Titanium alloy has the advantages of high strength,strong corrosion resistance,excellent high and low temperature mechanical properties,etc.,and is widely used in aerospace,shipbuilding,weapons and equipment,and other...Titanium alloy has the advantages of high strength,strong corrosion resistance,excellent high and low temperature mechanical properties,etc.,and is widely used in aerospace,shipbuilding,weapons and equipment,and other fields.In recent years,with the continuous increase in demand for medium-thick plate titanium alloys,corresponding welding technologies have also continued to develop.Therefore,this article reviews the research progress of deep penetration welding technology for medium-thick plate titanium alloys,mainly covering traditional arc welding,high-energy beam welding,and other welding technologies.Among many methods,narrow gap welding,hybrid welding,and external energy field assistance welding all contribute to improving the welding efficiency and quality of medium-thick plate titanium alloys.Finally,the development trend of deep penetration welding technology for mediumthick plate titanium alloys is prospected.展开更多
Laser twin-arc GTAW(LTA-GTAW)process has been developed by using the synergic interaction effects of laser and a coupled arc in a weld pool to achieve higher energy efficiency.In this study,bead-on-plate welding was c...Laser twin-arc GTAW(LTA-GTAW)process has been developed by using the synergic interaction effects of laser and a coupled arc in a weld pool to achieve higher energy efficiency.In this study,bead-on-plate welding was conducted on 8-mm-thick Q235B work-pieces to investigate the variation of hybrid arc profile,the influence of hybrid arc profile on weld forming,microstructure and mech-anical properties of the joint during the LTA-GTAW process.The influence of Laser-GTAW and LTA-GTAW methods on weld surface appearance,heat input per unit length,and weld metal microstructure were also demonstrated systematically.The LTA-GTAW can make the distribution of arc energy more reasonable in welding depth and width.When defocus is 0,I_(f)is 330 A,I_(b)is 240 A,laser power is 2.4 kW,and spacing between heat sources of tungsten electrode is 10 mm,the weld shape is better.Compared with Laser-GTAW,LTA-GTAW can achieve lower heat input at the same penetration depth,and the microstructure of the weld is refined.The tensile strength of the welded joint is 121.8%of the base material,and the fracture mode of the welded joint is ductile fracture,the comprehensive mechanical properties are better.展开更多
Friction stir lap welding of AA2195 Al-Li alloy and Ti alloy was conducted to investigate the formation,microstructure,and mechanical properties of the joints.Results show that under different welding parameters,with ...Friction stir lap welding of AA2195 Al-Li alloy and Ti alloy was conducted to investigate the formation,microstructure,and mechanical properties of the joints.Results show that under different welding parameters,with the decrease in welding heat input,the weld surface is smoother.The Ti/Al joint interface is flat without obvious Ti and Al mixed structure,and the hook structure is not formed under optimal parameters.Due to the enhanced breaking effect of the stirring head,the hook structural defects and intermetallic compounds are more likely to form at the Ti/Al interface at high rotational speed of 1000 r/min,thereby deteriorating the mechanical properties of joints.Decreasing the heat input is beneficial to hardness enhancement of the aluminum alloy in the weld nugget zone.Under the optimal parameters of rotation speed of 800 r/min and welding speed of 120 mm/min,the maximum tensile shear strength of joint is 289 N/mm.展开更多
Friction stir welding(FSW)is a relatively new welding technique that has significant advantages compared to the fusion welding techniques in joining non weld able alloys by fusion,such as aluminum alloys.Three FSW sea...Friction stir welding(FSW)is a relatively new welding technique that has significant advantages compared to the fusion welding techniques in joining non weld able alloys by fusion,such as aluminum alloys.Three FSW seams of AA6061-T6 plates were made us-ing different FSW parameters.The structure of the FSW seams was investigated using X-ray diffraction(XRD),scanning electron mi-croscope(SEM)and non destructive testing(NDT)techniques and their hardness was also measured.The dominated phase in the AA6061-T6 alloy and the FSW seams was theα-Al.The FSW seam had lower content of the secondary phases than the AA6061-T6 al-loy.The hardness of the FSW seams was decreased by about 30%compared to the AA6061-T6 alloy.The temperature distributions in the weld seams were also studied experimentally and numerically modeled and the results were in a good agreement.展开更多
As light metals,aluminum and magnesium have been widely used in automotive manufacturing,but the welding of Al/Mg joints is facing challenges.However,it is difficult to obtain high-quality aluminum/magnesium joints wi...As light metals,aluminum and magnesium have been widely used in automotive manufacturing,but the welding of Al/Mg joints is facing challenges.However,it is difficult to obtain high-quality aluminum/magnesium joints with traditional arc welding methods.As a solid-phase welding technology,ultrasonic metal welding has the characteristics of high welding efficiency and less welded defects.It is also suitable for welding sound metal bonds.Aluminum and magnesium ultrasonic welding has become a research hotspot.Therefore,the evolution of microstructures and mechanical performance of Al/Mg and multi-layer Al/Mg ultrasonic welding,and the new study works,including the molecular dynamic simulation of Al/Mg ultrasonic welding and hybrid based on ultrasonic welding are summarized.Furthermore,several promising research directions are proposed to guide in-depth investigations into the ultrasonic welding of Al/Mg dissimilar joints.展开更多
The steel tube arch rib in a large-span concrete-filled steel tube arch bridge has a large span and diameter,which also leads to a larger weld seam scale.Large-scale welding seams will inevitably cause more obvious we...The steel tube arch rib in a large-span concrete-filled steel tube arch bridge has a large span and diameter,which also leads to a larger weld seam scale.Large-scale welding seams will inevitably cause more obvious welding residual stress(WRS).For the purpose of studying the influence of WRS from large-scale welding seam on the mechanical properties of steel tube arch rib during arch rib splicing,test research and numerical simulation analysis on the WRS in arch rib splicing based on the Guangxi Pingnan Third Bridge,which is the world’s largest span concrete-filled steel tube arch bridge,were conducted in this paper,and the distribution pattern of WRS at the arch rib splicing joint was obtained.Subsequently,the WRS was introduced into the mechanical performance analysis of joints and structures to analyze its effects.The findings reveal that the distribution of WRS in the arch rib is greatly influenced by the rib plate,and the axial WRS in the heat-affected zone are primarily tensile,while the circumferential WRS are distributed in an alternating pattern of tensile and compressive stresses along the circumferential direction of the main tube.Under the influence of WRS,the ultimate bearing capacity of the joint is reduced by 29.4%,the initial axial stiffness is reduced by 4.32%,and the vertical deformation of the arch rib structure is increased by 4.7%.展开更多
