Journal of Advanced Joining Processes最新文献_第2页

AI-based monitoring system for real-time defect detection in wire arc additive manufacturing 基于人工智能的电弧增材制造缺陷实时检测系统

IF 4 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-12-26 DOI: 10.1016/j.jajp.2025.100371

J.E. Tapia Cabrera, F. Groschupp, F. Riegger, M.F. Zaeh

The high flexibility of additive manufacturing (AM) enables the repair of components with complex geometries, contributing to the sustainability of the economy by reducing waste and increasing product lifetime. Wire arc additive manufacturing (WAAM) is well-suited for repair due to the high deposition rates compared to other AM technologies. Moreover, the automation potential of WAAM offers a promising opportunity for increasing productivity. However, the automated repair presents new challenges for quality assurance. During the deposition of successive layers, defects, such as a lack of fusion between adjacent weld beads, may be concealed within the parts. Due to their impact on the mechanical properties, such discontinuities constitute non-conformities and require part rejection. Therefore, a real-time monitoring system is required to detect lack of fusion defects and to ensure the reliable performance of the repaired components. Weld pool imaging provides detailed insights into process anomalies. Nonetheless, the harsh welding environment degrades the data quality and requires advanced imaging algorithms to extract features for a reliable analysis. The artificial intelligence (AI) architecture “You Only Look Once” (YOLO) allows for a robust detection performance and real-time capability with its one-stage approach for object detection. In this work, a monitoring system using two sequentially coupled YOLO-based models was developed. First, a detection model identifies the lack of fusion defects within the weld pool images, producing bounding boxes around the detected areas. These bounding boxes are then used as an input for a segmentation model, which provides a more precise delineation of the defects within the identified regions. The models were evaluated on unseen data, achieving a recall of over 90 % while maintaining real-time capability. This result showed the high potential of AI-based monitoring systems for real-time defect detection in WAAM to ensure the quality of the repaired components.

增材制造（AM）的高灵活性使具有复杂几何形状的部件得以修复，通过减少浪费和延长产品寿命，为经济的可持续性做出贡献。由于与其他增材制造技术相比，电弧增材制造（WAAM）具有较高的沉积速率，因此非常适合修复。此外，WAAM的自动化潜力为提高生产力提供了一个有希望的机会。然而，自动化维修对质量保证提出了新的挑战。在连续层的沉积过程中，缺陷，如相邻焊珠之间缺乏熔合，可能隐藏在零件内部。由于它们对机械性能的影响，这种不连续性构成不合格，需要零件报废。因此，需要一个实时监测系统来检测融合缺陷的缺失，并保证被修复部件的可靠性能。焊接池成像提供了对工艺异常的详细见解。然而，恶劣的焊接环境会降低数据质量，需要先进的成像算法来提取特征以进行可靠的分析。人工智能（AI）架构“You Only Look Once”（YOLO）采用单阶段对象检测方法，具有强大的检测性能和实时能力。在这项工作中，开发了一个使用两个顺序耦合的基于yolo的模型的监测系统。首先，检测模型识别焊池图像中缺乏融合缺陷，在检测区域周围产生边界框。然后将这些边界框用作分割模型的输入，该模型提供了对已识别区域内缺陷的更精确的描述。这些模型在未见过的数据上进行了评估，在保持实时能力的同时，实现了超过90%的召回。这一结果显示了基于人工智能的监测系统在WAAM中用于实时缺陷检测以确保被修复部件的质量的巨大潜力。

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引用次数: 0

Use of expandable graphite as debonding on demand technology between glass fibre reinforced polyamide 6 and aluminium 使用可膨胀石墨作为玻璃纤维增强聚酰胺6与铝之间的按需剥离技术

IF 4 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-12-23 DOI: 10.1016/j.jajp.2025.100369

Abdelghani Laachachi , Oussema Kachouri , Julian Berndt , Gregor Zucker , Camilo Zopp , Jens Bartelt , Ahmed Makradi

A heat triggered debonding-on-demand thermoset-based adhesive is developed to join the glass fiber reinforced thermoplastic polyamide-6 to aluminium alloy sheet. The hybrid composite interface debonding mechanism is heat triggered at the end-of-life of the hybrid composite toward recycling of its components. The debonding-on-demand adhesive joint consist of an ARALDITE® brittle thermoset variant functionalized with 10% Expandable Graphite. TGA analysis and shear lab test are conducted to evaluate the effect of the Expandable Graphite on the degradation and mechanical performances of the ARALDITE® resin. Once validated the developed debonding-on-demand solution is up-scaled to a U-shape part made on inverse hybrid laminates.

