Liquid bridge blasting evolution behavior of rail AC flash welding

YANG Bo; DENG Jiarong; LIU Xin; LV Qibing

doi:10.12073/j.hjxb.20230220001

TRANSACTIONS OF THE CHINA WELDING INSTITUTION > 2024 > 45(2): 105-112. > DOI: 10.12073/j.hjxb.20230220001

YANG Bo, DENG Jiarong, LIU Xin, LV Qibing. Liquid bridge blasting evolution behavior of rail AC flash welding[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2024, 45(2): 105-112. DOI: 10.12073/j.hjxb.20230220001

Citation:

PDF (4868 KB)

Liquid bridge blasting evolution behavior of rail AC flash welding

School of Materials Science and Engineering, Southwest Jiaotong University, Chengdu, 610031, China

More Information

Received Date: February 19, 2023
Available Online: December 21, 2023

Graphical Abstract

Abstract

Abstract

The heating of the weldment, the protection of the end face, the removal of oxides and dirt during the rail flash welding process are all caused by the formation and blasting process of the liquid bridge. This paper analyzing the evolution behavior of the liquid bridge during the welding process plays an important role in understanding the rail flash welding process and further studying the welding heating and protection mechanism. Through the flash welding test of specially designed rail joints and conventional rail joints, the liquid bridge formation and blasting process images of rail AC flash welding process were collected by high-speed photography, and the obtained graphics were calculated and analyzed. The research results show that the formation and blasting time of the liquid bridge is millisecond, which will generate a large amount of high-pressure metal vapor beneficial to the end face protection and liquid bridge blasting, and the high temperature metal jet velocity after blasting can reach more than 90 m/s; During the formation and growth of the liquid bridge, there will be dynamic movement on the rail end face that will affect the uniform heating of the rail end face. The liquid bridge blasting is not at the initial formation position of the liquid bridge; During the welding process, the melt can appear the phenomenon of "secondary explosion"; Not only can the rail at the moving end form a liquid bridge, but also the vibration of the molten metal layer at the end is conducive to the formation of a liquid bridge.
- rail flash welding,
- liquid bridge blasting,
- evolutionary behavior,
- high speed photography

FullText(HTML)

References (12)

References

[1]	Ghazanfari M, Tehrani P H. Experimental and numerical investigation of the characteristics of flash-butt joints used in continuously welded rails[J]. Proceedings of the Institution of Mechanical Engineers, 2020, 234(1): 65 − 79. doi: 10.1177/0954409719830189
[2]	Zhang J, Zhang X, Li D, et al. Extrusion behavior of impurities in upsetting process of rail flash butt welding based on finite element method[J]. Journal of Materials Research, 2019, 34(19): 3351 − 3360. doi: 10.1557/jmr.2019.221
[3]	Stone H, Iwand C, Kristan J, et al. Flash butt rail weld vertical fractures[J]. Journal of Failure Analysis and Prevention, 2015, 15: 33 − 38. doi: 10.1007/s11668-014-9916-1
[4]	Ozakgul K, Piroglu F, Caglayan O. An experimental investigation on flash butt welded rails[J]. Engineering Failure Analysis, 2015, 57: 21 − 30. doi: 10.1016/j.engfailanal.2015.07.009
[5]	Han Y Q, Han J, Chen Y, et al. Stability of fiber laser-MIG hybrid welding of high strength aluminum alloy[J]. China Welding, 2021, 30(3): 7 − 11.
[6]	吴开源, 陈梓威, 黄浩, 等. 低频相位对双丝双脉冲GMAW熔滴过渡和焊缝成形的影响[J]. 焊接学报, 2022, 43(7): 43 − 48. Wu Kaiyuan, Chen Ziwei, Huang Hao, et al. Effect of low frequency phase on droplet transfer and weld formation of twin wire double-pulse GMAW[J]. Transactions of the China Welding Institution, 2022, 43(7): 43 − 48.
[7]	何顺鹏, 张曦, 李达, 等. U75V钢轨闪光焊闪光过程有限元分析[J]. 热加工工艺, 2019, 48(7): 233 − 236. He Shunpeng, Zhang Xi, Li Da, et al. Finite element analysis of flash welding process of U75V rail flash welding[J]. Hot Working Technology, 2019, 48(7): 233 − 236.
[8]	Wang X, Liu X, Zhang J, et al. Numerical simulation of end face heating in alternating current flash butt welding based on electrical–thermal bidirectional coupling[J]. The International Journal of Advanced Manufacturing Technology, 2022, 120(1-2): 173 − 183. doi: 10.1007/s00170-021-08599-7
[9]	张琪. 基于数字成像技术的闪光过梁爆破机制及焊接接头性能相关性研究[D]. 北京: 中国铁道科学研究院, 2017. Zhang Qi. Research on mechanism of flash beam blasting based on digital imaging technology and pertinence of welded joint property [D]. Beijing: China Academy of Railway Sciences, 2017.
[10]	宋宏图. 钢轨交流闪光焊接过程过梁爆破特征分析[J]. 焊接学报, 2018, 39(3): 120 − 123. doi: 10.12073/j.hjxb.2018380082 Song Hongtu. Study of flash beam blasting characteristics in the AC flash butt welding of rail[J]. Transactions of the China Welding Institution, 2018, 39(3): 120 − 123. doi: 10.12073/j.hjxb.2018380082
[11]	王莹莹. 钢轨闪光焊接头灰斑和微裂纹缺陷形成机理研究[D]. 北京: 中国铁道科学研究院, 2018. Wang Yingying. Research on formation mechanism of flat spots and micro-crack defects in rail welded joints[D]. Beijing: China Academy of Railway Sciences, 2018.
[12]	曲睿智, 黄良沛, 肖冬明. 选择性激光熔化过程中熔池演变与金属飞溅特性数值模拟[J]. 航空学报, 2022, 43(4): 405 − 424. Qu Ruizhi, Huang Liangpei, Xiao Dongming. Numerical simulation of melt pool evolution and metal spattering characterization during selective laser melting processing[J]. Acta Aeronautica et Astronautica Sinica, 2022, 43(4): 405 − 424.

