双钨极间接气体保护焊接电弧的数值模拟

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。     

空心钨极中心负压电弧基础特性研究

为了提高传统钨极惰性气体保护(Tungsten inert gas,TIG)焊电弧的能量密度和热源边界的能量梯度,保证焊接热输入均衡,规避输入能量分散,提出空心钨极中心负压电弧焊接方法,设计并构建空心钨极中心负压电弧焊接系统,介绍系统的组成及操作方法。利用高速摄像机拍摄空心钨极中心负压电弧的宏观形态,进行定点焊接烧蚀试验,并对阳极表面熔池尺寸和焊接接头的宏观形貌进行分析。试验结果表明,在电弧自身刚性的作用下,空心钨极中心负压电弧能够稳定地建立于空心钨极和阳极工件之间;与传统TIG焊电弧相比,在宏观形态上,空心钨极中心负压电弧的弧柱沿径向收缩,呈现拘束状,空心钨极的尖端呈现白炽状态;在焊接接头的宏观形貌上,空心钨极中心负压电弧对应焊接接头的熔深大,熔宽小,焊缝成形好。     

氮氩保护的TIG焊电弧等离子体的数值分析

以TIG焊接电弧为对象，依据磁流体动力学理论构建电弧的数学模型，运用ANSYS有限元分析软件对二维稳态下轴对称的、氩氮混合气体保护的TIG焊接电弧进行了数值分析，得到了30％N2＋70％Ar（体积分数）混合气体保护下焊接电弧的温度场、速度场的形态分布特征。通过与纯氩气保护的TIG焊接电弧温度、压力以及等离子体速度等分布的比较，得出了加入氮气作为保护气体时的TIG焊接电弧能量及形态的分布变化。对比结果表明，加入氮气作为保护气体，提高了TIG焊接电弧的电弧温度、等离子体速度和电弧压力，能得到更高能量密度的焊接电弧。     

TIG-MIG复合焊电弧间相互作用对焊接过程的影响

根据毕奥-萨伐尔定律,对惰性气体钨极保护-熔化极惰性气体保护(Tungsten inert gas-metal inert gas,TIG-MIG)复合焊TIG-MIG电弧间相互作用模型进行改进;结合不同倾斜电弧下电流密度分布的自适应模型,建立TIG-MIG复合焊的电弧力-热模型。对不同焊接电流下TIG-MIG复合焊电弧倾角展开计算,分析复合焊电弧间相互作用力对工件上热流密度分布和焊缝成形的影响,发现两电弧之间存在的排斥力能够增加TIG电弧的垂直度,从而提高TIG电弧热流密度,同时MIG电弧是影响TIG-MIG复合焊焊缝成形的主要因素。研究复合焊焊枪间距和两焊枪的前后位置对焊接过程的影响,发现TIG焊枪在前、MIG焊枪在后的方式更有利于焊接过程稳定。计算结果与试验结果的对比表明,所建立的模型能够较好地描述TIG-MIG复合焊接物理过程,这对优化其焊接工艺参数具有一定的指导意义和实际应用价值。     

方波交流GTAW电弧再引燃机理的研究

交流电弧再引燃主要影响因素是电流换向瞬间的电压、电弧空间的电离度和电极发射电子的能力。方波交流电源以其高的电流换向速率提高了交流焊接电弧再引燃的可靠性。但用交流钨极氩弧焊接铝时，由于铝工件熔点和沸点低，电子发射能力弱，在钨极接负变为工件接负时，电弧再引燃困难，仍须采用附加的稳弧措施。在双逆变式交流方波电源中，在利用前级高频逆变恒流电源的快速响应特性的基础上改进了后级的电路结构，克服了传统的高压脉冲或高频高压稳弧的缺点，可靠实现了交流钨极氩弧焊铝的电弧再引燃。     

