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
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
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
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
In order to solve the problem of poor formability caused by different materials and properties in the process of tailor-welded sheets forming,a forming method was proposed to change the stress state of tailor-welded s...In order to solve the problem of poor formability caused by different materials and properties in the process of tailor-welded sheets forming,a forming method was proposed to change the stress state of tailor-welded sheets by covering the tailor-welded sheets with better plastic properties overlapping sheets.At the same time,the interface friction effect between the overlapping and tailor-welded sheets was utilized to control the stress magnitude and further improve the formability and quality of the tailor-welded sheets.In this work,the bulging process of the tailor-welded overlapping sheets was taken as the research object.Aluminum alloy tailor-welded overlapping sheets bulging specimens were studied by a combination of finite element analysis and experimental verification.The results show that the appropriate use of interface friction between tailor-welded and overlapping sheets can improve the formability of tailor-welded sheets and control the flow of weld seam to improve the forming quality.When increasing the interface friction coefficient on the side of tailor-welded sheets with higher strength and decreasing that on the side of tailor-welded sheets with lower strength,the deformation of the tailor-welded sheets are more uniform,the offset of the weld seam is minimal,the limit bulging height is maximal,and the forming quality is optimal.展开更多
The quality of rebar welds directly impacts the overall service performance of highway infrastructure.However,current assessments of weld appearance quality primarily rely on traditional inspection methods such as man...The quality of rebar welds directly impacts the overall service performance of highway infrastructure.However,current assessments of weld appearance quality primarily rely on traditional inspection methods such as manual visual inspection,which suffer from significant limitations in accuracy,reliability,and efficiency.Given the increasing demand for safety performance inspections of highway infrastructure in China,traditional methods struggle to meet modern rapid inspection requirements.Therefore,this study proposes the design of a portable,non-destructive inspection device for rebar weld appearance,utilizing visible light vision and line-structured light 3D scanning technology.The device is equipped with an STM32 master control chip to manage encoder reading,scanning laser control,ring fill light,industrial camera synchronization,image acquisition,and serial port command transmission.Additionally,a weld image processing and detection software system was developed to receive,store,and identify weld defects.A field inspection prototype was created and subjected to various defect weld detection experiments in a laboratory setting.Experimental results demonstrate that the device can accurately measure weld parameters by acquiring multimodal images,fulfilling defect detection requirements.The device features high detection accuracy,portability,and user-friendliness,making it significant for the objective inspection and evaluation of rebar weld appearance and welding quality.展开更多
The study aimed to address the issue of elevated residual stress levels in dissimilar girth welds of cast steel joints.To achieve this,the hybrid welding technology,which yields high welding speeds while simultaneousl...The study aimed to address the issue of elevated residual stress levels in dissimilar girth welds of cast steel joints.To achieve this,the hybrid welding technology,which yields high welding speeds while simultaneously reducing residual stresses,has been introduced.This study utilizes a numerical simulation method to investigate the temperature and residual stress field in the hybrid welding of G20Mn5 casting-Q355 low-alloy steel welded pipe.A com-parison of the findings of this study with those of other welding processes revealed the technological advantages of hybrid welding.The research outcomes show that due to geometric discontinuities and material differences,the temperature field of the joint exhibits uneven distribution characteristics,and the peak temperatures on the Q355 steel side exceeds those on the G20Mn5 steel side.An evident stress gra-dient is present in the residual stress field of the joint post-welding,with peak stress located at the weld root on the Q355 steel.Compared with arc welding,the hybrid welding leads to decreased residual stresses and deformation,with high stress outside the heat-affected zone diminishing rapidly.Furthermore,it significantly improves the welding efficiency.This study elucidates the distribution and underlying causes of thermal and residual stress fields in dissimilar girth welds.This serves as a foundation for the application of hybrid welding technology in welded cast steel 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
