Yang Zhijun,Kou Hongchao,Chang Hui,Li Jinshan,Hu Rui,Zhou Lian
Vol. 30, Issue 4, Pages: 295-297(2010)
摘要:Ti-10V-2Fe-3Al alloy ingots were prepared by different vacuum consumable arc remelting (VAR) processes. The effects of melting current intensity and stirring magnetic field on solidification behavior of the ingots were investigated, and molten pool profile and solidification structure at different stages, such as arc starting, melting and feeding, were analyzed. The results indicate that without stirring magnetic field, coarse grain can be observed in the ingots with a narrow molten pool, while with stirring magnetic field, grain size becomes fine with wide molten pool and evident rotation. With increasing in current intensity, grain size becomes coarse in the ingot with deepening the molten pool.
关键词:VAR;Ti-10V-2Fe-3Al Alloy;Electromagnetic Stirring;Solidification Behavior;Molten Pool
Cao Zhiqiang1,Liu Jidong1,Zhang Hongliang1,Li Tingju1,Wang Jiachun2
Vol. 30, Issue 4, Pages: 297-299(2010)
摘要:The as-cast and homogenized microstructure of DC 7050 aluminum alloy were investigated by differential scanning calorimeter (DSC), optical microscope (OM),scanning electron microscope (SEM) and X-ray diffraction (XRD). The results reveal that there exists an amount of non-equilibrium Mg(AlZnCu)2 phase with η-MgZn2 crystal structure in DC 7050 aluminum alloy ingots. The non-equilibrium phase is fully dissolved into the alloy matrix at 477℃ to further transform into large spherical Al2CuMg (S phase) at 490℃. With homogenization treatment at 460℃, the non-equilibrium Mg(AlZnCu)2 phase with η-MgZn2 crystal structure totally disappeares in the alloy with occurrence of spherical S phase in both intercrystal and grain. During cooling process, η-MgZn2 phase and S phase are precipitated from the grain subsequently, however, S phase disappears in the grain of the 7050 alloy ingots at 260℃.
摘要:Effects of quenching process on mechanical properties of 7075 aluminum alloy were examined by the universal mechanical testing machine and SEM (scanning electron microscope) to obtain the optimal quenching parameters. The results reveal that a wide quenching temperature range can be employed for treating 7075 aluminum alloy, however, overheating can be observed at 490℃, so the optimal quenching temperature is selected at 470±5℃, meanwhile, the water temperature and transferring time should be controlled below 40℃ and 30 s, respectively. The time span between quenching and aging treatment has little effect on mechanical properties of 7075 aluminum alloy.
摘要:Two kinds of filling morphologies existed in filling process of indirect squeezing casting thin-walled components were described, and factors influencing filling morphology were approached on the basis of jet theory. Furthermore, it was pointed out that optimal filling velocity should be gradually accelerated. In addition, from the view point of fluid kinetics, the filling process of liquid metal was analyzed, and the conditions that the optimal filling velocity should be satisfied were determined theoretically. Finally, as an example, the optimal filling velocity of a thin-walled component was presented by the equation.
摘要:90% in existing more than 200 squeezing casting machines at home belongs to refitted universal hydraulic press , limiting its application in types, products, stability of castings and product efficiency. Last years, squeezing casting machine was greatly developed in utility, properties parameters, automation, product stability of quality as well as product efficiency, especially SCH horizontal squeezing casting machine and SCV vertical squeezing casting machine, showing tremendous potential market in many trades.
摘要:Internal structural characteristics, key processing methods, frictional and wear behavior as well as anti-impacting behavior of 3D network ceramic/metal composites were described. The wear resistance of the composites is improved as a result of 3D network ceramics restraining plastic deformation and high temperature softening of the matrix as well as serious three-body wear. Meanwhile, anti-impacting behavior of the composites is enhanced through dispersing and transferring the load imposed on point or plate spacially. In addition, the composites exhibit more damage tolerance, which is attributed to structural interlocking effects resulting from 3D double continuous structures, decreasing the failure tendency of the composites.
