The quality of rebar welds directly impacts the overall service performance of highway infrastructure.However,current assessments of weld appearance quality primarily rely on traditional inspection methods such as man...The quality of rebar welds directly impacts the overall service performance of highway infrastructure.However,current assessments of weld appearance quality primarily rely on traditional inspection methods such as manual visual inspection,which suffer from significant limitations in accuracy,reliability,and efficiency.Given the increasing demand for safety performance inspections of highway infrastructure in China,traditional methods struggle to meet modern rapid inspection requirements.Therefore,this study proposes the design of a portable,non-destructive inspection device for rebar weld appearance,utilizing visible light vision and line-structured light 3D scanning technology.The device is equipped with an STM32 master control chip to manage encoder reading,scanning laser control,ring fill light,industrial camera synchronization,image acquisition,and serial port command transmission.Additionally,a weld image processing and detection software system was developed to receive,store,and identify weld defects.A field inspection prototype was created and subjected to various defect weld detection experiments in a laboratory setting.Experimental results demonstrate that the device can accurately measure weld parameters by acquiring multimodal images,fulfilling defect detection requirements.The device features high detection accuracy,portability,and user-friendliness,making it significant for the objective inspection and evaluation of rebar weld appearance and welding quality.展开更多
The constant amplitude loading fatigue tests were carried out on the 6061/7075 aluminum alloy TIG fillet welded lap specimens in this study,and the weld seam cross-section hardness was measured.The experimental result...The constant amplitude loading fatigue tests were carried out on the 6061/7075 aluminum alloy TIG fillet welded lap specimens in this study,and the weld seam cross-section hardness was measured.The experimental results show that most specimens mainly failed at the 7075 side weld toes even though the base material tensile strength of 7075 is higher than that of 6061.The maximum stress-strain concentration in the two finite element models is located at the 7075 side weld toe,which is basically consistent with the actual fracture location.The weld zone on the 7075 side experiences severe material softening,with a large gradient.However,the Vickers hardness value on the 6061 side negligibly changes and fluctuates around 70 HV.No obvious defects are found on the fatigue fracture,but a large number of secondary cracks appear.Cracks germinate from the weld toe and propagate in the direction of the plate thickness.Weld reinforcement has a serious impact on fatigue life.Fatigue life will decrease exponentially as the weld reinforcement increases under low stress.It is found that the notch stress method can give a better fatigue life prediction for TIG weldments,and the errors of the predicted results are within the range of two factors,while the prediction accuracy decreases under low stress.The equivalent structural stress method can also be used for fatigue life prediction of TIG weldments,but the errors of prediction results are within the range of three factors,and the accuracy decreases under high stress.展开更多
The study aimed to address the issue of elevated residual stress levels in dissimilar girth welds of cast steel joints.To achieve this,the hybrid welding technology,which yields high welding speeds while simultaneousl...The study aimed to address the issue of elevated residual stress levels in dissimilar girth welds of cast steel joints.To achieve this,the hybrid welding technology,which yields high welding speeds while simultaneously reducing residual stresses,has been introduced.This study utilizes a numerical simulation method to investigate the temperature and residual stress field in the hybrid welding of G20Mn5 casting-Q355 low-alloy steel welded pipe.A com-parison of the findings of this study with those of other welding processes revealed the technological advantages of hybrid welding.The research outcomes show that due to geometric discontinuities and material differences,the temperature field of the joint exhibits uneven distribution characteristics,and the peak temperatures on the Q355 steel side exceeds those on the G20Mn5 steel side.An evident stress gra-dient is present in the residual stress field of the joint post-welding,with peak stress located at the weld root on the Q355 steel.Compared with arc welding,the hybrid welding leads to decreased residual stresses and deformation,with high stress outside the heat-affected zone diminishing rapidly.Furthermore,it significantly improves the welding efficiency.This study elucidates the distribution and underlying causes of thermal and residual stress fields in dissimilar girth welds.This serves as a foundation for the application of hybrid welding technology in welded cast steel joints.展开更多
In this work,microstructure and mechanical properties of Mg weld with addition of carbon nanotubes(CNTs)and Ti C particles were investigated.The results showed that the weld microstructure was mainly presented as equi...In this work,microstructure and mechanical properties of Mg weld with addition of carbon nanotubes(CNTs)and Ti C particles were investigated.The results showed that the weld microstructure was mainly presented as equiaxed grains with almost high angle grain boundaries.The introduction of reinforcements promoted the formation of precipitates and refined the grains effectively,the average grain size was refined by 51%and 23%with addition of CNTs and Ti C particles,respectively.The dislocation density and the fraction of CSL boundaries were increased with addition of CNTs,while those were decreased with addition of Ti C particles.Besides,the infrequent{10¯13}contraction twins formed within the weld due to the stress concentration caused by dislocation accumulation,which contributed to theΣ29 CSL boundary.The ultimate tensile strength and elongation rate were increased by 13.5%and 40%with addition of CNTs,while the ultimate tensile strength and micro-hardness were increased by 14.8%and 20.9%with addition of Ti C particles.展开更多
