超声复合电弧声调控特性研究

超声复合电弧作为一种新的焊接热源, 在电弧焊接过程中可利用超声实现对熔融金属的深度处理, 但是超声与电弧等离子体间相互作用机理还不清晰, 这成为阻碍该技术工程应用的关键问题. 本文通过实验与相应理论针对外加超声场对焊接电弧调控特性进行了研究. 为说明电弧特性, 针对试验中高速摄像采集的电弧图片进行了处理. 对比未加超声情况, 超声复合电弧受内外声场共同作用等离子体拘束程度明显提高, 电弧亮度增强, 弧柱高温区范围扩展至阳极, 中间粒子出现团聚并以一定频率上下抖动. 通过改变超声激励电流大小和声发射端高度, 电弧结构产生显著变化, 在谐振点附近, 电弧挺直度最强, 脉动频率最大. 试验结果显示通过外加超声可以达到对焊接电弧热等离子体调控的目的. 最后结合波动方程和二维声边界元模型, 分析了电弧内部声传播过程以及声场结构对等离子体粒子的作用规律, 这为进一步理解超声对电弧的调控机理打下良好基础.     

声表面波在圆弧处反射及透射的数值研究*

为了研究直达表面波在圆弧过渡面处传播性能的变化,采用有限元方法模拟了热弹机制下,线性脉冲激光辐照金属铝块表面时激发的表面波在近表面传播过程中,在不同曲率半径的圆弧处发生的反射及透射现象,建立了圆弧半径与反射表面波以及透射表面波时域信号特征之间的联系。计算结果表明:曲率半径与表面波中心波长的数值关系对表面波在圆弧处的传播有显著的影响;同时证明了根据透射表面波信号的到达时间可以反演圆弧半径的大小,为之后利用表面波信号定量检测材料表面圆弧凹痕的深度提供了理论依据。     

球冠型换能器声辐射指向性分析

为了研究球冠型换能器的声辐射特性,在分离变量法求解球面坐标系下波动方程的基础上,采用基于球谐基傅里叶变换及边界条件的求解模型,给出了球冠型换能器声辐射的远场声压计算表达式和远场指向性表达式;仿真计算了球冠换能器的远场指向性随球冠极角、球半径及振动频率变化的特性,球冠所在球障板的直径和介质中声波的波长比决定着球冠声辐射指向性,在低频或波长大于球障板直径时,球冠声辐射呈无指向性,随着频率的增高即波长的减小或者球障板直径的增大,球冠声辐射的指向性越明显,波束开角越趋向于球冠的开角,而且波束开角内出现波浪状起伏越明显;试制了高频球冠型换能器基阵,测试了换能器基阵300 kHz的指向性,测试结果与理论计算相符合,验证了理论计算表达式的正确性,可为设计球冠型换能器及基阵提供理论指导。      

Effects of radiator shapes on the bubble diving and dispersion of ultrasonic argon process

In this work, three ultrasonic radiators in different shapes have been designed in order to investigate the effects of radiator shapes on the argon bubble dispersion and diving as well as the degassing efficiency on magnesium melt. The radiator shape has a strong influence on the bubble diving and dispersion by ultrasound. A massive argon bubble slowly flows out from the radiator with the hemispherical cap, due to the covering hemispherical cap. Using a concave radiator can intensively crush the argon bubbles and drive them much deep into the water/melt, depending on the competition between the argon flow and opposite joint shear force from the concave surface. The evolution of wall bubbles involves the ultrasonic cavities carrying dissolved gas, migrating to the vessel wall, and escaping from the liquid. Hydrogen removal can be efficiently achieved using a concave radiator. The hydrogen content can be reduced from 22.3 μg/g down to 8.7 μg/g. Mechanical properties are significantly promoted, due to the structure refinement and efficient hydrogen removal.     

