封闭式消声器的焊接

某产品所用消声器是以降噪声为目的的,设计采用图1结构。 该结构由内、外两层简体焊接而成,内简体是封闭式的,由0.8mm厚的SUS304微孔板卷制而成,筒体长约1300mm,直径250mm,若焊接工艺不合理,焊接后筒体极易变形,且校正困难。外筒     

大型筒体焊接操作架的设计与改进

正1.概述筒体是球磨机、回转窑的主要部件。由于这些筒体达到了?3 000~?6 000mm、长度达到了10 000~20 000mm,因此筒体由若干个筒节采用埋弧焊方法组焊而成。这种方法焊接筒体环缝的特点是焊嘴固定不动,通过筒体在转胎上匀速旋转完成焊接。故焊接过程需采用焊接操作架夹具完成。由于以往的焊接操作架是用槽钢组焊而成,直接放在地     

高温合金薄壁圆筒焊接变形控制研究

为解决某型号航空发动机产品焊接加工难题,进行了Inconel 718高温合金薄壁圆筒零件焊接变形控制工艺研究。通过分析薄壁筒体焊接变形的原因,采取合理的接头设计、焊接工装设计、优化焊接工艺和焊后热处理及热处理防变形工装等措施,产品焊缝质量满足I级要求,焊缝圆度变形控制在0.2 mm以内。最终通过了验证,较好地控制了高温合金薄壁圆筒产品焊接变形,焊缝质量优良,可为相关薄壁圆筒产品焊接提供技术支持。     

小直径筒体的纵缝双面自动焊装置

生产中常常遇到ф600mm以下的小直径简体的焊接问题,这类小直径筒体的长度约为2m左右,壁厚多为6～8mm,直径一般为450～600mm.众所周知,对于600mm以下直径的容器,电焊工难于甚至无法进入筒体内施焊,通用的埋弧自动焊机也无法进入筒体内焊接.而这类小直径容器的纵缝要求     

筒体的三种焊接实用工装

针对筒体与接管焊接、筒体对接焊接时的筒体变形,设计了三种实用工装.实践证明,利用该工装焊接筒体与接管时产生的变形很小,且使用简便.     

风电塔筒法兰外翻变形的控制工艺

介绍了风电塔筒结构及塔筒法兰设计要求,阐述了风电塔筒法兰与筒体焊接的传统工艺及存在的问题,针对焊后法兰出现外翻变形的现象,在设计塔筒法兰时,采用了预留焊接反变形量的方法,对风电塔筒制造工艺进行了改进,通过试验表明,改进后的工艺简单实用、可操作性强,具有一定的推广价值。     

风电塔筒法兰外翻变形的控制工艺

介绍了风电塔筒结构及塔筒法兰设计要求,阐述了风电塔筒法兰与筒体焊接的传统工艺及存在的问题,针对焊后法兰出现外翻变形的现象,在设计塔筒法兰时,采用了预留焊接反变形量的方法,对风电塔筒制造工艺进行了改进,通过试验表明,改进后的工艺简单实用、可操作性强,具有一定的推广价值.     

铝制罐体自动焊琴键式气压装置的设计与制造

琴键式气压装置是用于大型铝制罐体纵缝自动焊的气动压紧装置,它与自动氩弧焊机、焊接操作机组成整个自动焊系统。 大型铝制罐体的容积一般为15000～26000m~3,材料为6mm厚的铝镁合金板。罐体由两节长度小于5m的筒体对接组成,筒体由5块成形弧板经纵     

筒式钢球磨煤机筒体变形后的修复

一、问题的提出 公司15号磨煤机在运行过程中,因衬板脱落而撞击筒体,造成20mm厚的筒体产生鼓包状凸起变形。变形面积范围800mm×3200mm,最高凸起达45mm。 根据现场情况,只能采取将凸起变形部分割掉,再镶嵌一块与割掉部分尺寸相同,并与筒体材料牌号、规格相同的材料。 为防止因割除后引起的筒体变形和镶嵌焊接后产     

薄壁筒体纵向接头和环形接头的焊接

<正> 1.前言图1是我厂生产的飞机发动机某零件的半成品——薄壁筒体,材料为固溶强化型镍基合金GH3039,料厚1.5毫米。该薄壁筒体上有四条纵向接头,一条环形接头。焊接后,由纵向接头的纵向收缩引起了薄壁筒体局部的弯曲变形(图2),由环形接头的纵向收缩引起薄壁筒体的径向变形(图3)。为了减小薄壁筒体的焊接变形,提高焊接生产率,我们采用了琴键气动夹具分别装夹Ⅰ、Ⅱ段,用自动氩弧焊焊接纵向接头,采用液压胀形夹具装夹薄壁筒体,用手工氩弧焊焊接环形接头,获得了优质焊接接头,焊缝成形美观。     

