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the tensile properties of friction stir welded aluminum alloy joints based on axial force, traverse speed, and rotational speed

Biranchi PANDA,A. GARG,Zhang JIAN,Akbar HEIDARZADEH,Liang GAO

《机械工程前沿（英文）》 2016年第11卷第3期页码 289-298 doi: 10.1007/s11465-016-0393-y

摘要：

Friction stir welding (FSW) process has gained attention in recent years because of its advantages over the conventional fusion welding process. These advantages include the absence of heat formation in the affected zone and the absence of large distortion, porosity, oxidation, and cracking. Experimental investigations are necessary to understand the physical behavior that causes the high tensile strength of welded joints of different metals and alloys. Existing literature indicates that tensile properties exhibit strong dependence on the rotational speed, traverse speed, and axial force of the tool that was used. Therefore, this study introduces the experimental procedure for measuring tensile properties, namely, ultimate tensile strength (UTS) and tensile elongation of the welded AA 7020 Al alloy. Experimental findings suggest that a welded part with high UTS can be achieved at a lower heat input compared with the high heat input condition. A numerical approach based on genetic programming is employed to produce the functional relationships between tensile properties and the three inputs (rotational speed, traverse speed, and axial force) of the FSW process. The formulated models were validated based on the experimental data, using the statistical metrics. The effect of the three inputs on the tensile properties was investigated using 2D and 3D analyses. A high UTS was achieved, including a rotational speed of 1050 r/min and traverse speed of 95 mm/min. The results also indicate that 8 kN axial force should be set prior to the FSW process.

关键词： tensile properties ultimate tensile strength tensile elongation friction stir welding tool rotational speed genetic programming welding speed

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搅拌摩擦焊镁合金隔声性能的研究

刘成武,钱林方

《中国工程科学》 2014年第16卷第8期页码 93-98

摘要：

伴随搅拌摩擦焊在镁合金上的广泛应用，对其隔声特性研究尤为重要，基于自适应网格技术，对搅拌摩擦焊过程进行数值模拟，为后续声学计算提供约束模态，解决了材料属性难以确定的问题，一定程度上实现了焊接与声学的结合。自行设计和制造了混响箱，用以测量焊接镁合金板的隔声量，弥补了混响室测试小试件的不足。进而使用finite element-statistical energy analysis（FE-SEA）混合法计算焊接件的隔声量，与试验结果进行对比，吻合良好，表明此方法行之有效。通过对比焊接前后镁合金板件的隔声量，发现在吻合低谷区，焊接后板件的隔声有所降低。为了研究焊接参数对隔声的影响，分别改变焊接速度和搅拌头旋转速度，观察隔声量的变化，结果表明，这些参数都需要合理的设置，并非越大或者越小越好。

关键词：搅拌摩擦焊混响箱 FE-SEA混合法焊接速度搅拌头旋转速度

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A novel soft-switching twin arc pulse MAG welding inverter

WANG Zhenmin, XUE Jiaxiang, WANG Fuguang, HUANG Shisheng

《机械工程前沿（英文）》 2007年第2卷第2期页码 224-227 doi: 10.1007/s11465-007-0039-1

摘要： The high-speed double wire pulse metal gas arc (MAG) welding process possesses advantages of automation and high efficiency and quality. Thus, it attracts much more attention nowadays. To meet the requirements of the double wire pulse MAG welding process, a novel double wire pulse MAG welding inverter integrated with technologies, such as soft-switching, double closed loop control, and synchronic control, is produced. A complete performance test was done for the pulsed MAG welding power supply by using a computer testing platform. The results of the experiment indicate that the novel welding inverter has an excellent performance both in the dynamic and the static characteristics. Also, the synchronic control between the master inverter and the slave inverter is reliable.

关键词： high-speed control computer experiment indicate platform

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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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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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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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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

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Review on electromagnetic welding of dissimilar materials

K. SHANTHALA,T. N. SREENIVASA

《机械工程前沿（英文）》 2016年第11卷第4期页码 363-373 doi: 10.1007/s11465-016-0375-0

摘要：

Electromagnetic welding (EMW) is a high-speed joining technique that is used to join similar or dissimilar metals, as well as metals to non-metals. This technique uses electromagnetic force to mainly join conductive materials. Unlike conventional joining processes, the weld interface does not melt, thus keeping the material properties intact. Extremely high velocity and strain rate involved in the process facilitate extending the EMW technique for joining several materials. In this paper, the research and progress in electromagnetic welding are reviewed from various perspectives to provide a basis for further research.

