U75VH热处理钢轨气压焊头正火工艺研究

钢轨经气压焊接后,为提高焊头性能,需进行焊后正火热处理,针对U75VH热处理钢轨气压焊头正火后,焊头硬度偏低以及焊缝出现马氏体异常组织等问题,开展了U75VH热处理钢轨气压焊头正火工艺研究,结果表明:随着正火加热温度和喷风压力升高,焊头硬度提高,软化区宽度减小;而随着喷风时间缩短,焊缝马氏体组织减少。通过正火工艺优化后,气压焊头的踏面硬度Hj/Hp值为0.95,纵断面洛式硬度H_(j)/H_(p)值为0.93,焊缝组织为珠光体和少量铁素体,焊缝各部位晶粒度为8.0~9.5级,各项性能指标均满足TB/T 1632.4—2014标准要求。

Electron beam welding of 304 stainless steel to QCr0.8 copper alloy with copper filler wire

Electron beam welding （EBW） of 304 stainless steel to QCr0.8 copper alloy with copper filler wire was carried out. Orthogonal experiment was performed to investigate the effects of process parameters on the tensile strength of the joints, and the process parameters were optimized. The optimum process parameters are as follows：beam current of 30 mA, welding speed of 100 mm/min, wire feed rate of 1 m/min and beam offset of-0.3 mm. The microstructures of the optimum joint were studied. The results indicate that the weld is mainly composed of dendriticαphase with little globularεphase, and copper inhomogeneity only occurs at the top of the fusion zone. In addition, a melted region without mixing exists near the weld junction of copper side. This region with a coarser grain size is the weakest section of the joints. It is found that the microhardness of the weld decreases with the increase of the copper content in solid solution. The highest tensile strength of the joint is 276 MPa.

Microstructure and properties of Cu/Al joints brazed with Zn-Al filler metals

The mechanical properties and microstructural distribution of the Cu/A1 brazing joints formed by torch-brazing with different Zn-A1 filler metals were investigated. The microstructure of the Zn-A1 alloys was studied by optical microscopy and scanning electron microscopy, and the phase constitution of the Cu/A1 joints was analyzed by energy dispersion spectrometry. The results show that the spreading area of the Zn-A1 filler metals on the Cu and A1 substrates increases as the A1 content increases. The mechanical results indicate that the shear strength reaches a peak value of 88 MPa when A1 and Cu are brazed with Zn-15AI filler metal. Microhardness levels from HV122 to HV515 were produced in the three brazing seam regions corresponding to various microstructure features. The Zn- and Al-rich phases exist in the middle brazing seam regions. However, two interface layers, CuZn3 and A12Cu are formed on the Cu side when the A1 content in the filler metals is 2% and more than 15%, respectively. The relationship between intermetallic compounds on Cu side and Zn-xA1 filler metals was investigated.

Microstructure and mechanical properties of dissimilar pure copper/1350 aluminum alloy butt joints by friction stir welding

The dissimilar friction stir welding of pure copper/1350 aluminum alloy sheet with a thickness of 3 mm was investigated. Most of the rotating pin was inserted into the aluminum alloy side through a pin-off technique, and sound welds were obtained at a rotation speed of 1000 r/min and a welding speed of 80 mm/min. Complicated microstructure was formed in the nugget, in which vortex-like pattern and lamella structure could be found. No intermetallic compounds were found in the nugget. The hardness distribution indicates that the hardness at the copper side of the nugget is higher than that at the aluminum alloy side, and the hardness at the bottom of the nugget is generally higher than that in other regions. The ultimate tensile strength and elongation of the dissimilar welds are 152 MPa and 6.3%, respectively. The fracture surface observation shows that the dissimilar joints fail with a ductile-brittle mixed fracture mode durin~ tensile test.

Effect of joining temperature on microstructure and properties of diffusion bonded Mg/Al joints

The joining of AZ31B Mg alloy to 6061 Al alloy was investigated at different joining temperatures by vacuum diffusion bonding method. The microstructures of Mg/Al dissimilar joints were studied by means of optical microscopy （OM）, scanning electron microscopy （SEM） and energy dispersive X-ray （EDX）. The results show that the thickness of each layer in the diffusion zone increases with the increase of joining temperature, and the microstructure changes obviously. At joining temperature of 440 °C, the diffusion zone is composed of Mg2Al3 layer and Mg17Al12 layer. At joining temperatures of 460 and 480 °C, the diffusion zone is composed of Mg2Al3 layer, Mg17Al12 layer, eutectic layer of Mg17Al12 and Mg-based solid solution. The width of high-hardness zone in the joint increases with increasing joining temperature, and the micro-hardnesses at different locations in the diffusion zone are significantly different. The joining temperature of 440 °C offers the highest tensile strength of 37 MPa, and the corresponding joint exhibits brittle fracture at the intermetallic compound layer of Mg17Al12.

