NON-EQUILIBRIUM STATIONARY STATE IN CHEMICAL REACTION OF SiO2/Fe AT INTERFACE OF SLAG/METAL AND ITS STABILITY DURING ARC WELDING

For characteristics of open and far from thermodynamic equilibrium in welding chemical reaction, a new kind of quantitative method, which is used to analyze direction and extent for chemical reaction of SiO2/Fe during quasi-steady state period, is introduced with the concept of non-equilibrium stationary state. The main idea is based on thermodynamic driving forces, which result in non-zero thermodynamic fluxes and lead to chemical reaction far away from thermodynamic equilibrium. There exists certain dynamic equilibrium relationship between rates of diffusion fluxes in liquid phase of reactants or products and the rate equation of chemical reaction when welding is in quasi-steady state. As result of this, a group of non-linear equations containing concentrations of all substances at interface of slag/liquid-metal may be established. Moreover the stability of this non-equilibrium stationary state is discussed using dissipative structure theory and it is concluded theoretically that this non-equilibrium stationary state for welding chemical reaction is of stability.     

Adaptive volumetric heat source models for laser beam and laser + pulsed GMAW hybrid welding processes

Laser + pulsed gas metal arc welding (GMAW) hybrid welding process is an attractive joining technology in industry due to its synergy of the two processes. It is of great significance to conduct fundamental investigations involving mathematical modeling and understanding of the hybrid welding process. In this study, an adaptive heat source model is first developed for laser beam welding. Through combining the ray-tracing method with the keyhole profile determination technique based on the local energy balance, the keyhole shape and size are calculated and correlated to the distribution parameters of the volumetric heat source model. Then, thermal action characteristics in laser + pulsed GMAW hybrid welding are considered from viewpoint of macro-heat transfer, and a combined volumetric heat source model for hybrid welding is developed to take consideration of heat input from laser, pulsed gas metal arc, and overheated droplets. Numerical analysis of thermal conduction in hybrid welding is conducted. The shape and size of fusion zone and weld dimension in the quasi-steady state are calculated for various hybrid welding conditions, which have a fair agreement with the experimental results.     

A computational study of inviscid hypersonic flows using energy relaxation method

Reasonable analysis of hypersonic flows requires a thermodynamic non-equilibrium model to properly simulate strong shock waves or high pressure and temperature states in the flow field. The energy relaxation method (ERM) has been used to model such a non-equilibrium effect which is generally expressed as a hyperbolic system of equations with a stiff relaxation source term. Relaxation time that is multiplied with source terms is responsible for non-equilibrium in the system. In the present study, a numerical analysis has been carried out with varying values of relaxation time for several hypersonic flows with AUSM (advection upstream splitting method) as a numerical scheme. Vibration modes of thermodynamic nonequilibrium effects are considered. The results obtained showed that, as the relaxation time reduces to zero, the solution marches toward equilibrium, while it shows non-equilibrium effects, as the relaxation time increases. The present computations predicted the experiment results of hypersonic flows with good accuracy. The work carried out suggests that the present energy relaxation method can be robust for analysis of hypersonic flows.     

Prediction of non-equilibrium kinetics of fuel-rich kerosene/LOX combustion in gas generator

Gas generator is the device to produce high enthalpy gases needed to drive turbo-pump system in liquid rocket engine. And, the combustion temperature in gas generator should be controlled below around 1,000K to avoid any possible thermal damages to turbine blade by using either fuel rich combustion or oxidizer rich combustion. Thus, non-equilibrium chemical reaction dominates in fuel-rich combustion of gas generator. Meanwhile, kerosene is a compounded fuel with various types of hydrocarbon elements and difficult to model the chemical kinetics. This study focuses on the prediction of the non-equilibrium reaction of fuel rich kerosene/LOX combustion with detailed kinetics developed by Dagaut using PSR (Perfectly Stirred Reactor) assumption. In Dagaut’s surrogate model for kerosene, chemical kinetics of kerosene consists of 1,592 reaction steps with 207 chemical species. Also, droplet evaporation time is taken into account in the PSR calculation by changing the residence time of droplet in the gas generator. Frenklach’s soot model was implemented along with detailed kinetics to calculate the gas properties of fuel rich combustion efflux. The results could provide very reliable and accurate numbers in the prediction of combustion gas temperature, species fraction and material properties.     

