Planning of circlelocus for multi-path/multi-layer welding robot with automatical error-correction

In this paper, a planning algorithm for multi path/multi layer circular locus is poposed. The algorithm is applied to weld the nipples on the header of boiler. Multi path/multi layer circular locus is planned according to three teaching points, which is lapped head on end to satisfy the requirement of technology. For the nipples wherever they are arranged radially or axially, even if there are errors caused by positioning and thermal deformations, providing that nipple's position and orientation relative to the teaching one can be measured, the multi path/multi layer circular locus can be planned without teaching any more. The algorithm has been applied in welding robot for manufacturing power station' boiler.

Optimization Design of the Multi-Layer Cross-Sectional Layout of An Umbilical Based on the GA-GLM

Marine umbilical is one of the key equipment for subsea oil and gas exploitation,which is usually integrated by a great number of different functional components with multi-layers.The layout of these components directly affects manufacturing,operation and storage performances of the umbilical.For the multi-layer cross-sectional layout design of the umbilical,a quantifiable multi-objective optimization model is established according to the operation and storage requirements.Considering the manufacturing factors,the multi-layering strategy based on contact point identification is introduced for a great number of functional components.Then,the GA-GLM global optimization algorithm is proposed combining the genetic algorithm and the generalized multiplier method,and the selection operator of the genetic algorithm is improved based on the steepest descent method.Genetic algorithm is used to find the optimal solution in the global space,which can converge from any initial layout to the feasible layout solution.The feasible layout solution is taken as the initial value of the generalized multiplier method for fast and accurate solution.Finally,taking umbilicals with a great number of components as examples,the results show that the cross-sectional performance of the umbilical obtained by optimization algorithm is better and the solution efficiency is higher.Meanwhile,the multi-layering strategy is effective and feasible.The design method proposed in this paper can quickly obtain the optimal multi-layer cross-sectional layout,which replaces the manual design,and provides useful reference and guidance for the umbilical industry.

Multi-layer perceptron-based data-driven multiscale modelling of granular materials with a novel Frobenius norm-based internal variable

One objective of developing machine learning(ML)-based material models is to integrate them with well-established numerical methods to solve boundary value problems(BVPs).In the family of ML models,recurrent neural networks(RNNs)have been extensively applied to capture history-dependent constitutive responses of granular materials,but these multiple-step-based neural networks are neither sufficiently efficient nor aligned with the standard finite element method(FEM).Single-step-based neural networks like the multi-layer perceptron(MLP)are an alternative to bypass the above issues but have to introduce some internal variables to encode complex loading histories.In this work,one novel Frobenius norm-based internal variable,together with the Fourier layer and residual architectureenhanced MLP model,is crafted to replicate the history-dependent constitutive features of representative volume element(RVE)for granular materials.The obtained ML models are then seamlessly embedded into the FEM to solve the BVP of a biaxial compression case and a rigid strip footing case.The obtained solutions are comparable to results from the FEM-DEM multiscale modelling but achieve significantly improved efficiency.The results demonstrate the applicability of the proposed internal variable in enabling MLP to capture highly nonlinear constitutive responses of granular materials.

Recent research progress in the mechanism and suppression of fusion welding-induced liquation cracking of nickel based superalloys

Nickel-based superalloys are extensively used in the crucial hot-section components of industrial gas turbines,aeronautics,and astronautics because of their excellent mechanical properties and corrosion resistance at high temperatures.Fusion welding serves as an effective means for joining and repairing these alloys;however,fusion welding-induced liquation cracking has been a challenging issue.This paper comprehensively reviewed recent liquation cracking,discussing the formation mechanisms,cracking criteria,and remedies.In recent investigations,regulating material composition,changing the preweld heat treatment of the base metal,optimizing the welding process parameters,and applying auxiliary control methods are effective strategies for mitigating cracks.To promote the application of nickel-based superalloys,further research on the combination impact of multiple elements on cracking prevention and specific quantitative criteria for liquation cracking is necessary.

