变极性等离子弧焊电弧物理特性的数值模拟

doi:10.11900/0412.1961.2016.00263

金属学报

2017, Vol. 53

Issue (5): 631-640 DOI: 10.11900/0412.1961.2016.00263

论文

本期目录 | 过刊浏览

变极性等离子弧焊电弧物理特性的数值模拟

陈树君,徐斌,蒋凡(

)

北京工业大学机电学院汽车结构部件先进制造技术教育部工程研究中心北京100124

Numerical Simulation of Physical Characteristics of Variable Polarity Plasma Arc Welding

Shujun CHEN,Bin XU,Fan JIANG(

)

Engineering Research Center of Advanced Manufacturing Technology for Automotive Components, Ministry of Education, Beijing University of Technology, Beijing 100124, China

引用本文:

陈树君,徐斌,蒋凡. 变极性等离子弧焊电弧物理特性的数值模拟[J]. 金属学报, 2017, 53(5): 631-640.
Shujun CHEN, Bin XU, Fan JIANG. Numerical Simulation of Physical Characteristics of Variable Polarity Plasma Arc Welding[J]. Acta Metall Sin, 2017, 53(5): 631-640.

全文: PDF(3720 KB) HTML

摘要:

基于磁流体动力学及Maxwell方程组,建立了变极性等离子电弧的三维瞬态计算模型,依据变极性等离子弧焊对铝合金板材穿孔焊接过程的物理特性,提出了随电弧极性变化的分时导电模型,通过计算得到了变极性等离子电弧的温度场、流场、电流密度和电弧压力的分布情况,以及电弧压力随时间的变化过程。通过实验测量了工件表面电弧中心压力,得到了不同极性时的电弧形态。结果表明：相同电流条件下,正极性时电弧温度场分布比反极性时更加分散,但正极性时电弧最高温度范围小于反极性时;反极性电弧压力和电流密度在电弧中心处均大于正极性,在径向距电弧中心一定距离处,2种极性时的电弧压力和电流密度的大小出现反转;电弧压力对焊接电流响应迅速,正极性电弧压力小于反极性电弧压力,焊接电流过零时,电弧压力会降低到较低的值,电流增加时电弧压力变化存在“过冲”现象;对实验与计算得到的变极性等离子电弧正反极性时电弧图像和工件表面电弧中心压力进行了对比,结果吻合良好。

关键词 ：变极性等离子电弧, 三维模型, 数值模拟

Abstract：

Variable polarity plasma arc (VPPA) is a kind of source to provide heat and force at welding process. It can remove the oxide layer with high melting point on the surface of base metal using the cleaning action of cathode spots (the special property of VPPA). So variable polarity plasma arc welding (VPPAW) is a very suitable method to join aluminum alloys which always have extremely tenacious surface oxides. It is great significant to understand clearly the physical characteristics of VPPA for predicting welding defects and making the welding process stable. Therefore, modeling and simulating VPPA are necessary and helpful to understand welding process theory and promote its application further. In this work, a three dimensional transient calculated model of VPPA was established. To describe the electrical characteristics of VPPA at different polarities, a sequential electric conducting model was proposed. With finite difference method, the temperature field, fluid flow and current density of VPPA were solved out. And the distribution of plasma arc pressure on the anode surface, as well as its evolution process as the time going on were analyzed. Arc pressure was measured experimentally to verify the calculated model. The results show that the arc temperature field of electrode negative (EN) is more compressed than that of electrode positive (EP). The range of high temperature at EN is a little larger. Arc pressure and current density of EN at central area are both higher than EP. Nonetheless, the magnitude of these values begins to reverse at a certain distance to center in radial direction. Moreover, the arc pressure rapidly responses to welding current. Pressure at EP is about 20% lower than that of EN. The pressure reduces to the lowest value when the current pass through 0. After that, while the current reaches to normal value, the pressure will immediately impact to a larger value, then quickly recover to an average value. Otherwise, to compare the experimental results with calculated results of arc images and arc pressure, they are in good agreement with each other.

