The blind-hole method is the most widely used approach to experimentally determine the distribution of residual stress. This paper aims to improve test accuracy of welding residual stress and conducts an experimental ...The blind-hole method is the most widely used approach to experimentally determine the distribution of residual stress. This paper aims to improve test accuracy of welding residual stress and conducts an experimental study on the strain release factors involved when using the blind-hole method for Q235 and Q345, two steels commonly used in building structures. The ranges of strain release factors A and B in the elastic stage, the effects of strain release factors on residual stress calculated values, and the plastic corrected strain release factors are analyzed considering of the effect of plastic deformation around the blind hole on measurement accuracy. Finally, a simplified calculation formula to determine strain release factors is proposed for use with the blind-hole method. Results show that in the elastic stage, strain release factor A for Q235 and Q345 ranges from-0.399 to-0.525 and strain release factor B from-0.791 to-0.960. Changing the strain release factors A and B shows that calculated residual tensile stress varies in relation to a decrease in both factor values. However, there is a increase in calculated residual compressive stress with a decrease in the strain release factor A value, but there is an decrease with a decrease in strain release factor B value. Calculated residual stress applied to elastic strain release factors is compared with that applied to amended plastic strain release factors for Q235 steel. The maximum deviation between calculated residual stress and test stress is reduced from 21.1 to 1.0%,and for Q345 steel from 26.5 to 1.2%. It is thus evident that the plastic correction formula proposed in this paper can be used in calculations when conducting a residual stress test.展开更多
A new type control method in friction welding is suggested in this pa- per,that is compositive control method of friction torque and friction time,it called Mt control method for short.The principle of Mt control meth...A new type control method in friction welding is suggested in this pa- per,that is compositive control method of friction torque and friction time,it called Mt control method for short.The principle of Mt control method and its feature are concisely explained.展开更多
Copper was surfaced on the Q235 substrate by shielded metal arc welding （SMAW） and tungsten inert-gas （TIG） arc welding, the regularity of iron element in deposited metal was analyzed by metallograph, scanning ele...Copper was surfaced on the Q235 substrate by shielded metal arc welding （SMAW） and tungsten inert-gas （TIG） arc welding, the regularity of iron element in deposited metal was analyzed by metallograph, scanning electron microscopy and energy disperse spectroscopy. The results indicate that with the increase of SMA W welding speed, the iron content decreases and the granular or spherical iron becomes more bulky in the overlay. The iron content obviously decreases with the increase of surfacing layers＇ numbers in multilayer welding because of the substrate dilution. On the third layer, the microstrueture of deposited metal is single-phase e-copper. Under the influence of welding methods, the granular or spherical crystal morphology is more likely to form in SMAW for the more divergent arc heat, but is dendrite in TIG welding because of centralized arc energy.展开更多
Considering the limitation of computational capacity, a new finite element solution is used to simulate the welding deformation of the side sill of railroad car＇ s bogie frame based on the local-global method. Firstl...Considering the limitation of computational capacity, a new finite element solution is used to simulate the welding deformation of the side sill of railroad car＇ s bogie frame based on the local-global method. Firstly, a volumetric heat source defined by a double ellipsoid is adopted to simulate the thermal distributions of the arc welding process. And then, the local models extracted from the global model are computed with refined meshes. On these bases, the global distortions of the subject studied are ascertained by transferring the inner forces of computed local models to the global model. It indicates that the local-global method is feasible for simulating the large welded structures by comparing the computed results with the corresponding actual measured values. The work provides basis for optimizing the welding sequence and clamping conditions, and has theoretical values and engineering significance in the integral design, manufacturing technique selection of the bogie frame, as well as other kinds of large welded structures.展开更多
