Research on laser-arc hybrid welding technology for long-distance pipeline construction

In recent years, the research on pipeline laser-arc hybrid welding technology has been the important and difficult in the field of welding all over the world. China Petroleum Pipeline Research Institute Co. Ltd. has firstly developed pipeline laser-arc hybrid welding system in China, and executed the welding tests based on X70/X80 steel. Preliminary experiment results showed that hybrid welding could meet the requirements of related standards such as API1104,ASME,etc., the mechanical properties of girth seam are qualified in the case that there were no internal defects. With the development of high-power fiber laser and the continuous improvement of welding equipment, laser-arc hybrid welding technology for pipeline field welding will be available soon.

Microstructure and properties of laser-arc hybrid welding of high-strength low-alloy steel

Laser-arc hybrid welding has the characteristics of optimal surface formation and greater penetration;it is extensively used in the welding of plates of medium thickness.However, for hybrid welding of lasers, the welding seam cooling rate is rapid;thus, the welding seam has a higher tendency to significantly harden, which has a negative impact on the weld quality of the high-strength low-alloy(HSLA) steel plates of medium thickness.In this study, laser-arc hybrid welding is performed on the BG890 QL HSLA steel produced by Baoshan Iron & Steel Co.,Ltd.,and the quenching tendency of the welded structure is examined.The results demonstrate that the specific growth direction of the columnar crystal structure of the laser-arc hybrid welded joint is obvious.However, at the center and top of the welded seam, there are equiaxed crystals.The impact properties at room temperature and-40 ℃ of the weld area are 58.0 J and 40.0 J,respectively, and those of the heat-affected zone(HAZ) are 147.0 J and 66.5 J,respectively.The impact performance can meet these requirements.Laser-arc hybrid welding of HSLA steel can yield strong and durable welds and the HAZ structure to meet the requirements of engineering applications.

Numerical simulation of temperature field in laser-arc hybrid welding of wear-resistant steel

Using ABAQUS software and cylindrical ellipsoid and body heat sources with a peak-heat-flux- attenuation function, a finite element model of the temperature field in the laser-arc hybrid welding of 4.5-mm BW300TP wear-resistant steel is proposed. The proposed model considers convection, radiation, molten pool flow, and heat conduction effect on temperature. A comparison of the simulation and actual welding test results confirms the reliability of the model. This welding heat-process model can provide the cooling rate at any position in the heat affected zone （HAZ） and can be used as a reference for the analysis of material properties and for process optimization.

Application and development in railway vehicles trend of new welding technologies manufacturing industry

This paper introduces the application of new automatic welding technologies in railway vehicles manufacturing industry, and presents the state of art of advanced friction stir welding technology, semi-penetration laser welding technology and laser-arc hybrid welding technology in manufacturing aluminum alloy body shell, stainless steel body shell and bogie. This paper also analyzes the application and development trend of three welding technologies in the future.

FEM Simulation of Distortion and Residual Stress Generated by High Energy Beam Welding with Considering Phase Transformation

A series of experiments was carried out so as to elucidate the effect of the phase transformation in the cooling process on welding distortion and residual stress generated by laser beam welding (LBW) and laser-arc hybrid welding (HYBW) on the high strength steel (HT780). Then, the experiments were simulated by 3D thermal elasticplastic analysis with FEM (Finite Element Method) which was performed with using the idealized mechanical properties considering the transformation superplasticity. From the results, the effects of the phase transformation on welding distortion and residual stress generated by LBW and HYBW were elucidated. Furthermore, the generality of the idealization of the mechanical properties was verified.

