焊接电流影响GMAW双丝焊电弧等离子体的数值模拟研究

基于电磁学理论和流体力学理论,建立熔化极气体保护焊(Gas metal arc welding,GMAW)双丝焊焊接电弧等离子体三维数学模型,利用流体力学软件Fluent对其进行求解。重点研究焊接电流对GMAW双丝焊电弧等离子体行为的影响规律,获得了电弧温度、电流密度、热通量、磁场分布等结果。研究发现,随着焊接电流的变化,电弧等离子体形状变化显著。随着焊接电流的增大,电弧最高温度和电弧偏转角随之增大,电流密度和工件表面热通量由双峰分布转变为单峰分布,并且热通量峰值随焊接电流的增大而增大。此外,随着焊接电流的增大,磁感应强度和磁场力随之最大,磁场分布由独立两个磁场向耦合磁场转变。为有效、定量地证明模拟结果准确性,开展焊接试验,利用高速摄像监测电弧行为,利用光谱测温测量电弧温度。结果表明模拟结果同试验结果吻合良好,研究结果为合理选择GMAW双丝焊焊接电流参数提供理论依据。     

基于汽车驱动桥壳再制造的堆焊可靠性研究

为了研究汽车驱动桥壳表面损伤后的堆焊修复层能否满足再制造的要求,选用H13CrMoA和ER50-6焊丝并采用亚激光瞬间熔工艺,在汽车驱动桥壳片表面制备不同厚度的堆焊层。利用金属磁记忆检测仪和扫描电镜分析堆焊试样的应力分布和断面组织特征,同时测试堆焊试样的硬度并进行渗透、磁粉和X射线三种无损检测。结果表明：ER50-6堆焊试样的堆焊层与母材硬度相近,母材热影响区未发生局部软化,堆焊层与母材结合良好,不存在焊接缺陷和应力集中区,应力分布不均匀程度低于H13CrMoA堆焊试样。
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Numerical analysis of weld pool for galvanized steel with lap joint in GTAW

Galvanized steel is widely used and its demand is growing in automotive industry due to high quality requirement for corrosion resistance. Although there are a lot of demands on using galvanized steel as automotive parts especially for outer body, it has a grave flaw in its welding process. The difficulty is low weldability due to various defects such as porosities and blow holes in weldment, which occurred during welding. A solution to prevent these defects is using hybrid welding process, with two more welding processes. One of the hybrid solutions is using Gas tungsten arc welding (GTAW) as leading position in order to remove the zinc (Zn) coating on the surface before the followed practical fusion welding process. In this research, a numerical analysis model which can predict the eliminated Zn coated layers and the area of Fusion zone (FZ). Developed numerical analysis model was validated through comparing experiment to simulation. Basically, arc heat flux, arc pressure, electromagnetic force and Marangoni flow were employed as the boundary conditions and body force terms. Governing equations such as the continuity, momentum, Volume of fluid (VOF) and energy equations were adopted as usual. In addition to previous model, concentrated arc heat flux and contact thermal conductance models are newly suggested and showed successful result. They are adopted to realize edge concentrated arc and interfacial thermal conductance in lap joint fillet arc welding. Developed numerical analysis model successfully simulated the weld pool and temperature profile therefore the predicted Zn removed area considerably coincided with experimental result.

     

Influence of axial magnetic field on shape and microstructure of stainless steel laser welding joint

The morphology and microstructure of the weld joint have significant influence on mechanical properties of welded specimens. In this paper, the mechanism on how the external magnetic field affected weld profile and microstructure was discussed by applying the longitudinal steady magnetic field to laser welding for SUS301 stainless steel. The optimal and scanning electron microscopes were used to measure the shape of the cross section and observe the microstructure after welding. The results showed that the shape of the cross section and microstructure could be significantly changed using the external magnetic field. Moreover, joint shape changed distinctly with the magnetic field intensity changing. With the increasing of magnetic flux density, the weld profile of the full penetration model changed from funnel to X type; meanwhile, the bottom weld width increased by 40%. In addition, the partial fusion zone occurred, and the weld width decreased by 20% while penetration increased by 18% when magnetic flux density turned into 380 mT. As far as microstructure of weld joint was concerned, it appeared that application of axial magnetic field led to indistinct fusion line and blocky austenite in big size rather than columnar grain in the center of the cross section. This phenomenon could be explained by numerical simulation results.     

