Plasma arc welding: Process,sensing, control and modeling

This article introduces the basic principles of plasma arc welding (PAW) and provides a survey of the latest research and applications in the field. The PAW process is compared to gas tungsten arc welding, its process characteristics are listed, the classification is made, and two modes of operation in PAW, i.e., melt-in and keyhole, are explained. The keyhole mechanism and its influencing factors are introduced. The sensing and control methodologies of the PAW process are reviewed. The coupled behaviors of weld pool and keyhole, the heat transfer and fluid flow as well as three-dimensional modeling and simulation in PAW are discussed. Finally, a novel PAW process variant, the controlled pulse keyholing process and the corresponding experimental system are introduced.     

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.     

Research evolution on intelligentized technologies for arc welding process

This paper presents some new evolutions of research works in the IRWTL at SJTU on intelligentized technologies for arc welding dynamic process and robot systems, including multi-information sensing of arc welding process, such as characteristic extraction of weld pool image, voltage, current, and sound, arc-spectral features; multi-information fusion algorithms for prediction of weld penetration; intelligentized modeling of welding dynamic process; intelligent control methodology for welding dynamic process; intelligentized technologies for robotic welding, such as guiding and tracking seam technology and intelligent control of weld pool and penetration in robotic welding process; and development of autonomous welding robot system for the special environment. The ideas of intelligentized welding manufacturing technology (IWMT) and intelligentized welding manufacturing engineering (IWME) are presented in this paper for systematization of intending researches and applications on intelligentized technologies for modern welding manufacturing. The studies of intelligentized welding presented in this paper establish the foundation work of intending researches and applications on intelligentized technologies for modern welding manufacturing.     

Improvement of welding heat source models for TIG-MIG hybrid welding process

Tungsten inert gas-metal inert gas (TIG-MIG) hybrid welding process is an effective way to improve welding productivity and quality due to advantages of the two processes. Mathematical analysis is crucial to fundamentally understand this synergetic welding process. In this study, based on experimental visualization of arc behaviors, some assumptions are proposed to deduce adaptive plane and volumetric heat source models separately for each involved welding method first. The influence of torch angles on distribution of temperature and geometry of weld bead are calculated and compared with experimental results. It shows that this developed algorithm of heat source can be employed to accurately predict welding process whether the electrode gun is slanted backward or forward to the direction of welding. Then TIG-MIG hybrid welding process is simulated and analyzed without considering the attractive or repulsive force of two arcs. The characteristic of TIG-MIG welding process is discussed compared to single MIG. It lays the foundation for the further research on the interaction of the two arcs during TIG-MIG hybrid welding.     

Numerical analysis of keyhole geometry and temperature profiles in plasma arc welding

In keyhole plasma arc welding (PAW), the formation of the keyhole involves complicated thermo-physical mechanism. The shape and dimensions of the keyhole directly determine the heat deposition along the thickness direction of the test plates, the penetration depth and the weld bead quality. Based on analysis of the forces acting on the weld pool, a keyhole model is established according to the force-balance condition on the keyhole wall. The shape and dimensions of quasi-steady state keyhole are numerically predicted. The keyhole shape and size are used to calibrate some distribution parameters of the combined volumetric heat source which takes into consideration the geometrical feature of welds with larger ratio of penetration depth to width and volumetric distribution characteristic of the plasma heat intensity along the plate thickness direction. The temperature fields on stainless steel plates are numerically simulated. The calculated fusion line at the transverse cross-section of PAW welds are compared with the experimental measurements. It is found that the predicted results are in agreement with the experimental data.     

