To satisfy the demand for good quality underwater welding and maintenance of nuclear power stations,a set of local dry automatic welding systems has been developed.These systems were based on an underwater robot that ...To satisfy the demand for good quality underwater welding and maintenance of nuclear power stations,a set of local dry automatic welding systems has been developed.These systems were based on an underwater robot that consisted of a special high-power underwater welding power supply,diving wire feeder,mini drain cap,welding robot,and special underwater welding torch.With a digital signal controller microprocessor as its core and combined with a dual inverter topology,the welding power supply was characterized by full-digital construction and multi-waveform flexible output.A compact diving wire feeding device was designed,based on the armature voltage negative feedback and high-frequency chopping pulse width modulation.This device yielded a high-efficiency seal of the driving motor with the help of dynamic and static sealing technology.To overcome the difficulty of local protection and deslagging in the welding area,a mini drain cap(with a duplexgas structure)based on the principle of the convergent nozzle was designed.The practical tests and the underwater welding experiments revealed that the underwater robotic local dry welding system is quite feasible.That is,the system could strike the arc stably and reliably in the shallow water environment,and formed beautiful welding seams.展开更多
Teleoperation control strategies for collaborative welding system which is targeting at giving full play to human’s superiority is designed and the fitness for teleoperation welding task of which are studied. During ...Teleoperation control strategies for collaborative welding system which is targeting at giving full play to human’s superiority is designed and the fitness for teleoperation welding task of which are studied. During the teleoperation welding process, 6-DOF controller’s signal can be converted into welding torch’s position, velocity or acceleration changing which is being controlled. For welding purposes, control strategies of four modes are designed, which are static position and posture mode, dynamic position and posture mode, velocity mode and acceleration mode. A test and analysis system for testing the tracking accuracy and reliability of control strategy based on virtual reality is developed. The tracking accuracies of the four control strategies are studied in the following tests with straight line trajectory, curve trajectory or space curve trajectory. The results show that the control strategy in dynamic position and posture mode has best stability and strong adaptability which is the most suitable for the teleoperation system.展开更多
According to the requirements of welding process for vortex type compressor of air conditioner manufactured in product line, a special girth welding machine with PLC as control core was developed, which had both uprig...According to the requirements of welding process for vortex type compressor of air conditioner manufactured in product line, a special girth welding machine with PLC as control core was developed, which had both upright and 45 ° incline service positions. And some key technologies were researched, such as structural design of machine body, reliable conduction of rotary weldments and quality control of welding process and so on. The experimental results showed that this machine could satisfy the requirements of welding quality and girth welding technology, results also proved the machine was a high-effwiency and low-cost automatic welding device.展开更多
The robust control law for gas tungsten arc welding dynamic process, which is a typical sampled-data system and full of uncertainties, is presented. By using the Lyapunov, second method, the robust control and robust ...The robust control law for gas tungsten arc welding dynamic process, which is a typical sampled-data system and full of uncertainties, is presented. By using the Lyapunov, second method, the robust control and robust optimal control for a class of sampled-data systems whose underlying continuous-time systems are subjected to structured uncertainties are discussed in time-domain. As a result, some sufficient conditions of robust stability and the corresponding robust control laws are derived. All these results are designed by solving a class of linear matrix inequalities （LMIs） and a class of dynamic optimization problem with LMIs constraints respectively. An example adapted under some experimental conditions in the dynamic process of gas tungsten arc welding system in which the controlled variable is the backside width of weld pool and controlling variable pulse duty ratio, is worked out to illustrate the proposed results, it is shown that the sampling period is the crucial design oarameter.展开更多
In this paper a modifed continuous energy law was explored to investigate transport behavior in a gas metal arc welding(GMAW)system.The energy law equality at a discrete level for the GMAW system was derived by using ...In this paper a modifed continuous energy law was explored to investigate transport behavior in a gas metal arc welding(GMAW)system.The energy law equality at a discrete level for the GMAW system was derived by using the finite element scheme.The mass conservation and current density continuous equation with the penalty scheme was applied 10 improve the stability.According to the phase-field model coupled with the energy law preserving method,the GMAW model was discretized and a metal transfer process with a pulse current was simulated.It was found that the numerical solution agrees well with the data of the metal transfer process obtained by high-speed photography.Compared with the numerical solution of the volume of fuid model,which was widely studied in the GMAW system based on the finite element method Euler scheme,the energy law preserving method can provide better accuracy in predicting the shape evolution of the droplet and with a greater computing efficiency.展开更多
To develop a control system of cantilever arm for barrels welding, a motion controller has been developed to fit the welding procedure. The main research fields of the controller are: (1) finding effective measures to...To develop a control system of cantilever arm for barrels welding, a motion controller has been developed to fit the welding procedure. The main research fields of the controller are: (1) finding effective measures to protect the controller against interferences; (2) decreasing welding current gradually in order to alleviate arc craters which are harmful to seam forming and welding quality; (3) planning the arm velocity to minimize the influence of the arm swing on arc length regulator; (4) adopting adaptive control algorithm with PD feedback and velocity feed-forward to reduce the influence of system inertia and velocity planning on the system transient performance.展开更多
