盲孔法测试Q690高强钢管镀锌前后残余应力

残余应力对轴心受压构件的稳定性等有重要影响,为考察Q690焊接高强钢管镀锌前后的截面纵向残余应力分布,该文采用盲孔法对截面规格分别为、和共计24个试件的残余应力进行测试。通过试验得出了每种截面规格圆钢管的纵向残余应力的数值大小和分布模式,并将相同截面规格的钢管在镀锌前后的残余应力分布进行了比较,试验结果表明,钢管镀锌后残余应力有了明显的降低。通过对Q690未镀锌钢管的试验结果总结发现,Q690高强钢管的截面最大纵向残余应力与其钢材屈服强度的比值明显小于普通钢材:普通钢材为0.35,而该次试验测得的最大值为0.15。     

Q420焊接圆钢管轴心受压稳定性能试验和设计方法研究

该文进行了15个Q420高强度钢材埋弧焊接圆钢管柱轴心受压试验研究,基于试验结果总结了其失稳变形特征,分析比较了15个试件的稳定系数与我国规范柱子曲线计算值的关系,并验证了有限元模型的可靠性。基于有限元参数分析计算结果,对比60个试件的稳定系数与我国规范柱子曲线计算值的关系,对Q420高强度钢材埋弧焊接圆钢管的整体稳定设计方法提出两种建议:一是对于我国规范柱子曲线选择的建议,即对于Q420埋弧焊接圆钢管可以按a类截面计算其稳定承载力;二是更新我国柱子曲线整体稳定系数φ的计算参数α₁、α₂、α₃,建议了一条新的设计曲线。     

Q690高强钢管焊接残余应力数值模拟

该文重点研究Q690焊接高强钢管截面纵向残余应力分布模式,利用商业有限元分析软件ANSYS对其进行数值模拟,运用其中的“生死单元”和热-结构耦合分析功能来模拟焊接过程,以管径与壁厚为变量,设计3组共12个有限元模型。通过对模型的数值分析,得到每个模型的截面纵向残余应力分布形式,经过对比分析得出其规律,并提出Q690焊接高强钢管截面纵向残余应力的简化分布模式。结果表明,其分布模式与Wagner提出的分布模式接近,但Q690高强钢管的纵向残余压应力峰值与其屈服强度的比值仅为0.2,要明显小于普通钢管纵向残余压应力峰值与其屈服强度的比值0.35。     

电阻焊直缝焊接套管残余应力分布的测定

采用X射线法结合环劈法对电阻焊直缝焊接套管的管体和焊缝的应力分布,以及焊接套管切割后应力的变化进行研究。结果表明：焊接套管残余应力在周向上分布不均,并且焊缝处残余应力很高,接近其屈服强度;焊接套管切割后管体外表面残余应力随着时效时间的增长由拉应力转为压应力,而内表面由压应力转为拉应力。     

国产Q460高强度钢材焊接工字形截面残余应力试验及分布模型研究

焊接残余应力是影响钢结构受压构件整体稳定性能的一种重要初始缺陷. 为研究国产Q460高强度钢材焊接工字形截面的残余应力分布, 该文采用分割法对8个不同截面尺寸和焊缝类型的截面试件进行了测量. 基于近2000组测量数据, 得到了不同试件全截面的残余应力分布和拉、压应力大小, 并研究了腹板和翼缘的板件宽厚比、板件厚度、焊缝类型以及腹板和翼缘的相关性等因素对残余应力的影响. 试验结果表明, 残余压应力的数值大小与截面尺寸直接相关而基本不受焊缝类型的影响, 残余拉应力的大小则与截面尺寸没有相关性;由于翼缘和腹板内的残余应力能够分别满足自平衡条件, 二者没有相互间的影响作用. 最后, 该文提出了能够准确描述试验结果和截面尺寸影响的国产Q460高强钢焊接工字形截面的残余应力分布模型和计算公式.     

