某油田企业职业健康体检结果分析与对策

对2007年度某油田企业职业健康体检结果样本进行了分析,并提出相应对策。     

旋幕式排风罩收集电焊烟尘的数值模拟

为解决电焊烟尘气流无组织排放对焊工健康和环境造成的严重影响,得出旋幕式排风罩的最佳设计参数及气流组织形式,选择GAMBIT软件建立排风罩的物理模型并进行网格划分,选用雷诺平均N-S方程(RANS)、Realizableκ-ε湍流模型及DPM离散相模型,利用Fluent计算流体力学软件对旋幕式排风罩捕集效率的相关参数进行模拟计算。结果表明:旋幕式排风罩能有效控制电焊烟尘气流的扩散;喷口角度对涡流产生的大小、位置和强度影响最大;最佳设计参数为有效吸程1. 5 m,喷口角度80°,喷口宽度14 mm;在该设计参数条件下,当罩面吸口风速为0. 3 m/s、喷口风速为1. 1m/s时,捕集效率达到最高,为98. 28%。     

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.     

Experimental investigation on flexural behavior of friction stir welded high density polyethylene sheets

Flexural strength is one of the main criteria in evaluation of the mechanical properties of polymeric joints. The flexural strength of thermoplastics, such as high density polyethylene (HDPE) sheets, is influenced by friction stir welding parameters. The determination of the welding parameters plays an important role in the weld strength. In the present study, the response surface method (RSM) was used as a statistical design of experiment technique to set the optimal welding parameters. The designed tool was consisted of a rotating pin, a stationary shoulder (shoe) and a heating system inside shoe. Rotational speed of the pin, tool traverse speed and shoe temperature were considered as varying parameters. Obtained results show a significant relationship between considered properties and processing parameters through an analysis of variance (ANOVA) study and the response surface method. It was found that welding at a high level of rotational speed and a lower level of tool travel speed increases weld flexural strength by reducing size of defects.     

Modeling and simulation of arc: Laser and hybrid welding process

Welding is a fabrication process to join two different materials. Among the many welding processes, the arc and laser welding processes are the most widely used. Great effort is required to understand the physical phenomena of arc and laser welding due to the complex behaviors which include liquid phase, solid phase and, gas phase. So it is necessary to conduct numerical simulation to understand the detailed procedures of welding. This paper will present the various numerical simulation methods of the arc welding processes such as arc plasma, gas tungsten arc welding, gas metal arc welding, laser welding, and laser–arc hybrid welding. These simulations are conducted by the finite element method, finite differential method and volume of fluid method to describe and analyze the various welding processes.     

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.     

Energy input during friction stir spot welding

Friction stir spot welding is performed on thin plates of an aluminum alloy. This paper presents the results on how the number of tool rotations affects the quality of the resulting spot weld. Different combinations of rotation rate and dwell time are investigated. A linear relationship was found to exist between the number of tool rotations completed during the spot weld and the resulting tensile shear strength. Spot welds that only completed 10 rotations were 177% stronger than those created at 50 tool rotations. The energy generated during the welding operation was quantified and also found to have a linear relationship with tensile shear strength. A modified open-loop position control system is proposed that monitors and limits the energy generated during friction stir spot welding by adjusting the dwell time.     

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.     

双管板换热器的设计与制造

根据双管板换热器的结构特点,从设计、制造、监造与使用维护方面全过程要点剖析,对主要重点进行系统性进行阐述,并与业内人士全方位交流与要点探讨。     

自动变光面罩亟待成为中国焊工防护标配

本文阐述了电弧焊弧光所造成的危害种类及其严重程度,并围绕自动变光焊接面罩的基本结构、工作原理、性能指标、防护效果等,重点介绍了防治电弧焊弧光危害的这种专门利器,明确提出了应该让自动变光焊接面罩尽快成为中国焊工防护用具的标准配置的观点。