Effect of welding current on morphology and microstructure of Al alloy T-joint in double-pulsed MIG welding

The effect of current on the morphology of Al alloy T-joint in double-pulsed metal inert gas（DP-MIG） welding process was investigated by simulation and experiment.A three-dimensional finite element model and the DP-MIG heat source of double-ellipsoidal volumetric model were developed to simulate the temperature and stress fields under different welding conditions.The macro-morphology and microstructure of welding joints at the corresponding currents were observed in the experiment.The results show that the best condition is at an average current of 90 A and current difference of 40 A,when the maximum temperature is 200 °C higher than the fusion points,with the temperature difference of about 100 °C and stress change of 10 MPa between thermal pulse and thermal base.Under these conditions,Al alloy T-joint with proper fusion condition has smooth fish-scale welding appearance and finer microstructure.Furthermore,the thermal curves and stress distribution in the experiment are consistent with those in the simulation,verifying the precision of the welding simulation.

Formation, microstructure and mechanical properties of double-sided laser beam welded Ti-6Al-4V T-joint

The T-joints of Ti?6Al?4V alloy were manufactured by double-sided synchronized laser beam welding with the homologous filler wire. The formation, microstructure and mechanical properties of welded joints as well as the correlations of each other were investigated. The results indicate that the quality of weld seams is good without defects such as discontinuity, beading, visible cracks or porosity, which is linked to the steady molten pool behavior and droplet transition. The morphologies of the heat affected zone (HAZ) located on the skin and stringer are disparate. The microstructure of the HAZ and fusion zone (FZ) is mainly comprised of acicular martensiticα′ phases. The microhardness of the HAZ and FZ is higher than that of the base metal (BM) and reaches a maximum value at the HAZ near FZ on the stringer. The tensile specimens along the skin and stringer fractured at the BM with ductile fracture surfaces.

Numerical simulation of temperature fields for T-joint during TIG welding of titanium alloy

Three-dimensional finite element model was established to simulate temperature fields of T-joint titanium sheets during TIG welding with finite element method （FEM） software. Temperature dependent material properties and the effect of latent heat were considered. A technique of element birth and death was used to simulate the process of welded metal filling. Dynamic variation process of temperature fields during T1G welding was achieved. The simulated results agreed well with the measured results.

Mechanical Stress Analysis of a 600MW Supercritical Boiler Superheater Outlet Header

The mechanical stress distribution and the stress concentrations of the superheater outlet header of a 600MW supercritical boiler were analyzed by the finite element method. The results showed that the stress concentrated at the inside conjunction area between the pipe and the header cylinder , and the value of the maximum mechanical stress concentration factor is 2.51.

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.

An Analysis of the Influence of Protective Films on the Inner Surfaces of CCPP Headers and Steam Pipelines on Their Thermal Stress State

At present, the main attention of researchers is paid to the deterioration of heat transfer when heating the outer surface of the pipe with the liquid or steam, flowing inside it, in the presence of films or deposits on its inner surface. However, when pipe is heating by heat carrier medium, flowing inside it, film on the inner pipe surface serve a dual protective function, protecting the pipe from corrosion and reducing its thermal stress. The article represents the results of the computational analysis of protective films influence on the thermal stressed state of headers and steam pipelines of combined-cycle power plants (CCPP) heat-recovery steam generators at different transient operating conditions particularly at startups from different initial temperature states and thermal shock. It is shown that protective films have a significant influence on the stresses magnitude and damage accumulation mainly for great temperature disturbances (for thermal shock). Calculations were carried out at various thicknesses of films and assuming that their thermal conductivity less than thermal conductivity of the steam pipelines metal.

