摩擦焊接新工艺及其设备

本文针对现有摩擦焊接加压程序的缺点,提出了一种新的摩擦焊接加压程序——四级加压程序。并设计制造了新型摩擦焊机,取得良好技术经济效果。     

工艺参数对紫铜搅拌摩擦焊焊接接头成形及力学性能的影响

对T2紫铜的搅拌摩擦焊工艺进行了试验研究,并分析了焊接工艺参数对接头成形和力学性能的影响。结果表明,搅拌头形状和焊接速度、搅拌头转速、搅拌头偏转角度等工艺参数对焊缝成形有重要的影响。当焊接规范合适时,可以得到成形美观、内部无缺陷、力学性能良好的接头。焊接接头的硬度分布沿焊缝中心基本对称,焊核区硬度较高,热影响区硬度最低。     

搅拌摩擦焊工艺参数对2519厚板焊接性能的影响

采用搅拌摩擦焊方法对10mm厚的2519高强铝厚板进行了焊接，研究了该铝合金厚板的搅拌摩擦焊工艺参数对其焊接性能的影响。结果表明：在一定范围内，随着转速或焊速的增加，焊缝强度都呈现出先增加后减小的特征，在转速为2000r／min、焊速为150mm／min时，可获得较好的焊接接头，其抗拉强度达到最大值298MPa。焊逢的薄弱环节出现在热影响区与热机影响区的过渡区。     

一种新型焊接工艺--搅拌摩擦焊

搅拌摩擦焊是20世纪90年代初开发出的一种新型焊接工艺，它可以焊接常用熔焊方法难以焊接的铝合金、钛合金等，并且具有一系列独特的优点。在此简要介绍了搅拌摩擦焊的原理、搅拌摩擦焊接接头性能、影响搅拌摩擦焊接的工艺参数以及搅拌摩擦焊常用设备。     

铜板搅拌摩擦焊接工艺优化

搅拌摩擦焊(FSW)是近几年发展起来的新型摩擦焊接技术。铝合金搅拌摩擦焊接已成为国内外研究的热点，但对铜及其合金搅拌摩擦焊接的研究尚不多见。通过大量试验分析，优化了铜板搅拌摩擦焊接工艺。研究表明：工业纯铜具有良好的搅拌摩擦焊接性能，优化工艺可获得强度超过母材的搅拌摩擦焊接接头。     

MB3镁合金搅拌摩擦连接工艺研究

针对工业用MB3镁合金进行了搅拌摩擦焊接试验。分析了各工艺参数及搅拌头形状对焊缝质量的影响。经过力学测试表明；对于3mm厚的MB33镁合金，采用搅拌头旋转速度为1500r／min，焊速48mm/min时焊接接头成形良好，性能优良。     

工艺参数对5A05铝合金搅拌摩擦焊接接头性能的影响

分别采用750r/min-47.5mm/min,950 r/min-47.5mm/min,1180 r/min-47.5mm/min,1500 r/min-47.5mm/min四种工艺参数对3mm厚的5A05铝合金进行了搅拌摩擦焊接.结果表明,焊速为47.5mm/min、转速为1180r/min时,可获得较好的焊接接头,其抗拉强度达到最大值270MPa,是母材强度的98%.焊接接头的硬度分布存在一定的规律,沿焊缝中心两侧基本对称,由中心向两侧硬度逐渐降低,当到达TMAZ/HAZ过渡区时达到最低值,其后逐渐增加,最终达到与母材相等.拉伸断口表现为韧性断裂的特征.     

钛合金线性摩擦焊工艺试验及焊接精度研究

通过TC4和TC17钛合金材料的线性摩擦焊工艺参数优化试验,获得了线性摩擦焊三个主要工艺参数(振幅、频率、焊接压力)和一个辅助控制参数(焊接缩短量)对焊接接头的焊接飞边、焊缝组织以及焊接精度的影响规律,为整体叶盘零件的工艺结构设计和工艺参数的选取提供了依据.     

铝合金材料搅拌摩擦焊焊接参数概述

概述了铝合金材料搅拌摩擦焊的焊接原理以及搅拌头形状、材料、焊接工艺参数等对接头成形及性能的影响,学习和应用相关知识,为后续铝合金材料搅拌摩擦焊提供试验依据、理论指导和技术支持.     

摩擦焊接工艺新发展(一)

摩擦焊接是一种先进的制造工艺，在各行各业中有着广泛的应用前景，近年来，摩擦焊接工艺又有了很大的发展，本文简要介绍五种新的腐蚀焊接工艺－超塑性焊接、线性摩擦焊接、搅拌摩擦焊接，嵌入摩擦焊接及第三体摩擦焊接。     

搅拌摩擦焊应用及焊接设备简介

介绍了搅拌摩擦焊的工艺过程，分析了搅拌摩擦焊焊缝及焊接过程的优缺点。对搅拌摩擦焊的应用和常用搅拌摩擦焊设备作了简要的描述。     

Development of small-sized friction stirs welding equipment for hand-operated welding

Much attention has been paid to FSW as a useful joining process that provides superior characteristics compared with conventional fusion welding. However, the FSW equipment must have a high stiffness due to the applied load and the tool torque, which increases the size of the equipment. Therefore, it is difficult to use the FSW technique on-site for repairs and/or hand-operated welding. In this study, the relationship between the FSW parameters and the process loads was investigated for the FSW with a counterbalanced tool and preheating to evaluate the possible miniaturization of the equipment. The results revealed that the counterbalanced tool concept with preheating was effective for the miniaturization of the equipment because it reduces the applied l and the tool torque during the FSW. Welding direction force Fx and transverse direction force Fy can be reduced below 70 N and 50 N respectively.     

