To enhance the reliability of aluminum alloy welding quality,this study investigates the effects of gas pulse parameters on the arc characteristics and weld quality in pulsed plasma gas variable polarity plasma arc we...To enhance the reliability of aluminum alloy welding quality,this study investigates the effects of gas pulse parameters on the arc characteristics and weld quality in pulsed plasma gas variable polarity plasma arc welding(PPG-VPPAW)of 5051 aluminum alloy.Results showed that increasing the gas duty cycle enhanced arc pressure fluctuation but reduced average arc pressure.When the duty cycle exceeded 1/2,excessive pressure fluctuations destabilized the weld pool.Arc voltage fluctuations also intensified with larger duty cycles,reducing arc heat input and stability.Severe variations in arc divergence and high-temperature area were observed at duty cycles above 1/2,leading to poor heat transfer.Weld morphology confirmed these findings:duty cycles of 1/5 and 2/5 produced uniform surfaces with dense fish-scale ripples,while 3/5 and 4/5 introduced defects such as humping and undercut.Mechanical testing showed that conventional variable polarity plasma arc welding(VPPAW)joints reached 262 MPa tensile strength and 18.3%elongation,corresponding to 79.8%and 85.1%of base metal values.At a duty cycle of 2/5,the tensile strength increased to 297 MPa and the elongation to 21.5%,representing the best overall performance.Variations in the gas pulse frequency did not significantly affect the average arc pressure or arc voltage.However,as the gas pulse frequency decreased,the fluctuation frequency of the arc pressure and arc voltage also decreased,while the fluctuation amplitude of the arc voltage increased.At 8 Hz,the tensile strength and elongation increased by 13.4%and 17.5%,respectively,compared with lower frequencies(4 and 2.6 Hz).展开更多
The effects of die structure such as the height of the welding,the welding angle and chamber the shape of the bridge on the welding quality of profiles were investigated by means of the commercial software DEFORM-3D.T...The effects of die structure such as the height of the welding,the welding angle and chamber the shape of the bridge on the welding quality of profiles were investigated by means of the commercial software DEFORM-3D.The numerical simulation results show that the welding quality of the hollow profiles has great sensitive to the die structure.With increasing the welding chamber height and decreasing the welding angle of the die leg can improve the welding quality.In addition,the welding quality index k of the new designed shape of the die leg is little down from 4.1 to 3.9 comparing the standard leg.展开更多
Analyzing and modeling the relation between monitoring information during welding and quality information of the joints is the foundation of monitoring resistance spot welding quality. According to the means of modeli...Analyzing and modeling the relation between monitoring information during welding and quality information of the joints is the foundation of monitoring resistance spot welding quality. According to the means of modeling, the known models can be divided into three large categories: single linear regression models, multiple linear regression models and multiple non linear models. By modeling the relations between dynamic resistance information and welding quality parameters with different means, this paper analyzes effects of modeling means on performances of monitoring models of resistance spot welding quality. From the test results, the following conclusions can be drawn: By comparison with two other kinds of models, artificial neural network (ANN) model can describe non linear and high coupling relationship between monitoring information and quality information more reasonably, improve performance of monitoring model remarkably, and make the estimated values of welding quality parameters more accurate and reliable.展开更多
A method was developed to realize quality evaluation on every weld-spot in resistance spot welding based on information processing of artificial intelligent. Firstly, the signals of welding current and welding voltage...A method was developed to realize quality evaluation on every weld-spot in resistance spot welding based on information processing of artificial intelligent. Firstly, the signals of welding current and welding voltage, as information source, were synchronously collected. Input power and dynamic resistance were selected as monitoring waveforms. Eight characteristic parameters relating to weld quality were extracted from the monitoring waveforms. Secondly, tensile-shear strength of the spot-welded joint was employed as evaluating target of weld quality. Through correlation analysis between every two parameters of characteristic vector, five characteristic parameters were reasonably selected to found a mapping model of weld quality estimation. At last, the model was realized by means of the algorithms of Radial Basic Function neural network and sample matrixes. The results showed validations by a satisfaction in evaluating weld quality of mild steel joint on-line in spot welding process.展开更多
