Traditional welding methods are limited in low heat input to workpiece and high welding wire melting rate. Twin-wire indirect arc（TWIA） welding is a new welding method characterized by high melting rate and low heat...Traditional welding methods are limited in low heat input to workpiece and high welding wire melting rate. Twin-wire indirect arc（TWIA） welding is a new welding method characterized by high melting rate and low heat input. This method uses two wires one connected to the negative electrode and another to the positive electrode of a direct-current（DC） power source. The workpiece is an independent, non-connected unit. A three dimensional finite element model of TWIA is devised. Electric and magnetic fields are calculated and their influence upon TWIA behavior and the welding process is discussed. The results show that with a 100 A welding current, the maximum temperature reached is 17 758 K, arc voltage is 14.646 V while maximum current density was 61 A/mm2 with a maximum Lorene force of 84.5 ~tN. The above mentioned arc parameters near the cathode and anode regions are far higher than those in the arc column region. The Lorene force is the key reason for plasma velocity direction deviated and charged particles flowed in the channel formed by the cathode, anode and upper part of arc column regions. This led to most of the energy being supplied to the polar and upper part of arc column regions. The interaction between electric and magnetic fields is a major determinant in shaping TWIA as well as heat input on the workpiece. This is a first study of electromagnetic characteristics and their influences in the TWIA welding process, and it is significant in both a theoretical and practical sense.展开更多
Twin-wire indirect arc gas shielded welding is a novel welding method. By recording the arc shape and welding parameters, the effects of welding parameters and included angle on arc characteristics are discussed in th...Twin-wire indirect arc gas shielded welding is a novel welding method. By recording the arc shape and welding parameters, the effects of welding parameters and included angle on arc characteristics are discussed in this paper. The experimental results show increasing welding current can prompt centralized and straight of arc due to increasing plasma force and electric magnetic pinch effect. Increasing arc voltage can increase the size and brightness of the arc, as a result of increasing arc energy. The reducing of included angle increases the electric magnetic pinch effect, the arc becomes slender and supplies higher energy. It is thought the smaller included angle is beneficial to obtain perfect weld bead.展开更多
Metal transfer of twin-wire indirect arc argon welding was investigated with high speed camcorder system based on a xenon lamp source and digital oscillograph, forces on droplet were analyzed in this paper. Results sh...Metal transfer of twin-wire indirect arc argon welding was investigated with high speed camcorder system based on a xenon lamp source and digital oscillograph, forces on droplet were analyzed in this paper. Results show metal transfer mode that of anodal and cathodal is not completely the same. It was divided into seven types of transfer mode; spray transfer and spray-projected transfer are the important transfer mode. The base-plate was melted by energy that of the arc and drop carrying, the drop transfer direction is different from that of the current flow, anodal and cathodal drop transfer at the same time, only the frequence and size are different.展开更多
Thermal sprayed Ni-5wt.% Al coating was fabricated on the substrate of 6061-T6 aluminum alloy by twin-wire arc spraying. Experimental results indicated that the average value of bond strength was around 46. 90 MPa, th...Thermal sprayed Ni-5wt.% Al coating was fabricated on the substrate of 6061-T6 aluminum alloy by twin-wire arc spraying. Experimental results indicated that the average value of bond strength was around 46. 90 MPa, the average hardness was 240 HV and the average value of surface roughness was about O. 14 mm. Friction and wear test results showed that the dry friction coefficient of Ni-5wt.% Al coating firstly decreased, and then tended to a slight increase after 200 cycles. In the early abrasion stage, adhesion wear played the key role for wear mechanics of Ni-5wt.% Al coating, but gradually abrasive wear became to replace adhesion wear.展开更多
A consumable aided tungsten indirect arc welding method has been studied. This method is different from the traditional TIG welding because it introduces an MIG welding torch into the traditional TIG welding system. A...A consumable aided tungsten indirect arc welding method has been studied. This method is different from the traditional TIG welding because it introduces an MIG welding torch into the traditional TIG welding system. An indirect arc is generated between the consumable electrode of the MlG welding torch and the tungsten electrode of the TIG welding torch, but not generated between the tungsten electrode of the welding torch and the base metal. Welding current flows from the consumable electrode to the tungsten electrode in the free-burning indirect are. The consumable aided tungsten indirect arc welding not only rapidly melts the welding wire but also effectively restrains the excessive fusion of the base metal. The welding experiment and the theoretical analysis confirm that this method can obtain a high deposition rate and a low dilution ratio during the welding process.展开更多
