Investigation on the deposition rate and the dilution ratio of plasma surface welding

A new kind of plasma technology with both high deposition rate and low dilution ratio was developed under the calculation and analysis of the arc flame characteristics of plasma arc,the kinematics behavior of powder and powder's heating in the arc. Compared with normal plasma surfacing method, the idea using constricting nozzle with small orifice diameter, long plasma arc and increasing the distance from meeting point of the two beams of powder to workpiece, to achieve the goals of high deposition rate and low dilution ratio, was put forward here. In order to prove this idea, a set of experimental system was built up and obtained satisfied results including high deposition rate(more than 25 kg/h )and low dilution ratio(less than 5%). The success of this study offers a promising prospect for developing the powder plasma surface welding in China and may open a way to improve this technology further in efficiency and quality.

Specular reflection based sensing surface deformation of gas tungsten arc weld pool

A sensing system is developed to measure the weld pool boundary and pool suoface deformation in gas tungsten arc welding. LaserStrobe technique is used to eliminate the strong arc light inteoference, and specular reflection from the pool suoface is sensed to describe the relation between the deformed stripes and pool surface depression. Clear images of both the pool boundary and the deformed stripes edges are obtained during gas tungsten arc welding process, which lays foundation for realtime monitoring the pool suoface depression and weld penetration.

RECONSTRUCTION OF WELD POOL SURFACE BASED ON SHAPE FROM SHADING

A valid image-processing algorithm of weld pool surface reconstruction according to an input image of weld pool based on shape from shading （SFS） in computer vision is presented. The weld pool surface information is related to the backside weld width, which is crucial to the quality of weld joint. The image of weld pool is recorded with an optical sensing method. Firstly, the reflectance map model, which specifies the imaging process, is estimated. Then, the algorithm of weld pool surface reconstruction based on SFS is implemented by iteration scheme and speeded by hierarchical structure. The results indicate the accuracy and effectiveness of the approach.

Oscillation Modes of Weld Pool in Stationary GTA Welding Using Structure Laser Method

Researchers have recently attempted to monitor pool oscillations using the three-dimensional laser vision method.However,the deficiency of simulation software will result in significant capital expenditure.Both simulations and experiments are performed in this study,and the Bessel equation is used to analyze the oscillation mode of a weld pool.The laser dot matrix images of(0,1),(1,1),(2,1),and(0,2)oscillation modes at different times are obtained via structured laser optical measurement simulation.The oscillation mode of a stationary gas tungsten arc weld pool is analyzed based on laser dot matrix images obtained from a structure laser experiment.Results show that the simulated laser dot matrix images are consistent with the experiment results.The oscillation mode of the weld pool can be recognized based on the laser dot matrix image.This study not only provides conditions for assessing the penetrating state of a weld pool,but also enable a further understanding of the oscillation mode of a weld pool and the development of more effective observation methods and measurement tools to effectively control and improve welding quality.

Development of an automatic weld surface appearance inspection system using machine vision

In this paper, an automatic inspection system for weld surface appearance using machine vision has been developed to recognize weld surface defects such as porosities, cracks, etc. It can replace conventional manual visual inspection method, which is tedious, time-consuming, subjective, experience-depended, and sometimes biased. The system consists of a CCD camera, a self-designed annular light source, a sensor controller, a frame grabbing card, a computer and so on. After acquiring weld surface appearance images using CCD, the images are preprocessed using median filtering and a series of image enhancement algorithms. Then a dynamic threshold and morphology algorithms are applied to segment defect object. Finally, defect features information is obtained by eight neighborhoods boundary chain code algorithm. Experimental results show that the developed system is capable of inspecting most surface defects such as porosities, cracks with high reliability and accuracy.