外加磁场对高速GMAW电弧和熔池行为的主动调控效应

在熔化极气体保护焊(Gas metal arc welding,GMAW)过程中,当焊接速度超过临界值后,焊缝成形变差,出现咬边和驼峰焊道,无法满足生产要求。研究证明,熔池中动量很大的后向液体流是产生驼峰焊道的主要原因。自主研发外加磁场发生装置,向熔池施加横向电磁力,对后向液体流进行主动干预,并调控熔池流态,从而抑制驼峰焊道的形成。在Q235低碳钢板上开展焊接工艺试验,获得了不同磁感应强度下的焊缝表面成形;采用高速摄像技术,拍摄焊接过程中的电弧和熔池图像,分析外加磁场对电弧形态、熔池流场和焊缝成形的影响规律,初步揭示外加磁场抑制驼峰焊道的机理。试验结果表明,外加横向磁场能明显调控熔池流态,减小后向液体流的动量,并能有效抑制驼峰焊道和咬边等缺陷,显著改善焊缝成形,提高临界焊接速度。     

基于TIG焊电弧-熔池统一模型分析焊接电弧

以TIG焊电弧为研究对象,建立了电弧—熔池的统一模型,并在此模型的基础上对焊接电弧进行了分析。建立此模型就避免了对阳极表面温度的假定,使得对焊接电弧的分析与实际情况更近了一步,从而也为将焊接电弧和熔池作为一个整体来进行分析奠定了基础。采用ANSYS软件分析并得到了阳极表面温度的变化情况,阳极表面电流密度的分布状况,得出热流密度与电流密度分布规律的一致性。并从电磁力和流体流动的角度揭示了电弧压力产生的原因,并通过试验验证了电流密度和电弧压力的分布情况。     

镁合金变极性等离子弧焊接头的微观组织分析

采用变极性等离子弧焊接实现了AZ31B变形镁合金板材的优质连接,焊后利用光学显微镜、电子探针 (EPMA)和X射线衍射(XRD)仪对焊接接头的微观组织、元素分布以及相组成进行了分析。结果表明,镁合金变极性等离子弧焊接头中没有明显的热影响区存在,接头成形好,焊缝组织均匀,晶粒细小;接头中主要的合金元素 Al、Zn在焊缝中分布均匀,没有发现区域偏析;接头中没有发现明显的Mg17Al12或其他杂质相的存在;由于焊接过程中存在着镁的蒸发、烧损,导致接头硬度值在沿焊缝的横向和纵向两个方向上都稍有变化。变极性等离子弧焊方法能够改善镁合金焊接接头组织并提高接头的性能,是一种理想的提高镁合金焊接质量的方法。     

3D analysis of synaptic vesicle density and distribution after acute foot‐shock stress by using serial section transmission electron microscopy

Behavioural stress has shown to strongly affect neurotransmission within the neocortex. In this study, we analysed the effect of an acute stress model on density and distribution of neurotransmitter‐containing vesicles within medial prefrontal cortex. Serial section transmission electron microscopy was employed to compare two groups of male rats: (1) rats subjected to foot‐shock stress and (2) rats with sham stress as control group. Two‐dimensional (2D) density measures are common in microscopic images and are estimated by following a 2D path in‐section. However, this method ignores the slant of the active zone and thickness of the section. In fact, the active zone is a surface in three‐dimension (3D) and the 2D measures do not accurately reflect the geometric configuration unless the active zone is perpendicular to the sectioning angle. We investigated synaptic vesicle density as a function of distance from the active zone in 3D. We reconstructed a 3D dataset by estimating the thickness of all sections and by registering all the image sections into a common coordinate system. Finally, we estimated the density as the average number of vesicles per area and volume and modelled the synaptic vesicle distribution by fitting a one‐dimensional parametrized distribution that took into account the location uncertainty due to section thickness. Our results showed a clear structural difference in synaptic vesicle density and distribution between stressed and control group with improved separation by 3D measures in comparison to the 2D measures. Our results showed that acute foot‐shock stress exposure significantly affected both the spatial distribution and density of the synaptic vesicles within the presynaptic terminal.     

压力容器窄间隙埋弧焊热处理脆化机理研究

用于制造高参数压力容器的低合金高强度铜采用窄间隙埋弧焊,为了消除焊接残余应力,在焊后需对焊接接头进行热处理,其冲击韧性大幅下降。为探讨其脆化机理,选用BHW-35钢为母材,H10Mn2NiMoA镀铜焊丝和SJ101焊剂为填充材料,焊后热处理工艺为920℃正火＋620℃和560℃二次回火。利用扫描透射电镜,对焊缝熔敷金属焊态和焊后热处理的显微组织变化进行了研究。结果表明,低合金高强度钢焊缝焊态时组织为针状铁素体,在晶内有细小碳化物弥散分布;经焊后热处理,由于回复作用板条状组织变粗或消失,在晶界磷元素的偏聚和大量的碳化物在晶界析出导致其冲击韧性下降。窄间隙埋弧焊是一种优质高效的焊接方法,焊接效率高,节约焊材,解决了大厚度工件焊接的技术问题。     

