Journal of Advanced Joining Processes最新文献_第7页

The Influence of temperature on the microstructure and properties of Cu/Al tube joints in magnetic pulse-assisted semi-solid brazing 温度对磁脉冲辅助半固态钎焊Cu/Al管接头组织和性能的影响

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-05-16 DOI: 10.1016/j.jajp.2025.100313

Zhenglei Rui , Shangyu Huang , Huajun Wang , Zhenghua Meng

This study addresses the technical challenge of copper/aluminum (Cu/Al) tube joining through the innovative application of magnetic pulse-assisted semi-solid brazing (MPASSB) technology. Through an integrated approach combining finite element simulation with microstructural characterization, this study systematically investigates how brazing temperature (390–440 °C) influences the microstructure and mechanical properties of Cu/Al tube joints. Notably, a novel finite element method-smoothed particle hydrodynamics (FEM-SPH) coupling model has been developed. This model enables precise simulation of fluid-solid interactions between tubes and filler metal during the brazing process, providing fresh insights into oxide layer removal mechanisms. The research reveals that brazing temperature serves as the critical parameter governing the elemental diffusion and microstructural evolution in the joint. As the temperature increases from 390 °C to 440 °C, the viscosity coefficient of the filler metal decreases significantly from 41.6Pa·s to 1.798Pa·s, resulting in enhanced fluidity that promotes interfacial interactions between the tubes and filler metal and effectively removes surface oxide films, thus improving joint quality. However, excessive temperature intensifies the filler metal ejection, increasing the risk of filler metal deficiency at the top of the joint. Mechanical testing demonstrates that joints brazed at 440 °C achieve optimal shear strength of 81.1 MPa, with fracture occurring at the copper-side (Cu-side) interface between the Al_4.2Cu_3.2Zn_0.7 intermetallic phase and the diffusion layer. This work establishes fundamental theoretical guidance for optimizing MPASSB process parameters and facilitates the efficient joining of Cu/Al tubes.

本研究通过磁脉冲辅助半固态钎焊（MPASSB）技术的创新应用，解决了铜/铝（Cu/Al）管连接的技术挑战。本研究采用有限元模拟与微观组织表征相结合的方法，系统研究了钎焊温度（390 ~ 440℃）对Cu/Al管接头微观组织和力学性能的影响。值得注意的是，本文提出了一种新的有限元方法-光滑颗粒流体动力学（FEM-SPH）耦合模型。该模型能够精确模拟钎焊过程中管道和填充金属之间的流固相互作用，为氧化层去除机制提供新的见解。研究表明，钎焊温度是控制接头中元素扩散和组织演变的关键参数。随着温度从390℃升高到440℃，填料金属的粘度系数从41.6Pa·s显著降低到1.798Pa·s，流动性增强，促进了管材与填料金属之间的界面相互作用，有效去除表面氧化膜，提高了接头质量。然而，过高的温度加剧了填充金属的喷出，增加了接头顶部填充金属不足的风险。力学试验结果表明，440℃钎焊接头抗剪强度为81.1 MPa，断裂发生在Al4.2Cu3.2Zn0.7金属间相与扩散层之间的铜侧（cu侧）界面。该工作为优化MPASSB工艺参数提供了基础理论指导，促进了Cu/Al管的高效连接。

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引用次数: 0

Heat treatment optimisation of 18 % Ni maraging steel produced by DED-ARC for enhancing mechanical properties 为提高机械性能，对氩弧焊18% Ni马氏体时效钢进行热处理优化

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-05-16 DOI: 10.1016/j.jajp.2025.100312

Maja Lindič , Damjan Klobčar , Aleš Nagode , Nikolaj Mole , Borut Žužek , Tomaž Vuherer

This article deals with the Directed Energy Deposition using Wire and Arc (DED-ARC) for maraging steel cladding. A technology for cladding using Gas Metal Arc Welding (GMAW) has been developed that enables the perfect deposition of maraging steel. The material characterisation was carried out in different material states: in the as-built, solution annealed and aged. The research included visual examinations, optical microscopy, Scanning Electron Microscopy / Energy-dispersive X-ray spectroscopy (SEM/EDS), fractography, hardness testing, tensile testing and impact toughness testing. The as-deposited state exhibited a microstructure with very long crystal grains and microsegregations orientated the direction of the heat sink, consisting of lath martensite. Consequently, a subsequent heat treatment is absolutely necessary in order to obtain a uniform fine-grained microstructure. Two different solution annealing processes were analysed, which allowed us to select the most suitable process for the first step of heat treatment followed by aging. A response surface methodology was used to optimise the aging conditions. The results show that additively manufactured maraging steel reaches a tensile strength of 1947 MPa, a hardness of 657 HV5 and a Charpy impact toughness of 11 J at peak aging condition, which is comparable to conventionally manufactured maraging steel.

