Experimental investigation and metallographic characterization of fiber laser beam welding of Ti-6Al-4V alloy using response surface method

In the present study, experimental investigations of fiber-laser-beam-welding of 5 mm thick Ti-6Al-4V alloy are carried out based on statistical design of experiments. The relationship between the process parameters such as welding power, welding speed, and defocused position of the laser beam with the output responses such as width of the fusion zone, size of the heat affected zone, and fusion zone area are established in terms of regression models. Also, the most significant process parameters and their optimum ranges are identified and their percentage contributions on output responses are calculated. It is observed that welding power and speed plays the major role for full penetration welding. Also, welding power shows direct effect whereas welding speed shows the inverse effect on the output responses. The bead geometry is influenced by the defocused position of the laser beam due to the change in power density on the workpiece surface. However, overall fusion zone area is unaffected. Mechanical characterization of the welded samples such as microstructural analysis, hardness, and tensile tests are conducted. It is noticed that the hardness value of the FZ is higher than the HAZ and BM zone due to the difference in cooling rate during welding which promotes the formation of α′ martensitic phase in the FZ. Also, an average hardness value in the FZ is compared for two different defocusing positions (i.e. 1 and 2 mm). It is found that hardness value is higher for 1 mm defocused position than 2 mm due the decrement in grain size below a critical range at 2 mm defocused position. The ultimate tensile strength and % elongation of the welded samples are degraded as compared to BM which can be further improved by post heat treatment.     

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DSP+FPGA的元器件焊接垂直度识别方法

为实现电路板上柱状元器件焊接垂直度的精准检测,设计了一款基于DSP+FPGA的垂直度识别系统。DSP承担核心算法任务,FPGA作为数据预处理单元,完成接口的逻辑、系统的互连以及数据通道。在硬件平台上嵌入了基于元器件形心配准的垂直度识别算法。首先对预处理的图像利用改进的Canny算法提取元器件的像素级边缘,并采用边缘跟踪算法去除噪点和干扰边缘并对元器件进行编号,在粗提取的边缘上用Zernike矩算法来精确定位元器件亚像素级边缘。在此基础上,提取元器件轮廓的最小外接矩形来修正边缘并得到每个元器件的形心坐标,最后根据形心的偏移距离来完成每个元器件垂直度的识别。实验结果表明,该垂直度识别系统的设计方案识别结果精度高,检测速度快,满足实时性要求,具有重要的实际工程意义。     

等离子弧焊接熔池演变过程的模拟和验证

本文建立了描述等离子弧焊接熔池相变传热与流动的三维数理模型,考虑表面张力、电磁力和浮升力的作用,并针对等离子弧焊接特点,改进组合式体积热源模型,上部采用双椭球热源,下部采用圆锥体热源。重点分析了焊接熔池形状和温度场的演变过程,熔合线的模拟形状与实验焊缝吻合,较好地呈现了焊缝的凸起和熔池宽度,验证了数学模型和热源模型的正确性。本文还进一步开展了焊接功率和焊接速度的影响分析。研究结果表明,流动对焊缝形状的影响不容忽略,而表面张力在三个流动驱动力中占主导地位;焊接功率越大,焊接速度越小,越有利于焊件焊透,数值模拟得到优化的焊接功率和速度有益于实际焊接生产质量及效率。     

Research on laser welding of vehicle body

Based on many experiments of CO₂ laser welding of vehicle body, joint microstructure and stress–strain curve of specimen are analyzed. The deep punching performance acquired by adopting Ar as protective gas is better than that of the one acquired by adopting N₂ as protective gas. Meanwhile the percentage of zinc in welding seam can be effectively controlled by means of blowing side protective gas. In this paper, welding penetration and width are shown to vary with laser power and speed of welding. The results indicate that some flaws such as gas hole, crack and softening of HAZ do not appear in laser welding seam in sheet steel of automobile bodies if technology parameters optimizes. The deep punching performance of tailor-welding sheet is fine.     