Key words： variable polarity plasma arc three dimensional model numerical simulation

收稿日期: 2016-06-27

基金资助:国家自然科学基金项目No.51505008和国家科技重大专项项目No.2014ZX04001-171

	服务

	把本文推荐给朋友
	加入引用管理器
	E-mail Alert
	RSS
	作者相关文章
	陈树君
	徐斌
	蒋凡
44.8K

链接本文:

https://www.ams.org.cn/CN/10.11900/0412.1961.2016.00263 或 https://www.ams.org.cn/CN/Y2017/V53/I5/631

图1 变极性等离子弧压力测试及电弧图像采集系统

图2 不同极性时变极性等离子电弧示意图

图3 求解区域及边界条件

表1 边界条件

图4 不同极性时变极性等离子电弧的温度场与流场分布

图5 变极性等离子电弧径向温度分布曲线

图6 变极性等离子电弧径向压力分布

图7 变极性等离子电弧轴线上等离子体流速分布

图8 不同极性时工件表面径向电流密度分布

图9 铝合金表面焊后形貌

图10 不同极性时变极性等离子电弧图像

图11 电弧中心处电弧压力随时间的演变

[1]	Jenney C L, O'Brien A. Welding Handbook[M]. 2nd Ed., Miami: American Welding Society, 2001: 309
[2]	Nunes A C Jr, Bayless E O Jr, Jones C S III, et al. Variable polarity plasma arc welding on the space shuttle external tank[J]. Weld. J., 1984, 63: 27
[3]	Chen Q, Sun Z G, Sun J W, et al.Closed-loop control of weld penetration in keyhole plasma arc welding[J]. Trans. Nonferrous Met. Soc. China, 2004, 14: 116
[4]	Dong C L, Zhu Y F, Zhang H, et al.Study on front side arc light sensing in keyhole mode plasma arc welding[J]. China Mech. Eng., 2001, 37(3): 30
[4]	(董春林, 朱轶峰, 张慧等. 穿孔等离子弧焊正面弧光传感技术研究[J]. 机械工程学报, 2001, 37(3): 30)
[5]	Satoru S.Sensing technology for the welding process[J]. Weld. Int., 2006, 20: 183
[6]	Thornton M F.Spectroscopic determination of temperature distributions for a TIG arc[J]. J. Phys. Appl. Phys., 1993, 26D: 1432
[7]	Haidar J, Farmer A J D. Temperature measurements for high-current free-burning arcs in nitrogen[J]. J. Phys. Appl. Phys., 1993, 26D: 1224
[8]	Zhang Y M, Zhang S B, Liu Y C.A plasma cloud charge sensor for pulse keyhole process control[J]. Meas. Sci. Technol., 2001, 12: 1365
[9]	Fanara C.Sweeping electrostatic probes in atmospheric pressure arc plasmas——Part II: Temperature determination[J]. IEEE Trans. Plasma Sci., 2005, 33: 1082
[10]	Chen S J, Jiang F, Lu Z Y, et al.Measurement and analysis of the welding arc current density and pressure distribution based on split anode method [A]. Proceedings of International Conference on Mechatronics and Automation[C]. Beijing: IEEE, 2011: 1544
[11]	Schwedersky M B, Gon?alves e Silva R H, Dutra J C, et al. Two-dimensional arc stagnation pressure measurements for the double-electrode GTAW process[J]. Sci. Technol. Weld. Join., 2016, 21: 275
[12]	Han Y Q, Lü Y H, Chen S J, et al.Influence of variable polarity plasma arc shape on arc force[J]. Trans. China Weld. Inst., 2005, 26(5): 49
[12]	(韩永全, 吕耀辉, 陈树君等. 变极性等离子电弧形态对电弧力的影响[J]. 焊接学报, 2005, 26(5): 49)
[13]	Saad E, Wang H J, Kovacevic R.Classification of molten pool modes in variable polarity plasma arc welding based on acoustic signature[J]. J. Mater. Process. Technol., 2006, 174: 127
[14]	Wang Y W, Zhao P S.Noncontact acoustic analysis monitoring of plasma arc welding[J]. Int. J. Pressure Vessels Piping, 2001, 78: 43
[15]	Yuan X Q, Li H, Zhao T Z, et al.Study of the characteristic of D.C. arc plasma torch[J]. Acta Phys. Sin., 2004, 53: 3806
[15]	(袁行球, 李辉, 赵太泽等. 直流电弧等离子体炬的特性研究[J]. 物理学报, 2004, 53: 3806)
[16]	Tian J G, Deng J, Li Y J, et al.Numerical simulation for a free-burning argon arc with MHD model[J]. Chin. J. Theor. Appl. Mech., 2011, 43: 32
[16]	(田君国, 邓晶, 李要建等. 自由燃烧电弧的磁流体动力学数值模拟[J]. 力学学报, 2011, 43: 32)
[17]	Shi Y, Guo C B, Huang J K, et al.Numerical simulation of pulsed current tungesten inert gas (TIG) welding arc[J]. Acta Phys. Sin., 2011, 60: 048102
[17]	(石玗, 郭朝博, 黄健康等. 脉冲电流作用下TIG电弧的数值分析[J]. 物理学报, 2011, 60: 048102)
[18]	Hsu K C, Etemadi K, Pfender E.Study of the free-burning high-intensity argon arc[J]. J. Appl. Phys., 1983, 54: 1293
[19]	Hsu K C, Pfender E.Two-temperature modeling of the free-burning, high-intensity arc[J]. J. Appl. Phys., 1983, 54: 4359
[20]	Kovitya P, Lowke J J.Two-dimensional analysis of free burning arcs in argon[J] J. Phys. Appl. Phys., 2000, 18D: 53
[21]	McKelliget J, Szekely J. Heat transfer and fluid flow in the welding arc[J]. Metall. Trans., 1986, 17A: 1139
[22]	Wu C S, Ushio M, Tanaka M.Analysis of the TIG welding arc behavior[J]. Comput. Mater. Sci., 1997, 7: 308