Q355钢板对接接头裂纹扩展所致焊接残余应力重分布研究

目的 定量研究裂纹扩展导致的焊接残余应力重分布效应,得到残余应力随裂纹扩展的变化规律。方法 首先采用盲孔法测试了Q355钢板对接接头的初始残余应力;其次利用线切割技术模拟了平行以及垂直于焊缝的裂纹扩展情况,并测试了裂纹扩展导致的残余应力变化量;最后根据测试数据提出了残余应力释放量Δσ与裂纹长度a之间的函数关系式,进一步得到了基于裂纹扩展的应力重分布计算公式。结果 Q355钢板对接焊的焊缝区纵向(沿焊缝方向)存在较大的残余拉应力,拉应力峰值出现在焊趾处,为屈服强度的1.13倍。焊缝区横向存在梯度较大、拉压交替变化的残余应力,压应力峰值出现在焊趾处,大小为52.6 MPa,拉应力峰值出现在距焊缝中心线17 mm处,大小为63.5 MPa。裂纹扩展能显著释放残余拉应力:裂纹沿焊缝中心扩展,横向残余拉应力峰值降低了45.8%;裂纹沿垂直于焊缝方向扩展,焊趾处的拉应力峰值降低了63.3%。结论 裂纹扩展会显著影响焊接构件的残余应力分布,根据实测数据提出的裂纹扩展应力重分布计算公式能够较好地反映残余应力重分布情况。     

6061-T6铝合金中厚板-节点套多层多道焊数值模拟

为研究铝合金中厚板-节点套接头在多层多道焊后的残余应力和变形分布,本文基于ABAQUS软件建立了该接头三维有限元模型,采用双椭球热源、生死单元法以及顺序耦合法,对6061-T6铝合金中厚板-节点套多层多道焊进行数值模拟,并分析了接头的温度场,以及在夹具约束下的焊接残余应力及变形的分布情况。研究结果表明:数值模拟与实际接头的熔池形状吻合度较高;摆动焊接过程中温度曲线呈多峰结构;焊件的升温速率明显大于冷却速率,且冷却速率随时间逐渐减小;焊接残余应力主要集中在焊缝及夹具区域,且小于6061-T6铝合金在室温下的屈服强度;接头的最大横向残余应力为129.9 MPa,中厚板上的横向残余应力大于节点套上的横向残余应力;接头的最大纵向残余应力为132.9 MPa,沿焊接方向,焊缝处的纵向残余应力呈山峰状分布;该接头在Y轴方向上的变形最大,为1.494 mm,该接头的最终变形结果为上凸变形。     

喷丸处理对2219铝合金搅拌摩擦焊焊接残余应力的影响

对2219铝合金板进行了搅拌摩擦焊(FSW)和喷丸处理，采用X射线衍射仪(XRD)测量了搅拌摩擦焊和喷丸产生的残余应力，分析了残余应力的分布特征，研究了弹丸直径、弹丸材料、喷射距离等参数对搅拌摩擦焊接残余应力分布的影响。结果表明：焊接后，焊缝附近存在较大的残余拉应力，焊缝中心线±20 mm范围内的平均应力高达100.9 MPa,而远离焊缝的母材区域接近零应力状态；喷丸后，试样残余应力分布发生显著变化，表层残余应力表现为压应力，并且该压应力数值随着深度的增加先增大后减小，最后保持为拉应力；增大弹丸直径可提高最大残余压应力值和残余压应力层深度，但当弹丸直径继续增大至1.2 mm时，最大残余压应力值不再继续增大；选用合适的弹丸材料可获得理想的残余压应力分布情况；随着喷射距离的增大，最大残余压应力值和残余压应力层深度先增大后减小。     

蜂窝构件开孔截面焊接残余应力分布研究

该文采用盲孔法,对7根蜂窝式钢构件开孔处截面焊接残余应力进行检测,对比六边形和圆形两种典型孔型下,不同开孔率、开孔方式蜂窝构件开孔处截面纵向焊接残余应力数值大小和分布范围。分析不同影响因素下,蜂窝构件开孔处板桥残余应力变化特点。结果表明:蜂窝构件开孔处截面焊接残余应力较实腹构件分布趋势相似,焊缝区残余应力峰值接近钢材屈服强度。蜂窝构件腹板开孔形状对焊接残余应力分布影响很小;板桥残余应力峰值随着开孔率的增大而减小;腹板直接开孔蜂窝构件较切割错位焊接蜂窝构件残余应力分布有所不同。在试验数据数值分析的基础上,提出了不同加工工艺下蜂窝构件开孔截面焊接残余应力分布模式,为后续蜂窝构件整体稳定承载力研究提供基础数据。     

