A two-dimensional axisymmetric model is established to study the effect of electrode change on the solidification of slag and metal pool profile during electroslag remelting process.The basic considerations of flow an...A two-dimensional axisymmetric model is established to study the effect of electrode change on the solidification of slag and metal pool profile during electroslag remelting process.The basic considerations of flow and heat transfer are included in the model,and the growth of ingot is described by the dynamic mesh technique.The electrode melting rate is predicted based on the transient thermal conductivity model between slag and electrode.The results indicate that in the electrode change stage,the slag temperature drops from 1847 to 1763 K gradually and the“hot heart”phenomenon is observed.And the metal pool profile is slightly changed with a depth decrease from 0.3984 to 0.3688 m.In the heating and melting stage of new electrode,the maximum slag temperature firstly increases from 1763 to 1892 K,then decreases to 1845 K,and finally at 3558 s,the maximum slag temperature is stable at 1884 K.Solidified slag shell with a maximum volume of 7.31×10^(-3) m^(3) is formed at the electrode tip,and then,the solidified slag melts completely.The depth of metal pool firstly rises to 0.3700 m and then drops to 0.3565 m.As the preheating temperature of the new electrode increases from 473 to 973 K,the maximum volume of solidified slag decreases from 0.00748 to 0.00592 m^(3),and the time from heating to melting of the new electrode decreases from 996 to 887 s.展开更多
The metal transfer mode of electron beam welding （EBW） with filler wire was studied experimentally. The spatial position between the electron beam and the filler wire was defined. Basing on the charge coupled device...The metal transfer mode of electron beam welding （EBW） with filler wire was studied experimentally. The spatial position between the electron beam and the filler wire was defined. Basing on the charge coupled device （CCD） visual sensing system, the metal transfer mode of filler wire was investigated. The results showed that there were five transfer modes during EBW process due to different wire feed rates and spatial positions between beam and filler wire, such as short-circuiting mode, molten metal bridge mode, small droplet mode, big droplet mode and mixed mode. By comparing the weld appearance of different transfer modes, the molten metal bridge transfer was proved to be the best transfer mode.展开更多
The welding deviation detection is the basis of robotic tracking welding, but the on-line real-time measurement of welding deviation is still not well solved by the existing methods. There is plenty of information in ...The welding deviation detection is the basis of robotic tracking welding, but the on-line real-time measurement of welding deviation is still not well solved by the existing methods. There is plenty of information in the gas metal arc welding（GMAW） molten pool images that is very important for the control of welding seam tracking. The physical meaning for the curvature extremum of molten pool contour is revealed by researching the molten pool images, that is, the deviation information points of welding wire center and the molten tip center are the maxima and the local maxima of the contour curvature, and the horizontal welding deviation is the position difference of these two extremum points. A new method of weld deviation detection is presented, including the process of preprocessing molten pool images, extracting and segmenting the contours, obtaining the contour extremum points, and calculating the welding deviation, etc. Extracting the contours is the premise, segmenting the contour lines is the foundation, and obtaining the contour extremum points is the key. The contour images can be extracted with the method of discrete dyadic wavelet transform, which is divided into two sub contours including welding wire and molten tip separately. The curvature value of each point of the two sub contour lines is calculated based on the approximate curvature formula of multi-points for plane curve, and the two points of the curvature extremum are the characteristics needed for the welding deviation calculation. The results of the tests and analyses show that the maximum error of the obtained on-line welding deviation is 2 pixels（0.16 ram）, and the algorithm is stable enough to meet the requirements of the pipeline in real-time control at a speed of less than 500 mm/min. The method can be applied to the on-line automatic welding deviation detection.展开更多
The selection of narrow band filter＇s center wavelength has an important influence on the quality of the weld pool image captured in passive vision mettmd for controlling arc welding process. In this paper, 29 narrow...The selection of narrow band filter＇s center wavelength has an important influence on the quality of the weld pool image captured in passive vision mettmd for controlling arc welding process. In this paper, 29 narrow band filters with different center wavelengths ranging from ultraviolet to near infrared wavelength were used to capture images of weld pool during both the peak current period and the base current period of P-GMA W （ pulsed gas metal arc welding）. The experimental results showed that the filters with near infrared center wavelength could weaken the arc most during the peak current period, while during the base current period the entire weld pool could be seen with the filters with wavelength above 600 nm. The camera spectral response and the radio of arc to weld pool emission were considered to analyze the phenomenon of experimental results.展开更多
It is difficult to acquire satisfied weld pool image by CCD sensor during gas metal arc welding（ GMAW） , for arc disturbs violently, welding current is great and working frequency is high. By using CMOS vision senso...It is difficult to acquire satisfied weld pool image by CCD sensor during gas metal arc welding（ GMAW） , for arc disturbs violently, welding current is great and working frequency is high. By using CMOS vision sensor to GMA W process, the vivid weld pool image is collected at any time, furthermore, whose gray compression ratio is controllable by sensor hardware circuit developed. Acquired weld pool image is firstly pre-processed by using Wiener filter and Ostu threshold segmentation algorithm. Subsequently separation between weld pool image and cathode mist region is conducted by means of mathematical morphological algorithm, and the edge of weld pool image is extracted by using Prewitt algorithm.展开更多
基金This project is supported by the National Natural Science Foundation of China(Grant Nos.52171031 and 52104324)the Fundamental Research Funds for the Central Universities(Grant No.N2025020).
