RAFMs 中厚板TIG 焊下的温度场和应力场研究

应用ANSYS 软件对低活化马氏体/铁素体钢(RAFMs)中厚板多道焊接过程进行三维有限元模拟,将得到的温度场和应力场分别与实验对比,对焊缝区和热影响区宽度进行预测,并通过焊接实验进行验证,同时对焊后的试件进行了金相分析和硬度测试。结果表明：温度场和应力场模拟结果和实测结果基本一致,焊缝区以及热影响区宽度的模拟结果和实测结果基本吻合;采用316L 焊丝填充的焊缝,焊缝与母材熔合较好,焊缝没有明显缺陷;硬度检测呈现：焊缝的硬度大大高于热影响区和母材。     

旁路耦合电弧焊温度场模拟及验证

针对旁路耦合电弧焊的特点, 建立了一种适于用旁路耦合电弧焊的复合热源模型. 利用该热源模型对不同焊接参数下的旁路耦合电弧焊温度场进行了数值分析, 得到了总电流相同时不同旁路电流下的焊缝熔深、母材温度和特征点焊接热循环曲线的模拟结果, 分析了旁路耦合电弧焊焊接参数对母材热输入的影响, 并将特征点热循环曲线的模拟结果与相同条件下的试验结果进行了比较. 结果表明, 焊接总电流相同时母材热输入随着旁路电流的增加而降低, 且越靠近焊缝母材热输入的降幅越大, 特征点焊接热循环曲线的模拟结果与试验结果基本一致, 旁路耦合电弧焊温度场模型是合理的, 所建立的热源模型能够正确反映焊接参数与母材热输入之间的关系.     

聚变堆用CLF-1 钢与316L 钢TIG 焊接接头组织与性能初步研究

对用W19123L 为焊丝的聚变堆用低活化CLF-1 钢与316L 钢的钨极氩弧焊(TIG)焊接接头金相组织及性能进行了初步研究。结果表明：焊接接头成型良好、无缺陷;金相组织表明焊接接头由CLF-1 侧(母材区、热影响区、熔合区)、过渡层、焊缝区、316L 侧(母材区、热影响区、熔合区)组成;室温拉伸试验结果优于母材的最低要求值;弯曲试验后的焊接接头内外表面完好,无裂纹产生,变形均匀;焊接接头冲击值成凹型分布,焊缝区冲击值最低,焊缝两侧热影响区冲击值次之,母材冲击值最高,316L 侧冲击值略高于CLF-1 侧,均满足焊接接头设计值;焊接接头上表面1.6mm 硬度波动较大,略高于1/2T 和下表面1.6mm 处,焊接接头1/2T 和下表面1.6mm 硬度分布较均匀,从CLF-1 侧到316L 侧有下降趋势。整体焊接性能基本稳定,满足异种钢焊接性能匹配要求。     

P92钢焊接接头蠕变损伤的非线性超声检测研究

为解决P92钢焊接接头蠕变损伤的无损检测问题,该文选用温度为650℃、施加应力为95 MPa的加速试验方法,制作不同蠕变时间的试样,对P92钢焊接接头进行蠕变性能试验。采用非线性超声波技术和金相检测对蠕变试样焊接接头各区域进行研究。结果表明:P92钢焊接接头母材、热影响区以及焊缝区域的非线性超声二次谐波幅值在蠕变试验后都呈上升趋势,在热影响区中的增加速率要快于其在母材和焊缝中,P92钢焊接接头热影响区非线性二次谐波参数的变化与蠕变损伤严重程度存在对应关系。该文为开展P92钢焊接接头蠕变损伤的无损检测工程应用打下了坚实的基础。     

等离子弧焊接熔池演变过程的模拟和验证

本文建立了描述等离子弧焊接熔池相变传热与流动的三维数理模型,考虑表面张力、电磁力和浮升力的作用,并针对等离子弧焊接特点,改进组合式体积热源模型,上部采用双椭球热源,下部采用圆锥体热源。重点分析了焊接熔池形状和温度场的演变过程,熔合线的模拟形状与实验焊缝吻合,较好地呈现了焊缝的凸起和熔池宽度,验证了数学模型和热源模型的正确性。本文还进一步开展了焊接功率和焊接速度的影响分析。研究结果表明,流动对焊缝形状的影响不容忽略,而表面张力在三个流动驱动力中占主导地位;焊接功率越大,焊接速度越小,越有利于焊件焊透,数值模拟得到优化的焊接功率和速度有益于实际焊接生产质量及效率。     

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利用单轴热扩散焊设备对中国固态包层模块结构材料CLF-1钢进行了初步的实验研究。实验结果表明,在焊缝界面结合率达到一定程度时,焊件接头的拉伸强度与塑性性能可以达到母材的水平;但焊件接头的冲击韧性则很敏感,其中最好的实验测试值只达到了母材相应值的48%,这与焊缝界面上残留污染物所导致的接头空隙缺陷有关。     

