Numerical simulation of filler metal droplets spreading in laser brazing

A finite element model was constructed using a commercial software Fidap to analyze the Cu-base filler metal droplet spreading process in laser brazing,in which the temperature distribution,droplet geometry, and fluid flow velocity were calculated.Marangoni and buoyancy convection and gravity force were considered,and the effects of laser power and spot size on the spreading process were evaluated.Special attention was focused on the free surface of the droplet,which determines the profile of the brazing spot. The simulated results indicate that surface tension is the dominant flow driving force and laser spot size determines the droplet spreading domain.     

基于自动阈值的窄间隙端接焊缝识别技术

特征点提取是焊缝视觉检测与定位的关键技术,特别是针对实际生产中间隙较小,尤其是超窄间隙的焊缝位置,现阶段的处理算法往往无法保证提取精度,误差大;对于一些间隙极小的细节位置甚至会自动忽略。本文针对端接接头提出一种基于自动阈值处理的自适应中值滤波算法和特征点提取算法对激光扫描图像进行处理的焊缝识别技术:在传统的中值滤波法的基础上,通过计算局部数据点的均值和方差确定有效阈值范围,在剔除噪声点的同时很好地保护了焊缝图像窄间隙细节特征;提出一种"细节放大"的特征点提取算法,将图像细节进行放大,增大窄间隙特征点与周围数据点的差异,显著降低提取难度;利用特征点时域分析,进一步将误差减小到原来的1/5~(1/2)。结果表明,本文方法能准确识别0.1~0.5mm之间的窄间隙焊缝,具有提取精度高、误差小(0.08mm)、抗干扰能力强等优点,对于实现较小间隙焊缝的自动化焊接具有重要意义。     

Influence of shielding gas pressure on welding characteristics in CO2 laser-MIG hybrid welding process

The droplet transfer behavior and weld characteristics have been investigated under different pressures of shielding gas in CO2 laser and metal inert/active gas (laser-MIG) hybrid welding process. The experimental results indicate that the inherent droplet transfer frequency and stable welding range of conventional MIG arc are changed due to the interaction between CO2 laser beam and MIG arc in laser-MIG hybrid welding process, and the shielding gas pressure has a crucial effect on welding characteristics. When the pressure of shielding gas is low in comparison with MIG welding, the frequency of droplet transfer decreases, and the droplet transfer becomes unstable in laser-MIG hybrid welding. So the penetration depth decreases, which shows the characteristic of unstable hybrid welding. However, when the pressure of shielding gas increases to a critical value, the hybrid welding characteristic is changed from unstable hybrid welding to stable hybrid welding, and the frequency of droplet transfer and the penetration depth increase significantly.