Effect of electrode change on solidification of slag and metal pool profile in electroslag remelting process

A two-dimensional axisymmetric model is established to study the effect of electrode change on the solidification of slag and metal pool profile during electroslag remelting process.The basic considerations of flow and heat transfer are included in the model,and the growth of ingot is described by the dynamic mesh technique.The electrode melting rate is predicted based on the transient thermal conductivity model between slag and electrode.The results indicate that in the electrode change stage,the slag temperature drops from 1847 to 1763 K gradually and the“hot heart”phenomenon is observed.And the metal pool profile is slightly changed with a depth decrease from 0.3984 to 0.3688 m.In the heating and melting stage of new electrode,the maximum slag temperature firstly increases from 1763 to 1892 K,then decreases to 1845 K,and finally at 3558 s,the maximum slag temperature is stable at 1884 K.Solidified slag shell with a maximum volume of 7.31×10^(-3) m^(3) is formed at the electrode tip,and then,the solidified slag melts completely.The depth of metal pool firstly rises to 0.3700 m and then drops to 0.3565 m.As the preheating temperature of the new electrode increases from 473 to 973 K,the maximum volume of solidified slag decreases from 0.00748 to 0.00592 m^(3),and the time from heating to melting of the new electrode decreases from 996 to 887 s.

基于摆动激光扫描的GMAW焊缝成形调控

将摆动激光与GMAW工艺复合,利用“8”字形摆动激光扫描液态熔池,对其温度场和流场进行调控,以改变熔池温度梯度,主动调控熔池流动以改善焊缝成形.在6061铝合金板材表面进行堆焊试验,重点探究了光丝间距、摆动幅度、激光功率对于焊缝成形的影响,采用高速摄像机拍摄激光扫描熔池过程.结果表明,摆动激光扫描可以有效抑制成形缺陷的发生,当摆动激光扫描熔池中部时可以获得最佳的焊缝成形效果.摆动激光扫描降低了熔池温度梯度分布,同时激光扫描产生的激光蒸发反力可以驱动熔池流动,促进了液态熔池的流动铺展,从而有效抑制了不规则焊缝成形缺陷,减少焊缝内部气孔和裂纹缺陷.调节摆动激光摆幅可以在一定范围内对焊缝宽度进行调控.

熔融锆铁金属层顶部注水试验设计及结果

通过向压力容器内注水的措施带走部分衰变热被认为是更高功率堆设计中缓解金属层“热聚焦”效应的潜在措施之一。但往金属层顶部注水可能存在复杂的物理现象,有必要开展试验研究,以验证该措施的可行性和有效性。本文以锆铁原型金属材料为工质,对金属层注水试验装置进行设计,并开展典型试验研究,对试验后的结果进行分析。研究结果表明:在本试验条件范围内,向金属层顶部注水未导致蒸汽爆炸、大量熔融物飞溅及氢气爆炸等现象,注水后金属层表面移出的热流密度高于实际电站下封头形成稳定熔池后向上的辐射换热热流密度。本文结果证明了通过向熔池顶部注水,有助于缓解金属层的“热聚焦”效应,可为严重事故下管理策略的制定提供有益指导。

基于深度学习的金属表面缺陷检测

由于金属产品生产过程中各种因素的影响,金属工件可能会存在一些表面缺陷.这会降低材料强度,缩短工件寿命,并且增加安全风险.因此,需要对金属产品表面进行质量检测,这也是保证工业生产质量的关键环节.与传统人工检测相比,基于机器视觉的表面缺陷检测方法具有速度快、精度高等优点.提出了一种改进的YOLOv5算法,用于金属表面缺陷检测研究,在原YOLOv5算法的基础上将空间金字塔池化结构SPP替换成SPPCSPC,提高模型对金属表面缺陷的检测能力.为了验证算法的有效性,分别采用YOLOv3,YOLOv4,YOLOv5及改进的YOLOv5算法对1 800张金属表面缺陷样本图像进行对比测试.结果表明,与YOLOv3,YOLOv4,YOLOv5原算法相比,改进的YOLOv5算法平均目标检测精度均值分别提高了4.3%,3.3%,2%.通过大量图片的学习,可以获得更好的精确率.

