输油管TIG焊接电弧温度的光谱诊断

测定电弧温度对于深入理解焊接电弧在不同环境下的物理特性,从而寻求改善焊接质量的新途径有重要意义.笔者介绍了电弧等离子体光谱理论及光谱诊断方法,对TIG焊电弧光谱进行了采样分析.通过对光谱数据的分析指出钨元素谱线具有较好的利用价值.利用等离子体光谱诊断法对不同电流和不同弧长的电弧光谱和电弧温度进行了对比分析,并时其变化规律做出了解释.本研究工作对于输油管TIG焊接电弧物理的研究具有参考价值.     

YAG激光+脉冲双电弧复合焊接等离子体物理特性研究

探究焊接热源等离子体物理特征有助于其工艺优化。在YAG激光+脉冲双GMAW复合焊接过程中,激光束与两个电弧共同作用于同一熔池中,3个热源之间的相互作用导致复合等离子体状态存在很大的随机性,难以精确测量复合后的等离子体的物理状态。基于光谱分析方法,结合高速摄像技术,对激光复合前后等离子体光谱辐射强度、电子温度、电子密度等物理特征进行研究。结果表明:与脉冲双GMAW焊接相比,YAG激光+脉冲双GMAW复合焊接的光谱辐射强度明显增强,但是没有新的谱线生成;两个电弧的弧根部位受激光的"吸引牵制"作用靠近激光作用点,金属粒子受到强烈的热作用而大量电离并聚集在工件表面和激光束附近,该局部区域的电子温度、电子密度升高,为电弧提供了一个额外的电离通道,电弧因此更为稳定。     

非转移弧等离子体炬及其射流的数值模拟

通过求解等离子体弧柱区的质量方程、动量方程、能量方程、电动势方程、磁场方程和组分方程,对非转移弧等离子体炬及其产生的等离子体射流的传热与流动特性进行了数值模拟研究,获得了等离子体炬及其射流区域的温度和速度分布。结果表明:呈现上升的伏安特性曲线;等离子体炬出口处温度和速度呈现抛物线分布;等离子体进气速度增加,等离子体速度增加,温度变化不明显;电流增加,等离子体速度和温度都明显增加。     

激光-MAG复合焊等离子体辐射分析

对于MAG焊、激光-MAG复合焊的等离子体辐射,采用中空探针,使特定点的辐射通过探针对其等离子辐射进行空间分布采集,对比分析激光复合前后等离子体辐射光谱的分布规律,并结合高速摄像,为激光-MAG复合焊的耦合机理研究和工程应用提供理论基础.结果表明,激光复合后,在电弧中心形成一个辐射明显增大的区域,区域外侧存在一个辐射降低区域;在电弧前侧激光复合作用位置,会形成一个以铁辐射谱线为主的"电离通道".激光复合后,电离通道的存在为电弧的稳定提供了基础;在中心区形成了能量集中的辐射通道,改变了电弧中能量的分布,使能量更集中于中心区域,获得比传统MAG焊更大的熔深.     

激光对TIG电弧温度分布影响的数值模拟

在激光-TIG复合焊接过程中,根据激光与电弧等离子体相互作用原理及控制方程,利用有限元数值模拟方法研究激光对TIG焊接电弧等离子体温度分布的影响.在电弧稳定状态下,分别计算了不同焊接电流和激光强度的电弧等离子体温度分布情况,并由此分析激光对电弧等离子体温度分布的影响.结果表明:随着焊接电流的下降,激光对电弧温度的影响作用越来越明显,并且激光光强越大,影响越明显;决定电弧温度分布的主要因素也由焊接电流转变为由激光光强和焊接电流共同作用.本研究为进一步研究焊接质量奠定理论基础.     