Metal-cored arc welding process for joining of modified 9Cr-1Mo (P91) steel

In the present work, metal-cored arc welding process was used for joining of modified 9Cr-1Mo (P91) steel. Metal-cored arc welding process is characterized by high productivity, slag-free process, defect-free weldments that can be produced with ease, and good weldability. Toughness is essential in welds of P91 steel during hydro-testing of vessels. There is a minimum required toughness of 47 J for welds that has to be met as per the EN1557:1997 specification. In the present study, welds were completed using two kinds of shielding gases, each composition being 80% Argon + 20% CO₂, and pure argon respectively. Microstructural characterization and toughness evaluation of welds were done in the as – weld, PWHT at 760 °C – 2 h and PWHT at 760 °C – 5 h conditions. The pure argon shielded welds (‘A2’ and ‘B2’) have higher toughness than 80% argon + 20% CO₂ shielded welds (‘A1’ and ‘B1’). Pure argon shielded welds show less microinclusion content with low volume fraction of δ-ferrite (<2%) phase. Themo-calc windows (TCW) was used for the prediction of equilibrium critical transformation points for the composition of the welds studied. With increase in post-weld heat treatment (PWHT) duration from 2 h to 5 h, there was increase in toughness of welds above 47 J. Using metal-cored arc welding process, it was possible to achieve the required toughness of more than 47 J after PWHT at 760 °C – 2 h in P91 steel welds.     

Microstructure and mechanical properties of alloy C-276 weldments fabricated by continuous and pulsed current gas tungsten arc welding techniques

Effects of switching over from gas tungsten arc welding (GTAW) to pulsed current gas tungsten arc welding (PCGTAW) on the quality of joints produced in Hastelloy C-276 material were investigated. Welding was carried out both by autogenous mode and using ERNiCrMo-3 filler wire. Microstructures of weld joints produced with and without current pulsing were studied using optical and scanning electron microscopy. Microsegregation occurring in GTAW and PCGTAW joints was investigated using energy dispersive X-ray spectroscopy (EDS). Strength and ductility of weld joints produced with and without pulsing were evaluated. The results show that pulsing results in refined microstructure, reduced microsegregation and improved strength of weld joints. Secondary phase(s) noticed in GTA weldments were found to be absent in PCGTA weldments. Autogenous PCGTA weldments were found to be the best in terms of: (i) freedom from microsegregation, (ii) strength and (iii) freedom from unwanted secondary phases.     

Microstructure of 2205 duplex stainless steel joint in submerged arc welding by post weld heat treatment

The 2205 duplex stainless steel (DSS) is of both good properties austenitic steel and ferritic steel, which applies to the shipbuilding industry usually. In this paper, the OM, XRD and microhardness test methods are used to analyze the variation of submerged arc welded (SAW) joints with and without post weld heat treatment (PWHT). The research results show that the σ phase disappear in the fusion edge zone near heat affect zone (HAZ) and an increase in the welded center zone during the follow-up PWHT, while the amount of γ phase is decreased in the welded center zone with PWHT. A segregation distribution of some second phases is also found in the welded center zone after PWHT. There have two pick values of microhardness arise in the fusion edge zone and the welded center zone separately without PWHT. However, a maximum value of microhardness at the fusion edge zone near HAZ is disappeared and the other is still held at the welded center zone during PWHT. It can be attributed to the changes of second phases, element diffusions and particle segregation during PWHT. A developing mechanism is issued to demonstrate the second phases transferring of the 2205 DSS SAW joints by PWHT.     

Influence of displacement constraints in thermomechanical analysis of laser micro-spot welding process

The evolution of mechanical components into smaller size generating a need for microwelding of these components using laser which offers better control as compared to arc and plasma processing. The present article describes the numerical simulation of laser micro-spot welding using finite element method. A two dimensional Gaussian distributed surface heat flux as a function of time is used to perform a sequentially coupled thermal and mechanical analysis. The model is used for simulating laser micro-spot welding of stainless steel sheet under different power conditions and configurations of mechanical constraints. The temperature dependent physical properties of SS304 have been considered for the simulation and an isotropic strain hardening model has been used. The simulated weld bead dimensions have been compared with experimental results and temperature profiles have been calculated. The maximum deformation of 0.02 mm is obtained with maximum laser power of 75 W. The thermal stress is more inducing factor to temperature induced residual stresses and plastic strain as compared to mechanical constraints. The plastic strain changes significantly by displacement constraints as compared to residual stress.     