电感耦合等离子体质谱法测定电镀废水中的9种金属元素

为利用电感耦合等离子体质谱法(ICP-MS)实现电镀废水中微量元素的准确测定分析,通过优化碰撞反应池氦气流量实现干扰的有效扣除,为了减小测试的记忆效应以及实现待测试样的长期稳定测试,优化Au浓度占比达到良好稳定的测试效果。该方法对电镀废水直接测定,结果表明,各元素线性相关系数(R 2)均大于0.999,方法检出限为0.012~0.126μg/L,精密度均低于4.40%,试验样本加标回收率均在89.7%~107.5%。该分析方法具有操作简便、准确度好、灵敏度高等优点,对于电镀废水中的微量元素可以快速准确定量,可为电镀行业助力,也可为环境样本低含量元素的应用检测技术提供技术指导和借鉴。

池式快堆堆本体中液体晃动效应的研究进展

堆本体是核反应堆的核心组件,也是核反应堆进行核聚变或核裂变反应的关键部位。池式快堆堆本体内部的液态金属冷却具有大自由液面特征,其内部液体出现晃动可能会对核反应堆的安全性和稳定性造成不利影响,因此开展池式快堆堆本体中液体晃动效应的研究具有重要意义。首先,阐述了液体的晃动效应,并介绍了池式快堆堆本体的结构形式;其次,从理论研究、数值模拟和振动台试验三个方面对池式快堆堆本体的液体晃动研究进行了讨论分析。研究结果表明:单一的理论方法、数值模拟或振动台试验难以准确捕捉液体晃动对堆本体结构的实际影响,结合使用这三种方法能够获得更为准确和全面的研究效果;最后,对既有研究进行了梳理与总结,以期为池式快堆堆本体的进一步抗震研究提供新的思路和启发。

CMT电弧增材制造铝合金传热传质与熔池行为数值模拟

为研究冷金属过渡(cold metal transition,CMT)电弧增材制造铝合金传热传质与熔池流动特性,基于Fluent软件建立了三维CMT电弧增材制造数值模型.模型中,采用动网格技术模拟焊丝竖直方向上的往复运动,利用流体体积法捕获气/液界面,焓-孔隙率法追踪固/液界面,并施加周期热量输入和阶段电弧力作用来等效电弧放电行为,研究分析了焊道成形传热传质过程与熔池动态行为.结果表明,焊道成形初期,熔池余高和坡度较大,形貌犹如半个球体,成形后期热量积累造成焊道余高后方较前方略小,而后端熔宽较前端略宽;单滴过渡周期内,焊丝机械回抽对熔池表面流动影响最为明显,液桥断裂产生较大反冲作用于熔池;熔池内部则是电磁力作为主导驱动力产生一股顺时针环流,环流随燃弧阶段周期切换而不断加强与减弱,并基本贯穿整个过渡周期,使得熔池内部热对流更加充分.模拟结果与试验结果显示吻合良好.

Analysis of metal transfer during electron beam welding with filler wire

The metal transfer mode of electron beam welding （EBW） with filler wire was studied experimentally. The spatial position between the electron beam and the filler wire was defined. Basing on the charge coupled device （CCD） visual sensing system, the metal transfer mode of filler wire was investigated. The results showed that there were five transfer modes during EBW process due to different wire feed rates and spatial positions between beam and filler wire, such as short-circuiting mode, molten metal bridge mode, small droplet mode, big droplet mode and mixed mode. By comparing the weld appearance of different transfer modes, the molten metal bridge transfer was proved to be the best transfer mode.

Welding Deviation Detection Algorithm Based on Extremum of Molten Pool Image Contour

The welding deviation detection is the basis of robotic tracking welding, but the on-line real-time measurement of welding deviation is still not well solved by the existing methods. There is plenty of information in the gas metal arc welding（GMAW） molten pool images that is very important for the control of welding seam tracking. The physical meaning for the curvature extremum of molten pool contour is revealed by researching the molten pool images, that is, the deviation information points of welding wire center and the molten tip center are the maxima and the local maxima of the contour curvature, and the horizontal welding deviation is the position difference of these two extremum points. A new method of weld deviation detection is presented, including the process of preprocessing molten pool images, extracting and segmenting the contours, obtaining the contour extremum points, and calculating the welding deviation, etc. Extracting the contours is the premise, segmenting the contour lines is the foundation, and obtaining the contour extremum points is the key. The contour images can be extracted with the method of discrete dyadic wavelet transform, which is divided into two sub contours including welding wire and molten tip separately. The curvature value of each point of the two sub contour lines is calculated based on the approximate curvature formula of multi-points for plane curve, and the two points of the curvature extremum are the characteristics needed for the welding deviation calculation. The results of the tests and analyses show that the maximum error of the obtained on-line welding deviation is 2 pixels（0.16 ram）, and the algorithm is stable enough to meet the requirements of the pipeline in real-time control at a speed of less than 500 mm/min. The method can be applied to the on-line automatic welding deviation detection.