Quality traceability plays an essential role in assembling and welding offshore platform blocks.The improvement of the welding quality traceability system is conducive to improving the durability of the offshore platf...Quality traceability plays an essential role in assembling and welding offshore platform blocks.The improvement of the welding quality traceability system is conducive to improving the durability of the offshore platform and the process level of the offshore industry.Currently,qualitymanagement remains in the era of primary information,and there is a lack of effective tracking and recording of welding quality data.When welding defects are encountered,it is difficult to rapidly and accurately determine the root cause of the problem from various complexities and scattered quality data.In this paper,a composite welding quality traceability model for offshore platform block construction process is proposed,it contains the quality early-warning method based on long short-term memory and quality data backtracking query optimization algorithm.By fulfilling the training of the early-warning model and the implementation of the query optimization algorithm,the quality traceability model has the ability to assist enterprises in realizing the rapid identification and positioning of quality problems.Furthermore,the model and the quality traceability algorithm are checked by cases in actual working conditions.Verification analyses suggest that the proposed early-warningmodel for welding quality and the algorithmfor optimizing backtracking requests are effective and can be applied to the actual construction process.展开更多
Performance of quality monitor models in spot welding determines the monitor precision directly, so it’s crucial to evaluate it. Previously, mean square error (MSE) is often used to evaluate performances of models, b...Performance of quality monitor models in spot welding determines the monitor precision directly, so it’s crucial to evaluate it. Previously, mean square error (MSE) is often used to evaluate performances of models, but it can only show the total errors of finite specimens of models, and cannot show whether the quality information inferred from models are accurate and reliable enough or not. For this reason, by means of measure error theory, a new way to evaluate the performances of models according to the error distributions is developed as follows: Only if correct and precise enough the error distribution of model is, the quality information inferred from model is accurate and reliable.展开更多
The force flow cooled superconducting cable-in-conduit conductor （CICC） is used in both of EAST toroidal field （TF） and poloidal field （PF） coils. The conductor consists of multi-stage NbTi superconducting cable...The force flow cooled superconducting cable-in-conduit conductor （CICC） is used in both of EAST toroidal field （TF） and poloidal field （PF） coils. The conductor consists of multi-stage NbTi superconducting cable and 1.5 mm thick square jacket. The cable is pulled through in a thin wall circular jacket and then compacted to square cross-section conductor. The jacket material is SUS316LN austenitic stainless steel seamless tubes （about 10 m each）, which is assembled by butt-welding up to 600 m. The results of the welding procedure investigation and quality assurance procedures carrying out are described in this paper.展开更多
Gas metal arc welding(GMAW)is also referred as the metal inert gas(MIG)welding which is a process of welding done by the formation of an electric arc between the consumable wire electrode and the workpiece.Through the...Gas metal arc welding(GMAW)is also referred as the metal inert gas(MIG)welding which is a process of welding done by the formation of an electric arc between the consumable wire electrode and the workpiece.Through the welding process,a continuous flow of inert gas is supplied,and it avoids the weld being subjected to react with atmospheric air.The process can be automatic or semi-automatic where the main input parameters like current and the voltage can be direct and constant,respectively.Not only the current and voltage the welding quality depends on some more input parameters such as arc gap,velocity,and temperature.In this paper,we explain about a setup which is capable of real-time monitoring of input parameters mentioned above and selecting the best MIG welding parameters for the mild steel.The setup is composed of several sensors and microcontrollers for the collection and the measurement of the input parameters.The samples were categorized according to the federate and the voltage adjustment of the selected welding machine.Then the final objective was to identify the samples of the weld with different parameter changes which are monitored through the system.For the analysis,the samples were subjected to tensile and hardness tests,and microstructure tests to find the dependence of the input parameters which effect for the weld quality.Finally,the experimental results verified the effectiveness of the system for the selection of the quality weld.展开更多
From the final statistical results of safety accidents of mechanical pressure vessels in China, it can be seen that the vast majority of safety accidents are caused by unqualified welding quality, which requires stric...From the final statistical results of safety accidents of mechanical pressure vessels in China, it can be seen that the vast majority of safety accidents are caused by unqualified welding quality, which requires strict control from the aspects of production process, industrial raw materials, heat treatment process, mechanical processing, physical chemistry and non-destructive testing to ensure that the production of pressure vessels meets the national requirements and prevent the occurrence of dangerous accidents. Unqualified welding quality includes many root causes: staff factors, materials used, welding process, etc. Pressure vessel manufacturers need to analyze these factors and take effective protective measures to further improve the welding quality, ensure the pressure level and improve the safety performance index of pressure vessels.展开更多