This study analyzed through-thickness distribution of residual stress in a 106 mm ultra-thick TC4 titanium alloy electron beam welded(EBW)joint after post weld heat treatment(PWHT)using X-ray diffraction(XRD)and deep-...This study analyzed through-thickness distribution of residual stress in a 106 mm ultra-thick TC4 titanium alloy electron beam welded(EBW)joint after post weld heat treatment(PWHT)using X-ray diffraction(XRD)and deep-hole drilling(DHD)methods,and investigated the microstructure and mechanical properties.During the PWHT at 600℃,a phase transformation(β→α)occurred in the EBW joint and affected the residual stress distribution and mechanical properties.The surface residual stress was mainly compressive stress,while the internal residual stress was mainly tensile stress in the welded joint.For the as-welded joint,the absolute value of surface residual stress was higher than the absolute value of internal residual stress.After PWHT,the residual stress in the treated joint was substantially reduced compared to the as-welded joint,particularly the surface stress,which relieved from−425 to−90 MPa.However,the residual stress relief effect had minimal positive impact on the internal region at 600℃.PWHT resulted in a shift of the joint fracture location from the fusion zone(FZ)to the base metal(BM),and therefore exerted no noticeable effect on the joint strength,but increased the joint elongation significantly.This study provides valuable insights into the regulation of residual stress distribution of ultra-thick titanium alloy plates.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
An alternating magnetic field(AMF)was introduced into the narrow gap laser-arc hybrid welding process for 2205 duplex stainless steel thick plates.The corrosion performance of the welded joints was evaluated through e...An alternating magnetic field(AMF)was introduced into the narrow gap laser-arc hybrid welding process for 2205 duplex stainless steel thick plates.The corrosion performance of the welded joints was evaluated through electrochemical studies.The results revealed that joints welded with the application of AMF had a lower corrosion current density compared to those welded without an external AMF.Additionally,these joints showed higher pitting potential and polarization resistance.Microscopic electrochemical analysis indicated that joints subjected to AMF exhibited minimal cathodic current in simulated seawater,with only slight fluctuations in the anodic current peak.Overall,the corrosion levels on the joint surfaces were relatively low.After 4 h of immersion in the corrosive medium,the average impedance of joints exposed to AMF increased by 60.7%compared to those not influenced by a magnetic field.These findings suggest that applying AMF during the narrow gap laser-arc hybrid welding process can significantly improve the corrosion resistance of duplex stainless steel welded joints,reducing their susceptibility to stress corrosion in seawater-like environments.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
High-entropy alloys(HEAs)have become essential materials in the aerospace and defense industries due to their remarkable mechanical properties,which include wear resistance,fatigue endurance,and corrosion resistance.T...High-entropy alloys(HEAs)have become essential materials in the aerospace and defense industries due to their remarkable mechanical properties,which include wear resistance,fatigue endurance,and corrosion resistance.The welding of high-entropy alloys is a cutting-edge field of study that is attracting a lot of interest and investigation from research organizations and businesses.Welding defects including porosity and cracks are challenging problem and limit the development of welding HEAs.This paper provides a comprehensive review of research on weldability of HEAs and the application of diverse welding techniques on welding HEAs over recent years.The forming mechanism and control strategies of defects during welding HEAs were provided in this work.Various welding techniques,including arc welding,laser welding,electron beam welding,friction stir welding,diffusion bonding and explosive welding,have been extensively investigated and applied to improve the microstructure and mechanical properties of HEAs joints.Furthermore,an in-depth review of the microstructure and mechanical properties of HEAs joints obtained by various welding methods is presented.This paper concludes with a discussion of the potential challenges associated with high-entropy alloy welding,thus providing valuable insights for future research efforts in this area.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