本文研究了金属丝电弧定向能沉积法（ed - Arc）在马氏体时效钢包层中的应用。研究了一种采用气体保护金属弧焊（GMAW）的熔覆技术，使马氏体时效钢得到完美的熔覆。在不同的材料状态下进行了材料表征：在建成时，溶液退火和时效。研究包括目视检查、光学显微镜、扫描电子显微镜/能量色散x射线能谱（SEM/EDS）、断口分析、硬度测试、拉伸测试和冲击韧性测试。沉积态的显微组织为板条马氏体，晶粒极长，微偏析取向于热沉方向。因此，为了获得均匀的细晶组织，随后的热处理是绝对必要的。分析了两种不同的固溶退火工艺，从而选择了最合适的工艺进行第一步热处理，然后进行时效处理。采用响应面法对老化条件进行优化。结果表明：在峰值时效状态下，添加剂制备的马氏体时效钢的抗拉强度为1947 MPa，硬度为657 HV5，夏比冲击韧性为11 J，与常规制备的马氏体时效钢相当。

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引用次数: 0

Controlling debond on demand performance in adhesive systems using structurally tuned expandable graphite fillers 用结构调整的可膨胀石墨填料控制粘接系统的按需脱粘性能

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-05-14 DOI: 10.1016/j.jajp.2025.100309

O Kachouri, J Bardon, D Ruch, A Laachachi

The emergence of debonding technologies has enabled adhesive systems to better align with the principles of sustainability and the circular economy by addressing the gap between the end-of-life stage of adhesively bonded products and the potential for component reuse. In this context, the present study explores the application of thermally responsive additives to induce controlled debonding in adhesive joints. In our previous investigations, it was shown that integrating various types of flame retardants (intumescent and non-intumescent) significantly reduced the debonding temperature, by altering the thermomechanical properties of the joint at temperatures substantially lower than the degradation onset of the unmodified adhesive system. Expandable graphite (EG), a thermally responsive material, has previously been employed with success for similar purposes. Its incorporation into the adhesive layer, even in trace amounts, results in a very significant expansion upon the application of heat, thereby providing an effective mechanism for disassembling adhesively bonded structural assemblies. The present study builds on this prior research and probes deeper into the manufacturing processes underlying EG. The primary hypothesis explored is whether tailoring these processes can result in modulating the thermal response of adhesives modified by EG, thereby achieving debonding at distinct temperature ranges suitable for a wide spectrum of applications. This study investigates EG-modified adhesives, assessing their mechanical properties, thermomechanical degradation, and microstructural changes using characterization techniques such as pull-off tests, microtomography, TGA, and DMA. Finally, the recycling potential is demonstrated through the successful reuse of debonded substrates after a simple cleaning process.

脱粘技术的出现，通过解决粘接产品生命周期结束阶段与组件再利用潜力之间的差距，使粘接系统更好地符合可持续性和循环经济原则。在此背景下，本研究探讨了热响应性添加剂在粘合接头中诱导可控脱粘的应用。在我们之前的研究中，我们已经表明，整合各种类型的阻燃剂（膨胀型和非膨胀型）可以显著降低脱粘温度，这是通过改变接头的热机械性能来实现的，其温度大大低于未改性粘合剂系统的降解温度。可膨胀石墨（EG）是一种热响应材料，以前曾成功用于类似目的。将其掺入粘合层，即使是微量的，也会在加热时产生非常显著的膨胀，从而为粘合结构组件的拆卸提供了有效的机制。本研究建立在先前研究的基础上，并深入探讨了EG的制造过程。研究的主要假设是，调整这些过程是否可以调节EG改性胶粘剂的热反应，从而在适合广泛应用的不同温度范围内实现脱粘。本研究研究了eg改性胶粘剂，利用表征技术，如拉伸测试、显微断层扫描、TGA和DMA，评估了它们的机械性能、热机械降解和微观结构变化。最后，通过简单的清洗过程后成功地重复使用脱粘基材，证明了回收潜力。

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引用次数: 0

Tailoring flux composition to control welding fume and hexavalent chromium emissions in flux cored arc welding 调整焊剂成分以控制焊剂芯弧焊中的焊烟和六价铬排放

