Brazing is a suitable technology to join different materials such as cemented carbides and steel. Even though this technology has been investigated for many years, insufficient joints can occur easily, as the brazing ...Brazing is a suitable technology to join different materials such as cemented carbides and steel. Even though this technology has been investigated for many years, insufficient joints can occur easily, as the brazing process is very sensitive concerning the handling parameters. Defects such as voids and cracks are hard to detect by commonly used visual inspection methods. Other nondestructive methods such as radiography or ultrasonic testing are usually not economical for the examination of these joints. Studies proved that the electrical resistance has the potential to serve as an effective alternative for the evaluation of brazed joints. In this study, the authors have compared the electrical resistance and the shear strength. For this, cemented carbides were brazed to steel by means of induction heating at an ambient atmosphere. A silver-based filler metal （ BrazeTec 4900 / Ag 449 ） and a flux （ BrazeTec spezial h / FH12） were selected to enable the brazing process. The brazing time and the temperature were varied in order to produce different joint qualities. After brazing, the resistance was measured on each joint with the 4-point probe method to facilitate a high accuracy. The results underline the possibility to use electrical resistance measurements as an effective tool for a quality control of brazed joints.展开更多
Water-cooled flat-type W/Cu Cr Zr plasma facing components with an interlayer of oxygen-free copper（OFC） have been developed by using vacuum brazing route.The OFC layer for the accommodation of thermal stresses was ...Water-cooled flat-type W/Cu Cr Zr plasma facing components with an interlayer of oxygen-free copper（OFC） have been developed by using vacuum brazing route.The OFC layer for the accommodation of thermal stresses was cast onto the surface of W at a temperature range of 1150oC-1200 oC in a vacuum furnace.The W/OFC cast tiles were vacuum brazed to a Cu Cr Zr heat sink at 940 oC using the silver-free filler material Cu Mn Si Cr.The microstructure,bonding strength,and high heat flux properties of the brazed W/Cu Cr Zr joint samples were investigated.The W/Cu joint exhibits an average tensile strength of 134 MPa,which is about the same strength as pure annealed copper.High heat flux tests were performed in the electron beam facility EMS-60.Experimental results indicated that the brazed W/Cu Cr Zr mock-up experienced screening tests of up to 15 MW/m^2 and cyclic tests of 9 MW/m^2 for 1000 cycles without visible damage.展开更多
To the transverse beam collimation system in a rapid cycling synchrotron,an important component is the primary collimator,which improves emittance of the beam halo particles such that the particles outside the predefi...To the transverse beam collimation system in a rapid cycling synchrotron,an important component is the primary collimator,which improves emittance of the beam halo particles such that the particles outside the predefined trajectory can be absorbed by the secondary collimators.Given the material properties and power deposition distribution,the beam scraper of the primary collimator is a0.17 mm tungsten foil on a double face-wedged copper block of 121.5 mm x 20 mm.The heat is transferred to the outside by a φ34 mm copper rod.In this paper,for minimizing brazing thermal stress,we report our theoretical analysis and tests on brazing the tungsten and copper materials which differ greatly in size.We show that the thermal stress effect can be controlled effectively by creating stress relief grooves on the copper block and inserting a tungsten transition layer into the copper block.This innovation contributes to the successful R&D of the primary collimator.And this study may be of help for working out a brazing plan of similar structures.展开更多
An attempt to investigate the mechanical response to the torsional load, torsional tests of TiA1/steel brazed joints were conducted at room temperature. The TiAl/steel joints used in the torsional loading tests were b...An attempt to investigate the mechanical response to the torsional load, torsional tests of TiA1/steel brazed joints were conducted at room temperature. The TiAl/steel joints used in the torsional loading tests were brazed under the optimum parameters of 1 173 K and 300 s. Torsional strength, fracture path and the behavior of the reaction phases were studied. The results show that the average torsional strength of the joints with the diameters of 13mm, 16 mm and 20 mm is 136 N · m, 270 N · m and 490 N · m, respectively; which is 81.9% , 85.5% and 86. 2% of the TiAl base metal, respectively. Fracture path and crack propagation process analysis shows, when subjected to the torsional load, Ag-based solid solution is deformed and cracks germinate at the interface of Ag-based solid solutioa/AlCu2 Ti particles or Ag-based solid solution/AlCu2 Ti layers, grow up and propagate into the Al-Cu- Ti brittle reaction layers, then propagate into the TiAl base metal, subsequently result in failure.展开更多