Welding seam tracking precision was decreased due to human hand tremor during the master-slave welding teleoperation. To solve this problem, a master-slave robot remote welding system was built, the system consisted o...Welding seam tracking precision was decreased due to human hand tremor during the master-slave welding teleoperation. To solve this problem, a master-slave robot remote welding system was built, the system consisted of a master manipulator with six degree of freedom （ DOF ） , an industrial computer control system and a slave Motoman HP3 J robot, and human hand tremor and digital filtering were discussed. An optimal digital filter was designed to clean human tremor signal for improving the welding seam tracking precision. The experimental results show that the digital filter suppresses the operator＇ s tremor signal.展开更多
This paper presents an integrated simulation model for full digital controlled PMIG/MAG welding system with Matlab/Simulink, and it consists of power inverter, digital control system and dynamic arc-load model. An int...This paper presents an integrated simulation model for full digital controlled PMIG/MAG welding system with Matlab/Simulink, and it consists of power inverter, digital control system and dynamic arc-load model. An integrated simulation study was done for full digital PMIG/MAG welding, and a method of connecting dynamic arc-load model to the system with controlled current source was presented, in addition, the simulation results were utilized to study the issues of digital control PMIG/MAG welding in this paper. The experimental results validated the developed simulation model, and this simulation study can be applied in implementation of the full digital PMIG/MAG welding and analysis of system dynamic process.展开更多
Dissimilar AZ31B magnesium alloy and DC56D steel were welded via AA1060 aluminum alloy by magnetic pulse welding.The effects of primary and secondary welding processes on the welded interface were comparatively invest...Dissimilar AZ31B magnesium alloy and DC56D steel were welded via AA1060 aluminum alloy by magnetic pulse welding.The effects of primary and secondary welding processes on the welded interface were comparatively investigated.Macroscopic morphology,microstructure,and interfacial structure of the joints were analyzed using scanning electron microscope,energy dispersive spectrometer,and X-ray diffractometer(XRD).The results show that magnetic pulse welding of dissimilar Mg/Fe metals is achieved using an Al interlayer,which acts as a bridge for deformation and diffusion.Specifically,the AZ31B/AA1060 interface exhibits a typical wavy morphology,and a transition zone exists at the joint interface,which may result in an extremely complex microstructure.The microstructure of this transition zone differs from that of AZ31B magnesium and 1060 Al alloys,and it is identified as brittle intermetallic compounds(IMCs)Al_(3)Mg_(2) and Al_(12)Mg_(17).The transition zone is mainly distributed on the Al side,with the maximum thickness of Al-side transition layer reaching approximately 13.53μm.Incomplete melting layers with varying thicknesses are observed at the primary weld interface,while micron-sized hole defects appear in the transition zone of the secondary weld interface.The AA1060/DC56D interface is mainly straight,with only a small number of discontinuous transition zones distributed intermittently along the interface.These transition zones are characterized by the presence of the brittle IMC FeAl_(3),with a maximum thickness of about 4μm.展开更多
Joining dissimilar materials encounters significant engineering challenges due to the contrast in material properties that makes conventional welding not feasible.Magnetic Pulse Welding(MPW)offers a solidstate joining...Joining dissimilar materials encounters significant engineering challenges due to the contrast in material properties that makes conventional welding not feasible.Magnetic Pulse Welding(MPW)offers a solidstate joining technique that overcomes these issues by using impact to create strong bonds without melting the substrate materials.This study investigates the weldability of aluminum alloy Al-5754 with Al-7075 and MARS 380 steel,used in armouring solutions of defense systems,by the use of MPW.In this work,weldability windows are investigated by varying standoff distances between the coating material and its substrate(0.25-4.5 mm)and discharge energies(5-13 kJ)with both O-shape and U-shape inductors.Mechanical strength of the welded joints were assessed through single lap shear tests,identifying optimal welding parameters.Then,the velocity profiles of the flyer plates were measured using heterodyne velocimetry to understand the dynamics of the impact.Then,substructures assembled with the optimal welding conditions were subjected to ballistic testing using 7.62 mm×51 mm NATO and 9 mm×19 mm Parabellum munitions to evaluate the resilience of the welds under ballistic impact.The outcomes demonstrate that MPW effectively joins Al-5754 with both Al-7075 and MARS 380,producing robust welds capable of withstanding ballistic impacts under certain conditions.This research advances the application of MPW in lightweight ballistic protection of defense systems,contributing to the development of more resilient and lighter protective structures.展开更多
