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Processing parameter optimization of fiber laser beam welding using an ensemble of metamodels and MOABC

《机械工程前沿（英文）》 2022年第17卷第4期 doi: 10.1007/s11465-022-0703-5

摘要： In fiber laser beam welding (LBW), the selection of optimal processing parameters is challenging and plays a key role in improving the bead geometry and welding quality. This study proposes a multi-objective optimization framework by combining an ensemble of metamodels (EMs) with the multi-objective artificial bee colony algorithm (MOABC) to identify the optimal welding parameters. An inverse proportional weighting method that considers the leave-one-out prediction error is presented to construct EM, which incorporates the competitive strengths of three metamodels. EM constructs the correlation between processing parameters (laser power, welding speed, and distance defocus) and bead geometries (bead width, depth of penetration, neck width, and neck depth) with average errors of 10.95%, 7.04%, 7.63%, and 8.62%, respectively. On the basis of EM, MOABC is employed to approximate the Pareto front, and verification experiments show that the relative errors are less than 14.67%. Furthermore, the main effect and the interaction effect of processing parameters on bead geometries are studied. Results demonstrate that the proposed EM-MOABC is effective in guiding actual fiber LBW applications.

关键词： laser beam welding parameter optimization metamodel multi-objective

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Effects on mechanical properties in electron beam welding of TC4 alloy by laser shock processing

LU Jinzhong, ZHANG Yongkang, KONG Dejun, REN Xudong, GE Tao, ZOU Shikun

《机械工程前沿（英文）》 2007年第2卷第4期页码 478-482 doi: 10.1007/s11465-007-0083-x

摘要： The surface of TC4 titanium alloy welding line by electron beam welding (EBW) was processed by high power Q-switched and repetition-rate Nd: glass laser. Effects of laser power and spot diameter on residual stress and micro-hardness of the TC4 alloy welding line by laser shock processing (LSP) have been analyzed. Results show that residual stresses almost do not change as laser power is 45.9 J, spot diameter is φ9 mm; While laser power is 45.9 J, spot diameter less than φ3 mm, the distribution of residual stress in welding line occurs obvious variation, which residual stress increase obviously with spot diameter decrease. When power density is bigger than 1.8×10 W/cm, residual stresses of electron beam welding line occur change by LSP, which improve obviously residual stress distribution; while laser power is bigger than 1.2×10 W/cm, the surface micro-hardness of electron beam welding line occurs change by LSP, which improve obviously micro-hardness distribution. Mechanical properties of TC4 titanium alloy welding line will be improved by LSP, which provides experimental foundation for further controlling the distributions of residual stress and micro-hardness during laser shock processing.

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激光相变热处理对TC４电子束焊缝残余应力的影响

鲁金忠,张永康,孔德军,任旭东,邹世坤,王西昌

《中国工程科学》 2007年第9卷第5期页码 72-76

摘要：

利用CO₂激光相变热处理技术对TC4钛合金电子束焊缝进行了处理，研究了激光功率、光斑直径、辅助气体等激光工艺参数对电子束焊缝残余应力分布的影响。实验结果表明，激光相变热处理改善了焊缝残余应力的分布，使焊缝表面残余应力由拉应力转变为压应力，其压应力值随着激光功率的增加而增大，随着激光光斑直径的减小而增加；辅助气体为O₂时残余压应力值比辅助气体为N₂大30～40MPa，激光相变热处理显著提高了TC4钛合金电子束焊缝的残余压应力及其使用寿命。

关键词：激光相变热处理 TC4钛合金电子束焊缝残余应力

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激光去除与连接技术发展研究

陈俐,巩水利,何恩光

《中国工程科学》 2020年第22卷第3期页码 78-84 doi: 10.15302/J-SSCAE-2020.03.012

摘要：

随着激光技术的发展，激光去除与连接技术深刻影响着制造业技术的发展，并以柔性、高效、高质的综合优势成为不可或缺的先进制造技术。在先进制造智能化发展的时代，激光技术、数字信息技术等的融合必将推动激光去除与连接技术的应用发展与创新。本文选取工业应用最广的激光焊接、激光切割、激光打孔、激光打标4 种激光去除与连接技术，概述了激光去除与连接技术的应用现状，分析了其在支撑先进制造发展过程中存在的问题。研究表明，激光去除与连接技术的发展应注重工艺基础和装备研究一体化的研究，解决激光加工单元部件、激光加工工艺、智能集成各环节的关键技术，强化工艺基础研究平台建设，关注技术创新和人才培养的多维度结合，以促进激光去除与连接技术从工艺应用开发到装备市场保障的生态链式的协同发展。