Effect of defects on the burst failure of butt fusion welded polyethylene pipes

With the increasing demand of Medium density polyethylene (MDPE) pipes for gas transmission, the safety concern related with welding defects is becoming a serious matter. In this paper, experimental burst tests and finite element analyses were employed to study butt fusion welded MDPE pipe joints with spherical and planar defects of various sizes. These defects were used to simulate lack of bonding during the welding. Test results showed that in all pipe test cases, the failure location originated from pipe substrates, even though the defect size was increased to 45% of the pipe’s wall thickness. The burst pressure could be estimated by the expression employed in the ASME BPVC, and in the burst pressure, the hoop stress was 20.28 MPa. Simulation results showed that the failure position was not only affected by the defect size, but also by the welding bead. It can be argued that a single welding defect whose maximum size is smaller than 15% of the thickness can be used without failure during short-term usage, even when there is no welding bead in the welded joint.     

基于ALE算法的空心薄壁铝型材模具结构优化

针对空心薄壁铝合金型材挤压成型后薄壁内凹缺陷进行了数值模拟分析,得到了其在稳态时不同方向上的金属流速分布及在焊合室内的金属压力分布状况。模拟结果表明:由于截面上不同部分之间产生了较大的流速差,且金属在不同方向上的流速不相同,从而导致了缺陷的存在。根据分析采用了增加阻流块的设计方案,以此达到阻碍金属流动,减小流速差的目的。经过仿真计算发现修改后的模具结构最终能获得合格的产品。     

大承载轴向混合磁力轴承磁性能分析

针对大承载储能飞轮对混合磁力轴承的设计要求,及考虑到混合磁力轴承的对称性,利用ANSOFT软件中的2D模块对其进行建模,并分析了磁力轴承在平衡位置工作点的磁密线分布,磁密分布及漏磁。分析结果表明该磁轴承整个磁路为不饱和,设计合理,以及计算得出漏磁系数相对较大,这是由于磁悬浮轴承整体结构较大,磁路较长,气隙大等原因造成的,该分析为后续的设计提供了可靠的依据。     

某加热器螺旋管泄露的原因

某加热器螺旋管在运行过程中发生泄露,通过宏观形貌和显微组织观察、化学成分分析、扫描电镜和能谱等方法研究了其泄露原因.结果表明:螺旋管发生蠕变开裂,开裂形式为脆性沿晶开裂;由于服役温度过低,该螺旋管焊接热影响区中沿晶界析出片线状碳化物,使得其附近形成贫铬区;在弯曲应力、振动应力和焊接残余应力作用下,碳化物周围出现较多空洞...     

活性剂等离子弧焊焊接电弧的特性

针对活性剂等离子弧焊焊接过程,采用红外热像伪着色法测定了活性剂等离子弧焊焊接电弧温度场,并建立了活性剂等离子弧焊焊接电弧热流密度径向分布模型,对焊接电弧外形的变化,焊接电弧电压与活性剂之间的关系进行了研究。研究结果表明：活性剂等离子弧焊焊接电弧的温度分布比较紧凑,温度场外形窄,温度分布范围较集中,电弧径向温度梯度较大。电弧径向温度分布呈现正态Gauss分布模式。活性剂等离子弧焊焊接电弧收缩,弧尾翼消失,尾焰加大,电弧穿透力增强,电弧电压升高。     

桥式抓斗卸船机滑轮座底部裂纹的处理及分析

针对650 t/h桥式卸船机滑轮座根部出现的裂纹问题,分析了桥式卸船机滑轮座的工作状态,指出产生裂纹的原因是该处结构承受较大的交变应力和存在焊接缺陷所致。针对原设计的不足,提出通过改变滑轮座的结构形式来改变其应力分布的修复方案。基于Ansys软件的研究结果表明,该方案降低了滑轮座底部应力,使裂纹扩展现象停留在＂裂纹萌生阶段＂,提高了设备的使用寿命。     

脉冲漏磁检测的三维场特征分析及缺陷分类识别

漏磁检测方法广泛应用于石油、运输及化工等行业中金属的缺陷检测.介绍了漏磁检测原理,采用有限元法建立了三维缺陷脉冲漏磁检测模型,分析了缺陷脉冲漏磁场B_x、B_y和B_z分量的特点.结果表明,与传统漏磁检测系统提取缺陷漏磁场水平分量B_x和法向分量B_z进行缺陷识别相比较,三维缺陷脉冲漏磁场分量的提取将提供更多有关缺陷尺寸、位置等信息,尤其是当外加磁场方向与缺陷主平面近似平行时.最后给出了实验验证,实验结果与仿真分析有较好的一致性,这说明有限元仿真分析对实际脉冲漏磁检测系统的设计有重要的指导意义.     