A phase-field model including magnetic field induced dendrite fragmentation was established and applied to the cases with different initial crystal nuclear positions for AA5754 aluminum alloy electromagnetic laser bea...A phase-field model including magnetic field induced dendrite fragmentation was established and applied to the cases with different initial crystal nuclear positions for AA5754 aluminum alloy electromagnetic laser beam welding.Compare the calculated results that include dendrite fragmentation caused by the thermal electromagnetic Lorentz force with the results that consider only the thermal electromagnetic Lorentz force,without fragmentation,at the characteristic time instants.Both in the early and late stages,the small fragmentation at the dendrite tip promotes the number of higher-order branches and their growth,especially in the direction perpendicular to the solidification.The later stage fragmentation has the possibility of breaking one grain into several,which verifies the possibility of grain refinement caused by dendrite fragmentation.The fracture surface caused by fragmentation also makes more solid-liquid interfaces and their growth.In addition,the cases with different initial nuclear positions were compared.The grain growth in the low-temperature zone can be inhibited by the equiaxed grains'fragmentation at the high-temperature area(179.8μm^(2) and 14.7% start at the center,115.4μm^(2) and 9.4% start at the high-temperature corner,134.3μm^(2) and 10.9%start at the low-temperature corner),which is another kind of grain refinement by the dendrite fragmentation.This kind of inhibition effect on grain growth in the low-temperature region will be enhanced with the increasing time interval between the two crystal nuclei’appearance(179.8μm^(2) and 14.7%when virtual grains appear at t=4.3803 s and t=4.3803 s,134.3μm^(2) and 10.9%at t=4.0977 s and t=3.9564 s,and 115.4μm^(2) and 9.4%at t=3.8151 s and t=3.5325 s).展开更多
In this study,a 1400 MPa-grade ultra-high-strength steel thin-plate butt-welded joint was selected as the research object,and the joint was fabricated using the metal inert gas(MIG)welding process with ER307Si filler ...In this study,a 1400 MPa-grade ultra-high-strength steel thin-plate butt-welded joint was selected as the research object,and the joint was fabricated using the metal inert gas(MIG)welding process with ER307Si filler wire.Residual stress distributions were measured via the hole-drilling method,while micro-hardness was assessed using a micro-hardness tester.Simultaneously,both transverse shrinkage and angular distortion of the welded joint were experimentally determined.According to the hardness distribution of the joint,a thermalmetallurgical-mechanical finite element model was developed based on SYSWELD software platform.This model incorporates solid-state phase transformations(SSPT)and softening effect in the HAZ,as well as strain hardening and annealing behaviors in the weld metal.The temperature field,residual stress distribution,and welding deformation of single-pass butt-welded joint were simulated by the developed computational method.The simulation results were validated against experimental measurements,confirming the accuracy and reliability of the proposed computational approach.Furthermore,based on the numerical results,the influence mechanisms of SSPT and material softening on residual stress and deformation were analyzed.The findings indicate that SSPT exhibits considerable influences on the magnitude and distribution of welding residual stress.It reduces the peak longitudinal residual stress from 1620 MPa to 1350 MPa and increases the peak transverse residual stress from 350 MPa to 402 MPa.The results also manifest that the softening effect further reduces the peak longitudinal residual stress by 300 MPa,while exhibits minor effect on transverse residual stress.However,the results show that neither the SSPT nor the softening effect presents obvious influence on welding deformation.展开更多
Low heat input welding is widely used in the industry.The microstructure and toughness of the welded joints under low heat input conditions have received less attention than those under high heat input.The impact toug...Low heat input welding is widely used in the industry.The microstructure and toughness of the welded joints under low heat input conditions have received less attention than those under high heat input.The impact toughness,microstructure and failure mechanisms of the coarse-grain heat-affected zone(CGHAZ)in a micro-alloyed steel were investigated by welding thermal simulation with the heat input ranging from 15 to 65 kJ/cm.The impact toughness of CGHAZ is highly sensitive to variations in low heat input.The failure mechanisms were discussed from the viewpoints of micro-voids formation and micro-cracks propagation.The micro-voids are preferred to be formed and grow at soft phase of grain boundary ferrite(GBF).At the heat inputs no more than 22 kJ/cm,martensite was dominantly formed,and the micro-cracks initiated from the GBF were propagated into the grain interiors,leading to the brittle fracture and low toughness.When the heat input was increased to 31.2 kJ/cm,granular bainite became the dominant constitute,causing cracks to deflect away from GBF and propagate into prior austenite grains.The high density high-angle and low-angle grain boundaries and the presence of retained austenite,effectively restricted the crack propagation,resulting in ductile fracture behavior and enhanced toughness.High heat input(62.3 kJ/cm)promoted coarse GBF formation,providing continuous paths for microcrack propagation.This direct intergranular crack progression caused brittle fracture and low toughness.Industrial cold cracking in the CGHAZ can thus be controlled by heat input optimization to maximize toughness.展开更多
The fabrication of 304L stainless welding wires with a diameter 1.6 mm by using electrochemical cold drawing(ECD)of bars with a diameter of 5.6 mm was investigated,as well as that via traditional cold drawing(TCD)for ...The fabrication of 304L stainless welding wires with a diameter 1.6 mm by using electrochemical cold drawing(ECD)of bars with a diameter of 5.6 mm was investigated,as well as that via traditional cold drawing(TCD)for comparison.The results indicated that the dilute H_(2)SO_(4)aqueous solution was an appropriate electrolyte for ECD,and increasing the H_(2)SO_(4)concentration and current density within a range improved the corrosion rate and uniformity,leading to an easier and more coordinated deformation through uniformly distributing geometrically necessary dislocations and curved large-angle grain boundaries,and decreasing their density,and thus,an enhanced electrochemical plasticization(EP).Under the optimized electrochemical parameters(0.5 mol L^(-1)H_(2)SO_(4)electrolyte and current density of 12.2 mA cm^(-2)),the average cumulative reduction rate required for annealing was up to~34%,obviously higher than~20%of TCD due to the decreased work-hardening from the EP,so that the number of annealing was significantly reduced from 10 of TCD to 5,when the drawing pass was 23.In addition,the surface of the ECD wire was distinctly smoother and brighter than that of the TCD one.These findings confirm the large potential in engineering applications of the ECD technology based on the EP effect.展开更多
