透明PP塑料激光焊接工艺研究

透明聚丙烯(PP)塑料对激光透过率较高,无法对激光能量进行吸收,采用在下层PP塑料上涂敷吸收剂的方法,实现激光焊接。对激光塑料焊接工艺参数进行正交实验,当吸收剂厚度为54μm,激光功率50 W,焊接速度为100 mm/s,光斑直径为1 mm时,此时焊缝剪切强度达到最大的35 MPa,为最佳工艺参数。进一步对焊缝截面进行切片分析,结果表明,当下层PP塑料吸收足够多的激光能量后,会使得焊缝熔池进一步扩展,焊缝深度和宽度增加,有利于提高焊缝剪切强度。     

不同波长激光能量对碳纤维复合材料损伤实验研究

本文利用YAG激光器及CO2激光器对固体火箭发动机壳体用碳纤维材料试件进行了两种典型波长（10.6μm和1.06μm）的高能量密度激光能量作用下的损伤实验研究,分析了波长对碳纤维试件损伤效果及损伤方式的影响。结果表明：在相同的功率密度条件下,YAG激光能量除造成表面树脂的分解碳化外,还会直接造成纤维的断裂,CO2激光能量对碳纤维材料的损伤则主要表现在内部的树脂分解;此外,YAG作用的试件单位面积内平均质量损失为28.64mg／cm^2,小于CO2激光作用时的平均值40.33mg／cm^2,约是其71％;平均每焦耳激光能量下的质量损失YAG为15.0mg／J,小于C02的试验结果21.4mg／J;从烧蚀热看,损失相同质量的条件下,需要YAG激光能量大于CO2激光能量。     

光纤激光打标工艺对黑色PMMA材料打标效果的影响

采用峰值功率为30 W的光纤激光打标设备,在不同线间距、激光功率、打标速度和激光频率等打标工艺参数下对黑色聚甲基丙烯酸甲酯(PMMA)材料进行光纤激光打标,研究了这些打标工艺参数对黑色PMMA材料打标效果的影响规律,并筛选出了黑色PMMA材料的最佳打标工艺参数。结果表明,随着线间距和打标速度的增大,黑色PMMA材料的打标图案均呈现出了从烧焦发黑到清晰明亮再到昏暗模糊的变化趋势;而随着激光功率的变大,打标图案却由清晰变模糊再变烧焦。当激光频率变大时,打标图案有从明亮逐渐变暗的趋势,但是变动幅度很小。获得的黑色PMMA材料的理想打标工艺参数区间为线间距0.17～0.21 mm,激光功率为峰值功率的10%～25%,打标速度300～500 mm/s,激光频率20～40 kHz。特别地,当线间距为0.2 mm、激光功率为峰值功率的10%、打标速度为300 mm/s、激光频率为20 kHz时,打标时间、打标宽度和打标深度分别为1.86 s,130 μm和30.38 μm,此时黑色PMMA材料的打标效果最佳。     

SN比试验在焊接工艺评定中的应用

应用SN比(Signal—Noise Ratio)试验设计与正交试验设计相结合的试验理论,对低合金高强钢管头焊接的预热时间和线能量这两个主要焊接工艺参数进行设计并SN比计算和方差分析,从而确定出最佳的工艺参数。     

工艺参数对车用聚丙烯复合材料红外激光打标性能的影响

采用Nd-YAG红外激光打标机,在不同参数设计下对车用聚丙烯复合材料进行红外激光打标,考察了各工艺参数对材料激光打标性能的影响,采用色差变化(ΔE)和明暗度变化(ΔL)定量地表征车用聚丙烯复合材料的激光打标效果,筛选出了最佳工艺参数。结果表明,步长、电流和频率是影响车用聚丙烯材料激光打标效果的主要参数,要获得理想的打标效果,参数选择需要控制在合适的范围之内。对于本实验车用聚丙烯复合材料而言,理想的红外激光打标工艺参数为电流14~15 A、频率1~3 kHz、步长0.005 mm。     

