粉煤灰/二氧化硅活性剂在Q235钢A-TIG焊中的应用

为了探究粉煤灰作为A-TIG焊活性剂的可行性,以粉煤灰和不同含量的二氧化硅制备复合活性剂在Q235钢基体表面进行A-TIG焊,研究了复合活性剂成分含量对焊缝截面形貌、显微组织和元素分布的影响.结果表明:采用粉煤灰-40%SiO_2作为复合活性剂进行A-TIG焊时,可将6 mm厚Q235钢板一次性焊透,焊缝深宽比可达到0.85;焊缝出现明显的中间收缩倾向,呈"深口杯"状,可实现单道焊双面成型的效果;其焊缝柱状晶数目较多、组织排列规则且具有方向性,熔合区和热影响区组织均匀细小,可降低焊接母材的过热倾向;相对于100%SiO_2活性剂,Si元素的溶入量和溶入深度显著增加,这说明粉煤灰中其他成分的存在对Si元素溶入焊缝、进而增加焊缝熔深起到促进作用.采用粉煤灰-40%SiO_2为活性剂进行A-TIG焊时焊缝熔深的增加机理可能是以电弧收缩理论为主,但考虑到Al元素溶入较深且溶入量较多,粉煤灰中其他物相又十分复杂,在高温电弧作用下各物相之间相互反应放热致使电弧热输入增加、其他组分在熔池中改变了熔池表面张力温度梯度等均可能致使焊缝熔深增加.     

Optimization of process parameters for transalkylation of toluene to xylene using response surface methodology

ABSTRACT

H-beta zeolite was modified by the ion exchange method to replace its H⁺ ions with Ce⁴⁺ ions. The catalytic performance of this cerium exchanged beta zeolite was evaluated for vapor phase transalkylation of 1,2,4 TMB (1,2,4 trimethylbenzene) with toluene for the production of xylene in a fixed bed, down-flow reactor. The modified zeolite was found to be highly active for this transalkylation reaction. The response surface methodology (RSM) is used for designing the experiments. The effect of three important reaction parameters viz. temperature, reactant ratio, and space time on response variables (toluene conversion and xylene selectivity) is studied and discussed. All the three selected reaction parameters were found to be significant for the toluene conversion; whereas, xylene selectivity was not much influenced by the temperature. The optimum values of the reaction parameters predicted by the model (temperature: 409.7°C, reactant ratio: 2.024, and space time: 4.451) were validated by an experimental run. The results of the experimental run were in close agreement with the model predicted results.     

Genetic-Algorithm-Based Computational Models for Optimizing the Process Parameters of A-TIG Welding to Achieve Target Bead Geometry in Type 304 L(N) and 316 L(N) Stainless Steels

The weld-bead geometry in 304LN and 316LN stainless steels produced by A-TIG welding plays an important role in determining the mechanical properties of the weld and its quality. Its shape parameters such as bead width, depth of penetration, and reinforcement height are decided according to the A-TIG welding process parameters such as current, voltage, torch speed, and arc gap. Identification of a suitable combination of A-TIG process parameters to produce the desired weld-bead geometry required many experiments, and the experimental optimization of the A-TIG process was indeed time consuming and costly. Therefore it becomes necessary to develop a methodology for optimizing the A-TIG process parameters to achieve the target weld-bead geometry. In the present work, genetic algorithm (GA)-based computational models have been developed to determine the optimum/near optimum process parameters to achieve the target weld-bead geometry in 304LN and 316LN stainless steel welds produced by A-TIG welding.     

奥氏体不锈钢A-TIG焊工艺研究

目的研究焊接参数对焊缝成形和接头宏观组织的影响。方法改变焊接电流、焊接速度、焊接电压以及活性剂中的一个参数,固定其他3个参数不变,对奥氏体不锈钢进行焊接,分析其接头宏观形貌、组织和力学性能。结果随着电流、电压的增加,焊接接头的熔深和熔宽都在增加,随着焊接速度的增加,焊接接头的熔深和熔宽都在降低,在相同参数下,将不同活性剂下的A-TIG焊接头的熔深和熔宽进行比较,发现涂敷C4活性剂接头熔深最大达到4.29mm,而常规TIG焊接头熔深为1.38mm,涂敷C4活性剂的接头熔深为TIG焊的3.11倍,且熔宽也有所减小。结论 C4活性剂A-TIG最佳工艺参数为:I=175 A,U=14 V,v=80 mm/min,此时能将6 mm板材焊透,成形良好,在此工艺下焊缝等轴晶范围最大,焊缝组织最为细小。相比于TIG焊,涂敷C4活性剂接头强度系数提升4.1%。     

