Spatter rate estimation of GMAW-S based on partial least square regression

This paper analyzes the drop transfer process in gas metal arc welding in short-circuit transfer mode （GMAW-S） in order to develop an optimized spatter rate model that can be used on line. According to thermodynamic characters and practical behavior, a complete arcing process is divided into three sub-processes： arc re-ignition, energy output and shorting preparation. Shorting process is then divided as drop spread, bridge sustention and bridge destabilization. Nine process variables and their distribution are analyzed based on welding experiments with high-speed photos and synchronous current and voltage signals. Method of variation coefficient is used to reflect process consistency and to design characteristic parameters. Partial least square regression （PLSR） is utilized to set up spatter rate model because of severe correlativity among the above characteristic parameters. PLSR is a new multivariate statistical analysis method, in which regression modeling, data simplification and relativity analysis are included in a single algorithm. Experiment results show that the regression equation based on PLSR is effective for on-line predicting spatter rate of its corresponding welding condition.     

D6AC超高强钢的细丝双弧焊接工艺试验研究

分析了D6AC超高强钢的焊接性，采用细丝双弧焊接方法，进行D6AC超高强钢的双弧焊接工艺试验研究。采用细丝双弧焊接技术，基本可以解决D6AC超高强钢焊接时存在高裂纹倾向的问题，并降低焊接成本，避免了脉冲TIG焊扫法的低效率和高能密度焊接方法的高成本问题。     

梯形动铁式交流焊机优化设计研究

对梯形动铁式交流焊机的优化目标进行了探讨,在此基础上建立了动铁式交流焊机优化设计的数学模型,编制了计算机优化设计软件,利用该软件对焊机进行了优化设计,结果表明:利用该软件所设计的交流焊机具有较低的制造成本和较高的综合性能     

基于神经网络的船体焊接规范自动预测方法研究

针对目前船体焊接规范参数设计的特点,设计了船体焊接规范自动决策的人工神经网络模型．通过实际焊接工艺数据对网络模型进行训练,把以规则显示表达的工艺设计知识转化为隐式网络权值,应用网络推理机快速、准确地预测船体焊接规范参数．实验表明所建神经网络模型具有较好的自学习和预测能力,为船体焊接工艺参数优选提供了一条新途径．     

串联半桥式场效应管弧焊逆变器可靠性分析

在建立了串联半桥式场效应晶体管弧焊逆变器主回路工作过程数学模型的基础上，讨论了电路主要参数对逆变器工作过程及其可靠性的影响，指出了弧焊逆变器设计中应注意的问题。     

埋弧自动堆焊工艺参数的确定

为提高焊接加工行业焊接效率,应用高效焊接工艺方法已成为行业的共识,文章主要研究了焊接工艺技术中的工艺参数对埋弧自动堆焊的影响规律。通过试验实现埋弧自动堆焊过程,采用逼近法优化了堆焊电流、电弧电压、堆焊速度等工艺参数,确定了合理选择堆焊工艺参数的原则和方法,从而对工业生产起到一定的指导作用。     

等离子体焊接枪的数值模拟

以等离子体钨极氩弧焊接枪为研究对象,通过求等离子体弧柱区域的能量方程、动量守恒、质量守恒及电流连续性方程,得到温度、速度、电流密度分布。数值模拟200A自由氩弧所得电弧等离子体温度分布与实验数据相当吻合。在此基础上研究了带有喷嘴的弧柱部分的数值模拟,以及温度、速度和电流密度的分布、电弧弧长和最高温度的关系。     

基于峰值电流模式的零电压软开关弧焊逆变器

针对目前弧焊逆变电源存在的问题，采用一种欠开关电路拓扑，结合移相控制软开关技术和电流峰值控制技术，研制了基于峰值电流模式的零电压软开关弧焊逆变器。测试结果表明，该逆变器能够实现全范围软开关，并且具有良好的限流和自校正能力，可有效地解决功率变压器的偏磁问题。     

Analysis of arc physical property of pulsed tungsten inert gas welding based on Fowler-Milne method

Pulsed tungsten inert gas (TIG) welding is widely used in industry due to its superior properties, so the measurement of arc temperature is important to analyse welding process. Arc image of spectral line in 794.8 nm is captured by high speed camera; both the Abel inversion and the Fowler-Milne method are used to calculate the temperature distribution of the pulsed TIG welding. Characteristic of transient variation in arc intensity and temperature is analyzed. When the change of current happens, intensity and temperature of arc jump as well, it costs several milliseconds. The further the axial position from the tungsten is, the greater the intensity jumps, and the smaller the temperature changes.     

发动机液压挺柱的氩弧焊接组装

针对某小型高速发动机,设计了一种液压挺柱。通过试验对各种组装方法加以分析、比较,最终确定采用氩弧焊接进行组装。试验结果显示液压挺柱工作可靠,说明采用氩弧焊接是可行的。     

WELDOX960E高强钢手工电弧焊焊接接头组织与力学性能

通过拉伸、弯曲、冲击、硬度和金相组织分析等试验,对手工电弧焊焊接WELDOX960E高强钢焊接接头组织和力学性能进行研究.研究结果表明：采用Phoenix SH Ni2 K130焊条、手工电弧焊焊接WELDOX960E高强钢时,可以获得拉伸、弯曲、冲击性能良好的接头;其焊缝组织为针状铁素体与粒状贝氏体的混合分布;熔合区及粗晶区组织为板条马氏体和少量白色M-A块区;正火区组织为块状铁素体、粒状贝氏体和珠光体;母材显微组织为回火索氏体;WELDOX960E高强钢焊缝硬度为270 ～ 300 HV,且距离熔合线30 mm处出现软化区.     

