Relationship between quality and attributes of elliptical spot welds of high strength steel

More high strength steel(HSS) sheets are being applied in the automobile industry to improve safety and fuel efficiency.When HSS is spot welded, the strength of the welded-joint is usually determined by the attributes of the weld nugget.However, it is diffcult to obtain the circular nugget and to establish the relationship between the weld attributes and welding quality because of a large number of variables and experimental uncertainty.In the paper, the numerical analysis model of tensile-shear strength test for HSS spot welds was established.And the critical ellipticity of the elliptical spot weld was determined through finite element analysis.Quantitative relationship between elliptical weld attributes and weld strength was investigated statistically using the Latin hypercube and regression analysis method.The sheet thickness, nugget ellipticity, hardness radio and yield strength have the most influential attributes in affecting welding quality.The research results can be used as a guideline for HSS resistance spot welding design.     

Microscopic structure and property of double-electrode gas metal arc welding of AZ31B magnesium alloy

This paper focuses on the research on double-electrode gas metal arc welding(DE-GMAW) of AZ31 B magnesium alloy sheet with 2 mm thickness. During the welding process, stable hybrid arc of metal inert gas(MIG) and tungsten inert gas(TIG) is employed as welding heat source. Optical and electron microscopes are used to observe the microstructures of the weld joint. X-ray diffraction(XRD) and energy dispersive spectroscopy(EDS) are employed to identify the components in fusion zone. Microhardness is also tested. When the MIG current is 80 A, the perfect weld joint is obtained, though figures of fish scales are observed in all joints in the research. The fusion zone is formed by dendrites, where β-Mg17(Al, Zn)12is dispersed. The hardness in fusion zone and heat affected zone(HAZ) is lower than that in base metal(BM). The average Vickers hardness of fusion zone and HAZ is about 58 and 56 respectively, while the Vickers hardness of BM is about 63.     

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.     

Overview on Environmental Comprehensive Management System Established in Imitation of Biome

Environmental comprehensive management system, called “the bionic community”, can be established in imitation of biome, which can transform the wastes generated in a certain field into the raw materials of other field. The establishment of the bionic community includes two aspects, i.e. , the matching technique and the management system. The main matching technique is the preparation of composite materials made of various wastes.This new kind of material can be divided into four types: polymer matrix, silicate matrix, metal matrix and carbon matrix (or ceramic matrix). The environmental comprehensive management system is formed by organizing a transtrades joint-management business entity with the products of composite material made of wastes at the core.     

Vacuum Brazing of TiAI Based Alloy with 40Cr Steel

The vacuum brazing of TiA1 based alloy with 40Cr steel was investigated using Ag-Cu-Ti filler metal.The experimental results show that the Ag, Cu, Ti atoms in the filler metal and the base metal inter-diffuse toward each other during brazing and react at the interface to form an inter-metallic A1Cu2Ti compound which joins two parts to produce a brazing joint with higher strength.     

Analysis and calculation of axial stiffness of tubular X-joints under compression on braces

This paper introduces the influence factors of axial stiffness of tubular X-joints. The analysis model of tubular joints using plate and shell finite element method is also made. Systematic single-parameter analysis of tubular X-joints is performed using Ansys program. The influences of those factors, including ratio of brace diameter to chord diameter (β), ratio of chord diameter to twice chord thickness (γ), ratio of brace wall thickness to that of chord (τ), brace-to-chord intersection angle (θ), and chord stress ratio, ratio of another brace diameter to chord diameter, in-plane and out-of-plane moment of braces, etc., on stiffness of tubular X-joints are analyzed.Two non-dimensional parameters-joint axial stiffness factor ηN and axial force capacity factor ωN are proposed,and the relationship curve of the two factors is determined. Computational formulas of tubular X-joint axial stiffness are obtained by multi-element regression technology. The formulas can be used in design and analysis of steel tubular structures.     