高频调制电弧的声学特性及其细化焊缝组织的应用

以等离子体电弧作为声源,利用高频电流进行调制,激发电弧可以产生超声波。研究了高频调制电弧的激发特性和声场特征,发现调制电弧所发射超声波在激励频段内呈现平坦的幅频特性,激励电流是影响电弧超声强度的主要因素,声压幅值与电弧等离子体流力的变化量成正比,声场呈现轴向强两侧弱的特征。同时介绍了利用电弧激发超声波在改善焊缝组织性能方面的应用。     

Nonlinear oscillation and acoustic scattering of bubbles

The scattered acoustic pressure and scattered cross section of bubbles is studied using the scattered theory of bubbles. The nonlinear oscillations of bubbles and the scattering acoustic fields of a spherical bubble cluster are numerically simulated based on the bubble dynamic and fluid dynamic. The influences of the interaction between bubbles on scattering acoustic field of bubbles are researched. The results of numerical simulation show that the oscillation phases of bubbles are delayed to a certain extent at different positions in the bubble cluster, but the radii of bubbles during oscillation do not differ too much at different positions. Furthermore, directivity of the acoustic scattering of bubbles is obvious. The scattered acoustic pressures of bubbles are different at the different positions inside and outside of the bubble cluster. The scattering acoustic fields of a spherical bubble cluster depend on the driving pressure amplitude, driving frequency, the equilibrium radii of bubbles, bubble number and the radius of the spherical bubble cluster. These theoretical predictions provide a further understanding of physics behind ultrasonic technique and should be useful for guiding ultrasonic application.     

Analysis of acoustic directivity of spherical cap transducers

In order to study the acoustic radiation from the spherical cap transducer,a theoretical model is used by solving the wave equation in spherical coordinates using the method of separation of variables,based on the spherical harmonic Fourier transform and boundary condition.The calculation formulas for the far field radiated pressure and directivity of spherical cap are derived.Some theoretical results are presented in the form of far-field directivity patterns of the spherical cap transducer for various polar angles of the spherical cap,radii of sphere baffle and operating frequencies.Both the diameter of the sphere baffle and the wavelength determine the directivity of acoustic radiation from a spherical cap.When the frequency is lower or the wavelength is longer than the diameter of the sphere baffle,the acoustic radiation from a spherical cap is omnidirectional.With the increase of the frequency or the diameter of the sphere baffle,the acoustic radiation from a spherical cap is more directional and the beamwidth more tends to spherical cap angle.Furthermore,the ripple in the beam is more obvious.The high frequency spherical cap transducer was fabricated and the directivity pattern was tested and the measurement data is shown to coincide with the theoretical results.This research can provide a guideline for designing the spherical cap transducers and arrays.     

Effects of relative positioning of energy sources on weld integrity for hybrid laser arc welding

This study is concerned with the effects of laser and arc arrangement on weld integrity for the hybrid laser arc welding processes. Experiments were conducted for a high-strength steel using a 4 kW Nd: YAG laser and a metal active gas (MAG) welding facility under two configurations of arc–laser hybrid welding (ALHW) and laser–arc hybrid welding (LAHW). Metallographic analysis and mechanical testing were performed to evaluate the weld integrity in terms of weld bead geometry, microstructure and mechanical properties. The morphology of the weld bead cross-section was studied and the typical macrostructure of the weld beads appeared to be cone-shaped and cocktail cup-shaped under ALHW and LAHW configurations, respectively. The weld integrity attributes of microstructure, phase constituents and microhardness were analyzed for different weld regions. The tensile and impact tests were performed and fracture surface morphology was analyzed by scanning electron microscope. The study showed that ALHW produced joints with a better weld shape and a more uniform microstructure of lath martensite, while LAHW weld had a heterogeneous structure of lath martensite and austenite.     

