Lap welding of titanium and mild steel sheets by seam welding

Titanium, a metal with superior sea water corrosion resistance, is increasingly used in titanium clad steel applications for ocean structures. Titanium clad steel is normally manufactured by hot rolling or explosive deposition. Joining of titanium and iron leads to the formation of hard and brittle intermetallic compounds that impair the bond strength. It is therefore necessary to use an insert metal to suppress the occurrence of these compounds, particularly during rolling.^1-3     

Electromagnetic impact welding of Mg to Al sheets

Abstract

Magnesium (Mg) and aluminium (Al) alloys have been lap welded using an electromagnetic impact welding technique. Metallographic examination of the welds has revealed sound and defect free interfaces. Complete metal continuity has been observed with a characteristic wavy interface. X-ray diffraction analysis has shown no intermetallic phases and suggested that this electromagnetic technique is a solid state welding process. All the shear strength samples welded with discharge energy of 6·7 kJ failed away from weld either in the plastically deformed zone or in the base metal. Optimum discharge energy has been determined as 6·7 kJ based on the shear strength results of the welds.     

冷压焊技术在焊接铝电磁线上的应用

介绍了冷压焊技术焊接铝电磁线的焊接原理、工艺及其应用。     

碳纤维-铝合金电磁铆接与准静态压铆对比

为了探究电磁铆接技术在碳纤维复合材料上的可行性,采用碳纤维-铝合金结构为研究对象。探究了碳纤维-铝合金电磁铆接接头的干涉量及剪切、拉脱性能,并与传统准静态压铆技术进行了对比。结果表明:无论是Φ4 mm铆钉,还是Φ6 mm铆钉,电磁铆接结构相对干涉量不仅均匀性更好,而且平均值更高,分别从4.96%提升到5.20%,6.85%提升到7.85%;电磁铆接接头剪切性能有较大提高,对于Φ4 mm铆钉和Φ6 mm铆钉,电磁铆接最大剪切力相比准静态压铆分别提高了19.7%和5.2%;电磁铆接接头拉脱性能有较小提高,对于Φ4 mm铆钉和Φ6 mm铆钉,电磁铆接最大拉脱力相比准静态压铆提高了3.9%和6.6%。结果说明电磁铆接技术更适合复合材料的连接。     

管道插接相贯线专用焊接机器人

管道插接相贯线焊缝是典型的、复杂的空间焊缝.针对管道插接焊缝的特殊焊接工艺要求,采用串并联混合方式设计了一种新型的5自由度焊接机器人,实现了机器人锚固、运动机构、焊枪姿态调节机构和送丝机构的一体化设计.设计了2自由度的自动定心手腕机构,实现了焊枪位置和焊枪姿态的独立控制,建立了专用焊接机器人的运动学模型.针对通用型的相贯线模型,建立了焊枪位置、焊枪姿态和焊接速度的实时控制数学模型.结果表明,该焊接机器人锚固牢固、定位准确,焊接过程可控性好,控制模型能够满足空间相贯线焊缝的焊接工艺要求.     

铁/铝爆炸复合双金属管界面的结合性能

采用爆炸焊接法制备Fe/Al双金属复合管,为表征复合管界面的结合性能进行了压缩、压扁及压剪实验。实验结果表明,复合管结合良好,其界面强度大于纯铝层的抗剪强度,并且能够承受轴向和径向变形。利用扫描电子显微镜观察了原始界面形貌。测试结果表明,结合良好的复合管界面呈波状或直线状。采用液压胀形工艺以Fe/Al双金属复合管制备出复合管正三通,发现良好的界面结合对铁/铝双金属管的塑性成型具有重要作用。     

Effect of trailing heat sink on residual stresses and welding distortion in friction stir welding Al sheets

Abstract

This paper investigates a trailing heat sink, which was designed and applied to friction stir welding (FSW) in order to control the residual stresses and welding distortion. Residual stresses, residual plastic strains and welding distortion of 2024-T3 and 5083-H321 Al sheets welded by FSW with and without the trailing heat sink were compared. The optimal placement of the heat sink was discussed. The results revealed that the reductions in peak tensile stresses were 66% for 2024-T3 and 58% for 5083-H321 by application of the trailing heat sink in FSW. In addition, the welding distortion could be reduced drastically by this method. The 5083-H321 sheet with a size of 1000×100×3·5 mm welded by this method was very flat and had almost no distortion. This method achieved in-process control of stresses and welding distortion, without additional complicated work before or after welding operation.     

多脉冲点焊与磁控点缝焊技术及其现状

论进了多脉冲点焊及磁控交流点、缝焊的原理、工艺特点及其发展现状，特别对可淬硬钢的二次、三次及多脉冲点焊作了较详细的介绍、并指出多脉冲点焊与磁控点缝焊能有效消除焊点应力、改善组织性能、消除焊接缺陷、细化组织等优点、     

焊接电流对Ti3Al/T C11合金焊缝区组织及合金元素扩散的影响

采用真空电子束焊对Ti₃Al合金与TC11合金进行焊接,研究焊接电流对Ti₃Al /TC11焊缝区组织及合金元素扩散的影响。结果表明,随焊接电流增大,焊缝区组织明显粗化,且晶粒尺寸差异逐渐减小;当焊接电流增大至25 mA时,焊缝区组织为粗大β柱状晶。焊接电流对焊缝区各合金元素含量影响较小,但对其均匀性影响较显著,这与焊缝区显微组织形貌有关。随焊接电流的增大,焊缝区合金元素含量均匀性变差。     