[1]	ZHANG Yang, LV Xiaoqing, XU Lianyong, JING Hongyang. Effect of workpiece inclination on weld pool shape and weld forming in pulsed MAG welding[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2019, 40(10): 36-42. DOI: 10.12073/j.hjxb.2019400260
[2]	FAN Ding, YANG Wenyan, XIAO Lei, HUANG Jiankang. Effect of high frequency longitudinal alternating magnetic field on droplet transfer and spatter rate in high current GMAW welding[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2019, 40(7): 1-5. DOI: 10.12073/j.hjxb.2019400172
[3]	SU Zhiting, LI Huan, WEI Huiliang, ZHANG Yuchang. Improvement of laser on metal transfer in pulsed MIG welding[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2016, 37(9): 91-95.
[4]	LIU Dashuang, WEI Yanhong, LIU Renpei. “Slag spatter” behavior of slag-free self-shielded flux cored wire[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2015, 36(5): 10-12,84.
[5]	LI Fang, HUA Xueming, WANG Weibin, WU Yixiong. Modeling of droplet transfer electrical characteristics in pulsed gas melted arc welding[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2009, (7): 97-100.
[6]	YANG Yun qiang, LI Huan, LI Jun yue, LI Guo hua. High-speed Photography with Multi-information Synchronizer for GMAW[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2002, (6): 29-32.
[7]	Liu Gang, Li Junyue, Yang Lijun, et al. Nature of Pulse Waveform of MIG/MAG Welding Arc Spectrum——Reflection of Metal Droplet Transfer[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2000, (1): 34-36.
[8]	Feng Lei, Chen Shujun, Yin Shuyan. Mechanism of Undercut Phenomenon in High Speed Welding[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 1999, (1): 18-23.
[9]	Li Chunxu, Wang Xijing, Wei Jikuen, Li Heqi. Technology and facilities of high-speed strip overlay welding[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 1991, (4): 208-212.
[10]	Shao Chengji, Ci Rongmin, Li Deyuan. A STUDY OF THE FLOWING SPEED OF ARC SPRAYING PARTICLES BY HIGH SPEED CAMERA[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 1990, (1): 1-11.

Cited By

Cited by

Periodical cited type(1)

袁炜，胡梦伟，王晓，张曦，吕其兵，陈辉，陈静青. 钢轨焊接接头电感应加热数值模拟及工艺. 焊接学报. 2024(12): 79-89 .

本站查看

Other cited types(0)

Get Citation

PDF

XML

Article views (103) PDF downloads (13) Cited by(1)

Turn off MathJax

Article Contents

Abstract

References

Liquid bridge blasting evolution behavior of rail AC flash welding