The contradiction between manufacturing accuracy and manufacturing efficiency is discussed in this paper.In order to solve this problem,a novel droplet-targeting laser hybrid indirect arc for additive manufacturing te...The contradiction between manufacturing accuracy and manufacturing efficiency is discussed in this paper.In order to solve this problem,a novel droplet-targeting laser hybrid indirect arc for additive manufacturing technology is proposed in which a couple of wires are melted using the alternating current with interwire indirect arc to achieve high deposition rate.On the other hand,droplets actively target the laser beam and detach from wire tip under the recoil pressure subjected to pulsed laser irradiating at desired position and with controlled mass for a precise bead forming.The process of alternative droplet growing at desired position are mathematically analyzed and then preliminary verified by experiment.By precisely controlling the wire feed speed and current frequency,the melting process at desired position and mass of wire is successfully obtained which is the fundamental for next-step for the droplet actively targeting laser.展开更多
Dilution of a pad weld must be limited to a certain critical level to improve its wear and/or corrosion properties.To do that,a novel single wire indirect arc metal inert gas welding process operated in streaming mode...Dilution of a pad weld must be limited to a certain critical level to improve its wear and/or corrosion properties.To do that,a novel single wire indirect arc metal inert gas welding process operated in streaming mode was realized.A metal inert gas welding torch,arranged perpendicular to a substrate in vertical position,is fixed with an auxiliary tungsten electrode horizontally.The arc is ignited between a wire through the torch and the auxiliary electrode.The substrate is not electrically connected.The welding current is set in the range of streaming mode.304 stainless steel was pad welded on Q235 substrates in vertical position by this process.Microstructures were analyzed with optical microscope.Dilution ratios were measured with stereo light microscope and calculated.The results show that,after eliminating interference of the massive torch setup,the dilution ratio of the pad weld with optimized parameters is 5.07%,much less than that with a metal inert gas welding process,which is 26.46%.The pad weld is bonded to the substrate without defects.Microstructures of the pad weld consist of columnar austenite and ferrite between the columns.The dilution ratio increases with increasing welding current or welding velocity,and decreases with increasing distance to the substrate.展开更多
The tenacity of heat-affected zone （HAZ） will decline and the size of grains will increase, because of the overheating on HAZ when submerged are welding （SAW） is ased to thick plate with high heat input. The shapi...The tenacity of heat-affected zone （HAZ） will decline and the size of grains will increase, because of the overheating on HAZ when submerged are welding （SAW） is ased to thick plate with high heat input. The shaping will worsen when SAW is used to thin plate with high current at high speed. A new SAW technology, the pulsed direct current （DC） automatic SAW, will be put forward in this paper in order to overcome the above shortcomings. And a pulsed controller with micro-controller unit （MCU） as the core, nixie tube （NT） and keyboard as the man-machine conversation interface is developed. The main functions of the pulsed controller include the output of pulsed welding current and the working with twinwire. The research has widely prospects in application with significant meanings in theory and practical engineering.展开更多
基金Supported by National Natural Science Foundation of China(Grant No.51171093)
文摘Traditional welding methods are limited in low heat input to workpiece and high welding wire melting rate. Twin-wire indirect arc（TWIA） welding is a new welding method characterized by high melting rate and low heat input. This method uses two wires one connected to the negative electrode and another to the positive electrode of a direct-current（DC） power source. The workpiece is an independent, non-connected unit. A three dimensional finite element model of TWIA is devised. Electric and magnetic fields are calculated and their influence upon TWIA behavior and the welding process is discussed. The results show that with a 100 A welding current, the maximum temperature reached is 17 758 K, arc voltage is 14.646 V while maximum current density was 61 A/mm2 with a maximum Lorene force of 84.5 ~tN. The above mentioned arc parameters near the cathode and anode regions are far higher than those in the arc column region. The Lorene force is the key reason for plasma velocity direction deviated and charged particles flowed in the channel formed by the cathode, anode and upper part of arc column regions. This led to most of the energy being supplied to the polar and upper part of arc column regions. The interaction between electric and magnetic fields is a major determinant in shaping TWIA as well as heat input on the workpiece. This is a first study of electromagnetic characteristics and their influences in the TWIA welding process, and it is significant in both a theoretical and practical sense.
文摘Twin-wire indirect arc gas shielded welding is a novel welding method. By recording the arc shape and welding parameters, the effects of welding parameters and included angle on arc characteristics are discussed in this paper. The experimental results show increasing welding current can prompt centralized and straight of arc due to increasing plasma force and electric magnetic pinch effect. Increasing arc voltage can increase the size and brightness of the arc, as a result of increasing arc energy. The reducing of included angle increases the electric magnetic pinch effect, the arc becomes slender and supplies higher energy. It is thought the smaller included angle is beneficial to obtain perfect weld bead.
