The packaging quality of coaxial laser diodes(CLDs)plays a pivotal role in determining their optical performance and long-term reliability.As the core packaging process,high-precision laser welding requires precise co...The packaging quality of coaxial laser diodes(CLDs)plays a pivotal role in determining their optical performance and long-term reliability.As the core packaging process,high-precision laser welding requires precise control of process parameters to suppress optical power loss.However,the complex nonlinear relationship between welding parameters and optical power loss renders traditional trial-and-error methods inefficient and imprecise.To address this challenge,a physics-informed(PI)and data-driven collaboration approach for welding parameter optimization is proposed.First,thermal-fluid-solid coupling finite element method(FEM)was employed to quantify the sensitivity of welding parameters to physical characteristics,including residual stress.This analysis facilitated the identification of critical factors contributing to optical power loss.Subsequently,a Gaussian process regression(GPR)model incorporating finite element simulation prior knowledge was constructed based on the selected features.By introducing physics-informed kernel(PIK)functions,stress distribution patterns were embedded into the prediction model,achieving high-precision optical power loss prediction.Finally,a Bayesian optimization(BO)algorithm with an adaptive sampling strategy was implemented for efficient parameter space exploration.Experimental results demonstrate that the proposedmethod effectively establishes explicit physical correlations between welding parameters and optical power loss.The optimized welding parameters reduced optical power loss by 34.1%,providing theoretical guidance and technical support for reliable CLD packaging.展开更多
Avoiding crystallization while maintaining the original microstructure and mechanical properties of the material are long-term goals of laser welding of Zr-based bulk metallic glass(BMG).In this paper,the effect of pu...Avoiding crystallization while maintaining the original microstructure and mechanical properties of the material are long-term goals of laser welding of Zr-based bulk metallic glass(BMG).In this paper,the effect of pulsed laser welding parameters on the microstructure,crystallization degree,and mechanical properties of Zr57Nb5Cu15.4Ni12.6Al10 BMG is investigated.Non-crystallized welding forming of a zirconium-based amorphous alloy is achieved by optimizing the process parameters of pulsed laser welding.The crystallization degree of Zr-based BMG is mainly determined by the welding speed and power.The welding depth and crystallization area fraction increase with an increase in the effective peak power density.The optimized welding process can effectively reduce the heat accumulation of the weld,thus avoiding crystallization.The flexural strength of the weld can be maintained at 96.5%of the matrix.展开更多
In order to obtain good welding quality, it is necessary to apply quality control because there are many influencing factors in laser welding process. The key to realize welding quality control is to obtain the qualit...In order to obtain good welding quality, it is necessary to apply quality control because there are many influencing factors in laser welding process. The key to realize welding quality control is to obtain the quality information. Abundant weld quality information is contained in weld pool and keyhole. Aiming at Nd：YAG laser welding of stainless steel, a coaxial visual sensing system was constructed. The images of weld pool and keyhole were obtained. Based on the gray character of weld pool and keyhole in images, an image processing algorithm was designed. The search start point and search criteria of weld pool and keyhole edge were determined respectively.展开更多
Quenched and tempered steels are prone to hydrogen induced cracking in the heat affected zone after welding. The use of austenitic stainless steel consumables to weld the above steel was the only available remedy beca...Quenched and tempered steels are prone to hydrogen induced cracking in the heat affected zone after welding. The use of austenitic stainless steel consumables to weld the above steel was the only available remedy because of higher solubility for hydrogen in austenitic phase. In this investigation, an attempt was made to determine a suitable consumable to replace expensive austenitic consumables. Two different consumables, namely, austenitie stain less steel and low hydrogen ferritic steel, were used to fabricate the joints by shielded metal are welding （SMAW） and flux cored arc welding （FCAW） processes. The joints fabricated by using low hydrogen ferritic steel consumables showed superior transverse tensile properties, whereas joints fabricated by using austenitic stainless steel consumables exhibited better impact toughness, irrespective of the welding process used. The SMAW joints exhibited superior mechanical and impact properties, irrespective of the consumables used, than their FCAW counterparts.展开更多
Striving for cleaner production is a sought-after manufacturing philosophy.Friction stir welding(FSW)is a joiningtechnique with par excellence and far less invasive to the environment than even best conventional weldi...Striving for cleaner production is a sought-after manufacturing philosophy.Friction stir welding(FSW)is a joiningtechnique with par excellence and far less invasive to the environment than even best conventional welding processes.It is energyefficient and free from consumables,affluent and radiations.It is,thus,accepted as a clean welding process that can produceacceptable quality joints.It suffers from some major challenges of defects of its own kind that subject the process open toimprovements so as to prove itself a reliable production process.This study presents a holistic characterization of defects commonlyfound in FSW joints.The finding of the present study reveals that most defects are caused by inadequate heat generation,impropermaterial movement around the pin and inadequate material consolidation behind the pin.The amount of heat generation andmaterial stirring depends on several FSW parameters which may lead to the defect formation,if not selected properly.The resultsreported in this work are derived from sound literature support and experimentation.Prescriptions are made in the form ofcharacteristics of defects such as likelihood of their location,main responsible parameters along with the recommendations forminimizing them.展开更多
