Three‑Dimensional Numerical Study on the Metal Rotating Spray Transfer Process of High‑Current GMAW

A three-dimensional numerical model based on the volume-of-fluid(VOF)method is typically preferred for studying high-current gas metal arc welding(GMAW)metal transfer mechanism and then controlling it.It is informed that the rotating spray transfer is extremely complicated,and some researchers have focused on simplified models without considering the energy conservation to make analysis manageable for the unstable metal transfer process.Using our created numerical model,the metal transfer of high-current GMAW with shielding gas of different conductivities has been studied by analyzing acting forces and fluid flows in the metal liquid column,especially for the contributions of the self-induced electromagnetic force,equivalent volume force of the capillary pressure of the surface tension(Named surface tension force in this work),static arc pressure.It is found that the unbalanced electromagnetic force greatly promotes the metal rotating motion in 500 A metal inert gas(MIG)welding with pure argon shielding gas and it pushes the metal liquid column to rotate.Considering the arc constricting effect in active shielding gas by simply changing the arc conductivity,it is found that the metal liquid column no longer rotates,it turns to swing since the unbalanced electromagnetic force is large enough to break the rotating motion.The calculated results of the metal liquid column deflected angle and rotating/swing frequency agree well with the experiment of high-speed camera observations.

Determining the boundaries of globular-to-spray transfer in robotic GMAW

Robotic gas metal arc welding （GMAW） experiments were conducted using an ERTOS-1 electrode with Ar ＋ 10% CO2 shielding gas, and the welding current and arc voltage signals were collected by a data acquisition system. The boundaries between globular transfer and spray transfer in terms of the welding current and arc voltage were determined according to the waveform of electric signals and the Fourier transform results of arc voltage. The optimum welding parameters for the two transfer modes were obtained, which laid a foundation for the numerical simulation and control of GMAW process.

基于RP的电弧喷涂法快速制造模具的精度研究

研究了基于快速原型和金属电弧喷涂(RP-AMS)法快速制造金属模具过程中的精度问题。从理论和实验两方面对模具制造精度有直接影响的光固化原型“抛光误差”进行了定量分析并给出减小抛光误差的补偿方法;以实验为基础,合理利用电弧喷涂法制造模具过程中的收缩特性和微膨胀特性,可以达到较好的综合误差控制效果。

冷金属过渡电弧增材制造技术研究进展

针对冷金属过渡(CMT)电弧增材制造技术存在的表面成形质量差、制件内部易形成孔隙等冶金缺陷、微观组织与性能调控困难等问题,从控形与控性两个方面出发,对CMT电弧增材制造技术研究进展进行了综述。首先,对CMT技术的原理及特点进行了分析与梳理;然后,对CMT电弧增材制造技术在“形”与“性”方面的调控方式进行了总结,具体阐述了制件的表面成形质量、内部冶金缺陷、微观组织与性能3个方面的调控方式;最后,通过对现有调控方式的局限性进行了分析,提出了CMT电弧增材制造技术的未来发展趋势。研究结果表明:未来CMT电弧增材制造技术的发展趋势包括:(1)“形”与“性”协同控制与优化;(2)CMT电弧增材制造难焊材料及复合材料;(3)调控方式的理论机制规律。