Numerical simulation of orthotropic steel deck bridges with two membrane layers systems

The finite element system CAPA-3D was utilized as the numerical simulation platform,two structural FE models of orthotropic steel bridge decks were set up,the static and dynamic FE simulations under different loading conditions were carried out,the special attention was given to identify the critical wheel load location,and the maximum tensile stress distribution and the variation of strain rate inside membrane layers.Simulation result shows that the FE models are capable of simulating the realistic behavior of orthotropic steel bridge.The distributions of strains and stresses inside the surfacing materials depend highly on wheel load level,wheel load frequency,wheel position,membrane bonding strength as well as the thicknesses and characteristics of surfacing layers.The maximum tensile stress of membrane layers is found around 0.4MPa,which coincides with the minimum requirement for the adhesive bonding strength of membrane material proposed by the standards NF P98-282and TP-BEL-B.The maximum membrane strain rate is found around 0.1,which is an important information that can be utilized for the characterization of membrane products.1tab,28figs,7refs.     

Numerical Simulation of Projection Welding Processes for Door Hinge of Automobile Based on Coupled Fields Analysis

Projection welding is a variation of electric resistance welding with the dynamic changes of the flow paths for heat and electrical properties with changing temperature caused by the large plastic deformation collapse of projection. As the joint type between the auto door hinge and the inner plate, projection welding may bring welding distortions and would affect the assembly quality of auto body. A comprehensive electric-thermal-mechanical numerical simulation was performed to quantitatively simulate the processes of projection welding by using a coupled finite element method. The mechanism of projection collapse and the formation process of nugget were discussed and good conclusions have been achieved comparing with the test results.     

Feature extraction and modeling of welding quality monitoring in pulsed gas touch argon welding based on arc voltage signal

Arc sensing plays a significant role in the control and monitoring of welding quality for aluminum alloy pulsed gas touch argon welding （GTAW）. A method for online quality monitoring based on adaptive boosting algorithm is proposed through the analysis of acquired arc voltage signal. Two feature extraction algorithms were developed in time domain and frequency domain respectively to extract six statistic characteristic parameters before removing the pulse interference using the wavelet packet transform （WPT）, based on which the Adaboost classification model is successfully established to evaluate and classify the welding quality into two classes and the classified accuracy of the model is as high as 98.81%. The Adaboost algorithm has been verified to be feasible in the online evaluation of welding quality.     

Comparison of Three Control Methods in Penetration Control of Pulsed Gas Tungsten Arc Welding

An artificial neural network model for backside bead width was established and three control meth-ods——PID. fuzzy and neuron were designed, simulated and tested. The test results of bead-on-plate weld of GTAW indicate that the artificial neural network (ANN) modeling and learning control method have more advan-tages than the conventional method. They show that the ANN modeling and learning control method is an effective approach to real time control of welding dynamics and ideal quality.     

Finite Element Analysis for Multi-pass Equal Channel Angular Pressing

Equal channel angular pressing (ECAP) is an attractive process method to produce bulk ultra-fine grained materials. There are many experiment evidences showing that the nature of the microstructural evolution in multi-pass ECAP depends on process routes. Isothermal three dimensional FEM simulations for multi-pass ECAP were performed using DEFORM3D finite element code. The material model of 6061Al-T6 was employed. Flow nets, effective strain distribution in the workpiece and loads during multi-pass ECAP using different routes were analysed respectively. The simulations show process routes influence material flow and effective strain distribution in the workpiece obviously but have few influence on loads.     

An Experimental Study on Bogie Frame of a High Speed Electrical Locomotive

For the dynamics of wheel/rail and car body, lightweighting of bogie frames is one of main concerns of designers. Lightweighting of the bogie frames may reduce the fatigue strength and life, especially in heavy haul and high-speed conditions. In this work, full-scale fatigue and fracture experiments are performed to meet the design requirements of bogie frame of a high-speed electrical locomotive. Multi-axial stress-states of some dangerous points are found both in service and numerical calculation. The Von-Mises equivalent stress criterion is used to evaluate the strength. Then crack initiation and propagation detected during the test are described. The reason why the crack growth rate may become slow in the weld structure of the bogie frame is explained using a residual stress concept. Miners accumulative damage rule and P-S-N curve are used to predict the life of the bogie frame under fatigue and fracture tests. The experimental approach and theoretical analysis give satisfactory results and design information.     