Underwater welding plays a crucial role in repairing surface defects in submerged structures and improving their surface properties,particularly their resistance to corrosive-wear.Underwater surfacing layers were depo...Underwater welding plays a crucial role in repairing surface defects in submerged structures and improving their surface properties,particularly their resistance to corrosive-wear.Underwater surfacing layers were deposited using welding currents of 120,135 and 150 A.The microstructural characteristics of underwater-deposited surfacing layers were analyzed.Due to the limited heat input at 120 A welding current,the underwater-deposited surfacing layer primarily consists of polygonal ferrite(PF)and pearlite.In contrast,the surfacing layer deposited in air exhibited a microstructure composed of acicular ferrite(AF),ferrite with a second-phase arrangement(FSP),PF,and pearlite.Additionally,the high heat transfer rate underwater induces the formation of columnar grains.As the welding current increased,the presence of AF,FSP,PF,and pearlite reappeared in the microstructure,and a fine-grain zone formed on the surface due to rapid water cooling.The columnar grain structure within the surfacing layer became increasingly distinct with rising welding current.Moreover,the increased welding current led to an elevated volume fraction of AF packets,subsequently raising the proportion of low-angle grain boundaries and dislocation density.Smaller grain size,equiaxed grain morphology,and higher dislocation density are identified as key factors influencing the properties,leading to a 36%increase in microhardness and an improvement in the corrosive-wear resistance of the surfacing layer.展开更多
Marine thin plates are susceptible to welding deformation owing to their low structural stiffness.Therefore,the efficient and accurate prediction of welding deformation is essential for improving welding quality.The t...Marine thin plates are susceptible to welding deformation owing to their low structural stiffness.Therefore,the efficient and accurate prediction of welding deformation is essential for improving welding quality.The traditional thermal elastic-plastic finite element method(TEP-FEM)can accurately predict welding deformation.However,its efficiency is low because of the complex nonlinear transient computation,making it difficult to meet the needs of rapid engineering evaluation.To address this challenge,this study proposes an efficient prediction method for welding deformation in marine thin plate butt welds.This method is based on the coupled temperature gradient-thermal strain method(TG-TSM)that integrates inherent strain theory with a shell element finite element model.The proposed method first extracts the distribution pattern and characteristic value of welding-induced inherent strain through TEP-FEM analysis.This strain is then converted into the equivalent thermal load applied to the shell element model for rapid computation.The proposed method-particularly,the gradual temperature gradient-thermal strain method(GTG-TSM)-achieved improved computational efficiency and consistent precision.Furthermore,the proposed method required much less computation time than the traditional TEP-FEM.Thus,this study lays the foundation for future prediction of welding deformation in more complex marine thin plates.展开更多
To improve the weld formation of underwater-welded Q355B steel and enhance its corrosion resistance,this study introduced pulsed laser welding technology into local dry underwater welding process,building upon continu...To improve the weld formation of underwater-welded Q355B steel and enhance its corrosion resistance,this study introduced pulsed laser welding technology into local dry underwater welding process,building upon continuous laser welding process.A systematic investigation was carried out covering process exploration,weld morphology,microstructure,and comprehensive properties.The results indicate that the pulsed laser weld seam exhibited a distinct ripple pattern on the surface,along with significantly less spatter compared to continuous laser weld seam.Both the weld penetration depth and weld bead width showed a decreasing trend with increasing pulse frequency.The weld metal was primarily composed of ferrite and martensite phases.As the pulse frequency increased,the ferrite content first rose and then declined,reaching a maximum of 39%at 80 Hz.The microhardness and tensile strength of the weld metal were both higher than those of the base material,and all tensile specimens fractured within the base metal during testing.Furthermore,the elongation initially increased and then decreased with rising pulse frequency.The weld produced at 80 Hz achieved the highest elongation of 23.1%,which was 8.9% higher than that of the continuous laser weld seam and reached 93.9% of the base material.Electrochemical corrosion tests revealed that the weld produced at 80 Hz exhibited the best corrosion resistance,reaching 67.0% of that of the base material,while the continuous laser weld seam attained only 47.3% of the base material.This study provides critical theoretical and data support for the process optimization and application of local dry underwater laser welding in the fabrication of marine engineering structures.展开更多
The dissimilar 2B06 and 7B04 Al alloy joints were prepared by refill friction stir spot welding(RFSSW),and the microstructural evolution and corrosion behavior of the joints were investigated.Based on microstructural ...The dissimilar 2B06 and 7B04 Al alloy joints were prepared by refill friction stir spot welding(RFSSW),and the microstructural evolution and corrosion behavior of the joints were investigated.Based on microstructural analysis,the welded joints exhibit distinct microstructural zones,including the stir zone(SZ),thermomechanically affected zone(TMAZ),and heat-affected zone(HAZ).The grain size of each zone is in the order of HAZ>TMAZ>SZ.Notably,the TMAZ and HAZ contain significantly larger secondary-phase particles compared to the SZ,with particle size in the HAZ increasing at higher rotational speeds.Electrochemical tests indicate that corrosion susceptibility follows the sequence of HAZ>TMAZ>SZ>BM,with greater sensitivity observed at increased rotational speeds.Post-corrosion mechanical performance degradation primarily arises from crevice corrosion at joint overlaps,but not from the changes in the microstructure.展开更多
基金This work was supported by the National Natural Science Foundation of China(Grant Numbers 51375173).
