无电焊接中厚度钢板焊接接头的组织结构与性能研究

采用无电焊接方法对12mm厚度钢板进行了焊接。分析了满足中厚度钢板焊接能量要求的技术途径;利用SEM,EDS,XRD等手段观察、分析了焊缝的组织成分与显微结构;测试了焊接接头的拉伸强度、弯曲强度、显微硬度等力学性能。结果表明:在选择高放热体系基础上,通过增大焊接笔直径、减小反应物料粒径、提高压坯密度等方法,可以有效增大焊接热效率,从而满足中厚度钢板焊接能量需求;焊缝组织分为热影响区、熔合区与合金区,焊缝合金与母材间通过熔合区形成了冶金结合;焊接接头因固溶强化和析晶强化的作用,具有良好的力学性能,拉伸强度、平均显微硬度与弯曲强度分别为357MPa、186HV0.2与644MPa,达到了野战应急抢修技术要求。     

铝热焊接工艺参数优化研究

为获得最佳铝热焊接工艺参数,对拉伸试件进行了正交试验和二次通用旋转组合试验,研究预热温度、加压时间和预留焊缝3因素对接头强度的影响,进而寻求一组使焊接接头强韧性最高的焊接工艺参数组合。利用电子显微镜等对试件拉伸断口进行了分析,通过对比2种开始加压时间下试件的显微组织和性能,研究了这2种方法对接头强韧性的影响。结果表明:采用设计的铝热焊接试验装置和优化出的随焊加压致密化工艺参数,可使焊接接头获得大变形组织,从而获得高的强度和韧性。该项研究可为提高铝热焊接质量提供基础数据。     

非均匀焊接接头的力学建模与断裂分析

建立了非均匀焊接接头"4区连接"的新模型,并利用积分变换-奇异积分方程的方法,研究了焊缝区的反平面断裂问题。数值计算表明:增大界面区的刚度或者适当地增大焊缝区、热影响区和界面区的宽度都有利于降低焊缝区裂纹的应力强度因子;相对于高匹配情形而言,低匹配焊接接头焊缝区的抗断裂能力明显较高。     

LD10CS铝合金箱体材料焊接区断裂韧性研究

本文叙述用表面裂纹法测试LD10铝合金箱底手工氩弧焊焊接接头焊肉和热影响区各个部位的断裂韧性,通过显微分析和断口形貌分析,对接头各部位的热循环和组织变化作了较详细的探讨,指出焊接接头各个部位常规力学性能与断裂韧性不同的变化规律,提出了改进焊接接头断裂韧性的意见。     

力学性能不均匀性焊接接头应力分布研究

应用有限元分析方法,针对平板对接接头横向拉伸试验和实际工作状态下打底焊道为等强匹配、填充焊道为超强匹配时焊接接头在外载荷作用下的应力分布进行计算分析。分析结果表明:焊接接头内部强度的不均匀性引起材料变形能力的差异是接头应力分布不均匀性的主要原因,打底焊道应力低于其屈服强度,填充焊道是焊缝金属的主要承载部分;焊接热影响区对降低打底焊道和填充焊道强度不同引起的应力集中起重要作用;实际工况下的接头应力分布较试验接头应力分布更加均匀,承载能力高于试验状态的承载能力,在试验状态和实际工况下,接头的抗拉强度分别是母材抗拉强度的97.4%和99.4%。     

7A52铝合金的搅拌摩擦焊工艺优化

对8 mm厚的7A52铝合金板材搅拌摩擦焊接后,分别测定了不同焊接规范下接头的抗拉强度.重点讨论了搅拌头旋转速度和焊接速度对抗拉强度的影响,并根据试验结果优化出最佳的焊接工艺为焊接速度v=118～150 mm/min,搅拌速度n=1 180～1 500 r/min,焊接倾角为2°,轴肩压入深度为0.2 mm.此时焊接接头具有高的力学性能,其抗拉强度可达430 MPa左右,为母材抗拉强度的88.5%,且具有较高的焊接效率.     