Thickness of the intermetallic compounds(IMC)layer at the interface has a significant effect on the mechanical properties of Mg/Al dissimilar joints.However,the thickness of IMC layer can be only obtained by metallurg...Thickness of the intermetallic compounds(IMC)layer at the interface has a significant effect on the mechanical properties of Mg/Al dissimilar joints.However,the thickness of IMC layer can be only obtained by metallurgical microscopy,which is destructive and has to break down the weld.Therefore,it is crucial to find a reliable approach that can non-destructively predict the thickness of IMC layer in practical application.In the current study,Mg alloy and Al alloy were friction stir butt welded(FSW)under different tool rotation speeds(TRS)to obtain different thicknesses of IMC layers.As the TRS increased from 400 rpm to 1000 rpm,thickness of the IMC layer increased from 0.4μm to 1.3μm,the peak welding temperatures increased from 259℃to 402℃,and the Z-axis downforces decreased from10.5 kN to 3.2 k N during welding process.Higher TRS would generally induce higher welding heat input,which promotes the growth of the IMC layer and the softening of base materials.The IMC layer formed through solid-state diffusion and transformation instead of eutectic reaction according to the welding temperature history and interfacial microstructure,and its evolution process was clearly observed by plan view.In order to incorporate the effect of dramatic change of welding temperature which is the characteristic feature of FSW,Psd Voigt function was used to fit the welding temperature histories.A new prediction formula was then established to predict thicknesses of IMC layers with considering sharp welding temperature change.Predicted thicknesses gave good agreement with measured thicknesses obtained experimentally under different welding parameters,which confirmed the accuracy and reliability of the new prediction formula.Based on this prediction formula,the time period of temperature higher than 200℃during welding was found critical for the thickening of interfacial IMC layers.展开更多
A three-dimensional numerical model of laser-arc hybrid plasma for aluminum alloy fillet joints is developed in this study.This mod-el accounts for the geometric complexity of fillet joints,the physical properties of ...A three-dimensional numerical model of laser-arc hybrid plasma for aluminum alloy fillet joints is developed in this study.This mod-el accounts for the geometric complexity of fillet joints,the physical properties of shielding gases with varying He-Ar ratios,and the coupling between arc plasma and laser-induced metal plume.The accuracy of the model is validated using a high-speed camera.The effects of varying He contents in the shielding gas on both the temperature and flow velocity of hybrid plasma,as well as the distribu-tion of laser-induced metal vapor mass,were investigated separately.The maximum temperature and size of arc plasma decrease as the He volume ratio increases,the arc distribution becomes more concentrated,and its flow velocity initially decreases and then sharply increases.At high helium content,both the flow velocity of hybrid plasma and metal vapor are high,the metal vapor is con-centrated on the right side of keyhole,and its flow appears chaotic.The flow state of arc plasma is most stable when the shielding gas consists of 50%He+50%Ar.展开更多
Refill friction stir spot welding process is difficultly optimized by accurate modeling because of the high-order functional relationship between welding parameters and joint strength.A database of the welding process...Refill friction stir spot welding process is difficultly optimized by accurate modeling because of the high-order functional relationship between welding parameters and joint strength.A database of the welding process was first established with 6061-T6 aluminum alloy and DP780 galvanized steel as base materials.This dataset was then optimized using a backpropagation neural network.Analyses and mining of the experimental data confirmed the multidimensional mapping relationship between welding parameters and joint strength.Subsequently,intelligent optimization of the welding process and prediction of joint strength were achieved.At the predicted welding parameter(plunging rotation speedω1=1733 r/min,refilling rotation speedω_(2)=1266 r/min,plunging depth p=1.9 mm,and welding speed v=0.5 mm/s),the tensile shear fracture load of the joint reached a maximum value of 10,172 N,while the experimental result was 9980 N,with an error of 1.92%.Furthermore,the correlation of welding parameters-microstructure-joint strength was established.展开更多
For high-power CO2 laser welding, besides two well known stable welding processes, i.e. stable deep penetration welding (DPW) and stable heat conduction welding (HCW), the authors have found the third welding process,...For high-power CO2 laser welding, besides two well known stable welding processes, i.e. stable deep penetration welding (DPW) and stable heat conduction welding (HCW), the authors have found the third welding process, i.e. unstable-mode welding (UMW) under the certain condition. UMW has its basic feature that the two welding modes (DPW and HCW) appear intermittently, with jumping of penetration depth and weld width between large and small levels. In this paper, effects of welding parameters (focal position, laser power and traveling speed) on laser welding mode and weld appearance have been comprehensively studied. Double-U curves of laser welding mode transition have been obtained, which indicate the ranges of the three mentioned welding processes. This work affords science foundation for selecting the welding process parameters correctly and obtaining stable laser welding.展开更多