With the increase of surface assembly density and the rapid development of surface mount technology (SMT), electronic products tend to be miniaturized and integrated. The welding quality and welding technology of surf...With the increase of surface assembly density and the rapid development of surface mount technology (SMT), electronic products tend to be miniaturized and integrated. The welding quality and welding technology of surface mount components have attracted more and more attention. Reflow processing technology is a comprehensive scientific research. There are many reasons for the welding quality defects of each electronic component. Any material performance change or unreasonable processing parameters may lead to hidden welding quality defects. Therefore, in the specific production process, it is necessary to make in-depth analysis of practical problems and constantly improve the reflow soldering process, so as to improve the reflow soldering quality, ensure the up-to-standard rate of new products and improve the stability of electronic products and commodity quality.展开更多
All-position robots are widely applied in the welding of complicated parts.Welding of intersecting pipes is one of the most typical tasks.The welding seam is a complicated saddle-like space curve,which puts a great ch...All-position robots are widely applied in the welding of complicated parts.Welding of intersecting pipes is one of the most typical tasks.The welding seam is a complicated saddle-like space curve,which puts a great challenge to the pose planning of end-effector.The special robots designed specifically for this kind of tasks are rare in China and lack sufficient theoretical research.In this paper,a systematic research on the pose planning for the end-effectors of robot in the welding of intersecting pipes is conducted.First,the intersecting curve of pipes is mathematically analyzed.The mathematical model of the most general intersecting curve of pipes is derived,and several special forms of this model in degraded situations are also discussed.A new pose planning approach of bisecting angle in main normal plane(BAMNP)for the welding-gun is proposed by using differential geometry and the comparison with the traditional bisecting angle in axial rotation plane(BAARP)method is also analytically conducted.The optimal pose of the welding-gun is to make the orientation posed at the center of the small space formed by the two cylinders and the intersecting curve to help the welding-pool run smoothly.The BAMNP method can make sure the pose vertical to the curve and center between the two cylinders at the same time,therefore its performance in welding-technique is superior to the BAARP method.By using the traditional BAARP method,the robot structure can become simpler and easier to be controlled,because one degree of freedom(DOF)of the robot can be reduced.For the special case of perpendicular intersecting,an index is constructed to evaluate the quality of welding technique in the process of welding.The effect of different combination of pipe size on this index is also discussed.On the basis of practical consideration,selection principle for BAARP and BAMNP is described.The simulations of those two methods for a serial joint-type robot are made in MATLAB,and the simulation results are consistent to the analysis.The mathematical model and the proposed new pose-planning method will lay a solid foundation for future researches on the control and design of all-position welding robots.展开更多
The influence of R/v ratio on joint quality in 2024-T351 aluminum alloy was studied. Specimens were subjected to friction stir welding with the rotation rates of 750, 950 and 1180 r/min and welding speed between 73 an...The influence of R/v ratio on joint quality in 2024-T351 aluminum alloy was studied. Specimens were subjected to friction stir welding with the rotation rates of 750, 950 and 1180 r/min and welding speed between 73 and 190 mm/min, providing R/v ratio between 5.00 and 10.27. The welded joints were tested by means of both non-destructive （visual, penetrant and X-ray inspection） and destructive （metallographic, tension and hardness） testing. In all specimens typical zones are revealed, with corresponding differences in grain size. Tensile efficiency of the joints obtained is in the range of 52.2%to 82.3%. The results show that the best quality is obtained at R/v ratio of 8.06, 10.17 and 10.27. This behavior is attributed to the assumption that the material flows around the pin with an optimal speed, i.e. sufficient amount of material is available to fill the gap and prevent tunnel formation. R/v ratio also showed influence on hardness distribution, onion features and crack initiation/propagation zones.展开更多
In order to solve the problem of porosity in laser deep penetration welding of GH3625 high-temperature alloy plates,five different ratios of high-purity helium gas and high-purity argon gas mixed gases were compared i...In order to solve the problem of porosity in laser deep penetration welding of GH3625 high-temperature alloy plates,five different ratios of high-purity helium gas and high-purity argon gas mixed gases were compared in welding experiments after various process parameter improvements and adjustments failed to achieve Class I welds.The experimental results show that using high-purity helium gas or a mixture of 50%high-purity helium gas and 50%high-purity argon gas can both achieve Class I welds.This indicates that using high-purity helium gas or an appropriate mixed gas instead of pure argon is one of the effective ways to solve the problem of porosity in laser deep penetration welding of high-temperature alloys.The mixture of 50%high-purity argon gas and 50%high-purity helium gas can reduce the consumption of high-purity helium gas,lower production costs,and is more suitable.展开更多