2A12铝合金焊接接头超声冲击处理前后拉伸性能分析

为克服铝合金薄板焊接接头强度偏低、韧性不足的缺点,用ER5356焊丝对不同厚度的2A12铝合金板材进行了手工氩弧焊接,并采用超声冲击处理对焊接接头进行全覆盖强化处理。采用金相显微镜观察了处理和未处理焊接接头的显微组织结构,对接头的力学性能进行了测试分析,分析了超声冲击处理改善2A12铝合金焊接接头力学性能的机理。结果表明：铝合金焊接接头经超声冲击强化处理后,6 mm和4 mm厚板材对接接头的抗拉强度分别提高了17.4%和23.7%,延伸率分别提高了28%和44%,焊缝表层组织得到明显细化。分析认为：晶粒大幅细化、组织致密化和缺陷减少,是超声冲击处理改善铝合金焊接接头抗拉伸性能的主要原因。     

TC4真空电子束焊后热处理对接头组织性能影响

<正>采用真空电子束焊接不等厚TC4钛环,焊后对接头进行整体退火、电子束局部退火、不退火方式获得3个接头。采用X射线测残余应力、通过拉伸、弯曲试验以及光学显微镜对焊接接头组织和性能进行研究。结果表明:焊后局部退火与整体退火能降低接头残余应力且使接头区域残余应力变化稳定,其作用效果相当;真空电子束局部退火能细化焊缝针状组织,改善热影响区组织。三种状态下接头都具有较高的抗拉强度并表现出良好的弯曲性能。在无法进行整     

基于Jmat-pro计算的Q345级别耐火钢焊接工艺评定

通过测定焊接热影响区连续冷却转变(SH-CCT)曲线图评定两种Q345级别低Mo(约0.25wt.%)耐火钢焊接工艺。试验结果表明,Q1钢当实际冷却时间t8/5>43s时,焊接的热影响区以及熔合区附近不会产生开裂,而当t8/5<43s时,热影响区或熔合区有开裂的可能;Q2钢当实际冷却时间t8/5>44s时,焊接热影响区和熔合区附近不会产生开裂,而当t8/5<44s时,热影响区或熔合区有开裂的可能。此外,Jmat-pro软件对Ac3的计算有一定的准确性,但对连续冷却转变(CCT)曲线误差较大,特别是Q2钢的计算值与实测值差距更大,只具有参考价值。     

22SiMn2TiB装甲钢异种焊接接头超声波探伤探头设计

用常规探头对22SiMn2TiB装甲钢与TWE312异种钢焊接接头进行缺陷检测,杂波和伪缺陷波导致灵敏度、信噪比不高。用扫描电镜观察到这种异种钢焊接接头主要为奥氏体+铁素体组织,其中奥氏体是主体组织。根据焊缝的组织特点,设计出了2.5P13×13K1.5型专用探头。在预制缺陷的焊接接头上进行了验证试验,结果表明2.5P13×13K1.5探头对接头内部的缺陷具有较高的检出率。     

Fabrication and analysis of TIG welding-brazing butt joints of in-situ TiB2/7050 composite and TA2

Lightweight hybrid structures of Al MMCs and titanium alloy dissimilar materials have great prospect in the defence industry application. So, it is necessary to join Al MMCs with Ti metal to achieve this structural design. In this work, in-situ TiB2/7050 composite and TA2 were firstly attempted to join by TIG welding-brazing technique. The result was that the intact welding-brazing butt joint was successfully fabricated. The joint presents dual characteristics, being a brazing on TA2 side and a welding on TiB2/7050 side. At brazing joint side, ER4043 filler metal effectively wets on TA2 under TIG heating condition, and a continuous interfacial reaction layer with 1—3μm is formed at welded metal/TA2 interface. The whole interfacial reaction layers are composed of Ti(AlSi)3 intermetallic compounds (IMCs), but their morphologies at the different regions present obvious distinguishes. The microhardness of the reaction layers is as much as 141—190 HV. At welding joints side, the fusion zone appears the equixaed crystal structure, and the grain sizes are much smaller than those of welded metal, which is attributed to the effect of TiB2 particulates from the melted TiB2/7050 on acceleration formation and inhibiting growth for the new crystal nucleus. The tensile test results show that average tensile strength of the optimal welding-brazing joint is able to achieve 138 MPa. The failure of the tensile joint occurs by quasi-cleavage pattern, and the cracks initiate from the IMCs layer at the groove surface of TA2 and propagate into the welded metal.     

