A new weld repair technique for friction stir welded aluminium structure:inertia friction pull plug welding

The paper gives an analysis on technical characteristics of repair techniques for friction stir welding defects. To overcome the defects,a new repair technique, inertia friction pull plug welding( IFPPW), was researched and its equipment was developed as well. Elementary datum was achieved by investigating the influences of technological parameters on mechanical properties and by analyzing the structural characteristics of repair joint with IFPPW. The study shows that the stability and reliability of welding process of IFPPW can be guaranteed through the constant energy from the flywheel.Integrated with the advantages of friction pull plug welding,the IFPPW,free from back anvil,is considered as a promising technique in repair of termination keyhole of bobbin tool friction stir welding and point-like defects in aluminum alloy welding.

Residual Stress and Fracture Toughness Study in A516 Gr70 Steel Joints Welded and Repaired by Arc Processes

Structural components made of steel are used in several areas and require welding for assembly. In some situations, repair of the weld bead, also performed by electric arc welding, can be used to correct, and eliminate any discontinuities. However, electric arc welding causes the presence of residual stresses in the joint, which can impair its performance and not meet specific design requirements. In this paper, welded joints made of ASTM A 516 GR 70 steel plates, with a thickness of 30.5 mm, welded by the MAG—Metal Active Gas process (20% CO2) and using a “K” groove were analysed. The joints were manufactured with seven welding passes on each side of the groove. After welding, one batch underwent repair of the bead by TIG welding (Tungsten Insert Gas) and another batch underwent two repairs by TIG welding. Were presented results of the behaviour of the residual stress profile measured by X-ray diffraction and the Vickers microhardness profile in the joints as well the fracture toughness in the conditions only welded and submitted to repairs. The results indicated that the greater number of repair passes reduced the residual compressive stress values obtained in the material manufacturing process and caused a stabilization on the Vickers hardness values. It was concluded that compressive residual stresses did not play a major role in the R-curve results. The presence of discontinuities in the welded joint caused greater influence on the behaviour of the R curve.

Microstructure and mechanical properties of repair welds of low-pressure sand-cast Mg?Y?RE?Zr alloy by tungsten inert gas welding

The sand castings of Mg-Y-RE-Zr series alloys are widely utilized in the large scales and complex shapes in the aerospace industry,as a result of which there are always some cast defects in the products. In this study, the feasibility of repair welding of sand-cast Mg-4 Y-3 RE-0.5 Zr alloy by tungsten inert gas(TIG) welding was scrutinized with different welding currents from 150 to 210 A. The results indicated that defect-free repaired joints with good appearance could be acquired at 170 and 190 A. Interestingly, the grain size of the fusion zone(FZ) was refined initially and then increased with the linear increment of welding current. Because at the higher heat inputs, although the cooling rate of the molten pool was reduced, substantial constitutional supercooling for the grain refinement was attained after the Zr particles were transformed into Zr solutes. The tensile strength of the repaired joint at 170 A was 195 MPa with the maximum joint efficiency of 87.8%, and the elongation reached to 124.4% of the sand-cast base material(BM). However, serious grain coarsening and continuous eutectic structures generated in heat-affected zone(HAZ) above 190 A resulted in the weakening of the joint due to the brittle intergranular fracture.

Repair welding process of friction stir welding groove defect

The groove defect formed in the friction stir welding dramatically deteriorates weld appearances and mechanical properties of the joints owing to its larger size and penetration. Therefore, the friction stir repair welding was utilized to remove such a groove defect, and the focus was placed on the mechanical properties and microstructural characteristics of the repair joints so as to obtain an optimum repair welding process. The experimental results indicate that the groove defect can be removed by friction stir repair welding, and the offset repair welding process is superior to the symmetrical repair welding process. In the symmetrical repair welding process, a large number of fine cavity defects and an obvious aggregation of hard-brittle phase Al2Cu occur, accordingly the mechanical properties of the repair joint are weakened, and the fracture feature of repair joint is partially brittle and partially plastic. A good-quality repair joint can be obtained by the offset repair welding process, and the repair joint is fractured near the interface between the weld nugget zone and thermal-mechanically affected zone.

The development and design of the repair welding procedure of the thick wall duplex stainless steel piping

In this paper,the performance characteristics of ASTM A790 S31803 and ASTM A182 F51 duplex stainless steel were introduced,and the weldabilities were analyzed. The welding repair procedures of thick wall duplex stainless steel were developed by welding procedure qualification. Research shows that the repair welding has less effect on mechanical properties of welded joint, and great influence on phase proportions and pitting corrosion resistance. The test results meet the requirements of project specifications. The repair welding procedure can be used in project,and only one time repair shall be used.

