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学者姓名：蒋凡
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Abstract ：
This study investigates the mechanism behind the dual-stagnation points flow phenomenon in the keyhole plasma arc welding (KPAW) melt pool and develops a corresponding control strategy. Positional information on flow stagnation points was obtained using the macroscopic morphology of the melt pool and liquid flow velocity measurements. The position of these stagnation points, determined by the directional flow of liquid metal, is crucial for characterizing the stability of the welding process. The study delves into the driving force mechanism that produces stable directional flow and a uniform temperature distribution within the melt pool. A significant discovery of this research is the identification of high-speed directional material transport channels within the melt pool. Furthermore, a correlation mechanism between the positions of stagnation points and the stable flow with temperature distribution has been constructed. To address the unstable and destabilization stages of the welding process, a dynamic material stability transfer control strategy was designed, based on liquid flow velocity and temperature distribution. This strategy ensures a smooth transition during the unstable stage and rapid self-healing of the melt pool during destabilization. This study provides a novel control strategy and a theoretical foundation for the automation and enhancement of the KPAW welding process, highlighting its necessity in advancing welding technology.
Keyword ：
Control strategy Control strategy Filler wire Filler wire Liquid metal Liquid metal Heat transfer Heat transfer Convection pattern Convection pattern
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| GB/T 7714 | Liu, Jingbo , Jiang, Fan , Tashiro, Shinichi et al. The mechanism of dual-stagnation points flow phenomenon in keyhole plasma arc melt pool and corresponding control strategy [J]. | JOURNAL OF MANUFACTURING PROCESSES , 2024 , 125 : 473-488 . |
| MLA | Liu, Jingbo et al. "The mechanism of dual-stagnation points flow phenomenon in keyhole plasma arc melt pool and corresponding control strategy" . | JOURNAL OF MANUFACTURING PROCESSES 125 (2024) : 473-488 . |
| APA | Liu, Jingbo , Jiang, Fan , Tashiro, Shinichi , Chen, Shujun , Tanaka, Manabu , Zhang, Chengyu et al. The mechanism of dual-stagnation points flow phenomenon in keyhole plasma arc melt pool and corresponding control strategy . | JOURNAL OF MANUFACTURING PROCESSES , 2024 , 125 , 473-488 . |
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Abstract ：
变极性等离子弧（Variable Polarity Plasma Arc, VPPA）焊是一种高效的铝合金和镁合金焊接方法，其主要优势在于等离子电弧具有高能量密度，可以在焊接时穿透熔池形成小孔，大幅度降低焊接变形和残余应力，提高焊接质量。了解熔池小孔行为、电弧物理特性和控制方法对于优化和提高焊接过程的稳定性至关重要。本文综述了VPPA焊接技术发展的最新情况，对VPPA焊接过程信息的检测研究为深刻认识焊接稳定性机理提供了有力保障，尤其是利用X射线成像系统观测熔融金属流动的研究，对提升VPPA穿孔熔池物理本质的认识做出了重要贡献。此外，针对不同位置VPPA焊接的研究增加了这一焊接工艺的灵活性，由VPPA焊接衍生的多种拓展工艺拓宽了该焊接方法的适用范围。VPPA穿孔焊接技术以其焊接变形小、焊后无缺陷、单面焊接双面一次成形等优势，成为航空航天领域铝合金中厚板材焊接制造的优选工艺。
Keyword ：
熔池检测 熔池检测 电弧物理 电弧物理 变极性等离子弧焊 变极性等离子弧焊 复合焊接 复合焊接 稳定性控制 稳定性控制
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| GB/T 7714 | 蒋凡 , 张成钰 , 徐斌 et al. 变极性等离子弧焊技术发展及其在航天制造领域应用现状 [J]. | 航天制造技术 , 2024 , PageCount-页数: 12 (03) : 15-26 . |
| MLA | 蒋凡 et al. "变极性等离子弧焊技术发展及其在航天制造领域应用现状" . | 航天制造技术 PageCount-页数: 12 . 03 (2024) : 15-26 . |
| APA | 蒋凡 , 张成钰 , 徐斌 , 张国凯 , 闫朝阳 , 陈树君 . 变极性等离子弧焊技术发展及其在航天制造领域应用现状 . | 航天制造技术 , 2024 , PageCount-页数: 12 (03) , 15-26 . |
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Abstract ：
