转速对20 mm厚2219铝合金搅拌摩擦焊接件的组织及性能的影响

对20 mm厚的2219 C10S铝合金板材进行搅拌摩擦焊对接试验,在进给速度为100 mm/min的条件下,对比研究转速为400～550 r/min时的对接接头的内部缺陷、宏观形貌及微观组织、显微硬度和拉伸力学性能的差异。结果表明,当转速为400～500 r/min时,焊接接头无缺陷,能获得内部质量较高的焊接接头。随着转速的增加,焊核区“洋葱环”的间距和轴肩影响区的范围增大,焊核区和热力影响区的硬度的降低越明显。接头的拉伸性能随转速的增大而降低,拉伸强度最高可达到334 MPa,接头断裂模式主要为韧性断裂,断裂位置发生在后退侧的热力影响区与热影响区的交界处,与显微硬度最小位置相吻合。当转速增大至525 r/min时,焊缝出现表面点状缺陷;当转速达到550 r/min时,焊缝出现连续的犁沟缺陷。     

空间推进系统铝合金组件激光焊阈值特性

为解决空间推进系统直属组件轻量化需求,对新采用的铝合金材料进行了激光焊阈值特性研究。结果表明,铝合金激光焊阈值区间与焊接速度和离焦量的绝对值正相关,但正向变化幅度远低于不锈钢、镍合金和钛合金等材料。对于光束质量不同的激光焊机来说,光束的焦斑直径越小,实焦焊时阈值区间越低;光束的发散角越小,相同离焦量下阈值区间越低。在-12°～12°内,铝合金激光焊阈值区间与入射角无关。保护气的吹送方向和吹送速度基本不改变铝合金激光焊的阈值区间,此特性与不锈钢等材料略有区别。     

基于AI+神经网络的数字化故障电弧识别方案研究

线路故障电弧的特征随着电力电子技术的提高更趋复杂，传统的故障电弧识别方式已无法应对新型用电系统。对比传统故障电弧识别方案，研究故障电弧产生类型和新型检测技术，提出基于谐波因素、总谐波畸变率、电流零休时间、电流变化速率、电流周期性等典型时域、频域特征的AI+神经网络的数字化故障电弧识别方案。该方案运用回归算法向量机对特征图进行分类处理，通过正向传输运算、反向传输运算和迭代回归运算三个步骤执行卷积神经网络，频繁迭代回归以获得最佳特征识别图。本文以调光器的故障电弧识别为例，对故障识别方案进行验证，结果表明采用此方案可实现更高效、更精准、更稳定地识别故障电弧。     

纳秒脉冲滑动弧放电等离子体裂解煤油实验研究

为改善极端条件下航空煤油的点火和燃烧性能,提高煤油活性,本文在大气压氮气环境下利用纳秒脉冲电源产生的滑动弧等离子体进行煤油裂解实验研究,得到了包含活性更高的气态轻质烃和氢气等小分子物质的裂解气。通过改变电源输出脉冲电压的上升沿时间和下降沿时间,得到了裂解气产量、碳氢比以及裂解气中各组分选择性的变化规律,并总结了相关的部分反应路径。实验结果如下：裂解气产量随着上升沿时间的增加而减小,随着下降沿时间的增加而上升,裂解气碳氢比则呈现相反的变化规律；裂解气主要组分中,乙烷选择性最高,在各实验工况下均超过30%；随着上升沿时间和下降沿时间的增加,裂解气中丙烷和丙烯的选择性均降低,氢气的选择性上升；上升沿时间和下降沿时间的变化对裂解效果产生影响的主要原因是改变了反应的路径。实验结果表明,纳秒脉冲滑动弧放电等离子体可以将煤油中的部分大分子烃类转化为气态轻烃和氢气等高活性组分。同时,增加纳秒脉冲电压下降沿时间能够改善滑动弧等离子体的裂解效果,获得更多活性更高的小分子物质。     

焊透深度和前进侧位置对FSW 贮箱锁底接头性能的影响

开展了2219MCS 叉形环和2219C10S 短壳组成的锁底接头的搅拌摩擦焊工艺试验,详细分析了

搅拌针长度和前进侧位置对锁底接头Hook 型缺陷、力学性能、断裂方式的影响规律。结果表明:搅拌摩擦焊

锁底接头在短壳一侧存在Hook 型缺陷,短壳位于前进侧时的搭接界面上翘曲率和迁移量均大于叉形环位于

前进侧,且随着搅拌针长度的增加,搭接界面的向上迁移量逐渐增大。相同的焊透深度时,叉形环位于前进侧

的力学性能优于短壳位于前进侧;相同的前进侧位置时,随着焊透深度的逐渐增加,接头力学性能逐渐降低。

锁底接头搭接界面缺陷形貌及迁移量的变化是引起力学性能变化的主要原因。优化的试验结果显示,当焊透

深度和短壳板材厚度相同,且叉形环位于焊缝前进侧的力学性能最优,常温可达到300 MPa,低温可达到370

MPa,延伸率均超过3. 5%。锁底接头的拉伸断裂方式与焊缝前进侧位置密切相关。当短壳位于前进侧时,从

短壳一侧热力影响区断裂;当叉形环为前进侧时,从焊缝焊核区断裂。

     

