钛合金薄板激光和钨极氩弧焊残余应力测试研究

采用小孔释放法对钛合金薄板激光焊和钨极氩弧焊(TIG焊)的焊接残余应力进行了测试，并分析了焊接方法、焊接线能量和焊后热处理对残余应力分布规律的影响。研究结果表明：激光焊残余应力分布规律与普通熔焊方法相似，但其分布区域较窄；在热影响区内，激光焊残余拉应力值比TIG焊的约低100MPa；在焊缝及其熔合线附近，激光焊残余应力却比TIG焊的高。对于不同线能量激光焊接，线能量越大，焊缝越宽，热影响区的残余应力也越大。焊后真空热处理能降低残余应力90％。     

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。     

动态低应力小变形无势裂随焊锤击焊接技术研究

从力学角度出发,首次提出随焊锤击的焊接技术,并结合跨焊缝两侧横向位移的测量及显微组织的研究,分析了随焊锤击防止焊接裂纹的作用机理,试验结果表明,随焊狂击技术可显著地改善焊缝显微组织及残余应力分布,防止焊接热裂纹的产生,并能够有效地控制LY12CZ铝合金薄板焊接横向及纵向收缩变形,可以认为随焊锤击是一种更合理,更具实用价值的低应力小变形无热裂的焊接技术新方法。     

大厚度奥氏体不锈钢筒体填丝激光焊接变形和应力分析

目的 研究大厚度奥氏体不锈钢筒体填丝激光焊接,优化结构设计和工艺设计。方法 建立大厚度奥氏体不锈钢筒体填丝激光焊接数值分析模型,通过数值模拟的方法,定量分析大厚度奥氏体不锈钢筒体焊接变形和应力。结果 零件下部38 mm厚焊缝位置处的最大径向收缩量为1.2 mm;零件下部60 mm厚焊缝位置处的最大径向收缩量为2.0 mm;零件中部60 mm厚焊缝位置处的最大径向收缩量为1.9 mm;零件上部60 mm厚焊缝位置处的最大径向收缩量为1.8 mm。填丝激光焊接轴向收缩量为0.55 mm。焊接残余应力最大值在450 MPa左右,应力主要分布在焊缝附近。热处理后,焊接残余应力都有明显降低,最大残余应力从450 MPa左右降低到200 MPa左右,焊接残余应力范围存在一定程度减小;焊接残余变形变化较小,热处理后某些位置的变形略微有所增大。结论 模拟结果表明,大厚度奥氏体不锈钢筒体填丝激光焊接变形和应力在可接受范围内,焊后热处理对释放残余应力有重要作用。     

动态低应力小变形无热裂随焊锤击焊接技术研究

从力学角度出发,首次提出随焊锤击的焊接技术,并结合跨焊缝两侧横向位移的测量及显微组织的研究,分析了随焊锤击防止焊接热裂纹的作用机理．试验结果表明,随焊锤击技术可显著地改善焊缝显微组织及残余应力分布,防止焊接热裂纹的产生,并能够有效地控制LY12CZ铝合金薄板焊接横向及纵向收缩变形．可以认为随焊锤击是一种更合理、更具实用价值的低应力小变形无热裂的焊接技术新方法．     

轨道车辆型材结构搅拌摩擦焊残余状态研究

目的 研究轨道车辆中典型的箱型和V筋结构型材搅拌摩擦焊残余状态。方法 采用顺序热力耦合方法进行了搅拌摩擦焊残余应力及变形的仿真研究。结果 给出了上下壁板焊缝区域的残余应力大小及分布规律,阐述了两种结构的横向和纵向残余变形特征。对V筋结构型材,分析了不同筋板角度对焊接残余状态的影响。结论 残余应力方面,主要表现为纵向残余应力,上下壁板两条焊缝的残余应力峰值相近,高应力分布区域宽度差别较大。残余变形方面,箱型结构呈马鞍形,V筋型材呈下凹形。V筋型材筋板夹角的变化对残余应力没有显著影响。筋板角度增大,纵向残余变形减小而横向残余变形增大。     

机械挤压矫正焊接变形的模拟与试验研究

利用自制的夹具对机械挤压矫正薄板焊接变形的效果进行了试验研究.采用有限元分析方法对常规焊件和机械挤压焊件的应力应变场及残余变形进行了模拟.试验和模拟结果均表明,对焊件施加平行于焊缝方向的纵向挤压力能够有效矫正薄板焊件的失稳变形.在适当的挤压力下,在远离焊缝的区域产生了纵向压缩塑性应变,而焊缝区由焊接过程导致的塑性应变值没有发生变化.机械挤压法能够降低薄板焊件焊缝区的纵向拉应力水平是其能够矫正焊接失稳变形的原因.     