The twin-body plasma arc has the decoupling control ability of heat transfer and mass transfer, which is beneficial to shape and property control in wire arc additive manufacturing. In this paper, with the wire feeding speed as a characteristic quantity, the wire melting control ability of twin-body plasma arc was studied by adjusting the current separation ratio (under the condition of a constant total current), the wire current/main current and the position of the wire in the arc axial direction. The results showed that under the premise that the total current remains unchanged (100 A), as the current separation ratio increased, the middle and minimum melting amounts increased approximately synchronously under the effect of anode effect power, the first melting mass range remained constant; the maximum melting amount increased twice as fast as the middle melting amount under the effect of the wire feeding speed, and the second melting mass range was expanded. When the wire current increased, the anode effect power and the plasma arc power were both factors causing the increase in the wire melting amount; however, when the main current increased, the plasma arc power was the only factor causing the increase in the wire melting amount. The average wire melting increment caused by the anode effect power was approximately 2.7 times that caused by the plasma arc power. The minimum melting amount was not affected by the wire-torch distance under any current separation ratio tested. When the current separation ratio increased and reached a threshold, the middle melting amount remained constant with increasing wire-torch distance. When the current separation ratio continued to increase and reached the next threshold, the maximum melting amount remained constant with the increasing wire-torch distance. The effect of the wire-torch distance on the wire melting amount reduced with the increase in the current separation ratio. Through this study, the decoupling mechanism and ability of this innovative arc heat source is more clearly.
Keyword ：
Melting amount Melting amount Twin-body plasma arc Twin-body plasma arc Current separation ratio Current separation ratio Melting control ability Melting control ability
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| GB/T 7714 | Zhang, Ruiying , Jiang, Fan , Xue, Long . Experimental Study on Wire Melting Control Ability of Twin-Body Plasma Arc [J]. | CHINESE JOURNAL OF MECHANICAL ENGINEERING , 2024 , 37 (1) . |
| MLA | Zhang, Ruiying et al. "Experimental Study on Wire Melting Control Ability of Twin-Body Plasma Arc" . | CHINESE JOURNAL OF MECHANICAL ENGINEERING 37 . 1 (2024) . |
| APA | Zhang, Ruiying , Jiang, Fan , Xue, Long . Experimental Study on Wire Melting Control Ability of Twin-Body Plasma Arc . | CHINESE JOURNAL OF MECHANICAL ENGINEERING , 2024 , 37 (1) . |
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Abstract ：
Functionally graded materials (FGMs), which constitute a new type of composite material, have received considerable attention in industry because of the spatial gradient of their composition and the microstructure-induced gradient in their material performance, which make them better suited for high-performance multifunctional applications. Additive manufacturing (AM) has become one of the most promising techniques for the manufacture of materials and structures because of its high flexibility. The combination of advanced materials (FGMs) and advanced manufacturing methods (AM) is expected to facilitate the further development of such engineering materials. In this paper, the definition, historical development and material gradient types of FGMs are introduced. The classification, process principle and typical research results of the AM of metal FGMs are summarized and discussed. In particular, the research status of wire and arc additive manufacture (WAAM), which is more suitable for the preparation of large-scale metal FGMs, is reviewed in detail according to the types of FGMs, and a double-wire bypass plasma arc additive manufacturing technique, which is suitable for inducing a gradient along the direction of single-pass cladding, is proposed. On the basis of this summary of the important achievements made to date, future research is proposed.