Friction stir welding(FSW),a highly effi cient solid-state joining technique,was invented at The Welding Institute,UK,in 1991.Utilizing frictional and adiabatic heating,plastic deformation and solid-state diff usion,F...Friction stir welding(FSW),a highly effi cient solid-state joining technique,was invented at The Welding Institute,UK,in 1991.Utilizing frictional and adiabatic heating,plastic deformation and solid-state diff usion,FSW has been widely accepted as a“green”welding technology owing to its energy effi ciency and environment friendliness.Now,FSW has achieved broad application in various industries,such as aerospace and transportation,and is considered the most signifi cant development in the fi eld of material joining over the past two decades.Friction stir processing(FSP),later developed based on the fundamental principles of FSW,has been demonstrated as an eff ective and versatile metalworking technique for modifying and fabricating metallic materials.展开更多
The statistical probability and their variation regularity of the measurable characteristic parameters in the CO 2 arc welding droplet short circuiting transfer process have been studied. The statistical analysis sh...The statistical probability and their variation regularity of the measurable characteristic parameters in the CO 2 arc welding droplet short circuiting transfer process have been studied. The statistical analysis shows that the sensitivity of each characteristic parameter with regard to the variation of the short circuiting transfer process is different. The sensitivity of 4 kinds among these characteristic parameters is more intense than that of the short circuiting transfer frequency. In order to take account of the synthetic influence of these characteristic parameters, by means of the characteristic parameters synthetic value, a quantitative evaluation function is built up to describe and evaluate the short circuiting transfer process of CO 2 arc welding in real time. The testing shows that the evaluation function can give a suitable synthetic valuation for the short circuiting transfer process with a variety of welding variables.展开更多
In this work, the current understanding and development of fliction-stir welding and processing of Ti- 6Al-4V alloy are briefly reviewed. The critical issues of these processes are addressed, including welding tool ma...In this work, the current understanding and development of fliction-stir welding and processing of Ti- 6Al-4V alloy are briefly reviewed. The critical issues of these processes are addressed, including welding tool materials and design, tool wea,, processing temperature, material flow, processing window and residual stresses. A particular emphasis is given to microstructural aspects and microstructure-properties relationship. Potential engineering applications are highlighted.展开更多
Based on the phase state reconstruction of welding current in short-circuiting gas metal arc welding using carbon dioxide as shielding gas, the approximate entropy of welding current as well as its standard deviation ...Based on the phase state reconstruction of welding current in short-circuiting gas metal arc welding using carbon dioxide as shielding gas, the approximate entropy of welding current as well as its standard deviation has been calculated and analysed to investigate their relation with the stability of electric arc and welding process. The extensive experimental and calculated results show that the approximate entropy of welding current is significantly and positively correlated with arc and welding process stability, whereas its standard deviation is correlated with them negatively. A larger approximate entropy and a smaller standard deviation imply a more stable arc and welding process, and vice versa. As a result, the approximate entropy of welding current promises well in assessing and quantifying the stability of electric arc and welding process in short-circuiting gas metal arc welding.展开更多
An experimental setup of acquiring the coaxial visual image of the molten pool and keyhole in high power Nd:YAG laser welding is introduced in this paper. It is one of the most difficult problems in acquiring coaxial ...An experimental setup of acquiring the coaxial visual image of the molten pool and keyhole in high power Nd:YAG laser welding is introduced in this paper. It is one of the most difficult problems in acquiring coaxial image that the coaxial imaging signal of molten pool and keyhole must be separated from the laser beam with high power. This problem was resolved by designing a dichroitic spectroscope. The characteristics of imaging signal were analyzed and the coaxial image of molten pool and keyhole was acquired. A smoothing filter and a homomorphic filter were designed to remove the low frequency noise and to enhance the image according to the characteristics of imaging signal. At last, edges of molten pool and keyhole were detected and extracted based on image segmentation with threshold.展开更多
A detailed microstructural characterisation of the emerging weld-line grain structure,for bead-upon-plate welds in Ti-6Al-4V(Ti64)of differing plate thickness,was performed.The microstructure studied was formed during...A detailed microstructural characterisation of the emerging weld-line grain structure,for bead-upon-plate welds in Ti-6Al-4V(Ti64)of differing plate thickness,was performed.The microstructure studied was formed during both steady state and non-steady state sections within the weld path,with the non-steady state portion being taken from the end of the plate as the weld bead and heat source overhang the edge of the plate.This allows for the effects of welding process conditions on the microstructural evolution to be determined.The weld pool geometry and 3D tomography of the weld-induced defects have been investigated.Detailed characterisation of microstructure and texture for different welding parameters and for steady and non-steady states have been used to identify physical parameters for the microstructure predictions that are difficult to obtain otherwise.The different states significantly affect the weld crown shape and formation,weld toe,weld bead depth and width.However,the heat affected zone(HAZ)re-mains unchanged.Regarding the microstructural evolution,both the steady and non-steady states have similar microstructure and texture.No defects were observed in the steady state section of welds,but sub-surface spherical pores have been observed in the non-steady state section of a weld.Finite element modelling to simulate the thermal-metallurgical-mechanical fields within the steady and non-steady state sections of the welds was considered,and the cooling rates predicted within steady state and non-steady sections were interrogated to improve the theoretical understanding of the microstructure and defect formation differences in these Ti64 EB weld regions.展开更多