关键词:Network Ceramics;3D Continuous Composites;Friction and Wear;Anti-impacting
Li Bing1,You Guoqiang1,Long Siyuan1,Zhang Baizai3,Yu Liang3
Vol. 30, Issue 4, Pages: 314-317(2010)
摘要:The rivet forming process was investigated by numerical simulation and point-tracking method based on the connecting technology between the aluminum alloy workpiece and the steel plate. Dynamic change of stress-strain at every point in deformation area and damage distribution of the deformation area were analyzed, which provided a theoretical basis for the study and design of the riveting process.
摘要:In order to resolve surface crack resulting from the casting thermal stress during the continuous casting ZF steel slabs, a geometric-physical model was established, in which the combination of the Adstefan software with temperature field measured actually was considered. Filling and solidification of the ingots were simulated by the model at different over-heating degrees, different drawing velocities and different tapers of the mould to observe the stress distribution in the slabs. The results reveal that with increasing in drawing velocities, thermal stress in the billet shell is decreased. However, excessive high drawing velocity can lead to thin the thickness of the shell, easily resulting in the leakage of liquid steel, even more the occurrence of reunion, so the surface crack would occur in the slabs during rolling process. With increasing in drawing velocities, leakage of liquid steel and reunion should be controlled as possible. With increasing in over-heating degree, thermal stress in the shell is increased, so during production, over-heating degree should be decreased as possible to decrease thermal stress. Meanwhile, with increasing in taper of mould, thermal stress in the shell is increased, so during production, proper taper of mould should be considered to decrease the thermal stress. At the same conditions, the thermals tress in the corner of the shell is evidently higher than that in the other positions. Camber angle can be adopted in design of the mould to effectively decline the thermal stress in the shell. In addition, effects of drawing velocity on thermal stress are higher than over-heating degree.
Liu Zheng,Jia Yingying,Mao Pingli,Li Yang,Wang Feng,Wang Hong,Zhou Le
Vol. 30, Issue 4, Pages: 321-323(2010)
摘要:With a given die temperature and pouring temperature, the Flow-3D software was employed to simulate filling and solidification of liquid magnesium alloy to observe the distribution and potential position of defects including gas hole and shrinkage porosity in the magnesium alloy steering bracket in condition of injection velocities of 4.3, 6.0 and 7.8m/s to determine the optimized pouring parameters. The results reveal that in conditions of the mould initial temperature of 220℃ and pouring temperature of 700℃, the desirable filling effects can be observed with injecting at 6.0 m/s, and qualified steering bracket without gas hole and shrinkage porosity is produced successfully.
关键词:Die Casting Magnesium Alloy;Numerical Simulation;Filling and Solidification;Processing Optimization;Die Castings;Temperature Field
Wang Jiaxuan,Jiang Lihong,Fang Min,Xiong Hongmiao,Luo Yizheng
Vol. 30, Issue 4, Pages: 323-325(2010)
摘要:We have developed an ultrasonic treatment apparatus to investigate effects of ultrasonic vibration on refinement of grain size in A356 alloy melt. The results reveal that grain size in A356 alloy is obviously refined with applying ultrasonic treatment. With increasing in ultrasonic power, grain becomes finer and finer in the structure of A356 alloy. In addition, ultrasonic temperature has some effects on refinement of grain size. Grain size change was observed with exerting ultrasonic vibration on the A356 alloy melt at 640, 620 and 600℃. It is found that desirable grain refinement can be obtained at 640 ℃.
L Shulin,Wu Shusen,Dai Wei,Zhu Zeming,Mao Youwu,Wan Li
Vol. 30, Issue 4, Pages: 326-329(2010)
摘要:Effects of processing parameters on 5052 semi-solid slurry prepared by ultrasonic vibration at 665℃ were researched. The results reveal that non-dendrite semi-solid slurry with grain size of approximately 110μm can be prepared by imposing ultrasonic for about 90 s on the alloy melt. With extending in ultrasonic time, grain shape becomes more and more round, however, roundness change can be neglected with holding more than 90 s. Starting-vibration temperature greatly affects the structure of the slurry. The 5052 aluminum semi-solid slurry with approximately 95μm in average grain size and spheroidized structure can be observed with introducing ultrasonic vibration at 675℃ for 90 s. Grain size is grown slowly in the slurry with holing within 2 min, however, grain begins to merge with holding for 4 min.