Optimization of welding parameters for resistance spot welding of TRIP steel with response surface methodology

Many automotive companies are endeavouring to reduce the weight of the car body in response to various environmental issues. One initiative is the development of TRIP (Transformation Induced Plasticity) steels with a high strength and ductility. Resistance spot welding is a complex process, which requires specific optimal welding conditions based on experimental data. However, the trial-and-error method to determine the optimal conditions requires a large number of experiments, and so response surface methodology has been employed to overcome this problem. The second-order model was used here. This has been used in the resistance spot welding process of the TRIP steel and galvanized TRIP steel with a zinc-coated layer to optimize the welding parameters. The welding current, welding time, and welding force were selected as input variables, and the shear strength and indentation were selected as output variables.     

响应曲面法优化优先透乙醇渗透汽化复合膜的操作条件

采用自制的硅橡胶-沸石杂化优先透乙醇渗透汽化复合膜,利用响应曲面法研究原料液温度和循环流速两个参数对乙醇质量分数为4.05%的乙醇-水体系渗透汽化分离过程的影响.试验表明,温度对膜的通量和分离因子都有显著的影响,温度升高通量增加,而在50℃以下分离因子随温度升高而增加,此后分离因子随温度升高而下降.循环流速的增加会导致通量和分离因子的下降.综合考虑分离因子和通量这两个响应值,利用回归方程求得本试验所采用的渗透汽化复合膜在乙醇一水体系中最优操作条件是:温度59.8℃,循环流速30 L/h,此时总通量和乙醇分离因子分别达到242.8 g/(m2·h)和20.6.     

Optimization of processing parameters in induction hardening using response surface methodology

In this paper, an effective procedure of response surface methodology (RSM) has been utilized for finding the optimal values of process parameters while induction hardening of AISI 1040 under two different conditions of the material i.e., rolled and normalized. Various process parameters, such as feed rate (speed at which the induction coil moves, which is measured in mm/sec), current, dwell time (time after which heat intensity starts to heat work piece in seconds) and gap between the work piece and induction coil have been explored by experiments. Hardness at two different conditions has been considered as performance characteristic. The experiment plan was based on rotatable, central composite design (CCD). The experimental results showed that the proposed mathematical models suggested could describe the performance indicators within the limits of the factors being investigated. The obtained optimal process parameters have been predicted and verified by confirmation experiments. Microstructure and SEM (scanning electron microscope) analyses were also done for justification of the work.     

Optimization of combined mechanical activation-roasting parameters of titania slag using response surface methodology

In this paper, the effects of mechanical activation and roasting on treating titania slag process were systematically investigated. Several operating parameters as independent variables, namely activation time, temperature and roasting time, and synthetic rutile content as dependent variable, were optimized using response surface methodology (RSM) with a central composite design (CCD). A second-degree equation for independent and dependent variables was computed and used to create the response surface and contours. It showed that linear effect of activation time, temperature and roasting time, interaction effect between activation time and temperature, square effect of activation time showed influence on synthetic rutile content. According to results from analysis of variance (ANOVA), the value of the determination coefficient (R² = 0.9767) indicates that the model was a good fit that 97.67% of the variation could be explained well by the model. The value of the adjusted determination coefficient (adj.R² = 0.9558) was also very high to advocate for a high significance of the model. The predicted synthetic rutile content after process optimization was found to agree satisfactory with the experimental values. The optimum experiment parameters were found as follows: activation time of 170.42 min, temperature of 1149.28 °C, and roasting time of 20.79 min. The specific polymorphic phase transition of titania slag before and after combination mechanical activation and roasting process were obtained and characterized by X-ray Diffraction (XRD), respectively.     

