焊接残余应力与变形(II)PPT演示课件

表面长尺度残余应力分布-sqrt(rt),LengthScaleinSurfaceResidualStressDistributions-sqrt(rt),1,纵向与横向残余应力对比,Longitudinalcomponent纵向部分Yieldmagnitudetensionwithinornearweld焊缝内或附近产生巨大拉力Dyingoutrapidlyandbecomecompressionawayfromweld在远离焊缝处迅速衰减且变成压力Transversecomponent:verysensitivetovariousparameters:横向部分：对各种变量非常敏感Jointgeometryandrestraint几何接头和约束Weldingprocedures焊接过程Platethicknessesandnumberofpasses平板厚度和焊缝数量,LongitudinalversusTransverseResidualStresses,图例平板对接焊缝,2,非完整测量在早期MPC报告中的碳钢管环焊,In-CompleteMeasurements-ACarbonSteelPipeGirthWeldinanEarlierMPCReport,3,碳钢搭接角焊接头全域测量的例子,CarbonSteelLapFilletJointAnExamplewithFullFieldMeasurements,4,举例：铝锂合金板（2195）上的VPPA对接焊缝,Example:AVPPAButtWeldinAl-LiAlloy(2195)Panel,5,全域残余应力分布的适当解释,FullFieldResidualStressDistributionsareRequiredforAppropriateInterpretation,6,3D残余应力特征和OD的发展,3DResidualStressFeaturesandDevelopment-OD,7,多道环焊中3D残余应力的特征,3DResidualStressCharacteristicsinaMulti-PassGirthWeld,8,举例：SS管环形焊,Example:SSPipeGirthWeld,9,理解特殊应用需求的重要性,Cuttingaccuracycontrol精确控制切割Longrangeresidualstressisofinterest注意大范围内的残余应力Bestdescribedatthemidsurface中面的描述最有效Plateelementmodeliseffective壳单元模型是有效的Challengesformeasurements检测的难题Surfaceeffects表面效应Through-thicknesseffects厚度影响,UnderstandingtheNeedinaSpecificApplicationisImportant,10,钢厂B,SteelMillB,11,补焊,Highlyrestrainedconditions强约束条件Strong3Dresidualstressfeatures强3D残余应力特征Oftenrequiringa3Dmodel通常需要3D模型,RepairWelds,12,炉壳回火焊道补焊,ABoilerShellTemperBeadRepairWeld,13,测量和模型验证-横向残余应力,焊缝中心处沿厚度方向的应力分布,穿过焊缝中心的应力分布,MeasurementsandModelValidationsTransverseResidualStresses,ThroughWallDistributions,atWeldCenter,AcrosstheWeld,atWeldCenter,14,欧洲TRAINSS的模拟焊接和测量数据,MockUpWeldandMeasurementDatafromEuropeanTRAINSSProject,15,层间温度=25C(假设）层间温度=200C,PredictionversusMeasurementsTRAINSSMockUpWeld预测与测量-TRAINSS模拟焊接,Inter-passtemp.=25C(assumed),Inter-passtemp.=200C,16,薄板对接-使用特殊壳模型的有限元模拟（2道焊）,AButtJointinaThinSheetFESimulationUsingaSpecialShellModel(2-PassWeld),17,补焊后残余应力分布,ResidualStressDistributionsAfterWeldRepair,18,控制补焊后的残余应力的热拉伸技术,AThermalStretchingTechniqueforMitigatingRepairWeldResidualStresses,19,在拉力作用下残余应力对应变分布的影响初始焊接与补焊对比,预测实测,ResidualStressEffectsonStrainDistributionsunderTension:InitialWeldv.s.Repair,20,补焊碾压对应变分布的影响-拉伸载荷,EffectsofRepairWeldPlanishingonStrainDistributions-TensionLoading,21,补焊的横向分量主要取决于修复尺寸,TransverseComponentinRepairWeldStronglyDependsonRepairDimensions,22