高功率激光-MAG复合焊接成形稳定性

采用激光-MAG(Metal active gas arc welding)复合焊接工艺,以焊缝表面成形、焊缝纵截面形貌和熔深波动程度为工艺稳定性评价依据,借助高速摄像系统和图像处理方法,对焊接过程中飞溅和等离子体两种关键过程信息进行特征识别和定量化表征,系统地研究激光功率从5 kW提高到30 kW时,焊接过程关键特征信息与焊接过程稳定性之间的关系。结果表明,随着激光功率的增加,焊缝表面成形出现周期性“上凸-下凹”现象,焊缝内部裂纹和熔深变化特征也随之周期性变化;等离子体面积和飞溅面积均随激光功率的提高呈增加趋势,且两者波动程度和熔深波动程度均呈正相关;等离子体面积增加会导致激光传输过程中能量衰减程度的加剧,使焊缝熔深增加趋势逐渐变缓,其波动程度是影响焊接过程稳定性的关键因素之一。

5083铝合金激光-MIG复合单面焊双面成形打底焊工艺优化

采用激光-熔化极惰性气体保护电弧(MIG)复合焊对5083铝合金板进行打底焊,以模拟铝合金罐体单面成形对接焊缝,研究了激光束摆动方式(不摆动、直线摆动、圆形摆动、方形摆动)、激光功率(2.5~4.0 kW)、组对间隙(0,1 mm)和错边(0,1 mm)对焊缝成形质量的影响,并分析了优化工艺下接头的力学性能。结果表明:在3.0 kW激光功率下,当激光束不摆动时,焊缝背面不连续并伴有凹坑,当激光束直线摆动时,焊缝内部存在大量气孔;在圆形激光束摆动模式下,当激光功率为2.5 kW时,焊缝背面未形成连续的全熔透焊缝,当激光功率为4.0 kW时,焊缝出现严重的下塌现象。3.0~3.5 kW激光功率以及圆形或方形激光束摆动模式能够实现单面焊背面自由成形,且焊缝成形良好,在不同组对间隙和错边条件下表现出较强的适应性;在激光功率为3.0 kW、激光束摆动模式为圆形摆动的优化工艺下,焊接接头抗拉强度达到母材的90%,正弯和背弯后接头中均未出现裂纹和其他开口缺陷,满足工程应用要求。

热塑性复合材料/金属搅拌摩擦焊研究进展

热塑性复合材料作为新型轻质材料,已经广泛应用于航空航天领域。金属与热塑性复合材料的异种材料连接因其能充分发挥两种材料各自的特性而备受关注。搅拌摩擦焊作为一种低热输入的焊接技术,在金属与热塑性复合材料异种焊接领域有广阔的应用前景。从热塑性复合材料与金属的搅拌摩擦焊焊接方法、炉具设计、焊接工艺参数以及连接机制等方面综合国内外研究成果进行系统性的综述,并对热塑性复合材料/金属异种搅拌摩擦焊的未来发展趋势做出展望。

电弧状态对铝合金激光-电弧复合焊接工艺过程稳定性的影响

焊接过程稳定性是决定焊缝质量的重要因素,而焊接飞溅和焊缝表面形貌是焊接过程稳定性的直接体现。为了得到稳定的铝合金激光-MIG电弧复合焊接过程,本研究采用高速摄影的方法统计焊接飞溅数量,并分析焊缝表面成形质量,对焊接过程稳定性进行了综合定性评价,结合激光焊接与电弧焊接基本原理,探讨了减少飞溅、稳定焊接过程的原理。在本试验条件下,提高纯Ar保护气的流量、电弧弧长和光丝间距,降低电弧电磁收缩力,可以减少飞溅数量。复合焊接飞溅数量减少的主要原因可以归结为两点:激光对熔池的预热作用扩大了熔池前端的面积,使熔滴融入熔池的过程更平稳;工艺优化使电弧对熔滴的作用力保持在合理范围。相关结果为复合焊接稳定的工业应用奠定了工艺基础,指明了工艺优化方向。

Microstructure and mechanical properties of weld metal in laser and gas metal arc hybrid welding of 440-MPa-grade high-strength steel

Fiber laser and gas metal arc hybrid welding of 440-MPa-grade high-strength marine steel was carried out at different welding speeds.The influence of welding speed on the micro structure and mechanical properties of weld metal was investigated.The weld-metal microstructure mainly consisted of pre-eutectoid ferrite,side-plate ferrite,acicular ferrite and lath bainite at a low welding speed.With the increase in welding speed,acicular ferrite and lath bainite were the dominant weld-metal microstructures.All samples failed at the base metal during tensile tests,which indicates that there is no soft zone in the hybrid welds.The welding speed had a significant effect on the impact toughness of the weld metal.The impact absorbed energy of the weld metal increased from 35 to 105 J with the increase in welding speed from 0.8 to 2.0 m/min.Large amounts of acicular ferrite and lath bainite were formed in the weld metal at a high welding speed,which resulted in an excellent impact toughness.

