引入6波段P-1辐射模型的三维空气电弧等离子体数值分析

引入了6波段P-1辐射模型,对三维空气电弧等离子体进行了仿真分析.其特点是不仅考虑了热辐射的发射问题,同时考虑了等离子体内热辐射的自吸收问题.通过计算获得了空气电弧等离子体温度和辐射能量的分布并进行了相应的分析.与净辐射系数方法相比较,P-1模型获得的温度分布较宽,其弧柱电压值更接近于实验测量值.研究表明,6波段P-1辐射模型能够更精确地求解空气电弧等离子体的辐射问题. 关键词： 热辐射 P-1模型 空气电弧等离子体 磁流体动力学     

等离子弧焊接多物理场耦合输运模型

本文基于电场、磁场、温度场和流场的多物理场耦合,建立了简单实用的电弧与工件一体化模型,既准确表征等离子弧焊接过程中的多物理场输运作用,又无需使用流体体积函数(VOF)计算气液两相界面,大大减少计算时间和成本。模型计算出电弧压力分布,将其简化为压力源项作用于工件表面,同时该界面上电弧与工件耦合传热,实现了电弧与工件的热-力传递。获得了焊接过程电弧和工件的温度、速度、电流密度和电磁力的分布规律,揭示了焊接熔池的形成和演变机制,并开展实验验证了模型的准确性。最后分析了不同工艺参数对电弧热流密度和压力的影响规律,为焊接质量优化提供理论指导。     

毛细管准直微束过程模拟与微束品质分析

利用GEANT4程序对复旦大学单粒子微束的毛细管准直过程进行了蒙特卡罗模拟。计算结果表明:当前采用的1 m孔径、1 mm长度的毛细玻璃管准直器能够引出峰值能量2.2 MeV、能量分辨130 keV、束径2.4 m的质子微束,可达到装置对微束能量与束径分辨的设计指标,从理论上明确了毛细管准直微束引出的可行性。针对影响入射目标细胞微束品质的主要因素,分析了微束品质与准直系统和入射束流各状态参数的依赖关系,为毛细管准直微束的引出与优化提供了必要的理论依据。     

毛细管准直微束过程模拟与微束品质分析

利用GEANT4程序对复旦大学单粒子微束的毛细管准直过程进行了蒙特卡罗模拟。计算结果表明：当前采用的1 m孔径、1 mm长度的毛细玻璃管准直器能够引出峰值能量2.2 MeV、能量分辨130 keV、束径2.4 m的质子微束,可达到装置对微束能量与束径分辨的设计指标,从理论上明确了毛细管准直微束引出的可行性。针对影响入射目标细胞微束品质的主要因素,分析了微束品质与准直系统和入射束流各状态参数的依赖关系,为毛细管准直微束的引出与优化提供了必要的理论依据。     

活性剂等离子弧焊焊接电弧的光谱与热分析

针对活性剂等离子弧焊焊接过程,利用光谱分析方法对活性剂等离子弧焊焊接电弧进行光谱分析,采用红外热像伪着色法测定活性剂等离子弧焊焊接电弧温度场,并建立活性剂等离子弧焊焊接电弧热流密度径向分布模型,对焊接电弧的成分及焊接电弧温度场进行了研究。研究结果表明,常规等离子焊焊接电弧以氩原子和氩一次电离离子的谱线为主,金属蒸气谱线不突出,焊接电弧以气体粒子为主,属于气体电弧;活性剂等离子弧焊焊接电弧的光谱中氩原子及氩一次离子谱线的辐射强度增强,Ti,Cr,Fe金属谱线大量涌现;活性剂等离子弧焊焊接电弧的温度分布比较紧凑,温度场外形窄,温度分布范围较集中,电弧径向温度梯度较大;电弧径向温度分布呈现正态Gauss分布模式。     

