Research on Residual Stress Distribution in Different Areas of Laser-MAG Arc Hybrid Welding by Numerical Simulation

In this research, through experiments and numerical simulations, the residual stress distribution of the top and bottom surfaces of the laser (TruDisk16002)-arc (MAG) hybrid welding seam and the weld cross-section are studied. The results show that when the arc power is 6.5KW and the laser power is 7.5KW, the weld is formed well. The residual stress on the bottom surface near the weld is higher than that on the top surface. The laser zone in the center of the weld has the largest residual stress, the arc zone is smaller, and the mixed zone is the smallest. The laser zone has the largest residual stress at the fusion line and the heat-affected zone, followed by the mixed zone, and the arc zone is the smallest. followed by the mixed zone, and the arc zone has the smallest.

Stabilization Methods in the Submerged Arc Discharge Synthesis of Carbon Nanostructures

Many papers, in which the submerged arc discharge (SAD) method in nanoparticle synthesis was used, reported similar operating parameters, but different electrode erosion rate values, different yields and purities of the obtained nanostructures, and a different sort of contaminants present in the synthesis. Analyzing these articles, we found insufficient attention to ensure the arc power stability, which is a key factor guaranteeing the product homogeneity and quality. This paper presents an analysis of different control strategies, remarks their advantages and drawbacks, and proposes the most appropriate technique to be used in SAD. The most appropriate technique is proposed from the SAD stabilization method analysis.

Synthesis of Fuzzy Logic Mathematical Model for Adaptive Control of the Mig/Mag Surfacing

A functional transformer with fuzzy logic is synthesized, which allows to get the estimations of weld beads height and width at the arbitrary values of entry parameters: wire feed speed and torch transverse oscillations amplitude. The influence of these input parameters on the base metal penetration and beads geometric parameters, welded using MIG/MAG process, were studied. Surfacing was performed by a robotic system with an arc power supply "Fronius TPS- 320i", which operated in the mode of arc process synergetic control. The formation of both individual beads and surfacing layers at different overlap coefficients has been studied. The arc surfacing process was realized in a mixture of protective gases (Ar+18%CO2) using a welding wire Св-08Г2С with a 1.0 mm diameter. Surfacing speed – 4 mm/s, frequency of welding torch oscillations – 1 Hz. The obtained experimental dependences of beads width and height, as well as the length of the welding pool can be used in both: creating of multi-pass MIG/MAG surfacing program for robotic restoration of critical purposes parts surfaces, and in preparing of FEM model of MIG/MAG surfacing.

Modeling of welding arc power supply diagrams in Matlab / Simulink

Purpose. Creation of virtual blocks and simulation laboratory stands for the study and comprehensive research of the dynamic properties of welding power supplies. Methodology. Review of literary sources on the subject, simulation modeling of electromagnetic processes in the MATLAB software environment, comparative analysis of obtained and available data. Findings. The comparative analysis of means of modeling of power sources of a welding arc is executed. One of the main parameters by which the environments were compared is functionality. Among the considered simulators, Simulink of the MATLAB software environment is the most effective one in the considered systems modeling. Using special features, its user can not only simulate, but also analyze the operation of the over time installation. Mathematical and functional models of welding arc power supplies were built using SimPowerSystems elements and blocks from the Simulink library with the involvement of the MATLAB system itself, which significantly expands the possibilities for such systems modeling. Mathematization of certain processes to some extent shows the level of reliability of the results and the degree of their scientific development. The developed models act as a laboratory, which allows you to set and explore any modes and characteristics. Numerical experiments and comparative analysis of numerical and field experiments are given. Experimental verification of the obtained results on specific examples showed the relevance of the problem and the correctness of its solution. Further research is related to the expansion of the range of simulated power sources of the electric arc, a comprehensive study of their dynamic properties and basic characteristics, experimental verification of the developed models, as well as comparative analysis and development of recommendations for model improvement. Originality. The method of circuit modeling of general-purpose electrical and electronic circuits was further developed by extending it to a new class of objects - the power supply system of electrical installations. Practical value. Construction of mathematical and functional models of complex systems with the involvement of MATLAB allows to take into account their main features, significantly expands the possibilities for modeling, study and research of power supplies. Based on the proposed approach, simulation laboratory stands of specific power supplies were developed and built, which allow to set and study any modes and characteristics.

Resource characteristics of the alternating current plasma torch "Zvezda"

The article presents the results of the study of material entrainment (erosion) of the most heatstressed nodes of the three-phase alternating current plasma torch "Zvezda" of megawatt power: electrodes and confusers. The data on entrainment were obtained by weighing the studied nodes after their cycles of operation at fixed modes. Air was used as the working fluid. The operating modes of the plasma torch varied in the ranges of arc power 0.5–1.2 MW, cur-rents 160–400 A, gas flow 70–170 g/s. When using different output nozzles, the pressure in the plasma torch varied from 0.2 to 1.65 MPa. The influence of various parameters of the operat-ing mode on the service life of the plasma torch is shown. Using the obtained data on the ero-sion of electrodes and confusers, their resource was evaluated.

Microstructure and Wear Behaviors of Plasma-Sprayed MoAlB Ceramic Coating

MoAlB ceramic coatings were prepared on a 316 steel surface by atmospheric plasma spraying with different arc power levels. The phase composition, microstructure and wear resistance of coatings against GCr15 and Si3N4 counterparts were studied. The MoAlB ceramic decomposed and was oxidized to form MoB and Al2O3 during plasma spraying. With the increase of the arc power, MoAlB experienced more decomposition, but the coatings became denser. When the arc power increased from 30 to 36 kW, the wear rates of coatings against GCr15 and Si3N4 balls reduced by 91% and 78%, respectively. The characterization of wear tracks shows that when against GCr15 counterparts, the main wear mechanisms are abrasive and adhesive wear, and when against Si3N4 counterparts, fatigue and abrasive wear are dominant. The refinement of wear resistance by increasing arc power can be attributed to the improvement of density and adhesive strength among splats.

Effect of arc breaks and short circuits on lack of fusion formation at sidewalls of groove during multi-pass weaving of pipelines

To evaluate the effect of the short-time arc breaks along the side-walls of grove during multi-pass welding virtual study of this effect is performed using deterministic mathematical model of arc welding process. It is established that breaks in arc burning lead to the appearance of craters, which may not be remelted during the subsequent pass. It is shown that the effect of the duration of the arc breaks on the craters depth increases with increase in the amplitude and period of oscillations. The effect of breaks is more noticeable if they occur when approaching the groove face than if they occur when moving from the groove face to the center of the pass. When analyzing the welding monitoring data, it is necessary to take into account not only the arc power, but also the parameters of transverse oscillations of the torch, including the phase of arc breaks relative to these oscillations.