Modeling, identification and simulation of DC resistance spot welding process for aluminum alloy 5182

Currently the aluminum alloy resistance spot welding(AA-RSW) has been extensively used for light weight automotive body-in-white manufacturing.However the aluminum alloys such as AA5182 have inferior weldability for forming the joint due to their high reflectiveness to heat and light.Therefore it is necessary to further develop the high performance control strategy and the set-up of a new welding schedule.The welding process identification is the essential issue where the difficulty arises from the fact that the AA-RSW is a nonlinear time-varying uncertain process which couples the thermal,electrical,mechanical and metallurgical dynamics.To understand this complicated physical phenomenon a novel dual-phase M-series pseudo-random electrical pattern is adopted to excite the AA-RSW electrical-thermal process and the thermal response is recorded according to the welding power outputs.Based on the experimental information,the transfer function of an AA-RSW electrical- thermal mechanism is identified,and the optimum model order and parameters are determined.Subsequently a control-oriented DC AA-RSW model is established to explore the welding power control algorithm.The simulated results of the control model show agreement with the experimental data,which validates its feasibility for the corresponding welding control.     

Effect of Deposition Time on Thickness and Corrosion Behavior of Zn-Fe Coating

Zn-Fe coatings on Q235 steel are prepared by pack cementation process at 390 ℃ for 2,4,6,8 and10 h to investigate the effects of the deposition time on the thickness and corrosion behavior of the Zn-Fe coatings.The thickness of the coating increases with the increase of the deposition time.The coating is composed of a thick outer layer and a thin inner layer.The formation of the coating depends on the inward diffusion of Zn atoms and the outward diffusion of Fe atoms.The outer layer is composed of Fe11 Zn40 and FeZn10 phases.The corrosion behavior of the Zn-Fe coatings is evaluated by immersion test and polarization test.The results show that the Zn-Fe coatings can effectively prevent the Q235 steel from corrosion.The corrosion resistance of the coating is proportional to the deposition time.     

Research on hydrogen environment fatigue test system and correlative fatigue test of hydrogen storage vessel

A 70 MPa hydrogen environment fatigue test system has been designed and applied in the manufacture of a hydrogen storage vessel. Key equipment is the 80 MPa flat steel ribbon wound high pressure hydrogen storage vessel. A reasonable stress distribution has been realized, that is low stress in the liner of the pressure vessel and even stress in the flat ribbon layers. This optimal stress distribution is achieved through the adjustment of the prestress in flat steel ribbons. A control system for the fatigue test system has also been designed. It consists of a double control model, i.e. manual control and automatic control, to satisfy different experimental requirements. The system is the unique one that can be used in the real hydrogen environmental fatigue test system in China. An experiment for the 70 MPa onboard composite material hydrogen vessel has been carried out on the system. The experimental result from this test is in close agreement with the practical operating conditions.     

Dry milling of the ultra-high-strength steel 30CrMnSiNi2A with coated carbide inserts

The ultra-high-strength steel (UHSS) plays an important role in the mechanical industry because of their special performances. The machinability of 30CrMnSiNi2A steel was studied in dry milling with two different coated tools in the present work. This paper introduced that 30CrMnSiNi2A steel was a kind of difficult-to-machine materials. The results showed that the cutting force components of feed direction and cutting width direction, i.e. F x and F y , increased slightly with increasing the cutting speed and feed rate. The values of axial force component F z were much larger than F x and F y , and increased obviously with increasing the milling speed. The workpiece surface had the minimum roughness at the cutting speed of 150 m/min. The physical vapor deposition (PVD) coated ((Ti, Al)N-TiN) insert was more suitable for machining 30CrMnSiNi2A steel than the chemical vapor deposition (CVD) coated (Ti(C, N)-Al 2 O 3 ) insert. Moreover, the main failure modes of PVD-coated insert were micro-chipping and coating spalling. The wear modes of CVD-coated insert were ploughing, coating spalling, and cratering. The serious adhesive wear and the abrasion with some adhesion were the main wear mechanism of PVD- and CVD-coated inserts, respectively.     