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-05-12 DOI: 10.1016/j.jajp.2025.100311

Sungyo Jung , Gi Taek Oh , Seungjin Jung , Chungsik Yoon

Flux-cored arc welding (FCAW) generates hazardous byproducts such as welding fumes and hexavalent chromium (Cr(VI)), posing significant health and environmental risks. This study investigated the effectiveness of modifying specific flux components in flux-cored wires (FCWs) to reduce these emissions. One base FCW and ten flux-modified FCWs were tested under controlled conditions, capturing emissions for gravimetric and Cr(VI) analysis. Flux compositions were determined using X-ray fluorescence. Statistical analyses, including difference tests, correlation, and multiple linear regression, were conducted to evaluate the association between the content of flux components and emission rates. Sodium (Na) content in the flux was positively associated with increased emission of welding fumes and Cr(VI), while titanium (Ti) content showed a negative association. Increasing the contents of fluorine (F), potassium (K), and chromium (Cr) in the flux raised welding fume emission but reduced Cr(VI) emissions. Strategic adjustments in flux composition, specifically increasing Ti, silicon (Si) and zirconium (Zr) while decreasing Cr, K, Na, and F content, significantly reduced welding fume emissions by up to 32.4 % and Cr(VI) emissions by 95.4 %. These findings suggest that tailoring flux composition can effectively mitigate occupational and environmental hazards, enhance welder safety, and promote more sustainable FCAW practices without compromising welding performance.

药芯弧焊（FCAW）产生有害的副产品，如焊接烟雾和六价铬（Cr(VI)），构成重大的健康和环境风险。本研究探讨了改性药芯焊丝（FCWs）中特定助焊剂成分以减少这些排放的有效性。在受控条件下测试了一种碱性FCW和十种改性FCW，捕获排放物进行重量和Cr（VI）分析。用x射线荧光测定通量组成。采用差异检验、相关分析和多元线性回归等统计分析方法对通量组分含量与排放率之间的关系进行了评价。助焊剂中钠（Na）含量与焊烟和铬（VI）排放量的增加呈正相关，钛（Ti）含量呈负相关。增加焊剂中氟(F)、钾(K)和铬（Cr）的含量，提高了焊烟排放，但降低了Cr（VI）排放。对焊剂成分进行战略性调整，特别是增加Ti、硅（Si）和锆（Zr），同时降低Cr、K、Na和F含量，可显著降低焊接烟尘排放量达32.4%，降低Cr（VI）排放量达95.4%。这些发现表明，调整焊剂成分可以有效地减轻职业和环境危害，提高焊工的安全性，并在不影响焊接性能的情况下促进更可持续的FCAW实践。

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引用次数: 0

Enhancing mechanical properties and isotropy in ultrasonic assisted powder bed fusion of metals using a laser beam (PBF-LB/M) via Dual Exposure 双曝光激光增强超声辅助粉末床金属熔合的力学性能和各向同性

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-05-09 DOI: 10.1016/j.jajp.2025.100307

Sebastian Platt , Jan Wegner , Arno Elspaß , Hanna Schönrath , Stefan Kleszczynski

Parts produced via powder bed fusion of metal using a laser beam process often exhibit mechanical anisotropy due to the directional solidification, complicating part design. This study explores the use of ultrasonic-assistance to reduce anisotropy by promoting microstructural homogenization through increased nucleation. Specimens were fabricated using a dual exposure strategy, to avoid the challenges that arise with the in-situ ultrasonic excitation of a powder bed. Furthermore, a comprehensive microstructural as well as mechanical analysis was carried out. Microstructural analysis revealed increased grain orientation variation in ultrasonically treated specimens. Mechanical testing showed improved tensile and yield strength and reduced anisotropy, with tensile and yield strength anisotropy decreasing by 55.4 % and 46.1 %, respectively. Despite increased surface roughness, ultrasonic treatment reduced anisotropy in ductility-related properties, highlighting its potential to improve the performance of additively manufactured parts by reducing anisotropy and simultaneously enhancing mechanical properties.