KTX真空室支撑焊接设计及有限元分析

提出了一种KTX 真空室支撑焊接方案,并利用有限元方法模拟计算了焊接温度场分布及焊接残余应力场分布。通过理论分析和有限元分析相结合的方法,对焊缝结构进行了强度分析。分析结果验证了焊接结构的可靠性,并为真空室支撑结构的焊接工艺提供了理论依据。     

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HL-2M真空室的主体材料被选为Inconel 625。通过研究3个产地的Inconel 625母材和焊缝的性能,对比分析了该种材料的各项性能参数。通过比较得到进口Inconel 625母材和焊接接头综合性能均最优。各项试验结果及分析对真空室部件的制造有重要的指导意义。     

特殊构件环焊缝射线检测工艺

激光焊接是利用激光熔化母材本身金属来填充焊缝，因此激光焊缝表面没有余高，并有少许凹陷，由于构件结构的特殊性，有关技术要求焊缝的焊接深度仅为16mm，焊缝宽度不得大于6mm，而实际上焊缝区域的母材厚度约为6-12．5mm变化，焊缝尺寸相对于母材厚度很小，造成焊缝在底片上形成的影像不明显。简体内部密封并以其他材料填充，在进行射线检测时射线不可能采取双壁单影法透照对焊缝实施检测，只能采用单壁单影的透照方法。另外，靠近简体内侧加工有工艺弧度，在射线透射方向上母材厚度有很大变化，     

等离子弧焊接熔池演变过程的格子Boltzmann模拟与验证

本文应用基于分子动理论的格子Boltzmann方法,建立了描述定点等离子弧焊接熔池动态演变过程的二维数理模型,对相变过程的传热与流动现象开展模拟;根据焊接过程能量分布特点改进等离子弧的组合式热源模型,采用total-enthalpy模型求解温度、速度分布及追踪相界面。研究结果表明,模拟的熔合线形状与实验焊缝吻合,格子Boltzmann模拟得到的计算精度及计算效率均优于基于连续流体假设的有限容积法,验证了格子Boltzmann方法用于等离子弧焊接模拟的可行性和优越性;熔池中出现两个方向相反的环流,流动对焊缝形状的作用不容忽略;熔池的流动方式影响了温度场、速度场及二者协同度,直接影响固相线上的热量传递,促进了焊缝中部凸起的形成。     

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A preliminary study of microstructure and properties of the welded joint of low activation CLF-1 steel used for fusion reactor and 316L dissimilar metal by tungsten inert gas (TIG) welding using W19123L as filler material, has been performed. The welded joint forming is proved well and without defect. The welded joint consists of CLF-1 zone [base metal (BM), heat affected zone (HAZ), fusion zone (FZ)], inside layer (IL), weld zone (WZ), and 316L zone (BM, HAZ, FZ). Tensile strength of the joint is better than the base metal minimum value in room temperature. Both surfaces of welded joint are without crack and with deformation uniformity under the bending test. The distribution of impact value of the joint is concave-like and satisfies the designed values for the welded joint, the WZ’s value is the lowest, the HAZ’s of both WZ zones is the second, the BM’s was the best, and the 316L steel zone’s is slightly larger than the CLF-1 zone’s. The hardness values of the point under the 1.6mm top surface of welded joint have a larger fluctuation range, and is slightly higher than those of 1/2T and above down surface 1.6mm position. The hardness distribution of 1/2T and above the down surface 1.6mm position is roughly uniform, and has a downward trend from the CLF-1 zone to 316L zone. Welding properties generally has remained stable and satisfy the requirement of dissimilar steel welding performance matching.     

Experimental investigation and metallographic characterization of fiber laser beam welding of Ti-6Al-4V alloy using response surface method

In the present study, experimental investigations of fiber-laser-beam-welding of 5 mm thick Ti-6Al-4V alloy are carried out based on statistical design of experiments. The relationship between the process parameters such as welding power, welding speed, and defocused position of the laser beam with the output responses such as width of the fusion zone, size of the heat affected zone, and fusion zone area are established in terms of regression models. Also, the most significant process parameters and their optimum ranges are identified and their percentage contributions on output responses are calculated. It is observed that welding power and speed plays the major role for full penetration welding. Also, welding power shows direct effect whereas welding speed shows the inverse effect on the output responses. The bead geometry is influenced by the defocused position of the laser beam due to the change in power density on the workpiece surface. However, overall fusion zone area is unaffected. Mechanical characterization of the welded samples such as microstructural analysis, hardness, and tensile tests are conducted. It is noticed that the hardness value of the FZ is higher than the HAZ and BM zone due to the difference in cooling rate during welding which promotes the formation of α′ martensitic phase in the FZ. Also, an average hardness value in the FZ is compared for two different defocusing positions (i.e. 1 and 2 mm). It is found that hardness value is higher for 1 mm defocused position than 2 mm due the decrement in grain size below a critical range at 2 mm defocused position. The ultimate tensile strength and % elongation of the welded samples are degraded as compared to BM which can be further improved by post heat treatment.     

