Effect of longitudinal magnetic field on grain growth of hollow stud welded joint

Aiming at the defects of large diameter hollow stud welding such as arc blow and incomplete fusion,drawn arc stud welding with the longitudinal magnetic field was used to 30CrNi3MoV steel and Q235 stud. The grain growth process of joint was studied. With the assistance of longitudinal magnetic field, the arc action area on the end face of the hollow stud was increased, and the end face of stud was melted evenly. The solidification and crystallization process of molten pool was changed due to magnetic field stirring. Within a certain range, the microstructure of the joint is gradually refined and the size is homogeneous with the increase of magnetic field. But too large current can be attributed to the very coarse grain structure. Besides, the proportion of small angle grain boundary was decreased during appropriate magnetic field current, while the proportion of large angle grain boundary was increased. Meanwhile, preferred orientation of grains of the joints was changed due to the magnetic stirring.

Dual-robot stud welding system for membrane wall

Purpose The membrane wall is one of the most important components in the boiler industry and numerous studs are welded on its surface. The membrane wall welding still remains a sector intensive in the manual and arduous works. This paper aims to propose a dual-robot system to automatically weld studs on the membrane wall. Design/methodology/approach In this paper, the authors proposed a dual-robot stud welding system for membrane walls. First, the membrane wall is divided into several zones and the welding paths are planned. Then, the pose of the pipes is calculated based on the data measured by light section sensors. The planned paths are compensated by the pose. Finally, the robots weld studs based on the compensated paths. Findings The method effectively eliminates manufacturing errors and welding distortions. The system can weld straight type and L-type membrane walls with high efficiency, high quality and high accuracy. Originality/value The system can weld straight type and L-type membrane walls with high efficiency and high quality. Experiments were performed in a factory to demonstrate the practicability of the method. The dual-robot system with two welding machines has approximately twice the efficiency of the manual welder with only one welding machine. The quality and accuracy of robot welding systems are higher than that of manual welding.

Effect of the welding process on microstructure, microhardness and residual stresses of capacitor discharge stud welded joint

Capacitor discharge (CD) stud welding is a common and fast connection technology. This paper presents an experimental and simulation study of the stud weld joint of copper stud and carbon plate. An optimized stud welding process was proposed based on microstructure, microhardness and residual stresses of CD stud welded joint. The results show that a narrow weld seam with widmanstaten structure were formed because of quickly cooling. For the longer stud extension length, the width of weld zone becomes wider and the microstructure becomes more uniform. As the increase of welding voltage and stud extension length, the microhardness increases then decreases. However, the residual stresses are increased with welding voltage increases, while they are decreased with the increases of stud extension length. The optimized welding voltage and stud extension length should be designed to 90 V and 5 mm, respectively. This study will provide a great significance to the stud welding on site.