Effect of friction stir processing on mechanical properties and heat transfer of TIG welded joint of AA6061 and AA7075

Tungsten inert gas (TIG) welding is the most commonly used joining process for aluminum alloy for AA6061 and AA7075 which are highly demanded in the aerospace engineering and the automobile sector, but there are some defects occur during TIG welding like micro-crack, coarse grain structure, and porosity. To improve these defects, the TIG welded joint is processed using friction stir processing (FSP). This paper presents the effect of friction stir processing on TIG welding with filler ER4043 and ER 5356 for dissimilar aluminum alloy AA6061 and AA7075. The mechanical characterization, finite element formulation and mathematical equations of heat transfer of TIG + FSP welded joints are investigated using ANSYS Fluent software by adjusting process parameters of FSP. The results show that the maximum compressive residual stress 73 MPa was obtained at the fusion zone (FZ) of the TIG weldment with filler ER4043, whereas minimum compressive residual stress 37 MPa was obtained at stir zone (SZ) of the TIG+FSP with filler 5356. The maximum heat flux 5.33 × 106 W/m2 and temperature 515 ℃ have observed at tool rotation 1600 rpm with a feed rate of 63 mm/min. These results give a satisfactory measure of confidence in the fidelity of the simulation     

Dissimilar friction stir spot welding of AA2024-T3/AA7075-T6 aluminum alloys under different welding parameters and media

This paper studies the friction stir spot welding of AA2024-T3/AA7075-T6 Al alloys in the ambient and underwater environments by clarifying the nugget features,microstructure,fracture and mechanical properties of the joints.The results show that the water-cooling medium exhibits a significant heat absorption capacity in the AA2024-T3/AA7075-T6 welded joint.Nugget features such as stir zone width,circular imprints,average grain sizes,and angular inter-material hooking are reduced by the water-cooling effect in the joints.Narrower whitish(intercalated structures)bands are formed in the under-water joints while Mg2Si and Al2CuMg precipitates are formed in the ambient and the underwater welded joints respectively.An increase in tool rotational speed(600-1400 rpm)and plunge depth(0.1-0.5 mm)increases the tensile-shear force of the welded AA2024-T3/AA7075-T6 joints in both the ambient and underwater environments.The maximum tensile-shear forces of 5900 N and 6700 N were obtained in the ambient and the underwater welds respectively.     

Effect of fusion welding processes on tensile properties of armor grade,high thickness,non-heat treatable aluminium alloy joints

AA5059 is one of the high strength armor grade aluminium alloy that finds its applications in the military vehicles due to the higher resistance against the armor piercing (AP) threats. This study aimed at finding the best suitable process among the fusion welding processes such as gas tungsten arc welding (GTAW) and gas metal arc welding (GMAW) by evaluating the tensile properties of AA5059 aluminium alloy joints. The fracture path was identified by mapping the low hardness distribution profile (LHDP) across the weld cross section under tensile loading. Optical and scanning electron microscopies were used to characterize the microstructural features of the welded joints at various zones. It is evident from the results that GTAW joints showed superior tensile properties compared to GMAW joints and this is primarily owing to the presence of finer grains in the weld metal zone (WMZ) and narrow heat-affected zone (HAZ). The lower heat input associated with the GTAW process effectively reduced the size of the WMZ and HAZ compared to GMAW process. Lower heat input of GTAW process results in faster cooling rate which hinders the grain growth and reduces the evaporation of magnesium in weld metal compared to GMAW joints. The fracture surface of GTAW joint consists of more dimples than GMAW joints which is an indication that the GTAW joint possess improved ductility than GMAW joint.     

Effect of tool pin profile on microstructure and tensile properties of friction stir welded dissimilar AA 6061e AA 5086 aluminium alloy joints

Joints between two different grades of aluminium alloys are need of the hour in many light weight military structures.In this investigation,an attempt has been made to join the heat treatable(AA 6061) and non-heat treatable(AA 5086) aluminium alloys by friction stir welding(FSW)process using three different tool pin profiles like straight cylindrical,taper cylindrical and threaded cylindrical.The microstructures of various regions were observed and analyzed by means of optical and scanning electron microscope.The tensile properties and microhardness were evaluated for the welded joint.From this investigation it is founded that the use of threaded pin profile of tool contributes to better flow of materials between two alloys and the generation of defect free stir zone.It also resulted in higher hardness values of 83 HV in the stir zone and higher tensile strength of 169 MPa compared to other two profiles.The increase in hardness is attributed to the formation of fine grains and intermetallics in the stir zone,and in addition,the reduced size of weaker regions,such as TMAZ and HAZ regions,results in higher tensile properties.     