高强钢焊接构件工字形横截面残余应力试验及统一分布模型研究

为研究不同强度等级高强钢焊接工字形截面残余应力的变化规律,采用分割法对960MPa钢材试件进行测量,得到了残余应力分布。将试验结果与大量其他强度等级(包括235MPa、345MPa、460MPa以及690MPa)钢材焊接工字形截面的残余应力进行对比分析,研究了残余拉应力和残余压应力随钢材强度的变化规律。研究结果表明,焊缝和翼缘焰切边附近残余拉应力与截面几何尺寸无明显相关性,且呈现随钢材强度增大而增大的变化规律,并始终低于钢材强度;翼缘和腹板的残余压应力与钢材强度无明显关系,但随板件宽厚比及板厚的增大而明显减小。基于这一规律及大量试验数据,提出了不同强度等级钢材焊接工字形截面残余拉应力和压应力的计算方法,确定了分布范围,制定了统一分布模型,为不同强度等级高强钢结构的研究提供了基础条件。     

Numerical analysis of residual stresses in welds of similar or dissimilar steel weldments under superimposed tensile loads

This paper presented the characteristics of residual stresses in welds of similar or dissimilar steel weldments by carrying out three-dimensional (3-D) thermal elastic–plastic finite element (FE) analyses. Moreover, residual stress behavior in welds of the weldments under superimposed tensile loads was further investigated. The materials used in this investigation were SM400, SM490, SM520 and SM570, widely used structural steels in welded structure. Results show that the maximum longitudinal residual stresses in welds of the similar steel weldments increase with increasing yield stress of the steel welded (SM400 < SM490 < SM520 < SM570). When tensile loads are superimposed to edges of the weldments, the maximum longitudinal residual stresses are increased to a higher value. In case of the dissimilar steel weldments, the difference between the longitudinal residual stresses in welds increases with increasing yield stress of the steel welded together with SM400 (SM490 < SM520 < SM570). When tensile loads are superimposed to edges of the weldments, same pattern is noted for the longitudinal stresses in welds and the difference is almost the same as that between the longitudinal residual stresses in welds.     

Prediction of residual stresses in welds of similar and dissimilar steel weldments

The fabrication of structural member using dissimilar steels renders steel structures lighter and more economical. However, it always involves welding process and produces different residual stresses in welds as compared with welding of similar steels. This paper presents the characteristics of residual stresses in welds of similar and dissimilar steel weldments by carrying out three-dimensional (3-D) thermal elastic-plastic finite element (FE) analysis. The materials used in this investigation were SM400, SM490, SM520 and SM570, widely used structural steels in welded structure. Results show that the maximum longitudinal residual stresses in welds of the similar steel weldments increase with increasing yield stress of the steel welded (SM400 < SM490 < SM520 < SM570). In case of the dissimilar steel weldments, the difference between the longitudinal residual stresses in welds increases with increasing yield stress of the steel welded together with SM400 (SM490 < SM520 < SM570).     

均匀受压两铰圆弧钢拱的平面内稳定设计曲线

采用大挠度弹塑性有限单元法对均匀受压两铰圆弧钢拱的平面内稳定性进行了研究,考虑了材料非线性、残余应力、初始几何缺陷的影响,得到了焊接工字型截面、热轧圆管截面和焊接箱型截面两铰圆弧钢拱的平面内稳定设计曲线,并与德国钢结构设计规范及美国结构稳定研究委员会的设计曲线进行了对比;建议的稳定设计曲线可用于均匀受压两铰圆弧钢拱的平面内稳定性设计,供我国拱形钢结构设计规程制定时参考。     

Residual Stress Evolution in Repair Welds

Abstract: The aim of this paper is to study the influence of the repair procedure on the evolution of residual stress distribution in butt welds. C-Mn steel coupon plates of 11 mm thickness were prepared, subjected to stress relief heat treatment and welded with two beads, using the gas metal arc welding process. After the deposition of two weld beads, two successive repair welds were made on the middle length of the second bead. Longitudinal and transverse residual stresses were measured in the vicinity of the weld, after deposition of the two weld beads and after each repair weld. Residual stress evaluation was conducted using an X-ray diffraction method. The repair welds caused a decrease in magnitude of the initial longitudinal residual welding stresses, and an increase of the transverse residual stress magnitude, in tension at points within the repair length, and in compression at points outside the repair length.     