Direct friction welding of Ti Al alloy to 40 Cr steel rods was conducted, and the microstructure and mechanical properties of the resultant joints in as-welded and post-weld heat treatment（PWHT） states were investig...Direct friction welding of Ti Al alloy to 40 Cr steel rods was conducted, and the microstructure and mechanical properties of the resultant joints in as-welded and post-weld heat treatment（PWHT） states were investigated. The martensitic transformation occurred and brittle Ti C phase formed near the interface due to C agglomeration, which degraded the joint strength and increased the microhardness at the interface in as-welded state. Feathery and Widmanstatten structure generated near the interface on Ti Al alloy side. After PWHT at 580 °C and 630 °C for 2 h, the sorbite formed and C dispersed at the interface, leading to the increase of the joint strength from 86 MPa in as-welded state to 395 MPa and 330 MPa, respectively. The heat-treated specimen fractured with quasi-cleavage features through the zone 1 mm away from the interface on TiA l alloy side, but the as-welded specimen failed through the interface.展开更多
The microstructure, microhardness and quasi-static failure behavior of resistance spot welds of AA6111-T4 aluminum alloy were experimentally investigated. Optical metallography and high-resolution hardness traverses w...The microstructure, microhardness and quasi-static failure behavior of resistance spot welds of AA6111-T4 aluminum alloy were experimentally investigated. Optical metallography and high-resolution hardness traverses were utilized to characterize the weld nugget, heat affected zone and base metal. The AA6111 spot welds displayed a softer nugget and hardened heat affected zone, compared with the base metal. The through-thickness hardness of the base metal sheet was not constant and had to be carefully considered to determine the effect of welding on material properties. Quasi-static lap-shear tensile tests were used to determine the failure load and failure mode. All tensile specimens failed through the interfacial fracture. This failure mode is consistent with the observed reduced hardness in the weld nugget.展开更多
Brittle fracture occurs frequently in rails and thermite welded joints, which intimidates the security and reliability of railway ser- vice. Railways in cold regions, such as Qinghai-Tibet Railway, make the problem of...Brittle fracture occurs frequently in rails and thermite welded joints, which intimidates the security and reliability of railway ser- vice. Railways in cold regions, such as Qinghai-Tibet Railway, make the problem of brittle fi＇acture in rails even worse. A series of tests such as uniaxial tensile tests, Charpy impact tests, and three-point bending tests were carried out at low temperature to investigate the mechanical properties and fracture toughness of U71Mn and U75V rail steels and their thermite welds. Fracture micromechanisms were analyzed by scanning electron microscopy （SEM） on the fracture surfaces of the tested specimens. The ductility indices （percentage elongation aider frac- ture and percentage reduction of area） and the toughness indices （Charpy impact energy Ak and plane-strain fracture toughness Kic） of the two kinds of rail steels and the corresponding thermite welds all decrease as the temperature decreases. The thermite welds are more critical to fracture than the rail steel base metals, as indicated by a higher yield-to-ultimate ratio and a much lower Charpy impact energy. U71Mn rail steel is relatively higher in toughness than U75V, as demonstrated by larger Ak and Klc values. Therefore, U71Mn rail steel and the corresponding thermite weld are recommended in railway construction and maintenance in cold regions.展开更多
Base metals of domestic pipeline steels were used to study the effect of Mn on corrosion properties of SSCC(Sulfide Stress Corrosion Cracking), and welds were carried out to study the effect of MnS on corrosion proper...Base metals of domestic pipeline steels were used to study the effect of Mn on corrosion properties of SSCC(Sulfide Stress Corrosion Cracking), and welds were carried out to study the effect of MnS on corrosion properties of HIC (Hydrogen Induced Cracking) both in solutions with wet hydrogen sulfide(H_2S). They were respectively conducted by referring to the standards of SSCC and HIC. Testing results revealed that with the increase of content Mn, the resistance of SSCC will be decreased, from the point of metallurgic view, and it is Mn element not C element to lead to the testing results of SSCC. Meanwhile, even under the condition without inclusions MnS, HIC in welds still occurred. That is to say, MnS is not necessary for HIC, the presence of local banded structures in which Mn and P are inclined to aggregate cause to the phenomena of HIC.展开更多