This study investigated multi-response optimization of the pulse metal active gas-tungsten inert gas( PMAG-TIG) twin arc hybrid root welding process for an optimal parametric combination to yield favorable back bead g...This study investigated multi-response optimization of the pulse metal active gas-tungsten inert gas( PMAG-TIG) twin arc hybrid root welding process for an optimal parametric combination to yield favorable back bead geometry of welded joints using grey relational analysis and Taguchi method.Eighteen experimental runs based on an orthogonal array following the Taguchi method were performed to derive objective functions to be optimized within the experimental domain.The objective functions were selected in relation to parameters of PMAG-TIG twin arc root welding back bead geometry: back bead width to root reinforcement ratio and deposited metal height.The Taguchi approach was followed by grey relational analysis to solve the multi-response optimization problem.The significance of factors on overall quality characteristics of the weld joint was also evaluated quantitatively using analysis of variance.Optimal results were verified through additional experiments,and showed to feasibility of applying grey relation analysis in combination with Taguchi technique for continuous improvement of product quality in the manufacturing industry.展开更多
In order to obtain a high-quality weld during the laser welding process, extracting the characteristic parameters of weld pool is an important issue for automated welding. In this paper, the type 304 austenitic stainl...In order to obtain a high-quality weld during the laser welding process, extracting the characteristic parameters of weld pool is an important issue for automated welding. In this paper, the type 304 austenitic stainless steel is welded by a 5 kW high-power fiber laser and a high-speed camera is employed to capture the topside images of weld pools. Then we propose a robust visual-detection approach for the molten pool based on the supervised descent method. It provides an elegant framework for representing the outline of a weld pool and is especially efficient for weld pool detection in the presence of strong uncertainties and disturbances. Finally, welding experimental results verified that the proposed approach can extract the weld pool boundary accurately, which will lay a solid foundation for controlling the weld quality of fiber laser welding process.展开更多
This paper introduced the basic theory and algorithm of the surrogate data method, which proposed a rigorous way to detect the random and seemingly stochastic characteristics in a system. The Gaussian data and the Ros...This paper introduced the basic theory and algorithm of the surrogate data method, which proposed a rigorous way to detect the random and seemingly stochastic characteristics in a system. The Gaussian data and the Rossler data were used to show the availability and effectivity of this method. According to the analysis by this method based on the short-circuiting current signals under the conditions of the same voltage and different wire feed speeds, it is demonstrated that the electrical signals time series exhibit apparently randomness when the welding parameters do not match. However, the electrical signals time series are deterministic when a match is found. The stability of short-circuiting transfer process could be judged exactly by the method of surrogate data.展开更多
This work was to reveal the residual stress profile in electron beam welded Ti-6Al-4V alloy plates（50 mm thick） by using finite element and contour measurement methods.A three-dimensional finite element model of 50-...This work was to reveal the residual stress profile in electron beam welded Ti-6Al-4V alloy plates（50 mm thick） by using finite element and contour measurement methods.A three-dimensional finite element model of 50-mmthick titanium component was proposed,in which a column–cone combined heat source model was used to simulate the temperature field and a thermo-elastic–plastic model to analyze residual stress in a weld joint based on ABAQUS software.Considering the uncertainty of welding simulation,the computation was calibrated by experimental data of contour measurement method.Both test and simulated results show that residual stresses on the surface and inside the weld zone are significantly different and present a narrow and large gradient feature in the weld joint.The peak tensile stress exceeds the yield strength of base materials inside weld,which are distinctly different from residual stress of the thin Ti-6Al-4V alloy plates presented in references before.展开更多
