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.     

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.     

粉末燃料冲压发动机内镁粉尘云层流燃烧模型

对粉末燃料冲压发动机预燃室内镁粉尘云燃烧过程进行了研究,建立了镁粉尘云的一维层流预混燃烧模型。研究表明,镁粉尘云层流火焰传播很稳定,燃烧过程中火焰结构基本不变,燃烧区很薄,而预热区厚度约是燃烧区的2-3倍。粉尘云中镁颗粒的蒸发和气相镁与氧气的均相反应是产生火焰的直接原因,也是火焰得以传播的关键。预热区气相温度升高主要靠燃烧区气体的导热和扩散过来的气相镁与氧气反应释放热量,而预热区颗粒相温度升高主要靠气相对其对流传热。分析了各参数对粉尘云燃烧的影响,颗粒相对浓度对粉尘云燃烧的影响比较复杂,在浓度较低的情况下,增大颗粒相对浓度有利于粉尘云快速燃烧;而在浓度较高的情况下,增大颗粒相对浓度则不利于粉尘云快速燃烧。随颗粒粒径的增加,火焰传播速度减小,火焰温度升高,预热区厚度增大。火焰传播速度和火焰温度随粉尘云初温增加线性增长,预热区厚度随粉尘云初温增加抛物线增长。数值模拟与文献中试验结果的变化趋势相一致。     

高硬再制造表面强化层的加热切削研究

应用高性能硬质合金、陶瓷刀具和CBN刀具对常温条件下难以加工的高硬堆焊材料进行加热切削试验。试验结果表明：尽管加热条件下冲击效应降低,但CBN刀具仍然破损严重;陶瓷刀具虽然也无法实现理想的切削,但切削过程中刀具破损模式从崩碎式失效转变为磨损失效;3种刀具中高性能硬质合金应用效果最佳,其最佳参数条件下,一个切削里程后刀面VB值仅为0．3mm,试验过程中,刀具磨损随表面加热温度、切削速度、切削深度的提高而增大,但随进给量取值的增大而减小,其中切削速度对刀具VB值的影响最大,而进给量和削切深度对刀具VB值的影响较小。综合分析还表明：试验中刀具磨损速率仍然受刀具红硬性极限的限制。     

7A52铝合金便携式搅拌摩擦焊接头的组织与性能分析

采用便携式搅拌摩擦焊设备,对3mm厚的7A52铝合金薄板进行了焊接,对焊接头的显微组织和机械性能进行了观察测试。研究结果表明:焊接头可分为动态再结晶区、热-机影响区和母材3个区域,而没有明显的热影响区。动态再结晶区组织发生再结晶,生成细小的等轴晶粒;热-机影响区有塑性变形流线,且范围较窄;母材区保持着原来的轧制组织。接头硬度的最薄弱环节在热-机影响区。接头抗拉强度达到母材的70%左右,能够满足战场应急抢修的需求。     

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。     

悬浮固相颗粒对储集层基质孔隙的堵塞规律研究

应用胜利油区8个不同区块的岩心及注入水,采用岩心流动实验手段,研究了注入水中悬浮颗粒对储层孔隙的堵塞特征,发现悬浮颗粒对储层的堵塞特征表现为孔隙逐步堵塞和迅速堵塞两种类型;悬浮颗粒浓度低且孔径与粒径的比值较大时易形成孔隙避步堵塞;悬浮颗粒浓度大或孔径与粒径的比值较小时易形成迅速堵塞;悬浮颗粒对储层的堵塞程度、堵塞类型是颗粒浓度、颗粒粒径与储层孔喉匹配综合作用的结果;迅速堵塞特征的初始堵塞效果主要取决于孔径与粒径的匹配关系,最终堵塞效果主要与注入水中的颗粒浓度有关;高浓度的小颗粒对孔隙基质的堵塞特征表现为迅速堵塞。     

Experimental Research on Dynamic Erosion of EPDM Insulation Subjected to Particle-Laden Flow

The instantaneous degradation of erosion surface of ethylene propylene diene monomer(EPDM)insulation subjected to the particle-laden flow in two operating conditions was measured by using a real-time X-ray radiography system.The images of its erosion state and dynamic ablation rate were obtained.And the charring-layer was analyzed by using SEM and energy spectrum.The experimental results indicate that the erosion rate of EPDM insulation layer impacted by low speed and low concentration particle flow is relatively small in the 1st second since the motor starting,but increases rapidly in 1 to 2.5 s,while the erosion rate of EPDM insulation layer impacted by high speed and high concentration particle flow increases rapidly in the 1st second;the ablation rate at the section eroded intensively by particle flow increases at first,then decreases,and goes to stabilization after 4.5 s;the higher speed and concentration particle flow are,the deeper particles get into charring layer,which lead to more thermal increment and thinner charring layer.     

