试板横焊操作要领分析与研究

试板的横焊是焊接技能教学与培训中学生必须掌握的基本技能之一。在大量实践的基础上系统总结试板横焊的操作过程、焊接规范、操作要领等,目的在于帮助有志于焊接事业的未来同行们快速掌握操作要领、提升技能水平,取得教与学的质量与效率提高的双赢。

焊条电弧焊仰焊试板的焊接

试板仰焊是省级焊工比武试件中技术要求最高、操作难度最大的竞技项目，它最能反映施焊焊工的操作技术水平。一般说来，凡能完成试板仰焊的焊工，基本上能够胜任压力容器制造或维修中各种位置的焊接，因此具有非常重要的现实意义。

试板焊条电弧焊仰焊操作要领与实践创新

仰焊是焊接位置处于水平下方的焊接,焊接操作人员仰视焊接过程的一种焊接方法,是四种基本位置焊接中消耗体能和操作难度最大的一种焊接方法。在不断实践的基础上,总结试板仰焊的操作要领并对部分关键操作进行大胆的实践创新,目的在于帮助具有一定焊接水平的学习者快速掌握仰焊操作要领,提升技能水平。

焊条电弧焊仰焊试板的焊接

就焊条电弧焊仰焊位置所采用的二种焊接方法即连弧法及熄弧法进行对比,针对其易产生的缺陷进行有效的分析,提出了需要注意的焊接操作要点,经过实践证明此办法是可行的。

电机风扇铸铝叶片的补焊

针对电机风扇叶片的断裂、测定叶片的化学成分、模拟风扇叶片的特性进行了机械性能测试、金相分析和安全性计算。在产品补焊前进行模拟叶片试焊和X射线探伤。合格后设计工装夹具进行叶片补焊,补焊的叶片满足设计要求。

ABB推出新型焊接机器人控制软件VirtualArc

众所周知,电弧焊接机器人工作速度快、精度高、可靠性强,是工厂里的制造能手。但鲜为人知的是,让这位能手"学会"如何工作却不是件容易的事。

Comparison of explosive welding of pure titanium/SUS 304 austenitic stainless steel and pure titanium/SUS 821L1 duplex stainless steel

Pure commercial titanium was welded with two types of stainless steel,namely SUS 304 austenitic stainless steel and SUS 821L1 duplex stainless steel.The wavy interface of SUS 821L1 was smaller than that of SUS 304.The vortex zone was observed from both longitudinal and transverse directions,and its composition was analyzed.The interface of Ti/SUS 821L11 was able to bear 401−431 MPa shear load while that of Ti/SUS 304 could withstand 352−387 MPa.The weldability window was used to analyze experimental phenomenon.Furthermore,the smoothed particle hydrodynamics(SPH)numerical simulation method was used to simulate the wavy interface.The trend of wavelength and amplitude change with strength and the stand-offs was consistent with the experimental results.

Comparison of experimental methods to evaluate seam welds quality in extruded profiles

The wedge and bulge expansion tests were compared in the assessment of the seam welds strength in a tubular profile extruded at two ram speeds.In the wedge test,the expansion was determined by moving a conical punch into the tube until the specimen fracture.In the bulge test,a hydrostatic tensile stress state was applied by expanding the specimen with an internal rubber plug.The two methodologies were compared in terms of load and hoop strain at fracture and by detecting the fracture morphology and location.Then,the effect of a number of design parameters was investigated in order to evaluate the robustness of the standard testing conditions.For both tests,ductile fractures appeared in the seam welds location,but the bulge test was more robust and conservative with respect to the wedge test,showing less scattered data.Thus,the performances of a second die for the tube profile,designed to optimize the seam welds quality,have been successfully assessed by the bulge test and results compared to those achieved by a novel numerical quality index,coming to a final good matching.