研制了一种热触发脱粘热固性粘接剂，用于玻璃纤维增强热塑性聚酰胺-6与铝合金板的粘接。杂化复合材料界面剥离机制是在杂化复合材料寿命结束时热触发的，以回收其组分。按需脱粘粘合剂接头由ARALDITE®脆性热固性变体组成，该变体具有10%可膨胀石墨的功能化。通过TGA分析和剪切实验，评价了可膨胀石墨对ARALDITE®树脂降解和力学性能的影响。一旦验证，开发的按需脱粘解决方案将扩展到在反向混合层压板上制造的u形部件。

引用次数: 0

Quality assurance of clinched joints using explainable machine learning 使用可解释的机器学习来保证固定关节的质量

IF 4 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-12-17 DOI: 10.1016/j.jajp.2025.100368

Johannes Gerritzen , Kunal Chopra , Gregor Reschke , Andreas Hornig , Alexander Brosius , Maik Gude

Quality assurance (QA) of clinched joints is predominantly performed by destructive testing. Recently, non-destructive evaluation (NDE) methods received increasing attention as a potential alternative. However, the inherently indirect measurement of underlying effects poses a significant challenge to its broader application. To tackle this, two experimental data sets, containing a total of 43 potential process deviations and defects are established using transient dynamic analysis (TDA). On these, several machine learning (ML) models are trained to detect the underlying deviations. The best-in-class model is used to identify a frequency band at which a classification accuracy of 88.58% across all 43 classes is achieved. Further analysis of the most discriminative model features reveals the importance of measuring both excitation as well as specimen response. This lays the foundation for further research towards defect specific in-line measurements of mechanical joints, further improving joint reliability.

紧固接头的质量保证（QA）主要是通过破坏性检测来完成的。近年来，无损评价（NDE）方法作为一种潜在的替代方法受到越来越多的关注。然而，对潜在影响的固有间接测量对其更广泛的应用构成了重大挑战。为了解决这个问题，使用瞬态动态分析（TDA）建立了两个实验数据集，其中包含总共43个潜在的工艺偏差和缺陷。在这些基础上，训练几个机器学习（ML）模型来检测潜在的偏差。使用同类最佳模型来确定一个频带，在该频带上，所有43个类别的分类准确率达到88.58%。进一步分析最具判别性的模型特征，揭示了同时测量激励和试样响应的重要性。这为进一步研究针对机械接头缺陷的在线测量奠定了基础，进一步提高了接头的可靠性。

引用次数: 0

Investigation of the effect of stress ratio on fatigue life in a microstructure-sensitive fatigue model for ultimate grain refinement and initiation grain refinement of high-speed friction stir welding of AA6061-T6 to Cu AA6061-T6 - Cu高速搅拌摩擦焊极限细化和起始细化细观疲劳模型中应力比对疲劳寿命的影响

IF 4 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-12-17 DOI: 10.1016/j.jajp.2025.100367

Esmaeil Mirmahdi , Davood Afshari , Masoud Mahmoodi

The formation of an ultimate grain refinement (UGR) microstructure in high-speed friction stir welding (HSFSW) significantly improves the mechanical properties of dissimilar joints. This study shows that achieving this microstructure not only increases tensile strength by up to 177 MPa (equivalent to 80% of the base metal strength of Cu) but also substantially enhances the fatigue resistance of the samples. To investigate fatigue behavior, tests were conducted under three different stress ratios (R = 0.1, R = 0.5, and R = -1). A microstructure-sensitive fatigue model (MSF-FEM) was developed to simulate the fatigue life of samples in both the initial grain refinement (IGR, coarse-grained) and ultimate grain refinement (UGR, ultrafine-grained) states. Modeling and experimental results indicated that as the R increased (from -1 towards 0.1), fatigue life decreased, with the longest fatigue life observed under fully reversed loading conditions (R = -1). Under these conditions, the fatigue life of UGR samples reached 4.8 ☓ 10⁴ cycles, and IGR samples reached 3.5 ☓ 10⁴ cycles. The results showed that UGR samples, compared to IGR, had an average increase of over 100% in fatigue life at different R; specifically, this improvement reached 100% at R = 0.1, 167% at R = 0.5, and 37% at R=-1. These findings indicate the simultaneous and significant effect of optimal microstructure and loading conditions on increasing the fatigue life of HSFSW joints.

