Inertia welding for assembly of copper squirrel cages for electric motors

The automotive industry is developing designs and manufacturing processes for new generations of electric motors intended for use in hybrid and electric vehicles. There is interest in replacing the aluminum traditionally used in induction motor rotors with copper to improve motor capability. This paper focuses on solid-state welding to join copper end rings to copper spokes in the fabrication of copper rotors. Inertia friction welding was explored to examine weldability of these copper components. A better understanding of inertia welding characteristics will help the advancements in its application for induction rotors. The limitations of this application are discussed.     

弧焊机器人用数控焊接变位机的研制

依据现有进口弧焊机器人的技术特点和工作要求 ,研制了与之配套的数控焊接变位机。该机工作台可进行旋转和倾斜两个运动 ,可使工件在最佳的位置进行焊接 ,与弧焊机器人一起构成了柔性加工单元。在实际焊接应用中 ,效果良好     

A method for double-sided friction stir spot welding

A rotating anvil similar to a pinless friction stir welding (FSW) tool can be applied to friction stir spot welding (FSSW) of thin metal plates. FSSW is a solid-state joining process that is currently being used by automotive manufacturers as an alternative to rivets and traditional resistance spot welding. The principal detractor of this process is the keyhole left by pin extraction, which can be detrimental to the weld strength. A pinless tool can be used to eliminate the keyhole. However, this approach is limited to joining thin sheet (≤1 mm). Using a rotating anvil with the FSSW process permits the joining of thicker cross sections, improves the mechanical strength of the spot weld and reduces the reaction forces on the spot welding frame. A numerical model of the process, tensile shear tests and macrosection analysis are used to evaluate the spot welds.Macrosection and numerical analysis reveals that the material flow between the pinless tool and rotating anvil is complex and unique to this process. It has been found that the use of a rotating anvil for FSSW is a viable means to create quality spot welds in thicker weldments.     

海洋用钢焊接接头的海水腐蚀行为研究

目的研究海洋用钢焊接接头的海水腐蚀行为。方法采用海水暴露试验、电偶腐蚀试验和腐蚀电位测量等方法。结果获得了5种海洋用钢焊接接头的海水腐蚀结果。结论海洋用钢焊接接头的熔合区易产生腐蚀沟槽。在全浸区、潮差区和飞溅区条件下,同一焊接接头的腐蚀行为相同,焊接接头的腐蚀严重程度顺序为全浸区>潮差区>飞溅区。焊缝-母材的电偶腐蚀试验结果与焊接接头的暴露腐蚀结果一致。     

油气集输管道内防腐技术应用进展

针对油气田集输管道的内腐蚀问题,分别介绍了耐蚀材料、衬里技术、涂镀层技术与药剂防腐技术等管道内防腐技术及其现场应用效果,指出了耐蚀金属材料防腐效果显著,但存在经济效益差的缺点。为降低成本,选用双金属复合管替代耐蚀金属材料,但其焊缝位置腐蚀失效频发,成为制约其应用的薄弱环节。耐蚀非金属材料防腐效果显著,但耐高温性能与力学性能较差,受温度、压力与CO_2、H_2S、固体颗粒等介质成分的影响,衬里技术与涂镀层技术的应用范围受到限制。药剂防腐技术的防护效果与药剂类型、加药工艺密切相关,需要根据腐蚀工况监测结果进行实时调整。针对上述内防腐技术存在的问题,提出了未来内防腐技术的发展方向为改进现有内防腐技术存在的不足,提升其防护效果。同时,应开发防腐效果显著、经济成本低、施工简便、易于推广应用的防腐材料与防腐工艺技术。     

A fuzzy multi-attribute approach to select the welding process at high pressure vessel manufacturing

Metal welding process selection calls for extensive know-how which deals with a huge amount of knowledge. Hence, the automation of knowledge through a knowledge-based system will greatly enhance the decision-making process. Fuzzy analytical hierarchy process (AHP)-TOPSIS investigates the relative welding process selection factors and it can compare and evaluate different welding processes between 0 and 1.This paper describes a knowledge-base system developed for identifying the most appropriate welding processes to suit specific circumstances. In the present study, nine important welding processes were used in the system. Ten parameters namely alloy class, material thickness, deposition rate, design application, joint configuration, operator factor, capital cost, equipment portability, filler metal utilization and welding position, are used to determine the best selection among competitive welding processes for high pressure vessel production. Also the sensitivity analysis was carried out for five cases.     