关键词：激光加工激光焊接激光切割激光打孔激光打标

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基于DBN模型的激光焊接状态在线监控研究 Article

张艳喜, 游德勇, 高向东, Seiji Katayama

《工程（英文）》 2019年第5卷第4期页码 671-678 doi: 10.1016/j.eng.2019.01.016

摘要：

本文开发了集辅助激光成像系统、紫外/可见波段视觉成像系统（波长小于780 nm）、光谱测量仪、光电传感器的多传感器系统，用以观察和分析激光焊接过程中的焊接状态信息。本文采用小波包分解方法对通过光电传感器获得的可见光波段传感信号和激光反射传感信号进行分解并提取相关特征。光谱仪采集到的信号的主要波长为400~900 nm，将其分为25个子带并采用统计方法来提取光谱信号特征。利用紫外/可见波段视觉成像系统采集的图像获取金属蒸气和飞溅的特征，而辅助照明视觉传感器系统主要是用来采集匙孔特征。本文基于上述焊接过程的实时量化特征建立了焊接状态监测的深度信念网络（DBN），并采用遗传算法对所提出的DBN模型参数进行优化。与传统的反向传播神经网络（BPNN）模型相比，本文建立的DBN模型在焊接状态监测方面具有更高的精度和鲁棒性。最后，本文通过三个附加焊接试验验证了该方法在激光焊接状态监控中的有效性和泛化能力。

关键词：在线监控多传感小波包分解深信度网络

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Laser vision sensing based on adaptive welding for aluminum alloy

CHEN Zhixiang, SONG Yonglun, ZHANG Jun, ZHANG Wanchun, JIANG Li, XIA Xuxin

《机械工程前沿（英文）》 2007年第2卷第2期页码 218-223 doi: 10.1007/s11465-007-0038-2

摘要： A laser vision sensing based on the adaptive tungsten inert gas (TIG) welding system for large-scale aluminum alloy components was established to fit various weld groove conditions. A new type of laser vision sensor was used to precisely measure the weld groove. The joint geometry data, such as the bevel angle, the gap, the area, and the mismatch, etc., aided in assembling large-scale aerospace components before welding. They were also applied for automatic seam tracking, such as automatic torch transverse alignment and torch height adjustment in welding. An adaptive welding process was realized by automatically adjusting the wire feeding speed and the welding current according to the groove conditions. The process results in a good weld formation and high welding quality, which meet the requirements of related standards.

关键词： adjustment adaptive tungsten transverse alignment large-scale aluminum geometry

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Laser interference fabrication of large-area functional periodic structure surface

Lei WANG, Zi-Han WANG, Yan-Hao YU, Hong-Bo SUN

《机械工程前沿（英文）》 2018年第13卷第4期页码 493-503 doi: 10.1007/s11465-018-0507-9

摘要：

Functional periodic structures have attracted significant interest due to their natural capabilities in regulating surface energy, surface effective refractive index, and diffraction. Several technologies are used for the fabrication of these functional structures. The laser interference technique in particular has received attention because of its simplicity, low cost, and high-efficiency fabrication of large-area, micro/nanometer-scale, and periodically patterned structures in air conditions. Here, we reviewed the work on laser interference fabrication of large-area functional periodic structures for antireflection, self-cleaning, and superhydrophobicity based on our past and current research. For the common cases, four-beam interference and multi-exposure of two-beam interference were emphasized for their setup, structure diversity, and various applications for antireflection, self-cleaning, and superhydrophobicity. The relations between multi-beam interference and multi-exposure of two-beam interference were compared theoretically and experimentally. Nanostructures as a template for growing nanocrystals were also shown to present future possible applications in surface chemical control. Perspectives on future directions and applications for laser interference were presented.

关键词： laser interference four-beam interference multi-exposure of two-beam interference additive fabrication

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The Application and the Prospect of Remanufacturing Technologies in the Metallurgical Industry

Jie Xiong,Jian-cheng Fan,Jv Yuan

《工程管理前沿（英文）》 2016年第3卷第2期页码 165-170 doi: 10.15302/J-FEM-2016023

摘要： Metallurgical equipment is subjected to severe working conditions and the components suffer from various types of physical damages such as abrasion, corrosion and crack. Advanced surface engineering technologies and resistant coatings on the damaged surface can improve surface properties, extend service lives, reduce maintenance costs and improve product quality in the metallurgical industry. This paper introduces remanufacturing technologies, including electroplating, overlaying welding, thermal spraying and laser surface cladding and their applications in the metallurgical industry, and analyzes the development tendency and prospect of remanufacturing technologies.