绝缘固壁约束片状偏钨极电弧载流区温度的静电探针差动分析

绝缘固壁和片状偏钨极的联合调控能够有效改变电弧温度分布,从而解决超窄间隙焊接过程中底角熔合不良的问题。为了明确绝缘固壁对片状偏钨极电弧温度的影响规律和调控机理,采用一种静电探针差动分析方法对绝缘固壁约束片状偏钨极电弧载流区进行诊断。结果表明,绝缘固壁对片状偏钨极电弧的固壁约束作用可提升电弧载流区温度峰值,使钨极厚度方向载流区温度分布范围明显收缩;约束作用能够强化片状偏钨极对电弧电流密度的引导作用,从而使电弧高温区沿钨极宽度方向向放电间隙小的位置发生整体偏移,且在电弧电场分布的影响下,沿弧长方向偏移程度由阳极向阴极减小;但过强的约束作用会导致钨极局部因电流密度过度集中而烧损,约束作用不足将无法对电弧载流区温度起到有效调控。     

低功率激光诱导电弧复合焊接钛合金薄板工艺研究

采用低功率脉冲YAG激光诱导非熔化极惰性气体保护(Tungsten inert gas,TIG)焊电弧复合热源实现了1 mm厚TC4钛合金薄板的优质焊接,研究激光诱导电弧复合焊接过程中热源能量匹配、热源间角度、对接间隙对焊缝成形的影响规律。结果表明,钛合金薄板低功率脉冲YAG激光诱导TIG电弧复合热源焊接过程中,激光能量与电弧能量之间的相互匹配将显著影响焊缝的表面成形。相对于电弧功率的变化,焊缝成形对激光功率变化的敏感度更高。随着热源间角度减小,激光诱导电弧复合热源传热能力增强;由于复合焊接速度快、热输入小、焊接试板横向变形小,当对接间隙为0~0.5 mm范围内时均能获得良好的焊缝成形。为了使焊缝成形均匀连续,焊接过程中需要对焊缝背面采用氩气进行保护,当保护气体流量为5~8L/min时获得最佳焊接接头。     

超声振动电弧复合焊接特性研究

介绍一种超声振动-电弧复合焊接方法。焊接时对电弧直接施加超声振动,通过电弧将超声波压力传递到熔池中。试验表明,焊接电弧压力在施加超声振动后有明显提高,并且使电弧压力分布发生有益改变。用超声振动电弧复合焊方法对304奥氏体不锈钢进行堆焊实验,结果显示该方法能够改变焊缝熔化形式,增加熔深。     

超超临界HR6W钢TIG焊接残余应力和变形有限元预测

采用钨极氩弧焊接(TIG)方法对超超临界HR6W钢厚板进行对接焊接,采用数值模拟方法分析焊接过程温度场,预测焊缝残余应力和焊接变形分布.结果表明,随着焊接道次增多,焊接变形逐渐增大,焊接变形为典型的角变形,以焊接线为中心线,呈对称分布,最大变形不超过1mm;随着焊接道次的增加,焊缝平均拉应力和压应力均先增大,后减小;焊缝中部区域存在残余压应力,焊缝首端和末端区域存在残余拉应力.     

不锈钢AA-TIG焊接法

针对不锈钢,提出一种新型活性TIG焊方法——电弧辅助活性TIG焊,即AA-TIG焊。采用CO2+Ar作为小电流钨极电弧的保护气体进行单弧AA-TIG焊,分别研究小电流钨极电弧和正常TIG焊工艺参数对焊缝熔深的影响,并针对试验范围内的最佳焊接规范研究不锈钢AA-TIG焊的焊缝成形、焊缝显微组织、化学成分和焊缝性能。采用AA-TIG焊可以单道焊透10mm厚的不锈钢板材,单面焊双面成形。与传统TIG焊相比,焊缝组织和化学成分几乎没有变化,焊缝的耐Cu/CuSO4腐蚀性能和低温冲击韧度都满足相关标准要求。     

激光-MIG双丝复合焊电弧特性与熔滴过渡研究

利用搭建的激光-熔化极惰性气体保护(Metal inert-gas,MIG)双丝复合焊接系统进行焊接试验。在试验中,主要研究激光功率、送丝速度、光丝间距和离焦量等几个主要变量对复合焊接稳定性、电弧特性和熔滴过渡的影响规律。分别选取电弧电压变异系数、电弧偏转角、熔滴过渡方式及过渡频率作为评价参量对稳定性、电弧特性和熔滴过渡进行分析。研究发现,随着激光功率增加,电弧偏转角先减小后增加,在1 000 W附近偏转角最小,焊接过程最稳定。引导丝熔滴始终为粗滴过渡,而跟随丝熔滴为粗滴过渡+少量短路过渡,熔滴过渡频率呈现先增加后下降的趋势。在送丝速度为4 m/min时引导丝和跟随丝的电弧稳定性最好,电弧偏转角先减小后增加最终趋于稳定。在离焦量为–1 mm时,引导丝和跟随丝熔滴过渡频率均达到最大值,分别为8.6Hz和6.3Hz。     