Keyword ：
functionally graded additive manufacturing functionally graded additive manufacturing material gradient type material gradient type wire and arc additive manufacture (WAAM) wire and arc additive manufacture (WAAM) functionally graded materials (FGMs) functionally graded materials (FGMs)
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| GB/T 7714 | Zhang, Ruiying , Jiang, Fan , Xue, Long et al. Review of Additive Manufacturing Techniques for Large-Scale Metal Functionally Graded Materials [J]. | CRYSTALS , 2022 , 12 (6) . |
| MLA | Zhang, Ruiying et al. "Review of Additive Manufacturing Techniques for Large-Scale Metal Functionally Graded Materials" . | CRYSTALS 12 . 6 (2022) . |
| APA | Zhang, Ruiying , Jiang, Fan , Xue, Long , Yu, Junyu . Review of Additive Manufacturing Techniques for Large-Scale Metal Functionally Graded Materials . | CRYSTALS , 2022 , 12 (6) . |
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Abstract ：
Droplet state and transition process directly determine the forming quality of deposited layer in wire and arc additive manufacturing(WAAM). In this study, an in-situ measurement system of the droplet state (temperature, velocity and mass) at plasma arc was established. An innovative staged heating method was proposed to reduce the measuring error of droplet temperature caused by the plasma arc. Meanwhile, a trajectory fitting method was studied to predict the droplet velocity, because droplet morphology was difficult to keep consistent during the transferring process. Then, the effect of current and plasma gas rate on the droplet state measurement were studied. This study will provide an effective measurement method for the droplet state in the high temperature plasma arc environment.
Keyword ：
PAW (Plasma Arc Welding) PAW (Plasma Arc Welding) Droplet temperature Droplet temperature Droplet velocity Droplet velocity Droplet mass Droplet mass Aluminum alloys Aluminum alloys
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| GB/T 7714 | Li, Cheng , Jiang, Fan , Xu, Bin et al. In-situ measurement of the droplet temperature, velocity and mass under plasma arc [J]. | MEASUREMENT , 2022 , 202 . |
| MLA | Li, Cheng et al. "In-situ measurement of the droplet temperature, velocity and mass under plasma arc" . | MEASUREMENT 202 (2022) . |
| APA | Li, Cheng , Jiang, Fan , Xu, Bin , Zhang, Guokai , Chen, Shujun , Yan, Zhaoyang et al. In-situ measurement of the droplet temperature, velocity and mass under plasma arc . | MEASUREMENT , 2022 , 202 . |
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Abstract ：
A novel bypass coupling variable polarity plasma arc was proposed to achieve the accurate adjusting of heat and mass transfer in the welding and additive manufacturing of aluminum alloy. However, the physical characteristics and decoupled transfer behavior remain unclear, restricting its application and development. A three-dimensional model of the bypass coupling variable polarity plasma arc was built based on Kirchhoff's law, the main arc and the bypass arc are coupled by an electromagnetic field. The model of current attachment on the tungsten electrode surface is included for simulating different heating processes of the EP and EN phases in the coupling arc. The distribution of temperature field, flow field, and current density of the bypass coupling variable polarity plasma arc was studied by the three-dimensional numerical model. The heat input on the base metal under different current conditions is quantified. To verify the model, the arc voltages are compared and the results in simulation and experiment agree with each other well. The results show that the radius of the bypass coupling arc with or without bypass current action on the base metal is different, and the flow vector of the bypass coupling arc plasma with bypass current is larger than the arc without bypass current. By comparing the heat transfer on the electrodes' boundary under different current conditions, it is found that increasing the bypass current results in the rise in heat input on the base metal. Therefore, it is concluded that using bypass current is unable to completely decouple the wire melting and the heat input of the base metal. The decoupled degree of heat transfer is one of the important factors for accurate control in the manufacturing process with this coupling arc.
