Temperature field simulation of laser-TIG hybrid welding

The three-dimensional transient temperature distribution of laser-TlG hybrid welding was analyzed and simulated numerically. Calculations were based on a finite element model, in which the physical process of hybrid welding was studied and the coupling effect of the laser and arc in the hybrid process was fully considered. The temperature fields and weld crosssections of the typical welding parameters are obtained using present model. The calculation results shou that the model can indicate the relationship of energy match between laser and arc to joints cross-sections objectively, and the simulation results are well agreed with the experimental results.     

Welding characteristics in different laser-TIG hybrid manners

An experiment for determining the laser-TIG hybrid welding characteristics was carried oat in three kinds of hybrid methods: CO2 laser-TIG coaxial hybrid, CO2 laser-TIG paraxial hybrid and Nd: YAG laser-TIG paraxial hybrid. The experimental results indicate that hybrid welding has two welding mechanisms in CO2 laser-TIG hybrid welding: deep penetration welding and heat conduction welding. As the effect of the laser-induced keyhole, the arc root is condensed, the current density and penetration depth increase significantly, the welding characteristic is apt to deep penetration welding.When current increases to some degree, the keyhole induced by laser disappears, which produces a shallow penetration and wide bead. The weld exhibits heat conduction welding characteristics. Furthermore, the arc images and weld bead crosssections of three kinds of hybrid manners were also compared and analyzed at different welding currents, which established the foundation for understanding the welding characteristics of laser-TIG hybrid welding comprehensively.     

Realizing precision pulse TIG welding with arc length control and visual image sensing based weld detection

Methods of arc length control and risual image based weld detection for precision pulse TIG welding were investigated. With a particular all-hardware circuit, arc voltage during peak current stage is sampled and integrated to indicate arc length, deviation of are length and adjusting parameters are calculated and output to drive a step motor directly.According to the features of welding image grabbed with CCD camera, a special algorithm was developed to detect the central line of weld fast and accurately. Then an application system were established, whose static arc length error is 0. 1 mm with 20 A average current and 1 mm given arc length, static detection precision of weld is 0. 01 mm, processing time of each image is less than 120 ms. Precision pulse TIG welding of some given thin stainless steel components with complicated curved surface was successfully realized.     

Microstructure and mechanical properties of wrought magnesium alloy AZ31B welded by laser-TIG hybrid

The laser-TIG hybrid welding was mainly used to weld the wrought magnesium alloy AZ31B. The tech-nical characteristics of laser-TIG hybrid welding process was investigated and the interactional mechanism between laser and arc was discussed, at the same time the microstructure and mechanical properties of the wrought magnesi-um alloy AZ31B using laser-TIG hybrid welding were analyzed by optical microscope, EPMA, SEM, tensile ma-chine, hardness machine. The experimental results show that the presence of laser beam boosts up the stability of the arc during high speed welding and augments the penetration of weld； the crystal grains of magnesium alloy weld are fine without porosity and cracks in the best welding criterion and the microstructure of HAZ does not become coarse obviously. The elements profile analysis reveals that Mg content in the weld is lower than that of the base metal, but Al content is higher slightly. Under this experimental condition, the wrought magnesium alloy AZ31B joint can be achieved using laser-TIG hybrid process and the tensile strength of the joint is equivalent to that of the base metal.     

Investigation on microprocessor based waveform control of short circuit transfer CO2 welding

A new kind of simple and flexible CO2 welding system was developed to carry out waveform control. The system consisted of IGBT inverter, PWM circuit and microprocessor unit （ MPU） , in which the output current of constant current （CC） power supply could be changed according to transient physical state, and the variable down slope rate control could be used to ensure a stable welding process. The welding experiment results proved the effectiveness of this control approach.     

镁合金T形件激光-TIG复合热源焊接

主要研究了激光-TIG电弧复合焊复合模式、热源间距(D_la)和激光脉冲参数对镁合金T形件成形的影响.研究发现TIG-激光的复合模式更有利于T形件的成形.在TIG-激光复合模式下,D_la随着焊接电流的提高而增加时会得到更大的焊接熔深,焊接电流为100 A,D_la为3 mm时可以得到良好的镁合金T形结构件焊缝成形.激光脉宽过小或过大都会对T形结构件焊缝根部的成形产生不良影响,脉冲较小时T形件立板与上板结合处的熔池金属极易产生过烧,从而导致焊接表面塌陷严重,甚至烧穿;脉冲过大时则造成立板与上板结合处熔化不足而产生不熔合现象.     