高速搅拌摩擦焊接（HSFSW）中形成的终极晶粒细化（UGR）组织显著改善了异种接头的力学性能。研究表明，实现这种微观结构不仅使试样的抗拉强度提高了177 MPa（相当于铜母材强度的80%），而且大大提高了试样的抗疲劳性能。为了研究疲劳行为，在三种不同的应力比（R = 0.1, R = 0.5和R = -1）下进行了试验。建立了微结构敏感疲劳模型（MSF-FEM），模拟试样在初始晶粒细化（粗晶态）和最终晶粒细化（超细晶态）状态下的疲劳寿命。模型和实验结果表明，随着R的增大（从-1到0.1），疲劳寿命减小，在完全反向加载条件下疲劳寿命最长（R = -1）。在此条件下，UGR试样的疲劳寿命达到4.8 104次，IGR试样的疲劳寿命达到3.5 104次。结果表明：不同R值下，UGR试样的疲劳寿命比IGR试样平均提高100%以上；具体来说，在R= 0.1时，这种改善达到100%，在R= 0.5时达到167%，在R=-1时达到37%。这些结果表明，优化组织和加载条件对提高HSFSW接头疲劳寿命有同步且显著的影响。

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引用次数: 0

Analysis of precipitation kinetics during refill friction stir spot welding and post-weld heat treatments in AA7050 using SAXS and numerical modeling 利用SAXS和数值模拟分析AA7050填充搅拌摩擦点焊和焊后热处理过程中析出动力学

IF 4 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-12-01 DOI: 10.1016/j.jajp.2025.100365

Susanne Henninger , Rupesh Chafle , Niklaas Becker , Camila C. de Castro , Benjamin Klusemann , Martin Müller , Peter Staron

The impact of the refill friction stir spot welding process (refill FSSW) on precipitates in a high-strength AA7050-T7651 alloy is studied. Cross-sections of the welded samples are analyzed via small-angle X-ray scattering (SAXS), yielding 2D maps of spatial distributions of precipitate volume fraction and mean radius. The welding plunge times are varied during refill FSSW, leading to an increase in the width of the heat-affected zone (HAZ) with increase in energy input. The mean radius of precipitates increases above 25 nm at the edges of the stir zone (SZ) and thermo-mechanically affected zone (TMAZ). Dissolution and growth of

η

-precipitates in the HAZ are measured in-situ and are successfully modeled with the PanPrecipitation software. Moreover, the effect of various post-weld heat treatments (PWHT) on the precipitate distribution in the weld is analyzed. Reprecipitation in the HAZ is seen already after short aging times. After 20 min, the volume fraction increases all over the HAZ and nearly reaches the volume fraction of the base material. In the SZ/TMAZ, GP zones are formed through natural aging after welding and the PWHT lead to phase transformations and an increase in volume fraction and precipitate growth. Precipitates grow to a size of 2.5 nm after PWHT at 120 ℃ and 6.5 nm at 163 ℃. Thus, the formation of

η^{'} + η

-phase is expected after PWHT. Hardness measurements show that the PWHT lead to a hardness increase in the SZ and outer HAZ, but a minimum remains in the TMAZ/HAZ, where precipitates coarsened during welding. No significant changes in the weld zone features and the corresponding microstructure are observed between the as-welded and PWHT joints, indicating that the time–temperature conditions do not induce transformations such as grain growth and/or static recrystallization.

