Short-arc machining is a novel electrical discharge machining method that utilizes high-energy arc discharge as the energy carrier.Due to its low cost and high processing efficiency,it has been widely applied in the e...Short-arc machining is a novel electrical discharge machining method that utilizes high-energy arc discharge as the energy carrier.Due to its low cost and high processing efficiency,it has been widely applied in the efficient processing of superalloys.To address the challenges of efficient and high-precision processing of superalloys,a processing method combining short-arc machining with precision milling is employed.Advanced material characterization techniques such as electron backscatter diffraction(EBSD)are utilized to analyze the physical properties of the recast layer and surface crystal characteristics.High-temperature low-cycle fatigue life tests are conducted to investigate the correlation between fatigue life and typical surface integrity parameters(surface roughness,residual stress),as well as crystallographic parameters(grain size,grain orientation spread,geometrically necessary dislocations).Processing parameter optimization is achieved with fatigue life as the target.The results indicate that at high temperatures during short-arc machining,the surface material underwent recrystallisation to form a recast layer with a grain size reduction of 85.5%and a heat affected layer depth of over 400μm.The trends in fatigue life are consistent with changes in residual stress,grain orientation spread and geometrically necessary dislocations.Selecting a larger axial depth of cut and lower feed per tooth is advantageous for achieving a higher fatigue life.The proposed research provides an instruction for high efficient precision machining of superalloys.展开更多
Short-arc pulsed gas metal arc welding(P-GMAW)was used to solve the dificulties of molten pool spreading and droplet transfer of Ni-based welding wire.Suppression of short-circuit current was used to reduce spatter.Ar...Short-arc pulsed gas metal arc welding(P-GMAW)was used to solve the dificulties of molten pool spreading and droplet transfer of Ni-based welding wire.Suppression of short-circuit current was used to reduce spatter.Arc length stabilizer was used to acquire a proper and stable arc length maintained at the critical position where short circuit starts to occur.Short-arc P-GMAW with or without arc length stabilizer was compared.The droplet transfer,arc behaviors and weld bead profiles were investigated and compared based on the high-speed photography and observation of weld cross-section.When the arc length stabilizer was deactivated,the arc length was unstable and too short.The droplet transfer mode was mainly short circuit partial transfer,with only a small part of the droplet transferred into the molten pool,with the characteristics of no obvious necking,a few spatters,small droplet impact,long short circuit duration and high short-circuit current.There was also a small proportion of short circuit complete transfer with obvious necking,larger droplet impact,shorter short-circuit duration and lower short-circuit current.With arc length stabilizer,droplet transfer modes were short circuit complete transfer and spray transfer.The spray transfer had the largest droplet impact,no short circuit and no spatter.With the arc length stabilizer activated,a deep penetration,a high penetration ratio,a small reinforcement and a large reinforcement factor were acquired.This provides an innovative method to solve the difficulties of droplet transfer and molten pool spreading and eliminate the incomplete fusion in the GMAW of 9%Ni steel with nickel-based alloy welding wire.展开更多
短弧积分法是卫星重力反演的一种常用方法,本质是基于边值条件的牛顿运动方程积分解法。鉴于Adams和KSG积分器分别是常用的一重和二重多步法积分器,本文提出了一种联合Adams和KSG的短弧积分公式的离散化方法,给出了积分离散化系数的计...短弧积分法是卫星重力反演的一种常用方法,本质是基于边值条件的牛顿运动方程积分解法。鉴于Adams和KSG积分器分别是常用的一重和二重多步法积分器,本文提出了一种联合Adams和KSG的短弧积分公式的离散化方法,给出了积分离散化系数的计算公式,便于短弧积分方程的快速离散化求解。以GRACE-FO卫星仿真计算为例,分别从积分离散化系数计算、位置和速度向量积分运算、球谐系数偏导数求解,以及重力场反演等多个角度,与传统短弧积分法进行对比分析。结果表明:①两种方法求得的离散化系数矩阵特征十分吻合,位置和速度方程离散化系数矩阵差异的均方根(root mean square,RMS)量级分别为10^(-9)和10^(-6),相比于传统方法,本文方法位置和速度方程的离散化系数矩阵求解效率分别提升了约80%和90%;②在相同弧长的情况下,本文方法相应的速度向量积分误差与传统方法相当,然而位置向量积分精度在较长弧段下略高于传统方法;③两种方法求得的位置和速度方程球谐系数偏导数总体上均吻合,由于高价信号能量小,高阶偏导数存在差异;④本文方法重力场反演结果与传统数值积分法精度相当,但解算效率提升了74.4%。展开更多