[23]	Kim Y J, Lee J C.Numerical analysis of free-burning argon arcs based on the local thermodynamic equilibrium model at various electrical currents[J]. Thin Solid Films, 2013, 547: 28
[24]	Lago F, Gonzalez J J, Freton P, et al.A numerical modelling of an electric arc and its interaction with the anode: part III. Application to the interaction of a lightning strike and an aircraft in flight[J]. J. Phys. Appl. Phys., 2006, 39D: 2294
[25]	Blais A, Proulx P, Boulos M I.Three-dimensional numerical mode-lling of a magnetically deflected dc transferred arc in argon[J]. J. Phys. Appl. Phys., 2003, 36D: 488
[26]	Xu G, Hu J, Tsai H L.Three-dimensional modeling of the plasma arc in arc welding[J]. J. Appl. Phys., 2008, 104: 103301
[27]	Tanaka M, Terasaki H, Ushio M, et al.A unified numerical mode-ling of stationary tungsten-inert-gas welding process[J]. Metall. Mater. Trans., 2002, 33A: 2043
[28]	Tanaka M, Terasaki H, Ushio M, et al.Numerical study of a free-burning argon arc with anode melting[J]. Plasma Chem. Plasma Process., 2003, 23: 585
[29]	Tanaka M, Ushio M, Lowke J J.Numerical study of gas tungsten arc plasma with anode melting[J]. Vacuum, 2004, 73: 381
[30]	Wang X X, Fan D, Huang J K, et al.A unified model of coupled arc plasma and weld pool for double electrodes TIG welding[J]. J. Phys. Appl. Phys., 2014, 47D: 275202
[31]	Wang X X, Fan D, Huang J K, et al.Numerical simulation of coupled arc in double electrode tungsten inert gas welding[J]. Acta Phys. Sin., 2013, 62: 228101
[31]	(王新鑫, 樊丁, 黄健康等. 双钨极耦合电弧数值模拟[J]. 物理学报, 2013, 62: 228101)
[32]	Wang X X, Fan D, Huang J K, et al.Numerical simulation of heat transfer and fluid flow in double electrodes TIG arc-weld pool[J]. Acta Matall. Sin., 2015, 51: 178
[32]	(王新鑫, 樊丁, 黄健康等. 双钨极TIG电弧-熔池传热与流动数值模拟[J]. 金属学报, 2015, 51: 178)
[33]	Fan D, Huang Z C, Huang J K, et al.Three-dimensional numerical analysis of interaction between arc and pool by considering the behavior of the metal vapor in tungsten inert gas welding[J]. Acta Phys. Sin., 2015, 64: 108102
[33]	(樊丁, 黄自成, 黄健康等. 考虑金属蒸汽的钨极惰性气体保护焊电弧与熔池交互作用三维数值分析[J]. 物理学报, 2015, 64: 108102)
[34]	Lowke J J, Tanaka M.'LTE-diffusion approximation' for arc calculations[J]. J. Phys. Appl. Phys., 2006, 39D: 3634
[35]	Tashiro S, Miyata M, Tanaka M.Numerical analysis of AC tungsten inert gas welding of aluminum plate in consideration of oxide layer cleaning[J]. Thin Solid Films, 2011, 519: 7025
[36]	McKellige J, Szekely J, Vardelle M, et al. Temperature and velocity fields in a gas stream exiting a plasma torch. A mathematical model and its experimental verification[J]. Plasma Chem. Plasma Process., 1982, 2: 317
[37]	Westhoff R, Szekely J.A model of fluid, heat flow, and electromagnetic phenomena in a nontransferred arc plasma torch[J]. J. Appl. Phys., 1991, 70: 3455
[38]	Bauchire J M, Gonzalez J J, Gleizes A.Modeling of a DC plasma torch in laminar and turbulent flow[J]. Plasma Chem. Plasma Proc., 1997, 17: 409
[39]	Yin F L, Hu S S, Yu C L, et al.Computational simulation for the constricted flow of argon plasma arc[J]. Comput. Mater. Sci., 2007, 40: 389
[40]	Zhou Q H, Li H, Xu X, et al.Comparative study of turbulence models on highly constricted plasma cutting arc[J]. J. Phys. Appl. Phys., 2009, 42D: 015210
[41]	Zhou Q H, Li H, Liu F, et al.Effects of nozzle length and process parameters on highly constricted oxygen plasma cutting arc[J]. Plasma Chem. Plasma Process., 2008, 28: 729
[42]	Zhou Q H, Yin H T, Li H, et al.The effect of plasma-gas swirl flow on a highly constricted plasma cutting arc[J]. J. Phys. Appl. Phys., 2009, 42D: 095208
[43]	Zhou Q H, Guo W K, Li H.Numerical simulation on the effect of shielding gas on the plasma cutting arc[J]. Acta Phys. Sin., 2011, 60: 025214
[43]	(周前红, 郭文康, 李辉. 保护气对切割弧特性影响的模拟研究[J]. 物理学报, 2011, 60: 025214)
[44]	Jian X X, Wu C S.Numerical analysis of the coupled arc-weld pool-keyhole behaviors in stationary plasma arc welding[J] Int. J. Heat Mass Transf., 2015, 84: 839
[45]	Jian X X, Wu C S, Zhang G K, et al.A unified 3D model for an interaction mechanism of the plasma arc, weld pool and keyhole in plasma arc welding[J]. J. Phys. Appl. Phys., 2015, 48D: 465504