Vision sensing of P-GMAW weld pool using narrow band filters with different center wavelengths

The selection of narrow band filter＇s center wavelength has an important influence on the quality of the weld pool image captured in passive vision mettmd for controlling arc welding process. In this paper, 29 narrow band filters with different center wavelengths ranging from ultraviolet to near infrared wavelength were used to capture images of weld pool during both the peak current period and the base current period of P-GMA W （ pulsed gas metal arc welding）. The experimental results showed that the filters with near infrared center wavelength could weaken the arc most during the peak current period, while during the base current period the entire weld pool could be seen with the filters with wavelength above 600 nm. The camera spectral response and the radio of arc to weld pool emission were considered to analyze the phenomenon of experimental results.

Weld pool vision sensing and image processing for GMAW

It is difficult to acquire satisfied weld pool image by CCD sensor during gas metal arc welding（ GMAW） , for arc disturbs violently, welding current is great and working frequency is high. By using CMOS vision sensor to GMA W process, the vivid weld pool image is collected at any time, furthermore, whose gray compression ratio is controllable by sensor hardware circuit developed. Acquired weld pool image is firstly pre-processed by using Wiener filter and Ostu threshold segmentation algorithm. Subsequently separation between weld pool image and cathode mist region is conducted by means of mathematical morphological algorithm, and the edge of weld pool image is extracted by using Prewitt algorithm.

SLM成形金属薄壁件表面缺陷形成机理研究

选区激光熔化技术(SLM)被认为是最具潜力的金属增材制造技术之一。对SLM成形316L不锈钢薄壁件侧壁表面形成机理与优化策略进行了研究。实验结果发现:随着体能量密度的逐渐提升,SLM成形金属薄壁件侧壁粘粉、凹陷(孔隙)等表面缺陷及壁厚精度均呈现分段性变化,即熔池烧结存在固相烧结、稳态传导和非稳定匙孔三种模式。不同体能量密度条件下的熔池热、动力学行为耦合作用改变,使得各种表面缺陷的分布、形貌乃至形成过程均不同。重点分析了叠层褶皱、道内震荡褶皱及飞溅沉积褶皱三类表面褶皱形貌的形成机理。上述研究为提高SLM成形复杂薄壁结构表面质量提供了实验与理论借鉴。

金属增材制造过程熔池动态监测研究综述

金属增材制造技术是近年来信息技术、新材料技术与制造技术等多学科融合发展的先进制造技术之一,然而,制件质量稳定性差和工艺可重复性低等缺点限制了该技术的广泛应用。其主要原因是金属增材制造过程是一个复杂的多物理场耦合的动态过程,而熔池作为重要载体包含着丰富的过程特征信息。熔池动态特征信息与制件质量和工艺可重复性密切相关,因此监测熔池动态能够为提高制件质量和工艺可重复性提供有力的数据支撑。通过对该领域文献的调研,总结了金属增材制造过程中熔池温度和形貌动态监测技术的研究现状,分析了现有技术存在的问题,展望了未来金属增材制造过程动态监测的研究方向和技术方法。

基于非负矩阵分解的熔池图像识别方法

为探求视觉传感智能识别焊接缺陷技术,利用电荷耦合器件(CCD)相机采集了熔化极气体保护焊(GMAW)熔池图像,分析了不同工艺条件下熔池动态变化过程及所对应的焊接缺陷,提出利用非负矩阵分解法对熔池图像进行解析,得到熔池图像的特征矩阵。通过最小二乘法计算未知焊接过程测试图像在特征矩阵的投影值,给出了焊接缺陷的自动识别方法。研究结果表明,焊接质量和熔池稳定程度有关联,熔池紊乱表现为熔池轮廓波动、浮渣离散等特点,熔池稳定程度下降伴随着焊接质量的下降,以及焊缝出现缺陷。利用非负矩阵分解法得到的熔池图像特征矩阵,能够对原始图像进行整体性描述(如熔池轮廓)和局部性描述(如浮渣区域、电弧区域等),具有物理可解释性,可用于识别焊接缺陷。

电感耦合等离子体质谱法测定小麦中的重金属元素

试验采用微波消解法对小麦粉进行前处理,建立了一种电感耦合等离子体质谱法同时测定小麦中Pb、Cd、Cr、As、Al等5种重金属元素含量的分析方法。通过改进样品前处理条件和仪器工作参数,并选取^(73)Ge和^(186)Re作为内标元素,有效克服了基体效应、接口效应和仪器波动的影响。在最佳试验条件下,方法检出限为0.001~0.435 mg/kg,各元素的线性相关系数均大于0.999,加标回收率为91.7%~112.1%,相对标准偏差(RSD)均小于5.8%(n=6)。该方法简单、快速、准确,适用于小麦中多元素同时测定。实际样品的ICP-MS分析结果表明,小麦中Pb、Cd、Cr、As、Al的含量极低,不会对人体构成潜在危害。