Keyword ：
numerical analysis numerical analysis bypass coupling VPPA bypass coupling VPPA decoupled heat transfer decoupled heat transfer physical characteristics physical characteristics
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| GB/T 7714 | Jiang, Fan , Miao, Qi , Xu, Bin et al. Numerical Analysis of Physical Characteristics and Heat Transfer Decoupling Behavior in Bypass Coupling Variable Polarity Plasma Arc [J]. | MATERIALS , 2022 , 15 (9) . |
| MLA | Jiang, Fan et al. "Numerical Analysis of Physical Characteristics and Heat Transfer Decoupling Behavior in Bypass Coupling Variable Polarity Plasma Arc" . | MATERIALS 15 . 9 (2022) . |
| APA | Jiang, Fan , Miao, Qi , Xu, Bin , Tashiro, Shinichi , Tanaka, Manabu , Lin, Sanbao et al. Numerical Analysis of Physical Characteristics and Heat Transfer Decoupling Behavior in Bypass Coupling Variable Polarity Plasma Arc . | MATERIALS , 2022 , 15 (9) . |
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Abstract ：
This study investigated heat and mass transfer as well as the effect of gravity on keyhole formation in the molten pool of keyhole plasma arc welding. The flow trajectory of the molten pool was obtained via high-speed camera images illuminated by a laser light system, and the temperature distribution was obtained using an infrared thermal camera. The experimental results showed that the molten metal flowed rearward and downward at the top surface of the weld pool and thereafter to the rear side of the keyhole. There are two types of reverse flow of molten metal on the rear side of the keyhole. The different welding positions had minimal effect on the flow pattern; however, the flow velocities were different. Further, for the temperature distribution, although the keyhole front side yielded a similar high-temperature area under different welding positions, the area of the high temperature on the keyhole rear side in the vertical position welding was much larger than that in the flat position. Consequently, the influence of the force on the keyhole molten pool was evaluated, and the flow pattern of the molten pool was found to be dominated by the sheer force. Moreover, the flow velocity and solidification morphology of the molten pool were affected by the gravity at different welding positions. In addition, the correlation mechanism of the temperature distribution, flow, and solidification morphology of the keyhole molten pool was analyzed using the combined action of shear force and gravity, which further revealed the mechanism of the influence of gravity on the keyhole welding process.(c) 2022 Elsevier Ltd. All rights reserved.
Keyword ：
The temperature distribution The temperature distribution VPPA welding VPPA welding Keyhole welding in different positions Keyhole welding in different positions Weld pool flow Weld pool flow Aluminum alloy Aluminum alloy
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| GB/T 7714 | Chen, Shujun , Liu, Jingbo , Jiang, Fan et al. Gravity effects on temperature distribution and material flow in the keyhole pool of VPPA Al welding [J]. | INTERNATIONAL JOURNAL OF HEAT AND MASS TRANSFER , 2022 , 191 . |
| MLA | Chen, Shujun et al. "Gravity effects on temperature distribution and material flow in the keyhole pool of VPPA Al welding" . | INTERNATIONAL JOURNAL OF HEAT AND MASS TRANSFER 191 (2022) . |
| APA | Chen, Shujun , Liu, Jingbo , Jiang, Fan , Xu, Bin , Zhang, Guokai , Li, Bo . Gravity effects on temperature distribution and material flow in the keyhole pool of VPPA Al welding . | INTERNATIONAL JOURNAL OF HEAT AND MASS TRANSFER , 2022 , 191 . |
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Abstract ：