研究了再填充搅拌摩擦点焊工艺（FSSW）对高强AA7050-T7651合金析出相的影响。通过小角x射线散射（SAXS）对焊接试样的横截面进行分析，得到析出相体积分数和平均半径的二维空间分布图。随着能量输入的增加，热影响区宽度也随之增大。在搅拌区（SZ）和热机械影响区（TMAZ）边缘，沉淀的平均半径增加到25 nm以上。在原位测量了热影响区内η相的溶解和生长，并成功地用PanPrecipitation软件进行了模拟。此外，还分析了不同焊后热处理对焊缝中析出相分布的影响。在短时效时间后，HAZ内的再沉淀已经出现。20 min后，热影响区内的体积分数逐渐增大，接近基材的体积分数。在SZ/TMAZ中，焊接后自然时效形成GP区，PWHT导致相变、体积分数增加和析出相生长。120℃PWHT后析出相尺寸为2.5 nm， 163℃PWHT后析出相尺寸为6.5 nm。因此，PWHT后η′+η相的形成是预期的。硬度测量表明，PWHT导致SZ和外HAZ的硬度增加，但在TMAZ/HAZ中硬度最小，在焊接过程中析出物变粗。焊态和PWHT接头之间的焊缝区特征和相应的组织没有明显变化，表明时间-温度条件不会诱导晶粒长大和/或静态再结晶等转变。

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引用次数: 0

Corrigendum to “Surface cracks repair in AA6061-T6 aluminum alloys using friction stir processing” [Journal of Advanced Joining Processes (2025) /100340] “用搅拌摩擦法修复AA6061-T6铝合金表面裂纹”的勘误表[高级连接工艺杂志(2025)/100340]

IF 4 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-12-01 DOI: 10.1016/j.jajp.2025.100346

Fadi Al-Badour , Ahmad H. Bawagnih , Ahmed Ali , Rami K. Suleiman , Necar Merah

引用次数: 0

Debonding-on-demand of vacuum-infused thermoplastic fibre-reinforced laminates with improved recyclability 提高可回收性的真空注入热塑性纤维增强层压板的按需脱粘

IF 4 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-12-01 DOI: 10.1016/j.jajp.2025.100364

V. Bekas, C. Hoffmann, V.C. Beber, K. Arnaut

Debonding-on-Demand (DoD) is key in enabling recyclability and modular design of lightweight composite structures. This work investigates the effectiveness of DoD mechanisms using resistive heating modified substrates and thermally expandable particles (TEPs) on structural adhesive bonding. Methyl methacrylate adhesives are applied on vacuum-infused thermoplastic GFRP laminates with an Elium© acrylic matrix. Characterisation includes thermal imaging, DSC, lap-shear testing and fracture surface analysis. To enable localised thermal DoD-triggering, modified substrates are fabricated with integrated resistive heating elements. Thermal stimulus is applied either externally (via oven) and locally (via resistive heating). The expansion of TEPs is confirmed by optical microscopy. The most effective DoD response occurs in specimens with modified substrates without TEP, attributed to significant softening of the adhesive above its glass transition temperature. Specimens with both structural adhesive and TEP show a moderate DoD effect, though the reference strength is lower due to TEP-induced disruptions within the adhesive. Externally heated triggering of TEP yields little DoD effect. Fracture surface analysis supports these findings, showing characteristic changes consistent with adhesive softening and cohesive strength reduction. Results highlight how the incorporation of localised resistive heating elements can allow an easier recycling and reversible joining, which contrary to TEPs, can be repeated.

按需脱粘（DoD）是实现轻质复合材料结构可回收性和模块化设计的关键。这项工作研究了使用电阻加热改性基材和热膨胀颗粒（TEPs）在结构粘合剂粘合上的DoD机制的有效性。甲基丙烯酸甲酯粘合剂应用于真空注入热塑性玻璃钢层压板与Elium©丙烯酸基体。表征包括热成像、DSC、剪切测试和断口分析。为了实现局部热dod触发，改进的基板由集成的电阻加热元件制成。热刺激可以通过外部（通过烤箱）和局部（通过电阻加热）进行。光学显微镜证实了TEPs的膨胀。最有效的DoD响应发生在没有TEP的改性基板的样品中，这归因于粘合剂在其玻璃化转变温度以上的显着软化。含有结构粘合剂和TEP的试样均表现出中等的DoD效应，尽管由于TEP引起的粘合剂内部破坏，参考强度较低。外部加热触发TEP产生很少的DoD效应。断口表面分析支持这些发现，显示出与粘合剂软化和内聚强度降低一致的特征变化。结果突出了局部电阻加热元件的结合如何允许更容易的回收和可逆连接，这与TEPs相反，可以重复。