活性剂增加不锈钢A-TIG焊熔深机理研究

目的研究涂敷活性剂条件下1Cr18Ni9Ti奥氏体不锈钢的熔深增加机理。方法采用B1活性剂,涂敷在1Cr18Ni9Ti奥氏体不锈钢表面,进行A-TIG焊试验,分析活性剂对电弧形貌、阳极斑点、电弧电压和焊缝熔深的影响情况。结果涂敷活性剂后,电弧和阳极斑点都发生了收缩,电弧宽度由4.97 mm变为4.12mm,减小了17.1%,阳极斑点长轴长度由9.92 mm变为8.22 mm,短轴长度由4.75 mm变为4.35 mm,电弧电压提高了2.7 V,阳极区和弧柱区收缩,提高了弧柱电场强度;相同参数下,涂敷活性剂后熔宽缩小0.62mm,熔深增加了3.01 mm,显著增加熔深。结论阳极斑点收缩和电弧收缩是活性剂增加不锈钢A-TIG焊熔深的主要原因。     

Optimizing energy harvesting parameters using response surface methodology

Energy harvesting is a process in which energy that would otherwise be wasted is stored and then used to power a system. Due to their unique properties piezoelectric materials are ideal for energy harvesting applications. In this study a pre-stressed piezoelectric composite was pressure loaded dynamically to harvest energy. The objective of this study was to optimize, using piezoelectric diaphragms, relevant parameters that have an effect on the energy harvesting process. Parameters considered were temperature, pressure, resistance and frequency. Response surface methodology was used to develop models to identify optimal parameter ranges and also to predict power conversion capabilities for specific parameter levels. Power densities of approximately 24.27 muW/mm³ were measured at optimal conditions. The model identified an optimal temperature of 12degC and a pressure of 240 kPa, which are in agreement with experimental results.     

A-TIG焊研究进展及前景展望

对活性化钨极氩弧焊(A-TIG)焊接工艺、活性剂的研发及其在增加焊缝熔深机理等方面的研究做了比较详尽的综述,并指出活性化TIG焊研究过程中存在的问题、发展前景及今后研究方向。认为对活性焊剂增加熔深的机理还有待深入研究,可以利用数值模拟过程结合活性化TIG焊试验深入研究活性焊剂增加焊缝熔深的机理。可以基于A-TIG焊基本思想结合其他方法研发新的活性焊方法。总之,A-TIG焊具有巨大的发展潜力和良好的应用前景。     

Optimization of the spray-drying process for developing aquasolv lignin particles using response surface methodology

Particle size and morphology are of high industrial importance due to the fact that product properties and performance can be affected by this factors. For instance, bulk properties, processability and appearance of the final product are given by particle size and shape. In this regard, the optimization of process parameters for particle development is required when targeting formulation of specific product and/or particular properties. Response surface methodology (RSM) was used to optimize the spray drying process for the development of aquasolv lignin particles with desired particle size and morphology. The inlet drying temperature X₁: 180–200 °C, atomization pressure X₂: 1.3–1.7 bar and feeding rate X₃: 65–75 mL min⁻¹ were kept as independent variables while the optimizing responses were_: Yield fine of particles with desired particle size and particle size (D₅₀). The quadratic part of the equation and statistical analysis showed substantial effect of the atomizing pressure and feeding rate on the responses and the optimized conditions validated the model. Optimum processing conditions for spray drying of aquasolv lignin were inlet temperature of 173 °C, 1.8 bar atomization pressure and 62 mL/min feeding rate. With this, desired responses of powder were 66% of yield and particle size of D₅₀ < 30 µm were obtained. The experimental values were found to be in agreement with the predicted values indicating the suitability of the model in predicting the particle size and yield of aquasolv lignin.     

Optimization of process parameters for the extraction of chromium (VI) by emulsion liquid membrane using response surface methodology

The emulsion liquid membrane technique was used for the extraction of hexavalent chromium ions from aqueous solution of waste sodium dichromate recovered from the pharmaceutical industry wastewater. The liquid membrane used was composed of kerosene oil as the solvent, Span-80 as the surfactant and potassium hydroxide as internal reagent. Trioctyl amine and Aliquat-336 were used as carriers. The emulsion stability was carried out at different surfactant concentration, agitation speed and emulsification time. Statistical experimental design was applied for the optimization of process parameters for the extraction of chromium by emulsion liquid membrane. The effects of process parameters namely, agitation speed, membrane to emulsion (M/E) ratio and carrier concentration on the extraction of chromium were optimized using a response surface method. The optimum conditions for the extraction of chromium (VI) using response surface methodology for Trioctyl amine were: agitation speed – 201.369 rpm, M/E ratio – 0.5887% (v/v) and carrier concentration – 4.0932% (v/v) and for Aliquat-336: agitation speed – 202.097 rpm, M/E ratio – 0.5873% (v/v) and carrier concentration – 3.9211% (v/v). At the optimized condition the maximum chromium extraction was found to be 89.2% and 96.15% using Trioctyl amine and Aliquat-336, respectively.     

