RAFM钢TIG焊和电子束焊疲劳性能实验和分析模拟

利用ANSYS 对低活化铁素体马氏体(RAFM)钢进行非熔化极气体保护焊(TIG 焊)与电子束焊的抗疲劳模拟分析，再利用SDS200 电液伺服疲劳试验机对TIG 焊和电子束焊的两种RAFM 钢试件进行实验。通过施加相同梯度负荷对TIG 焊和电子束焊试件进行焊缝的疲劳性能实验。与实验结果对比分析，结果显示电子束焊优于 TIG 焊，但在一定负载下可以用TIG 焊代替电子束焊。     

中国聚变工程实验堆水冷包层钢构件流道成形控制研究

针对CFETR水冷包层流道钢构件热等静压制备时易变形压塌问题，利用单轴扩散焊设备开展了焊接工艺参数优化试验。在此基础上，重新设计了流道焊接界面位置和尺寸，用两步热等静压扩散焊法制备出了流道变形可控的平板型第一壁钢构件模块。优化试验表明，低活化钢试样的固相扩散焊温度需高于950℃，焊后经过760℃/60min回火热处理试样力学性能可以得到有效回复。     

非线性工作状态压电换能器匹配技术

针对压电换能器在大功率下存在复杂非线性而导致匹配参数难以优化的问题,以大功率超声金属焊接为例,通过采集测试焊接过程换能器两端电压的幅值与频率,建立换能器反谐振电阻与驱动电压有效值、频率之间的数学模型;提出基于反谐振电阻模型的最优功率匹配方法,推导了匹配电感电容的计算公式。最后实验验证了数学模型的准确性,且当换能器输入功率在最优功率附近时,匹配网络电能传输效率最高。     

双金属爆炸焊接上限

本文根据热传导理论给出了爆炸焊接时双金属结合区附近的温度场解析解。并利用该解初步研究了双金属的爆炸焊接上限。     

多层金属爆炸焊接复板飞行姿态的计算方法

在两层金属爆炸焊接复板飞行姿态的理论计算基础上，运用质量守恒、动量守恒定理和契特公式推导了多层金属爆炸接复板飞行姿态的理论计算模型，经过实验验证，该计算模型和实验相符合，对于多层金属爆炸焊接工艺参数的设计具有很高的使用价值。     

Analysis of temperature and stress field in Al alloy’s twin wire welding

By analyzing the shape of twin wire welding’s arcs and the track of droplets’ transition, the phenomenon that the twin wire welding’s fore arc and rear arc all deflect to the middle of the two arcs is found. Based on this the double ellipsoid heat source model is amended, and a heat source model which can apply to calculate the twin wire welding’s temperature field is put forward. This model is testified by actual experiment of temperature sampling. By comparing the temperature field of twin wire welding and single wire welding, the results show that twin wire welding has slender weld pool the end part of which is ellipsoid, and its HAZ is narrower than that of single wire welding. So, twin wire welding can not only reduce the Al alloy generating hot crack, but can also weaken the “overaging” softened phenomenon of heat treated strengthening Al alloy. In the end, the evolving rules of 2219 Al alloy’s longitudinal and transverse stress when welded with twin wire welding are analyzed.     

Microstructure evolution and mechanical property of pulsed laser welded Ni-based superalloy

For evaluating the microstructure evolution and mechanical property of Ni-based Hastelloy C-276 weld joint by the pulsed laser welding, the influence of pulsed laser welding on the microstructure and mechanical property of the weld joint is investigated by the analysis of the microstructure morphology, microhardness, phase structure and tensile property. The results indicate that, in the fusion zone three sections are divided on the basis of the patterns of grain structures. In the weld joint, the element segregation is found, but the trend of brittle phase׳s formation is weakened. The weld microhardness presents just a little higher than that of base metal, and there is no obvious the softened heat affected zone. Meanwhile in the weld joint, the phase structure is still the face-center cubic with the tiny shift of peak positions and widened Full Width at Half-Maximum. The yield strength of weld joint is the same as that of base metal, and the tensile strength is nearly 90% of that of base metal. The decreased tensile strength is mainly attributed to the dislocation piling-up.     

Modeling and numerical simulation of the resistance spot welding of zinc coated steel sheets using rounded tip electrode: Analysis of required conditions

This paper investigates the essential conditions to improve the accuracy of a resistance spot welding computational study of advanced zinc coated steel sheets using rounded tip electrode. An experimental analysis is performed to highlight the required considerations for a suitable simulation. A sequential Electrical-Thermal-Metallurgical and Mechanical (ETMM) finite element analysis with appropriate precautions of the contact conditions enables to accurately simulate the nugget development during the welding. A critical smooth evolution of the contact radius is required. A fine meshing with an interfacial mesh size of at least 0.05 × 10⁻³ m combined with a coupling time step of 0.0025 s between the electrical-thermal-metallurgical and the mechanical analysis allows a regular incrementation of the contact radius, without burdening the time computing. Accurate values of the contact resistance depending on the interfacial pressure and temperature are essential for a good simulation of the nugget size. The ETMM calculation is successfully extended to the simulation of the welding of a typical two sheets assembly.     

Local zone wise elastic and plastic properties of electron beam welded Ti–6Al–4V alloy using digital image correlation technique: A comparative study between uniform stress and virtual fields method

Joining of materials using welding results in the formation of material zones with varying microstructure across the weld. Extraction of the mechanical properties of those individual heterogeneous zones are important in designing components and structures comprised of welds. In this study, the zone wise local extraction of the elastic and plastic properties of an electron beam welded Ti–6Al–4V titanium alloy has been carried out using both the uniform stress method (USM) and the virtual fields method (VFM) involving digital image correlation (DIC) technique. The surface strain field obtained using DIC technique from a transverse weld specimen tensile testing is used for extracting the zone wise strain evolution. Initially, using uniform stress assumption, zone wise full range stress–strain curves are extracted. In USM methodology, the elastic and plastic material models are fitted to the zone wise stress–strain curves and required parameters are extracted from it. But inherent disadvantage is lot of images need to be processed for the parameter extraction. Recently, VFM is gaining lot of popularity in characterization domain as it is robust, accurate and faster. VFM is based on the principle of virtual work where, the weak form of local equilibrium equations and kinematically admissible virtual displacement fields are utilized for parameter extraction. Hollomon׳s power law is used here as the hardening rule. Young׳s modulus, Poisson׳s ratio, yield stress, strength coefficient and strain hardening exponent are the parameters extracted zone wise using both USM and VFM. A Vicker׳s microhardness measurement is also conducted across the weld zone towards mapping the strength behavior. Fusion zone has reported higher yield strength, strength coefficient and Poisson׳s ratio. Young׳s modulus value is found decreasing from base metal towards the fusion zone. The trend observed in parameter variation across the weld zone obtained by both USM and VFM compares very well. Due to various advantages associated with VFM technique it is generally recommended for parameter extraction.