Many high-temperature pressure pipelines in thermal power plants are prone to failure due to long-term service-induced creep damage,which significantly impacts the normal operation of the equipment.Repair welding is a...Many high-temperature pressure pipelines in thermal power plants are prone to failure due to long-term service-induced creep damage,which significantly impacts the normal operation of the equipment.Repair welding is a widely adopted method to mitigate damage,including creep voids and cracks,in high-temperature pressure pipelines.However,the mechanical property degradation of aging material and excessive residual stresses from repair welding can lead to the formation of new cracks.To support scientifically sound decisions regarding life extension or replacement,the feasibility of repair welding for an aged CrMo steel high-temperature pressure pipeline weldment is investigated in this study.Firstly,the modified Kachanov-Rabotonov creep damage constitutive model is employed to predict the creep damage distribution of the weldment that had been in service for 26 years,identifying the most severely damaged location for scarfing.Subsequently,a numerical simulation study is conducted to analyze the residual stress in repair welding,with a focus on the influence of material performance degradation and excavation methods.The results indicate that the maximum creep damage in the CrMo steel weldment is concentrated in the heat-affected zone(HAZ)and the adjacent base metal(BM).Overall,the repair welding stresses simulated with degraded mechanical properties are lower than those with the virgin mechanical properties.However,the stress discontinuity at the interface between the repair welding zone and the BM is more pronounced due to the high-level mismatch in mechanical properties,which poses a significant risk for inducing repair welding cracks.Based on the consideration of avoiding stress concentration within the weld and reducing stress discontinuity at the weld boundary,the step repair method is recommended for engineering applications.展开更多
In engineering structures, the application of advanced alloys, such as the VCoNi medium-entropy alloy (VCoNi-MEA), with remarkable tensile strength (> 1 GPa) and superior ductility necessitates the employment of di...In engineering structures, the application of advanced alloys, such as the VCoNi medium-entropy alloy (VCoNi-MEA), with remarkable tensile strength (> 1 GPa) and superior ductility necessitates the employment of dissimilar joints. This study pioneers the dissimilar joining of VCoNi-MEA and 17–4 precipitation hardening stainless steel (17–4PH STS) using state-of-the-art green laser beam welding (LBW). To evaluate and optimize the experimental parameters, two welding speeds (200 and 300 mm/s) along with post-weld heat treatment (PWHT) were incorporated. High-quality welded joints with a single-phase face-centered cubic (FCC) structure in the fusion zone (FZ), minimal precipitates (< 1.6 %), and no visible cracks were successfully created. The LBW process demonstrated effective low-heat input characteristics, evident from a considerably narrow heat-affected zone (HAZ). Control over FZ width and grain size was achieved, measuring 600 and 112 µm at low welding speed and 250 and 49 µm at high welding speed, respectively, significantly lower than previous studies. A remarkably high yield strength (YS) of ∼620 MPa and ultimate tensile strength (UTS) up to 845 MPa were observed in the as-welded conditions, improving to ∼645 and 875 MPa, respectively, after PWHT. This enhancement in mechanical properties is primarily attributed to lattice friction induced by V addition. PWHT also improved joint ductility, increasing from 3.5 % to 8.6 % (low-speed) and from 6.3 % to 9.2 % (high-speed). The reduction in crystallographic orientation achieved using a higher welding speed and PWHT emerged as a major reason for improved mechanical properties. Slip-based deformation mechanisms dominated across all conditions, featuring crystallographically aligned slip bands. Interactions between existing and additional slip bands formed a dense dislocation network crucial for enhanced elongation after PWHT. Thermodynamic parameters elucidating phase stability in the observed FZs and contributions to superior YS were calculated and comprehensively discussed.展开更多
This study examines the effects of friction stir welding(FSW)and post-weld heat treatment(PWHT)on the grain boundary character distribution and corrosion resistance of cross sectional(top and bottom)regions of nickel-...This study examines the effects of friction stir welding(FSW)and post-weld heat treatment(PWHT)on the grain boundary character distribution and corrosion resistance of cross sectional(top and bottom)regions of nickel-and molybdenum-free high-nitrogen austenitic stainless steel(HNASS).FSW at 400 rpm and 30 mm/min resulted in finer grains(4.18μm)and higher coincident site lattice(CSL)boundaries(32.3%)at the top of the stir zone(SZ)due to dynamic recrystallization(DRX).PWHT at 900℃for 1 h led to grain coarsening(12.91μm the bottom SZ)but enhanced CSL boundaries from 24.6%to 30.2%,improving grain boundary stability.PWHT reduced the kernel average misorientation(KAM)by 14.9%in the SZ-top layer and 20.4%in the SZ-bottom layer,accompanied by a 25%decrease in hardness in the SZ-top layer and 26.7%in the SZ-bottom layer,indicating strain recovery and reduced dislocation density.Potentiodynamic polarization tests(PDP)showed a 18%increase in pitting potential and a 76%reduction in corrosion rate after PWHT.The improvement in corrosion resistance is attributed to the increase inΣ3 twin boundaries,which enhance grain boundary stability and reduce susceptibility to localized corrosion.These findings highlight the role of PWHT in refining the microstructure and strengthening corrosion resistance,making HNASS a promising material for demanding applications.展开更多