热塑性塑料激光透射焊接研究

针对混合20%玻纤的丙烯腈-苯乙烯共聚物(AGS)热塑性塑料,进行激光透射焊接试验,得到了线能量对AGS焊接质量的影响规律。在线能量为0.75~1J/mm之间时,剪切强度可达18MPa以上,焊接质量最优。     

乙烯裂解炉对流段 P91炉管焊接工艺评定及其应用

对于P91钢,焊前预热是必要的,通过试验研究了焊接线能量对P91钢焊接接头冲击韧性的影响,焊接线能量控制在12～15kJ／cm以内,控制层问温度,能获得良好的焊接接头。根据焊接接头的力学性能检验,规定回火参数[P]等于21是合理的。并依此制定工艺,成功地完成了该钢种在三台乙烯裂解炉中的焊接应用。     

超声波焊接技术在继电器塑料壳体连接中的应用

在简述了超声波焊接技术基本理论的基础上,分析了超声波焊接技术的优越性。对于继电器壳体和基座焊接而言,焊接的强度是影响其使用性能的主要因素。以聚对苯二甲酸丁二醇酯(PBT)为继电器壳体材料,聚碳酸酯(PC)/丙烯腈-丁二烯-苯乙烯共聚物(ABS)为基座材料,制备相应材料试件并进行焊接试验,分析了焊接时间、超声波振幅、延迟时间和保压时间对焊接强度的影响,并获得了异种材料焊接的最佳工艺参数。结果表明,随着焊接时间的增加,试件所能承受的最大拉力表现为先升高后下降的趋势;超声波振幅越大,焊接强度越高;延迟时间和保压时间对焊接强度的影响较小,几乎可以忽略。根据试验获得的最佳工艺参数,设计了继电器壳体焊接区域结构。焊接后继电器壳体与基座连接强度和密封性能良好,工艺稳定性可以满足生产要求。     

09MnNiDR钢手工电弧焊工艺参数研究

对09MnNiDR低温钢的手工焊焊接工艺参数及线能量进行研究,以获得合理的工艺参数。     

PC/PMMA异种透明塑料激光透射焊接工艺

针对在激光透射焊接透明塑料过程中使用吸收剂所带来的外观不佳以及污染等问题,探究了在不使用吸收剂的条件下对透明塑料进行直接焊接的可行性.使用1910 nm半导体激光器对聚碳酸酯(PC)与聚甲基丙烯酸甲酯(PMMA)异种透明塑料板材进行了无吸收剂激光透射焊接试验.以激光功率、焊接速度、离焦量作为影响焊接效果的三因素设计焊接...     

工艺参数对尼龙6选择性激光烧结制件致密度的影响

针对高性能聚合物尼龙6材料的选择性激光烧结(SLS)工艺,研究了不同激光功率与扫描速度对成型件致密度的影响并进行了工艺优化。实验中激光功率10~50 W,扫描速度1 000~5 000 mm/s,其他工艺参数保持恒定。引入能量密度对激光功率与扫描速度的综合作用进行研究。结果表明:随着激光功率的增加或扫描速度的增大,制件的致密度呈现先增大后减小的趋势;随着能量密度的增加,制件的致密度呈现先增大后减小的趋势。在不同工艺参数下,获得制件的最大致密度为86.74%,此时激光功率为30 W,扫描速度为2 000mm/s,能量密度为0.043 J/mm^2。选定致密度为衡量指标,通过响应面回归分析模型建立了激光功率、扫描速度与致密度的优选工艺图谱,得到最优的工艺参数为激光功率45 W,扫描速度3 465 mm/s,此时预测的制件致密度为88.971%。     

Application of response surface methodology for weld strength prediction in laser welding of polypropylene/clay nanocomposite

Welding as a fabrication process can be used to join materials, including composite and nanocomposites and laser welding process due to its advantages has found wide applications in this field. Its process parameters can play a significant role in determining the weld strength of laser-welded joints in polypropylene/clay nanocomposites. In this study, the effect of laser welding parameters, such as laser power, welding speed and focal position along with the clay content in a polypropylene/clay nanocomposite on weld strength were determined using response surface methodology. This methodology was applied for developing a mathematical model which can predict the main effects of the above parameters and their impacts on tensile strength of butt-welded laser joints in 2-mm thick polypropylene/clay nanocomposite sheets. The analysis of variance was performed to check the adequacy of the developed model. A comparison was also made between the predicted and actual results. The results showed that weld strength decreased when clay content was increased from 0 to 6 %, but welding speed increased from 30 to 60 mm/s. The above parameters were also optimized to achieve a high strength welded joint.     

