铝合金电阻点焊接头缺陷的搅拌摩擦修复

针对铝合金电阻点焊极易产生裂纹、缩孔等缺陷的问题,提出了基于无针搅拌摩擦热力耦合效应修复铝合金电阻点焊接头缺陷的方法.通过改变搅拌头转速和摩擦停留时间等参数,研究了热力耦合效应对裂纹及缩孔缺陷的修复效果和影响规律.结果表明,在合适的搅拌摩擦工艺下,单面处理可实现熔核内条型裂纹的修复,但缩孔缺陷仍然存在,性能没有明显改善;双面下冲处理能有效修复熔核内条型裂纹及缩孔缺陷,接头断裂方式为脆性断裂,最大拉剪力从3.20 kN增加到6.14 kN,证明搅拌摩擦热力耦合效应修复铝合金电阻点焊接头缺陷的方法是可行的.     

Characterization of Low-Pressure Cold-Sprayed Aluminum Coatings

Aluminum alloys are widely used as materials for engineering components of automobiles and airplanes because of their light weight and high corrosion resistance. However, cracks may develop sometimes in aluminum components, which have to be repaired by welding. It is difficult to weld aluminum components due to its high specific thermal conductivity and high coefficient of thermal expansion. The low-pressure cold-spray technique can be used instead of welding for repairing cracks. However, the effects of surface conditions on particle deposition and the mechanical properties of cold-sprayed coatings have not been investigated thus far. In this study, the effect of surface conditions focusing on active newly formed surface on aluminum particle deposition is studied and the mechanical properties of low-pressure cold-sprayed aluminum coatings are investigated by four-point bending tests. It is found that for efficient particle deposition it was necessary to obtain active newly formed surface of the substrate and particle surfaces by several impingements because the existence of inactive native oxide films has an adverse effect on the deposition. Furthermore, the strength of a cold-sprayed specimen is found to be higher than that of a cold-rolled specimen under compressive loading.     

喷丸对铝合金亚表面裂纹闭合修复的影响与试验

目的 研究喷丸修复7075-T651铝合金亚表面裂纹的愈合机理及修复效果。方法 建立材料亚表面裂纹在喷丸作用下的修复模型,运用Ansys进行数值模拟计算,并预测裂纹深度修复阈值;根据模型,利用线切割制造相应的裂纹,并对其进行喷丸修复,从残余应力、疲劳强度、微观结构等方面分析裂纹愈合的机理,并评估修复效果。结果 仿真结果表明,在弹丸直径D=0.5 mm、弹丸速度v=100 m/s时喷丸修复效果最佳,裂纹修复深度阈值为0.15mm;裂纹修复区域的表面应力为非裂纹区域的83.17%,实验结果与仿真结果相符;在修复裂纹后,试件的疲劳强度可以达到完好试样的70.32%。剧烈的喷丸冲击使裂纹亚表面材料产生较大的微观形变热,有利于组织形变,促使裂纹两侧的晶粒组织形成闭合挤压,宏观上表现为压应力下组织的紧密闭合,这种闭合起到了修复裂纹的作用,整体上属于物理性修复,但仍无法完全消除裂纹对材料的消极影响。结论 喷丸通过压力作用对亚表面材料的裂纹进行闭合修复,使材料的疲劳强度得到恢复,这对于铝合金结构件裂纹的早期修复和应急性修复具有积极作用。     

Defect assessment of welded specimen considering weld induced residual stresses using SINTAP procedure and FEA

The defect assessment in butt-welded joint of ASTM A36 steel plates and 7075-T7351 aluminum alloy plates containing transverse through thickness crack was analyzed using SINTAP procedure and FEA incorporating weld induced residual stresses. Weld induced longitudinal residual stress profile can be obtained through SINTAP procedure, FEA or experimental analysis. This residual stress profile can be fitted with the trapezoidal residual stress profile available in SINTAP. For three different cases, crack length and residual stress intensity factor (SIF) are calculated and its comparison with the results obtained through FEA is plotted with respect to crack length. The stress intensity factor for mechanical loading is also plotted in the same graph. Using this graphical plot, the total SIF, including residual stress and mechanical loading, can be calculated for any particular crack size. The total SIF can be compared with the fracture toughness of the material for damage tolerance analysis. Also a failure assessment diagram is drawn for welded 7075-T7351 aluminum alloy plates with different crack sizes for as-welded (only residual stress) and mechanical loading along with the existing weld induced residual stresses to show the safety level for a particular crack size and mechanical loading.     