YAG-MIG复合焊接条件下复合等离子体动态特征

利用高速摄像,对单YAG、单MIG、YAG-MIG激光电弧复合焊接铝锂合金5A90时的等离子体动态过程进行了深入研究。结果表明:①YAG-MIG复合焊的等离子体在MIG弧存在阶段,与MIG弧具有相近之处,其周期性与MIG相似,但在MIG弧熄灭阶段与MIG焊和YAG焊都有明显的区别;②在强MIG等离子体复合强YAG等离子体时,复合焊的等离子体强度和形状发生明显变化,且不是二者的简单叠加结果。它呈现一种不规则的弧,充分说明尽管在单激光焊接时等离子体较弱,但在复合焊时,它对MIG弧的影响不容忽视;③在MIG微弧复合强YAG金属蒸气/等离子体时,发现其等离子体的强度高于单一激光焊,且形状也有较大差别,表明此时虽然MIG电弧仅为微弧,但它对YAG金属蒸气/等离子体有显著的影响。     

气流再压缩等离子弧焊接电弧行为

电弧等离子体行为对焊接接头组织结构和性能具有决定性作用,开展气流再压缩等离子弧特性研究对于指导先进材料的气流再压缩等离子弧焊接工艺和提高焊接接头质量具有重要意义. 针对气流再压缩等离子弧焊接新工艺,基于流体动力学和电磁理论,建立气流再压缩等离子弧数值分析模型,采用ANYSYS Fluent软件,通过C语言进行二次开发,定量计算等离子弧温度分布、流场分布、电势分布,分析压缩气对等离子弧温度场、流场、电弧电压的影响规律. 模拟结果表明,压缩气对喷嘴内的等离子弧温度分布基本没有影响,压缩气对喷嘴外的等离子弧具有拘束压缩作用;压缩气对等离子弧流场分布基本没有影响;压缩气能够提高电弧电压. 相同电流条件下,与常规等离子弧焊接相比,气流再压缩等离子弧焊接电弧穿透能力有望提高.     

Ag／LaFe1-xNixO3-δ触点电弧的多波长光谱测量

介绍了一种等离子体电弧的多波长光谱诊断方法。利用一个CCD多通道光谱仪测得Ag／LaFe1-xNixO3-δ银基触点电弧的扫描多波长光谱。应用该光谱诊断方法研究了电弧等离子体中活性粒子及输入功率、通断频率和触点间距等工作参数对电弧的影响，确定了Ag／LaFe1-xNixO3-δ银基触点材料最有利的工作条件。这种非侵入式光谱诊断，为触点材料性能检测提供了一种有效的诊断方法。     

MnCl2引入对粉末熔池耦合活性TIG焊交流电弧的影响

粉末熔池耦合活性TIG焊接法是一种新型高效焊接方法,通过选择对应的活性剂粉末,可实现几乎所有金属的焊接.针对采用MnCl2作为活性剂的交流粉末熔池耦合活性TIG焊电弧,采集等离子体光谱,利用Boltzmann作图法分析了电弧等离子体温度随时间的变化规律,并结合电弧电压变化规律,通过与传统交流TIG电弧对比研究MnCl2对交流电弧的影响.结果表明,对于交流TIG电弧,EN时段的电弧光谱强度高于EP时段,EN时段的电弧电压小于EP时段,EN时段的电弧温度低于EP时段.而由于活性剂MnCl2的引入,交流粉末熔池耦合活性TIG电弧的中心温度与EN时段和EP时段的电弧电压均高于传统交流TIG电弧,焊缝熔深较传统交流TIG焊显著增加.     

低功率激光诱导/增强电弧等离子体的行为与机制研究

激光与电弧复合焊接工艺研究日趋完善,而关于激光与电弧相互作用行为和物理机制的研究则明显滞后,限制了激光-电弧复合焊接自动控制系统及焊接装备的开发。文中采用光谱分析和带通滤波电弧图像采集相结合的方法,研究了AZ31镁合金复合焊接过程中低功率激光(500 W)的加入对电弧等离子体形状、粒子组成的影响规律。基于电弧导电通道的角度讨论了激光对电弧放电行为的影响机制。研究发现,与单独电弧焊相比,激光的加入使电弧等离子体的高温区发生明显聚集,电弧导电通道变窄;电弧等离子体区氩元素谱线的强度显著降低,而镁元素谱线的强度显著升高,表明电弧的放电形式由惰性气体电离放电为主转换为以金属粒子电离放电为主;复合焊接电弧谱线强度的变化以及电弧高温区域收缩为实现激光一电弧复合焊接过程质量控制系统的开发提供可靠途径。     