A two-frequency acoustic technique for bubble resonant oscillation studies

A two-frequency acoustic apparatus has been developed to study the dynamics of a single gas or vapor bubble in water. An advantage of the apparatus is its capability of trapping a bubble by an ultrasonic standing wave while independently driving it into oscillations by a second lower frequency acoustic wave. For a preliminary application, the apparatus is used to study resonant oscillations. First, near-resonant coupling between the volume and the n = 3 shape oscillation modes of air bubbles at room temperature is studied, where n is the mode number. The stability boundary, amplitude versus frequency, of the volume oscillation forms a wedge centered at the resonant frequency, which qualitatively agrees with a theoretical prediction based on a phase-space analysis. Next, the resonant volume oscillations of vapor bubbles are studied. The resonant radius of vapor bubbles at 80 degrees C driven at 1682 Hz is determined to be 0.7 mm, in agreement with a prediction obtained by numerical simulation.     

The ultrasonic characteristics of high frequency modulated arc and its application in material processing

To solve the difficulty of introducing traditional ultrasonic transducers to welding molten pool, high frequency current is used to modulate plasma arc and ultrasonic wave is excited successfully. The characteristics of the excited ultrasonic field are studied. The results show that the amplitude-frequency response of the ultrasonic emission is flat. The modulating current is the main factor influencing the ultrasonic power and the sound pressure depends on the variation of arc plasma stream force. Experimental study of the welding structure indicates grain refinement by the ultrasonic emission of the modulated arc and the test results showed there should be an energy region for the arc ultrasonic to get best welding joints.     

Numerical analysis of plasma arc physical characteristics under additional constraint of keyhole

The physical characteristics of a plasma arc affect the stability of the keyhole and weld pool directly during keyhole plasma arc welding(KPAW). There will be significant change for these characteristics because of the interaction between the keyhole weld pool and plasma arc after penetration. Therefore, in order to obtain the temperature field, flow field, and arc pressure of a plasma arc under the reaction of the keyhole, the physical model of a plasma arc with a pre-set keyhole was established. In addition, the tungsten and base metal were established into the calculated domain, which can reflect the effect of plasma arc to weld pool further. Based on magneto hydrodynamics and Maxwell equations, a two-dimensional steady state mathematical model was established. Considering the heat production of anode and cathode, the distribution of temperature field, flow field, welding current density, and plasma arc pressure were solved out by the finite difference method. From the calculated results, it is found that the plasma arc was compressed a second time by the keyhole. This additional constraint results in an obvious rise of the plasma arc pressure and flow velocity at the minimum diameter place of the keyhole, while the temperature field is impacted slightly. Finally, the observational and metallographic experiments are conducted, and the shapes of plasma arc and fusion line agree with the simulated results generally.     

电弧特性及其对熔池形貌影响的数值模拟

通过电弧模型与熔池模型耦合数值模拟,研究了氩弧和氦弧特性及其对SUS304不锈钢钨极惰性气体保护（TIG）焊熔池形貌的影响.通过比较氩弧和氦弧的温度轮廓线以及阳极表面电流密度和热流密度分布发现,氦弧的径向距离比氩弧收缩明显,导致更多热量传递给阳极.模拟了氩弧和氦弧下浮力、电磁力、表面张力和气体剪切力分别对熔池形貌的影响.结果表明：不论是在氩弧还是在氦弧下熔池中表面张力是影响熔池形貌的最主要驱动力.在氩弧下,影响熔池形貌的另一个重要的驱动力是气体剪切力,而氦弧下则是电磁力.由于电磁力引起的内对流运动增加了熔深,从而导致相同氧含量时氦弧下的熔深和焊缝深宽比要高于氩弧下的熔深和焊缝深宽比.随着氧含量的增加,氩弧和氦弧下的焊缝深宽比均先增加而后保持不变.焊缝深宽比的模拟结果与实验结果符合较好. 关键词： 氩弧 氦弧 电弧特性 熔池形貌     

Analysis and improvement of sound radiation performance of spherical cap radiator

A spherical cap radiator is one of the important parts of an underwater wide-beam imaging system. The back radiation of a traditional spherical cap radiator, which is composed of a vibrating cap and a rigid baffle, is strong and its far-field directivity function may fluctuate in big amplitude in the vicinity of the polar axis. These shortcomings complicate the processing of the reflective waves received for imaging the targets. In this study, the back radiation is weakened by adding an acoustic soft material belt between the vibrating cap and the rigid baffle. And the fluctuation mentioned above is lowered remarkably by dividing the spherical cap radiator into many annuluses and a relatively smaller spherical cap, and by controlling the phase retardations of all elements appropriately. Furthermore, the numerical experiments are carried out by the finite element method (FEM) to prove the validity of the above methods.     