By using the rigid-visco-plasticity finite element method, the welding process of aluminum porthole die extrusion to form a tube was simulated based on Deform-3D software. The welding chamber height （H）, back dimens...By using the rigid-visco-plasticity finite element method, the welding process of aluminum porthole die extrusion to form a tube was simulated based on Deform-3D software. The welding chamber height （H）, back dimension of die leg （D）, process velocity and initial billet temperature were used in FE simulations so as to determine the conditions in which better longitudinal welding quality can be obtained. According to K criterion, the local welding parameters such as welding pressure, effective stress and welding path length on the welding plane are linked to longitudinal welds quality. Simulation turns out that pressure-to-effective stress ratio （ρ/σ） and welding path length （L） are the key factors affecting the welding quality, Higher welding chamber best and sharper die leg give better welding quality. When H=10 mm and D=0.4 mm, the longitudinal welds have the best quality. Higher process velocity decreases welds quality. The proper velocity is 10 mm/s for this simulation. In a certain range, higher temperature is beneficial to the longitudinal welds. It is found that both 450 and 465℃ can satisfy the requirements of the longitudinal welds.展开更多
The wedge and bulge expansion tests were compared in the assessment of the seam welds strength in a tubular profile extruded at two ram speeds.In the wedge test,the expansion was determined by moving a conical punch i...The wedge and bulge expansion tests were compared in the assessment of the seam welds strength in a tubular profile extruded at two ram speeds.In the wedge test,the expansion was determined by moving a conical punch into the tube until the specimen fracture.In the bulge test,a hydrostatic tensile stress state was applied by expanding the specimen with an internal rubber plug.The two methodologies were compared in terms of load and hoop strain at fracture and by detecting the fracture morphology and location.Then,the effect of a number of design parameters was investigated in order to evaluate the robustness of the standard testing conditions.For both tests,ductile fractures appeared in the seam welds location,but the bulge test was more robust and conservative with respect to the wedge test,showing less scattered data.Thus,the performances of a second die for the tube profile,designed to optimize the seam welds quality,have been successfully assessed by the bulge test and results compared to those achieved by a novel numerical quality index,coming to a final good matching.展开更多
Shielded Metal Arc Welding (SMAW) in Ductile Irons (DI) is often required by foundries for practical manufacturing reasons. The mechanical properties of the welded structures are strongly dependent on their HAZ’s wid...Shielded Metal Arc Welding (SMAW) in Ductile Irons (DI) is often required by foundries for practical manufacturing reasons. The mechanical properties of the welded structures are strongly dependent on their HAZ’s width. A model based on the behaviour of the ferritic matrix of high-Si DIs in order to make an approach in measuring their HAZ’s width is developed in this study. A series of thermal treatments on 3.35 and 3.75 wt% Si as-cast DIs and spot SMAWs is applied on these materials. The applied SMAWs are done on non-preheated and preheated samples (150℃ - 300℃). For welding we modify the amperage (100 - 140A). The micro-hardness Vickers changes in the ferrite of the as-cast samples and inside the HAZ of the welded ones can be attributed to the existence of residual stresses (RS) in the ferritic matrix and assist in estimating the HAZ’s width.展开更多
The results of a theoretical and finite element (FE) investigation of a two-material impression creep test method, using a rectangular indenter, are presented. The method uses a general formulation for steady-state cr...The results of a theoretical and finite element (FE) investigation of a two-material impression creep test method, using a rectangular indenter, are presented. The method uses a general formulation for steady-state creep deformation for multi-material components in conjunction with the results of FE analyses. The practical application of the proposed technique, in determining the secondary creep properties of heat-affected zone (HAZ) materials in welds, for which conventional creep testing methods cannot be used, is considered. A number of numerical examples are used to describe solution procedures and to verify the method.展开更多
A computer simulation technique for ultrasonic propagation is utilized for the simulation of ultrasonic nondestructive testing (NDT). In this paper, one goal of the simulation is to compute ultrasonic field radiated b...A computer simulation technique for ultrasonic propagation is utilized for the simulation of ultrasonic nondestructive testing (NDT). In this paper, one goal of the simulation is to compute ultrasonic field radiated by arbitrary transducers into pieces under examination. The other simulates a testing experiment. The simulation approach is based on the model for the computation of the ultrasonic field in isotropic media radiated from actual NDT transducers. After the field is known, remaining to be modeled is the interaction between this field and the scatters (defect) and the echo structure. The model of beam-defect interaction is based on the Kirchhoff’s diffraction approximations theory applied to elastodynamics. We assumed that the incident wave fronts on the defect are plane in the case of a focused immersed transducer and material is isotropic and homogeneous. The simulating results demonstrate that the model in ultrasonic NDT of welds is practical in further research and useful in optimizing testi展开更多