Obtaining weld pool vision information during aluminium alloy TIG welding

An image sensing system for the TIG (tungsten inert-gas arc) welding process of aluminium alloy was established. The relationships between the image sensing system and the characteristic of welding current were discussed in detail. Front and back images of the weld pool were obtained with different welding parameters. In order to process the image, the characteristics of an aluminium alloy were analysed. Image processing and pattern recognition were first used to obtain information from the TIG welding process for aluminium alloy. The image of the weld pool was pre-processed using a series of methods: a weighted median filter, a statistical threshold by expectation and the projection method. A neural network method was used to extract the edge of the images of the weld pool. The result of detecting the edge with a BP neural network were excellent. The symmetry of the weld pool for aluminium alloy was studied when the welding current is large. The edge of the image of the whole weld pool is obtained in a single side image and an accurate method for measuring the weld pool geometry parameter is provided. Experiments show that using the image sensing to control the TIG weld width for aluminium alloy is an effective method.     

铝合金贮箱法兰件自动化焊接工艺研究

对2219铝合金开展对接法兰的自动化焊接研究,在优化装配过盈量及焊接工艺的基础上,通过拉伸试验机、光学显微镜、扫描电镜对接头力学性能及微观组织进行分析研究。结果表明,对于典型厚度5 mm和8 mm的法兰件,通过单面两层自动焊接工艺优化后,其抗拉强度及塑性指标远大于贮箱制造要求,且低温下优于常温,可以满足产品需要。     

高效散热微通道液冷冷板焊接技术及成形工艺研究

通过分析微通道冷板的结构特点及技术要求,对微通道冷板的焊接方法、焊接工艺进行了分析研究.采用气保护炉钎焊方法,通过巧妙地采用过渡材料与接头设计,既突破了6063铝合金气保护炉钎焊的钎焊性较差的技术难题,满足了钎焊缝密封性要求,又可有效地避免钎料流入微通道.通过焊接工装及接头设计,在合理的工艺及气氛条件下,实现了6063铝合金微通道冷板的整体焊接成形,解决了微通道冷板的焊接技术难题.     

小于50mm间距的铝合金焊缝性能

通过EN AW-6082-T6铝合金30 mm、40 mm焊缝间距的焊接工艺试验,力学性能试验及金相试验的对比,分析铝合金相邻焊缝距离小于50 mm焊接接头的性能。结果表明,30 mm、40 mm焊缝间距的抗拉强度分别为166.48 MPa、175.34 MPa,其焊接结构横向拉伸强度明显下降且不能够满足标准要求;焊缝的面弯、背弯试验均合格,弯曲性能能够满足标准要求;其焊接热影响区的金相组织为柱状晶组织,两个焊缝的热影响区叠加,影响其拉伸强度。     

铝合金点焊过程的铜铝合金化研究

观测了LF2铝合金电阻点焊初期至达到电极寿命时焊点表面及Cr—Zr—Cu电极端面宏观形貌的连续变化过程。采用扫描电子显微镜(SEM)，对机加工状态及抛光处理的电极在点焊铝合金后进行了电极端面背散射分析，对机加工状态的电极在点焊铝合金后又进行了电极端面横向及纵向线扫描分析。采用X射线衍射仪，对沿电极轴向的3个不同电极端面进行了X射线衍射物相分析。结果表明，点焊初期，焊点表面即出现局部熔化及电极端面出现明显凹凸不平，电极端面的形貌及其尺寸发生变化，焊点表面成形质量恶化，电极端面加工状态对电极端面铜铝合金化影响不大，点焊过程电极端面存在较多铝，发生了铜铝合金化反应，合金化产物主要是铜铝金属间化合物(CuAl2)。     

铝合金双面自动 TIG立焊计算机控制系统

为实现空分设备的焊接自动化，本文研究了铝合金双面自动TIG立焊二级分布计算机控制系统，此系统的硬件包括5个子系统，即：焊接电源，弧长控制器，焊矩行走机构和检测机构，软件包括在线执行程序和离线服务程序。介绍了此系统的操作原理，规范说明和控制功能，解决了对计算机控制系统的高频干扰问题，使系统工作稳定，控制精度高，采用汉语菜单，操作方便。     