Influence of the submerged arc welding in the mechanical behaviour of the P355NL1 steel—part II: analysis of the low/high cycle fatigue behaviours

A normalized fine grain carbon low alloy steel, P355NL1 (EN10028-3), intended for service in welded pressure vessels, where notch toughness is of high importance, has been investigated. Applications with this steel usually require the intensive use of welds. One of the most common welding processes that are used in the manufacturing of pressure vessels is the submerged arc welding. This welding process is often automated in order to perform the main seam welds of the body of the vessels. The influence of the automated submerged arc welding, in the mechanical performance, is investigated. In this paper (Part II) the low and high cycle fatigue and crack propagation behaviours are compared between the base and welded materials. Several series of small and smooth specimens as well as cracked specimens made of base, welded and heat affected materials, respectively, were fatigue tested. Strain, stress and energy based relations for fatigue life assessment, until crack initiation, are evaluated based on experimental results and compared between the base and welded materials. Finally, the fatigue crack propagation behaviours are compared between the base, welded and heat affected materials.     

Research on fatigue behavior and residual stress of large-scale cruciform welding joint with groove

Fatigue fracture behavior of the 30 mm thick Q460C-Z steel cruciform welded joint with groove was investigated. The fatigue test results indicated that fatigue strength of 30 mm thick Q460C-Z steel cruciform welded joint with groove can reach fatigue level of 80 MPa (FAT80). Fatigue crack source of the failure specimen initiated from weld toe. Meanwhile, the microcrack was also found in the fusion zones of the fatigue failure specimen, which was caused by weld quality and weld metal integrity resulting from the multi-pass welds. Two-dimensional map of the longitudinal residual stress of 30 mm thick Q460C-Z steel cruciform welded joint with groove was obtained by using the contour method. The stress nephogram of Two-dimensional map indicated that longitudinal residual stress in the welding center is the largest.     

倾斜坡体中圆孔扩张的弹性应力分析

针对实际工程中遇到的斜坡边界下圆形孔扩张问题,提出了相应的计算方法。在考虑坡体自重应力的情况下,通过坐标变换将其转为水平边界半无限体中圆孔扩张,采用复变函数共形映射的方法得到应力解析。当圆形孔埋置较深时,将问题简化为无限体中圆孔的扩张,通过弹性力学的基本叠加得到最终应力解答。以一斜坡边界下圆形孔洞扩张为例,求解了圆孔周围径向正应力、环向正应力与切应力的分布。计算结果表明:斜坡倾角对坡体中应力分布影响显著,某点应力随距圆心距离的增大而减小,超过约4倍圆孔半径远处逐渐趋于稳定,其值接近于初始地应力场。当圆孔为深埋的情况时,与简化为无限平面的情况进行了对比,两种方法计算结果接近,距圆心2.5R远处岩体径向正应力和环向正应力均为负值,而切应力正负值间隔分布,各应力极值分布与斜坡倾向呈一定的相关性。     

高强船体钢双丝埋弧焊焊接接头CTOD试验研究

根据GB／T2358—1994标准,对16ram厚的高强船体钢焊接接头的焊缝中心-40℃的裂纹尖端张开位移（CTOD）进行测试,绝大部分试样的断裂韧性值是有效合格的,其CTOD值大于0．15mm,符合DNV验收标准。试验结果表明,在给定的双丝埋弧焊接工艺下,该钢种焊缝低温韧性好。该钢种中等厚度双丝埋弧焊焊接接头可以在不进行焊后热处理的情况下使用。     

A study on mechanical and microstructure characteristics of the STS304L butt joints using hybrid CO2 laser-gas metal arc welding

In order to examine mechanical characteristics of the stainless steel (STS304L) hybrid welded butt joints, two-dimensional thermal elasto-plastic analysis has been carried out. To this end, a 2D simulation model has been developed considering hybrid welding features. Based on thermal history data obtained from this heat source model, the residual stress distribution in weld metal (WM), heat affected zone (HAZ) and base metal (BM) characteristics have been calculated and found to be in reasonable agreement with the experimentally measured values. In order to investigate the effect of welding process, thermal elasto-plastic behaviour of the hybrid welded joints was compared with a welded joints obtained by conventional submerged arc welding (SAW) process. The results show that the longitudinal residual stress in the hybrid welded joints is less (13–15%) than that of the SA welded joints. Weld metal formed in both welding processes shows very fine dendritic structure. Due to higher heat input in SAW, the HAZ size of the SA welded joints is more than twice that of the hybrid welded joints. Therefore, from mechanical and metallurgical point of view, it could be confirmed that it makes a good sense to use SAW instead of hybrid CO₂ laser-gas metal arc welding (GMAW) for butt joint of the STS304L thick steel.