Cable welding wire（CWW）CO2gas shielded welding is an innovative process arc welding with high efficiency,high quality and low consumption,in which cable wire is used as consumable electrode.CWW CO2gas shielded weldi...Cable welding wire（CWW）CO2gas shielded welding is an innovative process arc welding with high efficiency,high quality and low consumption,in which cable wire is used as consumable electrode.CWW CO2gas shielded welding and submerged arc welding（SAW）are used for contrast studies on processing property of high strength steel A36used in ship structure.The results show that the shapes of weld seam,using CWW CO2gas shielded welding and SAW,are good and no weld defect such as air hole,flaw,slag inclusion,incomplete fusion,lack of penetration and so on are found in the weld seam.Because the rotating of arc during CWW CO2gas shielded welding process has a strong stirring effect on molten pool,the grain in the heat affected zone（HAZ）of the joints,using CWW CO2 gas shielded welding,is small.Tensile failure positions of joints by CWW CO2gas shielded welding and SAW are all in the base metal,but tensile strength of CWW CO2gas shielded welding joint is higher than that of SAW joint by an average of 2.3%.The average impact energy of HAZ,using CWW CO2gas shielded welding and SAW,is almost equal,but the average impact energy of the weld seam using CWW CO2gas shielded welding is increased by 6%,and the average impact energy of the fusion line is increased by 7%.The 180°bending tests for the joints of CWW CO2 gas shielded welding and SAW are all qualified,and the joints hardness is all less than HV 355,but hardness of CWW CO2gas shielded welding wire welding joint near the fusion line is obviously lower.It can be concluded that the properties of CWW CO2gas shielded welding are better than those of the SAW joint,and CWW CO2gas shielded welding is suitable for welding high strength steel A36used in ship structure.展开更多
Friction stir welding [FSW） has achieved remarkable success in the joining and processing of aluminium alloys and other softer structural alloys. Conventional FSW, however, has not been entirely successful in the joi...Friction stir welding [FSW） has achieved remarkable success in the joining and processing of aluminium alloys and other softer structural alloys. Conventional FSW, however, has not been entirely successful in the joining, processing and manufacturing of different desired materials essential to meet the sophis- ticated green globe requirements. Through the efforts of improving the process and transferring the existing friction stir knowledge base to other advanced applications, several friction stir based daughter technologies have emerged over the timeline, A few among these technologies are well developed while others are under the process of emergence. Beginning with a broad classification of the scattered fric- tions stir based technologies into two categories, welding and processing, it appears now time to know, compile and review these to enable their rapid access for reference and academia. In this review article, the friction stir based technologies classified under the categol^J of welding are those applied for join- ing of materials while the remnant are labeled as friction stir processing （FSP） technologies. This review article presents an overview of four general aspects of both the developed and the developing friction stir based technologies, their associated process parameters, metallurgical features of their products and their feasibility and application to various materials. The lesser known and emerging technologies have been emphasized.展开更多
In order to overcome the problems of many pores,large deformation and unstable weld quality of traditional laser welded aluminumcopper alloy joints,a red-blue dual-beam laser source and a swinging laser were introduce...In order to overcome the problems of many pores,large deformation and unstable weld quality of traditional laser welded aluminumcopper alloy joints,a red-blue dual-beam laser source and a swinging laser were introduced for welding.T2 copper and 6063 aluminum thin plates were lap welded by coaxial dual-beam laser welding.The morphology of weld cross section was compared to explore the influence of process parameters on the formation of lap joints.The microstructure characteristics of the weld zone were observed and compared by optical microscope.The results show that the addition of laser beam swing can eliminate the internal pores of the weld.With the increase of the swing width,the weld depth decreases,and the weld width increases first and then decreases.The influence of welding speed on the weld cross section morphology is similar to that of swing width.With the increase of welding speed,the weld width increases first and then decreases,while the weld depth decreases all the time.This is because that the red laser is used as the main heat source to melt the base metals,with the increase of red laser power,the weld depth increases.As an auxiliary laser source,blue laser reduces the total energy consumption,consequently,the effective heat input increases and the spatter is restrained effectively.As a result,the increase of red laser power has an enhancement effect on the weld width and weld depth.When the swing width is 1.2 mm,the red laser power is 550 W,the blue laser power is 500 W,and the welding speed is 35 mm/s,the weld forming is the best.The lap joint of T2 copper and 6063 aluminum alloy thin plate can be connected stably with the hybrid of blue laser.The effect rules of laser beam swing on the weld formation were obtained,which improved the quality of the joints.展开更多