文摘To satisfy the demand for good quality underwater welding and maintenance of nuclear power stations,a set of local dry automatic welding systems has been developed.These systems were based on an underwater robot that consisted of a special high-power underwater welding power supply,diving wire feeder,mini drain cap,welding robot,and special underwater welding torch.With a digital signal controller microprocessor as its core and combined with a dual inverter topology,the welding power supply was characterized by full-digital construction and multi-waveform flexible output.A compact diving wire feeding device was designed,based on the armature voltage negative feedback and high-frequency chopping pulse width modulation.This device yielded a high-efficiency seal of the driving motor with the help of dynamic and static sealing technology.To overcome the difficulty of local protection and deslagging in the welding area,a mini drain cap(with a duplexgas structure)based on the principle of the convergent nozzle was designed.The practical tests and the underwater welding experiments revealed that the underwater robotic local dry welding system is quite feasible.That is,the system could strike the arc stably and reliably in the shallow water environment,and formed beautiful welding seams.
文摘Teleoperation control strategies for collaborative welding system which is targeting at giving full play to human’s superiority is designed and the fitness for teleoperation welding task of which are studied. During the teleoperation welding process, 6-DOF controller’s signal can be converted into welding torch’s position, velocity or acceleration changing which is being controlled. For welding purposes, control strategies of four modes are designed, which are static position and posture mode, dynamic position and posture mode, velocity mode and acceleration mode. A test and analysis system for testing the tracking accuracy and reliability of control strategy based on virtual reality is developed. The tracking accuracies of the four control strategies are studied in the following tests with straight line trajectory, curve trajectory or space curve trajectory. The results show that the control strategy in dynamic position and posture mode has best stability and strong adaptability which is the most suitable for the teleoperation system.
文摘According to the requirements of welding process for vortex type compressor of air conditioner manufactured in product line, a special girth welding machine with PLC as control core was developed, which had both upright and 45 ° incline service positions. And some key technologies were researched, such as structural design of machine body, reliable conduction of rotary weldments and quality control of welding process and so on. The experimental results showed that this machine could satisfy the requirements of welding quality and girth welding technology, results also proved the machine was a high-effwiency and low-cost automatic welding device.
基金This project is supported by Doctor's Research Fund of Science Education Ministry of China(No.20060214004)Scientific Research Fund Education Ministry of China(No.206041)Scientific Research Fund of Harbin Sci-ence Bureau China(No.20051AAICG037).
文摘The robust control law for gas tungsten arc welding dynamic process, which is a typical sampled-data system and full of uncertainties, is presented. By using the Lyapunov, second method, the robust control and robust optimal control for a class of sampled-data systems whose underlying continuous-time systems are subjected to structured uncertainties are discussed in time-domain. As a result, some sufficient conditions of robust stability and the corresponding robust control laws are derived. All these results are designed by solving a class of linear matrix inequalities （LMIs） and a class of dynamic optimization problem with LMIs constraints respectively. An example adapted under some experimental conditions in the dynamic process of gas tungsten arc welding system in which the controlled variable is the backside width of weld pool and controlling variable pulse duty ratio, is worked out to illustrate the proposed results, it is shown that the sampling period is the crucial design oarameter.
基金Yanhai Lin was supported by the National Natural Science Foundation of China(Grant No.11702101)the Fundamental Research Funds for the Central Universities and the Promo-tion Program for Young and Middle aged Teacher in Science and Technology Research of Huaqiao University(Grant No.ZQN-PY502)+1 种基金the Natural Science Foundation of Fujian Province(Grant No.2019105093)Quanzhou High-Level Talents Support Plan.
文摘In this paper a modifed continuous energy law was explored to investigate transport behavior in a gas metal arc welding(GMAW)system.The energy law equality at a discrete level for the GMAW system was derived by using the finite element scheme.The mass conservation and current density continuous equation with the penalty scheme was applied 10 improve the stability.According to the phase-field model coupled with the energy law preserving method,the GMAW model was discretized and a metal transfer process with a pulse current was simulated.It was found that the numerical solution agrees well with the data of the metal transfer process obtained by high-speed photography.Compared with the numerical solution of the volume of fuid model,which was widely studied in the GMAW system based on the finite element method Euler scheme,the energy law preserving method can provide better accuracy in predicting the shape evolution of the droplet and with a greater computing efficiency.
文摘To develop a control system of cantilever arm for barrels welding, a motion controller has been developed to fit the welding procedure. The main research fields of the controller are: (1) finding effective measures to protect the controller against interferences; (2) decreasing welding current gradually in order to alleviate arc craters which are harmful to seam forming and welding quality; (3) planning the arm velocity to minimize the influence of the arm swing on arc length regulator; (4) adopting adaptive control algorithm with PD feedback and velocity feed-forward to reduce the influence of system inertia and velocity planning on the system transient performance.