RECALLABLE TRACKING TECHNIQUE FOR TOP WELD BEADS OF NARROW GAP SUBMERGED ARC WELDING

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Prediction of Welding Deformation of Underframe

IntroductionWelding deformation is a common and impor-tant problem in industry.In the last decades re-searchers have made efforts to predict and controlwelding deformation.There are usually three waysto determine the welding deformation:1 experi-ential formulas.2 Thermal elastic- plastic FEMmethod.3 Inherent strain method based onFEM[1～ 3 ] .Experiential formulas are only fit for simpleshape structures.Current thermal elastic- plasticmethod usually simulated either small or simplestructur…     

Prediction of Welding Residual Stress in 2. 25Cr-1Mo Steel Pipe

Introduction2.25Cr-1Mo-steel is widely used in thepetroleum industry and in steam power generatingof both nuclear and conventional power plants be-cause of its excellent high-temperature strength,corrosion resistibility,and resistance to high-tem-perature hydrogen attack.Because several alloy el-ements are added into2.25Cr-1Mo-steel,marten-site is prone to form after welding.It has been rec-ognized that phase transformation can radically af-fect the development of residual stresses[1-2].Inor…     

基于Marc和遗传算法的焊接工艺参数优化

焊接变形的大小主要受焊接速度、焊接电流、电压、送丝速度、焊接顺序等工艺参数的影响.根据焊接热加工特点和实际需要,针对设计变量数目繁多、类型多样的焊接工艺,采用遗传算法与有限元分析相结合的方式,对重点参数进行了优化.以二维平板对接焊的模型为例,以工件最小焊接变形量为优化目标,经过遗传算法进化后,结合有限元方法进行每组参数组合的焊接过程热力耦合分析,找出焊接能量和焊接速度的最优组合,为焊接工艺的优化和制定提供科学的评价和预测.     

机器人焊割柱管相贯线的路径规划研究

近年来,柱管接管相贯线接缝焊割由传统的手工焊逐渐被焊割机器人操作所代替。本文建立了圆锥、球体与柱管相贯线的一般化数学模型,并将空间相贯线展成平面曲线,利用等步长原理获取焊割轨迹的路径点。为保证焊割精度,步长的数值由输入的允许插补误差值经计算获得。文中还给出了柱管相贯线获取焊割路径点的流程图。此方法方便了焊割程序的编制,提高了工作效率,同时又保证了焊割的平稳性和精确性。最后给出了一个常见的柱管相贯实例,利用Matlab软件编程得到了其相贯线焊割路径点。     

动车组构架激光-MAG复合热源焊接工艺参数

针对高速列车转向架焊接构架中典型的平板对接接头、T型角接接头和管板搭接接头,采用激光-MAG电弧复合热源焊接方法进行了系统的焊接工艺试验,确定了平板对接、T型角接和管板搭接接头的坡口角度、钝边尺寸和组焊间隙,以及相应的激光-MAG复合热源焊接工艺参数,为激光-电弧复合焊接方法在构架制造中的应用提供了工艺参数和技术基础.     

客车顶蒙皮焊接半自动化设备的设计与调试

客车顶盖蒙皮自动点焊设备开发的成功，解决了客车顶盖蒙皮生产工艺落后的问题。如果采用电铆焊的方法对蒙皮与骨架进行连接，具有质量好、成本低、操作方便、焊件受热变形小及成形美观等优点。可扩展到侧围蒙皮与骨架的焊接。     

基于ASME标准的机车制动闸瓦托焊接疲劳分析

以ASME标准中的基于等效结构应力的主S-N曲线法对闸瓦托结构中的14条焊缝疲劳寿命进行分析.建立闸瓦托有限元模型,根据实际制动工况分析其承载载荷,计算制动过程中焊缝区域的应力分布,基于等效结构应力算法将应力进行转换,进而求解各条焊缝在实际工况载荷的疲劳寿命,并对疲劳寿命较低的危险焊缝进行预测及分析,结果表明该闸瓦托分别存在两条对称的主要危险焊缝和两条对称的次级危险焊缝.     

Analytical Solution for Model-Based Dynamic Power Factor Measurement in AC Resistance Spot Welding

On the basis of welding transformer circuit model, a new measuring method was proposed. This method measures the peak angle of the welding current, and then calculates the dynamic power factor in each half-wave. An artificial neural network is trained and used to generate simulation data for the analytical solution, i.e. a high-order binary polynomial, which can be easily adopted to calculate the power factor online. The tailored sensing and computing system ensures that the method possesses a real-time computational capacity and satisfying accuracy. A DSP-based resistance spot welding monitoring system was developed to perform ANN computation. The experimental results suggest that this measuring method is feasible.