Fe3Al/18-8扩散焊接头热处理后组织性能的变化

采用不同的热处理工艺对FeAl／18—8扩散焊接头进行热处理,利用金相显微镜、扫描电镜(SEM)、X射线衍射仪(XRD)等测试手段对热处理后的组织性能进行了分析。试验结果表明：经过焊后热处理的FeAl／18—8扩散焊接头组织更加均匀,扩散过渡区中弥散分布有第二相析出物,合理的焊后热处理工艺为：加热温度800℃、保温时间30min、炉冷至700℃再空冷。热处理后FeAl／18—8扩散焊接头的显微硬度降低．没有出现高硬度脆性相。     

Prediction of forming limit in deep drawing of Fe/Al laminated composite sheets using ductile fracture criterion

Axisymmetric deep drawing processes of laminates composed of mild steel and various aluminium alloy sheets are simulated by FEM. From the calculated stress and strain histories of elements in each layer, the fracture initiation site and the forming limit are predicted by using the ductile fracture criterion. The predictions so obtained are compared with experimental observations. The results exhibit that various types of fracture initiations in deep drawing of the laminated composite sheets are successfully predicted. Furthermore it is found that the drawability is improved by setting the mild steel sheet on the punch side for the case of aluminium alloy sheet with comparatively high ductility, and by sandwiching the aluminium alloy sheet with the mild steel sheets for the case of low ductility.     

Laser pressure welding of Al alloy and low C steel

Abstract

This study was performed to obtain fundamental knowledge concerning the development of laser pressure welding technology for the joining of dissimilar metals. Laser pressure welding of Al alloy A6061 and low C steel SPCC sheets was carried out to investigate the effects of the roller pressure, laser beam scanning speed and irradiation position on the tensile shear and peel strength of welded joints. The interfaces of the joints were observed and analysed by SEM and EDX, and the formation phases on the peeled surfaces were identified with XRD. It was revealed that prevention and suppression of oxidation during welding was extremely important to the production of a sound joint with good mechanical properties. The highest tensile strength and the highest peel strength of joints were obtained at a laser power of 1·8 kW, laser scanning speed of 30 Hz, laser irradiation position at the centreline, roller pressure of more than 245 MPa and welding speed of 0·5 m min^?1 in an Ar atmosphere. The fracture occurred not in the welded zone but in the A6061 base alloy specimen.     

铝/铁复合板与铝合金超声波辅助钎焊

利用超声波辅助钎焊的方法,在大气环境、中温、无钎剂条件下,实现了铝合金与薄膜铝/铁复合板的高强、可靠连接.研究了采用Zn-Al,Al-Si钎料得到的焊缝组织及其性能.结果表明,采用Zn-Al钎料钎焊5A06铝合金和复合板,超声波能有效破除氧化膜,铝膜溶解扩散易于控制,焊缝没有金属间化合物,在铝层未完全溶解时,抗剪强度均大于70 MPa,焊缝由α-Al,η-Zn,共晶和共析组织构成;采用Al-Si钎料钎焊1100纯铝和复合板,复合板铝膜短时间内完全溶解,焊缝存在复杂的Fe-Al-Si三元化合物,并发现明显的裂纹,抗剪强度约为20 MPa.     

管道焊口电加热器应用

为适应管道焊口预热温度和维持层间温度的需求,采用了管道焊口电加热器.介绍了管道焊口电加热器的基本结构、工作原理、性能和特点以及工程应用实例,该设备具有升温迅速、保温效果好、安全、节能环保等优点.该项技术达到了国际先进水平,具有显著的经济效益和社会效益.     

典型曲线焊缝的焊接变位机运动规划

对焊接变位机运动规划的任务进行了分解，建立了旋转倾斜型焊接变位机使待焊点处于最佳焊接位置时的数学模型，并编制了求解程序，对空间螺旋线型焊缝进行了模拟。     

Welded seam 3D calculation and seam location for welding robot system

Abstract

Using laser scanning techniques, scanning lens rotating around a laser diode and a circular laser trajectory was projected onto the surface of a weldment to detect it. Furthermore, one novel vision sensor based on the circular laser is developed. The three-dimensional (3D), circular laser based seam location sensor is investigated. On the basis of the light path system, 3D calculation algorithm is brought forward and used to locate the welded joint. After image denoise, filter, segmentation and thinning, characteristic points of the welded joint could be detected real time using a proposed vision sensor and confirmed by real experiments of butt welded joints with I groove and V groove, and lap, and fillet and ramp welded joints. The results show that circular laser based vision sensor can be used in seam locating and its calculation precision meets the requirement of seam tracking.     

Statistical models for spot welding of commercial aluminium sheets

The present paper reports experimental investigations on the spot welding of commercial aluminium sheets. Experiments were carried out to study the influence of spot welding parameters (welding current, welding time, electrode force and sheet thickness) on the strength of spot welded aluminum sheets with commercial purity. Experiments were planned on the basis of response surface methodology (RSM) technique. The mathematical models (failure load and nugget area) correlating process parameters and their interactions with response parameters have been established. These models have been used in selecting the optimum process parameters for obtaining the desired spot welding quality at the least possible consumed power.