Feasibility of surface-coated friction grade austenitic stir welding tools to join AISI 304 stainless steel

An attempt is made to develop the tools that are capable enough to withstand the shear, impact and thermal forces that occur during friction stir welding of stainless steels. The atmospheric plasma spray and plasma transferred arc hardfacing processes are employed to deposit refractory ceramic based composite coatings on the Inconel 738 alloy. Five different combinations of self-fluxing alloy powder and 60% ceramic rein- forcement particulate mixtures are used for coating. The best friction stir welding tool selected based on tool wear analysis is used to fabricate the austenitic stainless steel joints.     

Detection Algorithm for LFM Echo of Underwater Moving Targets Based on Discrete Fractional Fourier Transform

The mismatch between echo and replica caused by underwater moving target（UMT）＇s radial velocity degrades the detection performance of the matched filter（MF） for the linear frequency modulation（LFM） signal. By using the focusing property of fractional Fourier transform（FRFT） to that signal, a detection algorithm for UMT＇s LFM echo based on the discrete fractional Fourier transform（DFRFT） is proposed. This algorithm is less affected by the target＇s radial velocity compared with the other MF detection algorithm utilizing zero radial velocity replica（ZRVR）, and the mathematical relation between the output peak positions of these two algorithms exists in the case of existence of target echo. The algorithm can also estimate the target distance by using this relation. The simulation and experiment show that this algorithm＇s detection performance is better than or equivalent to that of the other MF algorithm utilizing ZRVR for the LFM echo of UMT with unknown radial velocity under reverberation noise background.     

Research on Explosive Welding Technology of Railway Connector

Railway signal transmission is the key to ensure the safe and normal operation of the train. The railway connecting line for signal transmission is important equipment to guarantee the railway signal transmission and reduce the imbalance of electric current. In point of engineering application, the explosive welding technology of railway connecting line is studied theoretically, the appearance, tensile strength, micro configuration of welding junction , welding area are detected after explosive welding. Experimental and detecting results show that the connecting quality of explosive welding is reliable, which lays the foundation for the engineering practice of technology.     

Experimental investigation of Tie6Ale4V titanium alloy and 304L stainless steel friction welded with copper interlayer

The basic principle of friction welding is intermetallic bonding at the stage of super plasticity attained with self-generating heat due to friction and finishing at upset pressure. Now the dissimilar metal joints are especially popular in defense, aerospace, automobile, bio-medical,refinery and nuclear engineerings. In friction welding, some special alloys with dual phase are not joined successfully due to poor bonding strength. The alloy surfaces after bonding also have metallurgical changes in the line of interfacing. The reported research work in this area is scanty. Although the sound weld zone of direct bonding between Tie6Ale4 V and SS304 L was obtained though many trials, the joint was not successful. In this paper, the friction welding characteristics between Tie6Ale4 V and SS304 L into which pure oxygen free copper(OFC) was introduced as interlayer were investigated. Boxe Behnken design was used to minimize the number of experiments to be performed. The weld joint was analyzed for its mechanical strength. The highest tensile strength between Tie6Ale4 V and SS304 L between which pure copper was used as insert metal was acquired. Micro-structural analysis and elemental analysis were carried out by EDS, and the formation of intermetallic compound at the interface was identified by XRD analysis.     

Optimal Guaranteed Cost Control Algorithm for Automatic Chain Shell Magazine

The automatic chain shell magazine is the primary subassembly of the automatic ammunition loading system of a big-caliber howitzer. Due to the change of the shell amount in the magazine during firing, its positioning control is a kind of control problem of systems with uncertain parameters. In order to realize accurate control of shell position, an optimal guaranteed cost control algorithm based on linear matrix inequality (LMI) theory was put forward. The motion equations of the magazine were built, and the motion equations for four special load situations were linearized; according to the basic theory of the guaranteed cost control, the motion equations were written as the standard forms for linear uncertain systems; the optimal guaranteed cost control law for the position control of the magazine was obtained by use of LMI toolbox in MATLAB package. Using this control law, the controlled dynamic simulation of the shell magazine was carried out. The simulation results indicate that the control algorithm has high control precision.     

