Sensitivity model for prediction of bead geometry in underwater wet flux cored arc welding

To investigate influence of welding parameters on weld bead geometry in underwater wet flux cored arc welding （FCAW）, orthogonal experiments of underwater wet FCAW were conducted in the hyperbaric chamber at water depth from 0.2 m to 60 m and mathematical models were developed by multiple curvilinear regression method from the experimental data. Sensitivity analysis was then performed to predict the bead geometry and evaluate the influence of welding parameters. The results reveal that water depth has a greater influence on bead geometry than other welding parameters when welding at a water depth less than 10 m. At a water depth deeper than 10 m, a change in travel speed affects the bead geometry more strongly than other welding parameters.

INVESTIGATION ON MICROSTRUCTURE AND TRIBOLOGICAL PROPERITIES OF CORED WIRE ARC SPRAYED Al/Al _2 O_3 COATINGS

Cored wires for electric arc spraying of Al/Al 2 O 3 MMC coatings were developed, with Al 2 O 3 powder as the core material and commercial aluminium strip as the retaining sheath. The bond strength, Al 2 O 3 content, microstructure, micro-hardness and wear resistance of coatings produced by arc spraying of the cored wires were experimentally investigated and were compared with those of pure aluminum coating.

Cold Cracking of Flux Cored Arc Welded Armour Grade High Strength Steel Weldments

In this investigation, an attempt has been made to study the influence of welding consumables on the factors that influence cold cracking of armour grade quenched and tempered （Q＆.T） steel welds. Flux cored arc welding （FCAW） process were used making welds using austenitic stainless steel （ASS） and low hydrogen ferritic steel （LHF） consumables. The diffusible hydrogen levels in the weld metal of the ASS and LHF consumables were determined by mercury method. Residual stresses were evaluated using X-ray stress analyzer and implant test was carried out to study the cold cracking of the welds. Results indicate that ASS welds offer a greater resistance to cold cracking of armour grade Q＆T steel welds.

Experimental Investigation on the Performance of Armour Grade Q&T Steel Joints Fabricated by Flux Cored Arc Welding with Low Hydrogen Ferritic Consumables

Quenched and Tempered （Q＆T） steels are widely used in the construction of military vehicles due to its high strength to weight ratio and high hardness. These steels are prone to hydrogen induced cracking （HIC） and softening in the heat affected zone （HAZ） after welding. The use of austenitic stainless steel （ASS） consumables to weld the above steel was the only available remedy to avoid HIC because of higher solubility for hydrogen in austenitic phase. Recent studies revealed that low hydrogen ferritic （LHF） steel consumables can also be used to weld Q＆T steels, which can give very low hydrogen levels in the weld deposits and required resistance against cold cracking. Hence, in this investigation an attempt has been made to study the performance of armour grade Q＆T steel joints fabricated by flux cored arc welding with LHF steel consumables. Two different consumables namely （i） austenitic stainless steel and （ii） low hydrogen ferritic steel have been used to fabricate the joints by flux cored arc welding （FCAW） process. The joints fabricated by LHF consumable exhibited superior transverse tensile properties due to the presence of ferrite microstructure in weld metal. The joints fabricated by ASS consumable showed higher impact toughness due to the presence of austenitic phase in weld metal microstructure. The HAZ softening in coarse grain heat affected zone （CGHAZ） is less in the joints fabricated using LHF consumable due to the lower heat input involved during fabrication compared to the joints fabricated using ASS consumables.

Arc Characteristic and Metal Transfer of Pulse Current Horizontal Flux-Cored Arc Welding

In this work, we utilized high-speed video photography to investigate the arc characteristics, metal transfer behavior, and welding spatter of the pulse-current flux-cored arc welding (P-FCAW) process in the horizontal position. The results indicate the presence of a stable “flux pole” during both the pulse-on and pulse-off periods when the mean current ranged from 140 to 170 A. The existence of this “flux pole” was beneficial for droplet transfer in the “axial droplet transfer” mode. With respect to welding spatter, with an increase in the welding current, we observed three kinds of spatter—explosive spatter, rebounded droplet spatter, and scattering spatter. With an increase in the pulse current from 310.6 to 345.6 A, the deflection of the arc reduced from 30.4° to 16.6°, which positively influenced the arc rigidity, particularly in the horizontal position. © 2017, Tianjin University and Springer-Verlag Berlin Heidelberg.