,补焊的横向分量主要取决于修复尺寸,TransverseComponentinRepairWeldStronglyDependsonRepairDimensions,23,深孔测量由英国布里斯托尔大学测量,Deep-holemeasurementsconductedatUniversityofBristol,UK,24,补焊,修复大r/t比例铝合金管或平板,修复碳钢罐体,修复SS管环形焊缝,RepairWelds,RepairLarger/tAl-AlloyVesselorPlate,RepairinCarbonSteelStorageTank,RepairinSSPipeGirthWeld,25,各种工艺的残余应力,Commonalitiesanddifferencesinresidualstresses残余应力的共性与区别Differentwelding/joiningprocesses不同焊接/连接过程Conventionalfusionwelding常规熔焊High-energybeamwelding高能束焊接Solidstatejoining固态连接Resistancewelding电阻焊Friction/inertiawelding摩擦焊/惯性焊Frictionstirwelding摩擦搅拌焊Otherthermalfabricationprocesses其他的热工艺过程Thermalcutting热切割Thermalforming热成型Someremarks备注,ResidualStressesfromVariousProcesses,26,高能束焊接产生的残余应力,EBwelding电子束焊接Laserwelding激光焊接Hybridlaser/MIGwelding混合激光焊接/MIG焊接,ResidualStressesduetoHigh-EnergyBeamWelding,27,共性与区别：常规工艺与高能束工艺,Higherenergydensityheatinput高能量密度的热输入Morerapidheatingandcooling快速加热和冷却Morelocalizedtemperaturedistribution更集中的温度分布Morelocalizedresidualstressdistributions更集中的残余应力分布Magnituderemainssimilar量值相似,CommonalitiesandDifferences:ConventionalversusHighEnergyBeamProcesses,28,热流特征：电弧焊与激光焊,电弧焊激光焊,HeatFlowCharacteristics:ArcWeldingversusLaserWelding,ConventionalArc,Laser,29,残余应力分布：常规电弧焊与激光焊接环形焊缝,轴向残余应力,MIG焊接,MIG焊接,MIG焊接,激光焊接,切向残余应力,ResidualStressDistributions:ConventionalArcversusLaserBeamWeldingGirthWelds,AxialResidualStress,MIGwelding,Laserwelding,HoopResidualStress,MIGwelding,Laserwelding,激光焊接,30,固态焊接工艺的残余应力,Resistancewelding电阻焊Friction/inertiawelding摩擦/惯性焊接Frictionstirwelding搅拌摩擦焊,ResidualStressesfromSolidStateWeldingProcesses,31,摩擦/惯性焊接工艺的残余应力,Frictionheatgeneration摩擦热量的产生Forging/extrusion锻造/挤压Heatflow+materialflow热流+材料流,ResidualStressesfromFriction/InertiaWeldingProcesses,32,圆钢的惯性焊接,温度变化,残余应力分布,InertiaWeldingofaRoundBar,TemperatureEvolution,ResidualStressDistributions,33,空心圆柱摩擦/惯性焊,热和材料流残余应力分布,Friction/InertiaWeldingofaHollowCylinder,HeatandMaterialFlow,ResidualStressDistributions,34,摩擦-搅拌焊,Friction+plasticworkheating摩擦+塑性加热Heavilyrestrainedconditions强约束条件Heatflow+constrictedmaterialflow热流+限制材料流,Friction-StirWelding,HeatandMaterialFlow,35,摩擦搅拌焊-SS304(03)中的残余应力,纵向残余应力的分布,ResidualStressesfromFrictionStirWeldingSS304(03),LongitudinalResidualStressDistributions,36,备注-FSW（摩擦搅拌焊）,ResidualstressesinFSWweldscanstillbehigh摩擦搅拌焊中仍然有较高的残余应力Localizedhightemperaturedistribution(belowmelting)高温分布集中（低于熔点）Materialflow(high