单脉冲测角在BM突防干扰机上的应用

高分辨雷达(HRR)使用目标HRRP检测目标,由此要求弹道导弹(BM)突防干扰机生成的多假目标信号中包含BM弹头HRRP信息,HRRP长度是HRRP的一个重要特征,需要通过测量雷达观测角计算得到,BM突防干扰机自旋,自身三维姿态难以提取,二维单脉冲测角系统难以应用,一维单脉冲测角系统根据自旋特点,可间断地测得雷达观测角,干扰机和BM弹头运动以及干扰机自旋对测角精度影响较小,间断得到的雷达观测角可以用来计算BM弹头HRRP长度,指出了干扰机章动是影响测角精度的主要因素,最后说明了探讨的方法对目前BM突防干扰机设计具有一定实际工程意义。     

相对静止气氛下硼颗粒着火过程

针对相对静止气氛下单颗粒硼的着火过程展开了系统研究,考虑硼颗粒周围径向气相流动以及硼颗粒与周围环境间的传热和传质过程,建立了一维硼颗粒着火模型。分析了硼颗粒在实现着火和未能实现着火两种典型情形下的颗粒相、气相组分参数以及颗粒外表面上Stefan流的变化规律,并对其成因展开了分析。研究表明,在实现着火和未能实现着火两种典型情形下,硼颗粒外表面的Stefan流都会经历先由周围空间流向颗粒表面,而后变为由颗粒表面流向周围空间的过程;考虑颗粒外表面处气相Stefan流作用后,硼颗粒的着火延迟时间减少,且压力越大,影响越大。     

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.     

防空导弹末段反导作战部署模型

防空导弹末段拦截弹道导弹的作战效能与防空导弹火力单元的部署位置密切相关,合理的战斗部署是成功反导的前提和关键.分析了防空导弹末段反导的条件和反导防御区,在此基础上探讨了防空导弹反导杀伤区纵深和相关射击诸元的算法.然后,使用末段低层和末段高层反导火力单元组成双层防御系统,对防御从一个方向和从扇区来袭弹道导弹的反导火力单元部署位置确定模型进行了研究.研究成果对防空导弹末段反导的作战使用具有参考价值.     

钎杆内孔的液压低频振动扩孔工艺实验

为完全去除中空钢钎杆内孔表面的氧化层和裂纹层的影响,采用深孔扩孔的方式加工钎杆内孔。针对深孔扩孔过程中存在的切屑排出困难、切削温度高、内孔表面加工质量差等问题,利用液压低频振动辅助枪钻对中空钢钎杆进行深孔扩孔,研究振动参数及加工参数对切屑形态、内孔表面质量、切削热的影响。实验结果表明:在转速为500 r/min、进给量为0.1 mm/r条件下,相对于普通扩孔,液压低频振动扩孔可减小切屑尺寸,减少切屑表面锯齿边缘现象,优化内孔加工表面,减少刀痕和划痕,降低加工温度。且当频率为36.7 Hz、振幅为0.58 mm时,切屑尺寸最小,内孔表面划痕最少,加工温度最低;随着进给量在0.80～0.12 mm/r范围内增大,切屑长度变大,内孔表面的刀痕和划痕增多;转速对切屑长度及内孔表面形貌影响较小。     

Characterization of magnetically impelled arc butt welded T11 tubes for high pressure applications

Magnetically impelled arc butt(MIAB) welding is a pressure welding process used for joining of pipes and tubes with an external magnetic field affecting arc rotation along the tube circumference. In this work, MIAB welding of low alloy steel(T11) tubes were carried out to study the microstructural changes occurring in thermo-mechanically affected zone(TMAZ). To qualify the process for the welding applications where pressure could be up to 300 bar, the MIAB welds are studied with variations of arc current and arc rotation time. It is found that TMAZ shows higher hardness than that in base metal and displays higher weld tensile strength and ductility due to bainitic transformation. The effect of arc current on the weld interface is also detailed and is found to be defect free at higher values of arc currents. The results reveal that MIAB welded samples exhibits good structural property correlation for high pressure applications with an added benefit of enhanced productivity at lower cost.The study will enable the use of MIAB welding for high pressure applications in power and defence sectors.     