Four different welding sequences of double-pulse MIG welding were conducted for 6061-T6 aluminum alloy automobile bumpers by using nonlinear elastoplasticity finite element method based on ABAQUS software.The post-wel...Four different welding sequences of double-pulse MIG welding were conducted for 6061-T6 aluminum alloy automobile bumpers by using nonlinear elastoplasticity finite element method based on ABAQUS software.The post-welding residual stress and deformation were definitely different among the four welding sequences.The results showed that the highest temperature in Solution A was approximately 200℃higher than the melting point of base metal.High residual stress was resulted from this large temperature gradient and mainly concentrated on the welding vicinity between beam and crash box.The welding deformation primarily occurred in both of the contraction of two-ends of the beam and the self-contraction of crash box.Compared with other welding sequences,the residual stress in Solution A was the smallest,whereas the welding deformation was the largest.However,the optimal sequence was Solution B because of the effective reduction of residual stress and good assembly requirements.展开更多
The composite structures/components made by friction stir lap welding(FSLW)of Mg alloy sheet and Al alloy sheet are of wide application potentials in the manufacturing sector of transportation vehicles.To further impr...The composite structures/components made by friction stir lap welding(FSLW)of Mg alloy sheet and Al alloy sheet are of wide application potentials in the manufacturing sector of transportation vehicles.To further improve the joint quality,the ultrasonic vibration(UV)is exerted in FSLW,and the UV enhanced FSLW(UVeFSLW)was developed for making Mg-to-Al dissimilar joints.The numerical analysis and experimental investigation were combined to study the process mechanism in Mg/Al UVeFSLW.An equation related to the temperature and strain rate was derived to calculate the grain size at different locations of the weld nugget zone,and the effect of grain size distribution on the threshold thermal stress was included,so that the prediction accuracy of flow stress was further improved.With such modified constitutive equation,the numerical simulation was conducted to compare the heat generation,temperature profiles and material flow behaviors in Mg/Al UVeFSLW/FSLW processes.It was found that the exerted UV decreased the temperature at two checking points on the tool/workpiece interface from 707/671 K in FSLW to 689/660 K in UVeFSLW,which suppressed the IMCs thickness at Mg-Al interface from 1.7μm in FSLW to 1.1μm in UVeFSLW.The exerted UV increased the horizontal materials flow ability,and decreased the upward flow ability,which resulted in the increase of effective sheet thickness/effective lap width from 2.01/3.70 mm in FSLW to 2.04/4.84 mm in UVeFSLW.Therefore,the ultrasonic vibration improved the tensile shear strength of Mg-to-Al lap joints by 18%.展开更多
GH4169 joints manufactured by Linear Friction Welding(LFW)are subjected to tensile test and stair-case method to evaluate the High Cycle Fatigue(HCF)performance at 650℃.The yield and ultimate tensile strengths are 58...GH4169 joints manufactured by Linear Friction Welding(LFW)are subjected to tensile test and stair-case method to evaluate the High Cycle Fatigue(HCF)performance at 650℃.The yield and ultimate tensile strengths are 582 MPa and 820 MPa,respectively.The HCF strength of joint reaches 400 MPa,which is slightly lower than that of Base Metal(BM),indicating reliable quality of this type of joint.The microstructure observation results show that all cracks initiate at the inside of specimens and transfer into deeper region with decrease of external stress,and the crack initiation site is related with microhardness of matrix.The Electron Backscattered Diffraction(EBSD)results of the observed regions with different distances to fracture show that plastic deformation plays a key role in HCF,and the Schmid factor of most grains near fracture exceeds 0.4.In addition,the generation of twins plays a vital role in strain concentration release and coordinating plastic deformation among grains.展开更多
The ultrafast laser-matter interaction is explored to induce new pioneering principles and technologies into the realms of fundamental science and industrial production.The local thermal melting and connection propert...The ultrafast laser-matter interaction is explored to induce new pioneering principles and technologies into the realms of fundamental science and industrial production.The local thermal melting and connection properties of the ultrafast laser welding technology offer a novel method for welding of diverse transparent materials,thus having wide range of potential applications in aerospace,opto-mechanical systems,sensors,microfluidic,optics,etc.In this comprehensive review,tuning the transient electron activation processes,high-rate laser energy deposition,and dynamic evolution of plasma morphology by the temporal/spatial shaping methods have been demonstrated to facilitate the transition from conventional homogeneous transparent material welding to the more intricate realm of transparent/metal heterogeneous material welding.The welding strength and stability are also improvable through the implementation of real-time,in-situ monitoring techniques and the prompt diagnosis of welding defects.The principles of ultrafast laser welding,bottleneck problems in the welding,novel welding methods,advances in welding performance,in-situ monitoring and diagnosis,and various applications are reviewed.Finally,we offer a forward-looking perspective on the fundamental challenges within the field of ultrafast laser welding and identify key areas for future research,underscoring the imperative need for ongoing innovation and exploration.展开更多
Tungsten/molybdenum alloys are widely utilized in the nuclear industry,aerospace and various other fields due to their high melting points and strength characteristics.However,poor sinterability and processability mak...Tungsten/molybdenum alloys are widely utilized in the nuclear industry,aerospace and various other fields due to their high melting points and strength characteristics.However,poor sinterability and processability make it difficult to manufacture largesize or complex-shaped parts.Hence,an in-depth study on the welding technology of tungsten/molybdenum alloys is urgent.An introduction of tungsten/molybdenum alloy welding defects and joining process was provided,along with recent advancements in brazing,spark plasma sintering diffusion bonding,electron beam welding and laser beam welding.The latest progress in alloy doping treatment applied to tungsten/molybdenum alloy dissimilar welding was also discussed,and existing welding problems were pointed out.The development prospects of weldability of tungsten/molybdenum alloy by various joining technologies were forecasted,thereby furnishing a theoretical and practical found.展开更多
