A study on detection of micro-cracks in the dissimilar metal weld through ultrasound infrared thermography

This study was conducted to investigate a possibility of detecting stress corrosion crack defects in a pipe welded with dissimilar metals (STS304 and SA106 Gr. b) through infrared ultrasound thermography and lock-in phase method. The ultrasound generator was set as 250 W in output and 19.8 kHz in frequency. With experiment results, this study could detect, cracks located inside the dissimilar metal weld pipe through lock-in infrared thermography and compare thermography images obtained from both the inside and the outside when the ultrasound vibration was applied to the outer part of the pipe. Besides, after cutting off the pipe in the axial direction, this study conducted PT inspection. As a result, it was found there existed more than a single crack in a certain range inside the pipe, which made hot spots appear in a wide range on the thermography image. Moreover, through ultrasound infrared thermography and lock-in phase method this study verified the possibility of detecting micro-sized shattered cracks through ultrasound thermography, which were not easy to detect with the existing techniques.     

A force-based failure criterion for spot weld design

This paper suggests a very simple, force-based formula that combines four failure modes into one dimensionless equation to govern spot weld failure under general static loading conditions. The four failure modes are shear, rotation, normal and peel. The normal separation mode and the peel mode are corresponding to mode I (opening mode). The tensile/shear mode is mode II (sliding mode), and the in-plane rotation mode is mode III (tearing mode). Test coupons and test fixtures are designed and tested to establish and verify this equation. To further verify this equation, a long difficult to understand automotive spot weld failure problem was studied. Applying finite element-calculated resultant loads to the proposed formula resulted in analytical values that correlated very well with the long time field observed spot weld failures. This analytical prediction reasonably explained the spot weld failure mechanism and provided good design directions to improve the durability of the auto structure.     

Failure of spot welds under in-plane static loading

Under in-plane loading conditions, two independent modes contribute to the failure of a spot weld: the in-plane shear mode and the in-plane rotational mode. In this work, the failures of both modes under large static load are examined individually. To study the combined failure of these two modes, two special test coupons are designed. The first coupon contains one spot weld. The second coupon contains five spot welds. Tests conducted in this work show that a very simple force-based failure criterion can be used to predict the failure of a spot weld under large in-plane combined static loads. Current multiaxial failure theory cannot explain this combined failure. This force-based spot weld failure criterion fits current automotive industry needs for body shell finite element application very well.     

Transient temperature fields and residual stress fields of metallic materials under welding

Based on the situation of welding thermal conduction and thermo-elasto-plasticityresearch,Ms paper explores some problems in this field.First,the boundary elementmethod for nonlinear problems is improved by linearization of nonlinear problems and usedin welding thermal conduction analysis.Second,the thermo-elasto-plastic finite elementmethod is used for the welding stress calculation,in which the phase transformation isconsidered by the"equivalent linear expansion coefficient method".The comparison of the calculated results with experimental data shows that themethods provided in this paper are available.     

焊接过程瞬态温度场与残余应力场

本文根据焊接热传导及热弹塑性的研究现状,对如下两个问题进行了探讨.首先,采用非线性问题线性化的方法对非线性非定常温度场问题的边界元法做了改进,并将其用于焊接热传导分析:其次,提出“等放线膨胀系数法”考虑相变对于应力场的影响,并将其用于焊接热弹塑性分析.实例的数值计算结果与实测数据的对比分析表明本文方法行之有效.     

双金属复合钢管界面及焊缝的微观结构

通过金相分析、微区成份分析、宏观和微观断口分析,主要研究钎焊层和焊缝区的微观结构及其对复合钢管工艺性能和使用性能的影响。研究结果表明,镍基钎焊层通过扩散形成界面,实现了完全的冶金结合。组成复合钢管的各层以及焊缝金属的力学性能相近,变形均匀,保证了复合钢管的可焊性和强韧性。铜钎焊复合钢管由于高温铜脆而引发焊接裂纹,且其钎焊层硬度明显高于基层和复层,导致层间剪切及沿界面发生分层脱离,固该铜基合金不宜做复合钢管钎焊料。