[1]	毕中南, 秦海龙, 刘沛, 史松宜, 谢锦丽, 张继. 高温合金锻件残余应力量化表征及控制技术研究进展[J]. 金属学报, 2023, 59(9): 1144-1158.
[2]	王重阳, 韩世伟, 谢峰, 胡龙, 邓德安. 固态相变和软化效应对超高强钢焊接残余应力的影响[J]. 金属学报, 2023, 59(12): 1613-1623.
[3]	张开元, 董文超, 赵栋, 李世键, 陆善平. 固态相变对Fe-Co-Ni超高强度钢长臂梁构件焊接-淬火过程应力和变形的影响[J]. 金属学报, 2023, 59(12): 1633-1643.
[4]	周小宾, 赵占山, 汪万行, 徐建国, 岳强. 渣-金界面气泡夹带行为数值物理模拟[J]. 金属学报, 2023, 59(11): 1523-1532.
[5]	夏大海, 邓成满, 陈子光, 李天书, 胡文彬. 金属材料局部腐蚀损伤过程的近场动力学模拟：进展与挑战[J]. 金属学报, 2022, 58(9): 1093-1107.
[6]	胡龙, 王义峰, 李索, 张超华, 邓德安. 基于SH-CCT图的Q345钢焊接接头组织与硬度预测方法研究[J]. 金属学报, 2021, 57(8): 1073-1086.
[7]	李子晗, 忻建文, 肖笑, 王欢, 华学明, 吴东升. 热导型等离子弧焊电弧物理特性和熔池动态行为[J]. 金属学报, 2021, 57(5): 693-702.
[8]	杨勇, 赫全锋. 高熵合金中的晶格畸变[J]. 金属学报, 2021, 57(4): 385-392.
[9]	王富强, 刘伟, 王兆文. 铝电解槽中局部阴极电流增大对电解质-铝液两相流场的影响[J]. 金属学报, 2020, 56(7): 1047-1056.
[10]	刘继召, 黄鹤飞, 朱振博, 刘阿文, 李燕. 氙离子辐照后Hastelloy N合金的纳米硬度及其数值模拟[J]. 金属学报, 2020, 56(5): 753-759.
[11]	王波,沈诗怡,阮琰炜,程淑勇,彭望君,张捷宇. 冶金过程中的气液两相流模拟[J]. 金属学报, 2020, 56(4): 619-632.
[12]	许庆彦,杨聪,闫学伟,柳百成. 高温合金涡轮叶片定向凝固过程数值模拟研究进展[J]. 金属学报, 2019, 55(9): 1175-1184.
[13]	戴培元,胡兴,逯世杰,王义峰,邓德安. 尺寸因素对2D轴对称模型计算不锈钢管焊接残余应力精度的影响[J]. 金属学报, 2019, 55(8): 1058-1066.
[14]	逯世杰, 王虎, 戴培元, 邓德安. 蠕变对焊后热处理残余应力预测精度和计算效率的影响[J]. 金属学报, 2019, 55(12): 1581-1592.
[15]	张清东, 林潇, 刘吉阳, 胡树山. Q&P钢热处理过程有限元法数值模拟模型研究[J]. 金属学报, 2019, 55(12): 1569-1580.

Viewed

Full text

Abstract

Cited

Shared

Discussed