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摘要 ：
In this paper, a heat transfer model of the filler wire in twin-body plasma arc welding (TPAW) was established. The total power transferred to the filler wire included anode effect power, resistance power and plasma arc power. The influences of the wire current, wire extension and plasma gas flow rate on the power transferred to the filler wire were studied using the location of the molten region of the filler wire as the characteristic parameter. The studies showed that the anode effect power caused by the increase in wire current can increase the total power transferred to the filler wire by 50 % or more while the current flowing through the tungsten electrode of the plasma torch remains constant. This is confirmed by analyzing the weld shape under different wire currents. The resistive heating of the wire excision is not a major component of the total power transferred to the filler wire, and the wire extension can be set to a reasonably wide range of values. There was a threshold value for the influence of the plasma gas flow rate on plasma arc power. When the plasma gas flow rate was greater than the threshold value, plasma arc power remained nearly constant as the plasma gas flow rate increased. Therefore, the total power transferred to filler wire in TPAW was composed of anode effect power and plasma arc power. © 2021 The Society of Manufacturing Engineers
关键词 ：
Anodes Anodes Electric arcs Electric arcs Electric welding Electric welding Fillers Fillers Flow of gases Flow of gases Flow rate Flow rate Hard facing Hard facing Heat transfer Heat transfer Plasma torches Plasma torches Plasma welding Plasma welding Wire Wire
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| GB/T 7714 | Zhang, Ruiying , Jiang, Fan , Chen, Shujun . Power transferred to the filler wire in twin-body plasma arc welding [J]. | Journal of Manufacturing Processes , 2021 , 62 : 566-576 . |
| MLA | Zhang, Ruiying 等. "Power transferred to the filler wire in twin-body plasma arc welding" . | Journal of Manufacturing Processes 62 (2021) : 566-576 . |
| APA | Zhang, Ruiying , Jiang, Fan , Chen, Shujun . Power transferred to the filler wire in twin-body plasma arc welding . | Journal of Manufacturing Processes , 2021 , 62 , 566-576 . |
| 导入链接 | NoteExpress RIS BibTex |
摘要 ：
The microstructure, texture, and mechanical properties of the asymmetric welded joint in variable polarity plasma arc (VPPA) welding were studied and discussed in this paper. The asymmetric welded joint was obtained through horizontal welding, where the effect of gravity caused asymmetric material flow. The results showed that the grain size and low angle grain boundary (LAGB) at both sides of the obtained welded joint were asymmetric; the grain size differed by a factor of 1.3. The average grain size of the Base Metal (BM), Lower-weld zone (WZ) and Upper-WZ were 25.73 +/- 1.25, 37.87 +/- 1.89 and 49.92 +/- 2.49 mu m, respectively. There is discrepancy between the main textures in both sides of the welded joint. However, the effect of asymmetric metal flow on the weld texture was not significant. The micro-hardness distribution was inhomogeneous, the lowest hardness was observed in regions with larger grain sizes and smaller low angle grain boundary. During tensile strength tests, the specimens fractured at the position with the lowest hardness although it has reached 89.2% of the strength of the BM. Furthermore, the effect of asymmetric metal flow and underlying causes of asymmetric weld properties in VPPA horizontal welding have been discussed and analyzed.
