Fatigue behaviour of FSW and MIG weldments for two aluminium alloys

The increasing use of aluminium alloys in transportation, such as railways, shipbuilding and aeronautics, calls for more efficient and reliable welding processes that would require more in depth understanding of fatigue failure. The objective of this work focuses on the contrasting difference of fatigue behaviour of joints made from the traditional process of metal inert gas (MIG) welding, and the emerging process of friction stir welding (FSW). Effort is made to relate the macroscopic mechanical behaviour to the microstructural feature of the weldments.     

干涉应变计法在焊缝材料力学性能测试中的应用

在焊接结构中,焊缝的不同区域(如热影响区和熔合区)的材料力学性能对整个结构的安全性、可靠性起着至关重要的影响。本文介绍了用于高精度应变测量的干涉应变计法(ISDG),并利用自行研制的微小试样拉伸试验机,对20Cr合金钢压力容器中部分焊缝材料,分热影响区和熔合区对其材料力学性能进行测试,在国内首次获得了焊缝不同区域的全历程应力-应变曲线,对热影响区材料的软化现象进行了定量的描述。     

Improvements in Residual Stress Measurement by the Incremental Centre Hole Drilling Technique

This paper presents results which advance and improve the usefulness, accuracy and efficiency of incremental centre hole drilling as a method of measuring near surface residual stress fields. Particular emphasis is placed on providing optimal values for the number of drilling step increments to be used and their corresponding size. Guidelines on the optimal values for the number and size of steps to use during measurements are presented for various ratios of hole radius to strain gauge rosette radius in the form of tabulated data. These guidelines are subsequently incorporated into a new data analysis program which permits very near surface residual stress fields to be accurately determined in real components. The benefits of the new approach are highlighted by reporting the results of measurements made on three industrial components, each of which has been subjected to a well-known engineering process. These components are a shot-peened spring-steel, a friction stir welded aluminium alloy, and a titanium alloy subjected to three different machining processes. The results reveal that the improvements to the incremental centre hole drilling technique can provide measured residual stresses from depths ranging from about 10 m to 1 mm.     

Numerical modeling of thermophysical processes in laser-beam welding with formation of a vapor channel

A quasi-two-dimensional mathematical model of laser welding of plates made of a binary alloy with allowance for metal vaporization and formation of a vapor channel is developed. A difference algorithm and a computer code are designed on the basis of this model. Processes of melting, vaporization, and solidification of the alloy of butt-welded aluminum plates are considered numerically as an example. The shape and depth of the vapor channel and welding bath are calculated for given conditions of the radiation power and welding velocity. Based on semi-empirical relations and numerical data obtained, the characteristic size of the dendritic structure of the solidified melt is estimated. __________ Translated from Prikladnaya Mekhanika i Tekhnicheskaya Fizika, Vol. 47, No. 5, pp. 88–96, September–October, 2006.     

金属管线高温环境下的断裂失效分析

超燃冲压发动机燃烧室试验台配置了大量金属管线,煤油作为燃料和冷却介质在其中输运,在实验过程中发生管线早期断裂失效,对此开展了分析。首先利用三维体视显微镜与扫描电镜进行了断口观察与分析,表明管线的开裂起源于焊缝根部,具有典型的多源起源特征;裂纹源区具有蓝色半圆形特征,表明存在焊接裂纹。同时,断口呈现明显的疲劳辉纹,间距为亚微米量级。根据辉纹间距与管材壁厚以及使用寿命分析,确定了疲劳载荷的频率范围;根据理论公式与有限元模态分析对管线的自振频率进行了估算,其结果与断口分析的结果吻合良好。以上研究结果表明管线断裂是典型的振动疲劳失效导致的。为此,建议在管线中部增加固定点约束,改变管线的自振频率以降低振幅,并改进焊接工艺,提高管线焊接质量。基于以上措施,有效解决了管线的早期断裂失效问题。     

