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
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 effects of applying an electromagnetic interaction of low intensity (EMILI) on the microstructure and corrosion resistance of 7075-T651 Al alloy plates (13 mm in thickness) during modified indirect electric arc (M...The effects of applying an electromagnetic interaction of low intensity (EMILI) on the microstructure and corrosion resistance of 7075-T651 Al alloy plates (13 mm in thickness) during modified indirect electric arc (MIEA) welding were investigated. The welding process was conducted in a single pass with a heat input of ~1.5 kJ/mm. The microstructural observations of the welds were correlated with the effect of EMILI on the local mechanical properties and the corrosion resistance in natural seawater by means of microhardness measurements and electrochemical impedance spectroscopy, respectively. Microstructural characterization of the welds revealed a grain refinement in the weld metal due to the electromagnetic stirring induced by EMILI of 3 mT during welding. In addition, observations in the scanning electron microscope showed that the precipitation of Cu-rich phases and segregation of eutectics were reduced in the heat affected zone (HAZ) also as an effect of EMILI. The high corrosion dissolution of the 7075-T651 welds in natural seawater and the extent of overaging in the HAZ were reduced when welding with EMILI of 3 mT. Thus, EMILI along with the MIEA technique may lead to welded joints with better microstructural characteristics, improved mechanical properties in the HAZ and reduced electrochemical activity.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
间接电弧焊接是一种新型的焊接方法,具有高效、节能、焊接应力和变形小的优点。为了研究间接电弧的电弧参数的分布特点以及这种焊接方法热输入低的根本原因,利用有限元分析软件,建立双钨极间接电弧的三维有限元数学模型,计算得到双钨极...间接电弧焊接是一种新型的焊接方法,具有高效、节能、焊接应力和变形小的优点。为了研究间接电弧的电弧参数的分布特点以及这种焊接方法热输入低的根本原因,利用有限元分析软件,建立双钨极间接电弧的三维有限元数学模型,计算得到双钨极间接电弧的温度、等离子体流速、电弧压力以及热流密度分布等特征参数;通过高速摄像拍摄到的电弧形态照片与计算得到的温度云图对比验证模拟结果的可信性。结果表明双钨极间接电弧面对称且向阳极方向偏转,呈上宽下窄的倒钟罩形态,阳极一侧的各项特征参数大于阴极一侧;与惰性气体钨极保护(Tungsten inert gas arc,TIG)焊接和等离子弧焊接相比,双钨极间接电弧被焊接工件不接电极,主要靠热流密度、等离子体流速、电弧压力等参数都比较低的弧柱区端部加热,造成工件焊接热输入低、熔深浅。展开更多
三丝间接电弧焊是一种新型电弧焊技术,电弧放电通道形成于三个电极之间,电极极性的连接方式会对焊接过程产生重要影响。为揭示不同极性连接方式的三丝气体间接电弧中厚板焊接过程工艺特点,采用主丝接正和主丝接负的连接方式分别对8 mm Q...三丝间接电弧焊是一种新型电弧焊技术,电弧放电通道形成于三个电极之间,电极极性的连接方式会对焊接过程产生重要影响。为揭示不同极性连接方式的三丝气体间接电弧中厚板焊接过程工艺特点,采用主丝接正和主丝接负的连接方式分别对8 mm Q345低碳钢板进行了对接焊试验。结果表明,在两种极性连接方式的三丝间接电弧中厚板焊接过程中,由于电弧形态以及熔滴过渡路径的差异,主丝接正时的稳定性不受电弧所处阶段的影响;而主丝接负时,熔滴在焊接阶段容易发生短路爆炸造成焊接稳定性下降,这是焊缝表面气孔以及接头局部未熔合缺陷产生的主要原因;随着焊接电流的增大,两种极性下的电弧弧柱区宽度均增大,且主丝接正时的弧柱区的电子温度均大于主丝接负时的。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.
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.
文摘The effects of applying an electromagnetic interaction of low intensity (EMILI) on the microstructure and corrosion resistance of 7075-T651 Al alloy plates (13 mm in thickness) during modified indirect electric arc (MIEA) welding were investigated. The welding process was conducted in a single pass with a heat input of ~1.5 kJ/mm. The microstructural observations of the welds were correlated with the effect of EMILI on the local mechanical properties and the corrosion resistance in natural seawater by means of microhardness measurements and electrochemical impedance spectroscopy, respectively. Microstructural characterization of the welds revealed a grain refinement in the weld metal due to the electromagnetic stirring induced by EMILI of 3 mT during welding. In addition, observations in the scanning electron microscope showed that the precipitation of Cu-rich phases and segregation of eutectics were reduced in the heat affected zone (HAZ) also as an effect of EMILI. The high corrosion dissolution of the 7075-T651 welds in natural seawater and the extent of overaging in the HAZ were reduced when welding with EMILI of 3 mT. Thus, EMILI along with the MIEA technique may lead to welded joints with better microstructural characteristics, improved mechanical properties in the HAZ and reduced electrochemical activity.
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.
文摘间接电弧焊接是一种新型的焊接方法,具有高效、节能、焊接应力和变形小的优点。为了研究间接电弧的电弧参数的分布特点以及这种焊接方法热输入低的根本原因,利用有限元分析软件,建立双钨极间接电弧的三维有限元数学模型,计算得到双钨极间接电弧的温度、等离子体流速、电弧压力以及热流密度分布等特征参数;通过高速摄像拍摄到的电弧形态照片与计算得到的温度云图对比验证模拟结果的可信性。结果表明双钨极间接电弧面对称且向阳极方向偏转,呈上宽下窄的倒钟罩形态,阳极一侧的各项特征参数大于阴极一侧;与惰性气体钨极保护(Tungsten inert gas arc,TIG)焊接和等离子弧焊接相比,双钨极间接电弧被焊接工件不接电极,主要靠热流密度、等离子体流速、电弧压力等参数都比较低的弧柱区端部加热,造成工件焊接热输入低、熔深浅。
文摘三丝间接电弧焊是一种新型电弧焊技术,电弧放电通道形成于三个电极之间,电极极性的连接方式会对焊接过程产生重要影响。为揭示不同极性连接方式的三丝气体间接电弧中厚板焊接过程工艺特点,采用主丝接正和主丝接负的连接方式分别对8 mm Q345低碳钢板进行了对接焊试验。结果表明,在两种极性连接方式的三丝间接电弧中厚板焊接过程中,由于电弧形态以及熔滴过渡路径的差异,主丝接正时的稳定性不受电弧所处阶段的影响;而主丝接负时,熔滴在焊接阶段容易发生短路爆炸造成焊接稳定性下降,这是焊缝表面气孔以及接头局部未熔合缺陷产生的主要原因;随着焊接电流的增大,两种极性下的电弧弧柱区宽度均增大,且主丝接正时的弧柱区的电子温度均大于主丝接负时的。