The optimization of deposited metal properties through the addition of rare earth elements to welding materials was explored.Utilizing optical microscope,scanning electron microscope,energy dispersive spectroscope,and...The optimization of deposited metal properties through the addition of rare earth elements to welding materials was explored.Utilizing optical microscope,scanning electron microscope,energy dispersive spectroscope,and X-ray diffractometer,combined with software tools like Matlab,Image-Pro Plus,and CHANNEL5,the influence mechanism of rare earth element addition on the strength,toughness,and inclusions of deposited metal in 1000 MPa grade high-strength steel was investigated.The results indicate that the incorporation of rare earth elements enhances the weldability of the welding materials.With the addition of rare earth elements,the tensile strength of the deposited metal increases from 935 MPa to 960 MPa.However,further addition leads to a decrease in tensile strength,while the yield strength continuously increases by 8.5%-17.2%.The addition of appropriate amounts of rare earth elements results in an increase in acicular ferrite and retained austenite content,as well as grain refinement in the deposited metal,leading to 8.5%-24.3% and 15.6%-42.2% enhancement in impact energy at−40℃ and−60℃,respectively.Additionally,the proper addition of rare earth elements modifies the inclusions and generates fine and dispersed composite inclusions that bond better with the matrix,thereby optimizing the properties of the deposited metal through various mechanisms.Adding an appropriate amount of rare earth elements can significantly enhance the properties of the deposited metal in 1000 MPa grade high-strength steel,and improve the match between high strength and toughness,meeting the demands for high-strength steel used in hydropower applications.展开更多
A three-dimensional finite element approach based on ABAQUS code was developed to investigate the effect of welding sequence on welding residual stress distribution in a thin-walled 6061 aluminum alloy structure. To o...A three-dimensional finite element approach based on ABAQUS code was developed to investigate the effect of welding sequence on welding residual stress distribution in a thin-walled 6061 aluminum alloy structure. To obtain sound numerical results, the therrno-mechanical behaviour was simulated using a direct-coupled formulation. Nine different simulation sequences were carried out by single-pass TIG welding of an octagonal pipe-plate joint, and the distributions of longitudinal and transverse residual stresses both on the outer and inner surfaces of the pipe were analyzed. The results suggest that the final residual stresses in the weld and its vicinity are not affected by the initial residual stresses of the structure. Selecting a suitable welding sequence can reduce the final residual stress in an octagonal pipe-plate joint.展开更多
The effect of current on the morphology of Al alloy T-joint in double-pulsed metal inert gas（DP-MIG） welding process was investigated by simulation and experiment.A three-dimensional finite element model and the DP-...The effect of current on the morphology of Al alloy T-joint in double-pulsed metal inert gas（DP-MIG） welding process was investigated by simulation and experiment.A three-dimensional finite element model and the DP-MIG heat source of double-ellipsoidal volumetric model were developed to simulate the temperature and stress fields under different welding conditions.The macro-morphology and microstructure of welding joints at the corresponding currents were observed in the experiment.The results show that the best condition is at an average current of 90 A and current difference of 40 A,when the maximum temperature is 200 °C higher than the fusion points,with the temperature difference of about 100 °C and stress change of 10 MPa between thermal pulse and thermal base.Under these conditions,Al alloy T-joint with proper fusion condition has smooth fish-scale welding appearance and finer microstructure.Furthermore,the thermal curves and stress distribution in the experiment are consistent with those in the simulation,verifying the precision of the welding simulation.展开更多
In order to realize the automatic welding of pipes in a complex operation environment,an automatic welding system has been developed by use of all-position self-shielded flux cored wires due to their advantages,such a...In order to realize the automatic welding of pipes in a complex operation environment,an automatic welding system has been developed by use of all-position self-shielded flux cored wires due to their advantages,such as all-position weldability,good detachability,arc's stability,low incomplete fusion,no need for welding protective gas or protection against wind when the wind speed is<8 m/s.This system consists of a welding carrier,a guide rail,an auto-control system,a welding source,a wire feeder,and so on.Welding experiments with this system were performed on the X-80 pipeline steel to determine proper welding parameters.The welding technique comprises root welding,filling welding and cover welding and their welding parameters were obtained from experimental analysis.On this basis,the mechanical properties tests were carried out on welded joints in this case.Results show that this system can help improve the continuity and stability of the whole welding process and the welded joints'inherent quality,appearance shape,and mechanical performance can all meet the welding criteria for X-80 pipeline steel;with no need for windbreak fences,the overall welding cost will be sharply reduced.Meanwhile,more positive proposals were presented herein for the further research and development of this self-shielded flux core wires.展开更多
An innovative physical simulation apparatus, including high speed camera, red thermal imaging system, and mechanical quantity sensor, was used to investigate the friction heat generation and atom diffusion behavior du...An innovative physical simulation apparatus, including high speed camera, red thermal imaging system, and mechanical quantity sensor, was used to investigate the friction heat generation and atom diffusion behavior during Mg-Ti friction welding process. The results show that the friction coefficient mainly experiences two steady stages. The first steady stage corresponds to the Coulomb friction with material abrasion. The second steady stage corresponds to the stick friction with fully plastic flow. Moreover, the increasing rates of axial displacement, temperature and friction coefficient are obviously enhanced with the increase of rotation speed and axial pressure. It can also be found that the there exists rapid diffusion phenomenon in the Mg-Ti friction welding system. The large deformation activated diffusion coefficient is about 105 higher than that activated by thermal.展开更多
基金financially supported by the Key Research and Development Program of Ningbo(Grant No.2023Z098)Natural Science Foundation of Inner Mongolia(Grant No.2023MS05040)+1 种基金Shenyang Collaborative Innovation Center Project for Multiple Energy Fields Composite Processing of Special Materials(Grant No.JG210027)Shenyang Key Technology Special Project of The Open Competition Mechanism to Select the Best Solution(Grant Nos.2022210101000827,2022-0-43-048).