The relation between acoustic emission signal and nugget during aluminum alloy spot welding was investigated in order to evaluate spot welding quality. Due to the nonlinearity of the signals, fractal theory was utiliz...The relation between acoustic emission signal and nugget during aluminum alloy spot welding was investigated in order to evaluate spot welding quality. Due to the nonlinearity of the signals, fractal theory was utilized to quantitatively describe the characteristics of the signals instead of classical Euclidean geometry which cannot describe the acoustic emission signal accurately. Through experiments and computing, the box counting dimension is found distinct from other acoustic emission signals and is a better approach to discriminating weld nugget stages. Results show that fractal dimensions increase from 1.51 to 1.78,and they are related to nugget areas added from non-fusion to over-heated nugget. And the box counting dimension can effectively evaluate the quality of the nugget in the spot welding and can be aoolied with current, displace, and other soot welding parameters.展开更多
More high strength steel （HSS） sheets are being applied in the automobile industry to improve safety and fuel efficiency. When HSS is spot welded, the strength of the welded-joint is usually determined by the attrib...More high strength steel （HSS） sheets are being applied in the automobile industry to improve safety and fuel efficiency. When HSS is spot welded, the strength of the welded-joint is usually determined by the attributes of the weld nugget. However, it is difficult to obtain the circular nugget and to establish the relationship between the weld attributes and welding quality because of a large number of variables and experimental uncertainty. In the paper, the numerical analysis model of tensile-shear strength test for HSS spot welds was established. And the critical ellipticity of the elliptical spot weld was determined through finite element analysis. Quantitative relationship between elliptical weld attributes and weld strength was investigated statistically using the Latin hypercube and regression analysis method. The sheet thickness, nugget eUipticity, hardness radio and yield strength have the most influential attributes in affecting welding quality. The research results can be used as a guideline for HSS resistance spot welding design.展开更多
Based on standards and the expertise, 10 indicators such as crack, reinforcement and splash, etc. are selected for welds quality description. The indicators are classified into three categories： appearance defects, s...Based on standards and the expertise, 10 indicators such as crack, reinforcement and splash, etc. are selected for welds quality description. The indicators are classified into three categories： appearance defects, shape defects and weld defects, and corresponding fuzzy evaluation sets are designed. Membership functions of each indicator are determined with fuzzy inference system （FIS） editor in Matlab based on the actual welding experience. A two-stage fuzzy evaluation model for weld quality is established in Simulink. Finally, the model is tested through evaluating 7 different types of welds. The results show that fuzzy evaluation calculation can be simplified by combining Simulink with Matlab-FIS, and the evaluation results are more accurate and objective compared with the experts＇ subjective e＇, iluation.展开更多
An investigation on the quality of PVC joints welded by friction stir welding （ FSW ） with different shape of pin was carried out. The results show that when the rotating speed of stir tool is 1 660 r/min and the we...An investigation on the quality of PVC joints welded by friction stir welding （ FSW ） with different shape of pin was carried out. The results show that when the rotating speed of stir tool is 1 660 r/min and the welding speed is 25 mm/min, the beads welded with upright taper pin are plump and joined well, the average tensile strength of which is 19. 1 MPa （the maximum is 20. 3 MPa）, being 49. 2% of that of parent material. The beads welded with cylindrical pin are also joined rather well plump and smooth, the average tensile strength of which is 17. 6 MPa, being 45.3% of that of parent material. The beads welded with inverted taper and cylindrical screw pin are only partially joined or disjoined. The optimum welding temperature range of PVC is 180 - 190℃. If the temperature beyond 200℃ the material will be burnt. If the temperature is under 170℃ the material will be joined partially or disjoined.展开更多
Types of bimetal clad plate, manufacturing methods, and their fields of application were summarized. In particular,key aspects of the welding of clad-rolled stainless steel were described, including the weldability of...Types of bimetal clad plate, manufacturing methods, and their fields of application were summarized. In particular,key aspects of the welding of clad-rolled stainless steel were described, including the weldability of the base and clad metals, design criteria for the transition layer, the selection of the type of welding process and consumables used, types of blanking and welding bevels, preparation and assembly prior to welding, welding procedure requirements, post-weld cleaning and heat treatment, and welding quality inspection. This paper will serve as a reference for the welding technology used in future consumer applications in related fields.展开更多