This project work focuses on the reduction of weld undercuts using the Taguchi method. The phenomenon of weld undercuts constitutes a major problem for the welding industry. When undercuts occur, and particularly when...This project work focuses on the reduction of weld undercuts using the Taguchi method. The phenomenon of weld undercuts constitutes a major problem for the welding industry. When undercuts occur, and particularly when such cuts are deep, it has a negative impact on the weld as it lowers the integrity and quality of the weldment. Therefore, efforts are made globally to reduce the depth of such weld undercuts to the barest minimum. Several optimization methods have been adopted;however, in this study, the Taguchi method is applied. “The smaller the better components” of the Taguchi method is applied. From the results obtained from applying this Taguchi method, the optimum process parameters obtained are A2-B1-C2, which are a voltage of 20 V, a current of 180 A, and a welding speed of 130 mm/s, required to form an undercut of 0.03 mm. Whereas the existing process parameters used by the company are A1-B3-C, which make an undercut to a depth of 0.09 mm. It is concluded that the use of Taguchi method has been able to reduce the depth of undercut as shown in this study. A step-by-step approach is presented in the study.展开更多
Based on the principle of residual deformation induced by superposition of the welding residual stress and working stress, the welding heat source efficiency has been determined by measuring displacement changes of sp...Based on the principle of residual deformation induced by superposition of the welding residual stress and working stress, the welding heat source efficiency has been determined by measuring displacement changes of specimens under loading and unloading in tensile tests, and combining with calculating welding parameters. Meanwhile, the welding heat source eficiencies obtained are compared with those of the measuring-calculating method. The research results show that the welding heat source efficiencies are almost the same as those obtained by the measuring-calculating method. Therefore, the welding heat source efficiency can be determined accurately by this method, and a new determining method of the heat source efficiency for the welding heat process calculating has been provided.展开更多
Based on the conventional uniaxial pre-tensile stress method during welding, this study presents a new method of welding with biaxial pre-stress. With the help of numerical simulation, experiments were carried out on ...Based on the conventional uniaxial pre-tensile stress method during welding, this study presents a new method of welding with biaxial pre-stress. With the help of numerical simulation, experiments were carried out on the self-designed device. Except for the control on residual stress and distortion us-welded, the experimental results also show its effect on the prevention of hot cracks, thus this method can make up for the disadvantage of the conventional pre-stress method. Hot cracks disappear when the value of pre-stress surpasses 0. 2 σs（yield limit）. Welded thin plates with low-level residual stress, little distortion and no hot cracks are obtained with longitudinal pre-tensile stress level between 0. 6σsand 0. 7σs and precompressive stress between 0. 2 σs and 0. 3 σs in transverse direction.展开更多
From the viewpoint of reliability and practicability, a general design method and the related considerationsfor transistor- inverted welding power supplies are proposed in this paper. The detail contents are composed ...From the viewpoint of reliability and practicability, a general design method and the related considerationsfor transistor- inverted welding power supplies are proposed in this paper. The detail contents are composed of the choice ofinverters, the choice and protection of transistors, the determination of inverting frequency, the design of transformers,and the choice of output rectifiers and rectifying diodes. Besides, a concrete design example of the transistor-invertedpower supply for plasma arc cutting is introduced.展开更多
Electric signals are acquired and analyzed in order to monitor the underwater arc welding process. Voltage break point and magnitude are extracted by detecting arc voltage singularity through the modulus maximum wavel...Electric signals are acquired and analyzed in order to monitor the underwater arc welding process. Voltage break point and magnitude are extracted by detecting arc voltage singularity through the modulus maximum wavelet （MMW） method. A novel threshold algorithm, which compromises the hard-threshold wavelet （HTW） and soft-threshold wavelet （STW） methods, is investigated to eliminate welding current noise. Finally, advantages over traditional wavelet methods are verified by both simulation and experimental results.展开更多