Welding of thin sheet of Al alloy (6082) by using Vario wire DC P-GMAW

This paper describes an investigation on the micro-structure, weld bead geometry, dilution rate and mechanical properties of the butt and overlap weld joints of 1-mm-thick 6082 aluminium alloy sheet. Weld joints were produced with the help of a variant of gas metal arc welding (GMAW) process, i.e. direct current-pulsed GMAW (DC P-GMAW), using a Vario wire. The capability of the new process has been assessed in terms of dilution, weld bead geometry, mechanical properties and porosity. The welding results with this new process showed good process stability in the welding of thin sheets of aluminium, while weld mismatch was found to increase with an increase in heat input. Weld bead geometry parameters such as weld size, throat and weld convexity increases with the increase in heat input. The dilution in case of lap joints (10–25%) was less than that of butt joints (60–80%). The increase in factor Φ (summarizing the effect of pulse parameters) increases the form factor and lowers the toe angle. Mechanical properties of the welds are poor as the tensile strength of 6082 alloy welds was around 150 MPa, and the percent elongation was about 1.3%, and it was primarily due to high porosity. Porosity (%) in weld joints was found in the range of 0.33–11.59%. The porosity is a major issue with DC P-GMAW welds.     

Effect of welding processes on tensile properties of AA6061 aluminium alloy joints

The present investigation is aimed at to study the effect of welding processes such as GTAW, GMAW and FSW on mechanical properties of AA6061 aluminium alloy. The preferred welding processes of these alloys are frequently gas tungsten arc welding (GTAW) and gas metal arc welding (GMAW) due to their comparatively easier applicability and better economy. In this alloy, the weld fusion zones typically exhibit coarse columnar grains because of the prevailing thermal conditions during weld metal solidification. This often causes inferior weld mechanical properties and poor resistance to hot cracking. Friction stir welding (FSW) is a solid phase welding technique developed primarily for welding metals and alloys that heretofore had been difficult to weld using more traditional fusion techniques. Rolled plates of 6 mm thickness have been used as the base material for preparing single pass butt welded joints. The filler metal used for joining the plates is AA4043 (Al-5Si (wt%)) grade aluminium alloy. In the present work, tensile properties, micro hardness, microstructure and fracture surface morphology of the GMAW, GTAW and FSW joints have been evaluated, and the results are compared. From this investigation, it is found that FSW joints of AA6061 aluminium alloy showed superior mechanical properties compared with GTAW and GMAW joints, and this is mainly due to the formation of very fine, equiaxed microstructure in the weld zone.     

Butt autogenous laser welding of AA 2024 aluminium alloy thin sheets with a Yb:YAG disk laser

Higher productivity, lower distortion and better penetration are the main advantages provided by laser welding in comparison with conventional processes. A Trumpf TruDisk 2002 Yb:YAG disk laser is used in this work to increases productivity and quality. Aluminium alloys lead to many technological issues in laser welding, resulting in shallow penetration and defects. In particular, AA 2024 aluminium alloy in a thin sheet is investigated in this paper, being it is used extensively in the automotive and aerospace industries. Bead-on-plate and butt autogenous laser welding tests with continuous wave emission on 1.25 mm thick AA 2024 aluminium alloy sheets were examined morphologically and micro-structurally. The geometric and mechanical features of the welding bead were evaluated via a three-level experimental plan. In addition to the power and speed which are traditionally referred to, beam defocusing was considered as an additional governing factor in a central composite design scheme because it massively affects keyhole conditions. Softening in the fused zone is discussed via Vickers micro-hardness testing and magnesium loss through energy dispersive spectrometry. After properly performing the modelling and optimisation of the fused zone and the cross-section shape factor as the response variables, the laser welding conditions for thin sheets of AA 2024 aluminium alloy are suggested. X-ray and tensile tests were conducted on the specimens obtained with the recommended processing parameters to characterise the AA 2024 disk laser welded beads.     

铝合金车体非刚性支撑搅拌摩擦焊修复设备研制

现有搅拌摩擦焊修复设备多为固定龙门式结构,且需要背部刚性支撑,移动适应性较差。针对铝合金货车车体破损修复问题,提出一种采用搅拌摩擦焊对其进行在线修补作业的方案,设计了一种移动式非刚性支撑搅拌摩擦焊修复设备。为了解决非刚性支撑焊接修复过程中支撑力不足、大变形等问题,设计了旋转伸缩臂、花瓣式砧板等结构,为焊接提供足够的顶锻力,并利用有限元分析对花瓣式砧板结构进行优化设计,改善支撑效果;设计了铣焊半径自动调整结构,用于不同大小尺寸破损的修复焊接。该移动式非刚性支撑搅拌摩擦焊修复设备能够在不拆解车体板材的情况下,修复6 mm厚铝合金车体,现场实际应用表明：采用该非刚性支撑搅拌摩擦焊修复效果良好,焊接表面光滑无飞边,内部无沟槽隧道缺陷,焊缝抗拉性能达到母材的71.6%左右。