轴向拉力对铝合金拉拔式摩擦塞焊接头组织及力学性能的影响

拉拔式摩擦塞补焊是一种固相连接技术,具有接头强度高,焊后残余应力和变形小等优点,在航天领域具有潜在的应用前景。研究轴向拉力对2A70铝合金拉拔式摩擦塞焊焊接成形及接头性能的影响,并分析焊接缺陷、微观组织及断口形貌特征。结果表明,轴向拉力在20~30 kN范围内能够得到良好的焊缝成形;轴向拉力为20 kN时,结合界面存在未焊合缺陷;轴向拉力提高至22 kN及以上,未焊合缺陷完全消除;轴向拉力提高至28~30 kN时,塞棒与母材形成完好的冶金结合,焊接接头的抗拉强度可达到376 MPa,接头系数为83.6%。当轴向拉力较低时（22~25 kN）,结合界面上易出现弱结合缺陷,微观特征为沿结合界面断续分布的微孔,可导致接头抗拉强度和断后伸长率下降;焊接接头中,塞棒侧热影响区硬度值最低,分析表明该区域的晶粒形态和尺寸未发生明显变化,但θ'相部分溶解,θ相发生粗化,导致局部强度下降;断口形貌显示,在优化参数下断口呈现韧性特征。研究结果可为铝合金拉拔式摩擦塞补焊工艺及机理分析提供借鉴和参考价值。     

Design and fabrication of a novel polishing tool for finishing freeform surfaces in magnetic field assisted finishing (MFAF) process

Surface finish is a critical requirement for different applications in industries and research areas. Freeform surfaces are widely used in medical, aerospace, and automobile sectors. Magnetic field assisted finishing process can be used very efficiently to finish freeform surfaces. In this process, magnetorheological fluid is used as the polishing medium and permanent magnet is used to control its rheological properties to generate finishing force during polishing. To avail sufficient magnetic field in the finishing zone, it is necessary to design an optimum polishing tool. In the present study, a specially designed polishing tool is designed using a finite element based software package (Ansys Maxwell^®) based on Maxwell equations. At first, dimension of the permanent magnet is determined for designing optimum tool geometry. After that, dimension and configuration of the magnet fixture are optimized. A special type of metal named mu-metal which is a nickel-iron based alloy is selected for magnet fixture due to its magnetic-field shielding property. Mu-metal directs the magnetic flux lines in such a way that in the finishing zone the magnetic flux can be concentrated on the workpiece surface required for finishing. Also, the Mu-metal magnet fixture shields the magnetic field from outside environment so that MR fluid as well as any surrounding magnetic materials do not stick to the polishing tool. Experiments are carried out to validate the Maxwell simulation results to compare the magnetic flux distribution on the workpiece surface which shows good agreement between them. Also, finishing of flat titanium workpieces are carried out and it is found that the novel polishing tool has the capability to finish the workpieces in the nanometer range.     

基于改进信赖域算法的三维不规则缺陷重构

漏磁检测广泛应用于铁磁性材料设备的在线检测当中,是一种有效的缺陷检测方法。如何利用缺陷漏磁信号进行三维不规则缺陷轮廓重构是漏磁检测中的关键问题。然而,三维不规则缺陷漏磁检测的有限元模型计算量大,因此难以快速获得精确的漏磁信号,并且由于缺陷重构的不适定性,研究中不容易获得不规则缺陷的精确轮廓。本文提出了一种用于计算三维不规则缺陷漏磁信号的单元磁偶极带叠加模型,并验证了使用该正演模型进行漏磁计算的有效性,针对三维缺陷轮廓重构的高维优化问题,提出了一种带边界约束的基于信赖域的投影Levenberg-Marquart算法,实现了三维不规则缺陷轮廓的重构。实验结果表明:该三维不规则缺陷重构方法不仅不需要大量的漏磁检测数据,并且相对于群智能算法,重构误差降低了90.1%,最大深度误差降低了53.9%,耗费时间减少了96.1%,实现了高精度的缺陷重构。     

活性剂增加铝合金交流A-TIG焊熔深机理研究

采用多组元活性剂AF305进行铝合金交流A-TIG焊时,熔深达到传统TIG焊的3倍以上。进行了交流、直流正接和直流反接A-TIG焊,发现极性不同时活性剂对熔深的影响也不同。研究了强制电弧收缩对交流焊熔深的影响,发现弧根整体收缩并不是AF305增加交流A-TIG焊熔深的主要机理,熔深显著增加主要与焊渣成片分布有关。对焊渣进行了SEM形貌观察和EDS成分分析,并采用氦弧焊证实了焊接过程中焊渣在熔池表面成片分布,电弧斑点极大收缩。向AF305活性剂中添加铝粉改变焊渣分布,研究焊渣分布与熔深的关系,证实了焊渣成片分布能增加焊接熔深。认为焊渣成片分布使得电弧斑点极大收缩,斑点压力以及电弧和熔池内的Lorentz力增强,最终焊接熔深显著增加。