Influence of welding speed and power on residual stress during gas tungsten arc welding (GTAW) of thin sections with constant heat input: A study using numerical simulation and experimental validation

The temperature distribution and residual stresses for a GTAW circumferential butt joint of AISI 304 stainless steel using numerical simulation have been evaluated. For evaluation of weld induced residual stresses, the analysis of heat source fitting was carried out with heat inputs ranging from 200 to 500 J/mm to arrive at optimal heat input for obtaining proper weld penetration and heat affected zone (HAZ). For this chosen heat input, the influence of different weld speeds and powers on the temperature distribution and the residual stresses is studied. The heat source analysis revealed the best choice of heat input as 300 J/mm. The residual stresses on the inner and outer surfaces, and along the radial direction were computed. Increase in temperature distribution as well as longitudinal and circumferential residual stresses was observed with the increase in weld speed and power. The validity of the results obtained from numerical simulation is demonstrated with full scale shop floor welding experiments.     

一种改进的MSBR工艺脱氮除磷性能的仿真模拟与试验研究

针对6池MSBR工艺除磷效果不佳和污泥上浮问题,通过新增厌氧池、调整浓缩池位置对其进行改造,提出了一个改进的7池MSBR工艺．应用活性污泥2号模型(ASM2)分别对两种工艺进行了仿真模拟,结果表明,改进工艺具有较好的脱氮除磷性能．在此基础上对7池MSBR工艺开展了实验室试验,试验结果显示,新工艺对耗氧有机物(以COD值计)、NH2．N、TP的去除率分别为94．2％、81．4％和88．7％,脱氮除磷效率均高于有关献报道的6池工艺．新工艺妥善处理了脱氮除磷等各单元之间的关系,因而强化了除磷脱氮能力．试验结果与模型模拟结果基本吻合,表明活性污泥模型对新工艺的开发具有一定的指导意义．     

基于Aspen Plus的MSW气化熔融工艺全流程模拟研究

城市固体废物（MSW）气化熔融工艺能够减少二噁英的生成和熔融固化重金属,是一种清洁高效的固体废物处理方式。已有研究多针对MSW的热解特性以及污染物的生成与排放,而对气化熔融工艺系统模块之间的影响和各反应器间物质流、能量流的联动变化过程研究不足。利用Aspen Plus模拟平台,基于吉布斯自由能最小化原理,对MSW气化熔融工艺进行了全流程模拟研究,分析了垃圾干燥温度、垃圾含水率、气化温度、气化介质以及灰熔点对工艺流程节点参数、物质流和能量流的影响,并提出了优化的工艺流程和运行参数。结果表明：在垃圾热解模拟时,垃圾含水率为9%,通过烟气循环能达到能量自给;在相同条件下,以水蒸气作为气化介质的气化效率最高,且在气化温度为850 ℃,水蒸气当量比为50%时,达到最佳工艺效果;当气化后产生的焦炭在熔融炉内燃烧刚满足灰熔点温度时,灰熔点的升高使气化剂比例、气化气有效气体摩尔流量和碳转化率不断降低。不同工况下的物质流、能量流的变化对实际工程具有指导意义。

     

三效催化转化器老化过程预测及数值仿真

基于三效催化转化器的老化机理，提出了老化过程的预测方法。然后将老化机理与化学反应机理相结合，建立包含老化过程的三效催化转化器反应模型，并进行数值仿真，得到三效催化转化器载体温度及氧浓度沿载体轴向的分布特性，最后计算得出预测三效催化转化器老化过程的主要参数以及老化前后转化效率的变化，并与实验值进行比较。     

内循环厌氧反应器流动模型及反应过程模拟

为揭示内循环厌氧反应器放大过程中所出现的规律,本文对反应器中流动模型和反应过程进行了模拟研究,通过对主反应区的停留时间分布的实验研究,确定了主反应区流型可用一平推流与两个并联的全混流进行串联的三参数组合模型进行模拟.在实验范围内,平推流区所占的体积分数约为36%,两个全混流区所占的体积分数分别为53%和11%.结合厌氧反应动力学方程,应用组合模型模拟了实际反应器的状态,并和实验值进行了对比,发现反应器出口处CH_4体积流量最大误差为9.67%,在可允许的范围内.同时,模拟了基质初始COD和温度变化对反应器出口状态的影响.研究表明,与其它模型相比,组合模型计算简洁,同时又有较好的精度,能够满足反应器的设计需要.     

