Analysis of Aluminum Alloy Double-Pulse MIG Welding Arc Signal Characteristics Based on Broadband Mode Decomposition

Welding voltage and current in arc signals are directly related to arc stability and welding quality.Process experiments with different parameters were organized according to the orthogonal experimental design method by constructing an aluminum alloy double-pulse metal inert gas(MIG)welding arc electric signal test platform.The data acquisition system of the aluminum alloy MIG welding process was established to obtain real-time arc signal information reflecting the welding process.The aluminum alloy’s collected double-pulse arc current signals are decomposed adaptively by broadband mode decomposition(BMD).The direct current(DC)signal,pulse signal,distortion signal,ripple signal,and noise signal are separated and extracted,and the composite multiscale fuzzy entropy(CMFE)is calculated for the component set of the electrical signal.The experimental results show that the current waveform obtained by the double-pulse MIG welding current signal is consistent with the corresponding weld forming diagram.Simultaneously,the composite multiscale fuzzy entropy is calculated for the arc characteristic parameters.The rationality of matching process parameters and arc stability of aluminum alloy’s double-pulse MIG welding were evaluated.

Experimental and clinical study of influence of high-frequency electric surgical knives on healing of abdominal incision

AIM： To study the influence of high-frequency electric surgical knives on healing of abdominal incision. METHODS： Two hundred and forty white rats were divided into 10^0, 10^2, 10^5, and 10^8 groups and rat models of abdominal operation were induced by using electric surgical knives and common lancets respectively. Then they were respectively given hypodermic injections of normal saline and 0.2 mL quantitative mixture of Escherichia coil, Staphylococcus aureus and Pseudornonas aeruginosa at a concentration of 10^2, 10^5 and 10^8. On the basis of the animal experiment, 220 patients undergoing abdominal operations （above type Ⅱ） were randomly allocated into one of following three groups： electric knife （EK, 93 cases）, electro-coagulation （EC, 55 cases） and control （72 cases）. High-frequency electric surgical knives were used to dissect abdominal tissues and electro-coagulation for hemostasis in EK group. Common lancets and electro-coagulation were applied in EC group. Common lancets and tieing silk suture were used in the controls. RESULTS： In all the groups except group 10^0, infection rate of incisional wounds made by electric surgical knives were remarkably higher than that with common lancets. Furthermore, there were significant differences in groups 10^2, 10^5, and 10^8 （P 〈 0.05）, but not in group 10^0 （P 〉 0.05） between EK and EC groups. Clinical studies showed a delayed wound healing in 16 cases （17.20%） in EK, 11 cases （16.36%） in EC and 2 cases （2.86%）in the control groups. A significant difference between EK and the control groups （χ^2= 8.57, P 〈 0.01）, and between EC and the control groups （χ^2 = 5.66, P 〈 0.05） was observed, but not between EK and EC （χ^2= 0.017, P 〉 0.05）. CONCLUSION： High-frequency electric knives may remarkably delay abdominal incision healing. Its application should be minimized so as to reduce the possibility of postoperative complications.

Potential Oxidative Stress in the Bodies of Electric Arc Welding Operators: Effect of Photochemical Smog

Objective To investigate whether photochemical smog emitted during the process of electric arc welding might cause oxidative stress and potential oxidative damage in the bodies of welding operators. Methods Seventy electric arc welding operators (WOs) and 70 healthy volunteers (HVs) were enrolled in a randomized controlled study design, in which the levels of vitamin C (VC) and vitamin E (VE) in plasma as well as the activities of superoxide dismutase (SOD), catalase (CAT) and glutathione peroxidase (GPX), and the level of lipoperoxide (LPO) in erythrocytes were determined by spectrophotometry. Results Compared with the average values of the above experimental parameters in the HVs group, the average values of VC and VE in plasma as well as those of SOD, CAT and GPX in erythrocytes in the WOs group were significantly decreased (P<0.005-0.0001), while the average value of LPO in erythrocytes in the WOs group was significantly increased (P<0.0001). The findings from the partial correlation analysis on the controlling of age suggested that with a prolonged duration of exposure to photochemical smog the values of VC, VE, SOD, and GPX, except for CAT, in the WOs were decreased gradually (P<0.05-0.005), the value of LPO in the WOs was increased gradually (P<0.001), and that with the ozone dose increased in the air in each worksite VC, VE, SOD, CAT and GPX decreased (P<0.005-0.001), but LPO increased (P<0.001). The findings from the reliability analysis for the VC, VE, SOD, CAT, GPX, and LPO values which were used to reflect oxidative stress and potential oxidative damage in the WOs showed that the reliability coefficients?alpha (6 items) was 0.8021, P<0.0001, and that the standardized item alpha was 0.9577, P<0.0001. Conclusion Findings in the present study suggest that there exists an oxidative stress induced by long-term exposure to photochemical smog in the bodies of WOs, thereby causing potential oxidative and lipoperoxidative damages in their bodies.

