粉煤灰复合活性剂在A-TIG焊中增加熔深的机理研究

为实现对工业废弃物粉煤灰的剩余价值利用,尝试以粉煤灰作为主要原料制备焊接复合活性剂,并在AZ91镁合金板上进行A-TIG焊.利用焊缝的电特性实时采集、焊接温度场采集、电弧力测试等手段研究活性剂对电弧影响,通过熔池Bi粒子示踪实验探究活性剂对表面张力温度梯度影响.结果 表明:与常规TIG焊相比,粉煤灰复合活性剂可以使焊缝熔深增深1.4倍,熔宽减小,深宽比是常规TIG焊的1.43倍.粉煤灰复合活性剂中氟化物的解离和电离吸热过程、带电粒子的电子扩散和复合过程可以促进电弧收缩,使焊接电压升高,热输入量提高.而活性剂中的氧化物既可以通过对电弧的机械压缩作用强迫电弧收缩,又可以通过电离产生的氧元素实现对熔池液态金属表面张力温度梯度系数的改变,提高熔池中心热输入.A-TIG焊AZ91镁合金熔深增加是电弧收缩理论和表面张力温度梯度改变理论共同作用的结果.     

TC4合金空心阴极真空焊接熔池动态行为的数值模拟

建立了空心阴极真空电弧焊(Hollow Cathode Vacuum Arc Welding, HCVAW)焊接TC4钛合金板(5mm厚)熔池中流体流动和传热过程动态行为的物理、数学模型,并对焊接过程进行了数值模拟计算和工艺试验、通过计算,找出了焊接速度和焊接电流等工艺参数对焊缝成型的影响规律,并计算出焊接过程中工件上的温度场分布和熔池中的流场分布,计算结果与实验结果基本相符.     

固定电弧脉冲TIG焊接熔池流体流动与传热模型

在浮力、电磁力和表面张力梯度共同作用下对固定电弧脉冲ＴＩＧ焊接熔池中的流体流动与传热的动态过程建立了数学模型。在控制方程组强烈耦合的情况下，将处理导热问题边界条件的附加源项法应用于处理动量边界条件，同时采用交替方向隐式迭代法及双块修正技术，使求解非稳态控制方程组的迭代收敛速度大为提高。计算结果展示了脉冲ＴＩＧ焊接过程中，随着焊接电流的周期性变化，熔池流场与热场的周期性变化规律以及熔池形成的动态发展过程。根据该模型得出的计算结果与试验测定结果吻合程度良好。     

TG合金空心阴极真空焊接熔池动态行为的数值模拟

建立了空心阴极真空电弧焊（Hollow Cathoda Vacuun Arc Welding,HCVAW)焊接TC4钛合金板（5mm)熔池中流体流动和传热过程动态行为的物理,数学模型,并对焊接过程进行了数值模拟计算和工艺试验,通过计算,找出了爆接速度和爆接电流等工艺参数对爆缝成型的影响规律,并计算出焊接过程中工作上的温度场分布和熔池中的流场分布,计算结果与实验结果基本相符。     

激光功率对钛合金双侧同步焊接温度场的影响

为研究激光功率对TC4钛合金T型结构双激光束双侧同步焊接温度场的影响,针对TC4钛合金T型结构的双激光束双侧同步焊接过程,建立了相应的有限元模型,利用有限元分析软件进行了焊接过程温度场的计算,研究了激光功率对熔池形状的影响规律,并对不同激光功率下的温度场进行了分析.结果表明:随着激光功率的增加,熔池的熔深、熔宽均有所增...     