文摘A two-dimensional axisymmetric model is established to study the effect of electrode change on the solidification of slag and metal pool profile during electroslag remelting process.The basic considerations of flow and heat transfer are included in the model,and the growth of ingot is described by the dynamic mesh technique.The electrode melting rate is predicted based on the transient thermal conductivity model between slag and electrode.The results indicate that in the electrode change stage,the slag temperature drops from 1847 to 1763 K gradually and the“hot heart”phenomenon is observed.And the metal pool profile is slightly changed with a depth decrease from 0.3984 to 0.3688 m.In the heating and melting stage of new electrode,the maximum slag temperature firstly increases from 1763 to 1892 K,then decreases to 1845 K,and finally at 3558 s,the maximum slag temperature is stable at 1884 K.Solidified slag shell with a maximum volume of 7.31×10^(-3) m^(3) is formed at the electrode tip,and then,the solidified slag melts completely.The depth of metal pool firstly rises to 0.3700 m and then drops to 0.3565 m.As the preheating temperature of the new electrode increases from 473 to 973 K,the maximum volume of solidified slag decreases from 0.00748 to 0.00592 m^(3),and the time from heating to melting of the new electrode decreases from 996 to 887 s.
文摘The metal transfer mode of electron beam welding （EBW） with filler wire was studied experimentally. The spatial position between the electron beam and the filler wire was defined. Basing on the charge coupled device （CCD） visual sensing system, the metal transfer mode of filler wire was investigated. The results showed that there were five transfer modes during EBW process due to different wire feed rates and spatial positions between beam and filler wire, such as short-circuiting mode, molten metal bridge mode, small droplet mode, big droplet mode and mixed mode. By comparing the weld appearance of different transfer modes, the molten metal bridge transfer was proved to be the best transfer mode.
基金Supported by National Natural Science Foundation of China(Grant Nos.51275051,51505035)National Hi-tech Research and Development Program of China(863 Program,Grant No.2009AA04Z208)Beijing Education Commission Innovation Ability Upgrade Program of China(Grant No.TJSHG201510017023)
文摘The welding deviation detection is the basis of robotic tracking welding, but the on-line real-time measurement of welding deviation is still not well solved by the existing methods. There is plenty of information in the gas metal arc welding（GMAW） molten pool images that is very important for the control of welding seam tracking. The physical meaning for the curvature extremum of molten pool contour is revealed by researching the molten pool images, that is, the deviation information points of welding wire center and the molten tip center are the maxima and the local maxima of the contour curvature, and the horizontal welding deviation is the position difference of these two extremum points. A new method of weld deviation detection is presented, including the process of preprocessing molten pool images, extracting and segmenting the contours, obtaining the contour extremum points, and calculating the welding deviation, etc. Extracting the contours is the premise, segmenting the contour lines is the foundation, and obtaining the contour extremum points is the key. The contour images can be extracted with the method of discrete dyadic wavelet transform, which is divided into two sub contours including welding wire and molten tip separately. The curvature value of each point of the two sub contour lines is calculated based on the approximate curvature formula of multi-points for plane curve, and the two points of the curvature extremum are the characteristics needed for the welding deviation calculation. The results of the tests and analyses show that the maximum error of the obtained on-line welding deviation is 2 pixels（0.16 ram）, and the algorithm is stable enough to meet the requirements of the pipeline in real-time control at a speed of less than 500 mm/min. The method can be applied to the on-line automatic welding deviation detection.
基金Acknowledgement The authors are grateful to the financial support for this project from the National Natural Science Foundation of China under grant No. 51005069.
文摘The selection of narrow band filter＇s center wavelength has an important influence on the quality of the weld pool image captured in passive vision mettmd for controlling arc welding process. In this paper, 29 narrow band filters with different center wavelengths ranging from ultraviolet to near infrared wavelength were used to capture images of weld pool during both the peak current period and the base current period of P-GMA W （ pulsed gas metal arc welding）. The experimental results showed that the filters with near infrared center wavelength could weaken the arc most during the peak current period, while during the base current period the entire weld pool could be seen with the filters with wavelength above 600 nm. The camera spectral response and the radio of arc to weld pool emission were considered to analyze the phenomenon of experimental results.
文摘It is difficult to acquire satisfied weld pool image by CCD sensor during gas metal arc welding（ GMAW） , for arc disturbs violently, welding current is great and working frequency is high. By using CMOS vision sensor to GMA W process, the vivid weld pool image is collected at any time, furthermore, whose gray compression ratio is controllable by sensor hardware circuit developed. Acquired weld pool image is firstly pre-processed by using Wiener filter and Ostu threshold segmentation algorithm. Subsequently separation between weld pool image and cathode mist region is conducted by means of mathematical morphological algorithm, and the edge of weld pool image is extracted by using Prewitt algorithm.
