超声无铆静力学性能强化试验与机制研究*

无铆连接是一种薄板材料连接新技术,可在无需预成孔和表面预处理情况下,实现同种、异种、多层薄板材料高效连接,但由于无铆接头静力学性能较低,极大地限制了该连接技术的推广与发展。为解决这一难题,本文选用5A06铝合金与TA1钛合金进行同种金属无铆铆接,并在此基础上进行了超声金属焊接复合实验,基于静拉伸测试和扫描电镜分析,探究超声焊对无铆接头力学性能的强化机制。试验结果表明：超声焊可有效提升无铆接头力学性能,特别是对于铝合金无铆接头;超声焊使得铝合金板塑性提高,钛合金板则得到硬化;超声焊后无铆接头的受力形式发生改变,从颈部受力变为先焊合区受力再颈部受力,这是超声焊复合强化的根本原因;超声焊可使铝合金无铆接头内部形成一定深度的固相焊,使铝合金接头力学性能得到大幅提升;TA1钛合金无铆接头内部固相焊较浅,力学性能提升相对较低。     

超声辅助搅拌摩擦焊仿真分析及实验

为解决传统的搅拌摩擦焊工艺存在的轴向压力过大、搅拌头易磨损、焊接表面存在缺陷等问题,设计了一种集搅拌头与夹心式纵扭超声振动换能器为一体的超声辅助搅拌摩擦焊工具头。对超声辅助搅拌摩擦焊工具头进行了模态分析与谐响应分析,确保换能器结构满足要求。应用仿真软件对超声辅助搅拌摩擦焊进行了流体场、温度场和声场仿真分析,验证了在搅拌摩擦焊过程中加入纵扭超声振动能够增强材料的软化率,提高焊接材料的塑性流动。搭建实验平台,进行了6061铝合金的超声辅助搅拌摩擦焊焊接实验。结果表明,纵扭超声的引入能够提高焊接过程中材料流动性,减小搅拌头的前进阻力和轴向压力,改善焊接表面质量。在焊头转速900 r/min、焊接速度1.4 mm/s、轴向压力2.6 kN、超声功率100 W时,焊接效果最好,能较好地应在铝合金、镁合金等焊接熔点比较低的轻金属焊接之中。     

钢芯弹冲击高强度钢过程的数值模拟分析

 通过材料特性实验获得7.62 mm×39 mm普通钢芯弹弹芯、N-1高强度钢靶板材料的力学本构模型参数,建立了弹体和靶板的精细有限元模型。对靶板钢材的J-C断裂准则进行改进,并在LS-DYNA软件中实现。应用改进的断裂准则进行了N-1钢受普通钢芯弹垂直冲击过程的数值模拟,计算结果可更准确地反映出实验中靶板出现的绝热剪切冲塞行为,冲塞尺寸较接近实验结果,弹道极限速度也与实验吻合。由此克服了基于原J-C断裂准则计算的缺陷——靶板发生与实验结果不符的拉伸型破坏、冲塞尺寸明显偏小。     

基于隐式IB-LBM的二维搅拌摩擦焊接模拟

本文首次采用隐式浸入边界格子Boltzmann方法(IB-LBM)对二维搅拌摩擦焊接过程中的输运现象及搅拌头受力状况进行数值模拟与分析。两个不同的多松弛方程被分别用来求解速度场及温度场,搅拌头受力由浸入边界法计算得到。采用一种可移动的分块网格技术加密变形区域。搅拌头-工件界面考虑部分黏着/滑移接触条件,并通过模拟得到的扭矩计算产热量,形成工艺内部产热的自适应。结合实验数据,分析了2024-T3铝合金焊材的热量物质流动特性以及搅拌头受力特点。讨论了搅拌头转速及焊接速度对产热以及搅拌头受力影响。另外,研究发现三平面搅拌针作用下的搅拌区域明显大于圆形搅拌针。     