摘要:Temperature control system for preparing semi-solid rheoforming slurry based on pulse-width modulation (PWM) was described, and working principle, working circuit of the system and structure and application of PWM control chip were analyzed. SiMo rod was adopted as heating unit. It is found that working current of SiMo rod is less than 200A (designed value) during temperature increases, holding temperature and temperature decrease process, realizing the goal of current-control. Temperature control system exhibits stability and non-oscillation in condition of disturbance, where constant temperature control is less than 0.5℃ and temperature fluctuation is in range of ±1℃, fully meeting requirements of heating for ferrous metal semi-solid more than 1500℃.
摘要:Effects of stirring velocity and secondary cooling rate on average grain size and shape factors of AZ91D semi-solid slurry were investigated. Stirring velocities and secondary cooling rate are taken as the dominant factors influencing solidification structure evolution of semi-solid AZ91D alloy. The results reveal that increasing in stirring velocities is beneficial for the refinement of primary phase size and the improvement of the particle roundness, while increasing in secondary cooling rate is helpful for the refinement of the grain size but harmful for the particle roundness. Constitutive equations between solidification structure and stirring velocities as well as secondary cooling rate were presented on the basis of multiple non-linear regression method, providing a reference for preparing desirable semi-solid slurry.
摘要:Mechanical properties of electromagnetic low pressure casting AlSi7Cu2Mg alloy were tested. The results show that average tensile strength and average elongation of electromagnetic low pressure casting AlSi7Cu2Mg alloy reach 322MPa and 4.66%, respectively, compared with those of ones prepared by gravity casting, increased by 4.89% and 23.94%, respectively.
Song Dongfu1,You Guoqiang1,Long Siyuan1,Lin Weihong2,Shi Yongjing2
Vol. 30, Issue 4, Pages: 336-338(2010)
摘要:The adhesion, hardness, finish and salt spray resistance of five kinds of organic coatings, such as acrylic, epoxy, silicone, ceramic silicone and fluorocarbon, on magnesium alloy die castings were examined comparatively, and availability of the coatings was evaluated in term of economic cost and technical economy. The results reveal that different organic coatings posses different technical economic characteristics. Epoxy resin coating exhibits significant technical economic advantages in corrosion protection, and ceramic silicone and fluorocarbon resin coatings are prominent in hardness and finish, however the corrosion resistance exhibits relatively lower with high cost, showing a lower technical economy, and silicone coating has comprehensive performance and low cost, revealing better technical economy. Although acrylic coating is cheap, poor corrosion resistance restricts its application, deteriorating technical economy.
Wang Jian,Hou Liqun,Qi Zhiwang,Chen Hong,Fan Yunbo
Vol. 30, Issue 4, Pages: 339-341(2010)
摘要:Combining with the manufacturing process of large 2A50 wrought aluminum alloy wheel by squeezing casting, effects of heat treatment on microstructure and mechanical properties of the squeezed casting 2A50 wrought aluminum alloy was investigated by means of optical microscope (OM), SEM(scanning electron microscope) and tensile testing. The results indicate that the burned temperature of the alloy reaches 530℃, tensile strength and elongation of the alloy with solid solution at 505 ℃ for 8 hours plus 515 ℃ for 2 hours and aging at 160 ℃ for 12 hours reach more than 400 MPa and more than 6.5%, respectively. Meanwhile, the alloy exhibits compact structure and refined grain size without anisotropy.
