FV520B钢激光焊接工艺参数优化及组织性能

借助正交试验方法优化FV520B钢板激光自熔焊焊接参数,以便为后续开槽焊叶轮的激光打底焊提供参数选择依据.利用极差分析法进行焊接参数初选,以熔深为响应量,在较大的参数范围内选出符合熔深条件的较小参数范围.经参数复选,确定的优化焊接参数为:激光功率4.2 kW,焊接速度35 mm/s,光斑直径1.2 mm.选用优化参数进行对接自熔焊,观察发现焊缝熔化区(FZ)组织主要为白色的马氏体和黑色的δ铁素体,并含有少量的碳化物,其中δ铁素体呈现出蠕虫状和板条状两种形态.激光线密度对焊缝熔深的影响较大,熔深随线密度的增大而增加,呈幂函数关系;焊缝的维氏硬度随线密度的增大而略有降低.优化参数后经对接焊得到的焊缝熔化区的硬度略低于母材(BM),热影响区(HAZ)软化比较明显.拉伸实验结果表明,由于缺陷的存在,焊缝的屈服强度、抗拉强度低于母材;而无缺陷或者极少缺陷的情况下,焊缝的强度优于母材.     

激光深熔焊接等离子体温度光谱测量对比

采用光谱仪探测CO₂激光深熔焊接等离子体及光纤激光焊接羽辉的光谱信号，分别利用波尔兹曼图法和相对强度法计算获取CO₂激光焊接等离子体的温度，并以较优的一种方法计算光纤激光羽辉温度。结果发现，对于同一个等离子体，采用相对强度法时，选择不同谱线获得的等离子体温度差异很大；当采用波尔兹曼图法时，使用不同谱线组合获得的等离子体温度非常接近。通过对两种方法获得结果的分析，认为采用波尔兹曼图法计算得到的等离子体温度精度更高，更具有可比性。而后采用波尔兹曼图法计算羽辉温度，发现光纤激光焊接羽辉辐射的谱线中连续谱强度不可忽略，与等离子体温度的计算略有不同。     

基于机器学习的薄板等离子弧搭接焊的熔深预测

在等离子弧搭接焊中,搭接焊接头的焊缝熔深是评价焊接质量的关键指标之一,而焊接过程中的热输入信息和熔池图像信息都与焊缝熔深有密切关系。本文通过建立304L不锈钢薄板等离子弧搭接焊数据采集系统,利用LabVIEW实时检测电信息,采用视觉传感技术实时获取薄板等离子弧搭接焊过程中的熔池图像,并通过图像处理方法获得熔池的几何参数信息,结合焊接工艺参数,选择峰值电流、峰值电压、焊接速度、离子气流量、保护气流量、熔池宽度和熔池后端长度作为输入量,焊缝熔深作为输出量,建立了基于支持向量机回归和BP神经网络的熔深预测模型。实验验证表明,采用径向基函数的支持向量机回归模型可以有效地对焊缝熔深进行预测,并具有很好的泛化能力,可为进一步实现在线优化焊接工艺参数提供依据。     

脉冲YAG激光小孔深熔焊

目前，激光加工技术已成为焊接、切割、打孔、表面处理的主要手段之一，发展迅速，具有越来越强的生命力。我们利用具有９０年代先进水平的激光加工设备，进行了一系列有关大功率激光加工技术的课题研究及项目开发工作，包括脉冲固体ＹＡＧ激光的深熔焊接问题。本文分析了...     

工业纯钛熔焊和钎焊接头的力学性能及组织特性

由于钛及其合金与人体组织相容性好,并且力学性能符合要求,因此已被广泛用作外科矫形和牙科植入材料,为减少钛植入体和牙齿间腐蚀的危险,采用钛制加固框架,因此需要用钎焊或熔焊连接.早先在Au-Pd基体钎焊和熔焊接头研究中发现,低熔点钎焊合金(735℃～785℃)接头强度低,而高熔点钎焊合金接头强度高.在单一拉伸应力作用下,激光熔焊接头强度与基材相当,但其疲劳强度是最低的.在牙科治疗中,激光熔焊和电弧焊适用于钛件,而钎焊钛件的资料尚缺乏.因此,下面选用二级工业纯钛做基材,采用钎焊,电弧焊和激光熔焊后,分析比较其各种接头的力学性能和组织特性等.     