基金This research is supported by National Natural Science Foundation of China （No. 50905043）.
文摘Welding seam tracking precision was decreased due to human hand tremor during the master-slave welding teleoperation. To solve this problem, a master-slave robot remote welding system was built, the system consisted of a master manipulator with six degree of freedom （ DOF ） , an industrial computer control system and a slave Motoman HP3 J robot, and human hand tremor and digital filtering were discussed. An optimal digital filter was designed to clean human tremor signal for improving the welding seam tracking precision. The experimental results show that the digital filter suppresses the operator＇ s tremor signal.
文摘This paper presents an integrated simulation model for full digital controlled PMIG/MAG welding system with Matlab/Simulink, and it consists of power inverter, digital control system and dynamic arc-load model. An integrated simulation study was done for full digital PMIG/MAG welding, and a method of connecting dynamic arc-load model to the system with controlled current source was presented, in addition, the simulation results were utilized to study the issues of digital control PMIG/MAG welding in this paper. The experimental results validated the developed simulation model, and this simulation study can be applied in implementation of the full digital PMIG/MAG welding and analysis of system dynamic process.
文摘Dissimilar AZ31B magnesium alloy and DC56D steel were welded via AA1060 aluminum alloy by magnetic pulse welding.The effects of primary and secondary welding processes on the welded interface were comparatively investigated.Macroscopic morphology,microstructure,and interfacial structure of the joints were analyzed using scanning electron microscope,energy dispersive spectrometer,and X-ray diffractometer(XRD).The results show that magnetic pulse welding of dissimilar Mg/Fe metals is achieved using an Al interlayer,which acts as a bridge for deformation and diffusion.Specifically,the AZ31B/AA1060 interface exhibits a typical wavy morphology,and a transition zone exists at the joint interface,which may result in an extremely complex microstructure.The microstructure of this transition zone differs from that of AZ31B magnesium and 1060 Al alloys,and it is identified as brittle intermetallic compounds(IMCs)Al_(3)Mg_(2) and Al_(12)Mg_(17).The transition zone is mainly distributed on the Al side,with the maximum thickness of Al-side transition layer reaching approximately 13.53μm.Incomplete melting layers with varying thicknesses are observed at the primary weld interface,while micron-sized hole defects appear in the transition zone of the secondary weld interface.The AA1060/DC56D interface is mainly straight,with only a small number of discontinuous transition zones distributed intermittently along the interface.These transition zones are characterized by the presence of the brittle IMC FeAl_(3),with a maximum thickness of about 4μm.
基金funded on the one hand by Agence de l'Innovation de Défense(AID)grant reference number 2021650044on the other hand by Ecole Centrale de Nantes。
文摘Joining dissimilar materials encounters significant engineering challenges due to the contrast in material properties that makes conventional welding not feasible.Magnetic Pulse Welding(MPW)offers a solidstate joining technique that overcomes these issues by using impact to create strong bonds without melting the substrate materials.This study investigates the weldability of aluminum alloy Al-5754 with Al-7075 and MARS 380 steel,used in armouring solutions of defense systems,by the use of MPW.In this work,weldability windows are investigated by varying standoff distances between the coating material and its substrate(0.25-4.5 mm)and discharge energies(5-13 kJ)with both O-shape and U-shape inductors.Mechanical strength of the welded joints were assessed through single lap shear tests,identifying optimal welding parameters.Then,the velocity profiles of the flyer plates were measured using heterodyne velocimetry to understand the dynamics of the impact.Then,substructures assembled with the optimal welding conditions were subjected to ballistic testing using 7.62 mm×51 mm NATO and 9 mm×19 mm Parabellum munitions to evaluate the resilience of the welds under ballistic impact.The outcomes demonstrate that MPW effectively joins Al-5754 with both Al-7075 and MARS 380,producing robust welds capable of withstanding ballistic impacts under certain conditions.This research advances the application of MPW in lightweight ballistic protection of defense systems,contributing to the development of more resilient and lighter protective structures.
基金supported by the Alexander von Humboldt Foundation,and Deutsche Forschungsgemeinschaft(DFG,German Research Foundation,Project No.506270597 and No.466939224).
文摘A phase-field model including magnetic field induced dendrite fragmentation was established and applied to the cases with different initial crystal nuclear positions for AA5754 aluminum alloy electromagnetic laser beam welding.Compare the calculated results that include dendrite fragmentation caused by the thermal electromagnetic Lorentz force with the results that consider only the thermal electromagnetic Lorentz force,without fragmentation,at the characteristic time instants.Both in the early and late stages,the small fragmentation at the dendrite tip promotes the number of higher-order branches and their growth,especially in the direction perpendicular to the solidification.The later stage fragmentation has the possibility of breaking one grain into several,which verifies the possibility of grain refinement caused by dendrite fragmentation.The fracture surface caused by fragmentation also makes more solid-liquid interfaces and their growth.In addition,the cases with different initial nuclear positions were compared.The grain growth in the low-temperature zone can be inhibited by the equiaxed grains'fragmentation at the high-temperature area(179.8μm^(2) and 14.7% start at the center,115.4μm^(2) and 9.4% start at the high-temperature corner,134.3μm^(2) and 10.9%start at the low-temperature corner),which is another kind of grain refinement by the dendrite fragmentation.This kind of inhibition effect on grain growth in the low-temperature region will be enhanced with the increasing time interval between the two crystal nuclei’appearance(179.8μm^(2) and 14.7%when virtual grains appear at t=4.3803 s and t=4.3803 s,134.3μm^(2) and 10.9%at t=4.0977 s and t=3.9564 s,and 115.4μm^(2) and 9.4%at t=3.8151 s and t=3.5325 s).