由于定向凝固，使用激光束工艺通过粉末床熔化金属生产的零件往往表现出机械各向异性，使零件设计复杂化。本研究探索利用超声辅助通过增加成核来促进微观结构均质化，从而降低各向异性。采用双曝光策略制备样品，以避免粉末床原位超声激励所带来的挑战。此外，还进行了全面的显微组织和力学分析。显微组织分析显示，超声处理后的样品晶粒取向变化增加。力学试验结果表明，抗拉强度和屈服强度各向异性得到改善，抗拉强度和屈服强度各向异性分别降低55.4%和46.1%。尽管表面粗糙度增加，但超声处理降低了延性相关性能的各向异性，突出了其通过减少各向异性同时提高机械性能来改善增材制造零件性能的潜力。

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引用次数: 0

Relationship between the developed interfacial area ratio and the adhesion of the bonded joint 发育界面面积比与粘结接头附着力的关系

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-05-09 DOI: 10.1016/j.jajp.2025.100310

Benjámin Márk Körömi , Zoltán Weltsch , Miklós Berczeli

Bonding technologies have evolved significantly over the past decades, playing a crucial role in the field of joining technologies. To date, however, there is no consensus among research groups as to whether surface texture or surface wettability, or both, affect the strength of bonded joints. Bonded joints, as a bonding technique, are highly dependent on the chemical composition of the adhesive or binder. It is also important to note that the strength and the quality of a bonded joint is greatly influenced by surface adhesion and its related phenomena. From a materials science perspective, surface adhesion is characterised by the level of surface wetting and the total surface energy. In addition, microtopographies and other geometrical features play a key role in bond formation. In this research, the goal is to create controlled microtopographies on DP600 steel surfaces, mainly using femtosecond pulsed laser surface treatment techniques. The ability of adhesives to fill microtopographies specifically, the extent and manner in which micro-scale geometries and structures are filled is also investigated. This allows for the establishment of correlations between the strength of adhesive bonds and the shape characteristics of the microtopography, both in the surface-activated and non-surface-activated states.

在过去的几十年里，焊接技术得到了长足的发展，在焊接技术领域发挥着至关重要的作用。然而，到目前为止，对于表面纹理或表面润湿性，或两者都影响粘接接头的强度，研究小组尚未达成共识。粘结接头作为一种粘结技术，高度依赖于胶粘剂或粘结剂的化学成分。同样重要的是要注意，粘结接头的强度和质量在很大程度上受到表面粘附及其相关现象的影响。从材料科学的角度来看，表面粘附的特征是表面湿润程度和总表面能。此外，微观形貌和其他几何特征在键的形成中起着关键作用。在本研究中，主要使用飞秒脉冲激光表面处理技术，在DP600钢表面上创建可控的微形貌。粘接剂填充微地形的能力，以及微尺度几何形状和结构填充的程度和方式也进行了研究。这允许在表面激活和非表面激活状态下建立粘合剂强度和微形貌形状特征之间的相关性。

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引用次数: 0

Optimizing microstructure and performance: The impact of pre-deformation and rotational speed on friction stir processed Cu-W composites 优化组织和性能：预变形和转速对搅拌摩擦加工Cu-W复合材料的影响

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-05-05 DOI: 10.1016/j.jajp.2025.100308

Masoomeh Oliaei, Roohollah Jamaati, Hamed Jamshidi Aval

This study investigated the effects of pre-deformation induced by asymmetric rolling on copper-based metal, as well as rotational speed during friction stir processing, on the microstructure, mechanical properties, and electrical conductivity of tungsten-reinforced copper matrix composites. The results show that increasing the rotational speed up to 800 rpm leads to a more uniform distribution of tungsten particles within the stir zone. However, at rotational speeds above 800 rpm, the distribution of tungsten reinforcing particles becomes less uniform. The accumulated strain in the stir zone increases from 0.3056 to 0.3967 s^-1 as the rotational speed rises from 600 to 1200 rpm. Additionally, as the tool rotational speed increases from 600 to 1200 rpm, the grain size in the stir zone grows from 6.2 ± 0.7 to 13.2 ± 1.5 µm. The Cu-W composite processed at a tool rotational speed of 800 rpm achieves the highest values in hardness (124.9 ± 8.9 HV0.1), ultimate tensile strength (307.4 ± 11.8 MPa), tensile toughness (92.1 ± 1.1 MJ/m³), and electrical conductivity (92.8 ± 1.3 %IACS). Compared to the as-rolled copper-based metal, the electrical conductivity of the Cu-W composite fabricated at 800 rpm increases by 8.8 %.

