钛合金电子束深熔焊传热传质及质量控制研究
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摘要
大厚度钛合金电子束焊接结构在航空航天工业中具有广阔的应用前景,但是目前在钛合金电子束深熔焊过程中极易出现钉尖缺陷,会显著降低接头性能,为了保证焊接质量,本文对钉尖缺陷的形成机理及其控制措施进行了研究。
采用数值模拟的方法建立了钛合金电子束深熔焊温度场模型,计算结果表明,电子束焊接过程中升温降温速度极快,当焊接过程进入准稳态之后,温度场分布基本保持不变,熔池中心的峰值温度维持在3200℃左右。并利用热电偶测温和对比焊缝横截面形貌的方法对模拟结果进行了验证,模拟结果与试验数据吻合较好,证明了所建数值分析模型是正确的。
在温度场计算结果的基础上,对钛合金电子束深熔焊的流场进行了计算,初步分析了熔池流场形成机理。研究表明,表面张力梯度、金属蒸汽反冲压力和流体静压力是熔池内液态金属流动的主要驱动力。熔池表面的流体在表面张力梯度的作用下运动最剧烈,其最大速度可达0.295m/s。随着熔深的加深,液态金属的运动逐渐减弱。以钨作为示踪元素,通过能谱分析研究了电子束深熔焊接头钨元素的分布情况,并进而分析了电子束深熔焊过程中,熔池内液态金属的流动和传质行为。最后,结合元素示踪试验和数值模拟结果,对电子束深熔焊熔池内流体流动规律进行了归纳总结。
结合电子束深熔焊流场模型,对大厚度钛合金电子束焊接接头钉尖缺陷的形成机理进行了研究。结果表明,电子束脉动是形成钉尖缺陷的直接原因,高饱和蒸汽压金属蒸汽是形成钉尖缺陷的重要原因。对熔透实施精确控制,实现全熔透焊接,是解决电子束深熔焊钉尖缺陷出现的最有效方案。
为了控制钉尖的产生,对钛合金电了束深熔焊熔透控制系统进行了研究。搭建了一套适合于电子束焊的彩色熔池图像视觉传感系统,实现了熔池图像的实时传感与采集。对熔池图像处理算法进行了研究,实现了熔宽的准确提取。根据试验数据,建立了钛合金电子束焊熔深的BP神经网络预测模型,能够根据焊接参数和熔宽预测熔深,可设计以熔宽为被控变量、电子束流为控制变量的模糊控制器。将BP神经网络模型和模糊控制器结合起来,建立钛合金电子束焊熔透控制系统模型,并对该模型进行了仿真试验,试验结果表明,所设计的控制系统动态性能和稳态性能良好。
The welded structure of electron beam welding of thick titanium alloy had broad application prospects in the aerospace industry, but now the process of electron-beam deep-penetration welding of titanium alloy easily occured the spiking defect, which will significantly reduce the performance of welded joint, so the forming mechanism and control measures of spiking defect were studied in order to ensure the quality of welding.
The numerical analytic model of temperature field of electron-beam deep-penetration welding was establish in this paper, The calculated results of temperature field show that the cooling rate and heating rate are very fast in the process of electron beam welding, the distribution of temperature field is basically unchanged when the welding process entered into the quasi-steady-state, the peak temperature of center of molten pool was maintained at about3200"C.The simulated result was verified by the thermocouple and contrast of cross section of weld, the simulated result was well consistent to the experimental data, which verified the reliability of the finite element model.
The flow field of titanium-alloy electron-beam deep-penetration welding was calculated on the base of established finite element model of temperature field, the formation mechanism of flow field was preliminary analyzed. The study shows that the gradient of surface tension hydrostatic pressure and recoil pressure of metal vapor are the most important driving forces of flow of liquid metal, and the flow of liquid metal in the surface of molten pool was the most violent, the maximum flow rate is0.295m/s, the flow of liquid metal gradually waned with the increase of penetration. The tungsten element was selected as the tracer, and the EDS analysis was used to measure the distribution of tungsten element in the electron-beam deep-penetration welded joints, and the flow and mass-transfer behavior of liquid metal of molten pool was further analyzed in the process of electron-beam deep-penetration welding, finally the tracer experiments and numerical simulated results were combined to summarize the flow law of fluid of molten pool of the electron-beam deep-penetration welding.
Combining the flow-field model of the electron-beam deep-penetration welding, the spiking defect of thick titanium-alloy electron-beam welded joint was studied. The study shows that the pulse of electron beam is the direct cause of forming spiking, the metal vapor with high saturated vapor pressure is the important cause of forming spiking. The precise control of penetration to achieve full-penetration welding is the most effective solution of the spiking defect of the electron-beam deep-penetration welding.
The quality control system of titanium-alloy electron-beam deep-penetration welding was studied in order to control the spiking defect. A set of visual sensing system of colored image of molten pool was fabricated which is suitable to electron beam welding, the system achieved the real-time sensing of the molten-pool image. The edge-detection algorithm of molten-pool image was developed, the clearly edge of molten pool was obtained by the program, which created the condition for the further extraction of molten width. A suit of extracting program of molten width was developed to extract exactly the molten width. A predictable model of BP neural network of penetration of titanium-alloy electron-beam welding was established according to the experimental data, which could predict the penetration by the welding parameters and molten width. The fuzzy controller was designed, its controlled variable was the molten width, its control variable was the electron beam current. The model of BP neural network and the fuzzy controller were combined to establish the control system model of penetration of titanium-alloy electron-beam welding, and the simulation experiment was carried out, the results show that the dynamic performance and the steady-state performance of designed control system are eminent.