Using stable isotopes and major ions to identify hydrological processes and geochemical characteristics in a typical karstic basin,Guizhou, southwest China

The investigation of hydrological processes is very important for water resource development in karst basins. In order to understand these processes associated with complex hydrogeochemical evolution, a typical basin was chosen in Houzai, southwest China. The basin was hydrogeologically classified into three zones based on hydrogen and oxygen isotopes as well as the field surveys. Isotopic values were found to be enriched in zone 2 where paddy fields were prevailing with well-developed underground flow systems, and heavier than those in zone 1. Zone 3 was considered as the mixture of zones 1 and 2 with isotopic values falling in the range between the two zones. A conceptual hydrological model was thus proposed to reveal the probable hydrological cycle in the basin. In addition, major processes of long-term chemical weathering in the karstic basin were discussed, and reactions between water and carbonate rocks proved to be the main geochemical processes in karst aquifers.     

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.     

The use of exploratory experimental designs combined with thermal numerical modelling to obtain a predictive tool for hybrid laser/MIG welding and coating processes

While hybrid laser welding and coating processes involve a large number of physical phenomena, it is currently impossible to predict, for a given set of influencing factors, the shape of the molten zone and the history of temperature fields inside the parts. This remains true for complex processes, such as the hybrid laser/MIG welding process, which consists in combining a laser beam with a MIG torch. The gains obtained result essentially from the synergy of the associated processes: the stability of the process, the quality of the seam realized, and the productivity are increased. This article shows how, by means of a reduced number of experiments (8), it is possible to predict the shape of the molten zone and the temperature field inside parts, for a given window of influencing factors. This method consists in combining the method of exploratory experimental designs with a numerical modelling of the thermal phenomena that occurs during the process, by using the ‘heat equivalent source” approach [1], [2], [3], [4]. Two validations of this method have been carried out: the first for a set of parameters inside the experimental design, and the other for a set of parameters that lies outside the experimental design, but inside the domain investigated.     

Modeling heat-transfer processes of resistance spot welding

Heat-transfer processes are considered for a model of resistance spot welding. Both numerical and analytical solutions to the heat conduction equation are obtained. Thermal fields are calculated. Welding parameters for low-carbon steel are found.     

Ultrasonic butt welding of aluminum,aluminum alloy and stainless steel plate specimens

Welding characteristics of aluminum, aluminum alloy and stainless steel plate specimens of 6.0 mm thickness by a 15 kHz ultrasonic butt welding system were studied. There are no detailed welding condition data of these specimens although the joining of these materials are required due to anticorrosive and high strength characteristics for not only large specimens but small electronic parts especially. These specimens of 6.0 mm thickness were welded end to end using a 15 kHz ultrasonic butt welding equipment with a vibration source using eight bolt-clamped Langevin type PZT transducers and a 50 kW static induction thyristor power amplifier. The stainless steel plate specimens electrolytically polished were joined with welding strength almost equal to the material strength under rather large vibration amplitude of 25 microm (peak-to-zero value), static pressure 70 MPa and welding time of 1.0-3.0 s. The hardness of stainless steel specimen adjacent to a welding surface increased about 20% by ultrasonic vibration.     

Interface microstructure and mechanical properties of laser welding copper–steel dissimilar joint

Relatively the high reflectivity of copper to CO₂ laser led to the difficulty in joining copper to steel using laser welding. In this paper, a new method was proposed to complete the copper–steel laser butt welding. The scarf joint geometry was used, i.e., the sides of the copper and steel were in obtuse and acute angles, respectively. During the welding process, the laser beam was fixed on the steel side and the dilution ratio of copper to steel was controlled by properly selecting the deviation of the laser beam. The offset of laser beam depended on the scarf angle between the copper and steel, the thickness of plate and the processing parameters used in the laser welding. The microstructure near the interface between Cu plate and the intermixing zone was investigated. Experimental results showed that for the welded joint with high dilution ratio of copper, there was a transition zone with numerous filler particles near the interface. However, if the dilution ratio of copper is low, the transition zone is only generated near the upper side of the interface. At the lower side of the interface, the turbulent bursting behavior in the welding pool led to the penetration of liquid metal into Cu. The welded joint with lower dilution ratio of copper in the fusion zone exhibited higher tensile strength. On the bases of the microstructural evaluation at the interface of the welded joint, a physical model was proposed to describe the formation mechanism of the dissimilar joint with low dilution ratio of copper.