研究了不对称轧制对铜基金属的预变形以及搅拌摩擦过程中的转速对钨增强铜基复合材料显微组织、力学性能和电导率的影响。结果表明，当转速提高到800 rpm时，搅拌区内钨颗粒的分布更加均匀。然而，当转速超过800转/分时，增强钨颗粒的分布变得不均匀。当转速从600转/分增加到1200转/分时，搅拌区累积应变从0.3056 s-1增加到0.3967 s-1。此外，当刀具转速从600转/分增加到1200转/分时，搅拌区的晶粒尺寸从6.2±0.7µm增加到13.2±1.5µm。当刀具转速为800 rpm时，Cu-W复合材料的硬度（124.9±8.9 HV0.1）、抗拉强度（307.4±11.8 MPa）、抗拉韧性（92.1±1.1 MJ/m3）和电导率（92.8±1.3% IACS）均达到最高值。与轧制时的铜基金属相比，在800转/分下制备的Cu-W复合材料的电导率提高了8.8%。

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引用次数: 0

Friction stir processing of AA1050/AA5052 composite produced by accumulative roll bonding process: Microstructure and mechanical properties 累积轧制复合材料AA1050/AA5052的搅拌摩擦加工：显微组织与力学性能

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-04-30 DOI: 10.1016/j.jajp.2025.100306

Hamid Partoyar , Hamid Reza Jafarian , Hamed Roghani , Ahad Mohammadzadeh , Akbar Heidarzadeh

A layered composite of AA1050-AA5052 alloys was fabricated through roll bonding, and accumulative roll bonding (ARB) and subsequently subjected to friction stir processing (FSP). In this process, the annealed AA5052 and AA1050 sheets are used as raw materials. At first, preheating at 200 °C for 6 min preceded the rolling process in an induction furnace, achieving a 67 % reduction in the cross-sectional area. Then, two ARB stages were conducted. At the flow, the FSP process was conducted at constant transversal speeds of 750 rpm and 1180 rpm. Microstructural details were analyzed using optical microscopy (OM), scanning electron microscopy (SEM), and electron backscatter diffraction (EBSD). Mechanical properties were assessed through tensile test, microhardness measurement, and wear test. The results showed that recrystallization occurred due to FSP applied to the rolled sheet. The tensile strength after ARB and FSP was measured as 270 and 150 MPa, respectively. These values show an increase of 3.3 times and 1.8 times, respectively, compared to annealed AA1050. The maximum elongation after ARB and FSP was measured at about 9 and 30 %. Work hardening and grain refinement, respectively, had a significant role in increasing the elongation of the AA1050/AA5052 composites created by ARB and FSP. Furthermore, FSP enhanced the wear resistance of the AA1050-AA5052 composite created with two ARB steps by 70 %.

通过轧制结合和累积轧制结合（ARB）制备了AA1050-AA5052合金层状复合材料，并进行了搅拌摩擦处理（FSP）。本工艺以退火后的AA5052和AA1050板材为原料。首先，在感应炉中进行轧制过程之前，在200°C下预热6分钟，使截面积减少67%。然后进行了两个ARB阶段。在流动中，FSP过程以恒定的横向速度750 rpm和1180 rpm进行。利用光学显微镜（OM）、扫描电镜（SEM）和电子背散射衍射（EBSD）分析了显微结构细节。通过拉伸测试、显微硬度测试和磨损测试来评估机械性能。结果表明，FSP对轧制薄板产生了再结晶。经ARB和FSP处理后的拉伸强度分别为270和150 MPa。与退火后的AA1050相比，这些数值分别增加了3.3倍和1.8倍。经ARB和FSP处理后的最大伸长率分别为9%和30%。加工硬化和晶粒细化分别对ARB和FSP制备的AA1050/AA5052复合材料的伸长率有显著提高作用。此外，FSP使两步ARB合成的AA1050-AA5052复合材料的耐磨性提高了70%。

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引用次数: 0

High-brightness laser welding with beam wobbling: Achieving high-strength Al/Steel joints for battery busbars 高亮度光束摆动激光焊接：实现电池母线的高强度铝/钢接头

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-04-28 DOI: 10.1016/j.jajp.2025.100305

M Chelladurai Asirvatham , Iain Masters , Geoff West , Paul Haney

Laser welding of aluminium tabs to nickel-plated interstitial-free (IF) steel was investigated using a high-brightness, single-mode laser with beam wobbling. The influence of interaction time, controlled by wobble amplitude and traverse speed, regulating energy distribution on weld microstructure and mechanical properties was systematically studied. Short interaction times (<25 µs) and large inter-wobble distances (>150 µm) minimized intermetallic compound (IMC) formation and maximized weld strength. Optimizing these parameters (wider wobble amplitudes of 0.6–0.8 mm and faster speeds of 75–100 mm/s) suppressed IMC-induced cracking, resulting in microstructures containing Fe-rich IMCs and Al-Fe₄Al₁₃ eutectic phases. Conversely, lower wobble amplitudes (<0.6 mm) and slower speeds (50–75 mm/s) promoted crack-prone Al-rich Fe₂Al₅ phases. Optimized welds exhibited excellent fatigue performance, withstanding 1 million cycles at 175 N, demonstrating the potential for using lighter, cost-effective aluminium busbars in battery interconnect applications.