破片模拟弹侵彻船用钢靶板的计算模型

为研究破片模拟弹侵彻钢板的过程,将模拟弹冲击钢装甲的侵彻过程分为初始接触、弹体侵入、剪切冲塞和穿甲破坏4个阶段进行理论分析。当靶板剩余厚度的剪切冲塞抗力小于延性扩孔抗力时,靶板的破坏模式完全转变为剪切冲塞;剪切塞块速度与剩余弹体速度相同时,推导出破片模拟弹侵彻钢靶板的能量转化及剩余速度公式,与实验及有限元分析结果吻合较好。研究结果对于破片侵彻钢靶板威力设计具有一定实用价值。     

确定焊点切向强度的超声方法

美国俄亥俄州州立大学焊接工程系的S·I·Rokhlin和Laszlo Adler提出了一种用超声波测量焊点抗剪强度的方法,这种方法的理论基础是:Lamb波通过固体板中孔径的穿透系数与这个孔径的大小有关.穿透系数与孔径的关系可以用解析表达式给出. 测量方法如图1所示.由上层板上发射换能器激发的兰姆波,入射到焊接区域,部分入射能量被反射,而大部分能量通过两板相接区域进入下面的板中,被     

基于声子晶体位错理论的二维超声塑料焊接系统

为了有效改善二维工具头辐射面振幅分布不均匀的问题,对二维超声塑料焊接系统进行了优化设计研究:首先,利用横向位错在大尺寸长条形工具头上构造近周期声子晶体同质位错结,调节带隙的宽度和位置,使得二维超声塑料焊接系统的工作频率位于工具头的横向振动的带隙内,进而有效地控制工具头X方向的横向振动;其次,利用近周期声子晶体斜槽结构进一步优化辐射面的振幅分布均匀度,并分析了斜槽结构参数对超声塑料焊接系统纵向共振频率和振幅分布均匀度的影响规律.模拟仿真结果表明,近周期声子晶体同质位错结和斜槽结构能够实现对二维超声塑料焊接系统的优化,为横向振动抑制理论的进一步研究提供了基础.     

舰船水下接触爆炸数值研究

计及船体外板的材料强度,基于SPH算法建立水下接触爆炸数值模型,提出混合密度、广义光滑长度等解决数值模拟中计算崩溃的问题,对舰船的水下接触爆炸进行数值模拟,计算结果和冲击波基本理论及接触爆炸试验吻合良好.结果表明,接触爆炸时钢结构会产生圆形冲塞破口,其破口大小和炸药的厚度接近,当板与炸药的正则化厚度达1.8时,板仅会发生较大的塑性变形而不会冲塞破坏.并得到钢的反射系数约为1.2,及接触爆炸钢板的近似变形公式.     

Ag箔钎焊YBCO高温超导块材

采用Ag箔在两种不同的工艺条件下对YBCO高温超导块材进行了钎焊连接,钎焊完成后,分别对原始超导块材和钎焊接头进行磁悬浮力测量和俘获磁场测试、以评价钎焊质量.磁悬浮力的测试结果表明,在两种工艺条件下,钎焊接头的磁悬浮力分别可达原始块材的69.88%和79.37%.俘获场测试结果表明,单畴原始母材的俘获场为单峰,钎焊接头的俘获场为双峰;同时,钎缝区域的俘获磁场强度较低,没有完全恢复接头母材的超导环流,而限制了钎焊接头超导性能的提高.     

低反向漏电自支撑衬底AlGaN/GaN肖特基二极管

氮化镓材料具有大的禁带宽度(3.4 eV)、高的击穿场强(3.3 MV/cm),在高温、高压等方面有良好的应用前景.尤其是对于铝镓氮/氮化镓异质结构材料而言,由极化效应产生的高面密度和高迁移率二维电子气在降低器件导通电阻、提高器件工作效率方面具有极大的优势.由于缺乏高质量、大尺寸的氮化镓单晶衬底,常规氮化镓材料均是在蓝宝石、硅和碳化硅等异质衬底上外延而成.较大的晶格失配和热失配导致异质外延过程中产生密度高达10~7—10¹⁰ cm^–2的穿透位错,使器件性能难以进一步提升.本文采用基于自支撑氮化镓衬底的铝镓氮/氮化镓异质结构材料制备凹槽阳极结构肖特基势垒二极管,通过对欧姆接触区域铝镓氮势垒层刻蚀深度的精确控制,依托单步自对准凹槽欧姆接触技术解决了低位错密度自支撑氮化镓材料的低阻欧姆接触技术难题,实现了接触电阻仅为0.37Ω·mm的低阻欧姆接触;通过采用慢速低损伤刻蚀技术制备阳极凹槽区域,使器件阳极金属与氮化镓导电沟道直接接触,实现了高达3×107开关比的高性能器件,且器件开启电压仅为0.67 V, 425 K高温下,器件反向漏电仅为1.6×10...     

