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。     

双钨极耦合电弧数值模拟

基于流体力学方程组和麦克斯韦方程组, 在合理的边界条件下, 建立了双钨极耦合电弧三维准静态数学模型. 通过对方程组的迭代求解, 获得了不同钨极间距和电弧长度下耦合电弧的温度场、流场、电弧压力和电流密度分布等重要结果, 与已有的实验研究符合良好. 模拟结果表明: 与相同条件下的钨极惰性气体保护焊电弧相比, 双钨极耦合电弧的最高温度和最大等离子流速较低, 阳极表面电弧压力和电流密度峰值明显减小; 钨极间距和弧长对耦合电弧的温度场、流场、电流密度和电弧压力等都具有显著的影响, 且耦合电弧阳极的电弧压力和电流密度分布不能用高斯近似进行描述. 关键词： 耦合电弧 三维模型 数值模拟     

ITER PF导体缩径机轧辊温升数值模拟研究

文中对ITER PF超导导体缩径机轧辊温升问题进行了数值模拟研究.针对不同导体坯料尺寸和轧辊形状单独建模进行热力耦合数值模拟,基于热力耦合模拟结果构造轧辊传热分析模型,获得了多道次轧制过程中各轧辊的温度场信息,确定了各轧辊处于热平衡状态时的温度场.研究结果表明,各轧辊在轧制400米PF导体后轧辊温度均达到平衡,且平衡状...     

高超声速飞行器前缘流固耦合计算方法研究

对高超声速流场和结构温度场进行了耦合计算分析, 同时基于准静态假设对结构应力进行了分析. 流场部分采用基于非定常Navier-Stokes (N-S)方程的有限体积法, 湍流模型采用SST k-ω 模型, 固体部分采用基于非稳态热传导方程的有限元法, 同时基于准静态假设对固体结构的应力应变进行了分析. 在流固交界面处, 高速流体从固体结构得到温度边界条件, 固体结构从高速流体得到热流边界条件, 从而实现了流场和固体温度场的紧耦合计算.通过与超声速无限长圆管绕流试验结果进行对比, 验证了该方法的可靠性. 同时对二维圆管结构在气动加热过程中的温度、应力等的变化进行了比较详细的分析. 研究结果表明: 随着气动加热时间的推进, 由于圆管结构的高温区在不断扩大, 导致了结构的热变形在不断地增大; 圆管最小变形区出现在θ为60°处; 同时研究发现在计算时间内圆管热变形对外部流场的影响可以忽略不计.     

涡轮叶栅气热耦合数值模拟

本文建立了透平机械叶栅流场与叶片温度场的气热耦合计算模型,编制了三维非正交曲线坐标系下的温度场求解程序,计算了实心及空心叶片的温度场分布。介绍了区域分解方法在耦合计算及并行计算中的应用,以矩形区域温度场求解程序为例研究了程序的并行化,最后进仃了叶栅流场计算与叶片导热计算程序的分区耦合计算。     

等离子弧焊接多物理场耦合输运模型

本文基于电场、磁场、温度场和流场的多物理场耦合,建立了简单实用的电弧与工件一体化模型,既准确表征等离子弧焊接过程中的多物理场输运作用,又无需使用流体体积函数(VOF)计算气液两相界面,大大减少计算时间和成本。模型计算出电弧压力分布,将其简化为压力源项作用于工件表面,同时该界面上电弧与工件耦合传热,实现了电弧与工件的热-力传递。获得了焊接过程电弧和工件的温度、速度、电流密度和电磁力的分布规律,揭示了焊接熔池的形成和演变机制,并开展实验验证了模型的准确性。最后分析了不同工艺参数对电弧热流密度和压力的影响规律,为焊接质量优化提供理论指导。     

药芯焊丝TIG焊电弧特性的光谱分析

利用光谱诊断方法结合高速摄像研究所提出的药芯焊丝的填丝TIG焊接新工艺的电弧特性,借助高速摄像研究药芯焊丝TIG焊的熔滴过渡方式;通过对焊接电弧进行光谱采集点扫描,对采集的谱线进行元素标定,以药粉中活性元素K和Na作为追踪目标,统计得到电弧中药粉成分的分布范围;并利用Boltzmann图法计算TIG焊电弧的温度场分布,分析了熔滴过渡方式对电弧温度场分布的影响。研究结果表明,通过调整丝极间距,得到药芯焊丝TIG焊的三种典型的熔滴过渡方式：滴状过渡(2 mm)、渣柱过渡(5 mm)和搭桥过渡(7 mm)。药粉中的活性元素K和Na等集中分布在熔池上方的电弧空间,且其分布受丝极间距的影响,丝极间距越小其分布越靠近钨极,容易造成对钨极的污染。不填丝TIG焊的电弧温度分布呈钟罩形,等温线关于钨极轴线近似对称分布;与不填丝TIG焊相比,药芯焊丝TIG焊的电弧温度场受熔滴过渡的影响发生了不同程度的扭曲,滴状过渡的电弧温度场扭曲严重,焊接过程中飞溅较大;相比于滴状过渡,渣柱过渡和搭桥过渡的电弧温度场扭曲程度较小且焊接过程稳定,适合该TIG焊方法的使用。     