Study on rectangular ultrasonic radiator of flexural resonant vibration in high modes

Based on the theory of coupling vibration and flexural vibration of thin rod of rectangular cross section, the fiexural vibration of rectangular thin plate was studied. The frequency equation was derived under the condition of freeboundaries. The normal modes and the relation between the normal modes and the resonant frequency were obtained. Experiments showed that the calculated resonant frequencies agree well with the measured results, and the rectangular thin plate in flexural vibration has abundant resonant frequencies. The radiator of flexural vibration used in ultrasonic cleaning and other techniques has the advantages of large acoustic radiating area, uniform acoustic field and easy adjustment of resonant frequencies, proving that it is a promising ultrasonic source.     

A novel compensation method for the measurement of radius of curvature

A test method for spherical mirrors with super-long radius of curvature that only one compensator is employed to measure the radii of curvature of both concave and convex mirrors is presented. With this testing system, the surface figure and radius of curvature of spherical mirrors can be measured simultaneously. Using the ABCD matrix method, a precise formula for radius of curvature calculation is deduced. Experimental results show that the relative measurement error of this method is less than 4.2×10⁻⁴.     

Improvement of laser keyhole formation with the assistance of arc plasma in the hybrid welding process of magnesium alloy

In the previous work, low-power laser/arc hybrid welding technique is used to weld magnesium alloy and high-quality weld joints are obtained. In order to make clear the interactions between low-power laser pulse and arc plasma, the effect of arc plasma on laser pulse is studied in this article. The result shows that the penetration of low-power laser welding with the assistance of TIG arc is more than two times deeper than that of laser welding alone and laser welding transforms from thermal-conduction mode to keyhole mode. The plasma behaviors and spectra during the welding process are studied, and the transition mechanism of laser-welding mode is analyzed in detail. It is also found that with the assistance of arc plasma, the threshold value of average power density to form keyhole welding for YAG laser is only 3.3×10⁴ W/cm², and the average peak power density is 2.6×10⁵ W/cm² in the present experiment. Moreover, the distribution of energy density during laser pulse is modulated to improve the formation and stability of laser keyholes.     

声驻波场中空化泡的动力学特性

以水为工作介质, 考虑了液体的可压缩性, 研究了驻波声场中空化泡的运动特性, 模拟了驻波场中各位置处空化泡的运动状态以及相关参数对各位置处空化泡在主Bjerknes力作用下运动方向的影响. 结果表明: 驻波声场中, 空化泡的运动状态分为三个区域, 即在声压波腹附近空化泡做稳态空化, 在偏离波腹处空化泡做瞬态空化, 在声压波节附近, 空化泡在主Bjerknes 力作用下, 一直向声压波节处移动, 显示不发生空化现象; 驻波场中声压幅值增加有利于空化的发生, 但声压幅值增加到一定上限时, 压力波腹区域将排斥空化泡, 并驱赶空化泡向压力波节移动, 不利于空化现象的发生; 当声频率小于初始空化泡的共振频率时, 声频率越高, 由于主Bjerknes 力的作用将有更多的空化泡向声压波节移动, 不利于空化的发生, 尤其是驻波场液面的高度不应是声波波长的1/4; 当声频率一定时, 空化泡初始半径越大越有利于空化现象的发生, 但当空化泡的初始半径超过声频率的共振半径时, 由于主Bjerknes力的作用将有更多的空化泡向声压波节移动, 不利于空化的发生.     

