Self-Adaptive Control System for Additive Manufacturing Using Double Electrode Micro Plasma Arc Welding

Wire arc additive manufacturing(WAAM)has been investigated to deposit large-scale metal parts due to its high deposition efficiency and low material cost.However,in the process of automatically manufacturing the high-quality metal parts by WAAM,several problems about the heat build-up,the deposit-path optimization,and the stability of the process parameters need to be well addressed.To overcome these issues,a new WAAM method based on the double electrode micro plasma arc welding(DE-MPAW)was designed.The circuit principles of different metal-transfer models in the DE-MPAW deposition process were analyzed theoretically.The effects between the parameters,wire feed rate and torch stand-off distance,in the process of WAAM were investigated experimentally.In addition,a real-time DE-MPAW control system was developed to optimize and stabilize the deposition process by self-adaptively changing the wire feed rate and torch stand-off distance.Finally,a series of tests were performed to evaluate the control system’s performance.The results show that the capability against interferences in the process of WAAM has been enhanced by this self-adaptive adjustment system.Further,the deposition paths about the metal part’s layer heights in WAAM are simplified.Finally,the appearance of the WAAM-deposited metal layers is also improved with the use of the control system.

Metal vapor behavior in double electrodes TIG welding

In present paper, the metal vapour behavior in double electrodes TIG welding was investigated by a numerical model, including the arc plasma and weld pool. The thermodynamic parameters and transport coefficients of the arc plasma were dependent on both the local temperature and the mass ratio of the metal vapour. A second viscosity approximation was used to formulate the diffusion coefficient of the metal vapour in the arc plasma. The temperature and flow fields together with the metal vapour concentration were simulated, and the influences of metal vapour on the arc plasma and the weld pool were analyzed. It was found that the metal vapour transport in the arc plasma was significantly influenced by the flow of the arc plasma, and the distribution of the metal vapour was more extended in the direction perpendicular to the line through the double electrodes tips. Both the arc plasma and the heat flux at the weld pool were constricted by the presence of the metal vapour, while the metal vapour had a minor effect on the total heat input to the work piece and the weld pool profile as a whole.

High-Efficiency Bottom-Emitting Organic Light-Emitting Diodes with Double Aluminum as Electrodes

Bottom-emitting organic light-emitting diodes （BOLEDs）, using AI/MoO3 as the semitransparent anode and LiF/Al as the reflective cathode and Alqa as the emitter, are fabricated. At the same time, the performance improvement of the BOLEDs having a capping layer inserted between the semitransparent anode and the glass substrate is studied. The optimized microcavity BOLED shows a current efficiency （5.49cd/A） enhancement of 10% compared with a conventional BOLED based on ITO （5.0cd/A）. Slight color variation is observed in 120° forward viewing angle with 5Onto BCP as the capping layer. Strong dependence of efficiency on A1 anode thickness and the thickness and refractor index of the capping layer is explained. The results indicate that the BOLEDs with the double-aluminum electrode have potential practical applications.

Multi-point discharge model: study on corona discharge of double-ended needle in large space

Corona discharge, as a common means to obtain non-equilibrium plasma, can generally obtain high-concentration plasma by increasing discharge points to meet production needs. However,the existing numerical simulation models used to study multi-point corona discharge are all calculations of small-scale space models, which cannot obtain the distribution characteristics of plasma in large space. Based on our previous research, this paper proposes a hybrid model for studying the distribution of multi-point discharge plasma in large-scale spaces, which divides the computational domain and computes separately with the hydrodynamic model and the ion mobility model. The simulation results are verified by a needle–ball electrode device. Firstly, the electric field distribution and plasma distribution of the needle electrodes with single tip and double tips are compared and discussed. Secondly, the plasma distribution of the needle electrode with the double tip at different voltages is investigated. Both computational and experimental results indicate that the charged particle concentration and current of the needle electrode with double tips are both twice as high as those of the needle electrode with a single tip. This model can extend the computational area of the multi-point corona discharge finite element model to the sub-meter(25 cm) or meter level, which provides an effective means to study the plasma distribution generated by multiple discharge points in large-scale space.