Target Controllability of Multi-Layer Networks With High-Dimensional Nodes

This paper studies the target controllability of multilayer complex networked systems,in which the nodes are highdimensional linear time invariant(LTI)dynamical systems,and the network topology is directed and weighted.The influence of inter-layer couplings on the target controllability of multi-layer networks is discussed.It is found that even if there exists a layer which is not target controllable,the entire multi-layer network can still be target controllable due to the inter-layer couplings.For the multi-layer networks with general structure,a necessary and sufficient condition for target controllability is given by establishing the relationship between uncontrollable subspace and output matrix.By the derived condition,it can be found that the system may be target controllable even if it is not state controllable.On this basis,two corollaries are derived,which clarify the relationship between target controllability,state controllability and output controllability.For the multi-layer networks where the inter-layer couplings are directed chains and directed stars,sufficient conditions for target controllability of networked systems are given,respectively.These conditions are easier to verify than the classic criterion.

A flexible ultra-broadband multi-layered absorber working at 2 GHz-40 GHz printed by resistive ink

A flexible extra broadband metamaterial absorber(MMA)stacked with five layers working at 2 GHz–40 GHz is investigated.Each layer is composed of polyvinyl chloride(PVC),polyimide(PI),and a frequency selective surface(FSS),which is printed on PI using conductive ink.To investigate this absorber,both one-dimensional analogous circuit analysis and three-dimensional full-wave simulation based on a physical model are provided.Various crucial electromagnetic properties,such as absorption,effective impedance,complex permittivity and permeability,electric current distribution and magnetic field distribution at resonant peak points,are studied in detail.Analysis shows that the working frequency of this absorber covers entire S,C,X,Ku,K and Ka bands with a minimum thickness of 0.098λ_(max)(λ_(max) is the maximum wavelength in the absorption band),and the fractional bandwidth(FBW)reaches 181.1%.Moreover,the reflection coefficient is less than-10 dB at 1.998 GHz–40.056 GHz at normal incidence,and the absorptivity of the plane wave is greater than 80%when the incident angle is smaller than 50°.Furthermore,the proposed absorber is experimentally validated,and the experimental results show good agreement with the simulation results,which demonstrates the potential applicability of this absorber at 2 GHz–40 GHz.

Design of Fully Automatic Specification Selection System for Resistance Welding Equipment

A system for fully automatic selection of welding specifications in resistance welding equipment has been developed to address the problem of workers frequently choosing the wrong specifications during manual welding of multiple parts on a single machine in automobile factories. The system incorporates an automatic recognition system for different workpiece materials using the added machine fixture,visual detection system for nuts and bolts,and secondary graphical confirmation to ensure the correctness of specification calling. This system achieves reliable,fully automatic selection of welding specifications in resistance welding equipment and has shown significant effects in improving welding quality for massproduced workpieces,while solving the problem of specification calling errors that can occur with traditional methods involving process charts and code adjustments. This system is particularly suitable for promoting applications in manual welding of multiple parts on a single machine in automobile factories,ensuring correct specification calling and welding quality.

Dynamic Multi-Layer Perceptron for Fetal Health Classification Using Cardiotocography Data

Fetal health care is vital in ensuring the health of pregnant women and the fetus.Regular check-ups need to be taken by the mother to determine the status of the fetus’growth and identify any potential problems.To know the status of the fetus,doctors monitor blood reports,Ultrasounds,cardiotocography(CTG)data,etc.Still,in this research,we have considered CTG data,which provides information on heart rate and uterine contractions during pregnancy.Several researchers have proposed various methods for classifying the status of fetus growth.Manual processing of CTG data is time-consuming and unreliable.So,automated tools should be used to classify fetal health.This study proposes a novel neural network-based architecture,the Dynamic Multi-Layer Perceptron model,evaluated from a single layer to several layers to classify fetal health.Various strategies were applied,including pre-processing data using techniques like Balancing,Scaling,Normalization hyperparameter tuning,batch normalization,early stopping,etc.,to enhance the model’s performance.A comparative analysis of the proposed method is done against the traditional machine learning models to showcase its accuracy(97%).An ablation study without any pre-processing techniques is also illustrated.This study easily provides valuable interpretations for healthcare professionals in the decision-making process.