A novel variable polarity welding power based on high-frequency pulse modulation

A new type of variable polarity welding power modulated with high-frequency pulse current is developed. Series of high-frequency pulse current is superimposed on direct-current-electrode-negative （DCEN）, which can improve the crystallization process in the weld bead as a result of the electromagnetic force generated by pulse current. Digital signal processor （DSP） is used to realize the closed-loop control of the first inverter, variable polarity output of the second inverter and high-frequency pulse current superposition.

Characterization of electrical properties of resistance welding machines

Due to the individual electrical and mechanical characteristics of resistance welding machines, choice of the right machine and welding parameters for an optimized production is often difficult. This is especially the case in projection welding of complex joints. In this paper, a new approach of characterizing the electrical properties of AC resistance welding machines is presented, involving testing and mathematical modelling of the weld current, the firing angle and the conduction angle of silicon controlled rectifiers with the aid of a series of proof resistances. The model predicts the weld current and the conduction angle （or heat setting） at each set current, when the workpiece resistance is given.

Effect of retained austenite and nonmetallic inclusions on the thermal/electrical properties and resistance spot welding nuggets of Si-containing TRIP steels

Five advanced high-strength transformation-induced plasticity(TRIP) steels with different chemical compositions were studied to correlate the retained austenite and nonmetallic inclusion content with their physical properties and the characteristics of the resistance spot welding nuggets. Electrical and thermal properties and equilibrium phases of TRIP steels were predicted using the JMatPro? software. Retained austenite and nonmetallic inclusions were quantified by X-ray diffraction and saturation magnetization techniques. The nonmetallic inclusions were characterized by scanning electron microscopy. The results show that the contents of Si, C, Al, and Mn in TRIP steels increase both the retained austenite and the nonmetallic inclusion contents. We found that nonmetallic inclusions affect the thermal and electrical properties of the TRIP steels and that the differences between these properties tend to result in different cooling rates during the welding process. The results are discussed in terms of the electrical and thermal properties determined from the chemical composition and their impact on the resistance spot welding nuggets.

Effects of Rare Earths on Electrical Conductivity, Melting-Welding and Corrosion Resistance by Electric Arc of Copper-Based Alloys

The effects of rare earths on electric conductivity fusion welding-resistance and erosion-resistance by electric arc of copper-based compound material by adding different amount of rare earths to copper base to get copper based compound materials were studied. Rare earths improve active ability among interfaces and optimize organizational structures. The conductivity of samples with rare earths is obviously better than that of materials without them. Moreover, wear ability and oxidization resistance of materials with rare earths can be improved greatly. For copper contact head with rare earths, electric arc corrosion resistance and welding-melting resistance are improved. Such alloys also decrease resistance change with increasing temperature. But the adding quantity of rare earths should be appropriate and formed handicraft should be properly regulated.

Electrical Characteristics of Plasma Plume During Pulse Wave Laser Welding

To detect the real-time plasma plume during pulse wave Nd:YAG laser welding, experimental studies were conducted based on asynchronous signal acquisition system. The electrical signals of the laser-induced plasma plume were obtained by a passive acquisition system. The plume was directly observed and recorded using synchronous high-speed camera. The results showed that the waveform of the signals was in accordance with the periodical laser power. The signals decreased after the laser was turned on and fl uctuated relatively steadily on the stable stage and then increased to 0 V after the laser beam was turned off . The decreasing time of the electrical signals was roughly 1.0 ms, and it decreased with the increasing peak power. However, the average power had insignifi cant eff ect on the signal decreasing time.

A novel wavelet method for electric signals analysis in underwater arc welding

Electric signals are acquired and analyzed in order to monitor the underwater arc welding process. Voltage break point and magnitude are extracted by detecting arc voltage singularity through the modulus maximum wavelet （MMW） method. A novel threshold algorithm, which compromises the hard-threshold wavelet （HTW） and soft-threshold wavelet （STW） methods, is investigated to eliminate welding current noise. Finally, advantages over traditional wavelet methods are verified by both simulation and experimental results.

On-line measurement of electrical variables of the transducer during ultrasonic welding and cutting

A measurement system for high power electrical variables with ultrasonic frequency was established. It can measure the effective values of the voltage and the current, the active power, the phase difference of voltage and current, the frequency of the transducer during ultrasonic welding and cutting. In sampling circuits of the system, the measured current is sensed by using a no capacitance and no inductance precision resistor and is treated with a difference amplifier, the measured voltage is processed by using a proportional amplifier. For achieving good amplitude frequency characteristics and rapid measurement of high frequency signals, the resistors, capacitors and amplifiers used in the system are rationally selected. Calibrating experiments show that relative errors are less than 1% for voltage and current effective values and less than 2.5% for active power, and absolute errors are ±1 Hz for frequency and ±1.7° for phase difference of voltage and current in the range of 17～23 kHz .