Effect of plasma spray operating conditions on plasma jet characteristics and coating properties

Using statistical design of experiments, the arc current, total gas flow rate, percent secondary gas (He), and powder feed rate have been varied to assess the torch behavior and establish its correlation to coating properties. The torch response includes arc voltage drop, torch efficiency, and plasma jet geometry. High-speed images of the luminous plasma jet for each operating condition have been acquired with a LaserStrobeℳ videocamera, and image analysis has been used to quantify the jet length and jet fluctuations as additional torch responses. Porosity and unmelted particles, which are determined using image analysis of a micrograph of a NiAl coating cross section, were selected as principal coating characteristics. These findings are expected to be useful for optimization of new spray processes and for evaluation of new torch designs.     

Non-transferred Arc Torch Simulation by a Non-equilibrium Plasma Laminar-to-Turbulent Flow Model

Non-transferred arc torches are at the core of diverse industrial applications, particularly plasma spray. The flow in these torches transitions from laminar inside the torch to turbulent in the emerging jet. The interaction of the plasma with the processing gas leads to significant deviations from local thermodynamic equilibrium (LTE) far from the arc core. The flow from a non-transferred arc plasma spray torch is simulated using a non-LTE (NLTE) plasma flow model solved by variational multiscale (VMS) and nonlinear VMS (VMS_n) methods, which are suitable for unified laminar and turbulent flow simulations. Non-plasma turbulent jet simulations indicate that the VMS_n method produces results comparable to those by the dynamic Smagorinsky method, often considered the workhorse for turbulent incompressible flow simulations. VMS and VMS_n approaches are applied to the simulation of incompressible, compressible, and NLTE plasma flows in non-transferred arc torch operating at representative conditions found in plasma spray processes. The NLTE plasma flow simulations reproduce the dynamics of the arc inside the torch together with the evolution of turbulence in the produced plasma jet in a cohesive manner. However, the similarity of results by both methods indicates the need for numerical resolution significantly higher than what is commonly afforded in arc torch simulations.     

Arc instabilities in a plasma spray torch

The control over coating quality in plasma spraying is partly dependent on the arc and jet instabilities of the plasma torch. Different forms of instabilities have been observed with different effects on the coating quality. We report on an investigation of these instabilities based on high-speed end-on observation of the arc. The framing rate of 40,500 frames per second has allowed the visualization of the anode attachment movement and the determination of the thickness of the cold-gas boundary layer surrounding the arc. The images have been synchronized with voltage traces. Data have been obtained for a range of arc currents, and mass flow rates for different gas injectors and for anodes displaying different amounts of wear. The analysis of the data has led to quantitative correlations between the cold-gas boundary layer thickness and the instability mode for the range of operating parameters. The arc instabilities can be seen to enhance the plasma jet instabilities and the cold-gas entrainment. These results are particularly useful for guiding plasma torch design and operation in minimizing the influence of plasma jet instabilities on coating properties.     

大气等离子射流中粒子飞行行为的试验测量

为考察等离子熔射中粉末的飞行过程,应用芬兰Oseir公司等离子喷涂在线监测和分析设备SprayWatch对射流中粒子的温度、飞行速度和粒子流量进行了测量,探讨了等离子弧电压、电流、功率以及送粉量等参数对粒子飞行状态的影响.结果表明:同等功率下,电流对粒子速度的影响高于电压,电压对粒子流量的影响高于电流,电压、电流对粒子温度则呈现交替重要的影响;在电流400A、电压50V下粒子流量随送粉量的增加呈现低-高-低的"山峦"状变化,反映了粒子飞行路径和分布的变化.     