Comparing the reinforcement capacity of welded steel mesh and a thin spray-on liner using large scale laboratory tests

Steel mesh is used as a passive skin confinement medium to supplement the active support provided by rock bolts for roof and rib control in underground coal mines. Thin spray-on liners(TSL) are believed to have the potential to take the place of steel mesh as the skin confinement medium in underground mines.To confirm this belief, large scale laboratory experiments were conducted to compare the behaviour of welded steel mesh and a TSL, when used in conjunction with rock bolts, in reinforcing strata with weak bedding planes and strata prone to guttering, two common rock conditions which exist in coal mines. It was found that while the peak load taken by the simulated rock mass with weak bedding planes acting as the control sample(no skin confinement) was 2494 kN, the corresponding value of the sample with 5 mm thick TSL reinforcement reached 2856 kN. The peak load of the steel mesh reinforced sample was only2321 kN, but this was attributed to the fact that one of the rock bolts broke during the test. The TSL reinforced sample had a similar post-yield behaviour as the steel mesh reinforced one. The results of the large scale guttering test indicated that a TSL is better than steel mesh in restricting rock movement and thus inhibiting the formation of gutters in the roof.

State of the art of impact testers for spot welds

Impact testing is a primary method to evaluate the impact property of resistance spot welding,which is an important quality index in automotive industry.For testing impact properties of spot welds,many customized testers have been developed.This paper summarized some of the impact testers reported in open literatures and the emphasis was placed on the equipment structures,functions,technical parameters,advantages and disadvantage,etc.Some key issues about the development of the testers such as kinematic energy input mode,fixture design,combined load testing,sensor and data acquisition were discussed.Finally,the problems and prospects in the research and development of impact testers for spot welds were pointed out.

Weld Characteristics and NC Bending Formability of QSTE340 Welded Tube

The mechanical characteristics of the weld joint were investigated by tensile test, microstructure test, and microhardness test. The welded tube NC bending tests were carried out to evaluate the weld on the formability of the QSTE340 welded tube. The results show that the wall thinning degree, cross-sectional deformation and springback angle increase significantly as the weld line is located on the outside of the bend compared with that located on the middle and inside, and the welded tubes produce nearly identical performance as the weld line is located on the middle and inside. The wall thickening degree decreases much as the weld line is located on the inside of the bend. So the welded tube can acquire good bending formability as the weld line is located in the region away from the outside of the bend.

The Friction Welding Method with Intermediate Material

For the purpose of improving the defects of the conventional friction welding method, the new friction welding technology has been examined. That is, the aim of the study is producing the joint of dissimilar materials evaluated to be difficult for friction welding and non-round shape joints. In this process, after the intermediate material generates the independent friction heat on every side of the specimens, it is removed instantaneously and upset process begins to weld the specimens for a joint. In this study, similar joint of A2017 aluminum alloy and one of S45C steel were examined. On the other hand, thermal elastic-plastic stress analysis by the finite element method was carried out using ANSYS mechanical.

Experimental and Finite Element Analysis of a T-Joint Welding

This paper presents the Finite Element （FE） modeling of a two-seam welding process for a T-joint with a V chamfer preparation： The aim of the model is to predict the deformations, distortions and residual stresses resulting from the welding of the plates and experiments have been carried out in order to compare to the FE model. The ＂birth and death＂ method is used in ANSYS to simulate the filler metal deposition and the heat generation and weld pool simulation are conducted accordingly with the double ellipsoid configuration as proposed by Goldak et al. The model takes into consideration the temperature dependent non-linear material properties and uses a new formulation to compute the temperature dependent combined coefficient of heat loss. Improvements in the calculation are achieved by combining two types of meshing. The FE simulation is divided into two consecutive parts： the thermal simulation followed by the structural simulation. The results of the numerical model are compared to experiments.