关键词 ：
asymmetric weld asymmetric weld material flow material flow microstructure microstructure tensile strength tensile strength VPPA VPPA
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| GB/T 7714 | Yan, Zhaoyang , Chen, Shujun , Jiang, Fan et al. Effect of Asymmetric Material Flow on the Microstructure and Mechanical Properties of 5A06 Al-Alloy Welded Joint by VPPA Welding [J]. | METALS , 2021 , 11 (1) . |
| MLA | Yan, Zhaoyang et al. "Effect of Asymmetric Material Flow on the Microstructure and Mechanical Properties of 5A06 Al-Alloy Welded Joint by VPPA Welding" . | METALS 11 . 1 (2021) . |
| APA | Yan, Zhaoyang , Chen, Shujun , Jiang, Fan , Zheng, Xing , Tian, Ooi , Cheng, Wei et al. Effect of Asymmetric Material Flow on the Microstructure and Mechanical Properties of 5A06 Al-Alloy Welded Joint by VPPA Welding . | METALS , 2021 , 11 (1) . |
| 导入链接 | NoteExpress RIS BibTex |
摘要 ：
This study aims to enhance the localized energy of the plasma arc to meet the requirement of thick metal plate welding. To achieve this, a novel hybrid heat source by coaxial arranging the laser and plasma arc was proposed, named laser-enhanced plasma arc (LPA). This special torch combines the two kind sources by a tubular tungsten electrode which the laser passes through, use laser to heat localized plasma arc to modify the energy distribution. The three-dimensional temperature field was measured to clarify the effect of laser on plasma arc energy distribution and the absorption characteristics of laser by plasma arc. The numerical simulation model was established to reveal the influence mechanism. Results show that there is a high laser absorption region in the plasma arc, and it exists obvious effects of plasma arc pressure and temperature on laser absorption rate. The location and size of the high laser absorption region change as the welding parameters because the temperature and pressure of plasma arc change. The results also substantiate that the hybrid source energy can be adjusted locally to increase the effective flame length of the plasma arc by changing the laser energy and plasma arc parameters, which is beneficial for thick metal plate welding. This study aims to enhance the localized energy of the plasma arc to meet the requirement of thick metal plate welding. To achieve this, a novel hybrid heat source by coaxial arranging the laser and plasma arc was proposed, named laser-enhanced plasma arc (LPA). This special torch combines the two kind sources by a tubular tungsten electrode which the laser passes through, use laser to heat localized plasma arc to modify the energy distribution. The three-dimensional temperature field was measured to clarify the effect of laser on plasma arc energy distribution and the absorption characteristics of laser by plasma arc. The numerical simulation model was established to reveal the influence mechanism. Results show that there is a high laser absorption region in the plasma arc, and it exists obvious effects of plasma arc pressure and temperature on laser absorption rate. The location and size of the high laser absorption region change as the welding parameters because the temperature and pressure of plasma arc change. The results also substantiate that the hybrid source energy can be adjusted locally to increase the effective flame length of the plasma arc by changing the laser energy and plasma arc parameters, which is beneficial for thick metal plate welding.
关键词 ：
Heat transfer of laser to arc Heat transfer of laser to arc Laser-enhanced plasma arc Laser-enhanced plasma arc Local energy adjustment Local energy adjustment Novel heat source Novel heat source
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| GB/T 7714 | Jiang, Fan , Wang, Shuo , Xu, Bin et al. Local energy adjustment mechanism in a novel laser-enhanced plasma arc heat source [J]. | INTERNATIONAL JOURNAL OF THERMAL SCIENCES , 2021 , 168 . |
| MLA | Jiang, Fan et al. "Local energy adjustment mechanism in a novel laser-enhanced plasma arc heat source" . | INTERNATIONAL JOURNAL OF THERMAL SCIENCES 168 (2021) . |
| APA | Jiang, Fan , Wang, Shuo , Xu, Bin , Cheng, Wei , Ma, Xinqiang , Chen, Shujun . Local energy adjustment mechanism in a novel laser-enhanced plasma arc heat source . | INTERNATIONAL JOURNAL OF THERMAL SCIENCES , 2021 , 168 . |
| 导入链接 | NoteExpress RIS BibTex |
摘要 ：
The metal transfer behaviour of slant feature of thin-walls fabricated by cold metal transfer (CMT) process in step-over deposition mode was observed by high speed camera. A slanted short circuiting transfer (SSCT) was generated during deposition and then analysed by asymmetrical magnetic and force model, complicating metal transfer behaviour in comparison with conventional deposition process. The SSCT allowed the droplet to transfer obliquely into the molten pool on previous layer, owing to the pushing force generated by unevenly distributed electromagnetic field in asymmetrical deposition model. The surface tension between wire and liquid metal is the most important force that retarded droplet transfer. The retraction force and electromagnetic force are the main forces to promote droplet transition. The positive forces that promote droplet transfer process can be arranged as Fem > Fr > Fg. The wall width was mainly affected by wire feed speed and the inclined angle can be significantly increased with increasing step-over distance.