2 000 MPa级热成形钢双光斑激光焊接接头成形研究

目的 探究焊接参数对PHS2000型热成形钢焊接接头宏观形貌的影响,利用双光斑激光焊接工艺减少焊接缺陷,得到形貌良好的焊接接头。方法 使用德国通快公司的Tru Disk 5000型双光斑激光器对2 000 MPa级热成形钢进行激光焊接。使用金相显微镜对不同参数下焊接接头正面和背面的宏观形貌及焊缝横截面的熔深和熔宽进行研究。结果 随着激光功率从3 500 W增大到4 400 W,焊接接头成形良好,熔深大体呈增大趋势,深宽比先下降后上升再下降;随着焊接速度从50 mm/min增大到250 mm/min,熔深、熔宽基本降低,深宽比总体呈下降趋势;随着芯环比的提高,焊缝背面成形变差,熔深在芯环比为55%～65%时较理想,深宽比总体呈W形上升;当离焦量为0mm时,焊缝背部出现了较为严重的烧损变色,并且在焊缝两侧产生了飞溅。而随着离焦量降低到-4 mm,烧损变色情况得到改善。结论 激光功率和芯环比对焊接接头成形的影响较为显著。得到了成形良好的焊接接头,且在激光功率为4 700 W、焊接速度为150 mm/min、芯环比为65%、离焦量为-2 mm的焊接参数下,1.4 mm厚2 000 MPa级热成...     

激光焊接等离子体三维图像重建的计算机模拟

激光焊接等离子体三维图像重建的计算机模拟     

激光熔覆-活化屏等离子体复合处理层耐磨性能研究

为了研究激光熔覆层性能对活化屏等离子体氮化处理层耐磨性能的影响,采用两种铁基合金粉末(Fe90和Fe314)在45钢基体表面进行激光熔覆,然后进行等离子体氮化复合处理,测试涂层干摩擦条件下的磨损性能。研究结果表明:复合处理后,Fe90激光熔覆层的硬度由750HV提高到1350HV,Fe314激光熔覆层的硬度由540HV提高到927HV;在相同载荷(30N)下,Fe90复合处理层的耐磨性提高到1.2倍,而Fe314复合处理的耐磨性降低为原来的42%;复合处理耐磨性能提高的关键在于激光熔覆层与氮化层的合理搭配,熔覆层能够提供足够的支撑。     

表面处理对TC4钛合金激光焊接的影响

目的 为了提高TC4钛合金焊缝强度,满足实际生产的要求.方法 对TC4钛合金表面分别进行砂纸打磨、喷砂、涂覆石墨层以及激光扫描处理,然后采用2000 W光纤激光器对TC4钛合金进行拼接焊接实验.结果 对表面处理后的焊接焊缝熔深、抗拉强度进行了测试,结果表明,相对于未经过表面处理的焊缝熔深,采用表面处理后的焊缝熔深均增加了30％,焊缝抗拉强度均有增加,其中采用激光扫描处理后的焊缝抗拉强度达到最高的1106 MPa,超过了母材的抗拉强度.结论 激光扫描处理后,在材料表面形成的毛化现象,增加了材料对激光的吸收率,提高了焊缝的熔深,同时激光扫描过程中,未引入任何的杂质,不会产生裂纹及气孔,使焊缝的抗拉强度大于母材,满足实际生产要求.     