Formation Mechanism of Inclusion in Self-Shielded Flux Cored Arc Welds

The formation mechanism of inclusion in welds with different aluminum contents was determined based on thermodynamic equilibrium in self-shielded flux cored arc welds.Inclusions in welds were systematically studied by optical microscopy,scanning microscopy and image analyzer.The results show that the average size and the contamination rate of inclusions in low-aluminum weld are lower than those in high-aluminum weld.Highly faceted AlN inclusions with big size in the high-aluminum weld are more than those in low-aluminum weld.As a result,the low temperature impact toughness of low-aluminum weld is higher than that of high-aluminum weld.Finally,the thermodynamic analysis indicates that thermodynamic result agrees with the experimental data.

Study on arc characteristics and behavior of metal transfer in pulse current flux-cored arc welding of mild steel

The variation in arc characteristics and behavior of metal transfer with the change in pulse parameters has been studied by high speed video camera during pulse current flux-cored arc weld deposition.A comparative study of similar nature has also been carried out during flux-cored arc weld deposition in globular and spray transfer modes.The effect of pulse parameters has been studied by considering their mean current and arc voltage.The arc characteristics studied by its root diameter,projected diameter and length,and the behavior of metal transfer noted by the metal transfer model and the droplet diameter have been found to vary significantly with the pulse parameters.The observation may help in understanding the arc characteristics with respect to the variation in pulse parameters which may be beneficial in using pulse current FCAW to produce desired weld quality.

圆弧抽芯注塑模具优化设计

基于圆弧抽芯注塑模具,根据塑件结构及材料性能特点,对浇口的位置及结构进行了优化设计,通过CAE模拟分析得到位于填充末端、最大壁厚处的塑件最大变形量为0.739 mm,变形量在设计允许范围内。以油缸作为驱动动力源,通过齿条驱动齿轮、内齿轮旋转,实现抽芯动作;将内齿轮设计为异形非标齿轮,减少了所占空间,实现了1模2腔布局。为解决圆弧型芯冷却水路难以加工的问题,设计的加工工序为先按照直型芯进行粗加工,钻孔加工型芯冷却水路,然后,将型芯加热弯曲为所需形状,并进行调质处理,最后对型芯进行精加工使其满足设计要求,达到了随形冷却效果。传动机构关键参数采用理论计算与CAE模拟分析相结合的法验证,测试结果表明,计算校核效率提高了约4倍。

CeO_(2)添加量对电弧增材制造铁基形状记忆合金组织和性能的影响

采用粉芯丝材+电弧增材制造技术制备了含不同质量分数(0,1%,2%,3%)CeO_(2)的Fe-14Mn-6Si-9Cr-5Ni铁基形状记忆合金,研究了CeO_(2)添加量对试验合金显微组织和形状记忆性能的影响。结果表明:添加质量分数1%的CeO_(2)后,合金晶内析出相减少,晶界处析出较大尺寸的稀土化合物,组织均匀,弯曲变形后未出现ε马氏体跨晶生长现象,且马氏体交叉状态较少;当CeO_(2)质量分数增加至2%和3%时,晶内析出相增多,分布均匀性变差,且在弯曲变形后ε马氏体跨晶生长和交叉特征增多;随着CeO_(2)添加量增加,试验合金的晶粒尺寸减小,层错概率增大,形状回复率先增大后减小,当CeO_(2)质量分数为1%时晶粒尺寸较小,层错概率较大,形状回复率最大,形状记忆性能最好。