电弧及辉光微等离子体大气压取样的发射光谱研究

在线化学分析需要实现开放环境下的样品取样和电离/激发。相比于激光切削或者激光诱导击穿,大气压微等离子体系统结构简单,更利于小型化。因而基于大气压微等离子体的在线化学分析技术引起行业的广泛关注。为了确定合适的微等离子体源进行样品的在线元素检测,需要进一步了解各放电模式及工作参数下微等离子体的自身特性以及取样效果。该工作主要研究了电弧及辉光放电微等离子体在大气压下对样品铁取样发射光谱的特性。实现了在开放环境下对高熔点金属样品的在线检测,并发现电弧放电微等离子体与光谱分析源联用具有更高的取样效率。高采样效率的电弧放电微等离子体源为实现金属及难解离样品的检测提供了一种新的方法。同时,相较于传统的取样装置,避免了复杂的样品制备、样品传输过程。实验装置采取简单的针对板放电结构,分别利用高压脉冲电源、直流电源获得电弧放电和辉光放电。实验的结果表明,在放电功率近似相等的条件下,电弧放电产生的微等离子体对样品铁取样的光学发射谱中,样品元素的特征谱线占据主导地位,同时伴随有空气中氮气的谱线,而且铁离子(FeⅡ)谱线的相对强度显著高于氮气分子谱线的相对强度。而在直流辉光放电中,样品铁原子(FeⅠ)谱线相对强度非常不明显。由此说明,电弧放电产生的微等离子体具有更高的采样效率。放电在样品表面留下的溅射坑也得出了相同的结论。增加辉光放电电流到25 mA,发现样品元素铁的谱线仍然没有明显的增强。同时,也研究了采样间距对两种采样模式的影响。实验结果表明,间距对两种模式的采样光谱没有显著的影响。采用主要成分为铝的合金铝箔进行了上述对比实验,得出相同的结论,即电弧放电微等离子体更适合作为光谱分析源来实现对金属样品的实时快速检测。     

基于COMSOL 的感应耦合等离子体炬多物理场研究

为了优化锂微粉等离子体球化的工艺,对感应耦合等离子体炬进行二维建模,将电磁场计算域扩展到等离子体放电区域之外的空气区域,利用COMSOL 软件进行多物理场模拟。得到了等离子体的电磁场、温度和速度分布,并对分布形成的物理机制进行分析。模拟发现等离子体区域线圈段存在上下两组对称的回流涡,线圈段中部靠近约束管处等离子体速度分布杂乱,有激烈的径向打壁现象,乱流预计会对约束管壁相应位置造成一条环状的破裂效果。基于模拟结果,提出在采用感应耦合等离子体球化锂微粉的工艺工程中,可以将注粉口下移,绕开上回流涡。     

激光—双丝复合焊接电弧等离子体温度计算及耦合机理分析

采用光纤式光谱仪,对激光—双丝脉冲MIG复合焊接电弧等离子体辐射规律进行探讨,结合焊接过程中的高速摄像图片探讨激光与电弧的耦合机理,并运用Boltzmann图法计算出电弧等离子体的电子温度。结果表明,加入激光后,电弧的亮度提高,辐射增强,电弧偏向激光作用位置,同时电弧收紧,电弧截面减小,电弧稳定性增强;激光功率、焊接电流和焊丝间距对电弧等离子体温度有比较大的影响,随着激光功率的增加、焊接电流增大和焊丝间距的减小,电弧等离子体电子温度升高。     

多束速调管频宽特性的初步分析

 介绍了多束速调管的结构特点和一些特性估计。对柱型输出腔,利用正交模分析的方法,导出了输出腔耦合系数的近似式,对多束速调管的频宽特性进行了初步分析。多束速调管输出效率和频宽的乘积的增加完全依赖束导流系数的增加,而耦合系数和腔特性阻抗随电子束束数的增加而降低,但降低速度较慢,因此,多束速调管的效率与频宽的乘积较单束要大。     

多束速调管频宽特性的初步分析

介绍了多束速调管的结构特点和一些特性估计。对柱型输出腔,利用正交模分析的方法,导出了输出腔耦合系数的近似式,对多束速调管的频宽特性进行了初步分析。多束速调管输出效率和频宽的乘积的增加完全依赖束导流系数的增加,而耦合系数和腔特性阻抗随电子束束数的增加而降低,但降低速度较慢,因此,多束速调管的效率与频宽的乘积较单束要大。     

Approximate entropy a new statistic to quantify arc and welding process stability in short-circuiting gas metal arc welding

Based on the phase state reconstruction of welding current in short-circuiting gas metal arc welding using carbon dioxide as shielding gas, the approximate entropy of welding current as well as its standard deviation has been calculated and analysed to investigate their relation with the stability of electric arc and welding process. The extensive experimental and calculated results show that the approximate entropy of welding current is significantly and positively correlated with arc and welding process stability, whereas its standard deviation is correlated with them negatively. A larger approximate entropy and a smaller standard deviation imply a more stable arc and welding process, and vice versa. As a result, the approximate entropy of welding current promises well in assessing and quantifying the stability of electric arc and welding process in short-circuiting gas metal arc welding.     