Experimental Research on the Mechanism of Lift Amplification and Vibration Suppression of Lorentz Force

The Lorentz force generated by electromagnetic field on the surface of the cylinder in the electrolyte solution may modify the structure of the flow boundary layer effectively. The transient control process of Lorentz force is investigated experimentally for lift amplification and vibration suppression. The experiments are conducted in a rotating annular tank filled with a low-conducting electrolyte. A cylinder with an electro-magnet- ic actuator is placed into the electrolyte. The lift force of cylinder is measured using the strain gages attached to a fixed beam, and the flow fields are visualized by the dye markers. The results show that the upper vortex on the cylinder is suppressed, and the wake becomes a line and leans to the lower side under the action of upside Lorentz force while the lower vortex on the cylinder is suppressed and limited in a small region. Therefore, the value of lift increases with the variation of flow field. However, the vortexes on the cylinder are suppressed fully under the action of symmetrical Lorentz force which leads to the suppression of lift oscillation and then the vibration of cylinder are suppressed fully.     

A Void Reference Sensor-Multiple Signal Classification Algorithm for More Accurate Direction of Arrival Estimation of Low Altitude Target

There exists MUSIC （multiple signal classification） algorithm for direction of arrival （DOA） estimation. This paper is to present a different MUSIC algorithm for more accurate estimation of low altitude target. The possibility of better performance is analyzed using a void reference sensor （VRS） in MUSIC algorithm. The following two topics are discussed： 1） the time delay formula and VRS-MUSIC algorithm with VRS located on the minus of z-axes; 2） the DOA estimation results of VRS-MUSIC and MUSIC algorithms. The simulation results show VRS-MUSIC algorithm has three advantages compared with MUSIC： 1） When the signal to noise ratio （SNR） is more than - 5 dB, the direction estimation error is 1/2 as much as that obtained by MUSIC; 2） The side lobe is more lower and the stability is better; 3） The size of array that the algorithm requires is smaller.     

Enhancement of wear and ballistic resistance of armour grade AA7075 aluminium alloy using friction stir processing

Industrial applications of aluminium and its alloys are restricted because of their poor tribological properties. Thermal spraying, laser surfacing, electron beam welding are the most widely used techniques to alter the surface morphology of base metal. Preliminary studies reveal that the coating and layering of aluminium alloys with ceramic particles enhance the ballistic resistance. Furthermore, among aluminium alloys,7075 aluminium alloy exhibits high strength which can be compared to that of steels and has profound applications in the designing of lightweight fortification structures and integrated protection systems. Having limitations such as poor bond integrity, formation of detrimental phases and interfacial reaction between reinforcement and substrate using fusion route to deposit hard particles paves the way to adopt friction stir processing for fabricating surface composites using different sizes of boron carbide particles as reinforcement on armour grade 7075 aluminium alloy as matrix in the present investigation. Wear and ballistic tests were carried out to assess the performance of friction stir processed AA7075 alloy. Significant improvement in wear resistance of friction stir processed surface composites is attributed to the change in wear mechanism from abrasion to adhesion. It has also been observed that the surface metal matrix composites have shown better ballistic resistance compared to the substrate AA7075 alloy. Addition of solid lubricant Mo S2 has reduced the depth of penetration of the projectile to half that of base metal AA7075 alloy. For the first time, the friction stir processing technique was successfully used to improve the wear and ballistic resistances of armour grade high strength AA7075 alloy.     

Quantitative Testing of Defect for Gun Barrels

The magnetic flux leakage （MFL） method is commonly used in the nondestructive evaluation （NDE） of gun barrels. The key point of MFL testing is to estimate the crack geometry parameters based on the measured signal. The analysis of magnetic leakage fields can be obtained by solving Maxwell＇s equations using finite element method （FEM）. The radial component of magnetic flux density is measured in MFL testing. The peak-peak value, the separation distance between positive and negative peaks of signal and the lift-off value of Hall-sensor are used as the main features of every sample. This paper establishes the multi-regression equations related to the width （the depth） of crack and the main characteristic values. The regression model is tested by use of the magnetic leakage data. The experimental results indicate that the regression equations can accurately predict the 2-D defect geometry parameters and the MFL quantitative testing can be achieved.     