焊剂片约束电弧焊接三明治板熔滴过渡与熔池波动研究

针对焊剂片约束电弧(FBCA)焊接高强钢三明治板熔池研究难点,采用侧边贴敷耐高温石英玻璃片方法,采集焊接动态过程信息,实现熔池边缘曲线的提取与特征参数的计算,研究不同参数下熔滴过渡模式及熔池边缘曲线波动情况,分析熔池振荡角与焊接稳定性及焊缝成形之间的关系。结果表明：不同参数下FBCA焊接存在短路过渡、粗滴过渡、排斥过渡、细滴过渡、射滴过渡、弧桥并存过渡六种过渡方式,对芯板内熔池边缘波动的影响依次减弱;随着熔池振荡角变化,熔池边缘曲线形状存在混合U形、深U形及浅U形,电弧燃烧稳定性依次增强;当焊接处于弧桥并存过渡模式、熔池边缘曲线为浅U形时,电弧稳定燃烧,电弧力作用均匀,焊接过程稳定,焊缝质量最好。     

基于Fluent的钛合金激光氮化机理及数值模拟

基于非等温产生的表面张力梯度导致熔池区域内的马兰戈尼对流对激光氮化传热和传质过程有重大的影响。本文采用计算流体软件Fluent对钛的激光氮化过程进行探究和重现,结合传热过程中材料温升引起的相变模型及流体体积函数(VOF)模型分析气—液降膜传质机理,通过建立瞬态激光氮化温度场和浓度场的耦合模型,对激光氮化过程的传热,熔池流动和传质机理进行数值模拟。分析结果给出了钛工件的熔池形成、内部流动、氮化层的氮含量及其分布与激光参数之间的关系,为激光氮化工艺参数优化提供了理论依据。     

Ti6Al4V合金双辉渗钼扩散系数的数值分析

以Ti6A14V合金双辉等离子渗钼的扩散行为为研究对象,针对具有沉积层和扩散层的典型钼合金化改性层的钼元素含量分布形态,采用数值分析方法计算了钼元素的扩散系数。结果表明:通过这种数值计算方法能较好地揭示Ti6A14V合金等离子渗钼的扩散行为,高钼浓度区域的钼扩散系数较小,而低钼浓度区域的钼扩散系数较大;不同沉积层的处理方法对钼扩散系数的计算结果影响显著。     

微尺度流道中流体流动前沿的喷泉流动仿真

采用经典G a lerk in有限元法和N ew ton-R aphson迭代法,配合适当的边界条件实现了微流道中牛顿流体和剪切变稀流体前沿喷泉流动的数值仿真。结果表明:两种流体在喷泉流动区域的速度压力分布规律相同,在微尺度条件下流体的本构特性对喷泉流动的形式影响较小,仅是剪切变稀流体的喷泉区域略大于牛顿流体。在微尺度条件下,喷泉效应仍然是一种纯流体动力学现象。表面张力对微流体前沿喷泉流动区域的速度压力分布影响很小,但其在流体前沿自由表面上产生的切向应力使流体前沿的形状产生较大变形,与理想的半圆形相差较远。     

低碳钢焊缝中心凝固相组织的元胞自动机法模拟

基于元胞自动机法扩展了现有的焊接熔池凝固过程形核、生长及溶质扩散模拟模型,模拟了Fe-0.05%C二元合金焊接过程中枝晶的生长形态和结晶过程中溶质的分布及扩散过程。同时,以Fe-C二元相图为基点,根据溶质浓度不同相组织不同原理模拟计算了焊接熔池凝固后相组织的分布,建立了a+P和P+Fe3CⅡ两种组织比例值与溶质浓度、冷却速度和形核基底数等参数的数学模型。结果表明:模拟得到的低碳钢焊缝组织分布与试验结果相符;基于溶质浓度变化的相组织控制模型能预测实际低碳钢的焊后焊缝组织。溶质浓度、冷却速度和形核基底数对a+P和P+Fe3CⅡ两种组织比例的影响都较为明显,影响效果相对独立;回归分析得到的组织控制方程高度显著,为焊缝的组织控制提供了一定的数据支持。     