Formation mechanism of transverse crack in repair welding for thick plate of Q345 high strength steel

Transverse cracks occur usually in repair welding for thick plate of high strength steel. It needs multiple times of repair welding. The quality of production and deliver deadline will be influenced. Therefore, it is very significant to investigate the cause and control of transverse crack in repair welding. In this paper, both ends restraint crack experiment is developed to produce delay transverse crack for high strength steel. Metallographic results show that four types of cracks are found in repair welding metal zone and heat affected zone. Large chevron transverse cracks are found in repair welding zone. Lots of micro transverse cracks are found in inter-layer repair welding metal zone, root HAZ and two ends of repair welding individually. The distribution character and formation mechanism of the transverse crack are further analyzed through hardness testing and residual stress measurement.

Effect of Conventional and Pulsed TIG Welding on Microstructural and Mechanical Characteristics of AA 6082-T6 Repair Welds

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.

Weldability of steel used in an aged bridge

A series of experiments was performed to investigate the weldability of steel used in an aged bridge.A steel material used in an aged railway bridge constructed in 1912 was extracted for this investigation.The chemical compositions of this steel were suitable for welding.However,the aged steel contained much sulfur.Cruciform welded joints were fabricated with this aged steel.Welding defects or cracks were not observed in the joints.The Vickers hardness test on the welded part did not confirm extreme hardening or softening.After yielding by the static tensile test,the cruciform joints were fractured at the welded parts.One of the specimens was fractured in the middle of the thickness of the aged steel.The Sulfur contained in the aged steel might cause this type of fracture.The results show that there may be a risk of brittle fracture not only from the welded part but also from the base metal.The chemical compositions of aged steel must be analyzed when repair welding is applied to the steel.

基于SYS WELD的运行管道在役焊接热循环数值模拟

采用焊接过程数值模拟软件SYSWELD建立模型,以水为运行介质,对X70管道在役焊接粗晶区的热循环进行了数值模拟,探讨了介质流速、管道壁厚和焊接热输入等因素对在役焊接热循环的影响规律,并对数值模拟结果进行了验证。结果表明,在役焊接粗晶区t8/5值随着水流速度的增大而减小,但减小的幅度不大;当流速小于0.5 m/s时,t8/3和t8/1随流速的增大而大幅减小,当流速大于0.5 m/s时,t8/3和t8/1随流速增大而缓慢减小。t8/5和t8/3均随着管道壁厚的增加而先增大后减小,在壁厚为8 mm时达到最大值;t8/1随着壁厚的增加而逐渐增大。随着焊接热输入的增加,t8/5,t8/3和t8/1均增大。焊接热循环计算结果和实测结果吻合较好,相对误差小于8%。

Research of precise pulse plasma arc powder welding technology of thin-walled inner hole parts

The inner hole parts played an oriented or supporting role in engineering machinery and equipment,which are prone to appear surface damages such as wear,strain and corrosion. The precise pulse plasma arc powder welding method is used for surface damage repairing of inner hole parts in this paper. The working principle and process of the technology are illustrated,and the microstructure and property of repairing layer by precise pulse plasma powder welding and CO2 gas shielded welding are tested and observed by microscope,micro hardness tester and X-ray residual stress tester etc. Results showed that the substrate deformation of thin-walled inner hole parts samples by precise pulse plasma powder welding is relatively small. The repair layer and substrate is metallurgical bonding,the transition zones( including fusion zone and heat affected zone) are relatively narrow and the welding quality is good. It showed that the thin-walled inner hole parts can be repaired by this technology and equipment.

Influence of Multiple Repair Welding on Microstructure and Properties of 06Cr19Ni10 Stainless Steel

Repair welding technology is widely used in the manufacturing and maintenance of rail transit equipment to repair welding defects.However,repair welding induces modifications in joint performance,and it is necessary to study the microstructure evolution behavior to reveal the reasons.In this study,the effects of multiple repair welding on the microstructure,mechanical,and fatigue properties of 06Cr19Ni10 stainless steel samples were studied.The surface texture and fracture morphology analyses of the samples were conducted by optical microscopy(OM),scanning electron microscopy(SEM),and its equipped backscattered electron diffraction(EBSD)technique.The mechanical and fatigue properties of the samples with different repair welding times were further obtained by hardness,tensile,and fatigue tests.The results show an increase in the grain size and the substructure content in the heat-affected zone(HAZ),and the austenite orientation is changed,attributable to multiple repair welding.Multiple heat inputs result in a significant increase in hardness from 165 HV to 185 HV,a noticeable decrease in tensile strength and elongation,and an upward trend in yield strength.Under the constant stress level,the heat input of multiple repair welding causes a decrease in the fatigue life and significantly reduces toughness in the instantaneous fracture zone of the secondary repair sample.