Accurate thermal simulation is the key in the simulation approach to defining the unique microstructure and properties of the HAZ regions. Simulation enables an expansion of the volume of material char- acteristic...Accurate thermal simulation is the key in the simulation approach to defining the unique microstructure and properties of the HAZ regions. Simulation enables an expansion of the volume of material char- acteristic of each H4Z region to a sufficient size for property determination.The combined influence of heat input,preheat temperature, plate thickness, and widing process on HAZ microstructure and properties relics on the accurate simulation of thermal cycles corresponding to different peak temperatures using an HAZ simulator like the Gleeble.Several computer programs have been developed to predict thermal excursions in various HAZ regions during welding. Some were developed based simply on the thermal propertics of a material;whereas, others were generated on the basis of actual experimental data.A suitable HAZ thermal simulation program must be ons that can authntically duplicate an ac- tual thermal cycle experienced during welding within reasonable limies. Therefore, the similarities and differences among the HAZ thermal cycles predicted by various methodologies should be fully under- stood. A total of sts thermal cycle prediction methodologies were compared in this evaluation. It was de- termined that some HAZ simulation programs have sever limitations due to the idealized assumptions considered in their development.According to the experieare at The University of Tennessee and the comparison results in this study, the HAZ thermal simulation programs; ' HAZ Calculator' and F(s, d); are recommended for accurate HAZ thermal cycle duplication.展开更多
The numerical model was developed using a SPH (Smoothed Particle Hydrodynamics) method and the projected transfer phenomena during a GMA (Gas Metal Arc) welding were simulated by the model to clarify mechanisms of the...The numerical model was developed using a SPH (Smoothed Particle Hydrodynamics) method and the projected transfer phenomena during a GMA (Gas Metal Arc) welding were simulated by the model to clarify mechanisms of the phenomena. As a result, the droplet transfer mode obtained from this calculation was regarded as a projected transfer mode in which the liquid column grew about 1 mm and a droplet grew up until its diameter became large the same as a wire diameter,?after that it was detached from the tip of the column. In addition, 10 droplets were formed for 0.1 s through these growth and detachment processes at the tip of a wire. To compare with the numerical results, actual GMA welding was carried out and molten metal droplet transfers were taken by high speed camera. The diameter of a wire, the length of a liquid column, the velocity of a droplet right before it reached a weld pool obtained by simulation showed good agreement with experiment.展开更多
In the presented study, the laser butt-welding of Ti 6Al 4V is investigated using 2.2 kw CO2 laser. Ti 6Al 4V alloy has widespread application in various fields of industries including the medical, nuclear and aerospa...In the presented study, the laser butt-welding of Ti 6Al 4V is investigated using 2.2 kw CO2 laser. Ti 6Al 4V alloy has widespread application in various fields of industries including the medical, nuclear and aerospace. In this study, Response Surface Methodology (RSM) is employed to establish the design of experiments and to optimize the bead geometry. The relationships between the input laser-welding parameters (i.e. laser power, welding speed and focal point position) and the process responses (i.e. welded zone width, heat affected zone width, welded zone area, heat affected zone area and penetration depth) are investigated. The multi-response optimizations are used to optimize the welding process. The optimum welding conditions are identified in order to increase the productivity and minimize the total operating cost. The validation results demonstrate that the developed models are accurate with low percentages of error (less than 12.5%).展开更多
In this paper a new method for preventing welding hot cracking—the inverse strain method(ISM)is developed on the principle of welding mechan- ics.Effectiveness and feasiblity of method in preventing welding hot crack...In this paper a new method for preventing welding hot cracking—the inverse strain method(ISM)is developed on the principle of welding mechan- ics.Effectiveness and feasiblity of method in preventing welding hot cracking of high strength aluminum alloy LY12CZ by synchronous rolling during welding (SRDW)along both sides of the weld at a suitable distance behind the welding arc are examined.Experimental resulte indicate that welding hot cracking of LY12CY can be effectively prevented and the mechanical properties of welded joint can also be improved by the method.It is an important new solution for preventing hot cracking in welding of sheet metal.展开更多