Double-electrode arc welding process: Principle,variants, control and developments

Double-electrode gas metal arc welding (DE-GMAW) is a novel welding process in which a second electrode, non-consumable or consumable, is added to bypass part of the wire current. The bypass current reduces the heat input in non-consumable DE-GMAW or increases the deposition rate in consumable DE-GMAW. The fixed correlation of the heat input with the deposition in conventional GMAW and its variants is thus changed and becomes controllable. At the University of Kentucky, DE-GMAW has been tested/developed by adding a plasma arc welding torch, a GTAW (gas tungsten arc welding) torch, a pair of GTAW torches, and a GMAW torch. Steels and aluminum alloys are welded and the system is powered by one or multiple power supplies with appropriate control methods. The metal transfer has been studied at the University of Kentucky and Shandong University resulting in the desirable spray transfer be obtained with less than 100 A base current for 1.2 mm diameter steel wire. At Lanzhou University of Technology, pulsed DE-GMAW has been successfully developed to join aluminum/magnesium to steel. At the Adaptive Intelligent Systems LLC, DE-GMAW principle has been applied to the submerged arc welding (SAW) and the embedded control systems needed for industrial applications have been developed. The DE-SAW resulted in 1/3 reduction in heat input for a shipbuilding application and the weld penetration depth was successfully feedback controlled. In addition, the bypass concept is extended to the GTAW resulting in the arcing-wire GTAW which adds a second arc established between the tungsten and filler to the existing gas tungsten arc. The DE-GMAW is extended to double-electrode arc welding (DE-AW) where the main electrode may not necessarily to be consumable. Recently, the Beijing University of Technology systematically studied the metal transfer in the arcing-wire GTAW and found that the desired metal transfer modes may always be obtained from the given wire feed speed by adjusting the wire current and wire position/orientation appropriately. A variety of DE-AW processes are thus available to suit for different applications, using existing arc welding equipment.     

电锅炉技术及其应用对环境影响的分析研究

针对电锅炉技术及其应用对环境影响,以绿色电力能源代替煤、油、气等常规化石能源,减少因化石能源在城镇人群聚集区终端使用造成"雾霾"类大气污染,已经成为一种新的发展趋势.本文系统分析了电锅炉的常用技术,分别阐述了不同种类电锅炉的技术原理、技术特点、工艺流程、应用领域,并通过实际应用案例,分析了电锅炉技术推广应用对城镇人口聚集区环境污染改善的效果,最后提出电锅炉技术的应用建议,为推行电锅炉技术选型提供依据,保证绿色环境的生成.     

冷喷涂镍涂层在不锈钢焊点腐蚀防护上的应用研究

目的 研究冷喷涂镍涂层对不锈钢焊点腐蚀行为的影响,为提高不锈钢焊接结构件的耐腐蚀性能提供依据。方法 采用冷喷涂技术在316L不锈钢电阻点焊结构件表面制备纯镍涂层,在金相组织、酸性盐雾腐蚀性能等检测分析基础上,研究不锈钢焊点在有涂层和无涂层条件下的腐蚀行为。结果 采用冷喷涂技术在不锈钢焊点表面制备出了孔隙率不大于0.5%的高致密纯镍涂层,带有涂层的不锈钢点焊结构件经过96 h酸性盐雾试验后,未发生腐蚀。结论 不锈钢表面钝化膜在点焊过程中发生破坏,基体裸露在腐蚀介质中,导致焊点区域发生腐蚀。在表面制备高致密镍涂层后,通过高耐蚀涂层对焊点进行屏蔽防护,有效提高其耐腐蚀性能,满足了某装备不锈钢结构件在酸性盐雾条件下的使用要求。     

B610E不同焊接接头在石油沉积水中的耐蚀性研究

通过室内浸泡、应力腐蚀试验对B610E高强储罐铜所用不同焊接方式在石油沉积水中的耐蚀性进行研究。结果表明,B610E气体保护焊材料的耐蚀性最好,将Q235＋B610E埋弧平焊对接后,由于存在电偶对,耐蚀效果最差。在石油沉积水中,B610E埋横焊具有中等SCC抗力,B610E气体保护焊、B610E气电立焊以及B610E＋Q235埋弧平焊对接具有高的SCC抗力。     

硅钢片冲孔模具的镶块修补技术

电机硅钢片冲孔模具在制造及使用中常因各种原因使某个槽孔损坏而需要修补.此文介绍了该类模具的修补技术.实践证明:该技术可延长硅钢片冲孔模具的使用寿命.     

铝合金结构腐蚀传感器综述

基于铝合金材料发生腐蚀后,其电特性发生了很大的变化,可以通过监测电特性的变化实现铝合金结构腐蚀程度评估的特性,重点描述了电流式、电阻式、阻抗式等腐蚀传感器的主要构造、功能及其工作原理。这些腐蚀传感器的研发和应用为早期发现飞机结构的腐蚀损伤提供了技术储备和有效手段,有利于及时采取修理或预防措施,从而减少或避免飞机结构发生重大腐蚀故障。最后提出了飞机结构腐蚀传感器研发的基本构想和总体思路,明确了其技术发展的重点方向。     

含铌微合金钢焊接性能研究

采用金相及透射电镜等方法研究了含铌微合金钢 14MnNbq焊接时焊缝区的组织特征 ,测试了其力学性能 ,结果表明钢中由于Nb的存在 ,使焊接区及热影响区组织发生变化 ,粗晶区得到细化 ,同时降低了焊缝脆化的倾向 ,使钢具有良好的焊接性能与力学性能。     