Transient out-of-plane distortion of multi-pass fillet welded tube to pipe T-joints

The out-of-plane distortion induced in a multi-pass circumferential fillet welding of tube to pipe under different weld sequences and directions was studied using Finite Element Method(FEM) based Sysweld software and verified experimentally. The FEM analyses consisted of thermal and mechanical analyses.Thermal analysis was validated with experimental transient temperature measurements. In the mechanical analysis, three different weld sequences and directions were considered to understand the mechanism of out-of-plane distortion in the tube to pipe T-joints. It was learnt that the welding direction plays a major role in minimizing the out-of-plane distortion. Further, during circumferential fillet welding of the tube to pipe component, the out-of-plane distortion generated in the x direction was primarily influenced by heat input due to the start and stop points, whereas the distortion in the z direction was influenced by time lag and welding direction. The FEM predicted distortion was compared with experimental measurements and the mechanism of out-of-plane distortion was confirmed.

Numerical analysis of temperature profile and weld dimensions in laser ＋ GMAW hybrid welding of aluminum alloy T-joint

The temperature fields in the transient state and weld dimensions in laser ＋ gas metal arc welding （GMAW） hybrid welding of aluminum alloy T-joint for different welding conditions were calculated using the developed heat source model, and the effect of welding speed on them was analyzed. The results show that the temperature field for the first weld pass only shows the feature of GMAW and the one for the second weld pass has the characteristics of both laser welding and GMAW. Welding speed can affect greatly weld dimensions and temperature distribution. When welding speed reaches 3.5 m/min, the fusion zones of two weld passes are separated and the maximum peak temperature of thermal cycle on the workpiece surface decreases largely.

A Study on Control System of Robot Working Unit for Automatically Welding Nipples onto Header of Boiler

The difficult problem of automatically welding nipples onto the header is first analyzed in this paper, and then the overall structure and operating principle of the robot working unit are introduced. The robot and the measuring device are located by employing the traveling lorry, and this unit enables the robot to adjust the tracks according to the errors received from the measuring device, and then the nipples are welded properly. This paper emphases on the development of the master-slave control system, in which the prograrmmable Logic Controller (PLC) is used as the master computer.

Hopping-Aware Cluster Header Capability for Sensor Relocation in Mobile IoT Networks

Mobile sensor nodes such as hopping sensors are of critical importance in data collection.However,the occurrence of sensing holes is unavoidable due to the energy limitation of the nodes.Thus,it is evident that the relocation of mobile sensors is the most desirable method to recover the sensing holes.The previous research conducted by the authors so far demonstrated the most realistic hopping sensor relocation scheme,which is suitable for the distributed environment.In previous studies,the cluster header plays an essential role in detecting the sensing hole and requesting the neighboring cluster to recover the sensing hole that occurred in the sensor node.However,the limitations of the cluster header in the previously proposed relocation protocol are not fully considered.Because the cluster header jumps more frequently than non-header nodes,its energy con-sumption is relatively high compared to other nodes.Therefore,it is most likely to lead to header node failure and can lead to data loss on the network.In this paper,the jumping ability and energy consumption of the cluster header are seriously considered.Additional ability to replace cluster headers in case of failure is also implemented.Simulation results show that the data collection time can be further increased,which demonstrates the validity of the proposed algorithms.

The trend of mechanizing road header for coal mine entry

In discussing coal mine entry construction with rock bolt technology, examinedthe craft and machinery problems as well as the conditions in which to use each kind ofmachine and tool.It exposed the intrinsic flaws of the widely used road header.The problemis that it was designed according to early timbering support state but is not suitable forrock bolt technology.The way to improve the function of existing road headers is notthrough parallel operations but using the SUDM (Shield Union Driving Machine), which isa new machine that improves construction.This article proposed a few solutions in designto solve this problem.

STUDY ON THE METHODS OF STRUCTURALDYNAMIC MODIFICATION OPTIMIZATION OF ROAD HEADERS

In this paper, taking AM-50 Road Heaer as an example, the metheds of structural dynamic modification optimization for road headers are studied using experimental modal analysis and physical parameters analysis. The machine’s modal model and lumped mass model are established and the vibration response simulation is calculated for the two models with the load spectral measured. On the above basis, the dynamic parameters of the models are optimised and some useful results have been obtained.The research methods in this paper can be used for the reference to the other lager type mining machines.