PCD工具的研制现状与发展

对国内外PCD工具研制现状进行了综合评述 ,认为加热方式、钎料钎剂的选择与合理使用以及焊接接头的结构设计是影响PCD工具焊接质量的主要因素 ,而加热方式对于PCD工具制作具有革命性意义。介绍了各种焊接方法的优缺点以及钎料、钎剂的开发进展。     

B4C/6061Al复合材料焊接接头组织与力学性能研究*

基于碳化硼中¹⁰B同位素优良的热中子吸收能力,铝基碳化硼复合材作为中子吸收材料越来越多的应用于核电站中。但碳化硼颗粒的加入使该材料的可焊性变差,因此研究其焊接行为变得十分必要。采用钨极氩弧焊(Tungsten inert gas,TIG)和搅拌摩擦焊(Friction stir welding,FSW)对体积分数为30%的B₄C/6061Al复合材料进行焊接,研究不同焊接方法、焊缝填充材料对复合材料对接接头微观组织及力学性能的影响。B₄C/6061Al复合材料焊接接头拉伸性能如下：FSW焊>TIG焊(Al-Si焊丝)>TIG焊(6061Al焊丝)>TIG焊(6061Al-Mg焊丝)>TIG焊(无填充)。TIG焊缝区容易产生气孔、B₄C颗粒分布不均匀及有害生成相是导致其力学性能不佳的主要原因。FSW可以有效避免基体金属与增强相的高温化学反应,使得焊缝区的晶粒细化,增强相颗粒的分布比TIG焊均匀,为30%B₄C/6061Al复合材料最佳焊接方法,其接头的室温拉伸强度达247 MPa,为母材强度的85%。     

单孔管道修复结构的全尺寸试验

管道现场抢修常用两种修复方式,一种是扣帽子,一种是补板.分别对扣帽子和补板方式修复的φ711×10管道进行全尺寸爆破试验,测量修复管道中的应变分布.结果表明,焊接帽子或补板的存在使管道修复部位的应力分布不均匀,出现一定程度的应力集中.焊接帽子和焊接补板修复的管道的屈服强度相近,约为完好管道屈服强度的85%.但焊接"帽子"对小孔处的变形约束作用小于焊接"补板"对小孔处变形约束作用,在管材没有足够韧性的情况下,容易引起管道在开孔处撕裂;焊接帽子和焊接补板修复的管道的爆破压力均低于但接近于完好管道的爆破压力,管道的破裂位置均远离焊接帽子或补板处,爆破是由于最大剪应力引起的韧性破坏.试验结果可以为打孔管道修复结构的安全性评价提供参考.     

脉冲MIG焊熔滴过渡控制的新进展

介绍脉冲MIG焊（熔化极惰性气体保护焊）熔滴过渡控制的发展现状,分析了现有控制法存在的局限性,阐述一种最新的控制法—熔滴过渡光谱控制法的原理、优越性及其进展。指出这方面的发展趋势。电弧光谱信号在反映脉冲MIG焊熔滴过渡方面有很大的优越性,其信号品质和灵敏度远胜过以往的信号。相应的光谱控制法已在实验室成功地实现了脉冲MIG焊1峰0基的精确控制,并可能推广用于2峰0基、3峰0基的控制,甚至推广用于连续电流焊条件下熔滴过渡的控制中,工艺适应性宽,前景广阔。     

Stability of elastic and viscoelastic systems under action of random stationary narrow-band loads

The stability is considered of the equilibrium state of elastic and viscoelastic systems, subjected to random parametric loads, with respect to perturbations of initial conditions. The stability is explored in the sense of Liapunov. The loads are assumed in the form of random narrow-band stationary processes. A numerical method for the analysis of the stability of such systems is offered, which is based on a method of statistical simulation of random processes, and on the determination of maximum Liapunov exponents. With the help of the method proposed the influence of the form of probability distributions, and of characteristics of the material, on the asymptotic stability of elastic and viscoelastic rods is investigated.     

大型射电望远镜悬索馈源支撑系统静刚度分析

针对大射电望远镜(LT)悬索支撑系统特殊的结构形式,对6索组成的馈源支撑系统的静刚度进行分析。首先,对舱索系统静平衡方程沿馈源舱运动方向上求导,同时考虑到悬索刚度随其应力变化而呈现几何非线性的特点,给出了馈源支撑系统静刚度的公式。其次,在上面结果的基础上,分析了一个定点位置下馈源舱在外界扰动下的振动情况,通过与大型射电望远镜50 m室外模型振动试验结果相比较,说明了静刚度求解方法的有效性。最后,给出了大型射电望远镜50m模型馈源舱运动空间边缘的悬索应力与馈源支撑系统刚度的关系。     