Modeling, Simulation and Control of Pulsed DE-GMA Welding Process for Joining of Aluminum to Steel

Joining of aluminum to steel has attracted significant attention from the welding research community,automotive and rail transportation industries.Many current welding methods have been developed and applied,however,they can not precisely control the heat input to work-piece,they are high costs,low efficiency and consist lots of complex welding devices,and the generated intermetallic compound layer in weld bead interface is thicker.A novel pulsed double electrode gas metal arc welding（Pulsed DE-GMAW）method is developed.To achieve a stable welding process for joining of aluminum to steel,a mathematical model of coupled arc is established,and a new control scheme that uses the average feedback arc voltage of main loop to adjust the wire feed speed to control coupled arc length is proposed and developed.Then,the impulse control simulation of coupled arc length,wire feed speed and wire extension is conducted to demonstrate the mathematical model and predict the stability of welding process by changing the distance of contact tip to work-piece（CTWD）.To prove the proposed PSO based PID control scheme’s feasibility,the rapid prototyping experimental system is setup and the bead-on-plate control experiments are conducted to join aluminum to steel.The impulse control simulation shows that the established model can accurately represent the variation of coupled arc length,wire feed speed and the average main arc voltage when the welding process is disturbed,and the developed controller has a faster response and adjustment,only runs about 0.1 s.The captured electric signals show the main arc voltage gradually closes to the supposed arc voltage by adjusting the wire feed speed in 0.8 s.The obtained typical current waveform demonstrates that the main current can be reduced by controlling the bypass current under maintaining a relative large total current.The control experiment proves the accuracy of proposed model and feasibility of new control scheme further.The beautiful and smooth weld beads are also obtained by this method.Pulsed DE-GMAW can thus be considered as an alternative method for low cost,high efficiency joining of aluminum to steel.

Characteristics of Electric Double Layer in Different Aqueous Electrolyte Solutions for Supercapacitors

Aiming to find suitable electrolytes for electric double layer capacitor （EDLC）,the relationship between the formation velocity of electric double layer and the specific capacitance in different electrolyte （H 2 SO 4,KOH,KCl,NH 4 Cl,and LiOH） solutions was investigated by cyclic voltammetry and AC impedance with varying frequency and potential,which was also analyzed based on Stern model and Gouy-Chapman diffusion layer model.It shows that the capacitance is positively correlated with the formation velocity of the electric double layers,which is affected by the type of ions applied,the concentration of the electrolyte solution,and the potential and frequencies as well.The electrolyte solutions of 6 mol/L KOH and 4 mol/L H2SO4 provide the largest capacitance,reaching 214 and 186 μF/cm^ 2,respectively.Both 6 mol/L KOH and 4 mol/L H 2 SO 4 solutions are suitable electrolytes for EDLC applications using Pt as electrodes.

The application of iron mesh double layer as anode for the electrochemical treatment of Reactive Black 5 dye

In this work a novel anode configuration consisting of an iron mesh double layer is proposed for the electrochemical treatment of wastewater. The removal of Reactive Black 5 dye（RB5） from synthetic contaminated water was used as a model system. At a constant anode surface area, identical process operating parameters and batch process mode, the iron mesh double layer electrode showed better performance compared to the conventional single layer iron mesh. The double layer electrode was characterized by RB5 and chemical oxygen demand（COD） removal efficiency of 98.2% and 97.7%, respectively, kinetic rate constant of 0.0385/min, diffusion coefficient of 4.9 × 10^（-5）cm^2/sec and electrical energy consumption of 20.53 kWh/kgdye removed. In the continuous flow system, the optimum conditions suggested by Response Surface Methodology（RSM） are： initial solution p H of 6.29,current density of 1.6 m A/cm^2, electrolyte dose of 0.15 g/L and flow rate of 11.47 m L/min which resulted in an RB5 removal efficiency of 81.62%.

Numerical Simulation of Thermal Characteristics in the Process of Electroslag Remelting for Production of Large Slab Ingots

The slag pool is a complex system which gathers electromagnetic field,thermal field and flow field in the process of electroslag remelting(ESR)for production of large slab ingots.In this manuscript,mathematic foundation and boundary conditions of the numerical simulation for thermal field in the ESR process of large slab ingots were analyzed, and mathematic model of heat generation in the slag pool and the solidification in the metal molten pool were founded by using the finite element software ANSYS.According to the simulation results,it can be found that the temperature distribution in the process of ESR for production of large slab ingots with double electrode series is different from that in the electroslag furnace with a single electrode.The region of the biggest current density and the highest temperature in the electroslag furnace with a single electrode is below the electrode,while the same region in the process of ESR with the double electrode series for production of large slab ingots locates between the two electrodes.The depth of the metal pool and the temperature of the slag bath simulated by mathematical model were close to the measured value in the experimental process,which verifies the reliability of the simulation method and the model,and it will provide a theoretical basis for the quality control of large slab ingots in the process of ESR.