文摘Titanium alloy has the advantages of high strength,strong corrosion resistance,excellent high and low temperature mechanical properties,etc.,and is widely used in aerospace,shipbuilding,weapons and equipment,and other fields.In recent years,with the continuous increase in demand for medium-thick plate titanium alloys,corresponding welding technologies have also continued to develop.Therefore,this article reviews the research progress of deep penetration welding technology for medium-thick plate titanium alloys,mainly covering traditional arc welding,high-energy beam welding,and other welding technologies.Among many methods,narrow gap welding,hybrid welding,and external energy field assistance welding all contribute to improving the welding efficiency and quality of medium-thick plate titanium alloys.Finally,the development trend of deep penetration welding technology for mediumthick plate titanium alloys is prospected.
基金supported by the Industrial Innovation Major Technology Global Unveiling Project of Jining City(2022JBZP004)Taishan Scholars Project.
文摘Laser twin-arc GTAW(LTA-GTAW)process has been developed by using the synergic interaction effects of laser and a coupled arc in a weld pool to achieve higher energy efficiency.In this study,bead-on-plate welding was conducted on 8-mm-thick Q235B work-pieces to investigate the variation of hybrid arc profile,the influence of hybrid arc profile on weld forming,microstructure and mech-anical properties of the joint during the LTA-GTAW process.The influence of Laser-GTAW and LTA-GTAW methods on weld surface appearance,heat input per unit length,and weld metal microstructure were also demonstrated systematically.The LTA-GTAW can make the distribution of arc energy more reasonable in welding depth and width.When defocus is 0,I_(f)is 330 A,I_(b)is 240 A,laser power is 2.4 kW,and spacing between heat sources of tungsten electrode is 10 mm,the weld shape is better.Compared with Laser-GTAW,LTA-GTAW can achieve lower heat input at the same penetration depth,and the microstructure of the weld is refined.The tensile strength of the welded joint is 121.8%of the base material,and the fracture mode of the welded joint is ductile fracture,the comprehensive mechanical properties are better.
基金National Natural Science Foundation of China(52275349)Key Research and Development Program of Shandong Province(2021ZLGX01)。
文摘Friction stir lap welding of AA2195 Al-Li alloy and Ti alloy was conducted to investigate the formation,microstructure,and mechanical properties of the joints.Results show that under different welding parameters,with the decrease in welding heat input,the weld surface is smoother.The Ti/Al joint interface is flat without obvious Ti and Al mixed structure,and the hook structure is not formed under optimal parameters.Due to the enhanced breaking effect of the stirring head,the hook structural defects and intermetallic compounds are more likely to form at the Ti/Al interface at high rotational speed of 1000 r/min,thereby deteriorating the mechanical properties of joints.Decreasing the heat input is beneficial to hardness enhancement of the aluminum alloy in the weld nugget zone.Under the optimal parameters of rotation speed of 800 r/min and welding speed of 120 mm/min,the maximum tensile shear strength of joint is 289 N/mm.
文摘Friction stir welding(FSW)is a relatively new welding technique that has significant advantages compared to the fusion welding techniques in joining non weld able alloys by fusion,such as aluminum alloys.Three FSW seams of AA6061-T6 plates were made us-ing different FSW parameters.The structure of the FSW seams was investigated using X-ray diffraction(XRD),scanning electron mi-croscope(SEM)and non destructive testing(NDT)techniques and their hardness was also measured.The dominated phase in the AA6061-T6 alloy and the FSW seams was theα-Al.The FSW seam had lower content of the secondary phases than the AA6061-T6 al-loy.The hardness of the FSW seams was decreased by about 30%compared to the AA6061-T6 alloy.The temperature distributions in the weld seams were also studied experimentally and numerically modeled and the results were in a good agreement.
基金supported by Key Projects of Science and Technology Research Plan of Hubei Provincial Department of Education(D20221306)the National Natural Science Foundation of China(51605103)Key Project of Hubei Provincial Science and Technology Department(2020BAB055).
文摘As light metals,aluminum and magnesium have been widely used in automotive manufacturing,but the welding of Al/Mg joints is facing challenges.However,it is difficult to obtain high-quality aluminum/magnesium joints with traditional arc welding methods.As a solid-phase welding technology,ultrasonic metal welding has the characteristics of high welding efficiency and less welded defects.It is also suitable for welding sound metal bonds.Aluminum and magnesium ultrasonic welding has become a research hotspot.Therefore,the evolution of microstructures and mechanical performance of Al/Mg and multi-layer Al/Mg ultrasonic welding,and the new study works,including the molecular dynamic simulation of Al/Mg ultrasonic welding and hybrid based on ultrasonic welding are summarized.Furthermore,several promising research directions are proposed to guide in-depth investigations into the ultrasonic welding of Al/Mg dissimilar joints.
基金funded by the Science and Technology Research Program of the Chongqing Municipal Education Commission(grant number KJQN202403002).
文摘The steel tube arch rib in a large-span concrete-filled steel tube arch bridge has a large span and diameter,which also leads to a larger weld seam scale.Large-scale welding seams will inevitably cause more obvious welding residual stress(WRS).For the purpose of studying the influence of WRS from large-scale welding seam on the mechanical properties of steel tube arch rib during arch rib splicing,test research and numerical simulation analysis on the WRS in arch rib splicing based on the Guangxi Pingnan Third Bridge,which is the world’s largest span concrete-filled steel tube arch bridge,were conducted in this paper,and the distribution pattern of WRS at the arch rib splicing joint was obtained.Subsequently,the WRS was introduced into the mechanical performance analysis of joints and structures to analyze its effects.The findings reveal that the distribution of WRS in the arch rib is greatly influenced by the rib plate,and the axial WRS in the heat-affected zone are primarily tensile,while the circumferential WRS are distributed in an alternating pattern of tensile and compressive stresses along the circumferential direction of the main tube.Under the influence of WRS,the ultimate bearing capacity of the joint is reduced by 29.4%,the initial axial stiffness is reduced by 4.32%,and the vertical deformation of the arch rib structure is increased by 4.7%.