基金Supported by National Natural Science Foundation of China(Grant No.52075042)。
文摘Short-arc machining is a novel electrical discharge machining method that utilizes high-energy arc discharge as the energy carrier.Due to its low cost and high processing efficiency,it has been widely applied in the efficient processing of superalloys.To address the challenges of efficient and high-precision processing of superalloys,a processing method combining short-arc machining with precision milling is employed.Advanced material characterization techniques such as electron backscatter diffraction(EBSD)are utilized to analyze the physical properties of the recast layer and surface crystal characteristics.High-temperature low-cycle fatigue life tests are conducted to investigate the correlation between fatigue life and typical surface integrity parameters(surface roughness,residual stress),as well as crystallographic parameters(grain size,grain orientation spread,geometrically necessary dislocations).Processing parameter optimization is achieved with fatigue life as the target.The results indicate that at high temperatures during short-arc machining,the surface material underwent recrystallisation to form a recast layer with a grain size reduction of 85.5%and a heat affected layer depth of over 400μm.The trends in fatigue life are consistent with changes in residual stress,grain orientation spread and geometrically necessary dislocations.Selecting a larger axial depth of cut and lower feed per tooth is advantageous for achieving a higher fatigue life.The proposed research provides an instruction for high efficient precision machining of superalloys.
基金the MARK III Materials Research Project of Ministry of Industry and Information Technology of China。
文摘Short-arc pulsed gas metal arc welding(P-GMAW)was used to solve the dificulties of molten pool spreading and droplet transfer of Ni-based welding wire.Suppression of short-circuit current was used to reduce spatter.Arc length stabilizer was used to acquire a proper and stable arc length maintained at the critical position where short circuit starts to occur.Short-arc P-GMAW with or without arc length stabilizer was compared.The droplet transfer,arc behaviors and weld bead profiles were investigated and compared based on the high-speed photography and observation of weld cross-section.When the arc length stabilizer was deactivated,the arc length was unstable and too short.The droplet transfer mode was mainly short circuit partial transfer,with only a small part of the droplet transferred into the molten pool,with the characteristics of no obvious necking,a few spatters,small droplet impact,long short circuit duration and high short-circuit current.There was also a small proportion of short circuit complete transfer with obvious necking,larger droplet impact,shorter short-circuit duration and lower short-circuit current.With arc length stabilizer,droplet transfer modes were short circuit complete transfer and spray transfer.The spray transfer had the largest droplet impact,no short circuit and no spatter.With the arc length stabilizer activated,a deep penetration,a high penetration ratio,a small reinforcement and a large reinforcement factor were acquired.This provides an innovative method to solve the difficulties of droplet transfer and molten pool spreading and eliminate the incomplete fusion in the GMAW of 9%Ni steel with nickel-based alloy welding wire.
文摘短弧积分法是卫星重力反演的一种常用方法,本质是基于边值条件的牛顿运动方程积分解法。鉴于Adams和KSG积分器分别是常用的一重和二重多步法积分器,本文提出了一种联合Adams和KSG的短弧积分公式的离散化方法,给出了积分离散化系数的计算公式,便于短弧积分方程的快速离散化求解。以GRACE-FO卫星仿真计算为例,分别从积分离散化系数计算、位置和速度向量积分运算、球谐系数偏导数求解,以及重力场反演等多个角度,与传统短弧积分法进行对比分析。结果表明:①两种方法求得的离散化系数矩阵特征十分吻合,位置和速度方程离散化系数矩阵差异的均方根(root mean square,RMS)量级分别为10^(-9)和10^(-6),相比于传统方法,本文方法位置和速度方程的离散化系数矩阵求解效率分别提升了约80%和90%;②在相同弧长的情况下,本文方法相应的速度向量积分误差与传统方法相当,然而位置向量积分精度在较长弧段下略高于传统方法;③两种方法求得的位置和速度方程球谐系数偏导数总体上均吻合,由于高价信号能量小,高阶偏导数存在差异;④本文方法重力场反演结果与传统数值积分法精度相当,但解算效率提升了74.4%。