An innovation is conducted on a K190πK rail auto welding machine because of its poor stability in quality of welding joints. A new control system based on a programmable controller is designed to replace the old o...An innovation is conducted on a K190πK rail auto welding machine because of its poor stability in quality of welding joints. A new control system based on a programmable controller is designed to replace the old one. The new control system is of higher accuracy in controlling sequence and good ability in anti disturbance, and is convenient to operate. The comparison tests are carried out. The experimental results show that the quality of welded joints is greatly increased by the improved welding mechine.展开更多
The probability, main effect factors and diffusion theory of structural superplastic diffusion bonding of W6Mo5Cr4V2/45 steel have been observed and analyzed by means of tensile test at the room temperature, scanning ...The probability, main effect factors and diffusion theory of structural superplastic diffusion bonding of W6Mo5Cr4V2/45 steel have been observed and analyzed by means of tensile test at the room temperature, scanning electron microscope and microhardness test. Results show that after fine graining treatment and short time superplastic pressing formation under the conditions of superplastic temperature and strain rate, W6Mo5Cr4V2/45 specimens can achieve solid state diffusion bonding and the property of welded area is the same as the other parts in the specimen. The diffusion path of carbon element is intergranular and of dislocation.展开更多
基金supported by the National Natural Science Foundation of China(Grant No.52275302 and 52322508)the R&D Program of Beijing Municipal Education Commission(Grant No.KZ20231000519)。
文摘To enhance the reliability of aluminum alloy welding quality,this study investigates the effects of gas pulse parameters on the arc characteristics and weld quality in pulsed plasma gas variable polarity plasma arc welding(PPG-VPPAW)of 5051 aluminum alloy.Results showed that increasing the gas duty cycle enhanced arc pressure fluctuation but reduced average arc pressure.When the duty cycle exceeded 1/2,excessive pressure fluctuations destabilized the weld pool.Arc voltage fluctuations also intensified with larger duty cycles,reducing arc heat input and stability.Severe variations in arc divergence and high-temperature area were observed at duty cycles above 1/2,leading to poor heat transfer.Weld morphology confirmed these findings:duty cycles of 1/5 and 2/5 produced uniform surfaces with dense fish-scale ripples,while 3/5 and 4/5 introduced defects such as humping and undercut.Mechanical testing showed that conventional variable polarity plasma arc welding(VPPAW)joints reached 262 MPa tensile strength and 18.3%elongation,corresponding to 79.8%and 85.1%of base metal values.At a duty cycle of 2/5,the tensile strength increased to 297 MPa and the elongation to 21.5%,representing the best overall performance.Variations in the gas pulse frequency did not significantly affect the average arc pressure or arc voltage.However,as the gas pulse frequency decreased,the fluctuation frequency of the arc pressure and arc voltage also decreased,while the fluctuation amplitude of the arc voltage increased.At 8 Hz,the tensile strength and elongation increased by 13.4%and 17.5%,respectively,compared with lower frequencies(4 and 2.6 Hz).
基金Founded by the National Key Technology R&D Program in the 11th Five Year Plan of China(2007BAE38B00)
文摘The effects of die structure such as the height of the welding,the welding angle and chamber the shape of the bridge on the welding quality of profiles were investigated by means of the commercial software DEFORM-3D.The numerical simulation results show that the welding quality of the hollow profiles has great sensitive to the die structure.With increasing the welding chamber height and decreasing the welding angle of the die leg can improve the welding quality.In addition,the welding quality index k of the new designed shape of the die leg is little down from 4.1 to 3.9 comparing the standard leg.
文摘Analyzing and modeling the relation between monitoring information during welding and quality information of the joints is the foundation of monitoring resistance spot welding quality. According to the means of modeling, the known models can be divided into three large categories: single linear regression models, multiple linear regression models and multiple non linear models. By modeling the relations between dynamic resistance information and welding quality parameters with different means, this paper analyzes effects of modeling means on performances of monitoring models of resistance spot welding quality. From the test results, the following conclusions can be drawn: By comparison with two other kinds of models, artificial neural network (ANN) model can describe non linear and high coupling relationship between monitoring information and quality information more reasonably, improve performance of monitoring model remarkably, and make the estimated values of welding quality parameters more accurate and reliable.
