Prediction of wire transfer behaviors in laser hot wire welding

With preheating wire by resistance heat, laser hot wire welding improves process stability and wire deposition efficiency, which gives broad potential applications in sugracing and narrow gap welding. It is a critical issue to control the temperature of preheated wire in this process. The temperature which is so high that the wire fuses outside molten pool or so low that the wire cannot melt timely in the molten pool, results in poor wire transfer stability and bad weld formation. This paper is purposed to calculate the wire temperature for the prediction of wire transfer behavior under various welding parameters. A heat conduction model is set up. Heat sources of the wire include resistance heat and reflected laser, and the heat source of molten pool is laser. The calculated temperature of wire part outside the molten pool is verified by infrared ratio temperature measurement. The calculated temperature of wire part in the molten pool is verified by measurement of the molten pool size. Analyzing the wire temperature and welding process observed by the high speed video imaging, the temperature criteria of wire transfer behaviors are obtained. Thus, numerical simulation of the wire temperature can be used to predict wire transfer behaviors in laser hot wire welding.

TIG welding-brazing joint of aluminum to stainless steel with hot wire

TIG welding-brazing process with high frequency induction hot wire technology was presented to create joints between 5A06 aluminum alloy and SUS32! stainless steel using ER1100 filler wire with different temperature. The joints were evaluated by mechanical test and microstructural analyses. The welding procedure using hot fiUer wire （400 ℃ ） significantly increases strength stability by 71% and average value of tensile strength by 30. 8 % of the joints, compared with cold wire. The research of microstructures in interfaces and welded seams reveals that using 400 ℃ hot filler wire can decrease the thickness of intermetallic compounds （ IMCs ） from 6 to 3.5 txm approximately, which is the main reason of mechanical property improvement.

Process improvement in laser hot wire cladding for martensitic stainless steel based on the Taguchi method

Laser hot wire cladding, with the prominent features of low heat input, high energy efficiency, and high precision, is widely used for remanufacturing metal parts. The cladding process, however, needs to be improved by using a quantitative method. In this work, volumetric defect ratio was proposed as the criterion to describe the integrity of forming quality for cladding layers. Laser deposition experiments with FV520B, one of martensitic stainless steels, were designed by using the Taguchi method. Four process variables, namely, laser power （P）, scanning speed （Vs）, wire feed rate （Vf）, and wire current （/）, were optimized based on the analysis of signal-to-noise （S/N） ratio. Metallurgic observation of cladding layer was conducted to compare the forming quality and to validate the analysis method. A stable and continuous process with the optimum parameter combination produced uniform microstructure with minimal defects and cracks, which resulted in a good metallurgical bonding interface.

Effects of Hot Wire Temperature on Properties of GeSi:H Films with High Hydrogen Dilution by Hot-Wire Chemical Vapor Deposition

GeSi:H films are prepared by hot-wire chemical vapor deposition(CVD) with high hydrogen dilution, DH=98%. Effects of hot wire temperature(Tw) on deposition rate, structural properties and bandgap of GeSi:H films are studied with surface profilemeter, Raman spectroscopy, Fourier transformed infrared spectroscopy, and UV-VIS-NIR spectrophotometer. It is found that the deposition rate(Rd) goes up with increasing of Tw, but increasing rate of Rd declines when Tw≥1 550 ℃. High Tw is beneficial to the formation of Ge-Si, but it has little effect on relative contents of the hydrogen bonds(Ge-H, Si-H, etc.) in the films. In the Tw range of 1 400-1 850 ℃, the maximum bandgap of the GeSi:H films is 1.39 eV at Tw =1 450 ℃ and the band gap decreases with Tw increasing when Tw≥1 450 ℃.

DATA PROCESSING ON LINEARIZATION OF HOT-WIRE ANEMOMETER

A method of data processing to determine the coefficients of linearization equations for 1050 anemometer (produced by Thermo-Systems Inc. -TSI, USA) with the sensors made of domestic hot wire using the program preferred in this Paper is described. By calculation and test, it is indicated that the error resulting from this method is about 0. 5% of the full scale and less than TSl's. By using this method we can set up the calibration curve according to the measurement range and the diameter of the hot wire at a certain accuracy.

Effect of hydrogen on low temperature epitaxial growth of polycrystalline silicon by hot wire chemical vapor deposition

Polycrystalline silicon （poly-Si） films were prepared by hot-wire chemical vapor deposition （HWCVD） at a low substrate temperature of 525 ℃. The influence of hydrogen on the epitaxial growth of ploy-Si films was investigated. Raman spectra show that the poly-Si films are fully crystallized at 525 ℃ with a different hydrogen dilution ratio （50%-91.7%）. X-ray diffraction, grazing incidence X-ray diffraction and SEM images show that the poly-Si thin films present （100） preferred orientation on （100） c-Si substrate in the high hydrogen dilution condition. The P-type poly-Si film prepared with a hydrogen dilution ratio of 91.7% shows a hall mobility of 8.78 cm2/（V-s） with a carrier concentration of 1.3 × 10^20 cm^-3, which indicates that the epitaxial poly-Si film prepared by HWCVD has the possibility to be used in photovoltaic and TFT devices.