对接试板焊接残余应力实测与数值模拟

使用压痕法对两副对接试板进行了表面焊接残余应力测试，并通过焊接有限元仿真获得了对接试板焊接残余应力分布规律，对比分析了表面残余应力实测和数值模拟结果。分析结果表明，焊接残余应力数值仿真结果和压痕法实测结果趋势一致，数值相差不大，残余拉应力峰值实测为599 MPa,仿真结果为597 MPa,表明数值模拟方法可预测焊接残余应力；焊缝及热影响区最大纵向残余应力属于拉应力，而最大横向残余应力为压应力，横向残余应力峰值低于纵向残余应力峰值；等效应力(Mises应力)峰值792 MPa,高于试板材料在常温下的初始屈服强度，表明该材料具有明显的加工硬化现象。     

焊接工艺参数对Q345钢平板焊接残余应力的影响

为研究焊接工艺参数对Q345钢平板焊接残余应力的影响,对采用药芯焊丝半自动焊接后的8 mm厚平板焊缝结构进行仿真模拟,在经验数值范围内设置不同的焊接工艺参数值,分析平板在横向和厚度方向的焊接残余应力分布情况。研究结果表明:横向的最大焊接残余应力分布在热影响区,且随着焊接速度的增大和焊接层间温度的降低而降低;沿厚度方向的最大焊接残余应力为115.92 MPa,位于平板中间层,随着焊接速度的增大而先减小后增大;平板焊接在横向的残余应力远大于厚度方向的应力。根据焊接残余应力的变化情况,运用二元回归分析法对横向和厚度方向的最大焊接残余应力进行函数拟合与检验,并开展多因素拟合模型的分析,得到焊接速度和焊接层间温度对焊接残余应力的综合影响规律。通过研究残余应力的变化趋势可选定焊接残余应力最小时的工艺参数范围,实现焊接工艺参数优化。     

焊接过程对焊接残余应力及残余变形的影响

采用热弹塑性有限元法，对直通焊和多人同时分段焊两种焊接过程的平板对接焊时焊接应力变形和圆柱壳板环缝的焊接变形进行比较，认为多人同时分段焊直通焊无论在降低焊接残余应力还是焊接残余变形都具有非常显著的效果。     

Prediction of welding distortion in butt joint of thin plates

This paper investigates distortions and residual stresses induced in butt joint of thin plates using Metal Inert Gas welding. A moving distributed heat source model based on Goldak’s double-ellipsoid heat flux distribution is implemented in Finite Element (FE) simulation of the welding process. Thermo-elastic–plastic FE methods are applied to modelling thermal and mechanical behaviour of the welded plate during the welding process. Prediction of temperature variations, fusion zone and heat affected zone as well as longitudinal and transverse shrinkage, angular distortion, and residual stress is obtained. FE analysis results of welding distortions are compared with existing experimental and empirical predictions. The welding speed and plate thickness are shown to have considerable effects on welding distortions and residual stresses.     

铝合金T型接头激光+GMAW复合焊残余应力数值分析

目的 研究激光+GMAW复合焊中不同激光功率参数对铝合金T型接头残余应力的影响,从而提高焊接性能。方法 分别考虑了热弹塑性理论、传热学以及T型接头几何特性,建立了铝合金T型接头激光+电弧复合焊残余应力的数值分析模型。采用双椭球体热源模型表征电弧热输入与熔滴晗,采用锥体热源模型对激光深熔焊进行描述。基于所建立的T型接头模型,使用ANSYS有限元软件对12 mm厚铝合金激光+ GMAW焊T型接头残余应力进行模拟计算,并研究其分布特征;使用X射线衍射法对T型接头处的残余应力进行测量从而对所建模型的准确性进行验证。同时,对比了不同激光功率下铝合金T型接头对残余应力的影响规律。结果 当激光功率分别为2、3、4、5 kW时,铝合金T型接头路径L3上的纵向残余应力最大值分别为270、263、258、251 MPa,米塞斯-等效应力最大值分别为265、261、257、250 MPa。结论 后焊的焊缝A对焊缝B有明显的热处理作用,使应力明显降低;在T型接头焊缝及近缝区,横向残余应力和厚度方向残余应力峰值均比纵向残余应力峰值小,且随着激光功率的增大,焊缝及近缝区拉应力峰值不断减小。     