Repair welding of AA 6082-T6 joints was carried out using ER 4043 filler through the TIG welding process with or without pulsed current.Microstructure and mechanical characteristics of the joints before and after repa...Repair welding of AA 6082-T6 joints was carried out using ER 4043 filler through the TIG welding process with or without pulsed current.Microstructure and mechanical characteristics of the joints before and after repairing were investigated by examining macrostructure,microstructure,and distributions of porosity in the weld metal(WM),and by hardness,tensile,and bending tests.We observed that the welding current,phase transformations in heat-affected zone(HAZ)and porosity introduced in the WM during welding influence on its mechanical properties in sequence.The experimental results showed that the bead width and penetration as well as size of pores in the joints were mainly influenced by the welding currents.The sound joints were obtained at a welding current of 140 A with or without pulsed current when welding speed and gas flow rate were set at 20 cm·min-1 and 15 L·min-1,respectively.Among them,the decrease in mechanical properties of repair weld(RW)was directly related to the phase transformations in the over-ageing zone due to the double welding thermal cycles and elevated distribution of porosity in the WM.In addition,it was observed that the comparatively smaller grain size and lower porosity in WM of the RW produced by pulsed TIG welding gave a positive effect on its mechanical properties.展开更多
The exact solution of stress distribution in fillet welds under the action of bending moment M is presented in this paper. Together with the exact solution of stress distribution in fillet welds under the action of co...The exact solution of stress distribution in fillet welds under the action of bending moment M is presented in this paper. Together with the exact solution of stress distribution in fillet welds under the action of concentrated force P given in an earlier paper([1]), designers of weldments can improve their work on the foundation of exact analytical solutions.展开更多
A novel automatic ultrasonic system used for the inspection of pipeline girth welds is developed, in which a linear phased array transducer using electronic scan is adopted. Optimal array parameters are determined bas...A novel automatic ultrasonic system used for the inspection of pipeline girth welds is developed, in which a linear phased array transducer using electronic scan is adopted. Optimal array parameters are determined based on a mathematical model of acoustic field for linear phased army derived from Huygens＇ principle. The testing method and the system structure are introduced. The experimental results show that the phased array transducer system has the same detectability as that of conventional ultrasonic transducer system, but the system architecture can be simplified greatly, and the testing flexibility and the testing speed can be improved greatly.展开更多
The paper presents a computational model for elastic waves in a structured weld adjacent to the free surface of an elastic solid. The main emphasis is on the interaction of waves with the micro-structure of the weld. ...The paper presents a computational model for elastic waves in a structured weld adjacent to the free surface of an elastic solid. The main emphasis is on the interaction of waves with the micro-structure of the weld. Effects of localisation and channeling of waves are addressed. A model of a grain structure within the weld is also considered.展开更多
Defect-free dissimilar Al/zinc coated steel and Al/AlSi coated steel welds were successfully fabricated by refill friction stir spot welding. However, Al alloy and uncoated steel could not be welded under the same wel...Defect-free dissimilar Al/zinc coated steel and Al/AlSi coated steel welds were successfully fabricated by refill friction stir spot welding. However, Al alloy and uncoated steel could not be welded under the same welding condition. Al-Zn eutectic layer formed at the Al/zinc coated steel interface showed nonuniformity in thickness and nanoscale intermetallic(IMC) produced was discontinuous. The bonding formation between the Al-Zn layer and the surrounding materials was attributed to a liquid/solid reaction mechanism. Bonding formation at Al alloy and AlSi coated steel interface was attributed to a solid/solid reaction mechanism, as the joining process did not involve with melting of base metals or AlSi coating materials. Kissing bond formed at the weld boundary acted as a crack initiation and propagation site,and the present study showed that weld strength of Al 5754/AlSi coated steel was greatly influenced by properties of original IMC layer.展开更多
Friction stir spot welding technique was employed to join pure copper （C11000） and pure aluminium （AA1060） sheets. The evolving properties of the welds produced were characterized. The spot welds were produced by ...Friction stir spot welding technique was employed to join pure copper （C11000） and pure aluminium （AA1060） sheets. The evolving properties of the welds produced were characterized. The spot welds were produced by varying the rotational speed, shoulder plunge depth using different tool geometries. The presence of a copper ring of different lengths was observed on both sides of the welds indicating that Cu extruded upward into the Al sheet which contributed to obtaining strong welds. The microstructure showed the presence of copper particles in the aluminium matrix which led to the presence of various intermetallics observed by the energy dispersive spectroscopy and X-ray diffraction. The maximum tensile failure load increases with an increase in the shoulder plunge depth, except for the weld produced at 800 r/min using a conical pin and a concave shoulder. A nugget pull-out failure mode occurred in all the friction stir spot welds under the lap-shear loading conditions. High peaks of Vickers microhardness values were obtained in the vicinity of the keyhole of most of the samples which correlated to the presence of intermetallics in the stir zone of the welds.展开更多