The existing research of welding arc mainly focuses on the stable combustion state and the research on the mechanism of welding arc ignition process is quite lack.The tungsten inert gas（TIG） touch arc ignition proce...The existing research of welding arc mainly focuses on the stable combustion state and the research on the mechanism of welding arc ignition process is quite lack.The tungsten inert gas（TIG） touch arc ignition process is observed via a high speed camera and the high time resolution spectral diagnosis system.The changing phenomenon of main ionized element provided the electrons in the arc ignition is found.The metallic element is the main contributor to provide the electrons at the beginning of the discharging,and then the excitated shielding gas element replaces the function of the metallic element.The electron density during the period of the arc ignition is calculated by the Stark-broadened lines of Hα.Through the discussion with the repeatability in relaxation phenomenon,the statistical regularity in the arc ignition process is analyzed.The similar rules as above are observed through the comparison with the laser-assisted arc ignition experiments and the metal inert gas（MIG） arc ignition experiments.This research is helpful to further understanding on the generation mechanism of welding arc ignition and also has a certain academic and practical significance on enriching the welding physical theoretical foundation and improving the precise monitoring on automatic arc welding process.展开更多
This review article aims to analyze and evaluate the advantages, shortcomings, technological advancements and hereafter prospects in welding and processing of magnesium and its alloys. Studies have accounted that repl...This review article aims to analyze and evaluate the advantages, shortcomings, technological advancements and hereafter prospects in welding and processing of magnesium and its alloys. Studies have accounted that replacing other metals with Mg alloys will bring about in monumental weight reduction with significant addition in strength that could lead to dramatic transformation of metallic era of 21st century and onwards. However,wide application of Mg and its alloys depends on the development of advanced welding &joining technologies. The current paradigm and progress in welding,joining and processing of magnesium and its alloys are reviewed,and research trend in this field is briefly discussed.展开更多
The dynamic thermal process during double-sided asymmetrical TIG backing welding of large thick plates （ 1 000 mm×700 mm×50 mm） is numerically simulated using MSC. MARC. The effect of arc distance on the t...The dynamic thermal process during double-sided asymmetrical TIG backing welding of large thick plates （ 1 000 mm×700 mm×50 mm） is numerically simulated using MSC. MARC. The effect of arc distance on the thermal cycle in weld zone during double-sided asymmetrical T1G backing welding is investigated. The results show that the workpiece experiences double-peak thermal cycle in double-sided asymmetrical TIG backing welding. On the one hand, the fore arc has the pre- heating effect on the rear pass, and the pre-heating temperature depends on the distance between the double arcs, the heat input of fore arc, and the initial temperature of workpiece. On the other hand, the rear arc has the post-heating effect on the fore pass. The mutual effects of two heat sources decrease with the increase of arc distance.展开更多
Computer vision has come into used in the fields of welding process control and automation. In order to improve precision and rapidity of welding image processing, a novel method based on fractal theory has been put f...Computer vision has come into used in the fields of welding process control and automation. In order to improve precision and rapidity of welding image processing, a novel method based on fractal theory has been put forward in this paper. Compared with traditional methods, the image is preliminarily processed in the macroscopic regions then thoroughly analyzed in the microscopic regions in the new method. With which, an image is divided up to some regions according to the different fractal characters of image edge, and the fuzzy regions including image edges are detected out, then image edges are identified with Sobel operator and curved by LSM (Lease Square Method). Since the data to be processed have been decreased and the noise of image has been reduced, it has been testified through experiments that edges of weld seam or weld pool could be recognized correctly and quickly.展开更多
In the proposed method, the current/arc is guided through the keyhole so that the energy of the plasma jet is compensated while it is consumed in heating the workpiece along the keyhole. As a result, deep narrow penet...In the proposed method, the current/arc is guided through the keyhole so that the energy of the plasma jet is compensated while it is consumed in heating the workpiece along the keyhole. As a result, deep narrow penetration has been achieved on 12.7 mm (1/2') thick stainless steel plates using 70 A welding current.展开更多
Sealing quality strongly affects heat pipe performance, but few studies focus on the process of heat pipe sealing. Cold welding sealing technology based on a stamping process is applied for heat pipe sealing. The bond...Sealing quality strongly affects heat pipe performance, but few studies focus on the process of heat pipe sealing. Cold welding sealing technology based on a stamping process is applied for heat pipe sealing. The bonding mechanism of the cold welding sealing process （CWSP） is investigated and compared with the experimental results obtained from the bonding interface analysis. An orthogonal experiment is conducted to observe the effects of various parameters, including the sealing gap, sealing length, sealing diameter, and sealing velocity on bonding strength. A method with the utilization of saturated vapor pressure inside a copper tube is proposed to evaluate bonding strength. A corresponding finite element model is developed to investigate the effects of sealing gap and sealing velocity on plastic deformation during the cold welding process. Effects of various parameters on the bonding strength are determined and it is found that the sealing gap is the most critical factor and that the sealing velocity contributes the least effect. The best parameter combination （AIB3CID3, with a 0.5 mm sealing gap, 6 mm sealing length, 3.8 mm sealing diameter, and 50 mm/s sealing velocity） is derived within the experimental parameters. Plastic deformation results derived from the finite element model are consistent with those from the experiment. The instruction for the CWSP of heat pipes and the design of sealing dies of heat pipes are provided.展开更多
基金funded by the National Key R&D Program of China,Grant No.2024YFF0504904.