Effect of process parameters on crack characteristics in laser welding of Al2O3 ceramic

The crack of ceramic weld is a worldwide problem for brittle material, high energy laser beam is expected to solve this problem. In this paper, the crack of fiber laser welding of Al₂O₃ ceramics was studied. The weld crack rate was used to characterize the crack condition of weld, and the influences of laser power, welding speed and defocusing distance on crack characteristics were carried out. The results showed that Al₂O₃ ceramics weld has obvious crack tendency, and the cracks mainly appeared on the weld center line. When the crack appeared on the weld center line, there was crack-free on the base metal. When the defocusing distance increased from +3 mm to +20 mm, the number of cracks gradually decreased. When the defocusing distance was greater than +17 mm, cracks-free appeared on the weld and base metal. Abaqus software was used to simulate the relationship between crack and stress based on thermal elastoplastic theory. The high crack areas, few crack areas and free crack areas were divided according to the maximum principal stress value. No matter what welding conditions, as long as the maximum principal stress was less than 1576 MPa, there was crack-free on the weld and base metal.     

Diode Laser Welding of Polyethylene

A high-power diode laser (HPDL) was used to weld high-density polyethylene (HDPE) sheets. Laser-welded joints were fabricated with different values of laser power and scan speed. Hot-tool welding was also employed to fabricate joints to make a comparison between this consolidated technology and HPDL welding. Initially, laser heating tests were carried out to study the laser–material interaction. Furthermore, welding tests were carried out and tensile mechanical tests were performed to characterize joints and sound specimens. A similar material behavior was recognized for all the specimens. While the laser process resulted in lower strength and ductility, in comparison to the tool-welding process, the aesthetics of the laser-welded joints were remarkable. The best values of the process parameters were individuated for the laser welding and were used to fabricate a closed structure having sharp edges. The same geometry cannot be obtained by any other welding technology.     

工艺参数对选择性激光烧结PS/SBS/纳米CaCO3制件弯曲强度影响

针对聚苯乙烯(PS)粉末选择性激光烧结(SLS)成型件强度较低的问题,采用机械混合法制备了PS/苯乙烯–丁二烯–苯乙烯嵌段共聚物(SBS)/纳米CaCO₃复合粉末,通过单因素实验分析了SLS工艺参数对成型件弯曲强度的影响,并通过正交试验和极差分析获得了最优工艺参数组合。实验结果表明,烧结件的弯曲强度随着激光功率的增大而升高,随着扫描速度、扫描间距和分层厚度的增大而降低;激光功率对PS/SBS/纳米CaCO₃复合粉末烧结件弯曲强度的影响最大,分层厚度对弯曲强度的影响最小,扫描速度和扫描间距的影响介于两者之间;最佳工艺参数组合为:激光功率27 W,扫描速度1300 mm/s,扫描间距0.24 mm,单层厚度0.22 mm。在此工艺参数组合下PS/SBS/纳米CaCO₃复合粉末烧结件的弯曲强度为13.38 MPa;改性纳米CaCO₃与PS和SBS的相容性较好,能有效起到增强的作用。     

Determination of optimal wood-dowel welding parameters for two North American hardwood species