造船(中钢板)焊接变形的自动火焰矫正工艺系统

焊接操作是造船生产最重要的作业形式之一,焊接变形是不可避免的,变形矫正就成为造船生产的重要工种。针对目前船舶变形矫正以手工经验操作为主的现状,开发了自动火焰矫正工艺系统,以船体建造过程中典型的三类构件的焊接变形为对象,用逻辑推理的方式生成手工火焰矫正的标准工艺方法,采用人工神经网络确定部分火焰矫正的工艺参数。实例操作获得了令人满意的变形矫正效果,证明该方法可有效地提高火焰矫正的效率与矫正质量的稳定性,并为实现火焰矫正的自动化提供了理论基础。     

高温熔盐泵的模态计算与分析

为了研究高温熔盐泵的运行可靠性,基于ANSYS Workbench对熔盐泵结构部件分别进行了无预应力和有预应力的模态计算。基于计算结果对熔盐泵的振动特性进行了分析,并对不同相位下转动和静止部件的固有频率和振幅的变化进行了比较。计算结果表明:无预应力时,转动和静止部件的第1阶和第2阶以及第4阶和第5阶固有频率较为接近,且同阶下,静止部件的固有频率远高于转动部件的固有频率;转动部件和静止部件各阶的固有频率均远离主要的激振频率,可有效避免共振的产生;同阶不同相位下,转动和静止部件的固有频率和振幅变化较小,叶轮相位对熔盐泵模态性能的影响可以忽略;有预应力下静止部件和转动部件的固有频率比无预应力下有小幅提升,且转动部件的增幅较高,其幅度为1.35%;转动部件的模态变形主要集中在叶轮端,而静止部件的进出水管变形更为明显。研究结果可为熔盐泵的开发与结构优化提供一定的参考。     

Numerical estimation of non-equilibrium condensation of steam in supersonic nozzles

Condensation phase change during the expansion of steam is an inevitable phenomenon encountered in several engineering applications. Under supersonic flow conditions, the expansion rate of flow will be very steep so that, steam continues to expand even after local pressure crosses the saturation curve. Steam gets supersaturated rapidly and the condensation departs far away from equilibrium state. By complicated sequences of spontaneous nucleation, several nucleation sites will be formed in the flow field. Water droplets may form at this sites by mass addition due to condensation. The latent heat liberated during phase change results in the formation of a condensation shock wave across which flow velocity gets reduced. Precise knowledge of this process is important since the presence of water droplets in steam can lead to erosion and subsequent reduction of performance. Non-equilibrium condensation can be numerically modeled using additional transport equations which solve for the mass fraction of condensate generated from the phase change process. In the present work, a five-equation non-equilibrium condensation model available in ANSYS FLUENT is studied and used. The methodology is validated against case studies reported in the literature. Later, parametric studies were conducted to investigate the effect of inlet saturation ratio of steam on the flow characteristic in two well-known steam nozzles.     

节流短管内制冷剂流动的两流体模型

制冷剂在短管内的两相节流过程存在显著的动力学和热力学非平衡特性。建立了描述节流短管内制冷剂两相流的六方程两流体模型,模型中考虑了相间速度滑移和温度滑移。计算表明,制冷剂在短管内比在毛细管(长管)内的闪蒸过程具有更大的相间速度滑移和温度滑移。对R134a在短管内的流量特性进行了预测,与试验数据偏差小于±20％。     

SPOT WELDING QUALITY FUZZY CONTROL SYSTEM BASED ON MULTISENSOR INFORMATION FUSION

The multisensor information fusion technology is adopted for real time measuring the four parameters which are connected closely with the weld nugget size(welding current,electrode displacement,dynamic resistance,welding time),thus much more original information is obtained.In this way,the difficulty caused by measuring indirectly weld nugget size can be decreased in spot welding quality control,and the stability of spot welding quality can be improved.According to this method,two-dimensional fuzzy controllers are designed with the information fusion result as input and the thyristor control signal as output.The spot welding experimental results indicate that the spot welding quality intelligent control method based on multisensor information fusion technology can compensate the influence caused by variable factors in welding process and ensure the stability of welding quality.     

Theoretical and experimental study of microstructures and weld pool geometry during GTAW of 304 stainless steel

In this work, temperature field and weld pool geometry during gas tungsten arc welding of 304 stainless steel are predicted by solving the governing equations of heat transfer and fluid flow under quasi-steady state conditions. The model is based on numerical solution of the equations of conservation of mass, momentum, and energy in the weld pool. Weld pool geometry, weld thermal cycles, and various solidification parameters are then calculated by means of the model predictions. The model considers the effects of various process parameters including welding speed and heat input. It is found that the weld pool geometry, predicted by the proposed model, is in reasonable agreement with the corresponding experimentally measured ones. In addition, the solidification behavior of the weld pool can be predicted properly by the model predictions.     