低功率YAG激光-TIG电弧复合焊接镁合金薄板工艺

以2 mm厚AZ31B变形镁合金薄板为研究对象开展低功率脉冲YAG激光-TIG电弧复合热源焊工艺研究,分析了激光与电弧的能量匹配对焊缝成形的影响规律.结果表明,镁合金薄板低功率YAG激光-TIG电弧复合热源焊接过程中,激光能量与电弧能量之间的相互匹配将直接影响焊缝的表面成形,获得理想焊接接头的工艺参数区间相对较狭小.为使焊缝成形均匀连续,焊接过程中需要对焊缝背面采用氩气进行保护,当保护气体流量为5～10 L/min时获得了具有最佳性能的焊接接头,其拉伸载荷达到镁合金母材的95%以上.     

电场提高激光-TIG复合焊熔深的机制

通过对比电场对单激光和单TIG焊接电弧在镁合金板材上堆焊熔深的影响,分析了外加电场对激光-TIG复合焊熔深的影响机制.同时通过研究在不同激光功率、不同TIG电流强度下电场的作用效果,对该机制进行了验证.结果表明,外加电场对激光-TIG复合焊熔深的作用是通过对激光小孔内等离子中带电粒子运动的控制来实现的.外加电场使小孔内电子向小孔底部运动时,可以增加焊接熔深;激光功率越大,外加电场增加熔深效果越明显;增大TIG焊接电流,削弱外加电场对熔深的增加作用.     

One-knob self-optimizing fuzzy control of CO_2 arc welding process

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波形控制CO2弧焊电源设计

针对CO2焊接工艺的特点,设计了一种实现波形控制的逆变弧焊电源,电源采用单片机控制,对焊接电压、焊接电流实时采样,可准确控制短路电流值.当短路发生后,电流先保持在一较低值,然后以指数规律上升,当检测到缩颈时,降低电流直到熔滴过渡后再燃孤;同时在燃孤阶段,控制燃弧电流的变化速度,保证充足的燃弧能量.以实现减小金属飞溅和改善焊缝成形.     

钛合金激光-TIG复合焊接保护状态对焊缝成形及性能影响

用激光-TIG复合热源对2.5 mm厚TA15钛合金进行对接焊试验.利用万能力学拉伸机、红外热成像仪、电子探针（EPMA）、扫描电镜（SEM）等分析手段对焊接接头进行测试分析,并与单TIG焊进行对比.分析焊接工艺参数和接头保护时间对焊接接头形貌和性能的影响.结果表明,实现2.5 mm厚钛合金全熔透焊接时,激光-TIG复合焊比单TIG焊速度更快、热输入更低,焊缝和热影响区更窄,晶粒更细;相同保护条件下,激光-TIG复合焊接头比单TIG焊接头具有更高的强度、塑性和更好的疲劳性能;激光-TIG复合焊缝冷却速率高于单TIG焊,获得良好的保护状态时所需保护时间更短.     

镁合金激光-TIG焊接温度场的红外测量与数值模拟

以变形镁合金AZ31B为研究对象,采用红外热像仪拍摄镁合金激光-TIG复合热源焊接过程中的焊接温度场,提出一种基于红外辐射测温原理.并针对红外热像仪的焊接温度场校正方法,采用热电偶验证该校正方法的准确性.利用数值模拟方法模拟整体温度场.试验结果表明,实温校正可准确校正试件表面状态一致区域的温度场,而表面校正可消除试件表面状态改变而引起的对温度场分布的影响,结合实温与表面校正方法能准确地校正镁合金激光-TIG复合热源焊接过程中电弧覆盖范围外的温度场,焊接温度场数值模拟可以比较准确预测并反映整体焊接温度场实际分布.     

细丝CO2气体保护铸铁冷焊

对灰口铸铁的缺陷，人们一直使用Z308焊条来焊补，这是十分昂贵的焊接方法．利用CO2气体保护焊，能够解决同样的问题，能产生较大的经济效益。