Effect of post-weld heat treatment on microstructure and properties of Ti-23Al-17Nb alloy laser beam welding joints

The mechanical properties of Ti-23Al-17Nb (mole fraction,%) laser beam welding alloy joint at room temperature are comparable to that of the base materials.However,the strength and ductility of the as-welded joint deteriorate seriously after high temperature circulation.The effect of post-welded heat treatment on the microstructure and mechanical properties of the joint was investigated.The heat treatment was taken at 980 ℃ for 1.5 h,then furnace cooling and air cooling were performed separately.The results indicate that proper post-welded heat treatment improves the ductility of the joint at high temperature.

Microstructural zones and tensile characteristics of friction stir welded joint of TC4 titanium alloy

TC4 titanium alloy was friction stir welded using a W-Re pin tool,and the defect-free weld was produced with proper welding parameters.The joint consists of stir zone,heat affected zone and base material.The stir zone is characterized by equiaxed dynamically recrystallized α phases and transformed β phases with fine α+β lamellar microstructure.The microstructure of the heat-affected zone is similar to that of the base material,but there is an increase in the volume fraction of β.Transverse tensile strength of the joint is 92% that of the base material,and the joint is fractured in the stir zone and the fracture surface possesses typical plastic fracture characteristics.The stir zone is the weakest part of the joint,through which the tensile characteristics of the TC4 joint can be explained.

Rotating extrusion technique and its effect on quality of aluminum alloy thin-plate weldments

A new technique named rotating extrusion was proposed that uses rotating extrusion action to rectify residual distortion of aluminum alloy thin-plate weldments to improve mechanical properties of welded joints. The basic principle and device of rotating extrusion were introduced. The residual distortion and stresses in rotating extrusion weldments were compared with those in conventional weldments. The differences in microstructure and mechanical properties between conventional welded joints and rotating extrusion welded joints were investigated and analyzed in order to make clear the effect of rotating extrusion on the performance of aluminum alloy weldments. Experimental results show that rotating extrusion can enhance the hardness and tensile strength of aluminum alloy welded joints evidently. This method has also potential effect on extending the life of welded structures.

Influence of tool pin design on properties of dissimilar copper to aluminum friction stir welding

Dissimilar friction stir welding （FSW） of copper and aluminum was investigated by nine different tool designs, while the rest of the process parameters were kept constant. Mechanical and metallurgical tests such as macrostructure, microstructure, tensile test, hardness, scanning electron microscope and electron X-ray spectrographs were performed to assess the properties of dissimilar joints. The results exhibited that, the maximum joint strength was achieved by the tool of cylindrical pin profile having 8 mm pin diameter. Besides, the fragmental defects increased as the number of polygonal edges decreased, hence the polygonal pin profiles were unsuitable for dissimilar FSW butt joints. Furthermore, the tensile strength increased as the number of polygonal edges increased. Stir zone of polygonal pin profiles was hard and brittle relative to cylindrical tool pin profiles for same shoulder surface. Maximum hardness of HV 283 was obtained at weld made by the polygonal square pin profile. The hard and brittle intermetallic compounds （IMCs） were prominently presented in the stir zone. Phases of IMCs such as CuAl, CuAl2, Cu3Al and Cu9Al4 were presented in the stir zone of dissimilar Cu-Al joints.

Effect of pin profile and process parameters on microstructure and mechanical properties of friction stir welded Al-Cu joints

In friction stir welding(FSW), pin profile has more influence on material flow especially in welding of dissimilar materials with different yield strengths. In the dissimilar welding of aluminium and copper, the material flow behaviour is complex to understand and thus a study is needed to reveal the mechanism of flow behaviour and the resultant mechanical properties. Three pin profiles, whorl pin profile(WPP), plain taper pin profile(PTP) and taper treaded pin profile(TTP) were chosen. The effects of pin profile on the microstructure, microhardness and tensile properties were studied. Optical microscope, scanning electron microscope, X-ray diffraction and EDS analysis were used to characterize the microstructural features. Among the three pin profiles, PTP profile results in defect-free stir zone and maximum joint properties of yield strength of 101 MPa, tensile strength of 116 MPa and joint efficiency of 68% compared with the other pin profiles. However, the microhardness plots are more or less identical for all the pin profiles but follows fluctuating trend. This is attributed to the heterogeneous distribution of hard Cu particle. The superior joint properties are mainly attributed to the defect-free stir zone formation and dispersion strengthening.