Development of small sized friction stir welding equipment for hand operated welding

Abstract

Friction stir welding (FSW) is widely used in various industrial fields. However, high tiffness is required for FSW equipment which has to withstand high applied load and tool torque and therefore, the equipment becomes large sized. It is difficult to employ FSW for site welding such as repair welding and/or manual welding. The authors made a prototype of FSW apparatus equipped with a counterbalanced tool and a local heating device. The relationship between the applied load and welding parameters was investigated and it was found that the force in the welding direction, Fx is reduced to 70 N or less and that in the transverse direction Fy is to 50 N or less. The combined use of the prototype equipment with a counterbalanced tool and the local heating is very effective to downsize FSW equipment.     

我国电焊机行业运行态势分析

根据电焊机行业的统计数据,分析了近几年行业运行态势;同时就国内外电焊机行业技术发展水平作了对比。通过对2011年运行中突出点的提炼,指出行业发展迫切需要关注的问题。市场需求和产品与技术发展的趋势,促使电焊机行业改变粗放式的模式,朝着高效、节能、绿色制造的方向稳定发展。     

Effect of friction stir welding tool design on welding thermal efficiency

ABSTRACT

Enhancing the heat transfer to the material being welded, instead of the tool, will improve the welding thermal efficiency. Friction stir welding of 5?mm thick 6061-T6 aluminium alloy plates was carried out with the newly produced tools. It was found that the thermal efficiency increased by 4.2% using a tool with all the new design features (i.e. hollow, fluted and thermally insulated) compared to the conventional tool for aluminium welding. To assess the benefits of the new tool design on steel FSW, a finite element numerical simulation study was undertaken. In this case, the simulation results yielded a welding thermal efficiency increase of 10–15% using a thermally coated tool, thereby offering potential productivity gains.     

Development of ceramic backing for friction stir welding and processing

Usually, a workpiece is deformed during friction stir welding due to high applied loads. Consequently, fully and consolidated friction stir-welded joints as well as tool life time can be affected promoting unscheduled manufacturing stops, which favour decreasing the welding productivity. Furthermore, the workforce is dislocated to not predicted maintenance steps. This work proposes the development of a special ceramic backing to joining and processing material using FSW technologies. Four ceramic deposits were tested over a steel plate, which allowed selecting those with less porosity and, thus, better strength. This backing allowed us to obtain full penetration welds for duplex stainless steels, to high forces during engagement for high-strength low-alloy steels and to obtain consolidated aluminium–steel dissimilar joints. For the last one, there was not adherence of the soft material in the workpiece. In addition, the ceramic backing allowed us to confine the heat and plasticized metal, as well as develop established welding parameters.     

Using friction welding for producing heat exchanger equipment from martensitic 15Kh5M steel

The results of mechanical and other types of tests of metal of welded joints in pipe blanks of 15Kh5M martensitic steel, produced by friction welding with rotation, are presented. On the basis of the analysis of the test results it is concluded that 15Kh5M can be efficiently welded by friction welding and that the method can also be used for producing the tube–tube plate sections of heat exchangers made of 15Kh5M steel with appropriate modernization of welding equipment.     

铝及铝合金的变极性等离子焊接设备与工艺

通过铝及铝合金焊接特点的分析,比较TIG、MIG、PAW不同焊接方法的优缺点;对不同板厚的防锈铝进行大量的变极性等离子焊接工艺试验,总结出变极性等离子焊接铝合金开设备的要求,以及分析等离子焊接工艺参数对成形的影响,制定了一套成熟的焊接工艺参数。试验结果表明：立焊变极性等离子焊接中厚板铝及铝合金有着明显的工艺优势,可以实现单面焊双面成形,焊前清理要求低,焊缝可达到Ⅰ级。     

我国焊割设备市场统计分析及预测

通过对我国焊割设备市场的主要供应商、应用行业、经销商进行调研,统计和分析出我国过去三年焊割设备的市场容量以及行业需求。并根据主要应用行业自身的发展和增长趋势、国家经济以及制造业的发展,预测焊割设备未来三年的市场需求以及增长。调研和分析数据表明,我国焊割设备市场需求增长强劲,市场规模日益增大。     

Study of hybrid welding repair process of friction stir welding grove defect

Abstract

Gas tungsten arc welding (GTAW) repair process and GTAW+FSW (friction stir welding) hybrid repair process are studied to remove the large size groove defect formed during FSW. The experimental results indicate that the groove defect can be removed by both the repair processes. The tensile strength of the GTAW repair joint is only 55% of that of the base metal. The tensile fracture occurs at the transition zone between the weld zone and the heat affected zone, and the fracture surface of the repair joint is characterised by clear brittleness. In contrast, the GTAW+FSW hybrid repair joint has a high tensile strength equivalent to 70% of that of the base metal. The tensile fracture occurs at the overlap thermomechanically affected zone between the two FSW nuggets, and the fracture feature of the hybrid repair joint is partially plastic and partially brittle.