To develop highly efficient and useful software, we need to understand the essential feature of the welding phenomenon. From the mechanical point view, welding is a transient nonlinear problem in which small but stron...To develop highly efficient and useful software, we need to understand the essential feature of the welding phenomenon. From the mechanical point view, welding is a transient nonlinear problem in which small but strongly nonlinear region is moving with the welding torch. Noting this characteristic, ISM （Iterative Substructure Method） was developed for the thermal-elastic-plastic analysis of large scale structures. It is also known that the welding distortion and the residual stress are produced by inherent strain. The inherent strain is the sum of irreversible strains such as plastic strain due to welding thermal cycles or phase transformation and creep strain. In addition to the inherent strain, the mismatch produced by cutting error and fitting is also an important cause of the welding distortions and residual stresses. Based on this understanding, an elastic FEM introducing the inherent strain and mismatch is developed. The potential capabilities of these methods are demonstrated through some examples.展开更多
The objective of the present paper is to develop nonlinear finite element method models for predicting the weld-induced initial deflection and residual stress of plating in steel stiffened-plate structures. For this p...The objective of the present paper is to develop nonlinear finite element method models for predicting the weld-induced initial deflection and residual stress of plating in steel stiffened-plate structures. For this purpose, three-dimensional thermo-elastic-plastic finite element method computations are performed with varying plate thickness and weld bead length (leg length) in welded plate panels, the latter being associated with weld heat input. The finite element models are verified by a comparison with experimental database which was obtained by the authors in separate studies with full scale measurements. It is concluded that the nonlinear finite element method models developed in the present paper are very accurate in terms of predicting the weld-induced initial imperfections of steel stiffened plate structures. Details of the numerical computations together with test database are documented.展开更多
基金supported by the National Natural Science Foundation of China (no. 51478120)
文摘The blind-hole method is the most widely used approach to experimentally determine the distribution of residual stress. This paper aims to improve test accuracy of welding residual stress and conducts an experimental study on the strain release factors involved when using the blind-hole method for Q235 and Q345, two steels commonly used in building structures. The ranges of strain release factors A and B in the elastic stage, the effects of strain release factors on residual stress calculated values, and the plastic corrected strain release factors are analyzed considering of the effect of plastic deformation around the blind hole on measurement accuracy. Finally, a simplified calculation formula to determine strain release factors is proposed for use with the blind-hole method. Results show that in the elastic stage, strain release factor A for Q235 and Q345 ranges from-0.399 to-0.525 and strain release factor B from-0.791 to-0.960. Changing the strain release factors A and B shows that calculated residual tensile stress varies in relation to a decrease in both factor values. However, there is a increase in calculated residual compressive stress with a decrease in the strain release factor A value, but there is an decrease with a decrease in strain release factor B value. Calculated residual stress applied to elastic strain release factors is compared with that applied to amended plastic strain release factors for Q235 steel. The maximum deviation between calculated residual stress and test stress is reduced from 21.1 to 1.0%,and for Q345 steel from 26.5 to 1.2%. It is thus evident that the plastic correction formula proposed in this paper can be used in calculations when conducting a residual stress test.
文摘A new type control method in friction welding is suggested in this pa- per,that is compositive control method of friction torque and friction time,it called Mt control method for short.The principle of Mt control method and its feature are concisely explained.
文摘Copper was surfaced on the Q235 substrate by shielded metal arc welding （SMAW） and tungsten inert-gas （TIG） arc welding, the regularity of iron element in deposited metal was analyzed by metallograph, scanning electron microscopy and energy disperse spectroscopy. The results indicate that with the increase of SMA W welding speed, the iron content decreases and the granular or spherical iron becomes more bulky in the overlay. The iron content obviously decreases with the increase of surfacing layers＇ numbers in multilayer welding because of the substrate dilution. On the third layer, the microstrueture of deposited metal is single-phase e-copper. Under the influence of welding methods, the granular or spherical crystal morphology is more likely to form in SMAW for the more divergent arc heat, but is dendrite in TIG welding because of centralized arc energy.