3A21铝合金激光焊与激光-氩弧焊复合焊微观组织及性能比较研究

采用激光焊接与激光-氩弧焊复合焊接2种方式对厚度为2mm的3A21铝合金板材进行对接焊,研究2种焊接方式下焊接接头微观组织、缺陷分布及硬度分布的不同。实验结果显示激光-氩弧复合焊接接头相比激光焊的接头显微组织更细密,且气孔数量明显减少。激光焊接接头的平均显微硬度与复合焊接头平均显微硬度相差不大,分别为52HV左右及51.3HV左右,均明显高于基体平均显微硬度值43HV。     

Real-time control of welding penetration during robotic GTAW dynamical process by audio sensing of arc length

This paper presents a new technology of real-time arc length monitoring and sag-depression prediction through arc sound signal, which is essential to realize the welding penetration control during gas tungsten arc welding of arc length. A set of automatic measurement and control system have been proposed to achieve real-time arc length control via audio sensing system. After preprocessing of arc sound signal, the piecewise linear models of arc sound signal were established under two different arc length variation 3–4 and 4–5–6 mm, analyzing the prediction errors of linear model, which were proved to be good enough for online monitoring of arc length in pulse GTAW. Based on the linear relationship between arc sound and arc length, the linear fitting model was implemented on predicting the surface height of weld pool. A segmented self-adaptive PID controller was proposed to achieve the monitoring and controlling of arc length;, the confirmatory experiments have been designed to test the control effect of arc-length monitoring based on arc sound signal.     

The acquisition and processing of real-time information for height tracking of robotic GTAW process by arc sensor

Aiming at the deficiencies of the vision technology that canot be used in the height tracking of the 3D weld seam during teaching-playback robot gas tungsten argon welding (GTAW) process, this paper designed a set of arc sensor system for height tracking of weld seam, which can effectively acquire arc voltage signals. The characteristic values of arc voltage signals are extracted and a linear relational model between arc voltage and arc length was established by using appropriate denoising algorithm. The experimental results demonstrate that the error between the arc length calculated by linear model and the real arc length was very small, which is accurate enough to meet the requirements of the follow-up height tracking and controlling during the welding robot GTAW process.     

窄间隙MAG焊电弧声与电弧作用位置的相关性

电弧-侧壁距离控制是保证窄间隙熔化极活性气体保护焊(Narrow gap metal active gas welding, NG-MAG)侧壁熔合良好的关键。通过对NG-MAG脉冲立焊过程中电弧声的预处理和分析,发现其时域波形呈周期性“振铃”衰减特性,频率与焊接电源脉冲频率相同;电弧声能量的频域分布范围为0.3～12.0 kHz,且能量主要集中在0.3～3.0 kHz和9.0～12.0 kHz两个频带,频谱分布与电弧-侧壁距离高度相关。在此基础上,采用小波变换(Wavelet transform, WT)和联合时频分析(Joint time-frequency analysis, JTFA)实现对电弧声信号的降噪处理和时频分析,结果发现,伴随电弧-侧壁距离的逐渐增大,电弧声能量的低频分布始终存在,呈现“断续-连续-断续”分布特征;而高频分布出现在电弧-侧壁距离2.6 mm以上,呈现“断续-连续”分布特征。利用NG-MAG脉冲立焊电弧声的时频分布规律可实现对电弧作用位置的监测预警,为NG-MAG焊接过程状态监控提供一种途径。     

Investigation on the influence of various welding parameters on the arc thermal efficiency of the GTAW process by calorimetric method