The non-destructive testing of brazed joint in honeycomb structure with thin panel （ thickness ： 0. 2 mm） was studied by ultrasonic C-scan method. Samples with different types of artificial defect were designed; th...The non-destructive testing of brazed joint in honeycomb structure with thin panel （ thickness ： 0. 2 mm） was studied by ultrasonic C-scan method. Samples with different types of artificial defect were designed; the characteristic signal and the main parameters of the test were determined by the pre-experiment, and then parameters were optimized by orthogonal design, finally the optimum process was verified by a single panel sample. The multiple reflection echoes were chosen as the characteristic signal. The optimal C-scan results were achieved when the 20 MHz focus probe was used, and the pass band range for received signal were selected as 8 - 17. 5 MHz. The defects such as incomplete penetration and core damage can be detected with ultrasonic C-scan, and the detection accuracy can reach to 1 ram.展开更多
The electron beam welding-brazing being used to join 5A06 Al alloy to TC4 Ti alloy decreases the formation of brittle intermetallic compound.Experiments were carried out to study the influence of electron beam welding...The electron beam welding-brazing being used to join 5A06 Al alloy to TC4 Ti alloy decreases the formation of brittle intermetallic compound.Experiments were carried out to study the influence of electron beam welding parameters on the tensile strength of welds,based on an orthogonal test and analysis method.The welding parameters include beam current,welding speed,scanning figure,scanning frequency,figure size,beam offset and focus current.The optimum parameters for3 mm 5A06 Al alloy and 2 mm TC4 alloy were as follows：acceleration voltage was 60 kV,beam current was 11 mA,welding speed was 600 mm/min,focus current was 0 mA,scan figure was O,scanning frequency was 1 000 Hz and beam offset was 0.5 mm.The results show that the joints were with good appearance and quality welded by the optimum parameters.The successful joints could be gained and the maximum tensile strength of Al/Ti dissimilar alloy joints could be up to 222.61 MPa using electron beam welding-brazing.展开更多
A new brazing technique of diamond was developed. Using this new technique optimum chemical and metallurgical bonding between the diamond grits and the carbon steel can be achieved without any thermal damages to diamo...A new brazing technique of diamond was developed. Using this new technique optimum chemical and metallurgical bonding between the diamond grits and the carbon steel can be achieved without any thermal damages to diamond grits. The results of microanalysis and X-ray diffraction analysis reveal that a carbide layer exists between the diamond and the matrix, which consists of Cr3C2, Cr7C3 and Cr23C6. Performance tests show that the brazed diamond core-drill has excellent machining performance. In comparison with traditional electroplated diamond core-drill, the brazed diamond core-drill manufactured using the new developed technique has much higher machining efficiency and much longer operating life.展开更多
A kind of aluminum cooler was manufactured by means of vacuum brazing technique, and the cooler was examined by hydraulic pressure test. The result indicates that the test pressure of the cooler can reach 15 MPa.The f...A kind of aluminum cooler was manufactured by means of vacuum brazing technique, and the cooler was examined by hydraulic pressure test. The result indicates that the test pressure of the cooler can reach 15 MPa.The fracture of the brazing joint belongs to the mixture type. There are secondary cracks, dimples, cleavage plane and grain-boundary features on the failure surface. The cracking process of aluminum cooler is as follows. The cracks are initiated on the interface, then expand under sub-critical state. When the stress on the remained zone reaches the maximum notch tensile strength of the brazing joint or the crack length reaches the critical value that the brazing joint fracture toughness property permits, the cooler will break sharply.展开更多