文摘The packaging quality of coaxial laser diodes(CLDs)plays a pivotal role in determining their optical performance and long-term reliability.As the core packaging process,high-precision laser welding requires precise control of process parameters to suppress optical power loss.However,the complex nonlinear relationship between welding parameters and optical power loss renders traditional trial-and-error methods inefficient and imprecise.To address this challenge,a physics-informed(PI)and data-driven collaboration approach for welding parameter optimization is proposed.First,thermal-fluid-solid coupling finite element method(FEM)was employed to quantify the sensitivity of welding parameters to physical characteristics,including residual stress.This analysis facilitated the identification of critical factors contributing to optical power loss.Subsequently,a Gaussian process regression(GPR)model incorporating finite element simulation prior knowledge was constructed based on the selected features.By introducing physics-informed kernel(PIK)functions,stress distribution patterns were embedded into the prediction model,achieving high-precision optical power loss prediction.Finally,a Bayesian optimization(BO)algorithm with an adaptive sampling strategy was implemented for efficient parameter space exploration.Experimental results demonstrate that the proposedmethod effectively establishes explicit physical correlations between welding parameters and optical power loss.The optimized welding parameters reduced optical power loss by 34.1%,providing theoretical guidance and technical support for reliable CLD packaging.
基金Supported by Guangdong Major Project of Basic and Applied Research,China(Grant No.2019B030302010)National Natural Science Foundation of China (Grant Nos.51735003,52205456)
文摘Avoiding crystallization while maintaining the original microstructure and mechanical properties of the material are long-term goals of laser welding of Zr-based bulk metallic glass(BMG).In this paper,the effect of pulsed laser welding parameters on the microstructure,crystallization degree,and mechanical properties of Zr57Nb5Cu15.4Ni12.6Al10 BMG is investigated.Non-crystallized welding forming of a zirconium-based amorphous alloy is achieved by optimizing the process parameters of pulsed laser welding.The crystallization degree of Zr-based BMG is mainly determined by the welding speed and power.The welding depth and crystallization area fraction increase with an increase in the effective peak power density.The optimized welding process can effectively reduce the heat accumulation of the weld,thus avoiding crystallization.The flexural strength of the weld can be maintained at 96.5%of the matrix.
基金Project (10776020) supported by the Joint Foundation of the National Natural Science Foundation of China and China Academy of Engineering Physics
文摘In order to obtain good welding quality, it is necessary to apply quality control because there are many influencing factors in laser welding process. The key to realize welding quality control is to obtain the quality information. Abundant weld quality information is contained in weld pool and keyhole. Aiming at Nd：YAG laser welding of stainless steel, a coaxial visual sensing system was constructed. The images of weld pool and keyhole were obtained. Based on the gray character of weld pool and keyhole in images, an image processing algorithm was designed. The search start point and search criteria of weld pool and keyhole edge were determined respectively.
文摘Quenched and tempered steels are prone to hydrogen induced cracking in the heat affected zone after welding. The use of austenitic stainless steel consumables to weld the above steel was the only available remedy because of higher solubility for hydrogen in austenitic phase. In this investigation, an attempt was made to determine a suitable consumable to replace expensive austenitic consumables. Two different consumables, namely, austenitie stain less steel and low hydrogen ferritic steel, were used to fabricate the joints by shielded metal are welding （SMAW） and flux cored arc welding （FCAW） processes. The joints fabricated by using low hydrogen ferritic steel consumables showed superior transverse tensile properties, whereas joints fabricated by using austenitic stainless steel consumables exhibited better impact toughness, irrespective of the welding process used. The SMAW joints exhibited superior mechanical and impact properties, irrespective of the consumables used, than their FCAW counterparts.