文摘Considering the limitation of computational capacity, a new finite element solution is used to simulate the welding deformation of the side sill of railroad car＇ s bogie frame based on the local-global method. Firstly, a volumetric heat source defined by a double ellipsoid is adopted to simulate the thermal distributions of the arc welding process. And then, the local models extracted from the global model are computed with refined meshes. On these bases, the global distortions of the subject studied are ascertained by transferring the inner forces of computed local models to the global model. It indicates that the local-global method is feasible for simulating the large welded structures by comparing the computed results with the corresponding actual measured values. The work provides basis for optimizing the welding sequence and clamping conditions, and has theoretical values and engineering significance in the integral design, manufacturing technique selection of the bogie frame, as well as other kinds of large welded structures.
基金supported by the National Natural Science Foundation of China(Grant No.11375038)Science Fund for Creative Research Groups of NSFC(Grant No.51621064)
文摘This study investigated multi-response optimization of the pulse metal active gas-tungsten inert gas( PMAG-TIG) twin arc hybrid root welding process for an optimal parametric combination to yield favorable back bead geometry of welded joints using grey relational analysis and Taguchi method.Eighteen experimental runs based on an orthogonal array following the Taguchi method were performed to derive objective functions to be optimized within the experimental domain.The objective functions were selected in relation to parameters of PMAG-TIG twin arc root welding back bead geometry: back bead width to root reinforcement ratio and deposited metal height.The Taguchi approach was followed by grey relational analysis to solve the multi-response optimization problem.The significance of factors on overall quality characteristics of the weld joint was also evaluated quantitatively using analysis of variance.Optimal results were verified through additional experiments,and showed to feasibility of applying grey relation analysis in combination with Taguchi technique for continuous improvement of product quality in the manufacturing industry.
基金Project was supported by the National Key R&D Program of China(Grant No.2017YFB1104404)
文摘In order to obtain a high-quality weld during the laser welding process, extracting the characteristic parameters of weld pool is an important issue for automated welding. In this paper, the type 304 austenitic stainless steel is welded by a 5 kW high-power fiber laser and a high-speed camera is employed to capture the topside images of weld pools. Then we propose a robust visual-detection approach for the molten pool based on the supervised descent method. It provides an elegant framework for representing the outline of a weld pool and is especially efficient for weld pool detection in the presence of strong uncertainties and disturbances. Finally, welding experimental results verified that the proposed approach can extract the weld pool boundary accurately, which will lay a solid foundation for controlling the weld quality of fiber laser welding process.
基金supported by the Young Scientists Fund of the National Natural Science Foundation of China(Grant No.51205283)
文摘This paper introduced the basic theory and algorithm of the surrogate data method, which proposed a rigorous way to detect the random and seemingly stochastic characteristics in a system. The Gaussian data and the Rossler data were used to show the availability and effectivity of this method. According to the analysis by this method based on the short-circuiting current signals under the conditions of the same voltage and different wire feed speeds, it is demonstrated that the electrical signals time series exhibit apparently randomness when the welding parameters do not match. However, the electrical signals time series are deterministic when a match is found. The stability of short-circuiting transfer process could be judged exactly by the method of surrogate data.
基金supported by the National Natural Science Foundation of China (No.50935008)
文摘This work was to reveal the residual stress profile in electron beam welded Ti-6Al-4V alloy plates（50 mm thick） by using finite element and contour measurement methods.A three-dimensional finite element model of 50-mmthick titanium component was proposed,in which a column–cone combined heat source model was used to simulate the temperature field and a thermo-elastic–plastic model to analyze residual stress in a weld joint based on ABAQUS software.Considering the uncertainty of welding simulation,the computation was calibrated by experimental data of contour measurement method.Both test and simulated results show that residual stresses on the surface and inside the weld zone are significantly different and present a narrow and large gradient feature in the weld joint.The peak tensile stress exceeds the yield strength of base materials inside weld,which are distinctly different from residual stress of the thin Ti-6Al-4V alloy plates presented in references before.