基金funded by the National Natural Science Foundation of China(Grant No.52471032).
文摘In this study,a 1400 MPa-grade ultra-high-strength steel thin-plate butt-welded joint was selected as the research object,and the joint was fabricated using the metal inert gas(MIG)welding process with ER307Si filler wire.Residual stress distributions were measured via the hole-drilling method,while micro-hardness was assessed using a micro-hardness tester.Simultaneously,both transverse shrinkage and angular distortion of the welded joint were experimentally determined.According to the hardness distribution of the joint,a thermalmetallurgical-mechanical finite element model was developed based on SYSWELD software platform.This model incorporates solid-state phase transformations(SSPT)and softening effect in the HAZ,as well as strain hardening and annealing behaviors in the weld metal.The temperature field,residual stress distribution,and welding deformation of single-pass butt-welded joint were simulated by the developed computational method.The simulation results were validated against experimental measurements,confirming the accuracy and reliability of the proposed computational approach.Furthermore,based on the numerical results,the influence mechanisms of SSPT and material softening on residual stress and deformation were analyzed.The findings indicate that SSPT exhibits considerable influences on the magnitude and distribution of welding residual stress.It reduces the peak longitudinal residual stress from 1620 MPa to 1350 MPa and increases the peak transverse residual stress from 350 MPa to 402 MPa.The results also manifest that the softening effect further reduces the peak longitudinal residual stress by 300 MPa,while exhibits minor effect on transverse residual stress.However,the results show that neither the SSPT nor the softening effect presents obvious influence on welding deformation.
基金supported by the National Natural Science Foundation of China(No.51804232)Beijing Municipal Natural Science Foundation(No.2212041)+1 种基金supported by the Interdisciplinary Research Project for Young Teachers of USTB(Fundamental Research Funds for the Central Universities)(FRF-IDRY-20-020)GIMRT Program of the Institute for Materials Research,Tohoku University(202303-RDKGE-0518).
文摘Low heat input welding is widely used in the industry.The microstructure and toughness of the welded joints under low heat input conditions have received less attention than those under high heat input.The impact toughness,microstructure and failure mechanisms of the coarse-grain heat-affected zone(CGHAZ)in a micro-alloyed steel were investigated by welding thermal simulation with the heat input ranging from 15 to 65 kJ/cm.The impact toughness of CGHAZ is highly sensitive to variations in low heat input.The failure mechanisms were discussed from the viewpoints of micro-voids formation and micro-cracks propagation.The micro-voids are preferred to be formed and grow at soft phase of grain boundary ferrite(GBF).At the heat inputs no more than 22 kJ/cm,martensite was dominantly formed,and the micro-cracks initiated from the GBF were propagated into the grain interiors,leading to the brittle fracture and low toughness.When the heat input was increased to 31.2 kJ/cm,granular bainite became the dominant constitute,causing cracks to deflect away from GBF and propagate into prior austenite grains.The high density high-angle and low-angle grain boundaries and the presence of retained austenite,effectively restricted the crack propagation,resulting in ductile fracture behavior and enhanced toughness.High heat input(62.3 kJ/cm)promoted coarse GBF formation,providing continuous paths for microcrack propagation.This direct intergranular crack progression caused brittle fracture and low toughness.Industrial cold cracking in the CGHAZ can thus be controlled by heat input optimization to maximize toughness.
基金supported by Major Science and Technology Project of Gansu Province(Grant No.23ZDGA010)National Natural Science Foundation of China(Grant No.51971105).
文摘The fabrication of 304L stainless welding wires with a diameter 1.6 mm by using electrochemical cold drawing(ECD)of bars with a diameter of 5.6 mm was investigated,as well as that via traditional cold drawing(TCD)for comparison.The results indicated that the dilute H_(2)SO_(4)aqueous solution was an appropriate electrolyte for ECD,and increasing the H_(2)SO_(4)concentration and current density within a range improved the corrosion rate and uniformity,leading to an easier and more coordinated deformation through uniformly distributing geometrically necessary dislocations and curved large-angle grain boundaries,and decreasing their density,and thus,an enhanced electrochemical plasticization(EP).Under the optimized electrochemical parameters(0.5 mol L^(-1)H_(2)SO_(4)electrolyte and current density of 12.2 mA cm^(-2)),the average cumulative reduction rate required for annealing was up to~34%,obviously higher than~20%of TCD due to the decreased work-hardening from the EP,so that the number of annealing was significantly reduced from 10 of TCD to 5,when the drawing pass was 23.In addition,the surface of the ECD wire was distinctly smoother and brighter than that of the TCD one.These findings confirm the large potential in engineering applications of the ECD technology based on the EP effect.
基金funded by the Open Research Fund of National Engineering Research Center of Water Resources Efficient Utilization and Engineering Safety(No.GJGCZX-JJ-202408).