Theoretical analysis of the elastic Kelvin-Helmholtz instability in explosive weldings

By considering the joint effects of the Kelvin-Helmholtz(KH) and Rayleigh-Taylor(RT) instabilities, this paper presents an interpretation of the wavy patterns that occur in explosive welding. It is assumed that the elasticity of the material at the interface effectively determines the wavelength, because explosive welding is basically a solid-state welding process. To this end, an analytical model of elastic hydrodynamic instabilities is proposed, and the most unstable mode is selected in the solid phase. Similar approaches have been widely used to study the interfacial behavior of solid metals in high-energy-density physics. By comparing the experimental and theoretical results, it is concluded that thermal softening,which significantly reduces the shear modulus, is necessary and sufficient for successful welding. The thermal softening is verified by theoretical analysis of the increase in temperature due to the impacting and sliding of the flyer and base plates, and some experimental observations are qualitatively validated.In summary, the combined effect of the KH and RT instabilities in solids determines the wavy morphology, and our theoretical results are in good qualitative agreement with experimental and numerical observations.

Dynamic interwell connectivity analysis of multi-layer waterflooding reservoirs based on an improved graph neural network

The analysis of interwell connectivity plays an important role in the formulation of oilfield development plans and the description of residual oil distribution. In fact, sandstone reservoirs in China's onshore oilfields generally have the characteristics of thin and many layers, so multi-layer joint production is usually adopted. It remains a challenge to ensure the accuracy of splitting and dynamic connectivity in each layer of the injection-production wells with limited field data. The three-dimensional well pattern of multi-layer reservoir and the relationship between injection-production wells can be equivalent to a directional heterogeneous graph. In this paper, an improved graph neural network is proposed to construct an interacting process mimics the real interwell flow regularity. In detail, this method is used to split injection and production rates by combining permeability, porosity and effective thickness, and to invert the dynamic connectivity in each layer of the injection-production wells by attention mechanism.Based on the material balance and physical information, the overall connectivity from the injection wells,through the water injection layers to the production layers and the output of final production wells is established. Meanwhile, the change of well pattern caused by perforation, plugging and switching of wells at different times is achieved by updated graph structure in spatial and temporal ways. The effectiveness of the method is verified by a combination of reservoir numerical simulation examples and field example. The method corresponds to the actual situation of the reservoir, has wide adaptability and low cost, has good practical value, and provides a reference for adjusting the injection-production relationship of the reservoir and the development of the remaining oil.

Target layer state estimation in multi-layer complex dynamical networks considering nonlinear node dynamics

In many engineering networks, only a part of target state variables are required to be estimated.On the other hand,multi-layer complex network exists widely in practical situations.In this paper, the state estimation of target state variables in multi-layer complex dynamical networks with nonlinear node dynamics is studied.A suitable functional state observer is constructed with the limited measurement.The parameters of the designed functional observer are obtained from the algebraic method and the stability of the functional observer is proven by the Lyapunov theorem.Some necessary conditions that need to be satisfied for the design of the functional state observer are obtained.Different from previous studies, in the multi-layer complex dynamical network with nonlinear node dynamics, the proposed method can estimate the state of target variables on some layers directly instead of estimating all the individual states.Thus, it can greatly reduce the placement of observers and computational cost.Numerical simulations with the three-layer complex dynamical network composed of three-dimensional nonlinear dynamical nodes are developed to verify the effectiveness of the method.

Multi-layer phenomena in petawatt laser-driven acceleration of heavy ions

Laser-accelerated high-flux-intensity heavy-ion beams are important for new types of accelerators.A particle-in-cell program(Smilei) is employed to simulate the entire process of Station of Extreme Light(SEL) 100 PW laser-accelerated heavy particles using different nanoscale short targets with a thickness of 100 nm Cr, Fe, Ag, Ta, Au, Pb, Th and U, as well as 200 nm thick Al and Ca. An obvious stratification is observed in the simulation. The layering phenomenon is a hybrid acceleration mechanism reflecting target normal sheath acceleration and radiation pressure acceleration, and this phenomenon is understood from the simulated energy spectrum,ionization and spatial electric field distribution. According to the stratification, it is suggested that high-quality heavy-ion beams could be expected for fusion reactions to synthesize superheavy nuclei. Two plasma clusters in the stratification are observed simultaneously, which suggest new techniques for plasma experiments as well as thinner metal targets in the precision machining process.