基金supported by the National Natural Science Foundation of China(No.52075330)the Interdisciplinary Program of Shanghai Jiao Tong University(No.YG2019QNA15)the Foundation of National Facility for Translational Medicine(Shanghai)(No.TMSK-2020-107)。
文摘Thickness of the intermetallic compounds(IMC)layer at the interface has a significant effect on the mechanical properties of Mg/Al dissimilar joints.However,the thickness of IMC layer can be only obtained by metallurgical microscopy,which is destructive and has to break down the weld.Therefore,it is crucial to find a reliable approach that can non-destructively predict the thickness of IMC layer in practical application.In the current study,Mg alloy and Al alloy were friction stir butt welded(FSW)under different tool rotation speeds(TRS)to obtain different thicknesses of IMC layers.As the TRS increased from 400 rpm to 1000 rpm,thickness of the IMC layer increased from 0.4μm to 1.3μm,the peak welding temperatures increased from 259℃to 402℃,and the Z-axis downforces decreased from10.5 kN to 3.2 k N during welding process.Higher TRS would generally induce higher welding heat input,which promotes the growth of the IMC layer and the softening of base materials.The IMC layer formed through solid-state diffusion and transformation instead of eutectic reaction according to the welding temperature history and interfacial microstructure,and its evolution process was clearly observed by plan view.In order to incorporate the effect of dramatic change of welding temperature which is the characteristic feature of FSW,Psd Voigt function was used to fit the welding temperature histories.A new prediction formula was then established to predict thicknesses of IMC layers with considering sharp welding temperature change.Predicted thicknesses gave good agreement with measured thicknesses obtained experimentally under different welding parameters,which confirmed the accuracy and reliability of the new prediction formula.Based on this prediction formula,the time period of temperature higher than 200℃during welding was found critical for the thickening of interfacial IMC layers.
基金supported by the National Natural Science Foundation of China(Grant No.52375340,51975263,52405366).
文摘A three-dimensional numerical model of laser-arc hybrid plasma for aluminum alloy fillet joints is developed in this study.This mod-el accounts for the geometric complexity of fillet joints,the physical properties of shielding gases with varying He-Ar ratios,and the coupling between arc plasma and laser-induced metal plume.The accuracy of the model is validated using a high-speed camera.The effects of varying He contents in the shielding gas on both the temperature and flow velocity of hybrid plasma,as well as the distribu-tion of laser-induced metal vapor mass,were investigated separately.The maximum temperature and size of arc plasma decrease as the He volume ratio increases,the arc distribution becomes more concentrated,and its flow velocity initially decreases and then sharply increases.At high helium content,both the flow velocity of hybrid plasma and metal vapor are high,the metal vapor is con-centrated on the right side of keyhole,and its flow appears chaotic.The flow state of arc plasma is most stable when the shielding gas consists of 50%He+50%Ar.
基金the financial supports provided by the National Key Research and Development Program of China(2023YFE0201500)the National Natural Science Foundation of China(52375315)+2 种基金the Key Talent Plan Project of Guangdong Province(2023TQ07C702)the Research and Development Program in Key Areas of Dongguan(20201200300122)the GDAS’Project of Science and Technology Development(2022GDASZH-2022010203).
文摘Refill friction stir spot welding process is difficultly optimized by accurate modeling because of the high-order functional relationship between welding parameters and joint strength.A database of the welding process was first established with 6061-T6 aluminum alloy and DP780 galvanized steel as base materials.This dataset was then optimized using a backpropagation neural network.Analyses and mining of the experimental data confirmed the multidimensional mapping relationship between welding parameters and joint strength.Subsequently,intelligent optimization of the welding process and prediction of joint strength were achieved.At the predicted welding parameter(plunging rotation speedω1=1733 r/min,refilling rotation speedω_(2)=1266 r/min,plunging depth p=1.9 mm,and welding speed v=0.5 mm/s),the tensile shear fracture load of the joint reached a maximum value of 10,172 N,while the experimental result was 9980 N,with an error of 1.92%.Furthermore,the correlation of welding parameters-microstructure-joint strength was established.
文摘For high-power CO2 laser welding, besides two well known stable welding processes, i.e. stable deep penetration welding (DPW) and stable heat conduction welding (HCW), the authors have found the third welding process, i.e. unstable-mode welding (UMW) under the certain condition. UMW has its basic feature that the two welding modes (DPW and HCW) appear intermittently, with jumping of penetration depth and weld width between large and small levels. In this paper, effects of welding parameters (focal position, laser power and traveling speed) on laser welding mode and weld appearance have been comprehensively studied. Double-U curves of laser welding mode transition have been obtained, which indicate the ranges of the three mentioned welding processes. This work affords science foundation for selecting the welding process parameters correctly and obtaining stable laser welding.