The role of torch instabilities in the suspension plasma spraying process

In spite of the fact that plasma spraying is a commonly used technique for coating elaboration, it remains important to follow in time the characteristics of the arc jet delivered by the plasma torch. Arc voltage and heat loss measurement could be used, together with the control parameters such as arc current and plasma gas flow rate, to investigate the global behavior of the torch in association with a simple analytical model. It is shown that the specific enthalpy and the isentropic coefficient of the plasma gas have a strong influence on the jet velocity, this latter being also significantly modified by the drift of the torch performance. This work is completed by the analysis of the plasma jet instabilities that are responsible for the discrepancy in particle thermal histories. The rear part of the torch is involved in self sustained oscillations, so that the torch shows the characteristics of a Helmholtz resonator, giving rise to periodic variations of the torch voltage, higher in amplitude than the commonly admitted restrike mode. It is also evoked, that the generated acoustic waves are interacting with the solvent vaporization.     

Synchronization of Suspension Plasma Spray Injection with the Arc Fluctuations

Poorly controlled heat and momentum transfers between plasma and material, plasma instabilities are some of the difficulties encountered in suspension plasma spraying. The improvement of this method is usually attempted by means of the reduction of arc fluctuations. This paper presents a new approach to the injection of reactive material in an arc jet. The principle is to produce a pulsed laminar plasma jet combined with phased injection of liquid droplets. This is achieved by the particular design of the plasma torch that works at moderate power and following a resonant mode. The droplets are injected using a piezoelectric device, based on drop-on-demand method, triggered by the voltage signal sampled at the torch connections. The results are evaluated by time-resolved imaging technique that shows how the trajectories are influenced by the moment at which the droplets penetrate the plasma jet.     

双钨极TIG电弧压强分布及其与等离子体喷射的关系

建立一个三维的统一的双钨极TIG焊模型,利用磁流体动力学理论对双钨极、电弧、阳极三个区域进行统一求解,获到双钨极电弧的压强分布,探究等离子体喷射与对电弧压强的关系。研究发现,双钨极TIG在钨极下方、阳极上方以及两束等离子体流交汇处存在较大的电弧压强,这些高压区的形成与等离子体喷射存在因果关系。计算发现,双钨极TIG焊在阳极表面上的最大压强远小于单钨极TIG焊的,这为双钨极TIG焊的应用提供了一些理论基础。     

Comparative study of the structure of gas-stabilized and water-stabilized plasma jets

The near-field structures of a gas- stabilized plasma jet and a water-stabilized plasma jet were investigated using a nano-pulsed laser probe and stroboscopic focusing schlieren techniques. The high exit temof the gas caused laminar flow conditions at the exit of the jet, producing instability waves in the region. Significant heat conduction to the ambient fluid and volumetric expansion of the ambient gases in the near- field were observed in the schlieren images of these jets. Considerable asymmetry in the mixing and entrainment region of the water- stabilized plasma jet was also visible, whereas no significant asymmetry occurred in the luminous core of the jet. The particles injected into the plasma jet, which were visualized by the pulsed- laser technique, were confined to a narrow central core of the jet in the near- field of the jet. The combination of the two visualization techniques used in the present study allowed nonintrusive monitoring of the plasma spray process in an effort to enhance the quality of the processed deposits.     

大气压层流等离子体射流特性及其用于材料表面处理的效果

在大气压条件下产生出能量衰减慢且分布均匀、噪音小的氩和氮氩混合气的层流等离子体射流。与湍流等离子体射流相比,由于对周围冷气体卷吸减少,层流射流在喷射方向的长度可增长６倍。试验表明,只有采用结构合理的等离子枪,综合调控供气和电参数条件,抑制气流的脉动和抖动,才能形成层流等离子体射流。结合数值计算对等离了体气流温度分布的定性分析,说明层流情况下射流径向能量分布集中,轴向温度变化平缓,有利于材料表面处理     

Plasma spraying using Ar-He-H2 gas mixtures

In plasma spraying, the properties of the plasma-forming gas largely control the characteristics of the plasma jet and the momentum, heat, and mass transfers to the particles injected in the flow. The objective of this work was to investigate the effect of gas composition on the static and dynamic behaviors of the plasma jet. The latter behaviors were investigated from measurements of arc voltage and plasma jet velocity. Ternary gas mixtures of argon, helium, and hydrogen were used. The results were expressed as correlations between arc voltage and flow velocity, and the operating parameters of the gun for a specific nozzle diameter.