关键词 ：
Additive manufacturing Additive manufacturing Metal transfer Metal transfer Slant feature Slant feature Step-over deposition Step-over deposition Wire feed speed Wire feed speed
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| GB/T 7714 | Yan, Zhaoyang , Zhao, Yun , Jiang, Fan et al. Metal transfer behaviour of CMT-based step-over deposition in fabricating slant features [J]. | JOURNAL OF MANUFACTURING PROCESSES , 2021 , 71 : 147-155 . |
| MLA | Yan, Zhaoyang et al. "Metal transfer behaviour of CMT-based step-over deposition in fabricating slant features" . | JOURNAL OF MANUFACTURING PROCESSES 71 (2021) : 147-155 . |
| APA | Yan, Zhaoyang , Zhao, Yun , Jiang, Fan , Chen, Shujun , Li, Fang , Cheng, Wei et al. Metal transfer behaviour of CMT-based step-over deposition in fabricating slant features . | JOURNAL OF MANUFACTURING PROCESSES , 2021 , 71 , 147-155 . |
| 导入链接 | NoteExpress RIS BibTex |
摘要 ：
Lightweight manufacturing reduces energy consumption and protects the environment; therefore, it offers an important direction of development in engineering. Variable polarity plasma arc (VPPA) welding is a light gauge aluminum and magnesium alloy joining technology capable of the highly efficient welding of medium-thickness metals via the keyhole effect, and without the complex pre-processing required by traditional methods. However, the stability of the keyhole weld pool is easily lost, resulting in a much narrower parameter window than that of conventional methods. Here, through keyhole morphology analysis and x-ray in situ imaging experiments, we reveal the material flow behavior, the mechanism behind the stability of the keyhole weld pool, and the reason for the very narrow process parameter window in VPPA welding processes. We discovered that the polarity pressure difference of the plasma arc, which is induced by the keyhole boundary shape and plasma arc intensity, drives the flow pattern to the top side of the keyhole, which is beneficial for keyhole filling and the formation of a stable weld bead. The influence of the difference in plasma arc pressure and the keyhole boundary on the flow field revealed in this study may guide the optimization process of light metal joining to achieve the highly efficient and defect-free manufacturing of large and complex structures. © 2021 Author(s).
关键词 ：
Aluminum alloys Aluminum alloys Electric welding Electric welding Energy utilization Energy utilization Flow fields Flow fields Flow patterns Flow patterns Joining Joining Magnesium alloys Magnesium alloys Manufacture Manufacture Plasma welding Plasma welding Welds Welds
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| GB/T 7714 | Xu, Bin , Chen, Shujun , Tashiro, Shinichi et al. Physical mechanism of material flow in variable polarity plasma arc keyhole welding revealed by in situ x-ray imaging [J]. | Physics of Fluids , 2021 , 33 (1) . |
| MLA | Xu, Bin et al. "Physical mechanism of material flow in variable polarity plasma arc keyhole welding revealed by in situ x-ray imaging" . | Physics of Fluids 33 . 1 (2021) . |
| APA | Xu, Bin , Chen, Shujun , Tashiro, Shinichi , Jiang, Fan , Tanaka, Manabu . Physical mechanism of material flow in variable polarity plasma arc keyhole welding revealed by in situ x-ray imaging . | Physics of Fluids , 2021 , 33 (1) . |
| 导入链接 | NoteExpress RIS BibTex |
摘要 ：
A variable-polarity plasma arc (VPPA) is an effective energy source for the welding of thick aluminum alloy plates. However, the mechanisms influencing the fluid flow and the inhomogeneous distribution associated with thick-plate VPPA welding remain unclear, restricting the application of this technology in welding of thick aluminum alloys. Here, the relationship between the microstructure of the weld bead, energy transfer, and fluid flow is clarified by combining in situ three-dimensional x-ray imaging and multi-physics modeling. We find that heat conduction at the keyhole wall is the main factor influencing the morphology of the weld pool. The plasma arc pressure hinders the upward flow of liquid metal, while shear forces promote this flow. This causes the metal close to the weld pool surface to flow slowly, while that inside the weld pool has much higher velocity. It is also concluded that the large crystal size observed in the lower layer of the weld is partly caused by heat treatment from the upper layer of the thick plate. An eddy with a high flow velocity to the rear of the weld pool destroys the crystal-growth process, and this is considered to be one of the reasons for fine crystals appearing in the upper part of the weld. The mechanisms revealed here will help us to guide the use of VPPA technology in the production of stable, high-quality welding of thick aluminum alloys. Published under an exclusive license by AIP Publishing.