搅拌摩擦焊下压力控制系统的开发及在模拟非刚性环境下的验证试验

搅拌摩擦焊接(Friction stir welding, FSW)是材料固态连接新技术,但FSW在焊接过程中一般会对工件施加较大的下压力,焊接设备和被焊工件在下压力的作用下均可能产生变形,使得常规FSW中设定的下压量这一关键参数偏离预期值,无法保证焊接工艺的稳定性。为了解决这一问题,开发一套下压力反馈控制系统,通过调节搅拌头对工件的下压量来调节下压力,使焊接过程中下压力保持稳定。该系统使用一台计算机作为顶层控制器,根据压力传感器反馈的实时下压力调节FSW设备Z轴的进给。使用该系统在悬空的钢板上焊接6082-T6铝合金平板对接焊缝,焊接过程中工件在下压力的作用下产生的弯曲变形高达0.931 mm,但所得的焊缝成形良好,沿焊缝方向不同位置的接头的横截面形貌基本一致,其横向拉伸应力应变曲线高度重合,接头的平均抗拉强度为222.8 MPa。结果表明,工件在下压力作用下产生变形的条件下,下压力控制的FSW系统仍能保证工艺稳定性。     

静轴肩摩擦搅拌焊温度场仿真分析与参数优化

为了解决非刚性支撑条件下传统搅拌头易陷入被焊接板材而导致焊接失败的问题,设计研发了静轴肩焊接结构。通过建立有限元仿真计算模型,并使用热红外成像仪对焊接表面温度进行实时监测,分析不同工艺参数下静轴肩摩擦搅拌焊焊接过程中的温度场变化情况。使用设计研发的静轴肩摩擦搅拌焊进行现场试验并对完成焊接表面无缺陷的焊缝与母材进行拉伸试验对比,检测其焊缝机械强度,并对断口进行微观组织分析。结果表明：在使用静轴肩搅拌头焊接过程中,产热量主要来源于搅拌针轴肩的摩擦生热和搅拌针端部的摩擦生热,搅拌针的侧面摩擦生热和静轴肩的摩擦生热占比较小;对产热量影响较大的是主轴压力和主轴转速,C轴转速对产热量影响不大;在主轴压力为2940～3430 N,主轴转速为1000 r/min,C轴转速为0.05 r/min的工艺参数下,完成焊接的焊缝表面光滑无飞边,内部无沟槽隧道缺陷,焊缝抗拉性能达到母材的71.5%左右;焊缝断口存在分层现象,靠近焊接表面的上层呈脆性断裂特性,下层呈延性断裂特性,与母材相比,焊缝试样的延伸率和抗拉强度均有所降低。     

全挂车形式叉车悬架弹性结构的优化设计

针对全挂车叉车原始样车的设计特点进行分析,指出原始设计的主要不足之处,提出一个旨在改善其高速行驶稳定性的悬架弹性结构修改方案。进而,将优化设计原理应用于悬架弹性结构的匹配设计领域。基于车辆系统的动、静力学分析,结合对整车高速行驶稳定性影响因素的讨论,建立相应的优化模型并进行求解,从而确定出能够满足整车高速行驶稳定性设计要求的悬架弹性元件的最佳刚度特性。最后,对优化设计的有效性加以检验。一方面,建立悬架系统与整车匹配分析的功能虚拟样机,对全挂车叉车在高速拖行状态下的稳定性进行仿真,结果表明：经过优化设计的全挂车叉车,其高速行驶稳定性获得了明显提高。另一方面,以优化设计结果为指导,完成了新一轮样车试制,并在实际道路条件下对优化前、后的样车进行高速拖行稳定性对比试验,结果同样表明：针对悬架弹性结构的优化设计,的确可改善整车的高速行驶稳定性。     

ROBUST CONTROL OF GAS TUNGSTEN ARC WELDING SYSTEM

The robust control law for gas tungsten arc welding dynamic process, which is a typical sampled-data system and full of uncertainties, is presented. By using the Lyapunov second method, the robust control and robust optimal control for a class of sampled-data systems whose underlying continuous-time systems are subjected to structured uncertainties are discussed in time-domain. As a result, some sufficient conditions of robust stability and the corresponding robust control laws are derived. All these results are designed by solving a class of linear matrix inequalities (LMIs) and a class of dynamic optimization problem with LMIs constraints respectively. An example adapted under some experimental conditions in the dynamic process of gas tungsten arc welding system in which the controlled variable is the backside width of weld pool and controlling variable pulse duty ratio, is worked out to illustrate the proposed results, it is shown that the sampling period is the crucial design parameter.