Study on non-electric welding and its application in emergency maintenance

Non-electric welding is a novel efficient technique for emergency maintenance, which utilizes the heat released by self-propagating combustion to join metals without needing arty power supply or gas sources. Non-electric welding material, named non-electric welding pen, was prepared by utilizing highly-exothermic thermit （ Cud ＋ Al） with other additive powders. The effects of reactant particle size and mixing uniformity on the combustion characteristic of the welding pen were investigated. The results show that the particle size of reactant powder has a significant effect on combustion velocity. With increasing the particle size of reactant powder, the combustion velocity decreases obviously. Moreover, mixing uniformity and particle size are shown to be main factors influencing heat produced in single time, and accordingly affect the combustion temperature. Welding experiments were performed with 45 steel as the base material, and results show that the joint is of a metallurgie bonding with the tensile strength above 280 MPa, which proves non-electric welding a fusion welding technique.

Relation between viscoplastic flow, periodic feature and Joule heat validity for electrically assisted friction stir welding

Electrically assisted friction stir welding is a promising way to improve liquidity of viscoplastic metal. However, this local heat source only can take into effect in a certain contact interface status. Semi-analytical model and FEM are adopted to analyze materials flow in electrically assisted FSW. Semi-analysis results show that Joule heating is validity with rotation speed 1 400 r/min and travel speed 400 mm/min. The maximum flow velocity is 0.033 m/s when travel speed is 400 mm/min, and it increases to 0.043 m/s with current assistant. Visco-plasticizing efficiency is a key factor to decide whether Joule heat is significant, and viscoplastic flow can periodically make circuit short. Periodic torque, axial force and onion rings surface show dynamic flow process, which can be used to illustrate the dynamic contact resistance feature and correct the calculation equation of Joule heat. This paper is aim to point out the potential relation between viscoplastic flow, periodic torque and Joule heating validity.

Challenge to Welding and Joining Technology for Applying Multi-material in Electric Vehicle Production

Advanced high strength steel,aluminum alloy and plastic materials are used in the right places for the purpose of reducing the weight of EV(electric vehicle)bodies and in-vehicle parts,and multi-material structures are advancing.Therefore,it is difficult to handle the welding and joining processes of automobile structures by the conventional arc welding and resistance spot welding,which have been applied to steel joining,and various joining processes are being applied depending on the material.Under above mentioned background,the authors have developed some unique joining processes for multi-materials that are used in the right place.This paper introduces the dissimilar metal joining between the galvanized steel and aluminum alloy by laser arc hybrid process,the metal/thermoplastic dissimilar material joining using laser process and the solid-state resistance spot joining process of advanced high strength steel for EV body structural parts.Moreover,the authors describe the high-speed plasma jet GTA(Gas Tungusten Arc)welding process of copper applied to electrical components such as motors.

Mechanical behavior of electric resistance welded pipes in pipe-making process

The changes in the mechanical behavior of electric resistance welded（ERW） pipes before and after the cage roll forming process were investigated through tensile experiments. It is found that the Bauschinger effect does not exist in the pipe product, while the work hardening effect introduced by pipe-making is the direct cause of the mechanical changes. The prestrain introduced during different pipe-making processes are accumulative to the work hardening effect. And the increment of the yield strength for making Ф 244.48 × 8.94 pipe is approximately 45 MPa, higher than that of hot-rolled plates. It is verified that the strain ε=t/D-t is an efficient index representing the work hardening effect from the engineering viewpoint.

A New Characterization Approach of Weld Nugget Growth by Real-Time Input Electrical Impedance

The in-process changes of weld nugget growth during the Resistance Spot Welding were investigated based on the resistance of input electrical impedance. To compute the time varying resistance of input electrical impedance, the welding voltage and current signals are measured simultaneously and then converted into complex-valued signals by using Hilbert transform. Comparing with the dynamic contact resistance as reported in literature, it showed that the time varying resistance of input electrical impedance can be accurately correlated with the physical changes of weld nugget growth. Therefore, it can be used to characterize the in-process changes of weld nugget growth. Several new findings were reported based on the investigation of spot welds under no weld, with and without weld expulsion conditions.