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| GB/T 7714 | Xu, Bin , Tashiro, Shinichi , Tanaka, Manabu et al. Physical mechanisms of fluid flow and joint inhomogeneity in variable-polarity plasma arc welding of thick aluminum alloy plates [J]. | PHYSICS OF FLUIDS , 2021 , 33 (8) . |
| MLA | Xu, Bin et al. "Physical mechanisms of fluid flow and joint inhomogeneity in variable-polarity plasma arc welding of thick aluminum alloy plates" . | PHYSICS OF FLUIDS 33 . 8 (2021) . |
| APA | Xu, Bin , Tashiro, Shinichi , Tanaka, Manabu , Jiang, Fan , Chen, Shujun . Physical mechanisms of fluid flow and joint inhomogeneity in variable-polarity plasma arc welding of thick aluminum alloy plates . | PHYSICS OF FLUIDS , 2021 , 33 (8) . |
| 导入链接 | NoteExpress RIS BibTex |
摘要 ：
电阻加热金属丝材增材制造技术对空间设备的修复和制造具有重要意义,在电阻加热金属丝材熔化沉积成形过程中,金属熔体的塑性变形影响金属零件的成形形貌.为了精确探究金属熔体的塑性变形,将不同的电流密度通过短路的金属丝材,通过高速摄像机观测金属丝材塑性变化,采用热像仪和电压电流采集系统分别采集了金属丝材熔化过程的温度变化和电信号变化.数值分析金属丝材塑性变形的机电热响应状态.结果表明,数值计算得出最大挠度是电流密度的线性函数,与试验结果一致,通过高密度电流的金属丝材会发生显着的塑性变形.在高电流密度的电流的作用下,释放出大量的焦耳热会引起局部温度的显着升高,从而导致屈服应力的降低,由于电-热-机械相互作...
关键词 ：
塑性变形 塑性变形 数值计算 数值计算 电阻增材 电阻增材
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| GB/T 7714 | 苑城玮 , 陈树君 , 蒋凡 et al. 电阻加热金属丝材塑性变形电-热-机械响应分析 [J]. | 焊接学报 , 2020 , 41 (12) : 1-6,97 . |
| MLA | 苑城玮 et al. "电阻加热金属丝材塑性变形电-热-机械响应分析" . | 焊接学报 41 . 12 (2020) : 1-6,97 . |
| APA | 苑城玮 , 陈树君 , 蒋凡 , 杨福前 . 电阻加热金属丝材塑性变形电-热-机械响应分析 . | 焊接学报 , 2020 , 41 (12) , 1-6,97 . |
| 导入链接 | NoteExpress RIS BibTex |
摘要 ：
Resistance heating metal wire materials additive manufacturing technology is of great significance for space environment maintenance and manufacturing. However, the continuous deposition process has a problem in which the metal melt is disconnected from the base metal. In order to study the difference between the second contact melting of the disconnected metal melt and the continuous melting of the metal wire as well as eliminate the problem of the uneven heat dissipation of the base metal deposition on the melting process of the metal wire, the physical test of melting the metal wire clamped by the equal diameter conductive nozzle was carried out from the aspects of temperature distribution, temperature change, melting time, dynamic resistance change, and the microstructure. The current, wire length, and diameter of the metal wire are used as variables. It was found that the dynamic resistance change of the wire can be matched with the melting state. During the solid-state temperature rise, due to the presence of the contact interface, the continuous melting and secondary contact melting of metal wires differ in dynamic resistance and the melting process. The continuous melting of the metal wire was caused by the overall resistance of the wire to generate heat and melt, and the temperature distribution is "bow-shaped". In the second contact melting, the heat generated by the contact interface resistance was transferred to both ends of the metal wire to melt, and the temperature distribution is "inverted V". The microstructure of the metal wire continuous melting and secondary contact melting solidification is similar. The continuous melting length of the metal wire is greater than the melting length of the secondary contact.