甲醇装置用废热锅炉管板的修复

甲醇装置用废热锅炉管板在使用过程中局部出现了裂纹,为保证设备的正常运行,需进行修复.由于换热管与管板材质均为低合金耐热钢,含有较多的Cr-Mo,空淬倾向大,焊接时易出现冷裂纹,同时为了消除焊接应力和焊缝金属组织,焊后必须进行热处理.结合Cr-Mo耐热钢的焊接特点、现场施工条件和缺陷情况,制定了管板修复方案,采用手工钨极...     

Effect of laser repairing on corrosion behaviour of metal–inert gas welding joint of 7N01 aluminium alloy

The heat affected zone (HAZ) on the metal–inert gas (MIG) welding joint of 7N01 aluminium alloy was repaired by multipass narrow gap laser welding. The Y–X direction precracked three‐point bending sample was used in the alternate immersion test. The morphology of specimen surfaces demonstrated that the exfoliation corrosion in the HAZ after laser repair (HAZ_a) was more serious than that before laser repair (HAZ_b). The electrochemical impedance spectroscopy after different immersion corrosion time indicated that the HAZ_a and HAZ_b had similar corrosion potentials. However, the pitting corrosion resistance of HAZ_a was lower than that of HAZ_b at the beginning of exfoliation corrosion. The stress corrosion crack (SCC) of 7N01P‐T4 aluminium alloy displayed a multicrack source and an intergranular crack propagated along the rolling grain boundary under the test condition. An unusual method was taken to measure the length of SCC. The results showed that laser repairing did not weaken the stress corrosion resistance of the original joint.     

Analysis and Modeling of Friction Stir Processing-Based Crack Repairing in 2024 Aluminum Alloy

A friction stir processing-based method was used to repair cracks in the 2024 aluminum alloy plates.The temperature field and plastic material flow pattern were analyzed on the basis of experimental and finite element simulation results.Microstructure and tensile properties of the repaired specimens were studied.The results showed that the entire crack repairing was a solid-phase process and plastic materials tended to flow toward the shoulder center and then resulted in the repairing of cracks.Meanwhile,the coarse grain structures were refined in repaired zone(RZ),while the grains in thermal-mechanically affected zone and heat-affected zone were elongated and driven to grow up.Meanwhile,large phases are crushed into small particles and dispersed inside the RZ.Finally,the strength of the repaired specimens can be restored dramatically and their ductility can be partially restored.After heat treatment,the tensile properties of the repaired specimens can be further enhanced.     

7N01铝合金脉冲MIG焊与直流CMT焊多次补焊试验

高速列车用7N01铝合金有较大热裂纹倾向,而补焊时该问题更突出.分别采用脉冲MIG焊和低热输入直流CMT焊对4 mm厚7N01铝合金对接接头进行1次、2次、3次补焊,分析了补焊焊接接头的宏观成形、微观组织和硬度.结果表明,脉冲MIG补焊时下塌量和熔宽均大于直流CMT补焊,脉冲MIG补焊焊道与先焊焊缝微观组织界面明显,先焊焊缝晶粒粗大且晶界发生重熔,熔合区变宽,而直流CMT补焊焊道界面不明显,焊缝微观组织晶粒细小,熔合区无明显变化;脉冲MIG焊3次补焊后软化现象较直流CMT补焊严重.采用直流CMT焊进行7N01铝合金补焊,可有效降低热裂纹倾向并缓解接头性能下降.     

类激光堆焊修复柴油发动机肩胛密封面

针对老旧柴油发动机肩胛密封面腐蚀损伤修复难的问题,选用HS121镍基合金焊丝作为焊接修复材料,采用类激光焊接技术对其进行修复。使用光学显微镜、X射线应力测定仪(XPS)、电化学工作站、高频往复摩擦磨损试验机、扫描电镜(SEM)和激光三维形貌仪对堆焊修复层截面微观组织形貌、残余应力、耐腐蚀和抗磨损性能等进行了观察和测试。结果表明,类激光堆焊修复层与母材属冶金结合,且无明显焊接缺陷;堆焊修复层表面的残余应力为普通氩弧焊的16%,腐蚀速率为基体的19.88%,耐磨性较基体提高了2.66倍。此外,修复层的自腐蚀电位正于发动机基体材料,自腐蚀电流密度值约为基体材料的1/2。     