-temperatureextrusion)材料流（高温挤压）Highlyrestrainedplasticdeformationprocess塑性变形过程受到强约束Distortions变形Typicallymuchlessthanthosefromarcwelding通常会比电弧焊小很多-Primarilyduetoseverejointrestraints主要由于严格的铰接约束-Forgingeffectsonweldnugget锻造对焊点熔核的影响“Snap”orbucklingmayoccurafterreleasingfixture松开夹具后可能发生“啪的一声”突然断裂或屈曲变形,RemarksFSW,37,热切割中的残余应力,Localizedtemperaturegradient温度梯度集中Restrainedplasticdeformation-alongcut约束塑性变形切割方向Freesurfacegeneration自由面的产生,最终的残余应力分布,温度分布和切缝成形-PAC,ResidualStressesinThermalCutting,Finalresidualstressdistributions,TemperaturedistributionandkerfformationPAC,38,残余应力-喷丸法和火焰切割,测量方法：X射线,ResidualStressesShotBlastingandFlamecutting,Measurementmethod:X-ray,39,切割导致的变形-CCW（逆时针）切割方向,平板；10英尺x8英尺,12x12平板热切割,放大系数：1,试验,模拟,CuttingInducedDistortions-CCWCuttingDirection,Plate:10feetx8feet,12”x12”PlateThermalCutting,MagnificationFactor:1,experiment,Simulation,40,切割导致的变形-CW（顺时针）切割,平板；10英尺x8英尺,12x12平板热切割,放大系数：1,试验,模拟,CuttingInducedDistortions:CWCutting,Plate:10feetx8feet,12”x12”PlateThermalCutting,MagnificationFactor:1,experiment,Simulation,41,板的残余应力对切割精度的影响,平轧后平板纵向残余应力,顺序1,顺序2,PlateResidualStressEffectsonCuttingAccuracy,Longitudinalresidualstressinplatefrommill,SequenceI,SequenceII,42,控制残余应力和变形的技术,In-process加工中Jointdesign接头设计Pass/weldseqencing焊道/焊接顺序Clamping/fixturing夹具Thermaland/ormechanicalcompensation热与/或机械补偿Post-process加工后Thermaland/ormechanicalstressimprovementtechniques热或机械应力改善技术FurnacebasedPWHT焊后热处理LocalPWHT局部焊后热处理Mechanicaloverloading(e.g.,hydrotest,etc)机械超载荷（例如：水压测试等）,ResidualStressandDistortionMitigationTechniques,43,一般原则,Duringwelding:焊接过程：Reducejointrestraint减少接头约束Introducemechanismstostretchweldmetalplasticallyoncooling冷却时引入机构会拉伸焊接材料产生塑性变形Afterwelding:焊接后Stretchweldarea拉伸焊接区域Thermal加热Mechanical机械力Both以上两者CreateanewresidualstressfieldtoaltertheoneresultedfromWelding产生新残余应力场从而改变焊接后的应力场,GeneralPrinciples,44,预测横向残余应力分布修复测试板,（修复后）,（磨冲后）,PredictedTransverseResidualStressDistributions-RepairinTestPlate,45,最优修复过程和残余应力结果,横向残余应力,采用过渡块最优修复过程,OptimizedRepairProceduresandResidualStressResults,OptimizedRepairProcedureswithTransitionBlocks,TransverseResidualStress,46,焊道顺序对横向残余应力影响,PassSequenceEffectsonTransverseResidualStresses,47,角度变形和分段退焊（焊序影响）,AngularDistortionsandBack-StepWelding(sequenceeffects),48,焊接装配,为什么夹具是重要的固定参考位置,WeldingAssembly,Whyfixturingisimportantmaintainingareferenceposition,49,对屈曲波长充分加紧是关键因素,SufficientClampingw.r