关键词 ：
continuous melting continuous melting dynamic resistance dynamic resistance resistance heating resistance heating temperature distribution temperature distribution
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| GB/T 7714 | Yuan, Chengwei , Chen, Shujun , Jiang, Fan et al. Mechanism of Continuous Melting and Secondary Contact Melting in Resistance Heating Metal Wire Additive Manufacturing [J]. | MATERIALS , 2020 , 13 (5) . |
| MLA | Yuan, Chengwei et al. "Mechanism of Continuous Melting and Secondary Contact Melting in Resistance Heating Metal Wire Additive Manufacturing" . | MATERIALS 13 . 5 (2020) . |
| APA | Yuan, Chengwei , Chen, Shujun , Jiang, Fan , Xu, Bin , Dong, Shanwen . Mechanism of Continuous Melting and Secondary Contact Melting in Resistance Heating Metal Wire Additive Manufacturing . | MATERIALS , 2020 , 13 (5) . |
| 导入链接 | NoteExpress RIS BibTex |
摘要 ：
A hybrid arc-wire welding method based on the variable polarity plasma arc (VPPA) and variable polarity pulse metal inert-gas (VP-PMIG) was proposed for manufacturing aluminum alloys. This paper aims to clarify the decoupling control process of heat and mass transfer in the hybrid welding process. To understand the arc physics and analyze the mass transfer behavior, the hybrid arc shape and droplet cross-sectional area with different parameters were obtained by high speed video photography. Further, the melting area of the base metal was analyzed by macro-metallography of the weld bead cross-section to study the heat transfer. It is found that the hybrid arc shape changes with time. The VPPA main arc is deflected to one side by the VP-PMIG, making the temperature distribution asymmetric, and during the VP-PMIG pulse necking occurs. The cross-sectional area of the droplet is more obviously affected by the VP-PMIG current than the VPPA current. Meanwhile, the VPPA current dominates the melting area of the base metal. Therefore, we conclude that heat transfer to the base metal is from the VPPA, while droplet transfer is mainly controlled by the VP-PMIG arc. These conclusions are confirmed by analyzing the decoupling degree of heat and mass transfer of the base metal by the VPPA and VP-PMIG arc.
关键词 ：
aluminum alloy aluminum alloy decoupling control decoupling control heat and mass transfer heat and mass transfer PMIG PMIG VPPA VPPA
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| GB/T 7714 | Jiang, Fan , Li, Cheng , Xu, Bin et al. Study on the Decoupled Transfer of Heat and Mass in Wire Variable Polarity Plasma Arc Welding [J]. | MATERIALS , 2020 , 13 (5) . |
| MLA | Jiang, Fan et al. "Study on the Decoupled Transfer of Heat and Mass in Wire Variable Polarity Plasma Arc Welding" . | MATERIALS 13 . 5 (2020) . |
| APA | Jiang, Fan , Li, Cheng , Xu, Bin , Tashiro, Shinichi , Tanaka, Manabu , Chen, Shujun . Study on the Decoupled Transfer of Heat and Mass in Wire Variable Polarity Plasma Arc Welding . | MATERIALS , 2020 , 13 (5) . |
| 导入链接 | NoteExpress RIS BibTex |
摘要 ：
As a new-type welding heat source, cross-coupling arc (CCA) is able to realize the decoupling control of heat transfer, force transfer and mass transfer in welding process. However, the physical mechanism of CCA still remains unclear, restricting the application and optimization of CCA welding technology. In order to explore the laws and causes of polar zone phenomena (PZP) in CCA welding and based on the electromagnetic field effect of the inter-wire arc (IWA) itself, the novel methods of an electrified tungsten rod crossing a free burning arc and an electrified parallel plate capacitor applied to both sides of a burning arc were designed to decouple the electromagnetic coupling field generated by the IWA. The arc shape during the experiments was recorded by a high-speed camera system in real time. The results show that the laws of PZP in CCA welding were supplemented and summarized. When the main arc polarity is direct current electrode negative, the main arc deflects to the IWA cathode, and when the main arc polarity is direct current electrode positive, the main arc deflects to the IWA anode. More importantly, the causes of PZP were found. The magnetic field generated by the IWA and the limitation in bottom area and position of the main arc tungsten electrode are the causes of PZP. The direction control of PZP could be achieved by adjusting the polarities of the IWA or the main arc and the PZP effect could be reduced by changing the current direction in the IWA.
关键词 ：
CCA CCA IWA IWA Magnetic field Magnetic field PZP PZP
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| GB/T 7714 | Dong, Shanwen , Jiang, Fan , Xu, Bin et al. Physical mechanism of polar zone phenomena in cross-coupling arc welding [J]. | JOURNAL OF MANUFACTURING PROCESSES , 2020 , 50 : 440-449 . |
| MLA | Dong, Shanwen et al. "Physical mechanism of polar zone phenomena in cross-coupling arc welding" . | JOURNAL OF MANUFACTURING PROCESSES 50 (2020) : 440-449 . |
| APA | Dong, Shanwen , Jiang, Fan , Xu, Bin , Li, Cheng , Chen, Shujun . Physical mechanism of polar zone phenomena in cross-coupling arc welding . | JOURNAL OF MANUFACTURING PROCESSES , 2020 , 50 , 440-449 . |
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