Investigation on Cracking in the Surfacing Welding Layer of Ni_3Al Based Alloy

Investigation has been made into the causes of cracking in the Surfacing welding layer of Ni3Al based alloy by analysing both the liqu id-to-solid transformation in the molten pool and the distribution of thermal stress within the surfacing welding layer. The results show that cracking in the surfacing welding layer is directly related to the producing of eutectic phase β' (NiAl) in the interdendritic region and high thermal stress within the surfacing welding layer. When the process of electric arc surfacing welding is changed from along straight line to along' Z' pattern, cracking in the surfacing welding layer of Ni3Al based alloy is prevented due to being reduced of both the cooling rate of liquid in the molten pool and the moving speed of the heat source. Reducing the melting volume of the substrate material by lowering the output power of electric arc welding would make the content of iron atoms in the molten pool decrease. and this also can reduce the trend of the eutectic reaction in the interdendfitic region and is helpful to Suppress cracking in the surfacing welding layer.

Static mechanics analysis of no bumping no vibration welding structure with double-inclined surface for high-speed & heavy-load CWR

It is known from our former theoretical analysis that the single-inclined welding surface which is inclined towards the transverse direction of the rail can only eliminate vertical bumping, and the single-inclined welding surface which is inclined towards the vertical direction of the rail can only eliminate lateral vibration. In this paper, we put forward a welding structure of double-inclined welding surface to eliminate the vertical bumping and lateral vibration at the same time, and analyze the stress state of continuous welded rail (CWR) by combining geometrical azimuth. Furthermore, the increase of bearing capacity of CWR with the double-inclined welding surface is theoretically analyzed.

Effects of alloy elements on microstructure and crack resistance of Fe-C-Cr weld surfacing layer

Effects of alloy elements on the microstructure and crack resistance of Fe-C-Cr weld surfacing layer were investigated. The results show that microstructures of the layer mainly consist of carbides and austenite matrix. Increasing C and Cr contents impair the crack resistance of the layer due to increased amount of brittle carbides. The addition of Ni, Nb or Mo improves the crack resistance of Fe-C-Cr weld surfacing layer by increasing the amount of austenite and forming fine NbC or M 7C 3 carbides in the layer. But, the excessive Nb (>2.50wt%) or Mo (>1.88wt%) impairs the crack resistance of the layer, which has relation with increased carbides or carbide coarsening and austenite matrix solid solution strengthening. The proper combination of C, Cr, Ni, Nb and Mo can further improve not only the crack resistance of Fe-C-Cr weld surfacing layer but also the erosion resistance as a result of fine NbC and M 7C 3 carbides distributing uniformly in austenite matrix. The optimal layer compositions are 3.05wt%C, 20.58wt%Cr, 1.75wt%Ni, 2.00wt%Nb and 1.88wt%Mo.

Effects of Alloying Elements on Microstructure and Erosion Resistance of Fe-C-Cr Weld Surfacing Layer

Effects of alloying elements on microstructure and erosion resistance of Fe-C-Cr weld surfacing layer have been studied. The experimental results show that increasing C and Cr content favors improving the erosion resistance of the layer, and the excessive C and Cr result in decreasing the erosion resistance at 90 deg. erosion. That Mo, Nb or Ti improves the erosion resistance of Fe-C-Cr weld surfacing layer is mainly attributed to increasing the amount of M7C3 and forming fine NbC or TiC in austenite matrix, but the excessive Mo, Nb or Ti is unfavorable. The addition of Mo, Nb and Ti in proper combination possesses stronger effect on improving the erosion resistance and the erosion resistance (εA) of Fe-C-Cr weld surfacing layer with fine NbC, TiC and M7C3 distributing uniformly in austenite matrix obviously increases to 2.81 at 15 deg. erosion and 2.88 at 90 deg. erosion when the layer composition is 3.05C, 20.58Cr, 1.88Mo, 2.00Nb and 1.05Ti (in wt pct).

Erosion resistance of Fe-C-Cr weld surfacing layers

Fe C Cr weld surfacing layers with different compositions and microstructures can be obtained by submerged arc welding with welding wire of the low carbon steel and high alloy bonded flux. With the increase of Cr and C in the layers the microstructures are changed from hypoeutectoid steel, hypereutectoid steel to hypoeutectic iron and hypereutectic iron. When the weld surfacing layers belong to the alloyed cast irons the erosion resistance can be raised with the eutectic increase and the austenite decrease. Good erosion resistance can be obtained when the proportion of the primary carbides is within 10 %. The experimental results lay a foundation to make double metal percussive plates by surfacing wear resistant layers on the substrates of the low carbon steels.