Mn和B元素对电弧熔覆高铬铸铁熔覆层显微组织和耐磨性能的影响

电弧熔覆技术是一种成本低且效率高的再制造技术,而高铬铸铁焊丝是常见的耐磨药芯焊丝体系之一。为了探究Mn和B元素对Q345钢板表面高铬铸铁药芯焊丝电弧熔覆再制造层的组织、硬度和耐磨性能的影响,采用光学显微镜、能谱仪、X射线衍射仪、摩擦磨损试验机、超景深显微镜和电子显微镜等对熔覆层的显微组织、元素组成、硬度分布、磨损过程和机理进行了表征分析。结果表明,在电弧熔覆过程中,电解锰和硼铁粉末发生溶解,与熔覆层中元素相互作用形成块状和板条状的初生碳化物及共晶组织。各熔覆层的组织主要有M_(7)C_(3)(M为Fe、Cr和Mn)、M_(3)C、Fe_(23)(C,B)_(6)、马氏体和残余奥氏体等相存在。随着Mn、B含量的增加,熔覆层表面的硬度逐渐上升。增加了质量分数0.70%的Mn元素的熔覆层硬度相对高铬铸铁熔覆层提升10.64%。继续添加质量分数1.20%的B元素,熔覆层表面硬度进一步提升。熔覆层表面耐磨性随着Mn和B含量的增加呈现出先上升后下降的趋势。C、Mn和B的质量分数分别为4.00%、0.80%和0.80%熔覆层的耐磨性能最高,为Q345的23.06倍。

实-药芯多丝电弧复合焊中药芯焊丝位置对焊接稳定性的影响

为了实现高强钢的优质高效焊接,提出了一种全新的Q960E高强钢的高效焊接工艺,即实-药芯多丝电弧复合焊工艺,该工艺通过一把集成式三丝焊枪实现两根实心焊丝复合一根药芯焊丝,既可以利用药芯焊丝实现焊接接头力学性能的优化,又可以利用3根焊丝实现高效焊接。其中药芯焊丝可以从两实心焊丝的正前方、正后方及侧面送入,通过对比分析焊接过程、焊道成形得出最佳药芯焊丝作用位置,并对最佳药芯焊丝作用位置下焊接接头的组织和显微硬度展开分析。结果表明:当药芯焊丝从正后方或侧面送入时,其中一根实心焊丝易与熔池接触发生短路过渡,前者会导致焊道宽窄不一,后者会导致焊道明显偏向药芯焊丝送入一侧。当药芯焊丝从正前方送入时,药芯焊丝呈一脉多滴过渡,且两实心焊丝均为一脉一滴过渡,此时焊接过程稳定,焊后焊道成形较好,焊道横截面形貌呈“双峰”状,是最佳的药芯焊丝送入位置。此外,当药芯焊丝从正前方送入时,焊缝区组织主要为细小的针状铁素体,粗晶区组织主要为粗大的板条马氏体和少量粒状贝氏体,细晶区组织主要为细小的马氏体,不完全淬火区组织主要为回火马氏体。此外,热影响区同时出现了软化和硬化现象,近不完全淬火区的母材硬度最低,仅为296 HV,完全淬火区硬度最高,达到396 HV,母材和焊缝区的硬度在320~340 HV之间。

金刚石涂层游动芯头制备及其在铜管生产中的应用

通过沉积方式和旋转装置设计,采用直流电弧等离子体喷射法在硬质合金游动芯头表面均匀沉积金刚石涂层,并利用白光干涉仪、扫描电子显微镜、Raman光谱仪和压痕法对涂层的表面粗糙度、形貌、质量均匀性和膜–基附着力等进行测试分析。结果表明:金刚石涂层抛光后的表面平均粗糙度S_(a)为76.4 nm,金刚石涂层脱落位置到压痕中心的平均距离为287.9μm,且各位置的金刚石涂层厚度均匀性和质量均较好。将制备的金刚石涂层游动芯头应用于高精度精密铜管生产线中,与硬质合金游动芯头对比,其在降低劳动强度、保证铜管一致性和延长芯头使用寿命方面都有显著效果。

镍铜合金FCAW-G堆焊工艺研究

采用药芯焊丝气体保护焊(FCAW-G)对Q345R钢试板进行了镍铜合金N04400堆焊工艺评定,依照NB/T47014—2011《承压设备焊接工艺评定》要求对堆焊层的弯曲、化学成分及金相组织进行了检测。试验结果表明:采用80%Ar+20%CO_(2)混合保护气体,选用型号为ENiCu7T0-4的药芯焊丝进行过渡层及耐蚀层的堆焊,可以获得性能优良的耐蚀层,其化学成分满足标准要求,为镍铜合金实现高效堆焊提供了一种新的工艺参考。