基金the University Grants Commission (UGC) for its financial assistance (vide sanction order No. F.3-40/2012(SAP-Ⅱ)) under its SAP (DRS-Ⅰ) sanctioned to the Department of Mechanical Engineering for the project entitled Friction Stir Welding and Ultrasonic Machiningfinancially supported by the King Saud University, Vice Deanship of Research Chairs
文摘Striving for cleaner production is a sought-after manufacturing philosophy.Friction stir welding(FSW)is a joiningtechnique with par excellence and far less invasive to the environment than even best conventional welding processes.It is energyefficient and free from consumables,affluent and radiations.It is,thus,accepted as a clean welding process that can produceacceptable quality joints.It suffers from some major challenges of defects of its own kind that subject the process open toimprovements so as to prove itself a reliable production process.This study presents a holistic characterization of defects commonlyfound in FSW joints.The finding of the present study reveals that most defects are caused by inadequate heat generation,impropermaterial movement around the pin and inadequate material consolidation behind the pin.The amount of heat generation andmaterial stirring depends on several FSW parameters which may lead to the defect formation,if not selected properly.The resultsreported in this work are derived from sound literature support and experimentation.Prescriptions are made in the form ofcharacteristics of defects such as likelihood of their location,main responsible parameters along with the recommendations forminimizing them.
文摘Friction stir welding(FSW),a highly effi cient solid-state joining technique,was invented at The Welding Institute,UK,in 1991.Utilizing frictional and adiabatic heating,plastic deformation and solid-state diff usion,FSW has been widely accepted as a“green”welding technology owing to its energy effi ciency and environment friendliness.Now,FSW has achieved broad application in various industries,such as aerospace and transportation,and is considered the most signifi cant development in the fi eld of material joining over the past two decades.Friction stir processing(FSP),later developed based on the fundamental principles of FSW,has been demonstrated as an eff ective and versatile metalworking technique for modifying and fabricating metallic materials.
文摘The statistical probability and their variation regularity of the measurable characteristic parameters in the CO 2 arc welding droplet short circuiting transfer process have been studied. The statistical analysis shows that the sensitivity of each characteristic parameter with regard to the variation of the short circuiting transfer process is different. The sensitivity of 4 kinds among these characteristic parameters is more intense than that of the short circuiting transfer frequency. In order to take account of the synthetic influence of these characteristic parameters, by means of the characteristic parameters synthetic value, a quantitative evaluation function is built up to describe and evaluate the short circuiting transfer process of CO 2 arc welding in real time. The testing shows that the evaluation function can give a suitable synthetic valuation for the short circuiting transfer process with a variety of welding variables.
文摘In this work, the current understanding and development of fliction-stir welding and processing of Ti- 6Al-4V alloy are briefly reviewed. The critical issues of these processes are addressed, including welding tool materials and design, tool wea,, processing temperature, material flow, processing window and residual stresses. A particular emphasis is given to microstructural aspects and microstructure-properties relationship. Potential engineering applications are highlighted.
基金Project supported by the National Natural Science Foundation of China(Grant Nos50375053 and 50575077)
文摘Based on the phase state reconstruction of welding current in short-circuiting gas metal arc welding using carbon dioxide as shielding gas, the approximate entropy of welding current as well as its standard deviation has been calculated and analysed to investigate their relation with the stability of electric arc and welding process. The extensive experimental and calculated results show that the approximate entropy of welding current is significantly and positively correlated with arc and welding process stability, whereas its standard deviation is correlated with them negatively. A larger approximate entropy and a smaller standard deviation imply a more stable arc and welding process, and vice versa. As a result, the approximate entropy of welding current promises well in assessing and quantifying the stability of electric arc and welding process in short-circuiting gas metal arc welding.
文摘An experimental setup of acquiring the coaxial visual image of the molten pool and keyhole in high power Nd:YAG laser welding is introduced in this paper. It is one of the most difficult problems in acquiring coaxial image that the coaxial imaging signal of molten pool and keyhole must be separated from the laser beam with high power. This problem was resolved by designing a dichroitic spectroscope. The characteristics of imaging signal were analyzed and the coaxial image of molten pool and keyhole was acquired. A smoothing filter and a homomorphic filter were designed to remove the low frequency noise and to enhance the image according to the characteristics of imaging signal. At last, edges of molten pool and keyhole were detected and extracted based on image segmentation with threshold.
基金support under the Manufacturing Portfolio collaborative project between Rolls-Royce plc,Partnership for Research in Simulation of Manufacturing and Materials (PRISM2),the University of Birmingham
文摘A detailed microstructural characterisation of the emerging weld-line grain structure,for bead-upon-plate welds in Ti-6Al-4V(Ti64)of differing plate thickness,was performed.The microstructure studied was formed during both steady state and non-steady state sections within the weld path,with the non-steady state portion being taken from the end of the plate as the weld bead and heat source overhang the edge of the plate.This allows for the effects of welding process conditions on the microstructural evolution to be determined.The weld pool geometry and 3D tomography of the weld-induced defects have been investigated.Detailed characterisation of microstructure and texture for different welding parameters and for steady and non-steady states have been used to identify physical parameters for the microstructure predictions that are difficult to obtain otherwise.The different states significantly affect the weld crown shape and formation,weld toe,weld bead depth and width.However,the heat affected zone(HAZ)re-mains unchanged.Regarding the microstructural evolution,both the steady and non-steady states have similar microstructure and texture.No defects were observed in the steady state section of welds,but sub-surface spherical pores have been observed in the non-steady state section of a weld.Finite element modelling to simulate the thermal-metallurgical-mechanical fields within the steady and non-steady state sections of the welds was considered,and the cooling rates predicted within steady state and non-steady sections were interrogated to improve the theoretical understanding of the microstructure and defect formation differences in these Ti64 EB weld regions.