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。     

多物质流体动力学方法与结构动力学方法结合的流固耦合计算技术

建立一种基于重叠网格空间覆盖判断的流固耦合计算技术,把流场计算的Euler多物质流体动力学计算过程和Lagrange结构动力学计算过程相结合以描述流固间的相互作用.介绍该计算技术的具体实现过程,讨论提高几何判断效率、避免耦合遗漏、流固计算时间步协调等处理技术.应用建立的流固耦合计算程序模拟爆炸容器中爆炸流场对容器内部结构、容器壳体的作用过程.计算结果表明其可以反映流场发展过程、流场结构相互作用和结构的运动变形和破坏过程.     

旁路耦合电弧焊温度场模拟及验证

针对旁路耦合电弧焊的特点, 建立了一种适于用旁路耦合电弧焊的复合热源模型. 利用该热源模型对不同焊接参数下的旁路耦合电弧焊温度场进行了数值分析, 得到了总电流相同时不同旁路电流下的焊缝熔深、母材温度和特征点焊接热循环曲线的模拟结果, 分析了旁路耦合电弧焊焊接参数对母材热输入的影响, 并将特征点热循环曲线的模拟结果与相同条件下的试验结果进行了比较. 结果表明, 焊接总电流相同时母材热输入随着旁路电流的增加而降低, 且越靠近焊缝母材热输入的降幅越大, 特征点焊接热循环曲线的模拟结果与试验结果基本一致, 旁路耦合电弧焊温度场模型是合理的, 所建立的热源模型能够正确反映焊接参数与母材热输入之间的关系.     

Microstructure and corrosion properties of diode laser melted friction stir weld of aluminum alloy 2024 T351

Friction stir welding is a promising solid state joining process for high strength aluminum alloys. Though friction stir welding eliminates the problems of fusion welding as it is performed below melting temperature (T_m), it creates severe plastic deformation. Friction stir welds of some aluminum alloys exhibit relatively poor corrosion resistance. This research enhanced the corrosion properties of such welds through diode laser surface melting.A friction stir weld of aluminum alloy 2024 T351 was laser melted using a 1 kW diode laser. The melt-depth and microstructure were investigated using optical and scanning electron microscopy. The melt zone exhibited epitaxially grown columnar grains. At the interface between the melted and the un-melted zone, a thick planar boundary was observed. Energy dispersive spectroscopy analyzed the redistribution of elemental composition. The corrosion properties of the laser melted and native welds were studied in aqueous 0.5 M sodium chloride solution using open circuit potential and cyclic potentiodynamic polarization. The results show noticeable increase in the pit nucleation resistance (390 mV) after the laser surface treatment. The repassivation potential was nobler to the corrosion potential after the laser treatment, which confirmed that the resistance to pit growth was improved.     

Infrared thermography for monitoring heat generation in a linear friction welding process of Ti6Al4V alloy

The increasing use of titanium alloys in a wider range of applications requires the development of new techniques and processes capable to decrease production costs and manufacturing times. In this regard welding and other joining techniques play an important role. Today, solid state friction joining processes, such as friction stir welding, friction spot welding, inertia friction welding, continuous-drive friction welding and linear friction welding (LFW), represent promising methods for part manufacturing. They allow for joining at temperature essentially below the melting point of the base materials being joined, without the addition of filler metal.However, the knowledge of temperature is essential to understand and model the phenomena involved in metal welding. A global measured value represents only a clue of the heat generation during the process; while, a deep understanding of welding thermal aspects requires temperature field measurement. This paper is focused on the use of infrared thermography applied to the linear friction welding process of Ti6Al4V alloy. The attention is concentrated on thermal field that develops on the outer wall of the two parts to be joined (i.e. heat generated in the friction zone), and on the maximum temperature that characterizes the process before and after the flash formation.     