电力机车高强钢零部件焊修工艺技术研究

为了研究焊修次数对电力机车转向架关键零部件30CrMo合金钢空心轴组织及性能的影响,并优化其焊修工艺,对30CrMo合金钢空心轴行了三次焊修试验,并对每次焊修后的接头进行了静强度试验、金相试验和疲劳试验。静强度试验包括拉伸和弯曲试验,金相试验观察了接头各区域的显微组织,疲劳试验采用旋转弯曲加载方式,以确定接头的疲劳极限。结果表明:多次焊修后,接头的拉伸性能良好,拉伸试件断于母材;弯曲性能良好,弯曲角度达180°时无断裂或裂纹产生;室温和低温冲击性能在多次焊修后略有下降,符合标准要求;三次焊修焊缝硬度在330~340 HV之间,明显高于母材及热影响区硬度值。金相组织分析表明,空心轴母材的组织为回火索氏体、上贝氏体及块状铁素体,热影响区的主要组织为回火索氏体和少量块状铁素体,熔合区的组织为回火索氏体,焊缝组织为经过调质后产生的回火索氏体。接头疲劳极限满足强度要求,第三次焊修中值疲劳极限最高,在指定寿命为1×10^(7)次循环下的中值疲劳极限为399 MPa。焊后调质处理可以有效地改善多次焊修对接头性能的影响。多次焊修后的30CrMo合金钢空心轴接头具有良好的拉伸、弯曲和疲劳性能,且随着焊修次数的增加,接头的疲劳强度逐渐提高。该研究结果为电力机车转向架关键部件的焊修工艺优化提供了理论依据。

BFe10-1-1摩擦塞补焊接头组织及性能研究

采用顶锻式摩擦塞补焊方法对5 mm厚的BFe10-1-1铜镍合金进行匙孔补焊实验,探讨了不同主轴转速下塞补焊接头的微观形貌、显微硬度、温度场分布及其力学性能。结果表明:主轴转速对铁白铜塞补焊成形有重要的影响,随着转速提高,接头底部缺陷逐渐缩小,塞棒区金属摩擦流线明显,晶粒呈破碎细化特征,接头从上到下,热影响区范围缩小明显。由于细晶强化作用,塞棒区显微硬度高于母材,且塞棒上侧显微硬度高于中下侧。在转速为2 100 r/min时得到接头拉伸强度最高,达到母材78%。接头表现出韧性断裂特征,随着转速提高,接头弱连接缺陷逐步下移,并不断缩小。

X80钢补焊残余应力模拟与试验验证

X80管线钢在铺设或者使用过程中会产生裂纹、气孔等缺陷而需要进行补焊修复。利用ABAQUS有限元分析软件建立了X80钢平板补焊模型,模拟分析了补焊前后X80钢焊接残余应力的变化情况,同时研究了3种不同补焊热输入量对焊接残余应力的影响。为验证模拟结果的准确性,开展了3种对应热输入量的补焊试验。模拟及试验研究结果表明,补焊残余应力高于初始焊残余应力,补焊后横向残余应力峰值较初始焊增加55.52%,补焊后纵向残余应力峰值已超过材料屈服强度。随着补焊热输入量的增大,Mises等效残余应力峰值和纵向残余应力无明显改变,但不同路径的横向残余应力变化规律有所不同。试验测量的残余应力值与模拟结果接近,两者的变化趋势一致。

通流改造机组高压主汽联合阀焊缝开裂分析及处理建议

针对某机组通流改造后高压主汽阀和高压调节阀的R337对接焊缝出现的横向裂纹问题进行深入分析。通过观察现场裂纹、分析样品以及评估材料性能,确定裂纹形成的主要原因。首先,焊材R337的选用不当导致了焊缝脆性的增加,其次,结构应力和交变应力的叠加作用加速了裂纹的扩展;ZG15Cr1Mo1V钢的碳当量较高,具有较大的淬硬倾向,容易产生冷裂纹,而Nb元素的加入则增加了再热裂纹的敏感性。针对裂纹形成的原因提出了处理建议,首先彻底清除原有的R337焊缝,并采用低匹配的R317焊条进行修复;在焊接过程中,严格控制预热温度、层间温度和焊接线能量,以减少焊接应力;焊后进行中频感应热处理,以均匀温度场并充分消减应力;考虑到ZG15Cr1Mo1V钢的再热裂纹倾向,建议在修复过程中采取适当的预防措施。