The important status of guide ring in large power plants and its manufacturing methods were introduced. The advantages of manufacturing methods including welding and electrolysis were discussed.In order to ensure the ...The important status of guide ring in large power plants and its manufacturing methods were introduced. The advantages of manufacturing methods including welding and electrolysis were discussed.In order to ensure the brazing quality of the guide ring,ultrasonic nondestructive testing(UNDT) method was used in this study.According to the features of the defects that may show up during brazing,the feasibility and reliability of UNDT were proved in theory.Based on the theory,an ultrasonic C-scan imaging test method was developed using a water immersion focusing probe.According to the features of the inspected images,the defects were segmented using a morphology image processing based method.The defects can be localized and sized by employing the algorithm of area reconstruction.At last,the combination ratio of brazing interface can be calculated and the brazing quality of the guide ring can be evaluated.展开更多
文摘Brazing is a suitable technology to join different materials such as cemented carbides and steel. Even though this technology has been investigated for many years, insufficient joints can occur easily, as the brazing process is very sensitive concerning the handling parameters. Defects such as voids and cracks are hard to detect by commonly used visual inspection methods. Other nondestructive methods such as radiography or ultrasonic testing are usually not economical for the examination of these joints. Studies proved that the electrical resistance has the potential to serve as an effective alternative for the evaluation of brazed joints. In this study, the authors have compared the electrical resistance and the shear strength. For this, cemented carbides were brazed to steel by means of induction heating at an ambient atmosphere. A silver-based filler metal （ BrazeTec 4900 / Ag 449 ） and a flux （ BrazeTec spezial h / FH12） were selected to enable the brazing process. The brazing time and the temperature were varied in order to produce different joint qualities. After brazing, the resistance was measured on each joint with the 4-point probe method to facilitate a high accuracy. The results underline the possibility to use electrical resistance measurements as an effective tool for a quality control of brazed joints.
基金supported by National Natural Science Foundation of China(No.11205049)the National Magnetic Confinement Fusion Science Program of China(No.2011GB110004)
文摘Water-cooled flat-type W/Cu Cr Zr plasma facing components with an interlayer of oxygen-free copper（OFC） have been developed by using vacuum brazing route.The OFC layer for the accommodation of thermal stresses was cast onto the surface of W at a temperature range of 1150oC-1200 oC in a vacuum furnace.The W/OFC cast tiles were vacuum brazed to a Cu Cr Zr heat sink at 940 oC using the silver-free filler material Cu Mn Si Cr.The microstructure,bonding strength,and high heat flux properties of the brazed W/Cu Cr Zr joint samples were investigated.The W/Cu joint exhibits an average tensile strength of 134 MPa,which is about the same strength as pure annealed copper.High heat flux tests were performed in the electron beam facility EMS-60.Experimental results indicated that the brazed W/Cu Cr Zr mock-up experienced screening tests of up to 15 MW/m^2 and cyclic tests of 9 MW/m^2 for 1000 cycles without visible damage.
基金supported by the National Natural Science Foundation of China(No.11375217)
文摘To the transverse beam collimation system in a rapid cycling synchrotron,an important component is the primary collimator,which improves emittance of the beam halo particles such that the particles outside the predefined trajectory can be absorbed by the secondary collimators.Given the material properties and power deposition distribution,the beam scraper of the primary collimator is a0.17 mm tungsten foil on a double face-wedged copper block of 121.5 mm x 20 mm.The heat is transferred to the outside by a φ34 mm copper rod.In this paper,for minimizing brazing thermal stress,we report our theoretical analysis and tests on brazing the tungsten and copper materials which differ greatly in size.We show that the thermal stress effect can be controlled effectively by creating stress relief grooves on the copper block and inserting a tungsten transition layer into the copper block.This innovation contributes to the successful R&D of the primary collimator.And this study may be of help for working out a brazing plan of similar structures.
基金This work was supported by the National Natural Science Foundation of China （ No. 50975062）, the Science Foundation of Educational Department of Jiangxi Province （ No. GJJ13064）.