Based on the microstructure characterization,electrochemical impedance spectroscopy,potentiodynamic polarization,and immersion corrosion,this work comparatively analyzed the differences in the electrochemical corrosio...Based on the microstructure characterization,electrochemical impedance spectroscopy,potentiodynamic polarization,and immersion corrosion,this work comparatively analyzed the differences in the electrochemical corrosion morphology and post-foil formation surface morphology of laser beam welded(LBW)sample and spin-formed sample,and compared the corrosion resistance and Cu foil formation ability of two samples in H_(2)SO_(4)/NaCl solution and CuSO_(4) reducing electrolyte.Results show that in H_(2)SO_(4) and NaCl solutions,LBW sample and spin-formed sample exhibit excellent passivation ability and corrosion resistance.Both samples show uniform corrosion morphologies and similar corrosion resistance in the strong acidic solution containing Cl^(-).Meanwhile,the Cu foil formation ability of the welded joint is similar to that of the spin-formed sample,and both samples obtain intact Cu foils with high-quality surfaces and small differences in properties.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.
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 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.
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 National Natural Science Foundation of China(Nos.52075347,51575364)and the Natural Science Foundation of Liaoning Provincial(No.2022-MS-295)。
文摘In order to solve the problem of poor formability caused by different materials and properties in the process of tailor-welded sheets forming,a forming method was proposed to change the stress state of tailor-welded sheets by covering the tailor-welded sheets with better plastic properties overlapping sheets.At the same time,the interface friction effect between the overlapping and tailor-welded sheets was utilized to control the stress magnitude and further improve the formability and quality of the tailor-welded sheets.In this work,the bulging process of the tailor-welded overlapping sheets was taken as the research object.Aluminum alloy tailor-welded overlapping sheets bulging specimens were studied by a combination of finite element analysis and experimental verification.The results show that the appropriate use of interface friction between tailor-welded and overlapping sheets can improve the formability of tailor-welded sheets and control the flow of weld seam to improve the forming quality.When increasing the interface friction coefficient on the side of tailor-welded sheets with higher strength and decreasing that on the side of tailor-welded sheets with lower strength,the deformation of the tailor-welded sheets are more uniform,the offset of the weld seam is minimal,the limit bulging height is maximal,and the forming quality is optimal.
基金Supported by the Central Public-Interest Scientific Institution Basal Research Fund(2023-9062)the Transport Power Pilot Project(2021-C334)。
文摘The quality of rebar welds directly impacts the overall service performance of highway infrastructure.However,current assessments of weld appearance quality primarily rely on traditional inspection methods such as manual visual inspection,which suffer from significant limitations in accuracy,reliability,and efficiency.Given the increasing demand for safety performance inspections of highway infrastructure in China,traditional methods struggle to meet modern rapid inspection requirements.Therefore,this study proposes the design of a portable,non-destructive inspection device for rebar weld appearance,utilizing visible light vision and line-structured light 3D scanning technology.The device is equipped with an STM32 master control chip to manage encoder reading,scanning laser control,ring fill light,industrial camera synchronization,image acquisition,and serial port command transmission.Additionally,a weld image processing and detection software system was developed to receive,store,and identify weld defects.A field inspection prototype was created and subjected to various defect weld detection experiments in a laboratory setting.Experimental results demonstrate that the device can accurately measure weld parameters by acquiring multimodal images,fulfilling defect detection requirements.The device features high detection accuracy,portability,and user-friendliness,making it significant for the objective inspection and evaluation of rebar weld appearance and welding quality.