Solidification behaviour in plasma are welding

Melting and solidification behaviour in the deep penetrution welding process is different from that in conventional welding process in deep penetration processes there is keyhole formation and the full thickness of the plate receives the are heat input unlike conventional processes in which the heat input is received only by the surface nodes. In the present study, the thermal analysis of molten pool formation and solidification keyhole welding using plasma are welding has been done using the finite element method. The model accounts for the several phenomena associated with welding, like the distributed are heat input over the top surface and along the thickness, the temperature-dependent material properties. convection and radiation heat losses etc. The analysis is performed for different combinations of parameters. viz welding current and welding speed, which have the maximum influence on molten pool shape and solidification behaviour. The model has also been validated by conducting experimental measurement of thermal cycles experienced by the plate for different welding parameters. The weld pool dimensions. viz. the length and widlh are found to increase with inincreasing current and decereasing welding speed. Thermal cycles at locations close to the weld reach a higher value of temperature and the time for peak temperature is also less but at farther locations the peak temperature reached is lower and the time for peak temperature is higher. Details of the model, the experimental results obtained and the solidifications charateristics of the pool are discussed in this paper.     

等离子+缆式焊丝脉冲GMAW复合焊熔池流体行为研究

目的 研究等离子+缆式焊丝脉冲GMAW复合焊过程的熔池流体行为.方法 综合考虑传热学以及流体动力学,建立Fluent数值分析模型.使用双椭球–锥体热源模型代表等离子弧焊传热模型,用双椭球热源表征GMAW电弧传热并考虑熔滴传热,同时考虑熔池受到的电磁力、浮力、表面张力、等离子流力等作用力.基于Fluent软件,对复合焊过...     

Numerical investigation of droplet impact on the welding pool in gas metal arc welding

A transient three‐dimensional model that describes physical phenomena inside a welding pool during gas–metal arc welding process is presented. The model considers such phenomena as heat‐mass transfer, electromagnetics, hydrodynamic processes and deformation of the weld pool free surface. The fluid flow in the weld pool is induced due to the presence of the mechanical impact of the droplets, thermo‐capillary surface tension, thermal buoyancy and electromagnetic forces. The weld pool surface deformation is calculated by considering arc pressure and droplet impact force. A comparative analysis of the impact of the electric current of the welding arc and different force factors causing the motion of liquid metal in the weld pool on the shape of the welded seam was carried out and discussed.     

等离子弧焊接熔池和小孔形成过程数值分析

目的 研究等离子弧焊接穿孔过程中熔池内部的金属流动情况和小孔动态变化过程。方法 通过“传热-熔池流动-小孔”之间的相互耦合关系,建立了等离子弧焊接穿孔过程的数值分析模型,通过VOF方法追踪了小孔界面,采用FLOW-3D软件模拟了等离子弧焊接熔池和小孔的形成过程,定量计算了等离子弧焊接温度场、熔池流场及小孔形状;分析了等离子弧焊接熔池和小孔行为;并通过等离子弧焊接实验数据验证了模拟结果。结果 当焊接时间为0~1.0 s时,小孔深度曲线与熔深曲线几乎相同,小孔底部紧贴熔池底部;在2.8 s以后,小孔深度曲线与熔深曲线有一定距离,小孔深度曲线在一定范围内波动,等离子弧焊接电弧挖掘作用到达极限,电弧压力与其他力达到平衡状态。模拟的焊缝熔深为8.04 mm、熔宽为13.20 mm,实验测得的焊缝熔深为8.00 mm、熔宽为13.42 mm。结论 构建的随小孔动态变化的曲面热源模型和电弧压力模型可以描述等离子弧焊接过程中的电弧热-力分布;模拟出了等离子弧焊接熔池和小孔动态演变过程;模拟得到的等离子弧焊接焊缝形貌与实验测得的焊缝形貌基本吻合。     

Modelling of arc welding: The importance of including the arc plasma in the computational domain