With the development of the manufacturing technology, electron beam welding（EBW） is capable of producing titanium alloy large parts in aero fields. To increase the applications and improve the properties, EBW with b...With the development of the manufacturing technology, electron beam welding（EBW） is capable of producing titanium alloy large parts in aero fields. To increase the applications and improve the properties, EBW with beam oscillation was investigated on TC4-DT alloy with50 mm thickness. We detected the welding samples by X-ray NDT, observed the microstructures of the welds, and tested the fatigue properties of the joints. The results showed that EBW with beam oscillation improved the weld morphology as well as welding quality, and the microstructure homogeneity of the welds and HAZ along the weld penetration were also improved. The fatigue properties of the joints with beam oscillation were more excellent than those of conventional EBW, even equal to those of the base metal under high stresses. The influences of the processing and the microstructure on the properties with beam oscillation were discussed.展开更多
基金Supported by the Central Public-Interest Scientific Institution Basal Research Fund(2023-9062)the Transport Power Pilot Project(2021-C334)。
文摘The quality of rebar welds directly impacts the overall service performance of highway infrastructure.However,current assessments of weld appearance quality primarily rely on traditional inspection methods such as manual visual inspection,which suffer from significant limitations in accuracy,reliability,and efficiency.Given the increasing demand for safety performance inspections of highway infrastructure in China,traditional methods struggle to meet modern rapid inspection requirements.Therefore,this study proposes the design of a portable,non-destructive inspection device for rebar weld appearance,utilizing visible light vision and line-structured light 3D scanning technology.The device is equipped with an STM32 master control chip to manage encoder reading,scanning laser control,ring fill light,industrial camera synchronization,image acquisition,and serial port command transmission.Additionally,a weld image processing and detection software system was developed to receive,store,and identify weld defects.A field inspection prototype was created and subjected to various defect weld detection experiments in a laboratory setting.Experimental results demonstrate that the device can accurately measure weld parameters by acquiring multimodal images,fulfilling defect detection requirements.The device features high detection accuracy,portability,and user-friendliness,making it significant for the objective inspection and evaluation of rebar weld appearance and welding quality.
基金Partially funded by the National Natural Science Foundation of China(No.51065012)。
文摘The constant amplitude loading fatigue tests were carried out on the 6061/7075 aluminum alloy TIG fillet welded lap specimens in this study,and the weld seam cross-section hardness was measured.The experimental results show that most specimens mainly failed at the 7075 side weld toes even though the base material tensile strength of 7075 is higher than that of 6061.The maximum stress-strain concentration in the two finite element models is located at the 7075 side weld toe,which is basically consistent with the actual fracture location.The weld zone on the 7075 side experiences severe material softening,with a large gradient.However,the Vickers hardness value on the 6061 side negligibly changes and fluctuates around 70 HV.No obvious defects are found on the fatigue fracture,but a large number of secondary cracks appear.Cracks germinate from the weld toe and propagate in the direction of the plate thickness.Weld reinforcement has a serious impact on fatigue life.Fatigue life will decrease exponentially as the weld reinforcement increases under low stress.It is found that the notch stress method can give a better fatigue life prediction for TIG weldments,and the errors of the predicted results are within the range of two factors,while the prediction accuracy decreases under low stress.The equivalent structural stress method can also be used for fatigue life prediction of TIG weldments,but the errors of prediction results are within the range of three factors,and the accuracy decreases under high stress.
基金The SEU Innovation Capability Enhancement Plan for Doctoral Students(No.CXJH_SEU 24115)Marine Economic Development Project of Guangdong Province(No.GDNRC[2022]25).
文摘The study aimed to address the issue of elevated residual stress levels in dissimilar girth welds of cast steel joints.To achieve this,the hybrid welding technology,which yields high welding speeds while simultaneously reducing residual stresses,has been introduced.This study utilizes a numerical simulation method to investigate the temperature and residual stress field in the hybrid welding of G20Mn5 casting-Q355 low-alloy steel welded pipe.A com-parison of the findings of this study with those of other welding processes revealed the technological advantages of hybrid welding.The research outcomes show that due to geometric discontinuities and material differences,the temperature field of the joint exhibits uneven distribution characteristics,and the peak temperatures on the Q355 steel side exceeds those on the G20Mn5 steel side.An evident stress gra-dient is present in the residual stress field of the joint post-welding,with peak stress located at the weld root on the Q355 steel.Compared with arc welding,the hybrid welding leads to decreased residual stresses and deformation,with high stress outside the heat-affected zone diminishing rapidly.Furthermore,it significantly improves the welding efficiency.This study elucidates the distribution and underlying causes of thermal and residual stress fields in dissimilar girth welds.This serves as a foundation for the application of hybrid welding technology in welded cast steel joints.