基金supported by National Natural Science Foundation of China (No.50275028)
文摘A method was developed to realize quality evaluation on every weld-spot in resistance spot welding based on information processing of artificial intelligent. Firstly, the signals of welding current and welding voltage, as information source, were synchronously collected. Input power and dynamic resistance were selected as monitoring waveforms. Eight characteristic parameters relating to weld quality were extracted from the monitoring waveforms. Secondly, tensile-shear strength of the spot-welded joint was employed as evaluating target of weld quality. Through correlation analysis between every two parameters of characteristic vector, five characteristic parameters were reasonably selected to found a mapping model of weld quality estimation. At last, the model was realized by means of the algorithms of Radial Basic Function neural network and sample matrixes. The results showed validations by a satisfaction in evaluating weld quality of mild steel joint on-line in spot welding process.
基金funded by Ministry of Industry and Information Technology of the People’s Republic of China[Grant No.2018473].
文摘Quality traceability plays an essential role in assembling and welding offshore platform blocks.The improvement of the welding quality traceability system is conducive to improving the durability of the offshore platform and the process level of the offshore industry.Currently,qualitymanagement remains in the era of primary information,and there is a lack of effective tracking and recording of welding quality data.When welding defects are encountered,it is difficult to rapidly and accurately determine the root cause of the problem from various complexities and scattered quality data.In this paper,a composite welding quality traceability model for offshore platform block construction process is proposed,it contains the quality early-warning method based on long short-term memory and quality data backtracking query optimization algorithm.By fulfilling the training of the early-warning model and the implementation of the query optimization algorithm,the quality traceability model has the ability to assist enterprises in realizing the rapid identification and positioning of quality problems.Furthermore,the model and the quality traceability algorithm are checked by cases in actual working conditions.Verification analyses suggest that the proposed early-warningmodel for welding quality and the algorithmfor optimizing backtracking requests are effective and can be applied to the actual construction process.
文摘Performance of quality monitor models in spot welding determines the monitor precision directly, so it’s crucial to evaluate it. Previously, mean square error (MSE) is often used to evaluate performances of models, but it can only show the total errors of finite specimens of models, and cannot show whether the quality information inferred from models are accurate and reliable enough or not. For this reason, by means of measure error theory, a new way to evaluate the performances of models according to the error distributions is developed as follows: Only if correct and precise enough the error distribution of model is, the quality information inferred from model is accurate and reliable.
基金The project supported by the National Meg-Science Engineering Project of the Chinese Government
文摘The force flow cooled superconducting cable-in-conduit conductor （CICC） is used in both of EAST toroidal field （TF） and poloidal field （PF） coils. The conductor consists of multi-stage NbTi superconducting cable and 1.5 mm thick square jacket. The cable is pulled through in a thin wall circular jacket and then compacted to square cross-section conductor. The jacket material is SUS316LN austenitic stainless steel seamless tubes （about 10 m each）, which is assembled by butt-welding up to 600 m. The results of the welding procedure investigation and quality assurance procedures carrying out are described in this paper.
文摘Gas metal arc welding(GMAW)is also referred as the metal inert gas(MIG)welding which is a process of welding done by the formation of an electric arc between the consumable wire electrode and the workpiece.Through the welding process,a continuous flow of inert gas is supplied,and it avoids the weld being subjected to react with atmospheric air.The process can be automatic or semi-automatic where the main input parameters like current and the voltage can be direct and constant,respectively.Not only the current and voltage the welding quality depends on some more input parameters such as arc gap,velocity,and temperature.In this paper,we explain about a setup which is capable of real-time monitoring of input parameters mentioned above and selecting the best MIG welding parameters for the mild steel.The setup is composed of several sensors and microcontrollers for the collection and the measurement of the input parameters.The samples were categorized according to the federate and the voltage adjustment of the selected welding machine.Then the final objective was to identify the samples of the weld with different parameter changes which are monitored through the system.For the analysis,the samples were subjected to tensile and hardness tests,and microstructure tests to find the dependence of the input parameters which effect for the weld quality.Finally,the experimental results verified the effectiveness of the system for the selection of the quality weld.
文摘From the final statistical results of safety accidents of mechanical pressure vessels in China, it can be seen that the vast majority of safety accidents are caused by unqualified welding quality, which requires strict control from the aspects of production process, industrial raw materials, heat treatment process, mechanical processing, physical chemistry and non-destructive testing to ensure that the production of pressure vessels meets the national requirements and prevent the occurrence of dangerous accidents. Unqualified welding quality includes many root causes: staff factors, materials used, welding process, etc. Pressure vessel manufacturers need to analyze these factors and take effective protective measures to further improve the welding quality, ensure the pressure level and improve the safety performance index of pressure vessels.