Rotational wood-dowel welding has been shown to rapidly produce wood joints of considerable strength without any adhesive. The technique offers an opportunity to increase productivity and reduce costs in the furniture industry. The objective of the study was to define optimal wood-dowel welding parameters for two North American hardwood species frequently used for indoor appearance products: sugar maple (Acer saccharum) and yellow birch (Betula alleghaniensis). Optimized parameters for individually studied species were determined using a rotational wood-dowel welding machine designed for the technique. A comparative analysis of wood-dowel welding parameters was performed. The investigated parameters for both species were grain orientation, rotational speed, and insertion speed. Temperature profile measurements at the interface during rotational wood-dowel welding were also carried out. Optimal welding mechanical properties were determined from the dowel withdrawal strength using a standard tensile strength test. Results revealed a significant interaction between species, rotational speed, and insertion speed. Sugar maple produced wood joints with higher withdrawal strength than yellow birch. The best results for sugar maple and yellow birch were obtained with a rotational speed of 1000?rpm. A 25?mm?s^?1 insertion speed produced significantly stronger welded joints in sugar maple than at 12.5?mm?s^?1. For yellow birch, a 16.7?mm?s^?1 insertion speed provided the best results. Both species and rotational speed had a significant effect on peak temperature at the interface during welding. Peak welding temperatures with optimal parameters were 244 and 282?°C for sugar maple and yellow birch, respectively.     

PS/CF复合粉末激光选区烧结工艺研究

为提高聚苯乙烯粉末烧结件的强度,制备了聚苯乙烯/碳纤维(PS/CF)复合粉末,采用正交实验方法研究了不同工艺参数对PS/CF复合粉末SLS烧结件弯曲强度的影响,确定了最优工艺参数。结果表明,复合粉末试样的弯曲强度最高可达7.49 MPa,比纯PS粉提高2.88倍;弯曲强度随扫描速度和层厚的增大而减小,随预热温度的增加而增大;PS/CF复合粉末的最优工艺参数为扫描速度1 800 mm/s,预热温度85℃,层厚0.18 mm。     

Experimental and numerical investigation on the strength of polymer-metal hybrid with laser assisted metal surface treatment

The aim of this study was to evaluate the effect of laser assisted treating metal surface on the strength of polymer-metal hybrid. The oxide film on the metal surface was removed by caustic soda and nitric acid solution. After that, the metal surface was treated by fiber laser, and the hot pressing connection between polymer and metal was completed by plate vulcanizing machine. And then, the tensile strength was obtained by using universal testing machine. The effect of different laser power, different scanning line width and different scanning speed on the bonding strength of polymer-metal hybrid was investigated. The correlation between the characteristics of metal surface and the bonding strength of polymer-metal hybrid was analyzed based on the micro structure morphology and scanning electron microscope (SEM). The results show that the bonding strength of polymer-metal hybrid increases first and then decreases with the increase of laser power. With the increase of scanning line width, the strength of polymer-metal hybrid increases. When the scanning speed is 500?mm/s, the strength of polymer-metal hybrid is the lowest. Based on the experiment, a simplified model is established and analyzed. Through using ABAQUS to conduct the numerical simulations, the results are consistent with the theoretical analysis and experimental data.     

PS/ABS复合粉末选择性激光烧结工艺参数的实验研究

针对选择性激光烧结件力学性能和尺寸精度差的问题,通过机械混合法制备了聚苯乙烯/丙烯腈-丁二烯-苯乙烯塑料(PS/ABS)的复合粉末。在预热温度85℃、8层网格支撑等条件下,采用单因素实验法研究激光功率、扫描速度、扫描间距和单层厚度对烧结件强度和相对误差的变化规律,并用正交试验对工艺参数进行优化。结果表明,烧结件的弯曲强度随着激光功率的增加而提高,随扫描速度、扫描间距和单层厚度的增加而降低。Z向尺寸相对误差随着激光功率的增加而增大,随着扫描速度、扫描间距和单层厚度的增加而减小;由极差分析可知,激光功率对PS/ABS烧结件弯曲强度和Z向尺寸相对误差的影响最大;最优的工艺参数组合为:激光功率30 W、扫描速度1 200 mm/s、扫描间距0.32 mm和单层厚度0.26 mm,此时烧结件的弯曲强度为7.85 MPa,Z向尺寸相对误差为1.30%。