An Adaptive Response Compensation Technique for the Constant-Current Hot-Wire Anemometer

An adaptive response compensation technique has been proposed to compensate for the response lag of the constant-current hot-wire anemometer (CCA) by taking advantage of digital signal processing technology. First, we have developed a simple response compensation scheme based on a precise theoretical expression for the frequency response of the CCA (Kaifuku et al. 2010, 2011), and verified its effectiveness experimentally for hot-wires of 5 μm, 10 μm and 20 μm in diameter. Then, another novel technique based on a two-sensor probe technique—originally developed for the response compensation of fine-wire thermocouples (Tagawa and Ohta 1997;Tagawa et al. 1998)—has been proposed for estimating thermal time-constants of hot-wires to realize the in-situ response compensation of the CCA. To demonstrate the usefulness of the CCA, we have applied the response compensation schemes to multipoint velocity measure- ment of a turbulent wake flow formed behind a circular cylinder by using a CCA probe consisting of 16 hot-wires, which were driven simultaneously by a very simple constant-current circuit. As a result, the proposed response compensation techniques for the CCA work quite successfully and are capable of improving the response speed of the CCA to obtain reliable measurements comparable to those by the commercially-available constant-temperature hot-wire anemometer (CTA).

An experimental investigation of wire electrical discharge machining of hot-pressed boron carbide

The present work discusses the experimental study on wire-cut electric discharge machining of hot-pressed boron carbide.The effects of machining parameters,such as pulse on time(TON),peak current(IP),flushing pressure(FP) and spark voltage on material removal rate(MRR)and surface roughness(R_a) of the material,have been evaluated.These parameters are found to have an effect on the surface integrity of boron carbide machined samples.Wear rate of brass wire increases with rise in input energy in machining of hot-pressed boron carbide.The surfaces of machined samples were examined using scanning electron microscopy(SEM).The influence of machining parameters on mechanism of MRR and R_a was described.It was demonstrated that higher TON and peak current deteriorate the surface finish of boron carbide samples and result in the formation of large craters,debris and micro cracks.The generation of spherical particles was noticed and it was attributed to surface tension of molten material.Macro-ridges were also observed on the surface due to protrusion of molten material at higher discharge energy levels.

壁面局部动态扰动作用下湍流边界层多尺度相互作用

对比分析大尺度高速/低速来流背景下,多种尺度间的相互作用,讨论通过主动减阻控制系统间歇输入能量实现流场减阻控制的可行性。实验使用压电振子对湍流边界层施加周期性局部扰动,同步采集压电振子上游固定探针和下游移动探针(沿法向高度移动)的流场信息。通过对压电振子上、下游不同尺度脉动速度信号的相关性分析,确定上下游信号的时空关系。通过预乘能谱图确定扰动信号及其高次谐波,并划分不同信号尺度。着重讨论大尺度高速/低速来流背景下,大尺度与扰动尺度、扰动尺度与小尺度的相互作用,发现大尺度高速背景对扰动信号有幅值调制作用。大尺度高速/低速来流背景下,扰动信号与小尺度信号存在固定的相位对应关系,且不受来流背景影响。明确以压电振子对流场进行主动间歇性控制时,在大尺度高速来流背景下施加局部动态扰动具有更好的调制控制效果。

Study of Hygrothermal Behavior of Bio-Sourced Material Treated Ecologically for Improving Thermal Performance of Buildings

Creating sustainable cities is the only way to live in a clean environment,and this problem can be solved by using bio-sourced and recycled materials.For this purpose,the authors contribute to the valuation of sheep wool waste as an eco-friendly material to be used in insulation.The paper investigates the thermal,hygrothermal,and biological aspects of sheep wool by testing a traditional treatment.The biological method of aerobic mesophilicflora has been applied.Fluorescence X was used to determine the chemical composition of the materials used.Also,thermal characterization has been conducted.The thermal conductivity is above 0.046(W·m^(-1)·K^(-1))and the thermal diffusivity is 1.56.10^(-6) m^(2)·s^(-1).Besides,the energy efficiency of using sheep wool in buildings was studied.Furthermore,its humidity behavior was evaluated in different aspects in both winter and summer.Results of biological analyses show the efficiency of the treatment by removing the majority of the microorgan-isms:the value of yeast and mildew was reduced from 38.10^(2) to 2.10^(2)(UFC·g^(-1)).In addition to that,sheep wool permits obtaining a low thermal transmittance on the scale of the walls and low cooling needs on the scale of the building with a gain of 45%and 52%,respectively.