Effect of process parameters on the morphology of aluminum/copper alloy lap joints by red and blue hybrid laser welding

In order to overcome the problems of many pores,large deformation and unstable weld quality of traditional laser welded aluminumcopper alloy joints,a red-blue dual-beam laser source and a swinging laser were introduced for welding.T2 copper and 6063 aluminum thin plates were lap welded by coaxial dual-beam laser welding.The morphology of weld cross section was compared to explore the influence of process parameters on the formation of lap joints.The microstructure characteristics of the weld zone were observed and compared by optical microscope.The results show that the addition of laser beam swing can eliminate the internal pores of the weld.With the increase of the swing width,the weld depth decreases,and the weld width increases first and then decreases.The influence of welding speed on the weld cross section morphology is similar to that of swing width.With the increase of welding speed,the weld width increases first and then decreases,while the weld depth decreases all the time.This is because that the red laser is used as the main heat source to melt the base metals,with the increase of red laser power,the weld depth increases.As an auxiliary laser source,blue laser reduces the total energy consumption,consequently,the effective heat input increases and the spatter is restrained effectively.As a result,the increase of red laser power has an enhancement effect on the weld width and weld depth.When the swing width is 1.2 mm,the red laser power is 550 W,the blue laser power is 500 W,and the welding speed is 35 mm/s,the weld forming is the best.The lap joint of T2 copper and 6063 aluminum alloy thin plate can be connected stably with the hybrid of blue laser.The effect rules of laser beam swing on the weld formation were obtained,which improved the quality of the joints.

A Well Productivity Model for Multi-Layered Marine and Continental Transitional Reservoirs with Complex Fracture Networks

Using the typical characteristics of multi-layered marine and continental transitional gas reservoirs as a basis,a model is developed to predict the related well production rate.This model relies on the fractal theory of tortuous capillary bundles and can take into account multiple gas flow mechanisms at the micrometer and nanometer scales,as well as the flow characteristics in different types of thin layers(tight sandstone gas,shale gas,and coalbed gas).Moreover,a source-sink function concept and a pressure drop superposition principle are utilized to introduce a coupled flow model in the reservoir.A semi-analytical solution for the production rate is obtained using a matrix iteration method.A specific well is selected for fitting dynamic production data,and the calculation results show that the tight sandstone has the highest gas production per unit thickness compared with the other types of reservoirs.Moreover,desorption and diffusion of coalbed gas and shale gas can significantly contribute to gas production,and the daily production of these two gases decreases rapidly with decreasing reservoir pressure.Interestingly,the gas production from fractures exhibits an approximately U-shaped distribution,indicating the need to optimize the spacing between clusters during hydraulic fracturing to reduce the area of overlapping fracture control.The coal matrix water saturation significantly affects the coalbed gas production,with higher water saturation leading to lower production.

A review of linear friction welding of Ni -based superalloys

Ni-based superalloys are one of the most important materials employed in high-temperature applications within the aerospace and nuclear energy industries and in gas turbines due to their excellent corrosion,radiation,fatigue resistance,and high-temperature strength.Linear friction welding(LFW)is a new joining technology with near-net-forming characteristics that can be used for the manu-facture and repair of a wide range of aerospace components.This paper reviews published works on LFW of Ni-based superalloys with the aim of understanding the characteristics of frictional heat generation and extrusion deformation,microstructures,mechanical proper-ties,flash morphology,residual stresses,creep,and fatigue of Ni-based superalloy weldments produced with LFW to enable future optim-um utilization of the LFW process.

MD Simulation of Diffusion Behaviors in Collision Welding Processes of Al-Cu, Al-Al, Cu-Cu

To investigate the effects of material combinations and velocity conditions on atomic diffusion behavior near collision interfaces,this study simulates the atomic diffusion behavior near collision interfaces in Cu-Al,Al-Al and Cu-Cu combinations fabricated through collision welding using molecular dynamic(MD)simulation.The atomic diffusion behaviors are compared between similar metal combinations(Al-Al,Cu-Cu)and dissimilar metal combinations(Al-Cu).By combining the simulation results and classical diffusion theory,the diffusion coefficients for similar and dissimilar metal material combinations under different velocity conditions are obtained.The effects of material combinations and collision velocity on diffusion behaviors are also discussed.The diffusion behaviors of dissimilar material combinations strongly depend on the transverse velocity,whereas those of the similar material combinations are more dependent on the longitudinal velocity.These findings can provide guidance for optimizing welding parameters.