高功率超声脉冲激励下金属板的非线性振动现象研究

对高功率超声脉冲作用下金属板中的超谐波、次谐波、准次谐波以及混沌等非线性振动现象进行了实验和理论研究.在实验中,高功率超声换能器产生脉冲调制的高频振动激励金属板产生非线性振动,利用激光测振技术测量不同尺寸和不同固定方式下金属板复杂的非线性振动情况,并对其进行了时序分析、频谱分析以及相空间分析.根据实验条件,提出包含非线性接触阻尼的振动-碰撞动力学模型,用以研究强超声振动-碰撞作用下的板非线性振动机制,并进行了相应的理论计算.计算结果表明,超声换能器的变幅杆与金属板之间的间歇性高频碰撞作用是金属板强非线性振 关键词： 非线性板振动 强超声脉冲激发 振动-碰撞动力学     

Ultrasonic butt welding of aluminum,aluminum alloy and stainless steel plate specimens

Welding characteristics of aluminum, aluminum alloy and stainless steel plate specimens of 6.0 mm thickness by a 15 kHz ultrasonic butt welding system were studied. There are no detailed welding condition data of these specimens although the joining of these materials are required due to anticorrosive and high strength characteristics for not only large specimens but small electronic parts especially. These specimens of 6.0 mm thickness were welded end to end using a 15 kHz ultrasonic butt welding equipment with a vibration source using eight bolt-clamped Langevin type PZT transducers and a 50 kW static induction thyristor power amplifier. The stainless steel plate specimens electrolytically polished were joined with welding strength almost equal to the material strength under rather large vibration amplitude of 25 microm (peak-to-zero value), static pressure 70 MPa and welding time of 1.0-3.0 s. The hardness of stainless steel specimen adjacent to a welding surface increased about 20% by ultrasonic vibration.     

Transverse and torsional complex vibration systems for ultrasonic seam welding of metal plates

Transverse and torsional complex vibration systems for ultrasonic seam welding of metal plate specimens, using a 27 kHz complex vibration disk welding tip vibrating in transverse and torsional vibration modes, were studied. Using a complex vibration welding system with a welding tip vibrating in elliptical or circular locus, thick plate specimens can be welded with a more uniform and larger area compared to a conventional ultrasonic welding system. The disk welding tip vibrates in an elliptical or circular locus. The complex vibration system can continuously weld multiple parts of metal plate specimens such as heat sinks with a large number of fins.     

Finite element modeling of heating phenomena of cracks excited by high-intensity ultrasonic pulses

A three-dimensional thermo-mechanical coupled finite element model is built up to simulate the phenomena of dynamical contact and frictional heating of crack faces when the plate containing the crack is excited by high-intensity ultrasonic pulses.In the finite element model,the high-power ultrasonic transducer is modeled by using a piezoelectric thermal-analogy method,and the dynamical interaction between both crack faces is modeled using a contact-impact theory.In the simulations,the frictional heating taking place at the crack faces is quantitatively calculated by using finite element thermal-structural coupling analysis,especially,the influences of acoustic chaos to plate vibration and crack heating are calculated and analysed in detail.Meanwhile,the related ultrasonic infrared images are also obtained experimentally,and the theoretical simulation results are in agreement with that of the experiments.The results show that,by using the theoretical method,a good simulation of dynamic interaction and friction heating process of the crack faces under non-chaotic or chaotic sound excitation can be obtained.     

