材眉状裂纹失效和界面撕裂失效两种形式组成;胶焊接头的疲劳失效过程中,首先是胶层粘接失效,随后疲劳裂纹从板间内表面热影响区边缘萌生,沿板厚与板宽方向扩展直至发生疲劳失效。     

超声检测信号的特征分析

目的 在无损检测中提高疵病实时检测和识别的正确性和可靠性。方法 提出了利用检测信号的波形特征分析进行疵病实时检测和识别的方法。结果 通过一应用实例,表明该方法对于提高检测可靠性是行之有效的。结论 用波形特征分析的方法可实现疵病的实时检测和提高检测精度。     

Development of damage in a 2D woven C/SiC composite under mechanical loading: II. Ultrasonic characterization

The non-linear mechanical behavior of a CVI-processed 2D woven C/SiC composite has been investigated by means of an ultrasonic method. This method provided the complete variation of the stiffness tensor of the material required to fully identify anisotropic damage, which was otherwise inaccessible by classical strain measurements. The various damage mechanisms induced by mechanical loading and their influence on the tensile behavior were determined and analyzed by comparing the variations of the components of the stiffness tensor obtained from the ultrasonic measurements with the prediction of microcracks by a system of slit cracks derived from a micromechanical model. Two damage modes were thus emphasized: transverse microcracking characterized by a deterministic accumulation and a random development of longitudinal microcracking, i.e. fiber/matrix and bundle/matrix debonding. Comparisons with the results obtained in Part I from both classical strain measurements and microstructural observations are also made and discussed, whenever possible.     

Failure Analysis of Friction Weld (FRW) in Truck Axle Application

A section of a fractured spindle from an axle housing was metallurgically examined. The axle fractured at the friction weld (FRW) interface and was from a truck with only about 8,000 miles of service. SEM and metallographic examinations of the weld fracture revealed that a ferritic band existed at the weld interface. A significant amount of oxides and some micro-porosity was observed in the ferrite. The existence of this type of microstructure compromised the strength of the weld and resulted in the overload fracture of the axle. FRW is supposed to be a solid-state process; however, melting-solidification was evident in this case, as suggested by the band of oxides caused by liquid phase oxidation of the molten layer at the interface and micro-shrinkage porosity formed during solidification of the liquid film. Process conditions that resulted in high heat input and liquidizing of the weld interface before the upsetting stage of the friction welding process should be mitigated. This article was published in Materials Science & Technology 2007 Conference and Exhibition: Exploring Structure, Processing, and Applications Across Multiple Materials Systems (Detroit, MI), September 17–20, 2007, What We Can Learn from Failure Analysis Symposium, ASM International, Materials Park, OH, 2007.     

超声微粒检测换能器的分析与设计

利用超声波在传播过程中遇障碍物会产生散射信号的特性进行微粒检测时,超声换能器的设计非常关键.通过对平面圆形活塞声源和凹球面聚焦声源的轴向声场分布比较分析,完成了超声微粒换能器的选型;基于一个假设的应用实例,对影响换能器性能的三个重要参数(焦距 D、晶片半径 a、和谐振频率 f)的确定原则进行了理论研究和仿真分析,给出了...     

奥氏体不锈钢管母材和焊缝的显微组织对超声检测的影响

采用金相试验手段研究了在不同焊接方法下同种奥氏体不锈钢管母材及焊缝的显微组织特性,以及在相同焊接方法下奥氏体钢管和碳钢钢管母材及焊缝的显微组织特性。用超声检测方法对试样焊缝中的人工刻槽缺陷和边缘端角进行灵敏度和信噪比的定量检测,研究了超声波在奥氏体不锈钢管和碳钢钢管中的传播特性差异。结果表明:在两种不同的焊接方法下,奥氏体不锈钢管母材及焊缝的显微组织状态基本相同,对超声检测的影响差异不大;在相同的焊接方法下,304奥氏体不锈钢管和20碳钢钢管的焊缝显微组织明显不同,超声波在奥氏体不锈钢管焊缝内的传播效果较差,检测存在一定困难;临界纵波双晶探头的灵敏度和信噪比均很高,在检测表面缺陷时能获得较好的效果。     

铝合金回填式搅拌摩擦点焊缺陷的超声检测及信号识别

目的 利用水浸聚焦超声C扫描对2524铝合金回填式搅拌摩擦点焊（RFSSW）接头进行检测并完成缺陷识别。方法 以A扫描时域信号为对象,绘制能量谱与金相作对照,确定焊合区;分析未焊合、聚集型孔洞及弥散型孔洞的时域和频域波形特征,并对频域信号进行小波分析,提取特征量。结果 缺陷区反射回波的归一化能量不低于0.02;不同形式的缺陷（聚集型孔洞、弥散型孔洞、弱连接）其频谱形状特征不同,具有不同的峰值个数。结论 通过金相验证,表明超声波C扫描对接头缺陷可进行有效的检测和区分。