A critical review on solid-state welding of high entropy alloys-processing,microstructural characteristics and mechanical properties of joints

The high entropy alloys(HEAs)are the newly developed high-performance materials that have gained significant importance in defence,nuclear and aerospace sector due to their superior mechanical properties,heat resistance,high temperature strength and corrosion resistance.These alloys are manufactured by the equal mixing or larger proportions of five or more alloying elements.HEAs exhibit superior mechanical performance compared to traditional engineering alloys because of the extensive alloying composition and higher entropy of mixing.Solid state welding(SSW)techniques such as friction stir welding(FSW),rotary friction welding(RFW),diffusion bonding(DB)and explosive welding(EW)have been efficiently deployed for improving the microstructural integrity and mechanical properties of welded HEA joints.The HEA interlayers revealed greater potential in supressing the formation of deleterious intermetallic phases and maximizing the mechanical properties of HEAs joints.The similar and dissimilar joining of HEAs has been manifested to be viable for HEA systems which further expands their industrial applications.Thus,the main objective of this review paper is to present a critical review of current state of research,challenges and opportunities and main directions in SSW of HEAs mainly CoCrFeNiMn and Al_xCoCrFeNi alloys.The state of the art of problems,progress and future outlook in SSW of HEAs are critically reviewed by considering the formation of phases,microstructural evolution and mechanical properties of HEAs joints.

Influence of heat input on microhardness and microstructure across the welding interface between stainless steel and low alloy steel

The welding interface is crucial to the service safety of dissimilar metal weld(DMW)joints between stainless steel(SS)and low alloy(LA)steel.Different status of welding interfaces was prepared by cladding SS consumables to LA steel substrates with different heat inputs via tungsten inert gas arc welding(TIG),followed by a series of microstructural characterizations and hardness tests.Results showed that a hardening and transition layer(TL)would be generated along the welding interface,and the width and hardening degree of the TL would increase with the heat input.Meanwhile,heavy load hardness tests showed that highly severe inhomogeneous plastic deformation and the microcrack would be generated in the interfacial region and the welding interface respectively in the highest heat input sample(1.03 kJ/mm).These results indicate that the increase in heat input would deteriorate the bonding performance of DMW joints.Further microstructural observations showed that the higher hardening degree of the highest heat input sample was mainly attributed to the stronger grain boundary,solution,and dislocation strengthening effects.

Bulging Distortion of Austenitic Stainless Steel Sheet on the Partially Penetrated Side of Non-Penetration Lap Laser Welding Joint

Non-penetration laser welding of lap joints in austenitic stainless steel sheets is commonly preferred in fields where the surface quality is of utmost importance.However,the application of non-penetration welded austenitic stainless steel parts is limited owing to the micro bulging distortion that occurs on the back surface of the partial penetration side.In this paper,non-penetration lap laser welding experiments,were conducted on galvanized and SUS304 austenitic stainless steel plates using a fiber laser,to investigate the mechanism of bulging distortion.A comparative experiment of DC01 galvanized steel-Q235 carbon steel lap laser welding was carried out,and the deflection and distortion profile of partially penetrated side of the sheets were measured using a noncontact laser interferometer.In addition,the cold-rolled SUS304 was subjected to heat holding at different temperatures and water quenching after bending to characterize its microstructure under tensile and compressive stress.The results show that,during the heating stage of the thermal cycle of laser lap welding,the partial penetration side of the SUS304 steel sheet generates compressive stress,which extrudes the material in the heat-affected zone to the outside of the back of the SUS304 steel sheet,thereby forming a bulge.The findings of these experiments can be of great value for controlling the distortion of the partial penetrated side of austenitic stainless steel sheet during laser non-penetration lap welding.

Effect of V content on microstructures and properties of TiC cermet fusion welding interface

The effects of vanadium(V)on the microstructures and mechanical properties of the TiC cermet fusion welding interface were studied by adjusting the content of V in the self-developed flux-cored wires using metal inert gas arc(MIG)welding for surfacing on the TiC cermet.The results show that the increase in V content promotes the element diffusion between TiC cermet and weld metal.There are no de-fects observed in the interface,and the diffusion of elements refers to excellent metallurgical bonding.The shear strength of the fusion zone initially decreases and then increases with the increase in V content.The maximum shear strength of the TiC cermet/weld interface,reaching 552 MPa,occurred when the V content reached 0.65%.Meanwhile,the average hardness in the transition zone reached 488.2 HV0.2.