基金Natural Science Foundation of Shandong Province (Z2002F03)College Scientific and Technological Project of Shandong Province (J09LD04)Shandong University of Science and Technology Spring Buds Program (2008BWZ059, 2009AZZ001)
文摘Metal transfer of twin-wire indirect arc argon welding was investigated with high speed camcorder system based on a xenon lamp source and digital oscillograph, forces on droplet were analyzed in this paper. Results show metal transfer mode that of anodal and cathodal is not completely the same. It was divided into seven types of transfer mode; spray transfer and spray-projected transfer are the important transfer mode. The base-plate was melted by energy that of the arc and drop carrying, the drop transfer direction is different from that of the current flow, anodal and cathodal drop transfer at the same time, only the frequence and size are different.
文摘Thermal sprayed Ni-5wt.% Al coating was fabricated on the substrate of 6061-T6 aluminum alloy by twin-wire arc spraying. Experimental results indicated that the average value of bond strength was around 46. 90 MPa, the average hardness was 240 HV and the average value of surface roughness was about O. 14 mm. Friction and wear test results showed that the dry friction coefficient of Ni-5wt.% Al coating firstly decreased, and then tended to a slight increase after 200 cycles. In the early abrasion stage, adhesion wear played the key role for wear mechanics of Ni-5wt.% Al coating, but gradually abrasive wear became to replace adhesion wear.
文摘A consumable aided tungsten indirect arc welding method has been studied. This method is different from the traditional TIG welding because it introduces an MIG welding torch into the traditional TIG welding system. An indirect arc is generated between the consumable electrode of the MlG welding torch and the tungsten electrode of the TIG welding torch, but not generated between the tungsten electrode of the welding torch and the base metal. Welding current flows from the consumable electrode to the tungsten electrode in the free-burning indirect are. The consumable aided tungsten indirect arc welding not only rapidly melts the welding wire but also effectively restrains the excessive fusion of the base metal. The welding experiment and the theoretical analysis confirm that this method can obtain a high deposition rate and a low dilution ratio during the welding process.
基金supported by National Natural Science Foundation of China(51475009)National Natural Science Funded Youth Projects(51505009)+1 种基金Natural Science Foundation of Beijing Projects(3162004)China Postdoctoral Science Foundation Program(2015M570021)。
文摘The contradiction between manufacturing accuracy and manufacturing efficiency is discussed in this paper.In order to solve this problem,a novel droplet-targeting laser hybrid indirect arc for additive manufacturing technology is proposed in which a couple of wires are melted using the alternating current with interwire indirect arc to achieve high deposition rate.On the other hand,droplets actively target the laser beam and detach from wire tip under the recoil pressure subjected to pulsed laser irradiating at desired position and with controlled mass for a precise bead forming.The process of alternative droplet growing at desired position are mathematically analyzed and then preliminary verified by experiment.By precisely controlling the wire feed speed and current frequency,the melting process at desired position and mass of wire is successfully obtained which is the fundamental for next-step for the droplet actively targeting laser.
文摘Dilution of a pad weld must be limited to a certain critical level to improve its wear and/or corrosion properties.To do that,a novel single wire indirect arc metal inert gas welding process operated in streaming mode was realized.A metal inert gas welding torch,arranged perpendicular to a substrate in vertical position,is fixed with an auxiliary tungsten electrode horizontally.The arc is ignited between a wire through the torch and the auxiliary electrode.The substrate is not electrically connected.The welding current is set in the range of streaming mode.304 stainless steel was pad welded on Q235 substrates in vertical position by this process.Microstructures were analyzed with optical microscope.Dilution ratios were measured with stereo light microscope and calculated.The results show that,after eliminating interference of the massive torch setup,the dilution ratio of the pad weld with optimized parameters is 5.07%,much less than that with a metal inert gas welding process,which is 26.46%.The pad weld is bonded to the substrate without defects.Microstructures of the pad weld consist of columnar austenite and ferrite between the columns.The dilution ratio increases with increasing welding current or welding velocity,and decreases with increasing distance to the substrate.
文摘The tenacity of heat-affected zone （HAZ） will decline and the size of grains will increase, because of the overheating on HAZ when submerged are welding （SAW） is ased to thick plate with high heat input. The shaping will worsen when SAW is used to thin plate with high current at high speed. A new SAW technology, the pulsed direct current （DC） automatic SAW, will be put forward in this paper in order to overcome the above shortcomings. And a pulsed controller with micro-controller unit （MCU） as the core, nixie tube （NT） and keyboard as the man-machine conversation interface is developed. The main functions of the pulsed controller include the output of pulsed welding current and the working with twinwire. The research has widely prospects in application with significant meanings in theory and practical engineering.