强流二极管阳极靶温度和热形变模拟

以电子束在靶中的能量沉积剖面为桥梁,建立了二极管阳极靶温度和热形变模拟方法。该方法可获知二极管不同工作状态下靶的温度分布和热形变情况,为靶热-力学损伤研究提供基础数据,为二极管构型设计和寿命提升提供技术支撑。将该方法应用于“强光一号”短γ二极管,计算结果显示:当阳极离子密度大于1014 cm?3时（强箍缩）,靶表面温度最高可达5500～6000 ℃,热形变量达约4.5 mm;无离子流时（弱箍缩）,温度处在4500 ℃左右,形变为2.8～3.5 mm。     

铝铜合金在范性形变过程中的低频内耗

在小型拉力试验机上测量了几种铝铜和铝镁合金试样在拉伸形变过程中的低频内耗,观测到在内耗-应变曲线上出现一系列的跳跃现象。研究了测量温度和一些冶金因素对于这种跳跃现象的影响。实验结果指出,出现这种现象的温度范围与铝铜合金中出现台阶状或锯齿状应力-应变曲线的温度范围相对应。这表明,这种现象与在范性形变过程中所进行的应变时效过程有关,是由于位错气团在形变过程中的更迭形成和解脱所引起。 关键词：     

Fretting Wear Behavior of UHMWPE Under Different Temperature Conditions

The fretting wear behavior of ultra-high molecular weight polyethylene (UHMWPE) against a GCr15 steel ball was investigated using an Optimal SRV-IV oscillating reciprocating friction and wear tester (Optimal Corp., Germany). The influence of temperature, stroke size and frequency was studied in detail under a normal load of 10 N. The results showed that the friction coefficients initially decreased and then increased afterward with the increasing of temperature, having the lowest value at 0°C. The wear loss of UHMWPE at a stroke of 100 µm showed a similar tendency as the friction coefficients, but monotonously increased with increasing of temperature for a stroke of 200 µm. According to an analysis of the worn surface, it was concluded that abrasive wear accompanied with local plastic deformation dominated the wear mechanism in the process of the fretting test at ?30°C. The plastic deformation was slightly less at 0°C than that at ?30°C. With the increasing of temperature, the hardness of UHMWPE decreased significantly, plastic deformation and adhesive wear became more severe. In addition, a lubricating transfer film was formed on the steel ball.     

Dynamic characterisation and longitudinal strength of swaged joints

Swaging is a cold working process involving plastic deformation of the work piece to change its shape. A swaged joint is a connection between two components whereby a swaging tool induces plastic deformation of the components at their junction to effectively bind them together. This is commonly used when welding or other standard joining techniques are not viable. Swaged joints can be found for example, in nuclear fuel assemblies to connect the edges of thin rectangular plates to a supporting structure or frame. The aim of this work is to find a model to describe the vibrational behaviour of a swaged joint and to estimate its strength in resisting a longitudinally applied load. The finite element method and various experimental rigs were used in order to find relationships between the natural frequencies of the plate, the joint stiffness and the force required to shift the plate against the restraining action of the swage connection. It is found that a swaged joint is dynamically equivalent to a simple support with the rotation elastically restrained and a small stiffness is enough to resist an important load.     

Investigation of the technology of laser welding of aluminum alloy 1424

In this study, certain technological variants of the laser welding of alloy 1424 of the Al–Mg–Li–Zr system are considered with the purpose of obtaining the durability level of the welded joint, which is close to that of the basic metal. It is shown that, in the case of using various types of plastic deformation of the welded joint, its durability can be increased considerably to 0.85–0.95 from that of the basic metal.     

YBCO带材低熔点焊接接头研究进展

以YBa_(2)Cu_(3)O_(7)(YBCO)带材为代表的二代高温超导带材被广泛应用于各类超导装备中,由于YBCO超导带材生产长度的限制,其接头技术将在带材的实用化发展中起到至关重要的作用,其中低熔点焊料焊接接头技术由于其工艺简单且能够满足目前二代高温超导材料的应用需求,成为现阶段接头制备的主流技术.本文基于YBCO基本属性,结合目前国内外的YBCO带材生产现状,系统全面地调研了低熔点焊料焊接接头技术的制作工艺及其性能的影响因素,明确了低熔点焊料焊接接头的关键影响因素,梳理了二代高温超导带材接头的焊接工艺流程,为二代高温超导带材接头的制备提供参考。     

镍碳固溶体在范性形变过程中的位错内耗

在小型拉力试验机上测量了含有不同碳量的镍在范性形变过程中的低频内耗,观察到当含碳量在某一适当范围以内时,内耗-应变曲线上出现了一系列的峯值。研究了不同热处理条件、预先冷加工以及测量温度对于这种内耗现象的影响。初步认为这一系列峯值是由于位错气团在形变过程中的更迭形成和解脱所引起的。