Arc efficiency of Gas Tungsten Arc Welding (GTAW) was determined by calorimetric method. A water-cooled anode calorimeter was designed and manufactured to measure the arc thermal efficiency, which was determined as a function of current, arc length, polarity and gas flow rate for GTAW of mild steel. With Direct Current Electrode Negative (DCEN) polarity and 5 mm arc length, a thermal efficiency of 67±4% was obtained, which was independent of the welding current. With Direct Current Electrode Positive (DCEP) polarity and 5 mm arc length, arc thermal efficiency was determined as 52±4%. The experimental data show that the arc efficiency decreases from 67% to 58% and 51% as the arc length increases from 5 mm to 11 and 17.5 mm, respectively. The experimental results also show that the arc efficiency is not significantly affected by the shielding gas flow rate.     

Numerical analysis for effect of process parameters of low-current micro-PAW on constricted arc

A model was put forward to simulate the electromagnetic phenomena and fluid field in plasma arc occurring during the low-current microplasma arc welding (low-current micro-PAW) process. The effects of the nozzle neck-in and welding current of micro-plasma arc on the arc electromagnetic field distribution were discussed. Finally, under the condition of different welding current, welding voltage, arc length, shield gas flow rate, and plasma flow rate, welding experiments of image sampling were carried out. Three types of microplasma arc, namely, needle plasma arc, columnar plasma arc, and opening model plasma arc, are founded by experiment. Based on the unified model, a thorough investigation of the low-current microplasma arc characteristics during the micro-PAW process was conducted. It was found that the process parameters have significant effects on the microplasma arc and the distributions of current density and electromagnet force distribution.     

Development of a MIAB welding module and experimental analysis of rotational behavior of arc—simulation of electromagnetic force distribution during MIAB welding of steel pipes using finite element analysis

Magnetically impelled arc butt (MIAB) welding is a unique forge welding process in which an arc is drawn in the gap between the two tubes to be welded in order to raise them to a high temperature to allow forging to form a solid-state weld. In this case, the arc is rotated with a high speed around the weld line by an electromagnetic force resulting from the interaction of the magnetic field and the arc current. This paper presents the details of the results and the conclusions of the experimental trials conducted on the MIAB module designed and developed based on the principle. Further, nonlinear electromagnetic analysis has been performed to determine the magnetic field and electromagnetic force distribution in MIAB process using finite element package ANSYS. Typical results of this analysis pertaining to magnetic field are compared with the experimental data for steel tubes (outer diameter 47 mm and thickness of 2 mm). It is observed that the results from finite element analysis and the experimental trials are in excellent agreement. The proposed three-dimensional finite element method model for electromagnetic force distribution facilitates comprehensive understanding of the arc rotation process in MIAB welding.     

基于电弧光谱的钢熔化极惰性气体保护焊质量判识

通过对熔化极惰性气体保护电弧焊(MIG焊)电弧光谱分布进行采集,研究其光谱分布的基本特征,并基于光谱分布的分析,通过预设干扰因素,对不同特征谱段光谱信号随焊接过程的变化进行采集,寻求MIG焊接质量在线光谱测控的理论依据和工程实现.研究结果表明,MIG焊电弧光谱在不同谱段存在金属谱线和Ar谱线聚集区.在不同弧长下的不同熔滴过渡形态,其光谱信号在特征谱段得到明显反映,电流变化引起的焊道变宽也有很好的特征信号;不同干扰因素引起的焊接缺陷,在焊接电弧光谱信号不同谱段的分布和变化规律不同,通过对特征谱段信息的采集,可以获得关于焊接过程信息的特征信号,从而实现对MIG焊接质量的分类判识.     

熔化极脉冲氩弧焊弧长动态调节性能研究

介绍了一种新型的单周期脉冲MIG焊控制法,该法采用非线性控制,通过实时采集电弧电压信号,控制每一个脉冲周期内的平均电弧电压和预设值相同,系统具有很强的弧长调节能力。当扰动发生时,在每一个周期内,电弧电压的平均值和设定值之间既不存在静态误差也不存在瞬态误差,弧长可以在数个周期内调整到稳定。在深入研究电弧动态调节过程的基础上,对原来方案进行优化设计。试验结果表明,该系统具有优异的电弧自身调节特性,焊接工艺性能良好。