Axial compression physical testing of traditional and bird beak SHS T-joints

The static tests of nine traditional and bird beak square hollow structure(SHS) T-joints with different β values and connection types under axial compression at brace end were carried out. Experimental test schemes, failure modes of specimens, jack load-vertical displacement curves, jack load-deformation of chord and strain intensity distribution curves of joints were presented. The effects of β and connection types on axial compression property of joints were studied. The results show that the ultimate axial compression capacity of common bird beak SHS T-joints and diamond bird beak SHS T-joints is larger than that of traditional SHS T-joint specimens with big values of β. The ultimate axial compression capacity of diamond bird beak SHS T-joints is larger than that of common bird beak SHS T-joints. As β increases, the increase of the ultimate axial compression capacity of diamond bird beak SHS T-joints over that of common bird beak joints grows. The ultimate axial compression capacity and the initial axial stiffness of all kinds of joints increase as β increases, and the initial axial stiffness of the diamond bird beak SHS T-joints is the largest. The ductilities of common bird beak and diamond bird beak SHS T-joints increase as β increases, but the ductility of the traditional SHS T-joints decreases as β increases.

Impact of Portable Executable Header Features on Malware Detection Accuracy

One aspect of cybersecurity,incorporates the study of Portable Executables(PE)files maleficence.Artificial Intelligence(AI)can be employed in such studies,since AI has the ability to discriminate benign from malicious files.In this study,an exclusive set of 29 features was collected from trusted implementations,this set was used as a baseline to analyze the presented work in this research.A Decision Tree(DT)and Neural Network Multi-Layer Perceptron(NN-MLPC)algorithms were utilized during this work.Both algorithms were chosen after testing a few diverse procedures.This work implements a method of subgrouping features to answer questions such as,which feature has a positive impact on accuracy when added?Is it possible to determine a reliable feature set to distinguish a malicious PE file from a benign one?when combining features,would it have any effect on malware detection accuracy in a PE file?Results obtained using the proposed method were improved and carried few observations.Generally,the obtained results had practical and numerical parts,for the practical part,the number of features and which features included are the main factors impacting the calculated accuracy,also,the combination of features is as crucial in these calculations.Numerical results included,finding accuracies with enhanced values,for example,NN_MLPC attained 0.979 and 0.98;for DT an accuracy of 0.9825 and 0.986 was attained.

Secure Web Application Technologies Implementation through Hardening Security Headers Using Automated Threat Modelling Techniques

This paper investigates whether security headers are enforced to mitigate cyber-attacks in web-based systems in cyberspace. The security headers examined include X-Content-Type-Options, X-Frame-Options, Strict-Transport-Security, Referrer-Policy, Content-Security-Policy, and Permissions-Policy. The study employed a controlled experiment using a security header analysis tool. The web-based applications (websites) were analyzed to determine whether security headers have been correctly implemented. The experiment was iterated for 100 universities in Africa which are ranked high. The purposive sampling technique was employed to understand the status quo of the security headers implementations. The results revealed that 70% of the web-based applications in Africa have not enforced security headers in web-based applications. The study proposes a secure system architecture design for addressing web-based applications’ misconfiguration and insecure design. It presents security techniques for securing web-based applications through hardening security headers using automated threat modelling techniques. Furthermore, it recommends adopting the security headers in web-based applications using the proposed secure system architecture design.

Generation and Application of A Standardized Load-Time History to Tubular T-joints in Offshore Platforms

Marine structures are mostly made of metals and always experience complex random loading during their service periods. The fatigue crack growth behaviors of metal materials have been proved from laboratory tests to be sensitive to the loading sequence encountered. In order to take account of the loading sequence effect, fatigue life prediction should be based on fatigue crack propagation（FCP） theory rather than the currently used cumulative fatigue damage（CFD） theory. A unified fatigue life prediction（UFLP） method for marine structures has been proposed by the authors＇ group. In order to apply the UFLP method for newly designed structures, authorities such as the classification societies should provide a standardized load-time history（SLH） such as the TWIST and FALSTAFF sequences for transport and fighter aircraft. This paper mainly aims at proposing a procedure to generate the SLHs for marine structures based on a short-term loading sample and to provide an illustration on how to use the presented SLH to a typical tubular T-joint in an offshore platform based on the UFLP method.