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.     

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.     

响应面分析法优化不锈钢激光切割工艺参数

为了获得良好的不锈钢激光切割质量,确定合理的切割工艺参数,本文以3 mm厚304不锈钢为研究对象,采用响应面法进行试验方案的设计和分析,利用超景深显微镜进行了试样表面切缝宽度、表面纹理最大峰值、挂渣量的测量,利用最小二乘法进行数据处理,研究了激光功率(X₁)、切割速度(X₂)、离焦量(X₃)以及辅助气体压力(X₄)对不锈钢切割表面切缝宽度、表面纹理最大峰值、挂渣量的影响规律,并基于响应面法得到了3个响应目标的预测函数.实验结果表明:X₂=2.48 m/min,X₃=-1.05 mm,X₄=1 MPa时,随着激光功率的增加,切缝宽度不断增大;X₁=300 W, X₄=1.2 MPa时,随着切割速度的加快切缝宽度逐渐减小,随着离焦量的增大切缝宽度先减小后增大;X₁=300 W,X₃=0 mm,X₄=1.40 MPa时表面纹理的最大波峰值RZ随着激光功率、离焦量以及切割速度的增大先减小后增大。以切缝宽度最窄、表面纹理最大峰值最小、挂渣量最少为响应目标确定了3 mm厚304不锈钢激光切割的最佳工艺参数为X₁=365.86 W,X₂=2.75 m/min,X₃=0 mm,X₄=1.4 MPa。试验验证发现:切缝宽度、表面纹理最大峰值、挂渣量的预测误差应分别控制在8.4%~12.7%、21%~24.9%、16.7%~19.5%。     

Optimization of a nanoparticle ball milling process parameters using the response surface method

Nanocrystalline TiO₂-CeO₂ powders were synthesized from their TiO₂ and CeO₂ oxides using mechanical ball milling process. The response surface method is applied to identify optimal parameters for the synthesis of TiO₂-CeO₂ photocatalyst. Analysis of variance and main effect plot are used to determine the significant parameters and set the optimal level for each parameter. Regression analysis showed good agreement of experimental data with the second-order polynomial model with a coefficients of determination: R²?=?0.991, R²_Adj.?=?0.940 and R²_Pred.?=?0.983. Under optimal experimental conditions of TiO₂:CeO₂ weight percentage ratio 71:29, milling speed 200?rpm, and milling time 115?min the highest photodegradation efficiency was achieved. On the basis of the above statistical analysis, it was found that the band gap energy of TiO₂-CeO₂ nanoparticles decreases with the increase of the milling speed and milling time with constant TiO₂:CeO₂ weight percentage ratio. Obtained results suggest that mechanical ball milling process is a rapid, efficient and low energy consumption method to synthesize TiO₂-CeO₂ photocatalyst.     

Effect of FSW parameters on microstructure and mechanical properties of AM20 welds

This paper aims to demonstrate the successful friction stir welding (FSW) conditions of AM20 magnesium alloy. The maximum yield strength and ultimate tensile strength of weld were found to be 75% and 65% of the base metal strength, respectively. The maximum bending angle of the welded joint was 45°. Observations revealed that less plunging depth, high shoulder diameter, and low tool rotational speed and welding speed give better tensile properties. Maximum temperature was observed at 1?mm away from the tool shoulder toward the advancing side. Micro-hardness variation is found to be decreasing along the depth of the weld, and nugget zone (NZ) gives the higher hardness values when compared with base material (BM) and other welded zones. Needle-like grains of the BM became equiaxed grains due to grain recrystalized by the FSW process. The grains in the NZ were finer than thermo-mechanically affected zone and almost same size of grains observed at bottom, middle, and top of the NZ.     

Optimization of gas tungsten arc welding process by response surface methodology

Gas tungsten arc welding is widely used for connecting of boiler parts made of A516-Gr70 carbon steel. In this study important process parameters namely current, welding speed and shielding gas flow rate were optimized using response surface methodology (RSM). The simultaneous effects of these parameters on tensile strength and hardness were also evaluated. Applying RSM, simultaneous effects of welding parameters on tensile strength and hardness were obtained through two separate equations. Moreover, optimized values of welding process parameters to achieve desired mechanical properties were evaluated. Desired tensile strength and hardness were achieved at optimum current of 130 A, welding speed of 9.4 cm/min and gas flow rate of 15.1 l/min.