Resistance mash welding for joining of copper conductors for electric motors

The automotive industry is developing designs and manufacturing processes for a new generation of electric motors intended for use in hybrid and electric vehicles. This paper is focused on using solid-state welding to join rectangular wires in the fabrication of motor stators. Resistance welding has not typically been applied to copper due to its very high electrical conductivity; however through optimization of the current and pressure profiles, excellent quality copper-to-copper joints have been demonstrated with a technique known as resistance mash welding. A better understanding of resistance mash welding characteristics will help advancements in its application for stators. The limitations of this application will be discussed.     

反应器引压端法兰焊接阀门断裂原因分析

通过对Z41H-160型阀体端法兰断裂件的宏观检查、化学成分分析、金相分析、断口形貌观察、EDS能谱分析和维氏硬度测试等研究,表明阀体热处理不当致使硬度超高,阀门结构不合理导致硫化物应力腐蚀是阀体断裂的主要原因。     

具有自动清洗功能的低温等离子油烟净化装置设计与实现

为了克服现有的油烟净化器清洗困难、清洗成本高的不足,提供一种具有自动清洗功能的低温等离子油烟净化器,该具有自动清洗功能的低温等离子油烟净化器可随时清洗吸附的油烟,并且清洗容易、成本低。     

低温等离子体-催化协同降解挥发性有机废气

低温等离子体-催化协同技术适合于各类挥发性有机物的治理,特别是大气量低浓度的有机废气的处理.高效催化剂的加入可 以显著提高等离子体反应中有机废气的降解效率,减少有害副产物的生成以及提高反应器的能量利用率.从反应器、催化剂以及背景气体等方面探讨了该技术实现产业化需要解决的问题,结合低温等离子体与催化剂的相互作用、等离子体...     

Vibrational energy loss analysis in battery tab ultrasonic welding

In ultrasonic metal welding processes, high-frequency ultrasonic energy is used to generate friction and heat at the interface between weld parts to produce solid-state bonds. It has been observed that sufficient energy is required to produce proper bonding, while excessive energy can cause such quality issues as weld fracture and perforation. Therefore, it is important to have a product/process design in ultrasonic welding to ensure efficient energy conversion from ultrasonics to welding energy, minimizing energy loss in the process. In this work, vibrational energy loss associated with the longitudinal and flexural vibrations of the Cu coupon during ultrasonic welding is studied by applying one-dimensional continuous vibration models. To facilitate our modeling, experimental results from the free response of Cu coupon were obtained to determine the damping characteristics of the Cu coupon in the welding process. Our analysis shows that substantial energy loss can occur during welding due to the flexural vibration of the Cu coupon, especially when the overhang (the upper part of the Cu coupon extended from the anvil) of the Cu coupon resonates at or close to the welding frequency (about 20 kHz), degrading the weld quality of battery tabs. This study contributes to understanding the fundamental dynamics of the Cu coupon during ultrasonic welding and its impact on weld quality.     

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.     

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.     

Development of chemically produced hydrogen energy-based impact bonding process for dissimilar metals

There has been a growing demand in the fabrication of dissimilar metal parts for application in the automotive, aerospace, defense, chemical and nuclear industries. Welding of dissimilar materials can be accomplished via impact welding, which can minimize the formation of a continuous inter-metallic phase, while chemically bonding dissimilar metals. This paper discusses an innovative technique for bonding dissimilar metals by chemically produced hydrogen energy by reacting aluminum powder and water. Experiments were carried out to study impact bond characteristics using copper and stainless steel cylindrical billets. The influence of nosed flyer billet angle and billet mass on bonding characteristics were studied. The test results have demonstrated that the nosed flyer billet angle has significant influence on wavy bond patterns at the interface. Among the three flyer billet nose angles of 9°, 12° and 15°, the billets with a flyer angle of 15° resulted in a complete wave morphological pattern along the whole sample cross-section. This study shows the potential of developing a cost effective system/machinery where discrete metal parts can be bonded at near net shape.     

Bitter coil design methodology for electromagnetic pulse metal processing techniques

Electromagnetic pulse metal processing techniques (EPMPT) such as welding, forming and cutting have proven to be an effective solution to specific manufacturing problems. A high pulse magnetic field coil is a critical part of these technologies and its design is a challenging task. This paper describes a Bitter coil design using a newly developed methodology for a simplified analytical calculation of the coil and complementary finite element models (FE) of different complexity. Based on the methodology a Belgian Welding Institute (BWI) Bitter coil has been designed and tested by means of short circuit experiments, impedance and B-field measurements. A good agreement between the calculated and the experimental design parameters was found.     

电晕放电等离子体技术处理水中四环素的研究

采用电晕放电等离子体技术降解水中的四环素,研究了在反应体系中,初始浓度、输入功率、电极间距、空气流量及初始pH对四环素去除效率的影响.同时,还对四环素在降解过程中不同时段的COD、TOC和B/C变化进行了研究,并对其降解产物进行了分析和讨论.实验结果表明:电晕放电等离子体对水中四环素具有较好的去除效果,在四环素初始浓度为200 mg·L-1、pH=2.47、初始电导率为1.50 mS·m-1、空气流量为0.06 m3·h-1、电极间距为4 mm、输入功率为45.0 W的条件下,反应20 min后,四环素的去除率可达到99.1%,COD去除率可达31.2%,TOC去除率可达80%左右,其B/C比提高为0.30,有效地改善了废水的可生化性.