We present results of computational simulations of tungsten-inert-gas and metal-inert-gas welding. The arc plasma and the electrodes (including the molten weld pool when necessary) are included self-consistently in the computational domain. It is shown, using three examples, that it would be impossible to accurately estimate the boundary conditions on the weld-pool surface without including the arc plasma in the computational domain. First, we show that the shielding gas composition strongly affects the properties of the arc that influence the weld pool: heat flux density, current density, shear stress and arc pressure at the weld-pool surface. Demixing is found to be important in some cases. Second, the vaporization of the weld-pool metal and the diffusion of the metal vapour into the arc plasma are found to decrease the heat flux density and current density to the weld pool. Finally, we show that the shape of the wire electrode in metal-inert-gas welding has a strong influence on flow velocities in the arc and the pressure and shear stress at the weld-pool surface. In each case, we present evidence that the geometry and depth of the weld pool depend strongly on the properties of the arc.     

磁场辅助电弧焊接旋转等离子体行为的数值模拟

目的 研究外加纵向磁场对倾斜电极TIG焊接的电弧温度分布、流动模式和工件所受热力作用的影响.方法 建立磁场-电弧复合焊接热、电、磁、流动的三维数学模型.通过数值模拟和高速摄像实验,揭示倾斜电极电弧在外加磁场作用下的流动、形貌及温度演化机制.结果 外加纵向磁场后,电弧流动速度明显增加,流动模式由沿电极方向喷射变为近似沿竖直方向旋转向下的流动模式;电弧对工件的热作用均匀性提高,热作用中心向电极正下方靠近,但在焊接横向方向上存在偏离;工件受到表面的电弧旋转拖拽力和内部的旋转洛伦兹力作用,最大洛伦兹力可达50000 N/m3.结论 基于所建立数学模型的模拟结果与实验电弧形貌吻合良好,结果表明,外加纵向磁场能够显著改变电弧的形态及流动模式,提高电弧热流密度的均匀性,并能够对熔池产生有效的搅拌作用.     

Numerical analysis of weld pool geometry in globular-transfer gas metal arc welding

The weld pool geometry and its dimension in the globular-transfer mode during gas metal arc welding (GMAW) were numerically analyzed by using the thermal conduction model, which considered the influence of the deformation of weld pool surface on heat flow in the quasi-steady state. According to the features of the globular-transfer mode, the additional heat energy from molten metal droplets was treated as a plane or volumetric heat source term to correspond to different welding conditions. The weld pool surface profile was predicted while considering the effect of droplet impingement on the depression of the weld pool. The bead-on-plate GMAW experiments were performed under different welding conditions to validate the model of numerical analysis. It has been found that the predicted results agree well with the measured ones.     

The mechanism of penetration increase in A-TIG welding

The mechanism of the increasing of A-TIG welding penetration is studied by using the activating flux we developed for stainless steel. The effect of flux on the flow and temperature fields of weld pool is simulated by the PHOENICS software. It shows that without flux, the fluid flow will be outward along the surface of the weld pool and then down, resulting in a flatter weld pool shape. With the flux, the oxygen, which changes the temperature dependence of surface tension grads from a negative value to a positive value, can cause significant changes on the weld penetration. Fluid flow will be inward along the surface of the weld pool toward the center and then down. This fluid flow pattern efficiently transfers heat to the weld root and produces a relatively deep and narrow weld. This change is the main cause of penetration increase. Moreover, arc construction can cause the weld width to become narrower and the penetration to become deeper, but this is not the main cause of penetration increase. The effects of flux on fluid flow of the weld pool surface and arc profiles were observed in conventional TIG welding and in A-TIG welding by using high-speed video camera. The fluid flow behavior was visualized in real-time scale by micro focused X-ray transmission video observation system. The result indicated that stronger inward fluid flow patterns leading to weld beads with narrower width and deeper penetration could be apparently identified in the case of A-TIG welding. The flux could change the direction of fluid flow in welding pool. It has a good agreement with the simulation results.