Cryo-FIB-Preparation and Cryo-SEM Investigation of Gold Nanolayers Used as Absorber for Laser Welding of Polymer Foils

The morphology of welded polymer foils was investigated by Scanning Electron Microscopy (SEM) using Focused Ion Beam (FIB) technology for cross-sectional preparation. Due to the sensitive structure of the copolymer Ethylene Tetrafluororethylene (ETFE), FIB preparation and SEM investigation were performed at cryo conditions. A gold nanolayer was used as absorber for the laser beam to weld the transparent copolymer foils. The embedding of the gold nanolayer inside the welding seam and its influence on the mechanical stability of the welding seams was demonstrated.     

聚变堆用CLF-1 钢与316L 钢TIG 焊接接头组织与性能初步研究

对用W19123L 为焊丝的聚变堆用低活化CLF-1 钢与316L 钢的钨极氩弧焊(TIG)焊接接头金相组织及性能进行了初步研究。结果表明：焊接接头成型良好、无缺陷;金相组织表明焊接接头由CLF-1 侧(母材区、热影响区、熔合区)、过渡层、焊缝区、316L 侧(母材区、热影响区、熔合区)组成;室温拉伸试验结果优于母材的最低要求值;弯曲试验后的焊接接头内外表面完好,无裂纹产生,变形均匀;焊接接头冲击值成凹型分布,焊缝区冲击值最低,焊缝两侧热影响区冲击值次之,母材冲击值最高,316L 侧冲击值略高于CLF-1 侧,均满足焊接接头设计值;焊接接头上表面1.6mm 硬度波动较大,略高于1/2T 和下表面1.6mm 处,焊接接头1/2T 和下表面1.6mm 硬度分布较均匀,从CLF-1 侧到316L 侧有下降趋势。整体焊接性能基本稳定,满足异种钢焊接性能匹配要求。     

Recent Advances in Friction Stir Welding/Processing of Aluminum Alloys: Microstructural Evolution and Mechanical Properties

Friction stir welding (FSW), a highly efficient solid-state joining technique, has been termed as “green” technology due to its energy efficiency and environment friendliness. It is an enabling technology for joining metallic materials, in particular lightweight high-strength aluminum and magnesium alloys which were classified as unweldable by traditional fusion welding. It is thus considered to be the most significant development in the area of material joining over the past two decades. Friction stir processing (FSP) was later developed based on the basic principles of FSW. FSP has been proven to be an effective and versatile metal-working technique for modifying and fabricating metallic materials. FSW/FSP of aluminum alloys has prompted considerable scientific and technological interest since it has a potential for revolutionizing the manufacturing process in the aerospace, defense, marine, automotive, and railway industries. To promote widespread applications of FSW/FSP technology and ensure the structural integrity, safety and durability of the FSW/FSP components, it is essential to optimize the process parameters, and to evaluate thoroughly the microstructural changes and mechanical properties of the welded/processed samples. This review article is thus aimed at summarizing recent advances in the microstructural evolution and mechanical properties of FSW/FSP aluminum alloys. Particular attention is paid to recrystallization mechanism, grain boundary characteristics, phase transformation, texture evolution, characteristic microstructures, and the effect of these factors on the hardness, tensile and fatigue properties as well as superplastic behavior of FSW/FSP aluminum alloys.     

Shielding gas influences on laser weldability of tailored blanks of advanced automotive steels

The effects of shielding gas types and flow rates on CO₂ laser weldability of DP600/TRIP700 steel sheets were studied in this work. The evaluated shielding gases were helium (He), argon (Ar) and different mixtures of He and Ar. Weld penetration, tensile strength and formability (Erichsen test) of laser welds were found to be strongly dependent upon the shielding gas types. The ability of shielding gas in removing plasma plume and thus increasing weld penetration is believed to be closely related to ionization potential and atomic weight which determine the period of plasma formation and disappearance. It was found that the higher helium shielding gas flow rate, the deeper weld penetration and the lower weld width.