激光-电弧复合焊接工艺参量的研究进展

激光-电弧复合焊接是近几年在国际上得到迅速发展和应用的焊接前沿新技术,是材料优质高效连接的最佳熔焊工艺。激光-电弧复合焊接结合了激光焊和电弧焊两种工艺,影响焊接过程的参量较多,而这些因素的设置对焊接过程的稳定性、焊接接头的质量都有重要影响。从激光器类型的选择、辅助电源类型的选择、焊接方向、激光离焦量、激光-电弧之间距离、激光与电弧能量的匹配以及保护气体等方面讨论了激光-电弧复合焊接过程中的工艺参量的优化设置问题,并对这些因素对焊缝成形的影响进行了分析,最后提出了激光-电弧复合焊接工艺的研究方向。

我国搅拌摩擦焊技术的研究现状与热点分析

从搅拌摩擦焊材料、工艺、焊接机理、有限元数值模拟、接头耐腐蚀性等方面分析了国内对搅拌摩擦焊研究取得的成果与现状,并预测了未来几年国内搅拌摩擦焊研究的热点和重点。分析认为:铝合金仍是未来几年搅拌摩擦焊的主要研究材料,而镁合金、铜合金、不锈钢、碳钢以及异种金属的搅拌摩擦焊将也将成为研究的热点。焊接工艺、有限元数值模拟以及接头性能和焊后加工处理也将成为搅拌摩擦焊研究的热点和重点。

5052铝合金CO_2激光-MIG复合焊接工艺对焊缝成形的影响

以10 mm厚的5052铝合金为研究对象,研究CO2激光-MIG复合焊接工艺参数对其焊缝成形的影响规律。结果表明:焊缝熔深及熔宽随电弧电流的增加先增加后减少而后再增加,随激光功率的增加逐渐增加,随焊接速度的增加迅速下降;热源间距对焊缝熔深影响较大,对焊缝外观形貌影响很小。在He气中加入Ar气对改善焊缝表面成形和咬边等有明显的效果,随着加入的Ar气量增大,效果越明显;加入少量的Ar气有利于提高焊缝熔深,过量反而降低焊缝熔深。激光功率低于1 500 W有轻微咬边,在2 500 W有激光"匙孔"现象出现;当焊接电流为130～145 A、激光功率为3.5～4.5 kW、焊接速度为1～2 m/min、离焦量为-1～0 mm、热源间距为2～3 mm、Ar气流量为5～15 L/min、He气流量为10～20 L/min时,得到较好的焊缝形貌及焊缝熔深。

激光-短路MAG复合热源焊接过程稳定性的影响因素

以低碳钢为研究对象,通过焊接电弧分析仪,对比研究了激光-短路MAG电弧复合热源焊接过程中焊接速度、激光与电弧的相对位置对焊接过程稳定性的影响规律.结果表明,随着焊接速度增加,MAG和激光-短路MAG复合热源焊接过程稳定性都会降低,但由于激光的引入,复合热源在高速焊接过程更稳定.与MAG相比,复合热源可以提高极限焊接速度1倍以上;复合热源焊接过程中,与激光在前引导焊接相比,电弧在前引导焊接过程稳定性更高.