铝合金双光束激光焊接工艺研究

在不同的焊接速度和焦斑间距下研究了5083铝合金的焊接行为,对焊缝熔深、熔宽和焊缝中的组织缺陷进行了系统研究。结果表明,适宜的双光束激光焊接工艺为:双光束夹角为20,焊接速度为2 m/min,焦距为0.4 mm,此时焊接过程稳定,焊接质量最佳。     

Focus control system for laser welding

We describe a focus control system for Nd:YAG laser welding based on an optical sensor incorporated into the fiber delivery system to detect light generated by the process. This broadband light is separated into two wavelength bands, and simple electronic processing gives a signal proportional to focal error as a result of chromatic aberrations in the optical delivery system. Focus control is demonstrated for bead-on-plate welds in different thicknesses of titanium alloy, aluminum alloy, mild steel, and stainless steel. The control system works for both pulsed and continuous laser radiation.     

图像处理在自动焊接中的应用和展望

图像处理技术在自动焊接领域的应用已引起国内外学者的广泛重视。通过图像传感技术获取焊接熔池直观丰富的图像信息，使用高效的图像处理算法，提取焊接熔池的特征信息，用以实现自动焊接过程质量实时传感与控制。本文综合论述了图像处理技术在自动焊接中的应用原理、数字图像的采集方法、数字图像的特征信息定义、广义数字图像处理技术及其对自动化焊接理论研究和实践应用的推动作用。通过总结图像处理技术的研究和应用现状，综合分析了图像处理技术在现代焊接技术中发展和应用的前景。     

Fusion Zone Microstructures of Laser and Plasma Welded Dissimilar Steel Joints

Dissimilar steel joints between 13CrMo44 low-alloyed ferritic steel and A1SI 347 austenitic stainless steel were produced using laser beam and plasma arC welding. Both autogenous welding (without Filler) and welding with nickel-based filler wire were employed in each process. Fusion zone microstructures were characterized using both optical and scanning electron microscopy. Compositional analysis was performed using scanning electron microscopy. Hardness was measured to provide data for identifying the microstructures. A clear correlation was observed between the composition, microstructure and hardness. The results show that both autogenous laser and plasma welding produce fusion zones with a mixed martensite/austenite microstructure. Autogenous plasma welds, however, possess less martensite than the laser welds. The formation of martensite was attributed to the material combination and the rapid cooling rate of the welding processes. The results also indicate that both laser and plasma welding with nickel-based filler wire can produce fully austenitic fusion zones. This is mainly due to the high nickel content in the filler wire. According to the results, laser and plasma welding with nickel-based filler wire are recommended as potential industrial processes.     

一种基于数据间相关性的激光喷丸声学监测技术

激光喷丸作为一种新兴的金属材料表面强化技术,与普通喷丸相比,具有更显著的改性作用,使其在航空等领域有着重要的应用价值。随着该技术的工业化程度不断加深,需要加强对其工作状态的监测诊断,保证其良好的运行状况。由于声学信号不仅携带有丰富的工作特征信息,而且获取成本较低,并能够实现无损检测,所以将声学信号应用于激光喷丸的状态监测。通过分析由等离子体冲击波衰减所产生的声波信号,提取信号特征,进行过程监测。针对于冲击信号的非线性特征,从信号内相邻数据间相关性的角度,提出了一种新的冲击声信号特征挖掘方法。一方面对于模拟冲击信号进行了分析,另一方面,对于激光喷丸实际声信号进行了处理,表明该方法能够识别冲击信号的特征变化,可以用于监测激光喷丸的工作过程,操作简单且速度较快,具有较好的应用前景。     

Active contour segmentation by use of a multichannel incoherent optical correlator

We describe an optoelectronic incoherent multichannel processor that is able to segment an object in a real image. The process is based on an active contour algorithm that has been transposed to optical signal processing to accelerate image processing. This implementation requires exact-valued correlations and thus opens attractive perspectives in terms of optical analog computation. Furthermore, this optical multichannel processor setup encourages incoherent processing with high-resolution images.     