文摘Underwater welding plays a crucial role in repairing surface defects in submerged structures and improving their surface properties,particularly their resistance to corrosive-wear.Underwater surfacing layers were deposited using welding currents of 120,135 and 150 A.The microstructural characteristics of underwater-deposited surfacing layers were analyzed.Due to the limited heat input at 120 A welding current,the underwater-deposited surfacing layer primarily consists of polygonal ferrite(PF)and pearlite.In contrast,the surfacing layer deposited in air exhibited a microstructure composed of acicular ferrite(AF),ferrite with a second-phase arrangement(FSP),PF,and pearlite.Additionally,the high heat transfer rate underwater induces the formation of columnar grains.As the welding current increased,the presence of AF,FSP,PF,and pearlite reappeared in the microstructure,and a fine-grain zone formed on the surface due to rapid water cooling.The columnar grain structure within the surfacing layer became increasingly distinct with rising welding current.Moreover,the increased welding current led to an elevated volume fraction of AF packets,subsequently raising the proportion of low-angle grain boundaries and dislocation density.Smaller grain size,equiaxed grain morphology,and higher dislocation density are identified as key factors influencing the properties,leading to a 36%increase in microhardness and an improvement in the corrosive-wear resistance of the surfacing layer.
基金Supported by the National Natural Science Foundation of China under Grant No.51975138the High-Tech Ship Scientific Research Project from the Ministry of Industry and Information Technology under Grant No.CJ05N20the National Defense Basic Research Project under Grant No.JCKY2023604C006.
文摘Marine thin plates are susceptible to welding deformation owing to their low structural stiffness.Therefore,the efficient and accurate prediction of welding deformation is essential for improving welding quality.The traditional thermal elastic-plastic finite element method(TEP-FEM)can accurately predict welding deformation.However,its efficiency is low because of the complex nonlinear transient computation,making it difficult to meet the needs of rapid engineering evaluation.To address this challenge,this study proposes an efficient prediction method for welding deformation in marine thin plate butt welds.This method is based on the coupled temperature gradient-thermal strain method(TG-TSM)that integrates inherent strain theory with a shell element finite element model.The proposed method first extracts the distribution pattern and characteristic value of welding-induced inherent strain through TEP-FEM analysis.This strain is then converted into the equivalent thermal load applied to the shell element model for rapid computation.The proposed method-particularly,the gradual temperature gradient-thermal strain method(GTG-TSM)-achieved improved computational efficiency and consistent precision.Furthermore,the proposed method required much less computation time than the traditional TEP-FEM.Thus,this study lays the foundation for future prediction of welding deformation in more complex marine thin plates.
基金supported by the National Natural Science Foundation of China(Grant number U23A20625,U2141216,52375334)the Science and Technology Planning Project of Nansha District(Grant number 2025ZD003)the Science and Technology Program of Guangdong Province(Grant number 2023B1515250003).
文摘To improve the weld formation of underwater-welded Q355B steel and enhance its corrosion resistance,this study introduced pulsed laser welding technology into local dry underwater welding process,building upon continuous laser welding process.A systematic investigation was carried out covering process exploration,weld morphology,microstructure,and comprehensive properties.The results indicate that the pulsed laser weld seam exhibited a distinct ripple pattern on the surface,along with significantly less spatter compared to continuous laser weld seam.Both the weld penetration depth and weld bead width showed a decreasing trend with increasing pulse frequency.The weld metal was primarily composed of ferrite and martensite phases.As the pulse frequency increased,the ferrite content first rose and then declined,reaching a maximum of 39%at 80 Hz.The microhardness and tensile strength of the weld metal were both higher than those of the base material,and all tensile specimens fractured within the base metal during testing.Furthermore,the elongation initially increased and then decreased with rising pulse frequency.The weld produced at 80 Hz achieved the highest elongation of 23.1%,which was 8.9% higher than that of the continuous laser weld seam and reached 93.9% of the base material.Electrochemical corrosion tests revealed that the weld produced at 80 Hz exhibited the best corrosion resistance,reaching 67.0% of that of the base material,while the continuous laser weld seam attained only 47.3% of the base material.This study provides critical theoretical and data support for the process optimization and application of local dry underwater laser welding in the fabrication of marine engineering structures.
基金supported by the National Natural Science Foundation of China (Nos. 52075449, 51975480)。
文摘The dissimilar 2B06 and 7B04 Al alloy joints were prepared by refill friction stir spot welding(RFSSW),and the microstructural evolution and corrosion behavior of the joints were investigated.Based on microstructural analysis,the welded joints exhibit distinct microstructural zones,including the stir zone(SZ),thermomechanically affected zone(TMAZ),and heat-affected zone(HAZ).The grain size of each zone is in the order of HAZ>TMAZ>SZ.Notably,the TMAZ and HAZ contain significantly larger secondary-phase particles compared to the SZ,with particle size in the HAZ increasing at higher rotational speeds.Electrochemical tests indicate that corrosion susceptibility follows the sequence of HAZ>TMAZ>SZ>BM,with greater sensitivity observed at increased rotational speeds.Post-corrosion mechanical performance degradation primarily arises from crevice corrosion at joint overlaps,but not from the changes in the microstructure.