采用高亮度、单模光束摆动激光器，研究了铝片与镀镍无间隙钢的激光焊接。系统研究了由摆动幅度和横移速度控制的相互作用时间、调节能量分布对焊缝组织和力学性能的影响。较短的相互作用时间（<25µs）和较大的摆动距离（>150µm）最大限度地减少了金属间化合物（IMC）的形成，最大限度地提高了焊接强度。优化这些参数（更宽的摆动幅度为0.6-0.8 mm，更快的速度为75-100 mm/s）抑制了imc引起的开裂，导致微观结构中含有富铁imc和Al- fe₄Al₁₃共晶相。相反，较低的摆动幅度（<0.6 mm）和较慢的速度（50-75 mm/s）促进了容易破裂的富Al Fe₂Al₅相。优化后的焊缝具有优异的疲劳性能，可承受175 N的100万次循环，这表明在电池互连应用中使用更轻、更具成本效益的铝母线的潜力。

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引用次数: 0

Deep learning-driven active sheet positioning using linear actuators in laser beam butt welding of thin steel sheets 基于线性执行器的深度学习驱动薄板主动定位在薄板激光对焊中的应用

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-04-22 DOI: 10.1016/j.jajp.2025.100303

Dominik Walther , Leander Schmidt , Timo Räth , Klaus Schricker , Jean Pierre Bergmann , Kai-Uwe Sattler , Patrick Mäder

Welding thin steel sheets in industrial applications is difficult because joint gaps occur during the process, which can lead to weld interruptions. Such welds are considered a reject and in order to avoid the weld to interrupt it is crucial to hinder the formation of joint gaps. Especially laser beam welding is affected by the emergence of gaps. Due to the narrow laser spot, product quality is highly dependent on the alignment and positioning of the sheets. This is typically done by clamping devices, which hold the workpieces in place. However, these clamps are suited for a specific workpiece geometry and require manual redesign every time the process changes. Adaptive clamping devices instead are designed to realize a time-dependent workpiece adjustment. Modeling the joint gap behavior to realize a controller for adaptive clamps can be difficult as the influence of heating, melting, and cooling on the joint gap formation is unknown and varies due to temperature dependent physical properties. Instead, the control parameters and actions can be derived using data-driven methods. In this paper, we present a novel data-driven approach how deep learning can be utilized to manipulate the sheet position during the weld with two actuators that apply force. A temporal convolution neural network (TCN) analyzes the change of the joint gap and predicts the required force to adapt the workpiece position. The developed method has been integrated into the welding process and improves the length of the average weld seam by 39.5% compared to welds without an active adjustment and 1.4% to welds that have been adapted with a constant force.

在工业应用中，焊接薄钢板是困难的，因为在焊接过程中会出现接头间隙，这可能导致焊接中断。这样的焊缝被认为是不合格的，为了避免焊缝中断，阻止接头间隙的形成是至关重要的。特别是激光束焊接受到缝隙出现的影响。由于激光光斑窄，产品质量高度依赖于板材的对准和定位。这通常是通过夹紧装置完成的，夹紧装置将工件固定在适当的位置。然而，这些夹具适合于特定的工件几何形状，并且每次工艺变化时都需要手动重新设计。而设计自适应夹紧装置是为了实现随时间变化的工件调整。由于加热、熔化和冷却对接头间隙形成的影响是未知的，并且由于温度依赖的物理性质而变化，因此对接头间隙行为建模以实现自适应夹具的控制器可能是困难的。相反，可以使用数据驱动的方法派生控制参数和动作。在本文中，我们提出了一种新颖的数据驱动方法，如何利用深度学习来操纵两个施加力的执行器在焊接过程中的薄片位置。时间卷积神经网络（TCN）分析了关节间隙的变化，并预测了适应工件位置所需的力。所开发的方法已集成到焊接过程中，与不进行主动调整的焊接相比，平均焊缝长度提高了39.5%，与采用恒定力的焊接相比，平均焊缝长度提高了1.4%。

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引用次数: 0