6009铝合金光纤激光-MIG电弧复合焊和光纤激光焊工艺对比研究

采用光纤激光-MIG复合焊和光纤激光焊分别对6009铝合金进行焊接,研究两种焊接方式下焊接接头的成型性、显微组织、拉伸性能、显微硬度、断口形貌的不同。研究表明:激光电弧复合焊的焊接速度是激光焊接的3倍;相比于激光焊,激光电弧复合焊焊缝中心显微组织更加细小;接头的抗拉强度达到母材的63%以上,而激光焊接的抗拉强度仅仅只有母材的38%;显微硬度试验表明:复合焊存在软化区,而激光焊接几乎没有软化区;断口分析表明:复合焊和激光焊的拉伸断口都是典型的韧窝状态,但是复合焊接的韧窝更加均匀。

激光-MIG复合焊工艺及其在轨道交通领域应用现状

阐述了激光-MIG复合焊接的基本原理和特点;介绍了铝合金激光-MIG复合焊接的工艺特性、研究现状及其在轨道交通车辆行业的工业应用。激光-MIG复合焊接充分集成激光焊接与MIG焊接的优点,能有效解决铝合金焊接的诸多问题,在轨道交通领域将会得到更加广泛的应用。

激光-电阻复合焊接铝合金T型接头工艺及性能

采用激光-电阻复合焊接方法进行铝合金T型接头焊接工艺试验,对激光-电阻复合焊接过程中的主要焊接工艺参数:滚轮电极形状、电流大小和激光功率对焊缝成形及接头性能的影响进行分析,并优化工艺参数以获得良好的焊缝成形和优质焊接接头。试验结果表明:采用弧形端面滚轮电极,在合适的电流和激光功率参数条件下,激光-电阻复合焊接T型接头不仅可以降低接头搭接面的间隙,而且改善焊缝成形,增加搭接面的焊缝宽度,使T型接头的拉伸剪切载荷与单独激光焊接相比得到显著提高。激光-电阻复合焊接有效改善了激光焊接存在的一些不足,拓展了激光焊接的工业应用范围。

激光-电弧复合焊接缺陷形成机理及抑制方法

近年来,随着电弧焊设备、激光器性能和工业集成技术的不断提高以及激光-电弧复合焊接机理和工艺研究的持续深入,激光-电弧复合焊技术在国内外众多重要工程领域应用越来越广泛。然而,由于激光-电弧复合焊热源间的强耦合作用及其众多的工艺参数难以优化控制,焊接过程仍会出现焊接缺陷,严重影响焊接接头质量和服役可靠性。本文在深入探讨激光-电弧热源协同机制和复合参数影响规律的基础上,重点阐明了激光-电弧复合焊接气孔、裂纹、咬边、驼峰等主要缺陷的形成机理和成形过程,同时进一步分析了不同焊接形式的缺陷抑制方法及其作用机理,以期为更好地理解激光-电弧复合焊这一优质高效焊接方法并推动其更广泛的工业应用提供参考。

增量型PID恒流恒压控制的Plasma-MIG复合电弧焊接

Plasma-MIG复合电弧焊接对电源的外特性输出及焊接过程控制有着很高的要求,以VC++软件开发工具为平台,推导了适合于Plasma-MIG复合电弧焊接的增量型PID控制算法,实现了对复合电弧焊接过程控制及电源外特性的要求.结果表明,增量型PID恒流恒压控制能够满足Plasma-MIG对电源外特性的输出要求.Plasma电弧和MIG电弧并不是相互独立的,两者以共享的电磁空间、导电气氛和焊丝为媒介建立起耦合关系.Plasma-MIG复合电弧焊接过程中,增量型PID控制下的Plasma电弧能够自发的调节自身电参数,来稳定电弧空间的电流密度,使得焊接过程中无飞溅.采用控制后,Plasma-MIG复合电弧焊焊接过程焊缝铺展好,焊接过程稳定,焊缝成形好.

动车组构架激光-MAG复合热源焊接工艺参数

针对高速列车转向架焊接构架中典型的平板对接接头、T型角接接头和管板搭接接头,采用激光-MAG电弧复合热源焊接方法进行了系统的焊接工艺试验,确定了平板对接、T型角接和管板搭接接头的坡口角度、钝边尺寸和组焊间隙,以及相应的激光-MAG复合热源焊接工艺参数,为激光-电弧复合焊接方法在构架制造中的应用提供了工艺参数和技术基础.