Contact Force Distribution and Static Load-carrying Capacity of Large Size Double Row Four-point Contact Ball Bearing

Clearance not only affects the startup torque, rotation precision and stiffness of bearing, but also affects the load distribution, load-carrying capacity and life of bearing. A computational model in which the clearance of bearing is that included is presented for detennining the contact force distribusion and stric load-carrying capacity of a double row four-point contact ball bearing which is subjected to the combined radial, axial and overturning moment loadings. The relation between the negative axial clearance and the contact force distribution is analyzed. The static load-canying capacity curvesthe established, and the effects of the changes in negative axial clearance, curvatthe radius coefficient of raceway groove and initial contact angle on the static load-carrying capacityse analyzed. The results show that, with the increase in the absolute value of negative clearance, the maximurn contact load decreases first and then increases. The clearance values in the range of -0.2 mm-0 mm have life effect on the static load-carrying capacity of bearing. With the increase in the curvature radius coefficient of raceway groove and the decrease in the initial contact angle, the static load capacity of bearing decreases.     

小口径炮弹弹带摩擦焊技术

介绍了小口径炮弹弹带的摩擦焊技木。用该ェ艺装配弹带时弹体不需开槽滚花,焊后焊接热影响区宽度小,钢侧为不完全淬火组织,铜侧晶粒细化,焊接接头剪切强度≥20OMPa.摩擦焊弹带的炮弹通过多轮射击考核,证实弹带摩擦焊技术完全能满足小口径炮弹弹带装配的技术要求。     

典型铜合金T3、B5、H96与35CrMnSi的摩擦焊接性研究

应用惯性径向摩擦焊工艺研究了T3、H96、B5三种铜合金与35CrMnSi的摩擦焊接性,确定三种材料的焊接性能否满足使用要求。通过强度检测、金相、硬度测试表明:三种铜合金与35CrMnSi均能形成良好的摩擦焊接头;接头剪切强度与铜合金等强,不会产生焊接气孔等熔化焊工艺存在的焊接缺陷。研究也表明,因为熔点与导热的影响,B5+35CrMnSi钢侧的热影响区较宽。三种材料与35CrMnSi的径向摩擦焊接性能满足使用要求。     

无槽弹带焊接技术研究

研究了一种新的焊接工艺方法－熔数焊接方法，采用该方法在30mm口径弹体上焊接纯铜弹带取得成功。试验表明，焊缝成型良好，在弹体不发生熔化的前提下实现了冶金结合。结合界面平直光洁，弹带中无泛铁现象发生，界面与弹带内基本无缺陷，轴向剪切强度，切向扭转剪切强度均大于弹带自身强度。靶试试验表明熔数焊接弹带性能满足弹药射击性能要求。     

预紧力与装配偏差对航天轴承摩擦力矩的影响研究

针对低速、轻载航天轴承的摩擦力矩,建立了固体润滑航天轴承摩擦力矩的数学模型。结合拟静力学建立轴承受力平衡方程,研究径向装配位置偏差引起钢球受载变化情况,分析了轴向预紧载荷与径向装配位置偏差对航天轴承摩擦力矩的影响规律。研究结果表明：弹性滞后摩擦力矩、微滑动摩擦力矩和自旋摩擦力矩都随着轴向预紧载荷、径向偏载荷增加而增大;在轴向预紧载荷作用下,摩擦力矩组成分量中的弹性滞后摩擦力矩和自旋摩擦力矩增长趋势为下凸,微滑摩擦力矩增长趋势为上凸;而在径向位置偏差引起的径向偏载荷作用下摩擦力矩组成分量增长趋势为上凸;微滑动摩擦力矩和弹性滞后摩擦力矩为航天轴承摩擦力矩的主要组成部分;轴向预紧载荷和径向偏载荷导致摩擦力矩随其增加而增加,其中对差动摩擦力矩的影响作用最为显著,对弹性滞后摩擦力矩的影响次之,对自旋摩擦力矩的影响最弱。     