基金financially supported by the National Natural Science Foundation of China(grant nos.52275364 and 52025052)。
文摘In this work,microstructure and mechanical properties of Mg weld with addition of carbon nanotubes(CNTs)and Ti C particles were investigated.The results showed that the weld microstructure was mainly presented as equiaxed grains with almost high angle grain boundaries.The introduction of reinforcements promoted the formation of precipitates and refined the grains effectively,the average grain size was refined by 51%and 23%with addition of CNTs and Ti C particles,respectively.The dislocation density and the fraction of CSL boundaries were increased with addition of CNTs,while those were decreased with addition of Ti C particles.Besides,the infrequent{10¯13}contraction twins formed within the weld due to the stress concentration caused by dislocation accumulation,which contributed to theΣ29 CSL boundary.The ultimate tensile strength and elongation rate were increased by 13.5%and 40%with addition of CNTs,while the ultimate tensile strength and micro-hardness were increased by 14.8%and 20.9%with addition of Ti C particles.
基金Project(51374048)supported by the National Natural Science Foundation of ChinaProject(2011CB013402)supported by the National Basic Research Program of ChinaProject(AWPT-Z01)supported by the State Key Laboratory of Advanced Welding and Joining,China
文摘Direct friction welding of Ti Al alloy to 40 Cr steel rods was conducted, and the microstructure and mechanical properties of the resultant joints in as-welded and post-weld heat treatment（PWHT） states were investigated. The martensitic transformation occurred and brittle Ti C phase formed near the interface due to C agglomeration, which degraded the joint strength and increased the microhardness at the interface in as-welded state. Feathery and Widmanstatten structure generated near the interface on Ti Al alloy side. After PWHT at 580 °C and 630 °C for 2 h, the sorbite formed and C dispersed at the interface, leading to the increase of the joint strength from 86 MPa in as-welded state to 395 MPa and 330 MPa, respectively. The heat-treated specimen fractured with quasi-cleavage features through the zone 1 mm away from the interface on TiA l alloy side, but the as-welded specimen failed through the interface.
基金Project(0211005303101)supported by the Fundamental Research Funds for the Central Universities,ChinaInternational Cooperation Project(2014DFA51270)supported by Ministry of Science and Technology of ChinaProject(2009-5043R)supported by the Ford Motor Company University Research Program,USA
文摘The microstructure, microhardness and quasi-static failure behavior of resistance spot welds of AA6111-T4 aluminum alloy were experimentally investigated. Optical metallography and high-resolution hardness traverses were utilized to characterize the weld nugget, heat affected zone and base metal. The AA6111 spot welds displayed a softer nugget and hardened heat affected zone, compared with the base metal. The through-thickness hardness of the base metal sheet was not constant and had to be carefully considered to determine the effect of welding on material properties. Quasi-static lap-shear tensile tests were used to determine the failure load and failure mode. All tensile specimens failed through the interfacial fracture. This failure mode is consistent with the observed reduced hardness in the weld nugget.
基金supported by the Research Foundation of the Ministry of Railways and Tsinghua University (No.T200410)the National Natural Science Foundation of China (Nos.50778102 and 51178244)
文摘Brittle fracture occurs frequently in rails and thermite welded joints, which intimidates the security and reliability of railway ser- vice. Railways in cold regions, such as Qinghai-Tibet Railway, make the problem of brittle fi＇acture in rails even worse. A series of tests such as uniaxial tensile tests, Charpy impact tests, and three-point bending tests were carried out at low temperature to investigate the mechanical properties and fracture toughness of U71Mn and U75V rail steels and their thermite welds. Fracture micromechanisms were analyzed by scanning electron microscopy （SEM） on the fracture surfaces of the tested specimens. The ductility indices （percentage elongation aider frac- ture and percentage reduction of area） and the toughness indices （Charpy impact energy Ak and plane-strain fracture toughness Kic） of the two kinds of rail steels and the corresponding thermite welds all decrease as the temperature decreases. The thermite welds are more critical to fracture than the rail steel base metals, as indicated by a higher yield-to-ultimate ratio and a much lower Charpy impact energy. U71Mn rail steel is relatively higher in toughness than U75V, as demonstrated by larger Ak and Klc values. Therefore, U71Mn rail steel and the corresponding thermite weld are recommended in railway construction and maintenance in cold regions.
文摘Base metals of domestic pipeline steels were used to study the effect of Mn on corrosion properties of SSCC(Sulfide Stress Corrosion Cracking), and welds were carried out to study the effect of MnS on corrosion properties of HIC (Hydrogen Induced Cracking) both in solutions with wet hydrogen sulfide(H_2S). They were respectively conducted by referring to the standards of SSCC and HIC. Testing results revealed that with the increase of content Mn, the resistance of SSCC will be decreased, from the point of metallurgic view, and it is Mn element not C element to lead to the testing results of SSCC. Meanwhile, even under the condition without inclusions MnS, HIC in welds still occurred. That is to say, MnS is not necessary for HIC, the presence of local banded structures in which Mn and P are inclined to aggregate cause to the phenomena of HIC.