一种改进的Lemaitre断裂准则及其在弯曲成形裂纹预测中的应用

针对弯曲成形中的裂纹缺陷,应用Lemaitre韧性断裂准则,同时考虑应力三轴度,最大主应力比,以及塑性应变对损伤的影响,对Lemaitre准则进行改进,有效预测了弯曲成形中金属板料的成形极限。以7075-T6铝合金为研究对象,模拟得到该合金板材的裂纹产生条件,获取改进的Lemaitre准则材料参数,确定破裂阈值。对6 mm厚7075-T6铝合金板材进行三点弯曲实验,并观察其金相组织。对其产生裂纹时的压下量与断裂准则所得的理论压下量进行比较,验证了改进后断裂准则对裂纹预测的准确性。通过对比产生裂纹时的压下量,结果表明,改进后的Lemaitre断裂准则所得理论压下量为9.7 mm,与模拟和实验结果一致,证明改进后的Lemaitre准则对弯曲成形裂纹预测具有一定的准确性。     

铝合金前臂断裂失效分析

某表面镀铜的铝合金前臂连接杆受单向下压应力作用,使用3个月后发生开裂,通过化学成分分析、宏观及微观断口分析、高倍金相检验、力学性能试验、显微硬度测定等方法对铝合金杆断裂原因进行了综合分析,结果表明：铝合金杆是弯曲应力作用下的疲劳断裂,疲劳从表面线性起裂,镀铜前材料本身存在裂纹缺陷,镀铜进一步渗入基体材料,工作中铝合金杆受到了单向应力进而加速导致疲劳开裂。     

6061-T6铝合金回填式搅拌摩擦点焊疲劳性能分析

对6061-T6铝合金点焊接头进行单点疲劳试验,确定6061-T6铝合金回填式搅拌摩擦点焊的疲劳断裂原因,得出6061-T6铝合金的S-N曲线以及条件疲劳极限.通过对载荷水平为1.5 kN的6061-T6 RFSSW疲劳试样进行金相分析以及断口扫描分析,得到了6061-T6铝合金疲劳断裂原因以及疲劳断口特征.结果表明,6061-T6点焊接头中的钩状缺陷和上下板结合处缺口尖端的应力集中是造成疲劳破坏的主要原因,疲劳裂纹始于上下板搭接处焊点的钩状缺陷外边缘,即缺口尖端处;在焊接过程中,应通过优化工艺参数尽量减小钩状缺陷的尺寸以及降低缺口处的应力集中,从而提高焊点的疲劳寿命.     

Effect of pre-strain on fatigue crack growth of 2E 12 aluminum alloy

The influences of pre-strain on the mechanical property and fatigue crack growth of 2E12 aluminum alloy were evaluated by SEM, TEM, mechanical property and fatigue tests. The axial fatigue tests were conducted under a constant amplitude sinusoidal wave loading at stress ratio of 0.1 in laboratory air and salt fog at room temperature. The results show that the yield stress of pre strain material is higher than that of the material without undergoing pre-strain, but pre-strain can not make the increase of the growth rate of fatigue crack. Fatigue crack growth rates of the alloy in salt fog are higher than those in air. The increased fatigue crack growth of the alloy in a given environment and more brittle striations can be observed in salt fog.     

Fatigue Behavior of Friction Stir-Welded Joints Repaired by Grinding

Fatigue is undoubtedly the most important design criterion in aeronautic structures. Although friction stir-welded joints are characterized by a high mechanical performance, they can enclose some defects, especially in their root. These defects along with the relatively low residual stresses of the friction stir-welding thermomechanical cycle can turn into primary sources of crack initiation. In this context, this article deals with the fatigue behavior of friction stir-welded joints subjected to surface smoothing by grinding improvement technique. The 4-mm-thick aluminum alloy 2024-T351 was used in this study. The fatigue strength of the base material, joints in the as-welded condition, and the sound and defective friction stir-welded joints improved by grinding were investigated in detail. The tests were carried out with a constant amplitude loading and with a stress ratio of R = 0. The fatigue results show that an improvement in fatigue behavior was obtained in the joints repaired by superficial grinding technique. The weld grinding technique is better especially for lower loads and increases the high cycle fatigue strength. The fatigue strength of the improved welded joints was higher than that of the base material.     

Springback evaluation of friction stir welded TWB automotive sheets

Springback behavior of automotive friction stir welded TWB (tailor welded blank) sheets was experimentally investigated and the springback prediction capability of the constitutive law was numerically validated. Four automotive sheets, aluminum alloy 6111-T4, 5083-H18, 5083-O and dual-phase DP590 steel sheets, each having one or two different thicknesses, were considered. To represent mechanical properties, the modified Chaboche type combined isotropic-kinematic hardening law was utilized along with the non-quadratic orthogonal anisotropic yield function, Yld2000-2d, while the anisotropy of the weld zone was ignored for simplicity. For numerical simulations, mechanical properties previously characterized [1] were applied. For validation purposes, three springback tests including the unconstrained cylindrical bending, 2-D draw bending and OSU draw-bend tests were carried out. The numerical method performed reasonably well in analyzing all verification tests and it was confirmed that the springback of TWB as well as of base samples is significantly affected by the ratio of the yield stress with respect to Young’s modulus and thickness.     