基于DSP的氩弧焊焊池实时监控图像分析技术

针对氩弧焊的特性，利用机器视觉技术实现了一种对氩弧焊熔池宽度进行测量的实时视频测量分析系统。在焊池宽度测量中采用了基于DSP的图像分析技术，不仅保证了测量精度，而且提高了系统的实时性。实验表明：该系统对氩弧焊焊池宽度测量精度高（10μm），响应时间快（50ms）。这种在线式氩弧焊监控系统相对于离线式氩弧焊产品来说，在加工产品的质量控制效果以及成本上都有更大的优势，非常适合流水线上不间断的高质量焊接加工，具有良好的应用前景。     

双面电弧焊接的传热模型

将等离子焊接(PAW)电弧和钨极氩弧焊(TIG)电弧串接,相对作用于工件的正反面形成双面电弧焊接(DSAW)系统,可以引导焊接电流沿工件厚度方向流过小孔,补偿等离子电弧穿透工件时消耗的能量,以有效地提高等离子弧的穿透能力.综合考虑影响双面电弧焊接正反面熔池几何形状的力学因素,建立了熔池表面变形的控制方程,以此为基础并采用帖体曲线坐标系建立了DSAW焊接传热的数学模型,分析了DSAW,PAW焊接传热的差异,从传热的角度解释了DSAW焊接熔深增加的原因.焊接工艺实验表明,计算结果与实测结果吻合良好. 关键词： 双面电弧焊接(DSAW) 传热模型 熔池表面变形模型     

Comparative study on interactions between laser and arc plasma during laser-GTA welding and laser-GMA welding

This paper describes an investigation on differences in interactions between laser and arc plasma during laser-gas tungsten arc (LT) welding and laser-gas metal arc (LM) welding. The characteristics of LT heat source and LM heat source, such as plasma behavior, heat penetration ability and spectral information were comparably studied. Based on the plasma discharge theory, the interactions during plasma discharge were modeled and analyzed. Results show that in both LT and LM welding, coupling discharge between the laser keyhole plasma and arc happens, which strongly enhance the arc. But, the enhancing effect in LT welding is much more sensitive than that in LM welding when parameters are adjusted.     

脉冲电流作用下TIG电弧的数值分析

建立了脉冲电流下自由燃烧的TIG电弧的二维轴对称数学模型,利用FLUENT软件,通过选择合适的边界条件和强烈耦合控制方程组对脉冲TIG电弧进行了数值模拟,得到了在焊接电流周期性变化下电弧形态、电弧温度场、电弧轴线方向上的温度和速度及焊接工件表面电弧压力的变化情况;针对电弧压力,得到了不同峰值电流、占空比、脉冲频率作用下的分布情况,并分析了它们在脉冲电流作用下的周期性变化规律.分析结果表明:当脉冲电流发生突变时,它们的变化滞后于脉冲电流的变化,且从基值电流向峰值电流变化时的响应速度更快,并最终达到一个相对稳 关键词： 脉冲TIG焊 电弧 数值模拟 FLUENT     

磁旋转弧等离子体中的弧电压突变现象

利用光学成像系统观察到了磁旋转弧等离子体实验中的电弧电压突变现象,电弧电压突变的范围约在40～100V之间。实验结果表明,电弧电压的变化与电弧弧长的变化密切相关。     

Effects of relative positioning of energy sources on weld integrity for hybrid laser arc welding