文摘With the increase of surface assembly density and the rapid development of surface mount technology (SMT), electronic products tend to be miniaturized and integrated. The welding quality and welding technology of surface mount components have attracted more and more attention. Reflow processing technology is a comprehensive scientific research. There are many reasons for the welding quality defects of each electronic component. Any material performance change or unreasonable processing parameters may lead to hidden welding quality defects. Therefore, in the specific production process, it is necessary to make in-depth analysis of practical problems and constantly improve the reflow soldering process, so as to improve the reflow soldering quality, ensure the up-to-standard rate of new products and improve the stability of electronic products and commodity quality.
基金supported by National Nautural Science Foundation of China(Grant No.50775002)Key Science and Technology Research Program of Beijing Municipal Commission of Education of China(Grant No.KZ200910005003)
文摘All-position robots are widely applied in the welding of complicated parts.Welding of intersecting pipes is one of the most typical tasks.The welding seam is a complicated saddle-like space curve,which puts a great challenge to the pose planning of end-effector.The special robots designed specifically for this kind of tasks are rare in China and lack sufficient theoretical research.In this paper,a systematic research on the pose planning for the end-effectors of robot in the welding of intersecting pipes is conducted.First,the intersecting curve of pipes is mathematically analyzed.The mathematical model of the most general intersecting curve of pipes is derived,and several special forms of this model in degraded situations are also discussed.A new pose planning approach of bisecting angle in main normal plane(BAMNP)for the welding-gun is proposed by using differential geometry and the comparison with the traditional bisecting angle in axial rotation plane(BAARP)method is also analytically conducted.The optimal pose of the welding-gun is to make the orientation posed at the center of the small space formed by the two cylinders and the intersecting curve to help the welding-pool run smoothly.The BAMNP method can make sure the pose vertical to the curve and center between the two cylinders at the same time,therefore its performance in welding-technique is superior to the BAARP method.By using the traditional BAARP method,the robot structure can become simpler and easier to be controlled,because one degree of freedom(DOF)of the robot can be reduced.For the special case of perpendicular intersecting,an index is constructed to evaluate the quality of welding technique in the process of welding.The effect of different combination of pipe size on this index is also discussed.On the basis of practical consideration,selection principle for BAARP and BAMNP is described.The simulations of those two methods for a serial joint-type robot are made in MATLAB,and the simulation results are consistent to the analysis.The mathematical model and the proposed new pose-planning method will lay a solid foundation for future researches on the control and design of all-position welding robots.
基金Ministry of Education and Science of Serbia for financial support through Project TR34018
文摘The influence of R/v ratio on joint quality in 2024-T351 aluminum alloy was studied. Specimens were subjected to friction stir welding with the rotation rates of 750, 950 and 1180 r/min and welding speed between 73 and 190 mm/min, providing R/v ratio between 5.00 and 10.27. The welded joints were tested by means of both non-destructive （visual, penetrant and X-ray inspection） and destructive （metallographic, tension and hardness） testing. In all specimens typical zones are revealed, with corresponding differences in grain size. Tensile efficiency of the joints obtained is in the range of 52.2%to 82.3%. The results show that the best quality is obtained at R/v ratio of 8.06, 10.17 and 10.27. This behavior is attributed to the assumption that the material flows around the pin with an optimal speed, i.e. sufficient amount of material is available to fill the gap and prevent tunnel formation. R/v ratio also showed influence on hardness distribution, onion features and crack initiation/propagation zones.
文摘In order to solve the problem of porosity in laser deep penetration welding of GH3625 high-temperature alloy plates,five different ratios of high-purity helium gas and high-purity argon gas mixed gases were compared in welding experiments after various process parameter improvements and adjustments failed to achieve Class I welds.The experimental results show that using high-purity helium gas or a mixture of 50%high-purity helium gas and 50%high-purity argon gas can both achieve Class I welds.This indicates that using high-purity helium gas or an appropriate mixed gas instead of pure argon is one of the effective ways to solve the problem of porosity in laser deep penetration welding of high-temperature alloys.The mixture of 50%high-purity argon gas and 50%high-purity helium gas can reduce the consumption of high-purity helium gas,lower production costs,and is more suitable.
基金Supported by National Natural Science Foundation of China(No.50575159)Ministry of Education of China(No.20060056058 ,No.106049)Natural Science Foundation of Tianjin(No.06YFJMJC03400) .