铸造TC4钛合金电子束焊残余应力测试

对铸造TC4钛合金进行电子束焊接,使用X射线衍射法对焊后母材、热影响区以及焊缝的表面残余应力分布状况进行测试和分析。结果表明：垂直于焊缝方向的测试点上,焊缝及热影响区在横、纵两个方向上主要存在拉应力;剪切应力数值均在±50MPa范围内,可以认为对焊缝性能没有影响。沿焊缝长度方向的测试点上,无论横向应力还是纵向应力,焊缝起始端的应力值要低于焊缝终止端的应力值。纵向残余应力表现为拉应力,横向残余应力由压应力逐渐向拉应力方向转变。     

Influence of Heat Input on Microstructure and Mechanical Properties of Laser Welding GH4169 Bolt Assembly—Numerical and Experimental Analysis

By conducting the numerical and experimental analysis, the influence of heat input on the microstructures and mechanical properties of laser welding GH4169 bolt assembly is systematically investigated. The weld formation, temperature field, and residual stress distribution during laser welding by using the finite element modeling are consistent with experimental results. The numerical simulation results show that the increase of heat input imparts lower residual stresses and higher temperature gradient. During the process of laser welding, the steepest temperature gradient and the peak residual stress arise in the fusion zone (FZ). In addition, the dissolution of γ″ and γ′ toward the fusion line increases in heat affected zone (HAZ), but only Laves phase is observed in FZ. With increasing heat input from 24 to 48 J mm⁻¹, the ultimate tensile strength of welded joints decreases. Both the lowest microhardness values and tensile failure of GH4169 alloy laser welded joint are in FZ. Herein, it is that the relationship among the heat input, microstructures, and mechanical properties of GH4196 bolt assembly in laser welding is systematically established, which will be of guiding significance for the selection of welding parameters in aerospace.     

Application of Response Surface Methodology in Describing the Residual Stress Distribution in CO2 Laser Welding of AISI304

Abstract:  Laser welding is a low-distortion welding process. Despite this advantage some detrimental residual stresses are still introduced during the process, which reduce the service life of the welded component. Therefore, it is important to estimate the magnitude and distribution of the residual stress. This study aims to create mathematical models to determine the relationship between laser welding parameters and the magnitude of the residual stress at different locations by using response surface methodology. In this study, the process input parameters are laser power, travel speed and focal point position. Laser butt-welding of AISI304 plates joints were investigated using a 1.5 kW continuous wave CO₂ Rofin laser as a welding source. Incremental hole-drilling method was employed to measure the magnitude and the distribution of the maximum residual stress. The experiment was developed using a three-factor, five-level central composite design with full replication. Analysis of variance and other adequacy measures were employed to check the adequacy of the developed models using the statistical package Design-Expert. Twenty-one models were developed to demonstrate the magnitude and distribution of the residual stress. The main effect of each factor and the interaction effect with other factors were determined quantitatively and presented graphically.     

Ti2AlNb合金电子束焊接头残余应力及变形的数值模拟

目的 研究平板对接电子束焊接过程中Ti2AlNb合金接头的残余应力及变形规律。方法 采用高斯圆柱体和高斯面组合热源模型模拟了6.6 mm厚的Ti2AlNb合金平板对接电子束焊过程,对比研究了高焊速高束流和低焊速低束流2种工艺参数下焊接接头的残余应力和变形分布规律,并用小孔法测量了焊缝中心及距焊缝中心10 mm位置的残余应力值。结果 在高焊速高束流参数下,获得了熔池体积小、熔池宽度窄(为3.62 mm)、深宽比高的焊缝;在该参数下焊缝横截面上的高应力集中区(应力在900 MPa以上)尺寸较小,其宽度仅为低焊速低束流参数下的89%;同时,在高焊速高束流参数下,焊缝法向变形最大值为0.79 mm,低于低焊速低束流参数下的0.82 mm;模拟计算所得残余应力与实测值的误差在5.64%以内。结论 高束流高焊速工艺具有热输入小、热量集中、加工效率高的特点,有助于获得高应力集中区域小、深宽比高、变形小的焊缝,比低束流低焊速工艺更具优势。     

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.