基金Projects(31665004,31715011) supported by the Open Fund of State Key Laboratory of Advanced Design and Manufacture for Vehicle Body,Hunan University,ChinaProject(15C0450) supported by the Educational Commission of Hunan Province of China
文摘Four different welding sequences of double-pulse MIG welding were conducted for 6061-T6 aluminum alloy automobile bumpers by using nonlinear elastoplasticity finite element method based on ABAQUS software.The post-welding residual stress and deformation were definitely different among the four welding sequences.The results showed that the highest temperature in Solution A was approximately 200℃higher than the melting point of base metal.High residual stress was resulted from this large temperature gradient and mainly concentrated on the welding vicinity between beam and crash box.The welding deformation primarily occurred in both of the contraction of two-ends of the beam and the self-contraction of crash box.Compared with other welding sequences,the residual stress in Solution A was the smallest,whereas the welding deformation was the largest.However,the optimal sequence was Solution B because of the effective reduction of residual stress and good assembly requirements.
基金supported by the National Natural Science Foundation of China(Grant No.52035005)the Key R&D Program of Shandong Province in China(Grant No.2021ZLGX01).
文摘The composite structures/components made by friction stir lap welding(FSLW)of Mg alloy sheet and Al alloy sheet are of wide application potentials in the manufacturing sector of transportation vehicles.To further improve the joint quality,the ultrasonic vibration(UV)is exerted in FSLW,and the UV enhanced FSLW(UVeFSLW)was developed for making Mg-to-Al dissimilar joints.The numerical analysis and experimental investigation were combined to study the process mechanism in Mg/Al UVeFSLW.An equation related to the temperature and strain rate was derived to calculate the grain size at different locations of the weld nugget zone,and the effect of grain size distribution on the threshold thermal stress was included,so that the prediction accuracy of flow stress was further improved.With such modified constitutive equation,the numerical simulation was conducted to compare the heat generation,temperature profiles and material flow behaviors in Mg/Al UVeFSLW/FSLW processes.It was found that the exerted UV decreased the temperature at two checking points on the tool/workpiece interface from 707/671 K in FSLW to 689/660 K in UVeFSLW,which suppressed the IMCs thickness at Mg-Al interface from 1.7μm in FSLW to 1.1μm in UVeFSLW.The exerted UV increased the horizontal materials flow ability,and decreased the upward flow ability,which resulted in the increase of effective sheet thickness/effective lap width from 2.01/3.70 mm in FSLW to 2.04/4.84 mm in UVeFSLW.Therefore,the ultrasonic vibration improved the tensile shear strength of Mg-to-Al lap joints by 18%.
基金supported by the National Natural Science Foundation of China(Nos.52074228,52305420,and 51875470)the China Postdoctoral Science Foundation(No.2023M742830)。
文摘GH4169 joints manufactured by Linear Friction Welding(LFW)are subjected to tensile test and stair-case method to evaluate the High Cycle Fatigue(HCF)performance at 650℃.The yield and ultimate tensile strengths are 582 MPa and 820 MPa,respectively.The HCF strength of joint reaches 400 MPa,which is slightly lower than that of Base Metal(BM),indicating reliable quality of this type of joint.The microstructure observation results show that all cracks initiate at the inside of specimens and transfer into deeper region with decrease of external stress,and the crack initiation site is related with microhardness of matrix.The Electron Backscattered Diffraction(EBSD)results of the observed regions with different distances to fracture show that plastic deformation plays a key role in HCF,and the Schmid factor of most grains near fracture exceeds 0.4.In addition,the generation of twins plays a vital role in strain concentration release and coordinating plastic deformation among grains.
基金supports from National Key R&D Program of China(Grant No.2023YFB4605500)National Natural Science Foundation of China(Grant No.52105498)+3 种基金Natural Science Foundation of Hunan Province(Grant No.2022JJ40597)the Science and Technology Innovation Program of Hunan Province(Grant No.2022RC1132)State Key Laboratory of Precision Manufacturing for Extreme Service Performance(Grant No.ZZYJKT2023-08)support in analyzing the status of ultrafast laser welding applications,as well as the corresponding project support(Grant No.HKF202400595).
文摘The ultrafast laser-matter interaction is explored to induce new pioneering principles and technologies into the realms of fundamental science and industrial production.The local thermal melting and connection properties of the ultrafast laser welding technology offer a novel method for welding of diverse transparent materials,thus having wide range of potential applications in aerospace,opto-mechanical systems,sensors,microfluidic,optics,etc.In this comprehensive review,tuning the transient electron activation processes,high-rate laser energy deposition,and dynamic evolution of plasma morphology by the temporal/spatial shaping methods have been demonstrated to facilitate the transition from conventional homogeneous transparent material welding to the more intricate realm of transparent/metal heterogeneous material welding.The welding strength and stability are also improvable through the implementation of real-time,in-situ monitoring techniques and the prompt diagnosis of welding defects.The principles of ultrafast laser welding,bottleneck problems in the welding,novel welding methods,advances in welding performance,in-situ monitoring and diagnosis,and various applications are reviewed.Finally,we offer a forward-looking perspective on the fundamental challenges within the field of ultrafast laser welding and identify key areas for future research,underscoring the imperative need for ongoing innovation and exploration.
基金National Natural Science Foundation of China(52071165,52475347)National Program of Foreign Experts of China(G2023026003L)+4 种基金China Postdoctoral Fund(2023M740475)Program for Science&Technology Innovation Talents in Universities of Henan Province,China(22HASTIT026)Program for the Top Young Talents of Henan Province,China,Frontier Exploration Projects of Longmen Laboratory,China(LMQYTSKT016)Key Scientific Research Projects of Colleges and Universities in Henan Province,China(24A460008)Key Science and Technology Project of Henan Province,China(242102220064,222102230111)。
文摘Tungsten/molybdenum alloys are widely utilized in the nuclear industry,aerospace and various other fields due to their high melting points and strength characteristics.However,poor sinterability and processability make it difficult to manufacture largesize or complex-shaped parts.Hence,an in-depth study on the welding technology of tungsten/molybdenum alloys is urgent.An introduction of tungsten/molybdenum alloy welding defects and joining process was provided,along with recent advancements in brazing,spark plasma sintering diffusion bonding,electron beam welding and laser beam welding.The latest progress in alloy doping treatment applied to tungsten/molybdenum alloy dissimilar welding was also discussed,and existing welding problems were pointed out.The development prospects of weldability of tungsten/molybdenum alloy by various joining technologies were forecasted,thereby furnishing a theoretical and practical found.