Neural-fuzzy control system application for monitoring process response and control of anaerobic hybrid reactor in wastewater treatment and biogas production

Based on the developed neural-fuzzy control system for anaerobic hybrid reactor (AHR) in wastewater treatment and biogas production, the neural network with backpropagation algorithm for prediction of the variables pH, alkalinity (Alk) and total volatile acids (TVA) at present day time t was used as input data for the fuzzy logic to calculate the influent feed flow rate that was applied to control and monitor the process response at di erent operations in the initial, overload influent feeding and the recovery phases. In all three phases, this neural-fuzzy control system showed great potential to control AHR in high stability and performance and quick response. Although in the overloading operation phase II with two fold calculating influent flow rate together with a two fold organic loading rate (OLR), this control system had rapid response and was sensitive to the intended overload. When the influent feeding rate was followed by the calculation of control system in the initial operation phase I and the recovery operation phase III, it was found that the neural-fuzzy control system application was capable of controlling the AHR in a good manner with the pH close to 7, TVA/Alk < 0.4 and COD removal > 80% with biogas and methane yields at 0.45 and 0.30 m3/kg COD removed.     

基于混合生命周期分析的我国海上风电场能耗及温室气体排放研究

随着我国海上风电的快速发展,对其资源环境成本进行系统核算对于全面评价海上风电的节能减排潜力具有重要意义.本研究采用混合生命周期评价方法,对我国第一个海上风电场—上海东海大桥海上风电场(二期)的能耗和温室气体排放进行核算,并将核算结果与典型陆上风电场和其它类型的可再生能源进行比较.结果表明:该海上风电项目全生命周期发电能耗为0.51 MJ·k Wh~(-1),相应的温室气体排放量为26.47g·k Wh~(-1)(以CO_2当量计);在设备制造与运输、建设施工、运行维护、回收处置4个阶段中,设备生产与运输阶段在能耗和温室气体排放的占比最大,分别贡献了能耗的91.23%和温室气体排放量的60.48%;横向比较发现,海上风电场单位发电量的能耗和温室气体排放均高于陆上风电项目,但与光伏、生物质、地热等可再生能源发电项目相比,海上风电项目全生命周期能耗和温室气体排放依然具有一定优势.     

生物膜复合系统脱氮除磷的特征及微生物群落结构分析

试验研究了序批式生物膜复合系统在不同有机负荷下氮磷等营养物质的去除特性.结果表明,复合系统在COD负荷为0.35kg.kg-1.d-1(以MLSS计)时能够很好解决脱氮除磷的泥龄矛盾,TP、TN、NH4+-N去除率分别能达到96%、89%和96%,高于对照组的SBR工艺.复合系统中,悬浮污泥对硝化起主要作用,悬浮态污泥和生物膜的硝化平均贡献比为1.66;附着态生物膜对反硝化和除磷起主要作用,生物膜和悬浮态污泥的反硝化贡献比为2.19,释磷贡献比为3.5,摄磷贡献比为3.76.利用PCR-DGGE技术发现,复合系统中存在丰富的脱氮功能菌和除磷功能菌,且悬浮态与附着态微生物的相似性仅为73%,区别较大,说明两者存在一定的分工协作,与反应器的处理特性相一致.     

大气边界层中起尘、降尘过程的模拟实验的相似性原则

风洞模拟实验是研究起、降尘过程最有效的手段。前人只研究了低湍流度气流中,平坦表面的实际起尘过程。作者提出一组扩展的相似性原则,用于模拟大气边界层湍流及复杂地形对趋、降尘过程的影响及防尘风障在此条件下的减尘效率,并得到一系列有意义的结果。      

雷达电磁环境的联合建模与仿真

随着雷达灵敏度、精度的提高,对电磁环境的依赖性也越来越大。首先分析了美军的联合建模与仿真系统（JMASS）,指出建立一个综合的、可重用的雷达电磁仿真环境是电子战仿真的关键;重点研究了基于球不变随机过程（SIRP）的K分布杂波模型,以及地面／海面的多路径效应模型;最后建立了雷达电磁环境的模型并进行了仿真。     

建模与仿真中大气环境的表示与交换

大气环境的表示与交换是大气环境建模与仿真的核心内容之一。从数据交换机制的角度,比较了“点对点”和基于SEDRIS的大气环境表示与交换,设计了一种用于分布式仿真平台且具有较强拓展性和可重用性的大气环境表示和交换方法。