Experimental and numerical investigation of laser shock synchronous welding and forming of Copper/Aluminum

A novel laser shock synchronous welding and forming method is introduced, which utilizes laser-induced shock waves to accelerate the flyer plate towards the base plate to achieve the joining of dissimilar metals and forming in a specific shape of mold. The samples were obtained with different laser energies and standoff distances. The surface morphology and roughness of the samples were greatly affected by the laser energy and standoff distances. Fittability was investigated to examine the forming accuracy. The results showed that the samples replicate the mold features well. Straight and wavy interfaces with un-bonded regions in the center were observed through metallographic analysis. Moreover, Energy Disperse Spectroscopy analysis was conducted on the welding interface, and the results indicated that a short-distance elemental diffusion emerged in the welding interface. The nanoindentation hardness of the welding regions was measured to evaluate the welding interface. In addition, the Smoothed Particle Hydrodynamics method was employed to simulate the welding and forming process. It was shown that different standoff distances significantly affected the size of the welding regions and interface waveform characteristics. The numerical analysis results indicated that the opposite shear stress direction and effective plastic strain above a certain threshold are essential to successfully obtain welding and forming workpiece.     

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.     

Combination of laser keyhole and conduction welding: Dissimilar laser welding of niobium and Ti-6Al-4V

Pulsed Nd:YAG laser welding of pure niobium plate to titanium alloy Ti-6Al-4V sheet in butt joint is studied regarding the laser/metal interaction modes. To obtain the optimized process parameters in dissimilar welding of Ti-6Al-4V/Nb, the melting ratio of laser beam energy for each weld counterpart is evaluated experimentally. Different laser welding modes of keyhole and conduction are predicted regarding the absorbed energy from the similar laser pulses on each weld counterpart. Laser keyhole and conduction welding were observed simultaneously through direct visualization of laser interaction with dissimilar metals using High Speed Imaging (HSI) system.     

Laser welding of polymers using unsymmetrical squaraine dyes

Transmission laser welding of plastic is typically achieved by incorporating a laser absorbing dye into one of the two pieces of plastic one wishes to weld together and mediating the welding process using a laser emitting light at a suitable wavelength. Desirable properties of laser absorbing dyes include: (1) the dye is colorless in the visible region but absorbs strongly in the region at the wavelength where the laser emits, (2) the dye has a good conversion of the energy from the laser to heat, (3) the dye is stable enough to be incorporated into the molten plastic, (4) the dye is soluble in the plastic of choice to give an even distribution in the plastic, and (5) the dye is nontoxic. Here, we explore an alternative approach to achieve laser welding of colorless plastics using a laser dye that is colored, but that can be bleached after the welding process. Nonsymmetrical squaraine dyes were prepared by condensation of squaric acid and two equivalents of various 3,5-dimethoxy-N,N-dialkylanilines. After the incorporation into polyethylene and laser welding, the plastic was bleached either by heat treatment or by irradiation with a high pressure Xe-lamp giving colorless polyethylene. © 2018 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2018 , 56, 2245–2254     

Analysis of the correlation between plasma plume and keyhole behavior in laser metal welding for the modeling of the keyhole geometry

The process of laser metal welding is widely used in industry. Nevertheless, there is still a lack of complete process understanding and control. For analyzing the process we used two high-speed cameras. Therefore, we could image the plasma plume (which is directly accessible by a camera) and the keyhole (where most of the process instabilities occur) during laser welding isochronously. Applying different image processing steps we were able to find a correlation between those two process characteristics. Additionally we imaged the plasma plume from two directions and were able to calculate a volume with respect to the vaporized material the plasma plume carries. Due to these correlations we are able to conclude the keyhole stability from imaging the plasma plume and vice versa. We used the found correlation between the keyhole behavior and the plasma plume to explain the effect of changing laser power and feed rate on the keyhole geometry. Furthermore, we tried to outline the phenomena which have the biggest effect on the keyhole geometry during changes of feed rate and laser power.