基金Project(2007BAE38BO4) supported by the National Science and Technology Pillar Program
文摘By using the rigid-visco-plasticity finite element method, the welding process of aluminum porthole die extrusion to form a tube was simulated based on Deform-3D software. The welding chamber height （H）, back dimension of die leg （D）, process velocity and initial billet temperature were used in FE simulations so as to determine the conditions in which better longitudinal welding quality can be obtained. According to K criterion, the local welding parameters such as welding pressure, effective stress and welding path length on the welding plane are linked to longitudinal welds quality. Simulation turns out that pressure-to-effective stress ratio （ρ/σ） and welding path length （L） are the key factors affecting the welding quality, Higher welding chamber best and sharper die leg give better welding quality. When H=10 mm and D=0.4 mm, the longitudinal welds have the best quality. Higher process velocity decreases welds quality. The proper velocity is 10 mm/s for this simulation. In a certain range, higher temperature is beneficial to the longitudinal welds. It is found that both 450 and 465℃ can satisfy the requirements of the longitudinal welds.
文摘The wedge and bulge expansion tests were compared in the assessment of the seam welds strength in a tubular profile extruded at two ram speeds.In the wedge test,the expansion was determined by moving a conical punch into the tube until the specimen fracture.In the bulge test,a hydrostatic tensile stress state was applied by expanding the specimen with an internal rubber plug.The two methodologies were compared in terms of load and hoop strain at fracture and by detecting the fracture morphology and location.Then,the effect of a number of design parameters was investigated in order to evaluate the robustness of the standard testing conditions.For both tests,ductile fractures appeared in the seam welds location,but the bulge test was more robust and conservative with respect to the wedge test,showing less scattered data.Thus,the performances of a second die for the tube profile,designed to optimize the seam welds quality,have been successfully assessed by the bulge test and results compared to those achieved by a novel numerical quality index,coming to a final good matching.
文摘Shielded Metal Arc Welding (SMAW) in Ductile Irons (DI) is often required by foundries for practical manufacturing reasons. The mechanical properties of the welded structures are strongly dependent on their HAZ’s width. A model based on the behaviour of the ferritic matrix of high-Si DIs in order to make an approach in measuring their HAZ’s width is developed in this study. A series of thermal treatments on 3.35 and 3.75 wt% Si as-cast DIs and spot SMAWs is applied on these materials. The applied SMAWs are done on non-preheated and preheated samples (150℃ - 300℃). For welding we modify the amperage (100 - 140A). The micro-hardness Vickers changes in the ferrite of the as-cast samples and inside the HAZ of the welded ones can be attributed to the existence of residual stresses (RS) in the ferritic matrix and assist in estimating the HAZ’s width.
基金the Engineering&Physics Science Research Council(EPSRC)the Institution of Mechanical Engineers(IMechE),UK,Ior financial support.
文摘The results of a theoretical and finite element (FE) investigation of a two-material impression creep test method, using a rectangular indenter, are presented. The method uses a general formulation for steady-state creep deformation for multi-material components in conjunction with the results of FE analyses. The practical application of the proposed technique, in determining the secondary creep properties of heat-affected zone (HAZ) materials in welds, for which conventional creep testing methods cannot be used, is considered. A number of numerical examples are used to describe solution procedures and to verify the method.
基金supported by the Doctoral Degree Fund of Xi’an Jiaotong University
文摘A computer simulation technique for ultrasonic propagation is utilized for the simulation of ultrasonic nondestructive testing (NDT). In this paper, one goal of the simulation is to compute ultrasonic field radiated by arbitrary transducers into pieces under examination. The other simulates a testing experiment. The simulation approach is based on the model for the computation of the ultrasonic field in isotropic media radiated from actual NDT transducers. After the field is known, remaining to be modeled is the interaction between this field and the scatters (defect) and the echo structure. The model of beam-defect interaction is based on the Kirchhoff’s diffraction approximations theory applied to elastodynamics. We assumed that the incident wave fronts on the defect are plane in the case of a focused immersed transducer and material is isotropic and homogeneous. The simulating results demonstrate that the model in ultrasonic NDT of welds is practical in further research and useful in optimizing testi
基金Funded by the Center of Excellence in Metals and Materials Engineering(CEMME),Faculty of Engineering,Prince of Songkla UniversitySupported by the National Science,Research and Innovation Fund(NSRF)and Prince of Songkla University(No.ENG6505079S)。
文摘Repair welding of AA 6082-T6 joints was carried out using ER 4043 filler through the TIG welding process with or without pulsed current.Microstructure and mechanical characteristics of the joints before and after repairing were investigated by examining macrostructure,microstructure,and distributions of porosity in the weld metal(WM),and by hardness,tensile,and bending tests.We observed that the welding current,phase transformations in heat-affected zone(HAZ)and porosity introduced in the WM during welding influence on its mechanical properties in sequence.The experimental results showed that the bead width and penetration as well as size of pores in the joints were mainly influenced by the welding currents.The sound joints were obtained at a welding current of 140 A with or without pulsed current when welding speed and gas flow rate were set at 20 cm·min-1 and 15 L·min-1,respectively.Among them,the decrease in mechanical properties of repair weld(RW)was directly related to the phase transformations in the over-ageing zone due to the double welding thermal cycles and elevated distribution of porosity in the WM.In addition,it was observed that the comparatively smaller grain size and lower porosity in WM of the RW produced by pulsed TIG welding gave a positive effect on its mechanical properties.