SURFACING ELECTRODE WITH CRACKING RESISTANCE AND WEARABILITY

A new surfacing electrode is developed with cracking resistance andwearability based on high microhardness of TiC and VC, carbides of Ti and V are formed in depositedmetal by means of high temperature arc metallurgic reaction. The results show the hardness ofsurfacing metal increases with the increase of ferrotitanium (Fe-Ti), ferrovanadium (Fe-V) andgraphite in the coat. However, when graphite reaches the volume fraction of 11 percent, the hardnessreaches its peak value, and when beyond 11 percent, the hardness falls off. As Fe-Ti, Fe-V andgraphite increase, the cracking resistance of deposited metal and usability of electrode declines.Carbides are dispersedly distributed in the matrix structure. The matrix micro structure ofdeposited metal is lath martensite. Carbides present irregular block. When using the researchedsurfacing electrode to continue weld with non-preheated, no seeable crack or only a few micro-crackscan be observed in the surface of deposited metal. The hardness is above 60 HRC. The wearresistance is better than that of EDZCr-C-15.

APPLICATION RESEARCH ON THE Ni _3 Al INTERMETALLIC COMPOUND IN CISRI

Research work and recent progress made toward the industrial applications of the Ni_3Al in CISRI are discussed in present paper. The development of a Ni_3Al base alloy named MX-246 hardened by carbides and fine dispersion of disordered γ is summaried. This alloy,with higher peak temperature of yield strength and higher strain hardening rate than alloyIC-218,has been successfully used as the material of rolling guider at elevated temperatures and in wear conditions. The Ni3Al base alloy of GH264 has been made into welding electrodes by horizontal continuous casting process, and recently successfully surfacing welded on hydraulic blades as cavitation erosion resistance material. The process of remelting Ni3Al base alloy in air was also developed. The processes of producing welding electrodes and remelting in air set the base of industrial applications of Ni3Al in welding, repairing and casting in mass production and into components of large size. Another application of the compound, manufacturing the jet engine rivets used at about 1300℃ , can be attributed to its excellent oxidation resistance and still keeping high strength up to the melting point.

Effects of Substrate Crystallographic Orientations on Microstructure in Laser Surface-Melted Single-Crystal Superalloy:Theoretical Analysis

A geometric analysis technique for crystal growth and microstructure development in single-crystal welds had been previously developed.And the effect of welding conditions on the tendency of stray grains formation during solidification was researched.In the present work,these analytical methods were further extended.Combined with an original vectorization method,a 3D Rosenthal solution was used to determine thermal conditions of the welds.Afterward,the dendrite growth orientation,the dendrite growth velocity and the thermal gradient along dendrite direction were calculated and lively plotted.Finally,the tendency of stray grains formation in the solidification front was forecasted and its distribution was presented with a 3D plot.The results indicate that substrate orientation has some impacts on the crystal growth pattern,dendrite growth velocity,distribution of thermal gradient and stray grain.Based on the research methods proposed in this work,any substrate crystallographic orientation can be studied,and predicted stray grains distribution can be visualized.

Strength Prediction of Aluminum–Stainless Steel-Pulsed TIG Welding–Brazing Joints with RSM and ANN

Pulsed TIG welding–brazing process was applied to join aluminum with stainless steel dissimilar metals. Major parameters that affect the joint property significantly were identified as pulsed peak current, base current, pulse on time,and frequency by pre-experiments. A sample was established according to central composite design. Based on the sample,response surface methodology（RSM） and artificial neural networks（ANN） were employed to predict the tensile strength of the joints separately. With RSM, a significant and rational mathematical model was established to predict the joint strength.With ANN, a modified back-propagation algorithm consisting of one input layer with four neurons, one hidden layer with eight neurons, and one output layer with one neuron was trained for predicting the strength. Compared with RSM, average relative prediction error of ANN was ／10% and it obtained more stable and precise results.