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引用次数: 0

Residual strain and strain evolution of dissimilar aluminium-steel friction stir lap welding during lap shear tests 异种铝-钢搅拌摩擦搭接在搭接剪切试验中的残余应变及应变演化

IF 4 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-12-01 DOI: 10.1016/j.jajp.2025.100362

Sergio R. Soria , Florencia Malamud , Markus Strobl , Leonardo N. Tufaro , Hernán G. Svoboda

Friction Stir Lap Welding (FSLW) is a technique used to join dissimilar materials, such as aluminium alloys and steel sheets, applied in the automotive industry. The residual strain distribution generated during the process, strongly affects the mechanical performance and long-term durability of the welded components. In this study, the residual strains generated during FSLW of aluminium alloy and steel sheets were investigated using Bragg edge neutron imaging (BEI). Different combinations of thin aluminium alloy and steel sheets with thicknesses between 0.8 mm and 2 mm were analysed. 5052 and 5182 alloys, in combination with AISI 1010 carbon steel and dual phase (DP) 1000 steel were employed. Additionally, the evolution of the actual strain under lap shear tests was monitored. The presence of the steel inclusions was detected by neutron transmission imaging. The BEI results showed tensile residual strain along the longitudinal direction in the steel sheets after the welding process, in all cases displaying a M-shaped strain field. During the lap shear tests, a reduction of the actual tensile strains was observed due to the lateral contraction produced in the mechanical testing.

搅拌摩擦搭接焊（FSLW）是一种用于连接不同材料，如铝合金和钢板的技术，应用于汽车工业。焊接过程中产生的残余应变分布严重影响焊接构件的力学性能和长期耐久性。本文采用Bragg边缘中子成像（BEI）对铝合金和钢板在FSLW过程中产生的残余应变进行了研究。分析了薄铝合金与厚度在0.8 ~ 2mm之间的钢板的不同组合。采用5052和5182合金，结合AISI 1010碳钢和双相（DP） 1000钢。此外，还监测了搭接剪切试验下实际应变的演变。用中子透射成像检测了钢夹杂物的存在。BEI结果显示，焊接后钢板的拉伸残余应变沿纵向分布，均呈现m型应变场。在搭接剪切试验期间，由于力学试验中产生的侧向收缩，观察到实际拉伸应变的减少。

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引用次数: 0

Investigation of the weld characteristics of AA6016-T4 friction stitch welds in overlap configuration and the influence of stitch length on static and fatigue strength 研究了AA6016-T4摩擦缝焊缝重叠结构的焊接特性及缝长对静强度和疲劳强度的影响

IF 4 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-12-01 DOI: 10.1016/j.jajp.2025.100363

Dominik Walz, Stefan Weihe, Martin Werz

High-strength, age-hardenable aluminum alloys in car body construction challenge conventional joining methods — especially in mixed-material body structures, as fusion welding is prone to hot cracking and to hydrogen porosity. As a solid-state process, friction stir welding circumvents these challenges and typically produces joints with a higher strength than fusion welding, particularly in high-strength aluminum alloys. While friction stir spot welding guns are commercially available, the joints produced with them exhibit significantly lower strength compared to linear welds. To address this issue, a friction stir welding gun capable of producing short stitch welds was developed for a possible application in car body manufacturing.

This work investigates friction stitch welds in AA6016-T4 sheet overlap joints and quantifies how the stitch length influences static strength, fatigue performance, hardness, and microstructure, compared to a continuous friction stir welded (FSW) joint. Short stitch welds obtained the highest lap-shear strength, achieving up to 83% joint efficiency, while longer welds reached between 65% and 68%. Metallography confirmed overlap-specific features, such as cold-lap imperfections in the weld, and showed that tool reentry can locally fragment the oxide line and diminish cold-lap severity, improving static strength. The fatigue performance of the stitch welds was lower than that of the strongest static condition, with short stitches particularly susceptible to notch effects due to overlap-specific features and reentry-related porosity. In general, intersecting stitch welds can surpass continuous FSW in static strength, but fatigue optimization will require mitigating the severity of the cold lap and reentry imperfections, for example, through adapted tool and pin designs.