Grain fragmentation in ultrasonic-assisted TIG weld of pure aluminum

Under the action of acoustic waves during an ultrasonic-assisted tungsten inert gas (TIG) welding process, a grain of a TIG weld of aluminum alloy is refined by nucleation and grain fragmentation. Herein, effects of ultrasound on grain fragmentation in the TIG weld of aluminum alloy are investigated via systematic welding experiments of pure aluminum. First, experiments involving continuous and fixed-position welding are performed, which demonstrate that ultrasound can break the grain of the TIG weld of pure aluminum. The microstructural characteristics of an ultrasonic-assisted TIG weld fabricated by fixed-position welding are analyzed. The microstructure is found to transform from plane crystal, columnar crystal, and uniform equiaxed crystal into plane crystal, deformed columnar crystal, and nonuniform equiaxed crystal after application of ultrasound. Second, factors influencing ultrasonic grain fragmentation are investigated. The ultrasonic amplitude and welding current are found to have a considerable effect on grain fragmentation. The degree of fragmentation first increases and then decreases with an increase in ultrasonic amplitude, and it increases with an increase in welding current. Measurement results of the vibration of the weld pool show that the degree of grain fragmentation is related to the intensity of acoustic nonlinearity in the weld pool. The greater the intensity of acoustic nonlinearity, the greater is the degree of grain fragmentation. Finally, the mechanism of ultrasonic grain fragmentation in the TIG weld of pure aluminum is discussed. A finite element simulation is used to simulate the acoustic pressure and flow in the weld pool. The acoustic pressure in the weld pool exceeds the cavitation threshold, and cavitation bubbles are generated. The flow velocity in the weld pool does not change noticeably after application of ultrasound. It is concluded that the high-pressure conditions induced during the occurrence of cavitation, lead to grain fragmentation in a pure aluminum TIG weld during an ultrasonic-assisted TIG welding process.     

Analysis of the space-time dynamics of acoustic fields on the surface of a solid

The space-time dynamics of an acoustic field produced by a piezoelectric transducer in a pulsed mode is studied. The detection of acoustic fields is achieved using a Doppler laser interferometer. It is shown that, for a pictorial representation of the dynamics of a pulsed process, it is convenient to use the patterns of instantaneous spatial field distributions within the scanning area, the observation of which at successive instants makes it possible to trace the acoustic field variations on a time scale considerably smaller than the period of the ultrasonic wave. Experimental data demonstrating the process of phase propagation along the sample boundary as a function of time are presented. They are in good agreement with theoretical results obtained by using various methods of acoustic field calculation and different scalar potential distributions over the transducer surface. It is shown that the velocity of phase propagation along the sample boundary, which is mainly determined by the wave front curvature of the elastic wave incident on the sample surface, can considerably exceed the wave velocity in the unbounded medium.     

Shock-wave model of acoustic cavitation

Shock-wave model of liquid cavitation due to an acoustic wave was developed, showing how the primary energy of an acoustic radiator is absorbed in the cavitation region owing to the formation of spherical shock-waves inside each gas bubble. The model is based on the concept of a hypothetical spatial wave moving through the cavitation region. It permits using the classical system of Rankine-Hugoniot equations to calculate the total energy absorbed in the cavitation region. Additionally, the model makes it possible to explain some newly discovered properties of acoustic cavitation that occur at extremely high oscillatory velocities of the radiators, at which the mode of bubble oscillation changes and the bubble behavior approaches that of an empty Rayleigh cavity. Experimental verification of the proposed model was conducted using an acoustic calorimeter with a set of barbell horns. The maximum amplitude of the oscillatory velocity of the horns' radiating surfaces was 17 m/s. Static pressure in the calorimeter was varied in the range from 1 to 5 bars. The experimental data and the results of the calculations according to the proposed model were in good agreement. Simple algebraic expressions that follow from the model can be used for engineering calculations of the energy parameters of the ultrasonic radiators used in sonochemical reactors.