Numerical method on load sharing problem of thick laminate joints

Accurately and efficiently predicting the load sharing of multi~bolt thick laminate joints is necessary to quicken the optimization of the large-scale structures over various design variables, and a two-dimensional （2D） finite element method （FEM） is introduced to meet such a demand. The deformation contributions of the joint zone are analyzed and calculated separately, including the shearing deformation of the fasteners shank, the bending deformation of the fasteners shank, and the bearing deformation of the fasteners and joint plates. These deformations are all transferred and incorporated into the components of the fastener＇s flexibility. In the 2D finite element model, the flexibilities of the beam elements and bush elements are used to simulate different components of the fastener＇s flexibility. The parameters of the beam elements which include the bending moment of inertia and intersection area, and the parameters of the bush elements which include the stiffness in different directions, are all obtained through equalizing the fasteners flexibilities. In addition, the secondary bending effect introduced by the single-lap joints is also taken into account to verify the flexibilities of the fasteners in practical application. The proposed FEM is testified to be more accurate than the traditional 2D FEMs and more efficient than the three-dimensional （3D） FEM in solving load sharing problem of multi-bolt single-lap thick laminate joints. With the increase of joint plates＇ thickness, the advantages of the proposed method tend to be more obvious. The proposed 2D FEM is an effective tool for designing bolted joints in large-scale composite structures.     

Fracture Mechanics for a Mode Ⅲ Crack in a Piezoelectromagnetic Material

Analytical solutions for a Griffith crack inside an infinite piezoelectromagnetic medium under combined mechanical-electrical-magnetic loadings are formulated using integral transform method. The singular stress, elec tric and magnetic fields in the piezoelectromagnetic material are obtained by the theory of linear piezoelectromagneticity. Fourier transforms are used to reduce the mixed boundary value problems of the crack, which is as sumed to be permeable, to dual integral equations. The solution of the dual integral equations is then expressed analytically. Expressions for strains, stresses, electric fields, electric displacements, magnetic fields and magnetic inductions in the vicinity of the crack tip are derived. Field intensity factors and energy release rate for piezoelectromagnetic material are obtained. The stresses, electric displacements and magnetic inductions at the crack tip show the traditional square root singularities; and the electric field intensity factor （EFIF） and the magnetic field intensity factor （MFIF） are always zero.     

Analysis of through-the-thickness stress distribution in thick laminate multi-bolt joints using global-local method

The stress distribution surrounding the fastener hole in thick laminate mechanical joints is complex. It is time-consuming to analyze the distribution using finite element method. To accurately and efficiently obtain the stress state around the fastener hole in multi-bolt thick laminate joints, a global-local approach is introduced. In the method, the most seriously damaged zone is 3D modeled by taking the displacement field got from the 2D global model as boundary conditions. Through comparison and analysis there are the following findings: the global-local finite element method is a reliable and efficient way to solve the stress distribution problem; the stress distribution around the fastener hole is quite uneven in through-the-thickness direction, and the stresses of the elements close to the shearing plane are much higher than the stresses of the elements far away from the shearing plane; the out-of-plane stresses introduced by the single-lap joint cannot be ignored due to the delamination failure; the stress state is a useful criterion for further more complex studies involving failure analysis.     

Optimal posture searching algorithm on mobile welding robot

An independently developed mobile welding robot system is introduced. Kinematics model is the base of robot planning. With the Denavit-Hartenberg method, robot kinematics equation can be gotten. The robot welding torch inclination angle consists of the working and moving angles. According to the kinematics model, both the two angles and torch position can be calculated. Under special moving angle, a two-step algorithm is used to obtain the optimal manipnlator posture. The calculation result shows that the Mgorithm has high precision.