关键词： remanufacturing technology electroplating overlaying welding thermal spraying laser surface cladding

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准分子激光前端光束形态控制技术研究

赵学庆,薛全喜,郑国鑫,黄珂,肖伟伟,易爱平,刘晶儒

《中国工程科学》 2009年第11卷第8期页码 52-57

摘要：

在高功率准分子激光系统中，前端光束形态直接决定着系统输出的光束形态，并直接与靶物理需求密切相关。主要介绍了窄脉冲准分子激光前端光束形态控制的实验研究进展，基于散射法获得了满足系统要求的部分相干源，直接利用三束激光脉冲堆积获得了平顶整形脉冲，并结合放大实验结果对上述实现方法进行了评价分析。

关键词：准分子激光光束平滑均匀性脉冲整形高功率

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Recent advances in micro- and nano-machining technologies

Shang GAO, Han HUANG

《机械工程前沿（英文）》 2017年第12卷第1期页码 18-32 doi: 10.1007/s11465-017-0410-9

摘要：

Device miniaturization is an emerging advanced technology in the 21st century. The miniaturization of devices in different fields requires production of micro- and nano-scale components. The features of these components range from the sub-micron to a few hundred microns with high tolerance to many engineering materials. These fields mainly include optics, electronics, medicine, bio-technology, communications, and avionics. This paper reviewed the recent advances in micro- and nano-machining technologies, including micro-cutting, micro-electrical-discharge machining, laser micro-machining, and focused ion beam machining. The four machining technologies were also compared in terms of machining efficiency, workpiece materials being machined, minimum feature size, maximum aspect ratio, and surface finish.

关键词： micro machining cutting electro discharge machining (EDM) laser machining focused ion beam (FIB)

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ARC welding method for bonding steel with aluminum

Zhenyang LU, Pengfei HUANG, Wenning GAO, Yan LI, Hanpeng ZHANG, Shuyan YIN

《机械工程前沿（英文）》 2009年第4卷第2期页码 134-146 doi: 10.1007/s11465-009-0033-x

摘要： When welding steel with aluminum, the appearance of intermetallic compounds of Fe and Al will decrease tenacity and increase rigidity, which leads to bad joint performance. A new type of low energy input (LEI) welding technology is introduced which can be used to weld steel with aluminum. Using the technology, brazing was located on the steel side and arc fusion welding on the aluminum side. The less heat input reduces the thickness of intermetallic compounds to 3-4 μm. Tensile strength tests prove that the joint breaks at the heat-affected zone and the strength is higher than 70% of the aluminum’s. Thus, the method can lead to a good performance joint.

关键词： joining of steel and aluminum low energy input welding arc welding fusion welding – brazing

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圆形金属腔旋流二氧化碳激光器

李再光,龚威

《中国工程科学》 2001年第3卷第1期页码 58-61

摘要：

现有的工业CO₂激光器，主要为横流、纵流和扩散冷却三种。文章提出一种新型激光器，即圆形金属腔CO₂激光器。该激光器的腔体由多个等距、同轴安装的金属腔单元组成。每个腔单元有多个流道，放电在流道与腔体接口处产生，气流将放电及被其激活的粒子吹人腔内，形成增益，输出激光。文章研究了电极结构，金属腔壁对工作气体的冷却作用和腔内的增益分布。研究结果表明：多通道放电吹入和腔内旋流，有利于腔内的均匀放电；金属腔壁有利于腔内对流冷却，降低对气流速度的要求，从而缩小激光器的体积。相邻的腔单元相对转动适当角度，可以提高腔内增益分布的圆周均匀性，从而获得光束质量好的激光束。

关键词：二氧化碳激光器圆形金属腔旋流光束质量

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Kinetics and mechanisms of reactions for hydrated electron with chlorinated benzenes in aqueous solution