Photon-limited synthetic-aperture imaging for planet surface studies

The carrier-to-noise ratio that results from phase-sensitive heterodyne detection in a photon-limited synthetic-aperture ladar (SAL) is developed, propagated through synthetic-aperture signal processing, and combined with speckle to give the signal-to-noise ratio of the resultant image. Carrier- and signal-to-noise ratios are defined in such a way as to be familiar to the optical imaging community. Design equations are presented to show that a 10-microm SAL in orbit around Mars can give centimeter-class resolution with reasonable laser power. SAL is harder to implement in the short-wave infrared and is probably not practical at visible wavelengths unless many separate images can be averaged. Some tutorial information on phase-sensitive heterodyne detection and on synthetic-aperture signal processing and image formation is provided.     

Online Monitoring of Welding Status Based on a DBN Model During Laser Welding

In this research, an auxiliary illumination visual sensor system, an ultraviolet/visible (UVV) band visual sensor system (with a wavelength less than 780 nm), a spectrometer, and a photodiode are employed to capture insights into the high-power disc laser welding process. The features of the visible optical light signal and the reflected laser light signal are extracted by decomposing the original signal captured by the photodiode via the wavelet packet decomposition (WPD) method. The captured signals of the spectrometer mainly have a wavelength of 400–900 nm, and are divided into 25 sub-bands to extract the spectrum features by statistical methods. The features of the plume and spatters are acquired by images captured by the UVV visual sensor system, and the features of the keyhole are extracted from images captured by the auxiliary illumination visual sensor system. Based on these real-time quantized features of the welding process, a deep belief network (DBN) is established to monitor the welding status. A genetic algorithm is applied to optimize the parameters of the proposed DBN model. The established DBN model shows higher accuracy and robustness in monitoring welding status in comparison with a traditional back-propagation neural network (BPNN) model. The effectiveness and generalization ability of the proposed DBN are validated by three additional experiments with different welding parameters.     

Optical techniques for real-time penetration monitoring for laser welding

Optical techniques for real-time full-penetration monitoring for Nd:YAG laser welding have been investigated. Coaxial light emission from the keyhole is imaged onto three photodiodes and a camera. We describe the spectral and statistical analyses from photodiode signals, which indicate the presence of a full penetration. Two image processing techniques based on the keyhole shape recognition and the keyhole image intensity profile along the welding path are presented. An intensity ratio parameter is used to determine the extent of opening at the rear of a fully opened keyhole. We show that this parameter clearly interprets a hole in formation or a lack of penetration when welding is performed on workpieces with variable thicknesses at constant laser power.     

大视场激光探测与告警技术

利用四路红外非制冷焦平面探测器、大视场光学系统、窄带滤光片和信号处理系统,构成了凝视成像激光探测与告警系统。光学系统采用三片式结构的广角镜头来实现大视场;使用先进的非球面光学设计技术,并以FPGA完成探测器响应信号的非均匀校正,以改善像质;通过光学系统的畸变校正,提高激光的探测方向精度;利用激光和背景强度之间的反差,通过激光目标检测算法进行告警。实验表明,该系统能在127视场范围内对波长为1.315靘, 2.7靘, 3.8靘, 10.6靘的4种激光进行告警,探测功率密度范围为0.05 ~50mW/cm2,探测方向精度可达1。     

Optical Sensor for real-time Monitoring of CO(2) Laser Welding Process

An optical sensor for real-time monitoring of laser welding based on a spectroscopic study of the optical emission of plasma plumes has been developed. The welding plasma's electron temperature was contemporarily monitored for three of the chemical species that constitute the plasma plume by use of related emission lines. The evolution of electron temperature was recorded and analyzed during several welding procedures carried out under various operating conditions. A clear correlation between the mean value and the standard deviation of the plasma's electron temperature and the quality of the welded joint has been found. We used this information to find optimal welding parameters and for real-time detection of weld defects such as crater formation, lack of penetration, weld disruptions, and seam oxidation.