汽车车身结构中的高强度、可时效硬化铝合金挑战了传统的连接方法，特别是在混合材料车身结构中，因为熔焊容易产生热裂和氢孔隙。作为一种固态工艺，搅拌摩擦焊接避免了这些挑战，并且通常产生比熔焊更高强度的接头，特别是在高强度铝合金中。虽然搅拌摩擦点焊枪是市售的，但与直线焊接相比，用它们生产的接头强度明显较低。为了解决这一问题，开发了一种能够产生短缝焊缝的搅拌摩擦焊枪，有望在汽车车身制造中得到应用。本文研究了AA6016-T4板重叠接头的摩擦缝焊接，并量化了与连续搅拌摩擦焊（FSW）接头相比，摩擦缝长度对静态强度、疲劳性能、硬度和微观结构的影响。短缝焊缝获得了最高的搭接剪切强度，接头效率高达83%，而长缝焊缝的接头效率在65%至68%之间。金相图证实了重叠的特定特征，例如焊缝中的冷搭缺陷，并表明工具再入可以局部破坏氧化线，降低冷搭的严重程度，提高静态强度。缝焊缝的疲劳性能低于最强静态条件下的疲劳性能，由于重叠的特定特征和与再入孔相关的孔隙率，短缝焊缝特别容易受到缺口效应的影响。一般来说，交叉缝焊缝的静态强度可以超过连续FSW，但疲劳优化需要减轻冷搭接和再入缺陷的严重程度，例如，通过调整工具和销的设计。

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引用次数: 0

Modeling and simulation of inertia and continuous drive friction welding of AISI 1215 steel AISI 1215钢惯性与连续驱动摩擦焊接的建模与仿真

IF 4 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-12-01 DOI: 10.1016/j.jajp.2025.100360

Carina Vauderwange , Dirk Lindenau , Heinz Palkowski , Hadi Mozaffari Jovein

To accurately simulate rotary friction welding (RFW), calibration of the material model and friction conditions is essential. This study focuses on developing a material model and simulation for RFW of AISI 1215 free-machining steel in the environment “virtua RFW”. Inertia (IFW) and continuous drive friction welding (CDFW) were physically performed with comparable energy inputs to calibrate the simulation. The aim of this study is to examine the calibration procedure in detail and subsequently perform a simulation-based process comparison of IFW and CDFW. For calibration, four material and friction factors were varied in an L16 Taguchi array. Different methods for evaluating simulation quality were assessed. Upset deviation and flash angle α measurement via image processing were determined to be the most suitable methods for evaluating the alignment between simulation and real welds. Optimal simulation parameters were identified for IFW, closely matching experimental results. Due to the velocity and pressure dependence of the friction behavior, a direct transfer of parameters to CDFW was not possible, requiring adjustments and regression analysis for accurate prediction. Optimized simulations showed differences in the thermomechanical behavior: IFW exhibited a steeper temperature gradient with a minimum cooling time t8/5 of 2.5 s and a double-wedge shape in the affected zone, while CDFW showed a broader, more uniform zone with a minimum cooling time t8/5 of 3 s. These findings improve the understanding of IFW and CDFW and provide calibrated simulation models that could facilitate more efficient process development.

为了准确地模拟旋转摩擦焊接（RFW），材料模型和摩擦条件的校准至关重要。本研究的重点是建立AISI 1215自由加工钢在“虚拟RFW”环境下的材料模型和RFW仿真。惯性焊接（IFW）和连续驱动摩擦焊接（CDFW）在物理上进行了比较的能量输入，以校准模拟。本研究的目的是详细检查校准程序，并随后对IFW和CDFW进行基于模拟的过程比较。为了校准，在L16田口阵列中改变了四种材料和摩擦因素。对不同的仿真质量评价方法进行了评价。通过图像处理确定了镦粗偏差和闪光角α是评价模拟焊缝与实际焊缝对中程度的最合适方法。确定了IFW的最优仿真参数，与实验结果吻合较好。由于摩擦行为依赖于速度和压力，因此不可能将参数直接传递到CDFW，需要进行调整和回归分析才能准确预测。优化后的模拟结果显示了热力学行为的差异：IFW表现出更陡的温度梯度，最小冷却时间为2.5 s，影响区呈双楔状，而CDFW表现出更宽、更均匀的区域，最小冷却时间为3 s。这些发现提高了对IFW和CDFW的理解，并提供了校准的模拟模型，可以促进更有效的工艺开发。

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引用次数: 0