采用数值模拟的方法建立了钛合金电子束深熔焊温度场模型,计算结果表明,电子束焊接过程中升温降温速度极快,当焊接过程进入准稳态之后,温度场分布基本保持不变,熔池中心的峰值温度维持在3200℃左右。并利用热电偶测温和对比焊缝横截面形貌的方法对模拟结果进行了验证,模拟结果与试验数据吻合较好,证明了所建数值分析模型是正确的。
在温度场计算结果的基础上,对钛合金电子束深熔焊的流场进行了计算,初步分析了熔池流场形成机理。研究表明,表面张力梯度、金属蒸汽反冲压力和流体静压力是熔池内液态金属流动的主要驱动力。熔池表面的流体在表面张力梯度的作用下运动最剧烈,其最大速度可达0.295m/s。随着熔深的加深,液态金属的运动逐渐减弱。以钨作为示踪元素,通过能谱分析研究了电子束深熔焊接头钨元素的分布情况,并进而分析了电子束深熔焊过程中,熔池内液态金属的流动和传质行为。最后,结合元素示踪试验和数值模拟结果,对电子束深熔焊熔池内流体流动规律进行了归纳总结。
结合电子束深熔焊流场模型,对大厚度钛合金电子束焊接接头钉尖缺陷的形成机理进行了研究。结果表明,电子束脉动是形成钉尖缺陷的直接原因,高饱和蒸汽压金属蒸汽是形成钉尖缺陷的重要原因。对熔透实施精确控制,实现全熔透焊接,是解决电子束深熔焊钉尖缺陷出现的最有效方案。
为了控制钉尖的产生,对钛合金电了束深熔焊熔透控制系统进行了研究。搭建了一套适合于电子束焊的彩色熔池图像视觉传感系统,实现了熔池图像的实时传感与采集。对熔池图像处理算法进行了研究,实现了熔宽的准确提取。根据试验数据,建立了钛合金电子束焊熔深的BP神经网络预测模型,能够根据焊接参数和熔宽预测熔深,可设计以熔宽为被控变量、电子束流为控制变量的模糊控制器。将BP神经网络模型和模糊控制器结合起来,建立钛合金电子束焊熔透控制系统模型,并对该模型进行了仿真试验,试验结果表明,所设计的控制系统动态性能和稳态性能良好。
The welded structure of electron beam welding of thick titanium alloy had broad application prospects in the aerospace industry, but now the process of electron-beam deep-penetration welding of titanium alloy easily occured the spiking defect, which will significantly reduce the performance of welded joint, so the forming mechanism and control measures of spiking defect were studied in order to ensure the quality of welding.
The numerical analytic model of temperature field of electron-beam deep-penetration welding was establish in this paper, The calculated results of temperature field show that the cooling rate and heating rate are very fast in the process of electron beam welding, the distribution of temperature field is basically unchanged when the welding process entered into the quasi-steady-state, the peak temperature of center of molten pool was maintained at about3200"C.The simulated result was verified by the thermocouple and contrast of cross section of weld, the simulated result was well consistent to the experimental data, which verified the reliability of the finite element model.
The flow field of titanium-alloy electron-beam deep-penetration welding was calculated on the base of established finite element model of temperature field, the formation mechanism of flow field was preliminary analyzed. The study shows that the gradient of surface tension hydrostatic pressure and recoil pressure of metal vapor are the most important driving forces of flow of liquid metal, and the flow of liquid metal in the surface of molten pool was the most violent, the maximum flow rate is0.295m/s, the flow of liquid metal gradually waned with the increase of penetration. The tungsten element was selected as the tracer, and the EDS analysis was used to measure the distribution of tungsten element in the electron-beam deep-penetration welded joints, and the flow and mass-transfer behavior of liquid metal of molten pool was further analyzed in the process of electron-beam deep-penetration welding, finally the tracer experiments and numerical simulated results were combined to summarize the flow law of fluid of molten pool of the electron-beam deep-penetration welding.
Combining the flow-field model of the electron-beam deep-penetration welding, the spiking defect of thick titanium-alloy electron-beam welded joint was studied. The study shows that the pulse of electron beam is the direct cause of forming spiking, the metal vapor with high saturated vapor pressure is the important cause of forming spiking. The precise control of penetration to achieve full-penetration welding is the most effective solution of the spiking defect of the electron-beam deep-penetration welding.
The quality control system of titanium-alloy electron-beam deep-penetration welding was studied in order to control the spiking defect. A set of visual sensing system of colored image of molten pool was fabricated which is suitable to electron beam welding, the system achieved the real-time sensing of the molten-pool image. The edge-detection algorithm of molten-pool image was developed, the clearly edge of molten pool was obtained by the program, which created the condition for the further extraction of molten width. A suit of extracting program of molten width was developed to extract exactly the molten width. A predictable model of BP neural network of penetration of titanium-alloy electron-beam welding was established according to the experimental data, which could predict the penetration by the welding parameters and molten width. The fuzzy controller was designed, its controlled variable was the molten width, its control variable was the electron beam current. The model of BP neural network and the fuzzy controller were combined to establish the control system model of penetration of titanium-alloy electron-beam welding, and the simulation experiment was carried out, the results show that the dynamic performance and the steady-state performance of designed control system are eminent.
引文
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