.t.BucklingWaveLengthisCritical,50,确定统一的焊后热处理参数,SimulatedPWHTParametersandTwoTypicalThick-SectionResidualStressCases,UniformPWHTParameterDefinition,模拟焊后热处理参数和两种典型的厚截面残余应力案例,51,比较残余应力的分布：焊后热处理前后有无蠕变现象,ComparisonofResidualStressDistributions:BeforeandAfterPWHTw/ocreep,52,比较焊后热处理前后有无蠕变径向应力,焊接状态下沿厚度方向的残余应力分布,700C后没有蠕变时沿厚度方向残余应力的分布,As-WeldedThrough-ThicknessResidualStress,Through-ThicknessResidualStressesafter700CheatingwithoutCreep,ComparisonofBeforeandAfterPWHTw/oCreepRadialStresses,53,比较残余应力的分布：焊后热处理前后有无蠕变现象,ComparisonofResidualStressDistributions:BeforeandAfterPWHT/oCreep,54,SimplyheatinguptoaPWHTtemperature,anyreductioninresidualstressisminimum(e.g.,10%)仅仅当加热至焊后热处理的温度，残余应力的减小是最小的（例如：10%）Dominantstressreliefmechanism:creeprelaxation主要应力的减小机理是：蠕变松驰,Observations小结,55,在焊后热处理时应力松弛的力学行为：Mises应力在B点处的变化过程,StressRelaxationCharacteristicsduringPWHTMisesStressHistoryatB,56,在焊后热处理时应力松弛的力学行为-Eq.蠕变应变在B点处的变化过程,StressRelaxationCharacteristicsduringPWHTEq.CreepStrainHistoryatB,57,持续时间的影响(2-1/4CrMo):10小时与20小时的对比,蠕变应变CreepStrain,HoldingTimeEffects(2-1/4CrMo):10hrsverus20hrs,应力Stress,58,局部焊后热处理环向加热带和交变应力的改进技术,Stressreliefmechanisms应力的减缓机理Residualstresstypeeffects残余应力类型的影响orr/tandteffectsr/t和t的影响Parametricanalysis:参数分析HB,SB,GCB,PWHTtemp.,etc.HB,SB,GCB,PWHTtemp.,etc,L-PWHTCircumferentialBandHeatingandAlternativeStressImprovementTechniques,59,参数定义环形加热带的局部焊后热处理,ParameterDefinitionsLocalPWHTwithCircumferentialBandHeating,60,焊接时的残余应力(r/t3,t=1.5”,20道,碳钢管）,AsWeldedResidualStresses(r/t3,t=1.5”,20Passes,CarbonSteelPipe),61,局部焊后热处理后的残余应力分布与前有相同尺寸,ResidualStressDistributionsafterLocalPWHTSameScaleasPreviousSlide,62,焊后热处理后的残余应力分布不同尺寸,ResidualStressDistributionsafterLocalPWHTDifferentScale,63,焊接状态下的轴向残余应力（弯曲类型）,AfterL-PWHT局部焊接热处理后：SB=3t(40mm),GCB=(5(Rt)=200mm),AfterL-PWHT局部焊接热处理后:SB:10t(130mm),GCB=(5(Rt)=200mm,As-WeldedAxialResidualStress(BendingType),64,随着时间变化的轴向应力分布,AxialStressDistributionsasaFunctionofTime,65,局部焊后热处理时的轴向应力分布,AxialStressdistributionsDuringLPWHT,66,感应加热应力法控制环向焊缝应力集中,InductionHeatingStressImprovementTechniqueforMitigatingSCCinGirthWelds,67,焊接状态时的残余应力,SB=3t(155mm),GCB=5(Rt)=2500mm,Tmax=620C,HeatingBlock：2t(25mm),Tmax=550C(NoInsulation),AnAlternativeStressImprovementTechnique交变应力的改进技术,As-weldedResidualStress,68,感应加热应力法（IHSI）技术对SS管环缝焊接的影响,加入感应热应力后的轴向残余应力,AInductionHeatingStressImprovementIHSITechniqueforSSPipeGirthWelds,69,AsWelded焊接状态,AfterTreatment热处理后,AlternativelocalPWHTforResidualStressImprovement交替局部焊后热处理对残余应力改善,70,L-PWHTstressreliefmechanismsinvolvescomplicatedinteractionsbetweenplasticityandcreep局部焊后热处理应力的减缓机理包含了塑性变形和蠕变间复杂的相互作用Residualstresstype(bendingorself-equilibrating)shouldbeconsideredinsizingsoakingbandsize残余应力的类型（弯曲或自平衡）应该考虑到焊道（高温保温带？）