Feasibility study of thermo-compensated resistance brazing welding of C/C composites and T2 copper with AgCuTi filler metal

The dissimilar materials joining of C/C composites to T2 copper were performed successfully by thermo-compensated Resistance Brazing Welding (RBW) with AgCuTi filler powder. The interfacial microstructure, phase composition, and shear strength of the resistance brazed joints were investigated by the relevant analysis method. Experiment results indicated that the order affecting the shear strength of the C/C-Cu joint was welding current, welding pressure, and welding time in turn. The shear strength of backward thermo-compensated RBW was higher than that of forward thermo-compensated RBW due to the Peltier effect. The maximum shear strength of the C/C-Cu joint was 11.56 MPa in the optimized welding parameter with welding current of 8.0 kA, welding time of 60 ms, and welding pressure of 0.10 MPa by backward thermo-compensated RBW. The interface structure at the resistance brazed joint with this welding parameter was C/C composites/TiC/Cu (s.s)/T2 copper. The TiC phase was verified at the interface of the brazed joint by Scanning Electron Microscope (SEM), Energy-Dispersive X-ray Spectrometer (EDS), and X-ray Diffraction (XRD). Considerable fractures occurred in the C/C composites and partial fracture occurred at the interfacial reaction layer.     

航天器可展开薄膜遮光罩的构型设计与优化

针对当前航天器遮光罩轻量化的需求，在保证薄膜遮光罩有效面积不变的前提下，根据质量和有效面积占比设计了一款柔性平面薄膜遮光罩。以提高薄膜边缘应力的同时尽量避免有效圆面积占比减少为优化目标，对薄膜遮光罩的边缘做弧边优化设计。结果表明，当薄膜遮光罩为正六边形时，既能保证结构对称性，又能获得较低的单位有效面积占比对应质量。通过应力叠加法建立了薄膜遮光罩的应力分布模型，求出薄膜边缘应力的理论计算值。探究了弧边拱高的增加对薄膜边缘应力和有效圆面积占比的影响规律，当二者的函数曲线相交于一点时，可取为薄膜弧边的最优拱高。根据设计的薄膜遮光罩参数，搭建薄膜遮光罩的试验样机并进行展开试验。薄膜遮光罩可完全展开，薄膜边缘张紧度高，证明了薄膜遮光罩系统方案设计的可靠性，弧边设计可有效提高薄膜边缘的应力水平。     

基于滑动弧的燃烧室头部强化燃烧特性

为了研究基于滑动弧的燃烧室头部强化燃烧效果，探究了燃烧室头部的点火过程以及不同等离子体电源输入功率下的点/熄火边界，利用像增强系统获得了CH*基团的分布云图。实验结果表明：输入功率的增大使得燃烧室的点/熄火边界均得到拓展，与160 W工况相比，输入功率为320 W时，点火边界平均拓宽约17.6%，与未放电相比，输入功率为320 W时，熄火边界平均拓宽约45.3%，滑动弧放电对熄火边界拓宽效果明显；当滑动弧能够点燃来流新鲜混合气时，输入功率的增加使得CH*基团分布向上游移动，当输入功率为320 W时，燃烧火焰驻留在燃烧室头部，当滑动弧激励器仅具有助燃作用时，输入功率的增加使得局部CH*基团辐射强度增强，热释放速率增加。     

Improving tensile-shear properties of friction stir lap welded dissimilar Al/Mg joints by eliminating hook defect and controlling interfacial reaction

To improve tensile-shear properties of fiction stir lap welded(FSLW) dissimilar Al/Mg joints, pin-tip profiles were innovatively designed and welding speed was optimized, and effects of them on formation, interface microstructure and mechanical properties of different FSLW joints were investigated. With increasing the welding speed, the tensile-shear load of FSLW joints produced by three pins presents an increasing firstly and then decreasing trend. Compared with Rpin, the hook and hole defect i...     

Microstructural formation and mechanical performance of friction stir double-riveting welded Al-Cu joints

A novel friction stir double-riveting welding (FSDRW) technology was proposed in order to realize the high-quality joining of upper aluminum (Al) and lower copper (Cu) plates, and this technology employed a Cu column as a rivet and a specially designed welding tool with a large concave-angle shoulder. The formations, interfacial characteristics, mechanical properties and fracture features of Al/Cu FSDRW joints under different rotational velocities and dwell times were investigated. The results showed that the well-formed FSDRW joint was successfully obtained. The cylindrical Cu column was transformed into a double riveting heads structure with a Cu anchor at the top and an Al anchor at the bottom, thereby providing an excellent mechanical interlocking. The defect-free Cu/Cu interface was formed at the lap interface due to the sufficient metallurgical bonding between the Cu column and the Cu plate, thereby effectively inhibiting the propagation of crack from the intermetallic compound layer at the lap interface between the Al and Cu plates. The tensile shear load of joint was increased first and then decreased when the rotational velocity and dwell time of welding tool increased, and the maximum value was 5.52 kN. The FSDRW joint presented a mixed mode of ductile and brittle fractures.