Effect of alternating ultrasonic frequency electric signal on the distribution of pore in aluminum alloy weld

The application of ultrasonic vibration in the welding process can effectively suppress the pore defects of the weld.The different ultrasonic application methods own different effects on the weld pore.In this paper,the ultrasonic frequency vibration in the weld pool is excited by the coupling of the ultrasonic frequency electrical signal and the welding electrical signal.The influence of ultrasonic excitation voltage and excitation frequency on porosity,number,location,and size of pore in weld was investigated.The results show that the variation of ultrasonic excitation voltage and frequency has a direct influence on the pore distribution.The pore defects can be decreased by the coupling of ultrasonic frequency electrical signal with reasonable parameters or increased by the coupling of ultrasonic frequency electrical signal with unreasonable parameters.The ultrasonic excitation frequency is fixed at 30 kHz and the ultrasonic excitation voltage is changed.The porosity of the weld is close to that of the weld without ultrasonic action when the ultrasonic excitation voltage is 25 V and 75 V.The porosity of the weld is significantly lower than that of the weld without ultrasonic action when the ultrasonic excitation voltage is 50 V and 100 V.The ultrasonic excitation voltage is fixed at 100 V and the ultrasonic excitation frequency is changed.The porosity of the weld is the largest and exceeds that of the weld without ultrasonic action when the ultrasonic excitation frequency is 20 kHz.The porosity of the weld is lower than that of the weld without ultrasonic action when the ultrasonic excitation frequency is 25,30,35,and 40 kHz.The pores were mainly concentrated on the upper part of the weld and the number of pores of small size increased significantly after the coupling of an ultrasonic frequency electrical signal,indicating that ultrasonic promoted the rise and escape of bubbles in the weld pool.

FRACTAL RESEARCH ON CRACKS PROPAGATION OF GAS PIPELINE X52 STEEL WELDING LINE UNDER HYDROGEN ENVIRONMENT

Based on the theory of hydrogen enhanced localized plasticity of the hydrogen induced cracking and the consideration of the effect of the residual stress produced by eliminated stress heat-treatment, a fractal model of hydrogen induced cracking was presented, and the relationships among the effective surface energy (H), fractal dimension D and stress intensity factor of hydrogen induced cracking, KIH, for welding pipeline under hydrogen environment was set up, from which the relationship of D and KISCC was obtained. The model has been verified experimentally to be correct.

Arc characteristics of submerged arc welding with stainless steel wire

The arc characteristics of submerged arc welding （SAW） with stainless steel wire were studied by using Analysator Hannover （AH）. The tests were carded out under the same preset arc voltage combined with different welding currents. By comparing the probability density distribution （PDD） curves of arc voltage and welding current, the changes were analyzed, the metal transfer mode in SAW was deduced, and the characteristics of a stable arc were summarized. The analysis results show that, with an increase of welding parameters, the short-circuiting peak in the PDD curves of arc voltage decreases gradually until it disappears, and the dominant metal transfer mode changes from flux-wall guided transfer to projected transfer and then to streaming transfer. Moreover, when the PDD curves of arc voltage are both unimodal and generally symmetrical, the greater the peak probability and the smaller the peak span, the more stable the arc becomes.

Application and development of friction stir welding technology in high speed EMU manufacturing

The application status of friction stir welding technology is introduced,and the application research of advanced FSW technology in the manufacture of high-speed electric multiple unit aluminum alloy body is analyzed,including the application of traditional friction stir welding technology to a combination of a lap joint and butt joint,and butt joint of large thick plate by both sides process,also introduces bobbin-tool friction stir welding to a butt joint and three-dimensional space curved friction stir welding to T-joint. At the same time the future development trend of new FSW technology derived from traditional FSW technology in rail vehicle manufacturing industry is put forward. As the fast developing of critical technology used on railway vehicles,quick applying advanced welding technology will affect products quality,manufacturing cost and production cycle time directly,and it certainly will be one of the approaches to develop markets by all the railway vehicles manufacturing enterprises.

Stability of fiber laser-MIG hybrid welding of high strength aluminum alloy

The effect of fiber laser on MIG arc was investigated with 8 mm 7075-T6 high strength aluminum alloy as base material.The arc shape,droplet transfer form and electrical signal in the process of MIG welding and laser-MIG hybrid welding were analyzed.The stability of the hybrid welding process was evaluated by standard deviation analysis.The results show that with the increase of laser power,a large number of laser-induced plasma enters the arc column area,providing more conductive channels,which makes the heat of MIG arc more concentrated and the short circuit transition disappear.Due to the continuous effect of laser,the keyhole becomes a continuous electron emission source,and a stable cathode spot will be formed near the keyhole,which enhances the stability of MIG arc at the base current state.By using the method of standard deviation analysis,the voltage standard deviation of single MIG welding arc and laser-MIG hybrid arc within 4 seconds was calculated.The standard deviation of single MIG arc voltage was 1.05,and the standard deviation of MIG arc voltage in laser-MIG hybrid welding was 0.71–0.86,so the hybrid welding process was more stable.