水下激光修复研究现状与发展趋势

海洋装备的维修养护与事故抢修技术既是人类进行远洋探索与资源开发的重要保障,又是核电站、水利工程等重要基础设施在役运维的有力技术支撑,而水下激光修复正是这一领域中极具前景的解决方案之一.激光修复技术作为陆地上常规环境中的优势技术,近年来也在水下环境中有了长足的发展,已在海洋油气资源的开采与运输、船舶应急维修、船坞港口装备、水利工程、核动力工程等领域得到了广泛的关注与研究.为了进一步总结并分析水下激光修复技术所面对的问题与现有解决方案,从水下激光修复技术的研究现状入手,综述了水下湿法、高压干法和局部干法激光修复技术的工艺问题及其产生机理,并分析对比了多种对应主流解决方案的改善效果与研究进展,最后对水下激光修复技术的发展趋势进行了总结与展望.

水轮机修复堆焊技术研究现状分析

传统能源逐渐枯竭,且对环境影响较大.国家大力推动绿色清洁能源的发展.水力发电占比也逐年提高,对水轮机相关技术的研究有了更高要求.我国河流泥沙含量大,泥沙含量越高,水轮机关键零部件磨损就越大.水轮机零部件修复技术存在成本高、效率低且质量难以保证等问题,因此亟需研究低成本高效率的智能堆焊修复技术.应用于轮机的先进堆焊技术可以促进绿色环保、提高能源利用率,同时也可促进国民经济发展和振兴机械工业.

海洋工程高强度钢立管焊接返修技术研究

在海洋工程中,立管承载着连接海上浮式设备和水下生产系统的使命,是深水油气田得以开发利用的关键通道。然而,由于立管需要承受高强度的工作压力,焊接施工难度较大,使其成为海上油气生产系统中最薄弱的环节。鉴于立管焊接施工的高标准和严要求,其施工流程一般仅允许返修一次。基于此,本文以国内海洋平台常用的X65钢立管为研究对象,对立管焊接返修技术的操作要点及技术难点进行了概括总结,旨在为我国海洋平台立管的焊接返修提供一定的理论指导和现实意义。

铸造低合金钢回火焊道技术适用性判别分析

回火焊道技术是通过第二层焊道的热循环来改善第一层焊道的组织和性能的焊接技术,但目前尚无明确标准规定其适用范围。以A217 WC6和A217 WC9钢为对象,采用Gleeble热模拟试验判断二次回火对两种铸造低合金钢性能的影响规律,进而用回火焊道技术制造焊接试样,进行焊态、热处理态下的组织和性能对比试验。试验结果表明,A217 WC6钢在一次高温热循环后,冲击功从70 J提升至126 J,硬度值从154 HV10增至375 HV10。二次热循环后,A217 WC6钢的硬度整体降低,回火峰值温度对其性能有显著影响。相比之下,A217 WC9钢的冲击功从77 J降至52 J,硬度值从182 HV10增至364 HV10,二次热循环对其性能影响不显著。焊接试样的性能和硬度变化趋势与Gleeble热模拟试验一致。由此得到结论:Gleeble热模拟试验可以判断钢种是否适用于回火焊道技术;A217 WC6钢较A217 WC9钢更适合采用回火焊道技术进行修复。

焊接热输入对P91钢焊接修复微观组织及性能的影响

为进一步揭示补焊热输入对补焊接头焊缝区微观组织与性能的影响规律,本文通过微观组织表征、显微硬度测试、拉伸实验和冲击实验等方法,对比研究了焊接热输入对P91钢焊接接头焊接缺陷、微观组织和力学性能的影响。结果表明,热输入为10kJ/cm时,补焊区焊缝金属中树枝晶呈平行状;热输入增加到15kJ/cm时,补焊区焊缝组织呈现出交叉互锁的燕尾搭接状形态;而热输入进一步增加到20kJ/cm时,补焊区的焊缝组织以平行状树枝晶为主和少量的交叉互锁的燕尾搭接状树枝晶组成。补焊区的析出相主要由NbC、Cr_(23)C6和Fe_(2)Nb(Laves相)组成,且随着热输入的增加,析出相熟化长大。力学性能分析表明,补焊区焊缝金属的强度和冲击韧性随热输入的增加均呈现出先增加后降低的变化趋势。热输入为15kJ/cm时,补焊区焊缝金属的枝晶形态和析出物形态所导致的“协同效应”使得显微裂纹形核、发育、扩展所需的能量阈值有所不同,进而补焊区的焊缝金属可以保持相对较高的韧性,因此热输入为15kJ/cm时,补焊区焊缝组织的强韧匹配最优。而3种热输入下的补焊区的焊接热影响区由于晶粒粗大以及补焊过程中的高拘束应力使得该区域的冲击韧性最差。