一种改进的粒子群优化算法

针对基本粒子群算法存在着收敛速度慢、效率低、易陷入局部最优等缺陷,为了更好地平衡全局和局部搜索能力,在粒子群算法中引入收缩因子,使算法中粒子不仅向种群最优的粒子进行学习,而且向种群中比自己优秀的所有粒子学习,增加了粒子的多样性。实验结果证明,与基本蚁群算法相比,改进的粒子群算法提高了收敛速度和效率,能一定程度地避免局部最优解的产生。     

Optimization of process parameters of aluminum alloy AA 2014-T6 friction stir welds by response surface methodology

The heat treatable aluminum-copper alloy AA2014 finds wide application in the aerospace and defence industry due to its high strength-toweight ratio and good ductility. Friction stir welding(FSW) process, an emerging solid state joining process, is suitable for joining this alloy compared to fusion welding processes. This work presents the formulation of a mathematical model with process parameters and tool geometry to predict the responses of friction stir welds of AA 2014-T6 aluminum alloy, viz yield strength, tensile strength and ductility. The most influential process parameters considered are spindle speed, welding speed, tilt angle and tool pin profile. A four-factor, five-level central composite design was used and a response surface methodology(RSM) was employed to develop the regression models to predict the responses.The mechanical properties, such as yield strength(YS), ultimate tensile strength(UTS) and percentage elongation(%El), are considered as responses. Method of analysis of variance was used to determine the important process parameters that affect the responses. Validation trials were carried out to validate these results. These results indicate that the friction stir welds of AA 2014-T6 aluminum alloy welded with hexagonal tool pin profile have the highest tensile strength and elongation, whereas the joints fabricated with conical tool pin profile have the lowest tensile strength and elongation.     

柴油机排气噪声的有源控制研究

对四缸四冲程柴油机（4－85）1500r／min时的排气噪声的低频进行了分析利用声辐射理论,设计出引入次级声场的装置．对排气管与机器相连接法兰盘上的振动信号与噪声信号进行了相干函数分析．此外,利用高速信号处理芯片TMS320C25完成了一套自适应控制系统的初步设计．     

Influence of magnetically constricted arc traverse speed (MCATS) on tensile properties and microstructural characteristics of welded Inconel 718 alloy sheets

The magnetically constricted arc technique was implemented to mitigate the heat input related metal-lurgical problems in Gas Tungsten Arc Welding (GTAW) of Inconel 718 alloy particularly Nb segregation and subsequent laves phase evolution in fusion zone. This paper reports the direct effect of magnetically constricted arc traverse speed (MCATS) on bead profile, tensile properties and microstructural evolution of Inconel 718 alloy sheets joined by Gas Tungsten Constricted Arc Welding (GTCAW) process. The mechanism amenable for the microstructural modification and corresponding influence on the tensile properties of joints is investigated both in qualitative and quantitative manner related to the mechanics of arc constriction and pulsing. It is correlated to the solidification conditions during welding. The relationship between MCATS and Arc Constriction Current (ACC) was derived. Its interaction effect on the magnetic arc constriction and joint performance was analysed. Results showed that the joints fabricated using CATS of 70 mm/min exhibited superior tensile properties (98.39% of base metal strength with 31.50% elongation). It is attributed to the grain refinement in fusion zone microstructure leading to the evolution of finer, discrete laves phase in interdendritic areas.     

槽头式野战管线水击波速计算方法研究

按照弹性水击理论,管线内发生水力瞬变时,其水击波速取决于管子的弹性、流体的可压缩性和管子受约束的情况。对于给定的输送介质,焊接式固定输油管线的水击波速是一个常数。而槽头式野战管线采用连接器连接,胶圈密封,这种特殊的连接方式改变了管子整体的弹性摸量,从而使水击波速的常规计算方法不再适用。本文研究了野战管线连接器连接方式时水击波速的影响,实验研究了在受到约束时,橡胶的弹性模量随所受压力的变化而变化的规律,推导出野战管线水击波速平均计算方法,推导的公式表明:与焊接式固定管线不同,野战管线的水击波速随管线内压力的增大而增大。