舰艇用高强钢强度及其耐蚀性现状及发展趋势

通过对国内外海军舰艇用高强钢的种类、性能、腐蚀问题和焊接等方面的介绍,分析了国内外海军舰艇用高强钢耐腐蚀性的现状及发展趋势,认为未来海军舰艇用高强钢将向高强度、大规格、低磁性及耐腐蚀方向发展。     

典型焊接结构CAD专家系统的研究与应用

论述了典型焊接结构CAD专家系统的内涵、设计思想和设计方法过程以及应用前景。     

Review on recent progress in on-line monitoring technology for atmospheric pollution source emissions in China

Emissions from mobile sources and stationary sources contribute to atmospheric pollution in China, and its components, which include ultrafine particles (UFPs), volatile organic compounds (VOCs), and other reactive gases, such as NH₃ and NO_x, are the most harmful to human health. China has released various regulations and standards to address pollution from mobile and stationary sources. Thus, it is urgent to develop online monitoring technology for atmospheric pollution source emissions. This study provides an overview of the main progress in mobile and stationary source monitoring technology in China and describes the comprehensive application of some typical instruments in vital areas in recent years. These instruments have been applied to monitor emissions from motor vehicles, ships, airports, the chemical industry, and electric power generation. Not only has the level of atmospheric environment monitoring technology and equipment been improving, but relevant regulations and standards have also been constantly updated. Meanwhile, the developed instruments can provide scientific assistance for the successful implementation of regulations. According to the potential problem areas in atmospheric pollution in China, some research hotspots and future trends of atmospheric online monitoring technology are summarized. Furthermore, more advanced atmospheric online monitoring technology will contribute to a comprehensive understanding of atmospheric pollution and improve environmental monitoring capacity.     

刍议电动自行车废弃蓄电池污染及其防治措施

电动自行车在给人们带来方便的同时,其废弃蓄电池的危害不容忽视,如果任其发展下去,将对人和环境造成不可逆转的戕害.各种电动自行车蓄电池的发展状况不同,目前电动自行车主要使用铅酸蓄电池,各种性能优越,但酸液如果泄漏,会对环境造成影响,需要对废弃蓄电池对环境的危害提出防治措施.政府必须重视电动自行车废弃蓄电池带来的问题,从蓄电池的技术创新和回收监督以及使用物理技术和生态技术治理被污染的土壤入手,全面着手减少其对环境的危害.如果改善了蓄电池的环保性能,我国电动自行车的发展前景会很好.     

油田用双金属机械复合管失效原因分析与对策

目的 分析研究双金属机械复合管的失效原因,并提出改进措施。方法 对比说明双金属机械复合管几种常见的典型制造方法及其优缺点,介绍应用中典型传统焊接工艺焊接的环焊缝腐蚀剌漏或穿孔、环焊缝开裂、内衬塌陷或鼓包以及爆管等常见的失效形式,利用现场应用的失效实例、统计数据和室内检测结果,分析这些失效类型的原因,并提出针对性建议或措施。结果 双金属机械复合管几种典型的制造方法各有优缺点,但其产品的内衬与基管的结合力均较小。造成其管材失效的主要原因有高压、高温、含CO2/Cl^–腐蚀介质、封焊结构、焊接工艺、外防腐层施工、应力腐蚀或电偶腐蚀等。根据现场应用实践,提出并应用了管端堆焊结构、环焊缝用镍基合金焊材、增加内衬厚度和小管径等防止失效的建议或措施,取得很好的防护效果。结论 造成此类管材失效的因素有腐蚀、封焊结构、焊接、外防腐施工及应力腐蚀或电偶腐蚀等,可采取堆焊结构、镍基合金焊材、厚衬层和小管径等措施。     

转炉煤气干法除尘回收系统关键技术的优化应用

转炉煤气干法除尘回收系统在运行中存在较多不稳定因素,故障时有发生,严重制约生产的均衡稳定。通过进行工艺、设备改进,优化应用蒸发冷却器喷淋水水质提升、蒸发冷却器桶壁高效化清理技术、电除尘器泄爆控制技术、电除尘器电场劣化控制技术、电除尘器阴极线在线更换技术等关键技术,逐步完善原技术的固有缺陷,有效解决了各类问题。通过转炉煤气干法除尘回收系统关键技术的优化应用,实现了设备系统的稳定高效运行,使其运行效率达到甚至超过了国内外同行的最好水平,同时使得原转炉煤气干法除尘回收技术得到了有效的补充和完善。     

填埋场渗漏检测高压直流电法等效电路模型的建立

通过对400V、350V、300V高压直流工作电压下小型模拟填埋场实验数据的分析 ,提出了简化的模型等效电路 .由于高密度聚乙烯(HDPE)衬层的存在使得模型具有了整流特性 ,其电容大小将随着衬层面积和供电电压的增加而增加 ;供电电极的接触电阻与大地的电阻率成正比 ,与电极的粗细及入土深度有关 .同时 ,接触电阻主要由电极附近的土壤电阻决定 ,大于10倍电极半径以外的土壤对接触电阻的影响不超过全部电阻的10% ,故降低电极附近土壤的电阻率可有效地降低电极的接触电阻 .