摘要:Aqueous releasing agent is extensively used in the die casting because of its series of advantages. Based on the selection of raw materials, through optimizing the composition proportion, the optimized proportion of aqueous releasing agent is composed of 25%machie oil, 12.5% lipid, 3.3% lanolin, 1.6% span 80, 3.2% OP-10, 0.2% xanthan gum, 0.3% antiseptic, 0.3% antioxidant, 0.3% defoamer and 53.4% water. The releasing agent prepared by phase conversion emulsion method exhibits a better stability,and high temperature wettability and film properties. The practical application shows that the releasing agent exhibits a preferable releasing ability with being diluted as 1∶90 ratio, which is equivalent to an abroad releasing agent in comprehensive properties, however, showing the better glossiness. Meanwhile, the releasing agent has the lower cost than that of two kinds of abroad ones, decreased by 40%50%.
摘要:Temperature distribution in the die during die casting process was calculated and analyzed by the FEM software ProCast, and effects of temperature of cooling water, diameters of water tubes and its position on temperature field in the die were approached quantitatively and comparatively. The results reveal that temperature field in the die is almost accordant with temperature increment with cooling at 30℃ and 50 ℃. Position and diameters of water tubes have a great effect on the temperature distribution in the dies and the isothermal layer. With distance of water tubes to the cavity surface of 35 mm, the temperature distribution in the dies is more reasonable than that to 45 mm as a result of a higher temperature increment resulting in faster thermal transfer and a lower temperature gradient. In addition, with 10.5 mm in diameters of water tubes, the temperature distribution in the dies is more desirable than that of ones when the diameters of the water tubes are 8 mm and 9 mm.
摘要:According to configures of D19 aluminum alloy lower cylinder block combining with practical production circumstance, low pressure casting was adopted to produce it. A scheme in which bearing face is set towards down and ingates are set at crankcase baffle is designed. Exhaust groove and venting plug were added at the position easily occurred in misrun. WFZJ458E low pressure casting machine with locking force more than 180 kN was used. Mould with six-open structure was designed, and temperature -control system with water cooling combining with air cooling was adopted. The results show that leakage rate of the lower cylinder block is less than 5% and qualification rate is more than 95%.
摘要:Aiming at the difficulties in forming the bottom of rectangle plate and high wrapping force caused by the deep cavity, the mould structure with movable inserts and ejecting by fixed mould was adopted. A movable insert on which overflow well is designed is set on the bottom of the deep cavity far away from the gate, which is beneficial for the formation of bottom of deep cavity. The movable insert and the castings were ejected together and then the former was taken away. Two parting surfaces were set on the mould, in which liable limit-distance mechanism was applied. Cavity plate of fixed die was taken as stripping plate, which eliminated the wrapping force to keep the castings stay in the movable die during secondary parting.
关键词:Rectangle Plate;Eject by Fixed Die;Secondary Parting;Die Casting Die
摘要:Production of K4537 superalloy gas turbine impeller by investment casting was described, and investment casting process was investigated systematically. The results show that it reduces the development time and production cost by rapid prototyping technology to produce mold shell. Porosities in the turboshaft can be effectively eliminated by adopting spherical running and feeding system and using suitable pouring and mold temperature. Filling of thin-walled blade can be ensured effectively by covering a layer of insulation blanket on blade. The gas turbine impeller with desirable metallurgical quality was successfully produced by adopting those methods, meeting the requirements of the design and use.
关键词:K4537 Superalloy;Investment Casting;Rapid Prototyping Technology;Gating System
摘要:A way to resolve crack defects of complicated ceramic mold core was described. Crack defects easily occurs in ceramic mold core with complicated structure, great difference in thin-thick wall and fine-neck shape during pressing and sintering process, which is difficult to be resolved by conventional ways. Pressing and sintering qualification rate of ceramic mold core can be greatly improved by pre-setting core-bone, obviously increasing the qualification rate of investment castings.
摘要:OCC (Ohno continuous casting) method is a special continuous directional solidification technology, which can be employed for preparing single crystal ingot. A method and equipment for producing single crystal copper pole have been described. Based on the sevo control and A/D transformation technology, the whole production process can be controlled by computer automatically. The single crystal copper pole produced by the equipment exhibits smooth surface and high ductibility and high electric conductivity, showing acceptable practical value.