基金The SEU Innovation Capability Enhancement Plan for Doctoral Students(No.CXJH_SEU 24115)Marine Economic Development Project of Guangdong Province(No.GDNRC[2022]25).
文摘The study aimed to address the issue of elevated residual stress levels in dissimilar girth welds of cast steel joints.To achieve this,the hybrid welding technology,which yields high welding speeds while simultaneously reducing residual stresses,has been introduced.This study utilizes a numerical simulation method to investigate the temperature and residual stress field in the hybrid welding of G20Mn5 casting-Q355 low-alloy steel welded pipe.A com-parison of the findings of this study with those of other welding processes revealed the technological advantages of hybrid welding.The research outcomes show that due to geometric discontinuities and material differences,the temperature field of the joint exhibits uneven distribution characteristics,and the peak temperatures on the Q355 steel side exceeds those on the G20Mn5 steel side.An evident stress gra-dient is present in the residual stress field of the joint post-welding,with peak stress located at the weld root on the Q355 steel.Compared with arc welding,the hybrid welding leads to decreased residual stresses and deformation,with high stress outside the heat-affected zone diminishing rapidly.Furthermore,it significantly improves the welding efficiency.This study elucidates the distribution and underlying causes of thermal and residual stress fields in dissimilar girth welds.This serves as a foundation for the application of hybrid welding technology in welded cast steel 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 Key Research and Development Program of China(No.2023YFC2810700)the Youth Innovation Promotion Association of the Chinese Academy of Sciences(2021193)the Science and Technology Cooperation Project between Jilin Province and Chinese Academy of Sciences(No.2024SYHZ0032).
文摘This study analyzed through-thickness distribution of residual stress in a 106 mm ultra-thick TC4 titanium alloy electron beam welded(EBW)joint after post weld heat treatment(PWHT)using X-ray diffraction(XRD)and deep-hole drilling(DHD)methods,and investigated the microstructure and mechanical properties.During the PWHT at 600℃,a phase transformation(β→α)occurred in the EBW joint and affected the residual stress distribution and mechanical properties.The surface residual stress was mainly compressive stress,while the internal residual stress was mainly tensile stress in the welded joint.For the as-welded joint,the absolute value of surface residual stress was higher than the absolute value of internal residual stress.After PWHT,the residual stress in the treated joint was substantially reduced compared to the as-welded joint,particularly the surface stress,which relieved from−425 to−90 MPa.However,the residual stress relief effect had minimal positive impact on the internal region at 600℃.PWHT resulted in a shift of the joint fracture location from the fusion zone(FZ)to the base metal(BM),and therefore exerted no noticeable effect on the joint strength,but increased the joint elongation significantly.This study provides valuable insights into the regulation of residual stress distribution of ultra-thick titanium alloy plates.
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(No.52265054)the Inner Mongolia Autonomous Region Natural Science Foundation Project(No.2022ZD03)+3 种基金the Inner Mongolia Autonomous Region Science and Technology Plan Project(No.2020GG0313)the Inner Mongolia Autonomous Region Natural Science Foundation Doctoral Fund Project,(No.2021BS05016)the Construction project of integrated research and development platform for key technologies in the development and processing of new nonferrous metal materials(No.RZ2300001971)the Basic Research Business Fee Project for Autonomous Region Directly Affiliated Universities(Nos.JY20220199 and JY20220028).