考虑区间不确定性的某弹丸提升装置参数优化

针对某自动装填系统弹丸提升装置在使用过程中出现的性能下降问题,提出一种考虑区间不确定性的提升装置参数优化方法。基于动力学分析软件ADAMS建立提升装置的机电液耦合模型,将液压系统参数和摩擦系数作为区间不确定量,利用区间数序关系将构件载荷及其波动区间最小转化为确定性优化目标。采用拉丁超立方抽样(LHS)技术进行抽样仿真,基于径向基函数(RBF)神经网络方法构建了提升装置的近似模型,大大提高了优化求解效率。基于多岛遗传算法和序列二次规划法的双层嵌套优化方法求得系统的鲁棒解,仿真结果与试验结果均验证了该方法在解决自动装填系统等复杂问题中的有效性和适用性。     

搅拌摩擦焊接中材料变形及残余应力分析

采用数值模拟手段,分析了在搅拌摩擦焊接过程中不同材料的变形情况及其残余应力的分布,研究了材料变形与残余应力之间的关系,并建立了异种金属搅拌摩擦焊接的模型。研究结果表明,搅拌摩擦焊接过程中材料的流动主要集中在焊接构件的后退侧,且在搅拌摩擦焊接过程中铝合金较钢表现出更好的流动性能。残余应力分布呈现典型的双峰特征,残余应力的最大值发生在热影响区的边界。拉伸残余应力较大的区域与等效塑性应变较大的区域具有较好的对应关系。异种金属焊接会增大焊接构件搅拌区内较软材料一侧的残余应力。     

搅拌摩擦焊材料塑性流动可视化研究现状

综述近年来国内外搅拌摩擦焊塑性流动可视化技术的研究现状,分析各种方法的基本原理及优缺点。研究现状表明:异种材料金相组织显示法可以观察到焊缝接头宏观流动,而对搅拌摩擦焊塑性流动的细节无法获取;彩泥法颜色鲜明,易于观察,但其是非晶体材料,故只能在一定程度上模拟搅拌摩擦焊的塑性流动状况;标识材料示踪法是搅拌摩擦焊材料塑性流动可视化工作的主要手段,其选用原则、焊接过程及焊后采用的可视化手段仍需进一步深入探讨;数值模拟是一种高效、低成本的研究方法,其具备再现焊接过程的能力,模拟过程的边界值、搅拌头的描述等方面需要进一步深入探讨。     

30mm厚7A52铝合金搅拌摩擦焊接组织与性能研究

针对30 mm厚的7A52铝合金,采用搅拌摩擦焊接技术进行单道焊接试验,利用光学显微镜等工具对焊接接头组织及力学特性进行研究。结果表明:沿焊缝区横截面的硬度分布呈现W形,TMAZ/HAZ过渡区为接头软化区,硬度最低值在前进侧的TMAZ/HAZ过渡区;焊接接头强度达到母材强度的85.8%,断裂于TMAZ/HAZ过渡区,为韧窝断口形貌。     

2519铝合金及焊缝应力腐蚀性能研究

用美国ER2319焊丝,采用钨极氩弧焊接和搅拌摩擦焊接工艺焊接2519铝合金板材。对两种焊接工艺焊接的板材焊缝部位取样,用慢应变速率试验方法,研究2519铝合金板材及两种焊接工艺焊接的接头,在3.5%NaCl溶液中,1.58×10-6s-1的慢应变速率下的应力腐蚀特性。试验结果表明:2519铝合金板材及焊缝抗应力腐蚀性能较好;用钨极氩弧焊接工艺焊接的试样,在惰性气体中试样断在焊缝的熔合线附近;搅拌摩擦焊接工艺焊接试样,不论在惰性气体还是在3.5%NaCl溶液中,均断裂在焊缝部位。焊缝区的抗应力腐蚀性能好于板材。     

6061-O铝合金搅拌摩擦焊研究

采用搅拌摩擦焊(FSW)方法对6mm厚的6061-O铝合金板材进行对接,利用光学显微镜(OM)和扫描电镜(SEM)分析母材和焊接接头的显微组织和断口形貌,并测试其拉伸性能和显微硬度。结果表明:焊接速度v为300mm/min时,当搅拌头旋转速度n低于800r/min,6061-O铝合金FSW接头出现明显的未焊合缺陷;当转速提高到1200r/min,接头缺陷消失,接头拉伸性能与母材接近。在所选工艺参数下获得的FSW接头硬度均比母材高,最高点均出现在焊核区;断口分析表明,断裂均为韧性断裂,且位置均出现在远离接头的前进侧热影响区。