关键词:Single Crystal Copper;Ohno Continuous Casting;Equipment;Automatic Control
摘要:EPC is greatly superior to common sand mold casting in producing complicated engine four-cylinder block. Processibility analysis and mould cutting principle of cylinder block foam pattern were expounded. Mould cutting of cylinder block foam pattern finally adopted a technological scheme that was horizontal pattern combining with vertical pattern by comparative analysis, in which processibility, contraction and cementing negative was reasonably considered. Combined with parameterization modeling technology in Pro/E software, the foamed plastic pattern and mould design were synchronously performed with the decrease of designed time.
摘要:Fe3Al intermetallic network structural materials were prepared by mechanical alloying, annealing and heat treatment, and effects of sintering temperature, temperature increment rate, porosity on compressive strength and fracture toughness of the materials were investigated through observing morphology using SEM (scanning electron microscope), XRD (X-ray diffraction), meanwhile, fracture mechanism of the materials were approached also. The results demonstrate that with increasing in sintering temperature, porosity in the Fe3Al intermetallics is gradually densified , and desirable structure and performance can be obtained with sintering at 1420℃, however, it is deteriorated for formation of the materials as a result of evidently collapsed deformation with further increasing in sintering temperature. Mechanical properties of the Fe3Al materials are mainly controlled by porosity rate. Porosity rate can be decreased with a lower sintering temperature-increment rate, which is beneficial for improving compressive strength and fracture toughness of the materials due to generation of frame with compact structure. Based on bridge theory and self-healing mechanism, ways of improving mechanical properties of the materials were described. Through adding Ti element and controlling proper porosity rate, compressive strength and fracture toughness of the materials were improved.
摘要:Connected ceramic preforms (B4C) with porosity of 46.8% were fabricated by pressureless sintering in vacuum, then B4C/Al-Si composites with high ceramic fraction were prepared by pressureless infiltrating aluminum alloy A356 into the boron carbide preforms B4C, whose relative density, compressive strength and flexure strength are more than 99%, 453MPa and 294MPa, respectively. Microstructural observation reveals that prepared composites exhibit compact structure and desirable interface bonding, in which formed Al, Si and Al3BC phases are uniformly distributed. Al phase is mainly distributed in the cavity of B4C frames and Si mainly existed in the interface of B4C and Al phase, which results in the tough combination of B4C and Al phases, meanwhile, uniformly distributed Al phase can be observed in surface and inner of composite samples. B4C ceramics is formed continuous frame in the fabricated B4C/Al-Si composites and metallic phase existed in the cavity plays the role in toughening and strengthening effects.
Liu Huiping,Liu Zhiyong,Wang Mingxing,Liu Zhongxia
Vol. 30, Issue 4, Pages: 369-371(2010)
摘要:Ti3Al alloys were prepared with taking Ti and Al powders as raw materials by direct sintering processing. Effects of molar ratio of raw materials and temperature on preparation of high pure Ti3Al alloy were analyzed, and microstructural evolution of the intermetallics during subsequent processing was described. High pure Ti3Al phase can be obtained with Ti via Al of 3.5∶1 (molar ratio). A certain amount of Ti3Al powders were prepared by sintering method, and then milled by planetary ball mill. XRD and SEM were employed to observe the powders at different milling time. The results reveal that grain size of the Ti3Al alloy is decreased, and some powders become amorphous structure during milling process.
摘要:Cu-based composite coating was formed on the surface of 6061 aluminum alloy by laser cladding method. The microstructure and chemical composition of the coating were analyzed to understand effects of the change of cladding alloy composition on quality, micro-hardness and wear resistance of the coating. The results reveal that cladding coating is mainly composed of (Cu, Ni) solid solution, Cu9Al4, AlFe0.23Ni0.77 and CoFe phase. In condition of optimized chemical composition, with Fe and Co contents of 7%, 9%, respectively, amounts of hard particle reinforcements are uniformly dispersedly distributed into Cu-Ni solid solution in cladding coating, which improves the wear resistance of the 6061 aluminum alloy matrix. Compared with those of 6061 aluminum alloy matrix, surface hardness of cladding coating is increased by 4.5 times, and frictional volume and frictional coefficient are decreased to 30% and to 0.301, respectively, after laser cladding treatment.