基金Provincial Key Research and Development Plan of Heilongjiang(2022ZX04A01)。
文摘The optimization of deposited metal properties through the addition of rare earth elements to welding materials was explored.Utilizing optical microscope,scanning electron microscope,energy dispersive spectroscope,and X-ray diffractometer,combined with software tools like Matlab,Image-Pro Plus,and CHANNEL5,the influence mechanism of rare earth element addition on the strength,toughness,and inclusions of deposited metal in 1000 MPa grade high-strength steel was investigated.The results indicate that the incorporation of rare earth elements enhances the weldability of the welding materials.With the addition of rare earth elements,the tensile strength of the deposited metal increases from 935 MPa to 960 MPa.However,further addition leads to a decrease in tensile strength,while the yield strength continuously increases by 8.5%-17.2%.The addition of appropriate amounts of rare earth elements results in an increase in acicular ferrite and retained austenite content,as well as grain refinement in the deposited metal,leading to 8.5%-24.3% and 15.6%-42.2% enhancement in impact energy at−40℃ and−60℃,respectively.Additionally,the proper addition of rare earth elements modifies the inclusions and generates fine and dispersed composite inclusions that bond better with the matrix,thereby optimizing the properties of the deposited metal through various mechanisms.Adding an appropriate amount of rare earth elements can significantly enhance the properties of the deposited metal in 1000 MPa grade high-strength steel,and improve the match between high strength and toughness,meeting the demands for high-strength steel used in hydropower applications.
基金Project(61075005)supported by the Fund of State Key Laboratory of Advanced Design and Manufacture for Vehicle Body in Hunan University,ChinaProject(09JJ1007)supported by Preeminent Youth Fund of Hunan Province,ChinaProject(51075132)supported by the National Natural Science Foundation of China
文摘A three-dimensional finite element approach based on ABAQUS code was developed to investigate the effect of welding sequence on welding residual stress distribution in a thin-walled 6061 aluminum alloy structure. To obtain sound numerical results, the therrno-mechanical behaviour was simulated using a direct-coupled formulation. Nine different simulation sequences were carried out by single-pass TIG welding of an octagonal pipe-plate joint, and the distributions of longitudinal and transverse residual stresses both on the outer and inner surfaces of the pipe were analyzed. The results suggest that the final residual stresses in the weld and its vicinity are not affected by the initial residual stresses of the structure. Selecting a suitable welding sequence can reduce the final residual stress in an octagonal pipe-plate joint.
基金Project(51475156)supported by the National Natural Science Foundation of China
文摘The effect of current on the morphology of Al alloy T-joint in double-pulsed metal inert gas（DP-MIG） welding process was investigated by simulation and experiment.A three-dimensional finite element model and the DP-MIG heat source of double-ellipsoidal volumetric model were developed to simulate the temperature and stress fields under different welding conditions.The macro-morphology and microstructure of welding joints at the corresponding currents were observed in the experiment.The results show that the best condition is at an average current of 90 A and current difference of 40 A,when the maximum temperature is 200 °C higher than the fusion points,with the temperature difference of about 100 °C and stress change of 10 MPa between thermal pulse and thermal base.Under these conditions,Al alloy T-joint with proper fusion condition has smooth fish-scale welding appearance and finer microstructure.Furthermore,the thermal curves and stress distribution in the experiment are consistent with those in the simulation,verifying the precision of the welding simulation.
文摘In order to realize the automatic welding of pipes in a complex operation environment,an automatic welding system has been developed by use of all-position self-shielded flux cored wires due to their advantages,such as all-position weldability,good detachability,arc's stability,low incomplete fusion,no need for welding protective gas or protection against wind when the wind speed is<8 m/s.This system consists of a welding carrier,a guide rail,an auto-control system,a welding source,a wire feeder,and so on.Welding experiments with this system were performed on the X-80 pipeline steel to determine proper welding parameters.The welding technique comprises root welding,filling welding and cover welding and their welding parameters were obtained from experimental analysis.On this basis,the mechanical properties tests were carried out on welded joints in this case.Results show that this system can help improve the continuity and stability of the whole welding process and the welded joints'inherent quality,appearance shape,and mechanical performance can all meet the welding criteria for X-80 pipeline steel;with no need for windbreak fences,the overall welding cost will be sharply reduced.Meanwhile,more positive proposals were presented herein for the further research and development of this self-shielded flux core wires.
基金Projects (51101126, 51071123) supported by the National Natural Science Foundation of ChinaProjects (20110491684, 2012T50817) supported by the China Postdoctoral Science FoundationProject (20110942K) supported by the Open Fund of State Key Laboratory of Powder Metallurgy of Central South University, China
文摘An innovative physical simulation apparatus, including high speed camera, red thermal imaging system, and mechanical quantity sensor, was used to investigate the friction heat generation and atom diffusion behavior during Mg-Ti friction welding process. The results show that the friction coefficient mainly experiences two steady stages. The first steady stage corresponds to the Coulomb friction with material abrasion. The second steady stage corresponds to the stick friction with fully plastic flow. Moreover, the increasing rates of axial displacement, temperature and friction coefficient are obviously enhanced with the increase of rotation speed and axial pressure. It can also be found that the there exists rapid diffusion phenomenon in the Mg-Ti friction welding system. The large deformation activated diffusion coefficient is about 105 higher than that activated by thermal.