Interface microstructure and mechanical properties of laser welding copper–steel dissimilar joint

Relatively the high reflectivity of copper to CO₂ laser led to the difficulty in joining copper to steel using laser welding. In this paper, a new method was proposed to complete the copper–steel laser butt welding. The scarf joint geometry was used, i.e., the sides of the copper and steel were in obtuse and acute angles, respectively. During the welding process, the laser beam was fixed on the steel side and the dilution ratio of copper to steel was controlled by properly selecting the deviation of the laser beam. The offset of laser beam depended on the scarf angle between the copper and steel, the thickness of plate and the processing parameters used in the laser welding. The microstructure near the interface between Cu plate and the intermixing zone was investigated. Experimental results showed that for the welded joint with high dilution ratio of copper, there was a transition zone with numerous filler particles near the interface. However, if the dilution ratio of copper is low, the transition zone is only generated near the upper side of the interface. At the lower side of the interface, the turbulent bursting behavior in the welding pool led to the penetration of liquid metal into Cu. The welded joint with lower dilution ratio of copper in the fusion zone exhibited higher tensile strength. On the bases of the microstructural evaluation at the interface of the welded joint, a physical model was proposed to describe the formation mechanism of the dissimilar joint with low dilution ratio of copper.     

Modeling and experimental analysis of the linear ultrasonic motor with in-plane bending and longitudinal mode

A novel linear ultrasonic motor based on in-plane longitudinal and bending mode vibration is presented in this paper. The stator of the motor is composed of a metal plate and eight piezoelectric ceramic patches. There are four long holes in the plate, designed for consideration of the longitudinal and bending mode coupling. The corresponding model is developed to optimize the mechanical and electrical coupling of the stator, which causes an ellipse motion at the contact tip of the stator when the composite vibrations with longitudinal and bending are excited. Its harmonic and transient responses are simulated and inspected. A prototype based on the model is fabricated and used to conduct experiments. Results show that the amplitude of the stator’s contact tips is significantly increased, which helps to amplify the driving force and speed of the motor. It is therefore feasible to implement effective linear movement using the developed prototype.     

Ultrasonic excitation affects friction interactions between food materials and cutting tools

In the food industry, ultrasonic cutting is used to improve separation by a reduction of the cutting force. This reduction can be attributed to the modification of tool–workpiece interactions at the cutting edge and along the tool flanks because of the superposition of the cutting movement with ultrasonic vibration of the cutting tool. In this study, model experiments were used to analyze friction between the flanks of a cutting tool and the material to be cut. Friction force at a commercial cutting sonotrode was quantified using combined cutting–friction experiments, and sliding friction tests were carried out by adapting a standard draw-off assembly and using an ultrasonic welding sonotrode as sliding surface. The impact of material parameters, ultrasonic amplitude, and the texture of the contacting food surface on friction force was investigated. The results show that ultrasonic vibration significantly reduces the sliding friction force. While the amplitude showed no influence within the tested range, the texture of the contact surface of the food affects the intensity of ultrasonic transportation effects. These effects are a result of mechanical interactions and of changes in material properties of the contact layer, which are induced by the deformation of contact points, friction heating and absorption heating because of the dissipation of mechanical vibration energy.     

Three dimensional evaluation of aluminum plates with wall-thinning by full-field pulse-echo laser ultrasound

We propose a full-field pulse-echo laser ultrasonic wave propagation imager (FF-PE-UPI) for the evaluation of structural defects. The FF-PE-UPI consists of a Q-switched laser for the generation of thermoelastic waves, a laser Doppler vibrometer (LDV) for sensing, and a two-axis translation stage for raster scanning of the combined generation and sensing laser beams. A-scan, B-scan, and C-scan data representations are used for the evaluation of structural defects. Three specimens were tested: a 4-mm aluminum plate with an area of 50% thickness reduction, a 6-mm aluminum plate with an area of 25% thickness reduction, and an 8-mm aluminum plate with engraved letters. The damages on the tested specimens were successfully visualized.