With the squeeze of electrode tips, the oxide film on aluminum (Al) alloy surface is broken and numbers of micro-gaps are formed randomly. The micro-gaps act as conducting spots at the beginning of welding, so the con...With the squeeze of electrode tips, the oxide film on aluminum (Al) alloy surface is broken and numbers of micro-gaps are formed randomly. The micro-gaps act as conducting spots at the beginning of welding, so the contact resistance is extremely high and unstable in spot welding of Al alloy. In this paper, a new contact resistance model is adopted to simulate the nugget forming process. This model describes the random distribution characteristic of conducting spots. The simulation results indicate that, within the first 5 ms of welding current (AC, 50 Hz), the temperature distribution at the workpieces interface is seriously irregular. In addition, the nugget does not nucleate from the weld center and grow continuously, however, it nucleates randomly from several points almost instantaneously and then merges into an entity quickly. Experimental results agreed with the numerical simulation.展开更多
Based on the pre-existing wire melting rate model of direct-current submerged arc welding （ DC-SAW） , a new numerical model of wire melting rate was developed for variable-polarity submerged are welding （VP-SAW） b...Based on the pre-existing wire melting rate model of direct-current submerged arc welding （ DC-SAW） , a new numerical model of wire melting rate was developed for variable-polarity submerged are welding （VP-SAW） by accounting for the combined effects of duty cycle β and offset α. The experimental measurements are in a good agreement with the results calculated by this new wire melting rate model, with the maximum discrepancy being less than 10%. Therefore it is evident that this new numerical model can successfully describe the dependence of wire melting rate on the duty cycle β and offset α.展开更多
基金Supported by National Natural Science Foundation of China (No. 50175080)
文摘With the squeeze of electrode tips, the oxide film on aluminum (Al) alloy surface is broken and numbers of micro-gaps are formed randomly. The micro-gaps act as conducting spots at the beginning of welding, so the contact resistance is extremely high and unstable in spot welding of Al alloy. In this paper, a new contact resistance model is adopted to simulate the nugget forming process. This model describes the random distribution characteristic of conducting spots. The simulation results indicate that, within the first 5 ms of welding current (AC, 50 Hz), the temperature distribution at the workpieces interface is seriously irregular. In addition, the nugget does not nucleate from the weld center and grow continuously, however, it nucleates randomly from several points almost instantaneously and then merges into an entity quickly. Experimental results agreed with the numerical simulation.
文摘Based on the pre-existing wire melting rate model of direct-current submerged arc welding （ DC-SAW） , a new numerical model of wire melting rate was developed for variable-polarity submerged are welding （VP-SAW） by accounting for the combined effects of duty cycle β and offset α. The experimental measurements are in a good agreement with the results calculated by this new wire melting rate model, with the maximum discrepancy being less than 10%. Therefore it is evident that this new numerical model can successfully describe the dependence of wire melting rate on the duty cycle β and offset α.