文摘The exact solution of stress distribution in fillet welds under the action of bending moment M is presented in this paper. Together with the exact solution of stress distribution in fillet welds under the action of concentrated force P given in an earlier paper([1]), designers of weldments can improve their work on the foundation of exact analytical solutions.
文摘A novel automatic ultrasonic system used for the inspection of pipeline girth welds is developed, in which a linear phased array transducer using electronic scan is adopted. Optimal array parameters are determined based on a mathematical model of acoustic field for linear phased army derived from Huygens＇ principle. The testing method and the system structure are introduced. The experimental results show that the phased array transducer system has the same detectability as that of conventional ultrasonic transducer system, but the system architecture can be simplified greatly, and the testing flexibility and the testing speed can be improved greatly.
基金supported by a scholarship funded by Serco Technical Assurance Services
文摘The paper presents a computational model for elastic waves in a structured weld adjacent to the free surface of an elastic solid. The main emphasis is on the interaction of waves with the micro-structure of the weld. Effects of localisation and channeling of waves are addressed. A model of a grain structure within the weld is also considered.
基金supported by the Natural Science and Engineering Council(NSERC)of Canada,the Canadian Foundation for Innovation
文摘Defect-free dissimilar Al/zinc coated steel and Al/AlSi coated steel welds were successfully fabricated by refill friction stir spot welding. However, Al alloy and uncoated steel could not be welded under the same welding condition. Al-Zn eutectic layer formed at the Al/zinc coated steel interface showed nonuniformity in thickness and nanoscale intermetallic(IMC) produced was discontinuous. The bonding formation between the Al-Zn layer and the surrounding materials was attributed to a liquid/solid reaction mechanism. Bonding formation at Al alloy and AlSi coated steel interface was attributed to a solid/solid reaction mechanism, as the joining process did not involve with melting of base metals or AlSi coating materials. Kissing bond formed at the weld boundary acted as a crack initiation and propagation site,and the present study showed that weld strength of Al 5754/AlSi coated steel was greatly influenced by properties of original IMC layer.
基金financial support of the University of Johannesburg and the assistance from Mr Riaan Brown (Nelson Mandela Metropolitan University) for operating the MTS PDS I-Stir machine are acknowledged
文摘Friction stir spot welding technique was employed to join pure copper （C11000） and pure aluminium （AA1060） sheets. The evolving properties of the welds produced were characterized. The spot welds were produced by varying the rotational speed, shoulder plunge depth using different tool geometries. The presence of a copper ring of different lengths was observed on both sides of the welds indicating that Cu extruded upward into the Al sheet which contributed to obtaining strong welds. The microstructure showed the presence of copper particles in the aluminium matrix which led to the presence of various intermetallics observed by the energy dispersive spectroscopy and X-ray diffraction. The maximum tensile failure load increases with an increase in the shoulder plunge depth, except for the weld produced at 800 r/min using a conical pin and a concave shoulder. A nugget pull-out failure mode occurred in all the friction stir spot welds under the lap-shear loading conditions. High peaks of Vickers microhardness values were obtained in the vicinity of the keyhole of most of the samples which correlated to the presence of intermetallics in the stir zone of the welds.
基金financially supported by the National Natural Science Foundation of China(No.50935008)Special Major Science and Technology of China(No.2010ZX04007041)the National Key Laboratory of High Energy Density Beam Processing Technology of China
文摘With the development of the manufacturing technology, electron beam welding（EBW） is capable of producing titanium alloy large parts in aero fields. To increase the applications and improve the properties, EBW with beam oscillation was investigated on TC4-DT alloy with50 mm thickness. We detected the welding samples by X-ray NDT, observed the microstructures of the welds, and tested the fatigue properties of the joints. The results showed that EBW with beam oscillation improved the weld morphology as well as welding quality, and the microstructure homogeneity of the welds and HAZ along the weld penetration were also improved. The fatigue properties of the joints with beam oscillation were more excellent than those of conventional EBW, even equal to those of the base metal under high stresses. The influences of the processing and the microstructure on the properties with beam oscillation were discussed.