文摘This project work focuses on the reduction of weld undercuts using the Taguchi method. The phenomenon of weld undercuts constitutes a major problem for the welding industry. When undercuts occur, and particularly when such cuts are deep, it has a negative impact on the weld as it lowers the integrity and quality of the weldment. Therefore, efforts are made globally to reduce the depth of such weld undercuts to the barest minimum. Several optimization methods have been adopted;however, in this study, the Taguchi method is applied. “The smaller the better components” of the Taguchi method is applied. From the results obtained from applying this Taguchi method, the optimum process parameters obtained are A2-B1-C2, which are a voltage of 20 V, a current of 180 A, and a welding speed of 130 mm/s, required to form an undercut of 0.03 mm. Whereas the existing process parameters used by the company are A1-B3-C, which make an undercut to a depth of 0.09 mm. It is concluded that the use of Taguchi method has been able to reduce the depth of undercut as shown in this study. A step-by-step approach is presented in the study.
文摘Based on the principle of residual deformation induced by superposition of the welding residual stress and working stress, the welding heat source efficiency has been determined by measuring displacement changes of specimens under loading and unloading in tensile tests, and combining with calculating welding parameters. Meanwhile, the welding heat source eficiencies obtained are compared with those of the measuring-calculating method. The research results show that the welding heat source efficiencies are almost the same as those obtained by the measuring-calculating method. Therefore, the welding heat source efficiency can be determined accurately by this method, and a new determining method of the heat source efficiency for the welding heat process calculating has been provided.
文摘Based on the conventional uniaxial pre-tensile stress method during welding, this study presents a new method of welding with biaxial pre-stress. With the help of numerical simulation, experiments were carried out on the self-designed device. Except for the control on residual stress and distortion us-welded, the experimental results also show its effect on the prevention of hot cracks, thus this method can make up for the disadvantage of the conventional pre-stress method. Hot cracks disappear when the value of pre-stress surpasses 0. 2 σs（yield limit）. Welded thin plates with low-level residual stress, little distortion and no hot cracks are obtained with longitudinal pre-tensile stress level between 0. 6σsand 0. 7σs and precompressive stress between 0. 2 σs and 0. 3 σs in transverse direction.
文摘From the viewpoint of reliability and practicability, a general design method and the related considerationsfor transistor- inverted welding power supplies are proposed in this paper. The detail contents are composed of the choice ofinverters, the choice and protection of transistors, the determination of inverting frequency, the design of transformers,and the choice of output rectifiers and rectifying diodes. Besides, a concrete design example of the transistor-invertedpower supply for plasma arc cutting is introduced.
文摘Electric signals are acquired and analyzed in order to monitor the underwater arc welding process. Voltage break point and magnitude are extracted by detecting arc voltage singularity through the modulus maximum wavelet （MMW） method. A novel threshold algorithm, which compromises the hard-threshold wavelet （HTW） and soft-threshold wavelet （STW） methods, is investigated to eliminate welding current noise. Finally, advantages over traditional wavelet methods are verified by both simulation and experimental results.
文摘Accurate thermal simulation is the key in the simulation approach to defining the unique microstructure and properties of the HAZ regions. Simulation enables an expansion of the volume of material char- acteristic of each H4Z region to a sufficient size for property determination.The combined influence of heat input,preheat temperature, plate thickness, and widing process on HAZ microstructure and properties relics on the accurate simulation of thermal cycles corresponding to different peak temperatures using an HAZ simulator like the Gleeble.Several computer programs have been developed to predict thermal excursions in various HAZ regions during welding. Some were developed based simply on the thermal propertics of a material;whereas, others were generated on the basis of actual experimental data.A suitable HAZ thermal simulation program must be ons that can authntically duplicate an ac- tual thermal cycle experienced during welding within reasonable limies. Therefore, the similarities and differences among the HAZ thermal cycles predicted by various methodologies should be fully under- stood. A total of sts thermal cycle prediction methodologies were compared in this evaluation. It was de- termined that some HAZ simulation programs have sever limitations due to the idealized assumptions considered in their development.According to the experieare at The University of Tennessee and the comparison results in this study, the HAZ thermal simulation programs; ' HAZ Calculator' and F(s, d); are recommended for accurate HAZ thermal cycle duplication.