的尺寸大小的分类R/tandsqrt(rt)areimportantparameterstodetermineglobalbendingreactionsduetolocalbandheatingR/t和sqrt(rt)是重要的参数，决定着局部带加热引起的整体弯曲变形CreepstraindevelopmentatPWHTtemperature到达热处理温度时发生蠕滑应变PlasticstraindevelopmentduringtheentireL-PWHT在整个局部焊后热处理过程中都有塑性应变发生Furtherinvestigationsareneededtoproviderecommendation进一步的研究还需要提供些建议Alternativelocallow-temperaturestressimprovementtechniquescouldbemoreeffective选择局部低温应力改进技术更有效,ObservationsLocalPWHTwithCircumferentialBandHeating小结环焊接加热带局部焊后热处理,71,AxialStress,HoopStress环向应力,As-welded焊接状态,Withload加载时,Afterload卸载后,HydrotestEffectsonGirthWeldResidualStress-75%Yield压力试验对环缝焊接残余应力的影响-75%屈服,轴向应力,72,Mise应力,as-welded焊接状态,Withload加载时,afterload卸载后,HydrotestEffectsonGirthWeldResidualStress-75%Yield压力试验对环焊残余应力的影响-75%屈服,73,AxialStress轴向应力,HoopStress切向应力,as-welded焊接状态,withload加载时,afterload卸载后,HydrotestEffectsonGirthWeldResidualStress-75%Yield压力试验对环焊残余应力的影响-75%屈服,74,AxialStress轴向应力,HoopStress切向应力,as-welded焊接状态,withload加载时,afterload卸载,HydrotestEffectsonGirthWeldResidualStress-110%Yield压力试验对环焊残余应力的影响-110%屈服,75,HydrotestEffectsonGirthWeldResidualStress-110%Yield压力试验对环焊残余应力的影响-110%屈服,as-welded焊接状态,withload加载时,afterload卸载,Mise应力,76,HydrotestEffectsonGirthWeldResidualStress压力试验对环焊残余应力的影响,77,HydrotestEffectsonGirthWeldResidualStress-75%Yield压力试验对环焊残余应力的影响-75%屈服,Mise应力,as-welded焊接状态,withload加载时,afterload卸载后,78,HydrotestEffectsonGirthWeldResidualStress-75%Yield压力试验对环焊残余应力的影响-75%屈服,AxialStress轴向应力,HoopStress环向应力,as-welded焊接状态,withload加载时,afterload卸载后,79,HydrotestEffectsonGirthWeldResidualStress-75%Yield压力试验对环焊残余应力的影响-75%屈服,as-welded焊接状态,Mise应力,withload加载时,afterload卸载后,80,HydrotestEffectsonGirthWeldResidualStress-75%Yield压力试验对环焊残余应力的影响-75%屈服,AxialStress轴向应力,HoopStress环向应力,as-welded焊接状态,withload加载时,afterload卸载后,81,HydrotestEffectsonGirthWeldResidualStress压力试验对环焊残余应力的影响,82,HydrotestEffectsonSeamWeldResidualStress-75%Yield压力试验对滚焊残余应力的影响-75%屈服,CircumferentialStress周向应力,AxialStress轴向应力,as-welded焊接状态,withload加载时,afterload卸载,83,HydrotestEffectsonSeamWeldResidualStress-75%Yield压力试验对滚焊残余应力的影响-75%屈服,