一种控制焊接等离子弧热源输出分布的装置及方法，属于焊接质量控制方法领域。通过对常规等离子焊枪喷嘴进行必要的改进，即在原有焊枪喷嘴的压缩孔道内壁每间隔90°开一个气流通道(共计四个气流通道)，形成了控制等离子弧热源输出分布的装置，搭配本发明所提供的四种控制方法，可有效控制等离子弧热源输出分布，也提高了电弧与熔池的稳定性，增加了焊接过程的可控性，实现了一途多用的效果，以此满足不同焊接实际的需要。
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| GB/T 7714 | 蒋凡 , 何颖杰 , 徐斌 et al. 一种控制焊接等离子弧热源输出分布的装置及方法 : CN202110245605.7[P]. | 2021-03-05 . |
| MLA | 蒋凡 et al. "一种控制焊接等离子弧热源输出分布的装置及方法" : CN202110245605.7. | 2021-03-05 . |
| APA | 蒋凡 , 何颖杰 , 徐斌 , 陈树君 . 一种控制焊接等离子弧热源输出分布的装置及方法 : CN202110245605.7. | 2021-03-05 . |
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Abstract ：
一种基于斑点簇定向移动控制的变极性等离子弧焊接气孔抑制方法属于成形制造领域。装置分别由变极性等离子弧穿孔焊接系统和产生脉冲磁场装置组成，脉冲磁场控制正极性等离子弧焊接阶段工件表面阴极斑点位置，使阴极斑点聚集于穿孔焊接的小孔前端，在小孔达到该位置之前先行将工件表面的致密氧化膜清理，由于阴极斑点的电流密度大，根据电磁力作用原理，磁场作用下将阴极斑点集中于一处清除氧化膜，调整磁场方向使阴极斑点簇在穿孔熔池表面移动，利用斑点的热作用蒸发释放气泡。该作用模式不仅可以快速有效地清理氧化膜，减少焊缝气孔缺陷，还可以增加工件对电弧的能量吸收，提高能量利用率，可以在大型复杂结构或高合金材料的焊接中得到应用。
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| GB/T 7714 | 徐斌 , 赵世宗 , 苗祺 et al. 一种基于斑点簇定向移动控制和质量补偿的变极性等离子弧焊接气孔抑制方法 : CN202110797740.2[P]. | 2021-07-15 . |
| MLA | 徐斌 et al. "一种基于斑点簇定向移动控制和质量补偿的变极性等离子弧焊接气孔抑制方法" : CN202110797740.2. | 2021-07-15 . |
| APA | 徐斌 , 赵世宗 , 苗祺 , 蒋凡 , 陈树君 . 一种基于斑点簇定向移动控制和质量补偿的变极性等离子弧焊接气孔抑制方法 : CN202110797740.2. | 2021-07-15 . |
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Abstract ：
In this paper, a heat transfer model of the filler wire in twin-body plasma arc welding (TPAW) was established. The total power transferred to the filler wire included anode effect power, resistance power and plasma arc power. The influences of the wire current, wire extension and plasma gas flow rate on the power transferred to the filler wire were studied using the location of the molten region of the filler wire as the characteristic parameter. The studies showed that the anode effect power caused by the increase in wire current can increase the total power transferred to the filler wire by 50 % or more while the current flowing through the tungsten electrode of the plasma torch remains constant. This is confirmed by analyzing the weld shape under different wire currents. The resistive heating of the wire excision is not a major component of the total power transferred to the filler wire, and the wire extension can be set to a reasonably wide range of values. There was a threshold value for the influence of the plasma gas flow rate on plasma arc power. When the plasma gas flow rate was greater than the threshold value, plasma arc power remained nearly constant as the plasma gas flow rate increased. Therefore, the total power transferred to filler wire in TPAW was composed of anode effect power and plasma arc power. © 2021 The Society of Manufacturing Engineers
Keyword ：
Wire Wire Flow of gases Flow of gases Heat transfer Heat transfer Plasma welding Plasma welding Plasma torches Plasma torches Fillers Fillers Anodes Anodes Flow rate Flow rate Electric welding Electric welding Hard facing Hard facing Electric arcs Electric arcs
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| GB/T 7714 | Zhang, Ruiying , Jiang, Fan , Chen, Shujun . Power transferred to the filler wire in twin-body plasma arc welding [J]. | Journal of Manufacturing Processes , 2021 , 62 : 566-576 . |
| MLA | Zhang, Ruiying et al. "Power transferred to the filler wire in twin-body plasma arc welding" . | Journal of Manufacturing Processes 62 (2021) : 566-576 . |
| APA | Zhang, Ruiying , Jiang, Fan , Chen, Shujun . Power transferred to the filler wire in twin-body plasma arc welding . | Journal of Manufacturing Processes , 2021 , 62 , 566-576 . |
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