文摘The numerical model was developed using a SPH (Smoothed Particle Hydrodynamics) method and the projected transfer phenomena during a GMA (Gas Metal Arc) welding were simulated by the model to clarify mechanisms of the phenomena. As a result, the droplet transfer mode obtained from this calculation was regarded as a projected transfer mode in which the liquid column grew about 1 mm and a droplet grew up until its diameter became large the same as a wire diameter,?after that it was detached from the tip of the column. In addition, 10 droplets were formed for 0.1 s through these growth and detachment processes at the tip of a wire. To compare with the numerical results, actual GMA welding was carried out and molten metal droplet transfers were taken by high speed camera. The diameter of a wire, the length of a liquid column, the velocity of a droplet right before it reached a weld pool obtained by simulation showed good agreement with experiment.
文摘In the presented study, the laser butt-welding of Ti 6Al 4V is investigated using 2.2 kw CO2 laser. Ti 6Al 4V alloy has widespread application in various fields of industries including the medical, nuclear and aerospace. In this study, Response Surface Methodology (RSM) is employed to establish the design of experiments and to optimize the bead geometry. The relationships between the input laser-welding parameters (i.e. laser power, welding speed and focal point position) and the process responses (i.e. welded zone width, heat affected zone width, welded zone area, heat affected zone area and penetration depth) are investigated. The multi-response optimizations are used to optimize the welding process. The optimum welding conditions are identified in order to increase the productivity and minimize the total operating cost. The validation results demonstrate that the developed models are accurate with low percentages of error (less than 12.5%).
文摘In this paper a new method for preventing welding hot cracking—the inverse strain method(ISM)is developed on the principle of welding mechan- ics.Effectiveness and feasiblity of method in preventing welding hot cracking of high strength aluminum alloy LY12CZ by synchronous rolling during welding (SRDW)along both sides of the weld at a suitable distance behind the welding arc are examined.Experimental resulte indicate that welding hot cracking of LY12CY can be effectively prevented and the mechanical properties of welded joint can also be improved by the method.It is an important new solution for preventing hot cracking in welding of sheet metal.
文摘To develop highly efficient and useful software, we need to understand the essential feature of the welding phenomenon. From the mechanical point view, welding is a transient nonlinear problem in which small but strongly nonlinear region is moving with the welding torch. Noting this characteristic, ISM （Iterative Substructure Method） was developed for the thermal-elastic-plastic analysis of large scale structures. It is also known that the welding distortion and the residual stress are produced by inherent strain. The inherent strain is the sum of irreversible strains such as plastic strain due to welding thermal cycles or phase transformation and creep strain. In addition to the inherent strain, the mismatch produced by cutting error and fitting is also an important cause of the welding distortions and residual stresses. Based on this understanding, an elastic FEM introducing the inherent strain and mismatch is developed. The potential capabilities of these methods are demonstrated through some examples.
文摘The objective of the present paper is to develop nonlinear finite element method models for predicting the weld-induced initial deflection and residual stress of plating in steel stiffened-plate structures. For this purpose, three-dimensional thermo-elastic-plastic finite element method computations are performed with varying plate thickness and weld bead length (leg length) in welded plate panels, the latter being associated with weld heat input. The finite element models are verified by a comparison with experimental database which was obtained by the authors in separate studies with full scale measurements. It is concluded that the nonlinear finite element method models developed in the present paper are very accurate in terms of predicting the weld-induced initial imperfections of steel stiffened plate structures. Details of the numerical computations together with test database are documented.