L360QS+UNS N08825双金属复合管热丝TIG自动焊接工艺

双金属复合管作为一种油气输送管道材料,具有较强的耐蚀性能,特别适用于输送强腐蚀性介质。我国川渝地区的油气资源含有较高的硫化氢(H2S)和其他硫化物,管道内部形成了复杂的腐蚀环境,易导致管道内壁腐蚀、应力腐蚀开裂等多种失效形式。川渝地区油气管道常采用镍基合金、不锈钢等高性能的耐腐蚀材料,其中铁山坡项目中选用了L360QS+UNS N08825双金属复合管作为输送管道材质。针对825镍基复合管传统手工焊接方式效率不高,质量受人为因素影响大的问题,通过焊材匹配、自动焊接设备选型、焊接工艺参数优化等手段,开展焊接试验,研发了L360QS+UNS N08825双金属复合管热丝TIG自动焊接工艺,并在铁山坡项目中进行了实施应用,取得了显著的效果,一次焊接合格率可达99.2%,同时针对焊接缺陷返修和易出现的质量问题进行了分析,提出了相应的工艺措施。该工艺对于同类材质管道焊接具有重要的指导意义和参考价值。

BDD电极对苯酚降解氧化的试验研究

基于掺硼金刚石(BDD)电极的电化学高级氧化技术是解决难降解有机污染物的有效方法之一。通过热丝化学气相沉积法(Hot Filament CVD,HFCVD)结合动态掺硼工艺,在WC-Co衬底上成功合成了BDD薄膜。在此基础上,利用已制备的WC-Co/BDD电极,以苯酚为目标污染物,探究了不同电流密度、电解质浓度、pH值、苯酚初始浓度对其降解效率的影响。试验结果显示,在电流密度为0.03 A/cm^(2),电解质为1.5 g/L Na_(2)SO_(4)的条件下,无论是在酸性还是碱性环境中,对于质量浓度为1000 mg/L的苯酚溶液,3 h内COD的去除率均达到95%;对于质量浓度低于500 mg/L的苯酚溶液,其COD去除率在相同时间内均接近100%。基于WC-Co/BDD电极的电化学高级氧化技术对苯酚的矿化效果极为显著。

亚声速可压缩流场叶片边界层热线测速方法研究

为了能够开发一种简单有效的亚声速可压缩流场叶片边界层速度测量方法,从而为叶型设计和相关数值研究工作提供支撑,本文围绕热线风速测量技术,针对可压缩流场密度变化对热线标定结果的影响,以及实际测量中速度、密度耦合而无法直接获取的问题,通过理论分析,提出了适用于边界层测量的恒定压力热线标定方法和引入叶表稳态静压进行速度解耦的方法,并对所提出方法的主要误差进行了分析评估。在此基础上进行了热线标定和边界层速度测量试验验证,明确了恒定压力热线标定数学模型系数随压力的线性变化规律,同时针对温度非线性影响提出了一种基于过热比调整的修正方法,该方法能够将约13℃的温度偏差对热线电压的影响降低到1%以内,进一步简化了恒定压力热线标定流程,结合基于叶表稳态静压的速度解耦方法,为亚声速可压缩流场叶片边界层瞬态速度测量提供了一种简单可行的高频响测速方法。

Si对缆索钢丝绳用热轧盘条组织和力学性能的影响

利用扫描电镜和能谱(EBSD)仪器对两种不同Si含量的热轧盘条的横截面和纵截面的组织形貌进行观测,并用万能试验机测试热轧盘条的拉伸性能,结果表明:随着Si含量的增加,珠光体转变的过冷度增加,热轧盘条的珠光体团尺寸和珠光体片间距减小。Si元素使Mn元素在渗碳体中偏聚,增加了渗碳体的稳定性,减小了渗碳体片层的球化倾向。Si元素使盘条横、纵截面珠光体的织构强度减弱,珠光体组织更加均匀,取向更加随机。Si元素能大幅度提升热轧盘条和成品钢丝的强度,小幅度提升塑性。低Si盘条的抗拉强度为1134 MPa,均匀伸长率为7.1%;高Si盘条的抗拉强度为1263 MPa,均匀伸长率为7.3%。低Si钢丝的抗拉强度为1937 MPa,均匀伸长率为2.2%;高Si钢丝的抗拉强度为2106 MPa,均匀伸长率为2.3%。