基金Sponsored by National Natural Science Foundation of China(51275224,51005106)Prospective Joint Research Project ofJiangsu Province of China(BY2012184)
文摘Cable welding wire（CWW）CO2gas shielded welding is an innovative process arc welding with high efficiency,high quality and low consumption,in which cable wire is used as consumable electrode.CWW CO2gas shielded welding and submerged arc welding（SAW）are used for contrast studies on processing property of high strength steel A36used in ship structure.The results show that the shapes of weld seam,using CWW CO2gas shielded welding and SAW,are good and no weld defect such as air hole,flaw,slag inclusion,incomplete fusion,lack of penetration and so on are found in the weld seam.Because the rotating of arc during CWW CO2gas shielded welding process has a strong stirring effect on molten pool,the grain in the heat affected zone（HAZ）of the joints,using CWW CO2 gas shielded welding,is small.Tensile failure positions of joints by CWW CO2gas shielded welding and SAW are all in the base metal,but tensile strength of CWW CO2gas shielded welding joint is higher than that of SAW joint by an average of 2.3%.The average impact energy of HAZ,using CWW CO2gas shielded welding and SAW,is almost equal,but the average impact energy of the weld seam using CWW CO2gas shielded welding is increased by 6%,and the average impact energy of the fusion line is increased by 7%.The 180°bending tests for the joints of CWW CO2 gas shielded welding and SAW are all qualified,and the joints hardness is all less than HV 355,but hardness of CWW CO2gas shielded welding wire welding joint near the fusion line is obviously lower.It can be concluded that the properties of CWW CO2gas shielded welding are better than those of the SAW joint,and CWW CO2gas shielded welding is suitable for welding high strength steel A36used in ship structure.
基金financial support on this work from the National Natural Science Foundation of China(Grant Nos.51475272 and 51550110501)Shandong University for the Postdoctoral fellowship
文摘Friction stir welding [FSW） has achieved remarkable success in the joining and processing of aluminium alloys and other softer structural alloys. Conventional FSW, however, has not been entirely successful in the joining, processing and manufacturing of different desired materials essential to meet the sophis- ticated green globe requirements. Through the efforts of improving the process and transferring the existing friction stir knowledge base to other advanced applications, several friction stir based daughter technologies have emerged over the timeline, A few among these technologies are well developed while others are under the process of emergence. Beginning with a broad classification of the scattered fric- tions stir based technologies into two categories, welding and processing, it appears now time to know, compile and review these to enable their rapid access for reference and academia. In this review article, the friction stir based technologies classified under the categol^J of welding are those applied for join- ing of materials while the remnant are labeled as friction stir processing （FSP） technologies. This review article presents an overview of four general aspects of both the developed and the developing friction stir based technologies, their associated process parameters, metallurgical features of their products and their feasibility and application to various materials. The lesser known and emerging technologies have been emphasized.
基金supported by Guangdong Science and Technology Plan Project(Grant No.20170902,No.20180902)Yangjiang Science and Technology Plan Project(Grant No.SDZX2020063)+1 种基金Shenzhen Key Projects of Innovation and Entrepreneurship Plan Technology(JSGG20210420091802007)Yunfu 2023 Science and Technology Plan Project(S2023020201).
文摘In order to overcome the problems of many pores,large deformation and unstable weld quality of traditional laser welded aluminumcopper alloy joints,a red-blue dual-beam laser source and a swinging laser were introduced for welding.T2 copper and 6063 aluminum thin plates were lap welded by coaxial dual-beam laser welding.The morphology of weld cross section was compared to explore the influence of process parameters on the formation of lap joints.The microstructure characteristics of the weld zone were observed and compared by optical microscope.The results show that the addition of laser beam swing can eliminate the internal pores of the weld.With the increase of the swing width,the weld depth decreases,and the weld width increases first and then decreases.The influence of welding speed on the weld cross section morphology is similar to that of swing width.With the increase of welding speed,the weld width increases first and then decreases,while the weld depth decreases all the time.This is because that the red laser is used as the main heat source to melt the base metals,with the increase of red laser power,the weld depth increases.As an auxiliary laser source,blue laser reduces the total energy consumption,consequently,the effective heat input increases and the spatter is restrained effectively.As a result,the increase of red laser power has an enhancement effect on the weld width and weld depth.When the swing width is 1.2 mm,the red laser power is 550 W,the blue laser power is 500 W,and the welding speed is 35 mm/s,the weld forming is the best.The lap joint of T2 copper and 6063 aluminum alloy thin plate can be connected stably with the hybrid of blue laser.The effect rules of laser beam swing on the weld formation were obtained,which improved the quality of the joints.