This study is concerned with the effects of laser and arc arrangement on weld integrity for the hybrid laser arc welding processes. Experiments were conducted for a high-strength steel using a 4 kW Nd: YAG laser and a metal active gas (MAG) welding facility under two configurations of arc–laser hybrid welding (ALHW) and laser–arc hybrid welding (LAHW). Metallographic analysis and mechanical testing were performed to evaluate the weld integrity in terms of weld bead geometry, microstructure and mechanical properties. The morphology of the weld bead cross-section was studied and the typical macrostructure of the weld beads appeared to be cone-shaped and cocktail cup-shaped under ALHW and LAHW configurations, respectively. The weld integrity attributes of microstructure, phase constituents and microhardness were analyzed for different weld regions. The tensile and impact tests were performed and fracture surface morphology was analyzed by scanning electron microscope. The study showed that ALHW produced joints with a better weld shape and a more uniform microstructure of lath martensite, while LAHW weld had a heterogeneous structure of lath martensite and austenite.     

Self-lubricative coating grown by micro-plasma oxidation on aluminum alloys in the solution of aluminate-graphite

Aluminum trioxide ceramic coatings with high hardness were grown on surfaces of 2024 Aluminum alloys by micro-plasma oxidation in an aluminate electrolytic solution, which highly improve wear-resisting properties of 2024 Aluminum alloys. However, ceramic coating surfaces are porous and very coarse, which is disadvantageous to practical applications. In this paper, in order to increase the density of the pores and decrease the friction coefficient of the ceramic coatings, different concentrations (2-8 g/l) of graphite were added into the aluminate electrolytic solution. The thickness and hardness of the produced ceramic coatings were measured by HVS-100 micro-hardness tester and thickness tester. The friction coefficient of the coatings was studied by a frictionometer. The phase composition and surface morphology of the MPO films were evaluated through X-ray diffraction (XRD) and scanning electron microscope (SEM). The results show that the thickness of the ceramic coating is about 22 ± 1 μm, surfaces of the ceramic coatings are very uniform and that the coatings consist of mainly aluminum trioxides and a certain amount of graphite, which indicates graphite have entered the ceramic films during the micro-plasma oxidation process. Wear properties results show that the friction coefficient of the ceramic coatings decreased when graphite entered the ceramic films. When the concentration of graphite is 4 g/l, the wear properties of the coatings is the most excellent and the friction coefficient decreases to the lowest, that is 0.09.     

Observation of the mechanisms causing two kinds of undercut during laser hybrid arc welding

Two different kinds of undercut were identified when laser hybrid welding hot rolled HSLA-steel in either the as-rolled condition or with the top surface mill scale removed. The presence of mill scale on the steel surface was found to give a sharp angled undercut combined with a sharp oxide inclusion at the edge of the weld which would have the same mechanical effect as a crack in this position. Removal of the surface oxides before welding resulted in the elimination of the oxide inclusions and a more rounded undercut geometry indicative of superior mechanical properties, particularly fatigue life. The mechanisms of the formation of both types of undercut have been analysed by high speed photography and SEM.     

Effect of acoustic field parameters on arc acoustic binding during ultrasonic wave-assisted arc welding

As a newly developed arc welding method, power ultrasound has been successfully introduced into arc and weld pool during ultrasonic wave-assisted arc welding process. The advanced process for molten metals can be realized by utilizing additional ultrasonic field. Under the action of the acoustic wave, the plasma arc as weld heat source is regulated and its characteristics make an obvious change. Compared with the conventional arc, the ultrasonic wave-assisted arc plasma is bound significantly and becomes brighter. To reveal the dependence of the acoustic binding force on acoustic field parameters, a two-dimensional acoustic field model for ultrasonic wave-assisted arc welding device is established. The influences of the radiator height, the central pore radius, the radiator radius, and curvature radius or depth of concave radiator surface are discussed using the boundary element method. Then the authors analyze the resonant mode by this relationship curve between acoustic radiation power and radiator height. Furthermore, the best acoustic binding ability is obtained by optimizing the geometric parameters of acoustic radiator. In addition, three concave radiator surfaces including spherical cap surface, paraboloid of revolution, and rotating single curved surface are investigated systematically. Finally, both the calculation and experiment suggest that, to obtain the best acoustic binding ability, the ultrasonic wave-assisted arc welding setup should be operated under the first resonant mode using a radiator with a spherical cap surface, a small central pore, a large section radius and an appropriate curvature radius.