文摘An alternating magnetic field(AMF)was introduced into the narrow gap laser-arc hybrid welding process for 2205 duplex stainless steel thick plates.The corrosion performance of the welded joints was evaluated through electrochemical studies.The results revealed that joints welded with the application of AMF had a lower corrosion current density compared to those welded without an external AMF.Additionally,these joints showed higher pitting potential and polarization resistance.Microscopic electrochemical analysis indicated that joints subjected to AMF exhibited minimal cathodic current in simulated seawater,with only slight fluctuations in the anodic current peak.Overall,the corrosion levels on the joint surfaces were relatively low.After 4 h of immersion in the corrosive medium,the average impedance of joints exposed to AMF increased by 60.7%compared to those not influenced by a magnetic field.These findings suggest that applying AMF during the narrow gap laser-arc hybrid welding process can significantly improve the corrosion resistance of duplex stainless steel welded joints,reducing their susceptibility to stress corrosion in seawater-like environments.
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Project(52105351)supported by the National Natural Science Foundation of ChinaProject(24KJA460002)supported by the Natural Science Foundation of the Higher Education Institutions of Jiangsu Province,ChinaProject(G2023014009L)supported by the High-end Foreign Experts Recruitment Plan of China。
文摘High-entropy alloys(HEAs)have become essential materials in the aerospace and defense industries due to their remarkable mechanical properties,which include wear resistance,fatigue endurance,and corrosion resistance.The welding of high-entropy alloys is a cutting-edge field of study that is attracting a lot of interest and investigation from research organizations and businesses.Welding defects including porosity and cracks are challenging problem and limit the development of welding HEAs.This paper provides a comprehensive review of research on weldability of HEAs and the application of diverse welding techniques on welding HEAs over recent years.The forming mechanism and control strategies of defects during welding HEAs were provided in this work.Various welding techniques,including arc welding,laser welding,electron beam welding,friction stir welding,diffusion bonding and explosive welding,have been extensively investigated and applied to improve the microstructure and mechanical properties of HEAs joints.Furthermore,an in-depth review of the microstructure and mechanical properties of HEAs joints obtained by various welding methods is presented.This paper concludes with a discussion of the potential challenges associated with high-entropy alloy welding,thus providing valuable insights for future research efforts in this area.
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.
基金Supported by National Natural Science Foundation of China(Grant Nos.52275168,51805546).
文摘Many high-temperature pressure pipelines in thermal power plants are prone to failure due to long-term service-induced creep damage,which significantly impacts the normal operation of the equipment.Repair welding is a widely adopted method to mitigate damage,including creep voids and cracks,in high-temperature pressure pipelines.However,the mechanical property degradation of aging material and excessive residual stresses from repair welding can lead to the formation of new cracks.To support scientifically sound decisions regarding life extension or replacement,the feasibility of repair welding for an aged CrMo steel high-temperature pressure pipeline weldment is investigated in this study.Firstly,the modified Kachanov-Rabotonov creep damage constitutive model is employed to predict the creep damage distribution of the weldment that had been in service for 26 years,identifying the most severely damaged location for scarfing.Subsequently,a numerical simulation study is conducted to analyze the residual stress in repair welding,with a focus on the influence of material performance degradation and excavation methods.The results indicate that the maximum creep damage in the CrMo steel weldment is concentrated in the heat-affected zone(HAZ)and the adjacent base metal(BM).Overall,the repair welding stresses simulated with degraded mechanical properties are lower than those with the virgin mechanical properties.However,the stress discontinuity at the interface between the repair welding zone and the BM is more pronounced due to the high-level mismatch in mechanical properties,which poses a significant risk for inducing repair welding cracks.Based on the consideration of avoiding stress concentration within the weld and reducing stress discontinuity at the weld boundary,the step repair method is recommended for engineering applications.