70^(#)钢热轧盘条拉拔断裂的原因分析

70^(#)钢热轧盘条用于拉拔加工成多种钢丝产品,因此要求其具有良好的拉伸性能。但是,在实际生产中,某些因素通常会导致70^(#)钢热轧盘条抗拉强度降低,在拉拔过程中发生断裂,严重影响其产品质量,造成了巨大的经济损失。针对70^(#)钢热轧盘条在使用过程中出现拉拔断裂的问题,采用光学显微镜、扫描电子显微镜(SEM)、电子探针(EPMA)等检测设备分别从断裂试样的形貌、组织、成分等方面分析了拉拔断裂的原因。结果表明,在盘条中心处存在缩孔和疏松是造成拉拔断裂的主要原因。对连铸轻压下技术进行了优化,通过调整压下区间和压下量,提高了连铸坯的内部质量,消除了盘条中的缩孔和疏松,有效减少了盘条拉拔断裂现象。本研究为行业内相似问题的探究和解决提供了参考。

CMOS红外光源的设计与实现

基于红外气体传感器微型化、低成本和低功耗的发展需要,设计了一种用于非色散红外(NDIR)集成气体传感器的互补金属氧化物半导体(CMOS)红外光源。它以非等间隔的蛇形钨(W)薄膜电阻作为加热丝,以二氧化硅(SiO_(2))和氮化硅(Si_(3)N_(4))多层复合介质薄膜为支撑形成悬空膜片式微热板,以氧化铜(CuO)和二氧化锰(MnO_(2))纳米材料复合薄膜作为辐射增强层。基于COMSOL软件进行了热电耦合仿真,证明结构设计合理性。采用标准CMOS工艺、硅(Si)的深刻蚀工艺以及静电流体动力学打印技术流片制造了该CMOS红外光源芯片。性能测试结果表明:该红外光源从室温升温至469℃的热响应时间约为41 ms,电功耗仅为138 mW,辐射区温度分布均匀,引入辐射增强层使表面比辐射率提高约35%,红外光源的辐射功率和红外光谱辐射强度测试结果表明:该涂层有效地增强了红外辐射。

薄镀层热成形钢激光填丝焊的焊缝特征及性能

为降低镀覆在钢板表面的铝硅镀层对激光接头的不利影响,采用薄镀层热成形钢材料配合激光填丝焊技术,获得了焊缝内铝质量分数小于1%的激光填丝焊接头。对该接头进行了宏观及微观组织分析,发现热成形后焊接接头组织被全马氏体组织取代,避免了软化现象。力学性能分析表明,热成形前后试样的抗拉强度从约570 MPa提高到约1 500 MPa,接头的薄弱环节位于母材,高速拉伸对接头的抗拉强度没有不良影响,而断裂伸长率受影响较大。

热丝TIG在接管Ni基合金内壁堆焊工艺要点

针对公司正在生产的蒲城德士古式气化炉,因其堆焊要求特殊,上下筒体全部堆焊Ni基材料,难度大并且质量不易保证,尤其在筒体大直径接管内壁堆焊过程中,如何获得高质量的接管内壁堆焊,对整体堆焊质量和生产效率有着非常大的影响。文中针对上述气化炉堆焊技术要求,以公司采用热丝TIG设备堆焊蒲城大直径接管内壁为实例,综述了热丝TIG在接管内壁堆焊Ni基合金的应用情况。结果表明,焊缝裂纹率减少了16%,焊后无损检测一次性合格率提升了40%,焊接效率提高了近30%。

热丝激光熔覆Cr-W-Mo-V钢涂层组织与腐蚀磨损性能

随着海洋油气资源的开发,钻采装备面临腐蚀与磨损的耦合损伤。开发耐磨耐蚀涂层材料及制备技术是海洋装备安全、可靠运行的保障。利用热丝激光熔覆技术在20钢基材表面制备Cr-W-Mo-V钢涂层,通过光学显微镜(OM)、X射线衍射仪(XRD)、扫描电子显微镜(SEM)等分析涂层的显微组织和相组成,采用往复电化学腐蚀摩擦磨损试验仪分析涂层的干摩擦、电化学腐蚀及在3.5 wt.%NaCl溶液中的腐蚀磨损行为。制备的涂层组织均匀、致密,无裂纹、气孔等缺陷,主要由碳化物、马氏体和残余奥氏体组成,显微组织主要为柱状晶和胞状晶。涂层的平均硬度约为780 HV_(0.1),约是基材硬度的6.5倍,自腐蚀电位为-0.386 V,自腐蚀电流密度为3.45×10^(-6)A/cm^(2),具有优异的耐蚀性。在3.5 wt.%NaCl溶液中,随摩擦载荷的增大,涂层的开路电位下降,摩擦因数下降,腐蚀电流密度增大,摩擦对腐蚀有明显促进作用。随外加电位增加,涂层腐蚀电流密度增大,摩擦因数降低。热丝激光熔覆技术制备的Cr-W-Mo-V钢涂层结构致密、组织均匀,具有优异的腐蚀磨损性能,可用于海洋油气钻采装备在腐蚀磨损苛刻环境下零部件的表面改性。