Influence of flash trap profiles on joint properties of friction welded CP-Ti tube to 304L stainless steel tube plate using external tool

Titanium tube and stainless steel tube plate were welded by an innovative friction welding of tube to tube plate using an external tool (FWTPET). Copper was used as an interlayer for joining the dissimilar materials and also to minimize the effect of intermetallics formed at the joint interface. The process parameters that govern FWTPET process are plunge rate, rotational speed, plunge depth, axial load and flash trap profile. Among them, the flash trap profile of the tube has a significant influence on the joint integrity. Various flash trap profiles like vertical slots, holes, zig-zag holes, and petals were made on the titanium tube welded to the stainless steel tube plate. Macroscopic and microscopic studies reveal defect-free joints. The presence of copper interlayer and intermetallics was evident from X-ray diffraction (XRD), scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS) studies. The microhardness survey was presented across and along the interface. A novel test procedure called “plunge shear test” was developed to evaluate the joint properties of the welded joints. The highest shear fracture load of 31.58 kN was observed on the sample having petals as flash trap profile. The sheared surfaces were further characterized using SEM for fractography.

Influences of diffusion bonding process parameters on bond characteristics of Mg-Cu dissimilar joints

In many circumstances,dissimilar metals have to be bonded together and the resulting joint interfaces must typically sustain mechanical and/or electrical forces without failure,which is not possible by fusion welding processes.The melting points of magnesium(Mg)and copper(Cu)have a significant difference(nearly 400℃)and this may lead to a large difference in the microstructure and joint performance of Mg-Cu joints.However,diffusion bonding can be used to join these alloys without much difficulty.This work analyses the effect of parameters on diffusion layer thickness,hardness and strength of magnesium-copper dissimilar joints.The experiments were conducted using three-factor,five-level,central composite rotatable design matrix.Empirical relationships were developed to predict diffusion layer thickness,hardness and strength using response surface methodology.It is found that bonding temperature has predominant effect on bond characteristics.Joints fabricated at a bonding temperature of 450℃, bonding pressure of 12 MPa and bonding time of 30 min exhibited maximum shear strength and bonding strength of 66 and 81 MPa, respectively.

Fatigue behaviour of welded joints assembled by longitudinal corrugated plates

Fatigue is usually the cause for the cracks identified at bridge elements in service. With an increase in the introduction of corrugated steel web girders in recent highway bridge construction, the understanding of the fatigue behaviour of welded details in such structures becomes an important issue for the design. The typical welded details were represented as welded joints assembled by longitudinal corrugated plates. All the experiments were performed under fatigue loading using a servo-control testing machine. The test results from the failure mode observation with the aid of infrared thermo-graph technology show that the failure manner of these welded joints is comparable to that of the corrugated steel web beams reported previously. It is indicated from the stiffness degradation analysis that the welded joints with larger corrugation angle have higher stiffness and greater stiffness degradation in the notable stiffness degradation range. It is shown from the test S-N relations based on the free regression and forced regression analyses that there is a good linear dependence between lg(N) and lg(ΔS). It is also demonstrated that the proposed fracture mechanics analytical model is able to give a prediction slightly lower but on the safe side for the mean stresses at 2 million cycles of the test welded joints.

Effects of rapid solidification process and 0.1%Pr/Nd addition on characteristics of Sn-9Zn solder alloy and interfacial properties of Cu/solder/Cu joints

Rapidly solidified Sn-9Zn-0.1Pr(/Nd) alloy foils were prepared by melt-spinning method. Through comparison, the effects of rapid solidification process and 0.1%Pr/Nd(mass fraction) addition on the microstructure, thermodynamic characteristic of Sn-9Zn solder alloy were analyzed. The tensile-shear tests were used to evaluate the mechanical properties of solder/Cu joints. The results show that the rapid solidification process can greatly refine the microstructure of Sn-9Zn-0.1Pr(/Nd) alloys. After rapid solidification, the effects of Pr/Nd addition on microstructure are depressed. The pasty range of the rapidly solidified Sn-Zn-RE solders is also reduced significantly. The mechanical properties of solder/Cu joints are obviously improved using the rapidly solidified Sn-9Zn-0.1Pr(/Nd) solder alloy, which results in the formation of uniform interface. The promotion effect of Nd addition in Sn-9Zn alloy on the interfacial reaction of solder/Cu joint is more remarkable than that of Pr.

Relationship between interfacial structure and property of steel-mushy Al-28Pb bonding pate

The interfacial properties of steel-mushy Al-28Pb bonding plate with different interfacial structures, and the influence of ratio of Fe-Al compound at the interface on interfacial shear strength were investigated. The results show that there is a nonlinear relationship between the ratio of Fe-Al compound at the interface and the interfacial shear strength. When the ratio of Fe-Al compound at the interface is smaller than 71.4%, with the increase of the ratio of Fe-Al compound at the interface, the interfacial shear strength increases gradually; when the ratio of Fe-Al compound at the interface is larger than 71.4%, with the increase of the ratio of Fe-Al compound at the interface, the interfacial shear strength decreases continuously; when the ratio of Fe-Al compound at the interface is 71.4%, the largest interfacial shear strength 70.2MPa is obtained.