Haixia YUAN,Huxiang PAN,Jin SHI,Hongjing LI,Wenbo DONG

《环境科学与工程前沿（英文）》 2015年第9卷第4期页码 583-590 doi: 10.1007/s11783-014-0691-8

摘要： The reactions between chlorinated benzenes (CBzs) and hydrated electron ( ) were investigated by the electron beam (EB) and laser flash photolysis (LFP) experiments. Under the EB irradiation, the effects of irradiation dose, initial concentration and the number of Cl atoms on the removal efficiencies were further examined. At 10 kGy, the removal efficiencies of mono-CB, 1,3-diCB, 1,2-diCB and 1,4-diCB were 41.2%, 87.2%, 84.0%, and 84.1%, respectively. While irradiation dose was 50 kGy, the removal efficiencies increased to 47.4%, 95.8%, 95.0%, and 95.2%, respectively. Irradiation of CBzs solutions has shown that the higher the initial concentration, the lower the percentage of CBzs removal. In addition to this, the dechlorination efficiencies of 1,2-dichlorobenzene (1,2-diCB), 1,3-dichlorobenzene (1,3-diCB) and 1,4-dichlorobenzene (1,4-diCB) were much higher than that of chlorobenzene (mono-CB). The kinetics of the reactions was achieved with nanosecond LFP. The rate constants of second-order reaction between with mono-CB, 1,2-diCB, 1,3-diCB and 1,4-diCB were (5.3±0.4) × 10 , (4.76±0.1) × 10 , (1.01±0.1) × 10 and (3.29±0.2) × 10 L·mol ·s , respectively. Density functional theory (DFT) calculations were performed to determine the optical properties of unstable CBzs anion radicals, and the main absorption peaks lied in the range of 300–550 nm. The primary reaction pathway of CBzs with was gradual dechlorination, and the major products were Cl and benzene (CBzs(-Cl )). Furthermore, biphenyl (or chlorobiphenyl) was observed during the LFP, which was probably formed by recombination of benzene radicals.

关键词： chlorinated benzenes hydrated electron electron beam laser flash photolysis

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Study of mechanism of activating flux increasing weld penetration of AC A-TIG welding for aluminum alloy

HUANG Yong, FAN Ding, FAN Qinghua

《机械工程前沿（英文）》 2007年第2卷第4期页码 442-447 doi: 10.1007/s11465-007-0076-9

摘要： When multi-component flux AF305 is used as surface activating flux for an aluminum alloy, the weld pene tration of activating flux-tungsten inert-gas (A-TIG) welding is over two times more than that of conventional TIG welding. Using A-TIG welding with the modes of alternating current (AC), direct current electrode negative (DCEN) and direct current electrode positive (DCEP), respectively, the flux differently affects weld penetration when the polarity is different. After studied the effect of compelled arc con striction on weld penetration of AC welding, it is believed that the constriction of the whole arc root is not the main mechanism that flux AF305 dramatically improves weld penetration. The penetration has a relationship with the separate distribution of slag on the weld surface. Then, an observation of scanning electron microscopy (SEM) and an electronic data systems (EDS) analysis of slag were performed respectively. The separate distribution of slag on the weld pool during welding and the great constriction of arc spots were confirmed by TIG welding with helium shielding gas. The relationship between slag distribution and weld penetration was studied by adding aluminum powder into flux AF305 to change the distribution of slag. During welding, the separate distribution of slag on the weld pool results in the great constriction of arc spots, an increase in arc spot force, and an increase in Lorentz force within the arc and weld pool. Finally, the weld penetration is increased.

关键词： A-TIG welding surface DCEN electrode negative increase

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Offline motion planning and simulation of two-robot welding coordination

Tie ZHANG, Fan OUYANG

《机械工程前沿（英文）》 2012年第7卷第1期页码 81-92 doi: 10.1007/s11465-012-0309-4

摘要：

This paper focuses on the two-robot welding coordination of complex curve seam which means one robot grasp the workpiece, the other hold the torch, the two robots work on the same workpiece simultaneously. This paper builds the dual-robot coordinate system at the beginning, and three point calibration method of two robots’ relative base coordinate system is presented. After that, the non master/slave scheme is chosen for the motion planning, the non master/slave scheme sets the poses versus time function of the point u on the workpiece, and calculates the two robot end effecter trajectories through the constrained relationship matrix automatically. Moreover, downhand welding is employed which can guarantee the torch and the seam keep in good contact condition all the time during the welding. Finally, a Solidworks-SimMechanics simulation platform is established, and a simulation of curved steel pipe welding is conducted. The results of the simulation illustrate the welding process can meet the requirements of downhand welding, the joint displacement curves are smooth and continuous and no joint velocities are out of working scope.

关键词： complex curve seam two robots coordinated welding motion planning