Liu Zhiwen1,Yan Hongge1,Zhu Suqin1,Tang Zhi2,Chen Jihua1
Vol. 30, Issue 4, Pages: 376-379(2010)
摘要:Microstructure and mechanical properties of the Mg-2Si alloys prepared with fine Si powders as the raw materials were investigated by OM (optical microscope), SEM (scanning electron microscope), XRD (X-ray diffraction) and tensile testing. The results show that the primary Mg2Si particles are characterized by the fine polyhedral shape with size less than 10μm and length of eutectic Mg2Si rods is less than 100μm after fine silicon powders with size less than 48μm is added into the aluminum melt at 700℃ and holding for 3 min. Amounts of fine primary α-Mg phase and primary Mg2Si phase are precipitated from the aluminum melt during solidification as a result of many Si rich regions and Si-poor regions occurred in the melt with addition of Si powders, forming compact skeleton frame to divide the residual melt and restrain the growth of the eutectics, which is responsible for the improvement of mechanical properties.
关键词:Mg-2Si Alloys;Fine Si Powders;Primary Mg2Si;Eutectic
摘要:Wear resistance and microstructure of self-melting silicon brass 60Cu-Zn-Si alloy with heat treatment at 200, 400, 600, 800℃, respectively, for 1 hour and quenching in water, were analyzed. It is found that with increasing in temperature, wear weight loss of 60Cu-Zn-Si alloy is firstly decreased and then increased. The lowest weight loss of the alloy can be observed after solid solution treatment at 400 ℃, showing desirable wear resistance. In addition, microstructural observation shows that 60Cu-Zn-Si alloy after solid solution treatment at 400 ℃ exhibits uniform structure with fine grain size, in which fine disperoids is uniformly distributed.
摘要:HPb58-2A dodecagon abnormal-shape tubes with 5 mm in the smallest thickness and crack free was produced with recycled scrap cooper by continuous casting at 950℃ and 180350 mm/min in condition of cooling at 40℃. Microstructure of the tubes was analyzed by optical microscope (OM), SEM (scanning electron microscope) and EDS (energy dispersive spectrum). The results reveal that Fe based solid solution is formed into dendrite due to exhibiting preferred growth with mass ratio of Si via Fe increasing to 0.078, while with mass ratio of Si via Fe of 0.178, Fe-Si phase shows polygonal structure. α phase is solidified ahead to β phase , which results in the higher Pb concentration in latter solidified β phase and the highest ones in interface of α phase and β phase. During cooling process, Pb particles is dispersedly grown in α phase and β phase, and size of Pb particles in both α phase and in β phase are less than 0.5μm and 0.75μm, respectively. In addition, size of Pb particles exhibiting rosette structure in the β phase in interface reaches up to 2.5 μm. Fine Pb particle can not only ensure excellent cutting performance but also increase mechanical properties of continuous casting abnormal-shape tubes.
关键词:Recycled Scrap Copper;Pb Brass;Fe Based Solid Solution;Pb Based Solid Solution;Horizontal Continuous Casting
摘要:Effects of B modification treatment on as-cast microstructure, mechanical properties and corrosion resistance of Cu-Ni white copper alloy in simulated sea water were investigated. The results reveal that B element can greatly improve the plasticity , strength and hardness of the white copper alloy as a result of remarkably refining as-cast microstructure. Meanwhile, corrosion resistance of the Cu-Ni while copper alloy is improved also with B addition, which is attributed to the generation of compound beneficial for improving compactness of oxide film in corrosion product to further restrain the corrosion behavior.
摘要:Origination of defects, such as shrinkage porosity, pin hole, gas hole and inclusion, in valve housing was analyzed. Aiming at these defects, through some measures, including adjusting pouring position, optimizing gating system and adding foam ceramic filter and arbitrary chill and arbitrary riser as well as strictly controlling melt quality, defects in the valve housing were eliminated basically, and passing rate of the valve housings for compression resistance testing exceeded 80%.