Refrigerant Distribution Characteristics in Vertical Header of Flat-Tube Heat Exchanger without Internal Protrusion

A heat exchanger that arranges flat tubes horizontally has a vertical header that distributes the refrigerant to each tube. When the heat exchanger works as an evaporator, differences in flow conditions at each branch, such as the ratio and distribution of vapor and liquid, due to the differences in densities and momentums of vapor and liquid in the two-phase flow make equal distribution difficult. This paper describes the distribution characteristics of a four-branch header that has a rectangular cross-section without the internal protrusion of flat tubes in the case of the inflow of the refrigerant R32 from the bottom of the header by using an equipment that can estimate the distribution ratio of the liquid and vapor phase to each branch. This paper also discusses the distribution characteristics on the basis of the flow visualization in the header. The flow visualization shows that a liquid level that contains vapor phase exists in the header and affects the distribution greatly.

钠冷快堆小栅板联箱压降对组件流量分配影响研究

钠冷快堆堆芯采用大栅板联箱、小栅板联箱和组件的三级流量分配方式,小栅板联箱的压降影响组件的流量分配,进而影响堆芯的安全,因此进行钠冷快堆小栅板联箱压降对组件流量分配影响研究有重要意义。根据小栅板联箱压降造成组件流量分配偏差的机理,提出了理论计算模型和堆芯组件优化设计的方法,并针对中国实验快堆(CEFR)堆芯进行了组件压降的优化设计,通过优化设计降低了CEFR燃料组件流量分配负偏差。结果表明,在进行钠冷快堆堆芯热工水力设计时,需要结合实际堆芯布置分析组件压降设计值的优化方向,并进行敏感性分析,以确定组件的最优设计压降,将小栅板联箱压降对组件流量分配影响降低到最低程度。本文结果可为钠冷快堆堆芯热工水力设计提供参考。

机械-液压组合式大豆割台仿形装置设计与仿真

针对传统大豆割台仿形范围有限导致割台损失大、粮箱内含杂量高等问题,设计了一种机械-液压组合式大豆割台仿形装置,通过分段仿形提高了大豆割台的仿形范围。基于大豆割台几何关系,构建了割台液压油缸伸缩量和割台离地高度变化量之间的函数关系,为割台高度自适应调控提供了理论支撑。为了实现割台高度的自动化调控,设计了一种割台离地高度检测装置,并针对其工作过程中出现的仿形板下陷、跳动等问题,利用RecurDyn进行了动力学仿真,确定了复位扭簧的最佳扭矩为16N·m。通过田间试验验证了大豆割台仿形装置的仿形效果,为大豆收获机械设计提供了理论参考。

基于二阶欠阻尼阶跃响应的收获机割台液压缸选型分析

割台是谷物收获机的重要组成部分,割台性能的好坏决定着收获机在收获作业时的作业质量。割台液压缸选型确定方面,传统方式大多采用对割台质量及液压系统工作负载进行分析,利用经典力学的方式进行割台油缸的选型。随着自动控制理论的发展,割台高度闭环控制技术也越来越多地开始出现在国外领先收获机机型上,仅考虑力学负载分析的方法已经无法满足割台高度自动控制系统的需要。针对控制系统稳态分析的要求,割台油缸在满足工作负载的前提下,还需考虑系统的超调量、反应时间及过调震荡时间等因素。为此,进行割台升降运动过程建模分析,论证出割台控制模型为二阶欠阻尼模型系统,发现固有频率ωn与阻尼比ζ决定着系统动态指标。通过对液压缸内部分析,求出了割台液压缸系统的传递函数,确定出当其他机械参数不变时,割台油缸的管径影响着割台液压缸系统的固有频率ωn与阻尼比ζ。综合采用上升时间tr、峰值时间tp、超调量σ%和调节时间ts等4种系统稳态指标确定了最佳割台油缸参数,并进行了Amesim仿真试验。研究结果为后续无人驾驶谷物联合收获机的研发设计提供了割台装置控制策略的理论依据。