真空金属蒸气电弧作用下阴极表面蚀坑形成过程

真空金属蒸气电弧作用下阴极表面热流密度和压力的不同时空分布情况,影响阴极表面蚀坑形成过程。结合阴极表面蚀坑形成过程中表面张力和马朗戈尼效应共同影响,建立考虑固、液、气态相变过程的二维轴对称流体动力学瞬态模型,描述阴极表面"火山口"形成的热力学行为,获得阴极最初喷射蒸气的表面结构和时间。阴极熔池相变过程中,熔融金属熔池中心形变和温度梯度较大,熔池流动由表面张力和马朗戈尼效应共同驱动,将熔坑中心热量转移至边缘,在蚀坑边缘,表面张力为熔池流动的主要驱动力。温度上升至临界温度,出现新的喷射爆炸点,"火山口"表面形成金属蒸气密度为10^25m^-3的覆盖层,密度分布与阴极蚀坑形状有关;增加热流密度、减小外部压力或增大作用半径,阴极表面覆盖层出现时间提前来到,蚀坑形状各异;当作用半径过小时,注入能量低,阴极斑点形成过程中蚀坑底部厚,半径小,蚀坑附近未产生金属蒸气覆盖层。

太湖地区不同土地利用影响下水稻土重金属有效性库变化

在太湖地区调查选择了乡镇工业环境、集约化农业丰产方及长期肥料试验地等几种人类农业利用类型和环境影响的地块 ,采集水稻土耕层样本作若干重金属的有效性库分析 .结果表明 ,各种环境和利用影响下太湖地区水稻土重金属有效性库都存在升高的趋势 ,其程度介于 3 0 %至 2 0 0 % ,且以表层最为突出 .近工业区环境和长期单施化肥下这种有效性库变化最为剧烈 ,其土壤Cu、Pb有效性库分别达到 7 96～ 2 1 5mg·kg- 1、2 4 7～ 3 4 7mg·kg- 1和 8 3 4～ 4 4 2mg·kg- 1、9 0 1～ 4 95mg·kg- 1.这种有效性升高伴随着总量的积累趋势可能是太湖地区土壤环境质量演变的当前特点 。

制冷剂/油在泡沫金属加热表面池沸腾换热特性

实验研究了制冷剂/润滑油混合物在泡沫金属加热表面核态池沸腾的换热特性,分析了润滑油浓度和泡沫金属结构对池沸腾换热特性的影响。实验使用3种结构参数的泡沫金属作为加热表面,其参数分别为10ppi/90%孔隙率、10ppi/95%孔隙率和30ppi/98%孔隙率,厚度均为5mm。实验使用的制冷剂为R113,润滑油为VG68,润滑油浓度为0～5%。实验结果表明:泡沫金属的存在极大提高了制冷剂/油混合物的池沸腾传热系数,最多提高1.6倍;润滑油的存在恶化制冷剂在泡沫金属加热表面池沸腾的换热特性,传热系数最多降低15%;相比平加热面,润滑油对泡沫金属加热表面池沸腾换热恶化的程度低。基于混合物性,开发了制冷剂/油混合物在泡沫金属加热表面池沸腾换热关联式,预测值与95%的实验数据偏差在±10%之内。

电流对GH4169合金电渣重熔过程影响的数值模拟研究

借助模拟软件MeltFlow,模拟了电渣重熔过程中各物理场的分布情况,分析了电流变化对凝固过程中各种物理场的影响。结果表明,各物理场随电流的增大呈规律性变化,且在不同的电流大小下分布规律相似;计算模拟结果与硫印实验结果吻合良好,能够预测不同工艺条件下缺陷的产生及程度,能够设计和优化现有的工艺并改进钢锭质量。

重金属(Cd、Cu、Zn和Pb)在淮南塌陷塘鲫鱼体内的分布特征及健康风险

从淮南煤矿区塌陷塘采集鲫鱼样品,分析重金属元素(Cd、Cu、Zn和Pb)在鲫鱼体内的富集特征,结果发现,Cd、Cu、Zn和Pb在塌陷区鲫鱼(Carassius auratus Gibelio)肌肉中含量均低于《无公害食品水产品中有毒有害物质限量》(NY5073—2006)、食品中污染物限量(GB2762—2005)和FAO/WHO标准.重金属元素在鲫鱼体内的富集器官主要为内脏和鳃,Cd和Pb主要富集在内脏,Zn主要富集在鱼鳃,Cu的富集器官随着地域变化(对照为鳃,塌陷区为内脏).目标危险系数(THQ)分析发现Cu导致的健康风险较高,Cd最低,单一重金属THQ值和复合重金属的TTHQ值均小于1,说明研究区域内的鱼肉均不产生对人体危害的健康风险.