基金supported by the Nano&Material Technology Development Program through the National Research Foundation of Korea(NRF)funded by the Ministry of Science and ICT(Nos.RS-2023-00234757 and RS-2024-00402289)。
文摘In engineering structures, the application of advanced alloys, such as the VCoNi medium-entropy alloy (VCoNi-MEA), with remarkable tensile strength (> 1 GPa) and superior ductility necessitates the employment of dissimilar joints. This study pioneers the dissimilar joining of VCoNi-MEA and 17–4 precipitation hardening stainless steel (17–4PH STS) using state-of-the-art green laser beam welding (LBW). To evaluate and optimize the experimental parameters, two welding speeds (200 and 300 mm/s) along with post-weld heat treatment (PWHT) were incorporated. High-quality welded joints with a single-phase face-centered cubic (FCC) structure in the fusion zone (FZ), minimal precipitates (< 1.6 %), and no visible cracks were successfully created. The LBW process demonstrated effective low-heat input characteristics, evident from a considerably narrow heat-affected zone (HAZ). Control over FZ width and grain size was achieved, measuring 600 and 112 µm at low welding speed and 250 and 49 µm at high welding speed, respectively, significantly lower than previous studies. A remarkably high yield strength (YS) of ∼620 MPa and ultimate tensile strength (UTS) up to 845 MPa were observed in the as-welded conditions, improving to ∼645 and 875 MPa, respectively, after PWHT. This enhancement in mechanical properties is primarily attributed to lattice friction induced by V addition. PWHT also improved joint ductility, increasing from 3.5 % to 8.6 % (low-speed) and from 6.3 % to 9.2 % (high-speed). The reduction in crystallographic orientation achieved using a higher welding speed and PWHT emerged as a major reason for improved mechanical properties. Slip-based deformation mechanisms dominated across all conditions, featuring crystallographically aligned slip bands. Interactions between existing and additional slip bands formed a dense dislocation network crucial for enhanced elongation after PWHT. Thermodynamic parameters elucidating phase stability in the observed FZs and contributions to superior YS were calculated and comprehensively discussed.
文摘This study examines the effects of friction stir welding(FSW)and post-weld heat treatment(PWHT)on the grain boundary character distribution and corrosion resistance of cross sectional(top and bottom)regions of nickel-and molybdenum-free high-nitrogen austenitic stainless steel(HNASS).FSW at 400 rpm and 30 mm/min resulted in finer grains(4.18μm)and higher coincident site lattice(CSL)boundaries(32.3%)at the top of the stir zone(SZ)due to dynamic recrystallization(DRX).PWHT at 900℃for 1 h led to grain coarsening(12.91μm the bottom SZ)but enhanced CSL boundaries from 24.6%to 30.2%,improving grain boundary stability.PWHT reduced the kernel average misorientation(KAM)by 14.9%in the SZ-top layer and 20.4%in the SZ-bottom layer,accompanied by a 25%decrease in hardness in the SZ-top layer and 26.7%in the SZ-bottom layer,indicating strain recovery and reduced dislocation density.Potentiodynamic polarization tests(PDP)showed a 18%increase in pitting potential and a 76%reduction in corrosion rate after PWHT.The improvement in corrosion resistance is attributed to the increase inΣ3 twin boundaries,which enhance grain boundary stability and reduce susceptibility to localized corrosion.These findings highlight the role of PWHT in refining the microstructure and strengthening corrosion resistance,making HNASS a promising material for demanding applications.
基金Key Research and Development Program of Shaanxi Province(2022GY-410)Funding of Western Titanium Technologies Co.,Ltd(WX2210)。
文摘Based on the microstructure characterization,electrochemical impedance spectroscopy,potentiodynamic polarization,and immersion corrosion,this work comparatively analyzed the differences in the electrochemical corrosion morphology and post-foil formation surface morphology of laser beam welded(LBW)sample and spin-formed sample,and compared the corrosion resistance and Cu foil formation ability of two samples in H_(2)SO_(4)/NaCl solution and CuSO_(4) reducing electrolyte.Results show that in H_(2)SO_(4) and NaCl solutions,LBW sample and spin-formed sample exhibit excellent passivation ability and corrosion resistance.Both samples show uniform corrosion morphologies and similar corrosion resistance in the strong acidic solution containing Cl^(-).Meanwhile,the Cu foil formation ability of the welded joint is similar to that of the spin-formed sample,and both samples obtain intact Cu foils with high-quality surfaces and small differences in properties.