基金supported by National Natural Science Foundation of China(Grant No. 50375005)
文摘The existing research of welding arc mainly focuses on the stable combustion state and the research on the mechanism of welding arc ignition process is quite lack.The tungsten inert gas（TIG） touch arc ignition process is observed via a high speed camera and the high time resolution spectral diagnosis system.The changing phenomenon of main ionized element provided the electrons in the arc ignition is found.The metallic element is the main contributor to provide the electrons at the beginning of the discharging,and then the excitated shielding gas element replaces the function of the metallic element.The electron density during the period of the arc ignition is calculated by the Stark-broadened lines of Hα.Through the discussion with the repeatability in relaxation phenomenon,the statistical regularity in the arc ignition process is analyzed.The similar rules as above are observed through the comparison with the laser-assisted arc ignition experiments and the metal inert gas（MIG） arc ignition experiments.This research is helpful to further understanding on the generation mechanism of welding arc ignition and also has a certain academic and practical significance on enriching the welding physical theoretical foundation and improving the precise monitoring on automatic arc welding process.
基金Sponsored by the State Key Laboratory of Advanced Welding and Joining,Harbin Institute of Technology(Grant No.AWJ-Z16-05)
文摘This review article aims to analyze and evaluate the advantages, shortcomings, technological advancements and hereafter prospects in welding and processing of magnesium and its alloys. Studies have accounted that replacing other metals with Mg alloys will bring about in monumental weight reduction with significant addition in strength that could lead to dramatic transformation of metallic era of 21st century and onwards. However,wide application of Mg and its alloys depends on the development of advanced welding &joining technologies. The current paradigm and progress in welding,joining and processing of magnesium and its alloys are reviewed,and research trend in this field is briefly discussed.
文摘The dynamic thermal process during double-sided asymmetrical TIG backing welding of large thick plates （ 1 000 mm×700 mm×50 mm） is numerically simulated using MSC. MARC. The effect of arc distance on the thermal cycle in weld zone during double-sided asymmetrical T1G backing welding is investigated. The results show that the workpiece experiences double-peak thermal cycle in double-sided asymmetrical TIG backing welding. On the one hand, the fore arc has the pre- heating effect on the rear pass, and the pre-heating temperature depends on the distance between the double arcs, the heat input of fore arc, and the initial temperature of workpiece. On the other hand, the rear arc has the post-heating effect on the fore pass. The mutual effects of two heat sources decrease with the increase of arc distance.
文摘Computer vision has come into used in the fields of welding process control and automation. In order to improve precision and rapidity of welding image processing, a novel method based on fractal theory has been put forward in this paper. Compared with traditional methods, the image is preliminarily processed in the macroscopic regions then thoroughly analyzed in the microscopic regions in the new method. With which, an image is divided up to some regions according to the different fractal characters of image edge, and the fuzzy regions including image edges are detected out, then image edges are identified with Sobel operator and curved by LSM (Lease Square Method). Since the data to be processed have been decreased and the noise of image has been reduced, it has been testified through experiments that edges of weld seam or weld pool could be recognized correctly and quickly.
基金This work is supported by the National Natural Science Foundation under Grant DMI-9812981
文摘In the proposed method, the current/arc is guided through the keyhole so that the energy of the plasma jet is compensated while it is consumed in heating the workpiece along the keyhole. As a result, deep narrow penetration has been achieved on 12.7 mm (1/2') thick stainless steel plates using 70 A welding current.
基金Supported by National Natural Science Foundation of China(Grant Nos.51175186,51675185)Guangdong Provincial Natural Science Foundation of China(Grant No.S2013020012757)EU project PIIF-GA-2012-332304(Grant No.ESR332304)
文摘Sealing quality strongly affects heat pipe performance, but few studies focus on the process of heat pipe sealing. Cold welding sealing technology based on a stamping process is applied for heat pipe sealing. The bonding mechanism of the cold welding sealing process （CWSP） is investigated and compared with the experimental results obtained from the bonding interface analysis. An orthogonal experiment is conducted to observe the effects of various parameters, including the sealing gap, sealing length, sealing diameter, and sealing velocity on bonding strength. A method with the utilization of saturated vapor pressure inside a copper tube is proposed to evaluate bonding strength. A corresponding finite element model is developed to investigate the effects of sealing gap and sealing velocity on plastic deformation during the cold welding process. Effects of various parameters on the bonding strength are determined and it is found that the sealing gap is the most critical factor and that the sealing velocity contributes the least effect. The best parameter combination （AIB3CID3, with a 0.5 mm sealing gap, 6 mm sealing length, 3.8 mm sealing diameter, and 50 mm/s sealing velocity） is derived within the experimental parameters. Plastic deformation results derived from the finite element model are consistent with those from the experiment. The instruction for the CWSP of heat pipes and the design of sealing dies of heat pipes are provided.