文摘An attempt to investigate the mechanical response to the torsional load, torsional tests of TiA1/steel brazed joints were conducted at room temperature. The TiAl/steel joints used in the torsional loading tests were brazed under the optimum parameters of 1 173 K and 300 s. Torsional strength, fracture path and the behavior of the reaction phases were studied. The results show that the average torsional strength of the joints with the diameters of 13mm, 16 mm and 20 mm is 136 N · m, 270 N · m and 490 N · m, respectively; which is 81.9% , 85.5% and 86. 2% of the TiAl base metal, respectively. Fracture path and crack propagation process analysis shows, when subjected to the torsional load, Ag-based solid solution is deformed and cracks germinate at the interface of Ag-based solid solutioa/AlCu2 Ti particles or Ag-based solid solution/AlCu2 Ti layers, grow up and propagate into the Al-Cu- Ti brittle reaction layers, then propagate into the TiAl base metal, subsequently result in failure.
文摘The non-destructive testing of brazed joint in honeycomb structure with thin panel （ thickness ： 0. 2 mm） was studied by ultrasonic C-scan method. Samples with different types of artificial defect were designed; the characteristic signal and the main parameters of the test were determined by the pre-experiment, and then parameters were optimized by orthogonal design, finally the optimum process was verified by a single panel sample. The multiple reflection echoes were chosen as the characteristic signal. The optimal C-scan results were achieved when the 20 MHz focus probe was used, and the pass band range for received signal were selected as 8 - 17. 5 MHz. The defects such as incomplete penetration and core damage can be detected with ultrasonic C-scan, and the detection accuracy can reach to 1 ram.
基金supported by the National Natural Science Foundation of China(Grant No.51105346)
文摘The electron beam welding-brazing being used to join 5A06 Al alloy to TC4 Ti alloy decreases the formation of brittle intermetallic compound.Experiments were carried out to study the influence of electron beam welding parameters on the tensile strength of welds,based on an orthogonal test and analysis method.The welding parameters include beam current,welding speed,scanning figure,scanning frequency,figure size,beam offset and focus current.The optimum parameters for3 mm 5A06 Al alloy and 2 mm TC4 alloy were as follows：acceleration voltage was 60 kV,beam current was 11 mA,welding speed was 600 mm/min,focus current was 0 mA,scan figure was O,scanning frequency was 1 000 Hz and beam offset was 0.5 mm.The results show that the joints were with good appearance and quality welded by the optimum parameters.The successful joints could be gained and the maximum tensile strength of Al/Ti dissimilar alloy joints could be up to 222.61 MPa using electron beam welding-brazing.
文摘A new brazing technique of diamond was developed. Using this new technique optimum chemical and metallurgical bonding between the diamond grits and the carbon steel can be achieved without any thermal damages to diamond grits. The results of microanalysis and X-ray diffraction analysis reveal that a carbide layer exists between the diamond and the matrix, which consists of Cr3C2, Cr7C3 and Cr23C6. Performance tests show that the brazed diamond core-drill has excellent machining performance. In comparison with traditional electroplated diamond core-drill, the brazed diamond core-drill manufactured using the new developed technique has much higher machining efficiency and much longer operating life.
文摘A kind of aluminum cooler was manufactured by means of vacuum brazing technique, and the cooler was examined by hydraulic pressure test. The result indicates that the test pressure of the cooler can reach 15 MPa.The fracture of the brazing joint belongs to the mixture type. There are secondary cracks, dimples, cleavage plane and grain-boundary features on the failure surface. The cracking process of aluminum cooler is as follows. The cracks are initiated on the interface, then expand under sub-critical state. When the stress on the remained zone reaches the maximum notch tensile strength of the brazing joint or the crack length reaches the critical value that the brazing joint fracture toughness property permits, the cooler will break sharply.
基金the Fund of the State Key Laboratory of Advanced Welding and Joining,Harbin Institute of Technology(No.welding 10-013)
文摘The important status of guide ring in large power plants and its manufacturing methods were introduced. The advantages of manufacturing methods including welding and electrolysis were discussed.In order to ensure the brazing quality of the guide ring,ultrasonic nondestructive testing(UNDT) method was used in this study.According to the features of the defects that may show up during brazing,the feasibility and reliability of UNDT were proved in theory.Based on the theory,an ultrasonic C-scan imaging test method was developed using a water immersion focusing probe.According to the features of the inspected images,the defects were segmented using a morphology image processing based method.The defects can be localized and sized by employing the algorithm of area reconstruction.At last,the combination ratio of brazing interface can be calculated and the brazing quality of the guide ring can be evaluated.