关键词： electromagnetic welding impact dissimilar materials

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Structure and performance of welding joint of Q235 steel welded by SHS welding

Junzhi HU, Sumei WANG, Xiaoli ZHAO, Shilin ZHU, Botao YU,

《机械工程前沿（英文）》 2010年第5卷第2期页码 189-193 doi: 10.1007/s11465-010-0003-3

摘要： A self-propagating high-temperature synthesis (SHS) welding-pen that can weld steel workpiece from 6 to 10 mm is developed and welds the Q235 steel. The structure and properties of the welding joint are studied. The result indicates that this type of welding is melting and the fusion zone is clear. The tensile-strength of the welding joint is 283 MPa, flexural strength is 628 MPa, impact toughness is 46.43 J·cm, and the microhardness of the welding joint and fusion zone are 230 HV and 255.6€HV, respectively. The mircohardness of the fusion zone and the welding line are higher than that of the matrix.

关键词： self-propagating high-temperature synthesis (SHS) welding welding line structure and performance melting

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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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轻量化材料焊接车间智能化要素分析

周安亮,王德成

《中国工程科学》 2017年第19卷第5期页码 103-108 doi: 10.15302/J-SSCAE-2017.05.018

摘要：

本文从轻量化材料焊接最终目标和需求、数字化和智能化技术发展趋势、焊接车间柔性构建三个维度出发，结合先进制造车间智能化和焊接工艺数字化技术发展趋势，分析得出了轻量化材料焊接车间智能化需满足的焊接控制管理实时化、焊接过程质量控制闭环化、焊接性分析数据化、焊接工艺分析智能化、快速互换装夹（柔性化）、焊缝质量检测工具化、焊接生产管理数字化、焊接基础数据库无纸化八大基本要素，并对这些要素分别进行了阐述，相关结论可以作为焊接车间智能化改造或新建的参考。

关键词：焊接工艺焊接车间智能化轻量化材料战略研究

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Research on overlaying welding rod of high hardness maraging steel

PAN Yong-ming, CHEN Shao-wei

《机械工程前沿（英文）》 2006年第1卷第4期页码 465-467 doi: 10.1007/s11465-006-0060-9

摘要： The development of new maraging steel overlaying welding rod, which contains Co, Mo, W and V alloy, solved the problems of poor homogeneity of hardness and mechanical process, prolonged the service life of wear-resistant components and increased the productive efficiency of repairing, greatly benefiting the national economy.

关键词： development productive efficiency national homogeneity mechanical

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长距离输油输气管道建设——焊接工艺制订及焊接设备选型

郭海云,李桓,李国华,胡连海

《中国工程科学》 2001年第3卷第12期页码 76-79

摘要：

举世瞩目的西气东输工程开工在即，大投资、长距离、大管径、短工期、高质量、地质条件多样、施工单位众多等是其主要特点。其中焊接工艺的制订及焊接设备的选型涉及许多技术问题，将对施工进度、施工质量、施工单位的经济效益产生重大影响，应引起足够重视。

关键词：输油输气管道建设焊接设备选型

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Non-electric welding and its application on equipment under emergency conditions

HU Junzhi, HU Chunhua, MA Shining, XIN Wentong

《机械工程前沿（英文）》 2007年第2卷第2期页码 239-242 doi: 10.1007/s11465-007-0042-6

摘要： This paper introduces the working principle, characteristics, development, welding techniques, and applications of non-electric welding. We analyzed the microstructure of the welding bead and the tensile strength of the non-electric welded joints. The results indicate that the welding technique is simple, the performance of the welding line is excellent, and that the application is broad. Therefore, non-electric welding shows favorable application value and potential prospect.

关键词： development strength technique application favorable application

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Quality monitoring of resistance spot welding based on electrode displacement characteristics analysis

ZHANG Pengxian, ZHANG Hongjie, CHEN Jianhong, MA Yuezhou

《机械工程前沿（英文）》 2007年第2卷第3期页码 330-335 doi: 10.1007/s11465-007-0058-y

摘要： A new method is developed to monitor joint quality based on the information collection and process in spot welding. First, twelve parameters related to weld quality are mined from electrode displacement signal on the basis of different phases of nugget formation marked by simultaneous dynamic resistance signal. Second, through correlation analysis of the parameters and taking tensile-shear strength of the spot-welded joint as evaluation target, different characteristic parameters are reasonably selected. At the same time, linear regression, nonlinear regression and radial basis function (RBF) neural network models are set up to evaluate weld quality between the selected parameters and tensile-shear strength. Finally, the validity of the proposed models is certified. Results show that all of the models can be used to monitor joint quality. For the RBF neural network model, which is more effective for monitoring weld quality than the others, the average error validated is 2.88% and the maximal error validated is under 10%.

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标题作者时间类型操作

the tensile properties of friction stir welded aluminum alloy joints based on axial force, traverse speed, and rotational speed

Biranchi PANDA,A. GARG,Zhang JIAN,Akbar HEIDARZADEH,Liang GAO

期刊论文

搅拌摩擦焊镁合金隔声性能的研究

刘成武,钱林方

期刊论文

A novel soft-switching twin arc pulse MAG welding inverter

WANG Zhenmin, XUE Jiaxiang, WANG Fuguang, HUANG Shisheng

期刊论文

ARC welding method for bonding steel with aluminum