Effect of tool rotational speed on the particle distribution in friction stir welding of AA6092/17.5 SiCp-T6 composite plates and its consequences on the mechanical property of the joint

This study investigates the effect of tool rotational speed (TRS) on particle distribution in nugget zone (NZ) through quantitative approach and its consequences on the mechanical property of friction stir welded joints of AA6092/17.5 SiC_p-T6 composite. 6 mm thick plates are welded at a constant tool tilt angle of 2° and tool traverse speed of 1 mm/s by varying the TRS at 1000 rpm, 1500 rpm and 2000 rpm with a taper pin profiled tool. Microstructure analysis shows large quantity of uniformly shaped smaller size SiC particle with lower average particle area which are homogeneously distributed in the NZ. The fragmentation of bigger size particles has been observed because of abrading action of the hard tool and resulting shearing effect and severe stress generation due to the rotation of tool. The particles occupy maximum area in the matrix compared to that of the base material (BM) due to the redistribution of broken particles as an effect of TRS. The migration of particles towards the TMAZ-NZ transition zone has been also encountered at higher TRS (2000 rpm). The microhardness analysis depicts variation in average hardness from top to bottom of the NZ, minimum for 1500 rpm and maximum for 2000 rpm. The impact strength at 1000 rpm and 1500 rpm remains close to that of BM (21.6 J) while 2000 rpm shows the accountable reduction. The maximum joint efficiency has been achieved at 1500 rpm (84%) and minimum at 1000 rpm (68%) under tensile loading. Fractographic analysis shows mixed mode of failure for BM, 1000 rpm and 1500 rpm, whereas 2000 rpm shows the brittle mode of failure.     

LD10cs 铝合金焊接接头疲劳裂纹扩展速率的研究

本文研究用表面裂纹法测试LD10cs铝合金板材焊接接头各部位疲劳裂纹扩展速率。结果表明:焊接接头各部位疲劳裂纹扩展速率随焊接热循环引起的金属组织变化而变化,有一定规律性。熔合线和焊趾处疲劳裂纹扩展速率较其他部位大。焊缝加强高的存在,引起焊趾处应力集中,使该处疲劳性能进一步恶化,成为焊接接头疲劳性能最差的部位。结合金相组织和扫描电镜分析,对影响焊接接头各部位疲劳裂纹扩展速率的各种因素作了较详细的探讨,并提出了改进焊缝质量的建议。     

基于模态分析的挠性接头角刚度测量研究

挠性接头是动力调谐陀螺的关键元件,刚度是其重要指标。针对挠性接头角刚度的测量,提出了一种基于模态分析的动态角刚度测量方法。该方法采用阶跃激励,利用高精度传感器和数据采集卡测量挠性接头的振动并采集数据,然后对采集数据进行数字滤波、FFT变换和频谱细化,计算出挠性接头的动态角刚度,同时相应地求出了角阻尼比系数。该方法解决了长期以来采用静态测试法测量挠性接头角刚度所带来的问题,具有测量精度高、操作方便、测试效率高、重复性好等特点。     

Investigation on the process parameters of TIG-welded aluminum alloy through mechanical and microstructural characterization

Multi-pass TIG welding was conducted on plates (15×300×180 mm3) of aluminum alloy Al-5083 that usually serves as the component material in structural applications such as cryogenics and chemical processing industries. Porosity formation and solidification cracking are the most common defects when TIG welding Al-5083 alloy, which is sensitive to the welding heat input. In the experiment, the heat input was varied from 0.89 kJ/mm to 5 kJ/mm designed by the combination of welding torch travel speed and welding current. Tensile, micro-Vicker hardness and Charpy impact tests were executed to witness the impetus response of heat input on the mechanical properties of the joints. Radiographic inspection was performed to assess the joint's quality and welding defects. The results show that all the specimens displayed inferior mechanical properties as compared to the base alloy. It was established that porosity was progressively abridged by the increase of heat input. The results also clinched that the use of me-dium heat input (1-2 kJ/mm) offered the best mechanical properties by eradicating welding defects, in which only about 18.26% of strength was lost. The yield strength of all the welded specimens remained unaffected indicated no influence of heat input. Partially melted zone (PMZ) width also affected by heat input, which became widened with the increase of heat input. The grain size of PMZ was found to be coarser than the respective grain size in the fusion zone. Charpy impact testing revealed that the absorbed energy by low heat input specimen (welded at high speed) was greater than that of high heat input (welded at low speed) because of low porosity and the formation of equiaxed grains which induce better impact toughness. Cryogenic (-196 C) impact testing was also performed and the results corroborate that impact properties under the cryogenic environment revealed no appreciable change after welding at designated heat input. Finally, Macro and micro fractured surfaces of tensile and impact specimens were analyzed using Stereo and Scanning Electron Microscopy (SEM), which have supported the experimental findings.