文摘The relation between acoustic emission signal and nugget during aluminum alloy spot welding was investigated in order to evaluate spot welding quality. Due to the nonlinearity of the signals, fractal theory was utilized to quantitatively describe the characteristics of the signals instead of classical Euclidean geometry which cannot describe the acoustic emission signal accurately. Through experiments and computing, the box counting dimension is found distinct from other acoustic emission signals and is a better approach to discriminating weld nugget stages. Results show that fractal dimensions increase from 1.51 to 1.78,and they are related to nugget areas added from non-fusion to over-heated nugget. And the box counting dimension can effectively evaluate the quality of the nugget in the spot welding and can be aoolied with current, displace, and other soot welding parameters.
基金the National Natural Science Foundation of China (No. 50575140)
文摘More high strength steel （HSS） sheets are being applied in the automobile industry to improve safety and fuel efficiency. When HSS is spot welded, the strength of the welded-joint is usually determined by the attributes of the weld nugget. However, it is difficult to obtain the circular nugget and to establish the relationship between the weld attributes and welding quality because of a large number of variables and experimental uncertainty. In the paper, the numerical analysis model of tensile-shear strength test for HSS spot welds was established. And the critical ellipticity of the elliptical spot weld was determined through finite element analysis. Quantitative relationship between elliptical weld attributes and weld strength was investigated statistically using the Latin hypercube and regression analysis method. The sheet thickness, nugget eUipticity, hardness radio and yield strength have the most influential attributes in affecting welding quality. The research results can be used as a guideline for HSS resistance spot welding design.
基金This work was supported by National Natural Science Foundation of China （No. 50875088 ） and Foundation for Distinguished Young Teachers＇ Training of Guangdong（Yq2013106）.
文摘Based on standards and the expertise, 10 indicators such as crack, reinforcement and splash, etc. are selected for welds quality description. The indicators are classified into three categories： appearance defects, shape defects and weld defects, and corresponding fuzzy evaluation sets are designed. Membership functions of each indicator are determined with fuzzy inference system （FIS） editor in Matlab based on the actual welding experience. A two-stage fuzzy evaluation model for weld quality is established in Simulink. Finally, the model is tested through evaluating 7 different types of welds. The results show that fuzzy evaluation calculation can be simplified by combining Simulink with Matlab-FIS, and the evaluation results are more accurate and objective compared with the experts＇ subjective e＇, iluation.
文摘An investigation on the quality of PVC joints welded by friction stir welding （ FSW ） with different shape of pin was carried out. The results show that when the rotating speed of stir tool is 1 660 r/min and the welding speed is 25 mm/min, the beads welded with upright taper pin are plump and joined well, the average tensile strength of which is 19. 1 MPa （the maximum is 20. 3 MPa）, being 49. 2% of that of parent material. The beads welded with cylindrical pin are also joined rather well plump and smooth, the average tensile strength of which is 17. 6 MPa, being 45.3% of that of parent material. The beads welded with inverted taper and cylindrical screw pin are only partially joined or disjoined. The optimum welding temperature range of PVC is 180 - 190℃. If the temperature beyond 200℃ the material will be burnt. If the temperature is under 170℃ the material will be joined partially or disjoined.
文摘Types of bimetal clad plate, manufacturing methods, and their fields of application were summarized. In particular,key aspects of the welding of clad-rolled stainless steel were described, including the weldability of the base and clad metals, design criteria for the transition layer, the selection of the type of welding process and consumables used, types of blanking and welding bevels, preparation and assembly prior to welding, welding procedure requirements, post-weld cleaning and heat treatment, and welding quality inspection. This paper will serve as a reference for the welding technology used in future consumer applications in related fields.
文摘An innovation is conducted on a K190πK rail auto welding machine because of its poor stability in quality of welding joints. A new control system based on a programmable controller is designed to replace the old one. The new control system is of higher accuracy in controlling sequence and good ability in anti disturbance, and is convenient to operate. The comparison tests are carried out. The experimental results show that the quality of welded joints is greatly increased by the improved welding mechine.
文摘The probability, main effect factors and diffusion theory of structural superplastic diffusion bonding of W6Mo5Cr4V2/45 steel have been observed and analyzed by means of tensile test at the room temperature, scanning electron microscope and microhardness test. Results show that after fine graining treatment and short time superplastic pressing formation under the conditions of superplastic temperature and strain rate, W6Mo5Cr4V2/45 specimens can achieve solid state diffusion bonding and the property of welded area is the same as the other parts in the specimen. The diffusion path of carbon element is intergranular and of dislocation.