ARCS动机激励视域下的化学微格教学探析

如何有效提升化学师范生在微格教学训练中的学习积极性,是当前高等师范类院校所面临的共同问题。本文基于ARCS动机激励模型,将微课资源库应用于化学微格教学的翻转课堂模式,探索了ARCS动机激励模型在数字化微格教学中的应用,旨在有效激发化学师范生在微格训练过程中的内在学习动机,增强师范生的学习主动性,进一步提高微格教学训练效率;帮助化学师范生在校内外导师共同指导下提高综合教学能力,增强职场竞争能力。

A Design Model of Core Snubber for EAST NBI

A transformer type iron core snubber, as a protective device against the stray capacitance during the breakdown in EAST, is analyzed in detail. Three kinds of topology are presented. Then with the analysis for equivalent circuit, the ranges of three key parameters, i.e., secondary side resistance, leakage inductance and snubber inductance, are determined. By con- sidering the saturation of the magnetic material, a design principle is Mso presented. A nearly 1：10 core snubber is tested. It is proved that a high permeability core with secondary resistor can restrain the discharge current effectively.

Research on porosity of underwater wet FCAW duplex stainless steel

To study the influence laws of welding parameters on weld porosity, underwater wet flux-cored arc welding （ FCAW） duplex stainless steel S32101 was carried out in a hyperbaric chamber, and the second-order multiple regression equation was established. The interactive effects of welding parameters on the porosity were analyzed by the three dimensional response surfaces and the contour plots. The results present that the interaction effect between water depth and voltage on the porosity is the most significant. Theoretically, a non-pores weld bead can be gained by reasonably matching these parameters with water depth less than 10 m. Always, the weld porosity reaches its peak value with a 7 mm/s welding speed.

Difference in particle characteristics and coating properties between spraying metallic and ceramic powder cored wires

The sprayed particles of metallic and cermet wires were collected to analyze the atomization state of the particles in arc spraying forming, the microstructure and properties of metallic and ceramic coatings were investigated and compared. Particle size analyzer was used for quantifying particle size. The XRD, SEM and optical microscope(OM) were used to analyze the phase composition and microstructure of the particles and coatings. From the experimental results, some difference of particle characteristics was established between the spraying metallic and ceramic cored wires, and the microstructure and properties of coatings depend strongly on the particles behaviors. The result shows that Fe-TiB2/Al2O3 composite coating has a high potential for abrasive wear applications.

Ti和Nb对铁基堆焊合金组织性能的影响

改变Ti或Nb的添加量制备Fe-Cr-C-B系铁基堆焊合金.借助扫描电镜、X射线衍射仪、洛氏硬度计和磨损试验机对堆焊合金组织性能进行测试分析.结果表明,在含Ti或Nb的堆焊合金中,初生奥氏体晶粒细化,共晶组织呈断网状均匀分布,并分别有黑色圆形或块状TiC和菱形或三角形NbC硬质相颗粒生成,添加5%Ti的堆焊合金组织最细小.TiC或NbC硬质相颗粒在组织中呈均匀弥散分布,能够作为耐磨质点与细化的初生奥氏体和共晶组织构成耐磨骨架,共同抵抗磨粒的楔入与切削作用.当Ti添加量为5%时,含Ti堆焊合金达到最优耐磨性,硬度为66 HRC,磨损量为0.048 7 g;当Nb添加量为4%时,含Nb堆焊合金达到最优耐磨性,硬度为65 HRC,磨损量为0.052 4 g.在同等条件下,含有适量Ti的铁基堆焊合金具有更优的耐磨性.

某塑胶U型管注塑模具设计

针对塑胶U型管内壁型芯脱模难度大的特点,将U型管塑件内壁型芯分解为2个直型芯与1个圆弧型芯的拼合结构,在模具动模侧设计了3组油缸驱动抽芯机构完成3个型芯的抽芯动作。2组油缸驱动抽芯机构完成2个直型芯抽芯,其中1组在完成直抽芯过程中,同时驱动动模型腔、摆件板旋转10°,达到共同推动塑件在圆弧型芯上旋转预脱模,防止由摆件板单独推动塑件旋转脱模,引起塑件塑性变形;设计模具二次开模,解决了动模型腔在旋转过程中与相关零件干涉的问题;第3组油缸驱动齿条齿轮传动机构,带动摆件板推动U型管塑件旋转,完成圆弧型芯脱模运动,解决了传统圆弧型芯旋转脱模所需脱模空间大、出现运动干涉,以及圆弧型芯难以冷却等问题。