Mechanisms governing deformation and damage during elevated-temperature fatigue of an aluminum-magnesium-silicon alloy

The cyclic deformation and fracture characteristics of aluminum alloy 6061 are presented and discussed. The specimens were cyclically deformed using fully reversed tension-compression loading under total strain-amplitude control, over a range of temperatures. The alloy showed evidence of softening to failure at all test temperatures. The degree of softening during fully reversed deformation increased with test temperature. The presence of shearable matrix precipitates results in a microstructure that offers a local decrease in resistance to dislocation movement, causing a progressive loss of strengthening contributions to the matrix. At elevated temperatures, localized oxidation and embrittlement at the grain boundaries are exacerbated by the applied cyclic stress and play an important role in accelerating crack initiation and subsequent crack propagation. The fracture behavior of the alloy is discussed in light of competing influences of intrinsic microstructural effects, deformation characteristics arising from a combination of mechanical and microstructural contributions, cyclic plastic strain amplitude and concomitant response stress, and the test temperature.     

Bending mechanical property and failure mechanisms of woven carbon fiber-reinforced aluminum alloy composite

Copper-coated woven carbon fiber-reinforced aluminum alloy composite was prepared by spark plasma sintering (SPS). Microstructure, three-point bending mechanical property, and the failure mechanisms of the composite were investigated. Microstructure observation shows that the carbon fibers bond compactly with matrix alloy. Compared with the matrix aluminum alloy, the bending strength, ductility, fracture energy, and cracking resistance of the composite are evidently improved. Microstructure analyses reveal that the high specific strength of carbon fibers and transfer of stress from matrix alloy to carbon fibers are responsible for the increase of the composite bending strength. The expanding of cracks is restrained, and cracking resistance of the composite is improved by adding woven carbon fiber. Attributed to the carbon fibers’ debonding, cracks deflection, and multipath propagation mechanisms, the fracture energy of the composite increases.     

淬火残余应力对铝合金厚板裂纹应力强度因子及扩展趋势的影响

为探究淬火残余应力对铝合金厚板疲劳裂纹扩展的影响规律,建立7075铝合金厚板表面三维裂纹数值仿真模型。采用顺序热力耦合法求解淬火残余应力场,将残余应力场作为初始载荷条件求解裂纹应力强度因子,并与无残余应力场的应力强度因子值进行对比,研究两种条件下应力强度因子的分布规律和两者之间的异同;通过分析在初始淬火残余应力条件下不同半径裂纹受不同均匀拉应力荷载作用时的裂纹应力强度因子随裂纹位置角的演变曲线,探究淬火残余应力对裂纹扩展趋势的影响规律。结果表明,淬火残余应力的存在改变了铝合金厚板应力强度因子的分布规律和裂纹的扩展趋势,淬火残余应力使表层附近的裂纹扩展受到遏止,裂纹易于在厚度方向优先扩展。     

铝电解槽壳长侧板弯曲变形的修复工艺

铝电解槽钢壳长侧板因温度较高,散热差,导致其发生弯曲变形,造成应力集中于长侧板的中部区域.通过对三台铝电解槽壳进行修复,找出了铝电解槽钢壳长侧板合理的修复工艺.结果表明,该工艺可缩短修复时间、提高生产效率、降低修复成本,为类似铝电解槽钢壳修复工艺的制定提供依据.     

采用冷胀形工艺降低2219铝合金环的淬火残余应力

通过固溶时效工艺可以显著提升2219铝合金的力学性能，但在淬火过程中会产生较大的残余应力，对其尺寸稳定性、疲劳强度、应力腐蚀等性能产生不利影响。为降低2219铝合金环件的淬火残余应力，在淬火和人工时效之间引入冷胀形工艺。首先，采用有限元法模拟分析了2219铝合金环淬火、冷胀形后残余应力的数值及分布规律。其次，采用钻孔法测量了环在淬火、人工时效和固溶-冷胀形-人工时效后的残余应力。研究了冷胀形工艺参数对残余应力数值和均匀性的影响。结果表明，引入冷胀形工艺可以使2219铝合金环件淬火残余应力降低85%以上。