Study on Interfacial Bonding State of Ag-Cu in Cold Pressure Welding

The interfacial bonding of Ag-Cu (they are limited soluble) formed by the technology of cold pressure welding was discussed from the point of metallurgic view in this paper. Meanwhile, tensile test and microscopic test were adopted for studying the state of interfacial bonding, suggesting that the joint of Ag-Cu has not only strong welding joint but also atomic diffusion on the interface. For Ag-Cu, the interaction of dislocation caused by plastic deformation will cause the strain and the vibration of microconstructer defects, accompanied by emitting energy. The energy increases the atomic action and the amplitude of atomic vibration, and the result is that the atom can diffuse to several lattice parameters deep from interface to inner metals. Therefore, under the condition of chemical potential gradient, the special technique, cold pressure welding rather than basic requirements of diffusion should be taken into account. During the cold pressure welding, plastic deformation plays an important role for it causes the metals′ displacement, crystal defects, further activates the surface atoms. Finally, the fracture of atomic bonding leads to the atomic exchange and diffusion between the new metals′ surfaces.In other words the metals Ag,Cu can achieve solidate bonding by cold pressure welding accompanied by the atomic diffusion. Moreover, theoretical analysis and calculation on the basis of thermodynamics, crystallogy, so- lid physics,etc, have been applied to calculate the amount of atomic diffusion, which has further proved the testing results that joint Ag-Cu has strong bonding strength through the mechanism of atomic diffusion.

Influence of plasma-MIG welding parameters on aluminum weld porosity by orthogonal test

The plasma-MIG welding torch was developed.5A06 aluminum alloys with V-grooves were welded in a single pass in the plasma-MIG welding process and the joints were examined by X-ray diffractometry analysis and mechanical tests.The orthogonal experimental design was used to study the influence of plasma-MIG welding parameters on the aluminum weld porosity.The mixed orthogonal matrix L16(4 4×2 3) and analysis of variance (ANOVA)technique were employed to optimize the welding parameters.The experimental results indicate that the effect of plasma gas flow rate is dominant,the secondary factors are MIG welding voltage,welding speed,wire feed rate and plasma current in turn.Confirmation experiments were conducted under optimum conditions and there was almost no porosity in the welded joints,thus good mechanical performance joints were obtained.

Health condition monitoring with multiple physical signals in tensile test for double-material friction welding

The manifold physical signals including micro resistance,infrared thermal signal and acoustic emission signal in the tensile test for double-material friction welding normative samples were monitored and collected dynamically by TH2512 micro resistance measuring apparatus,flir infrared thermal camera and acoustic emission equipment which possesses 18 bit PCI-2 data acquisition board.Applied acoustic emission and thermal infrared NDT(non-destructive testing) means were used to verify the feasibility of using resistance method and to monitor dynamic damage of the samples.The research of the dynamic monitoring system was carried out with multi-information fusion including resistance,infrared and acoustic emission.The results show that the resistance signal,infrared signal and acoustic emission signal collected synchronously in the injury process of samples have a good mapping.Electrical,thermal and acoustic signals can more accurately capture initiation and development of micro-defects in the sample.Using dynamic micro-resistance method to monitor damage is possible.The method of multi-information fusion monitoring damage possesses higher reliability,which makes the establishing of health condition diagnosing and early warning platform with multiple physical information monitoring possible.

3D finite element analysis of the residual stresses in butt-welded plates with modeling of the electrode-movement

In this paper the residual stresses in a butt-welded plate of 2.25Cr 1Mo has been analyzed using a 3D and transient finite element (FE) model.Also the effect of the welding-electrode speed has been studied using death and birth of FEs.For this purpose,a coupled thermo-mechanical FE solution has been used to obtain the temperature distribution and the resulting residual stresses.Also,the variations of the physical properties of the material with temperature have been taken into account.Results show that the residual stresses in the heat affected zone (HAZ) are maximum and change along the weld and also in the plate-thickness.It has been shown that use of the 3D and transient model will lead to more accurate and realistic results which are well compared with the experimental test data.