摘要:The change behavior of thermoelectromagnetic convection in silicon melt under the steady magnetic field during direction solidification of polysilicon was simulated by COMSOL Multiphysics version4.3abased on finite element method(FEM).The results show that with 0≤B<0.4T,the flow region of silicon melt and average flow velocity are increased with increasing in the magnetic flux intensity.The magnetic field plays a promoting role in the flow of silicon melt.When the magnetic field intensity reaches 0.4T,the maximum of the average velocity in silicon melt is 60.15μm/s.With 0.4T<B≤1.0T,the flow region of silicon melt and average flow velocity are decreased with increasing in magnetic flux intensity,which is declined quickly compared with growth stage of flow.The inhibitory effect of the magnetic field on the flow rate of silicon melt exhibits obvious.Finally,influence of the thermoelectric magnetic force and electromagnetic force on the thermoelectromagnetic convection in silicon melt was described according to the theory of thermoelectric magnetohydrodynamic.
摘要:Al-12.5Si alloy was melted for directional solidification.Through adjustment of alloy composition,temperature gradient and solidification velocity,processing parameters for different eutectic morphologies such as eutectoid flat plane,cell grain,columnar grain,equiaxed grain,were presented in directional solidification.The effects of alloy composition,temperature gradient and solidification velocity on eutectic solidification modes were analyzed.
摘要:A large aluminum alloy wheel rim for the vehicle was produced by the isothermal forging.During isothermal forging process,blank and mould keep the same temperature and constant strain rate to avoid the decrease of blank temperature during deformation process and cooled mould effects.Using throughout-hole extrusion and pre-producing blank,the required deformation rate can be realized through continuous reverse extrusion,greatly decreasing deforming force and eliminating the crack in wheel rim.
摘要:SAF2906duplex stainless steel was nitrided at 610 ℃for 60,90,120,150 and 180min,respectively,then followed by the same post-oxidation process with heating temperature at 400℃for 30 min.The microstructure and wear resistance of the treated samples were investigated by means of OM(optical microscope),SEM(scanning electron microscopy),XRD(X-ray diffraction),microhardness test and wear resistance test.Microstructure observation indicates that the surface layer of the samples after QPQ treatment is composed of oxide layer,compound layer and diffusion layer from the surface to the center.The oxide layer is composed of Fe3O4.The main phase of the nitrided layer,such as compound layer and diffusion layer,consists of CrN,α-N,Fe2-3N and Sphase.With nitriding time increase,the growth rate of the compound layer is gradually slowed down,and the loose microstructure exhibits more serious.Porosity of the surface layer is increased with the extension of time,and its relative density is declined.The surface hardness of QPQ treated samples is 3times more than the substrate,which is first increased and then decreased with increasing in nitriding temperature,and the optimum hardness is1164HV0.2at 120 min.The dry sliding results show that the wear resistance of QPQ treated samples reaches at least 20 times than that of the substrate,and the desirable wear resistance is presented at 120 min.The worn surface morphology observation reveals that the abrasion form of the substrate belongs to plough cutting,while the abrasion form of QPQ treated samples belongs to micro-cutting.
摘要:Based on the structure of cast copper cooling stave,two kinds of gating systems were designed,and the casting process was simulated by the ProCAST software in order to visualize the casting defects.And then,the process was optimized based on the simulated results,and the final casting process of cast copper cooling stave was determined.The trial production shows that the cast copper cooling stave can meet the requirement.
摘要:In digital management mode,as the carrier of enterprise’s casting process,the casting process card is often not comprehensive and detailed,which results in the mismatch between workshop production and casting process.Besides,the current casting process card can not form closed loop feedback with production process and quality information,so can not effectively control the cost of casting process.Aiming at the problems mentioned,a casting process card reference model based on digital technology was proposed.The casting process card reference model is composed of modeling,mould assembling,casting,blasting and so on,which covers mould process,operating route job,process BOM,process cost,quality require,feedback of production and quality test.The practical application reveals that the process card reference model can effectively guide workshop production,control casting quality well,form process BOM fast and accurately and better control process cost.
关键词:Foundry Enterprises;Casting Process Card;Workshop Production;Casting Process Level
摘要:Semi-solid 2024 aluminum alloy billets were prepared by conventional RAP route(recrystallization and remelting),and a cap parts were produced with the semisolid billets by thixoforging.The inhomogeneity of microstructure and composition as well as processing parameters of billet prepared were analyzed.The results show that the microstructure solidified from liquid phase is relatively minor at the center of billet,and liquid phase deposition at the flange region is major,resulting in shrinkage defects and micro-cracks.The composition segregation exhibits serious increasingly near to the flange region,and the segregation can be reduced with in the crostructure with fine grains.
摘要:Using the slot gating system,with filling temperature of 590 ℃,mould preheating temperature of 200℃,injection speed of 5m/s,the filling and solidification process of A356 alloy electric field sensor shell were simulated by the ProCAST software to improve and optimize the gating system parameters.The results show that using semi-solid casting in form of the gate with castings tangential,gasentrapment and shrinkage porosity can be decreased to ensure mechanical performance consistency of the electric field sensor,and the overall quality of the electric field sensor is improved.Adopting the optimized parameters experiment,qualified electric field sensor was produced successfully.
关键词:Semi-Solid Die Casting;Numerical Simulation;Gating System;Porosity Shrinkage
摘要:Microstructure evolution and the quantitative relationship between theα-Mg grain size as well as shape factor and process parameters of both the semi-continuous cast and extruded AZ80 magnesium alloy were investigated after semi-solid isothermal treatment(SST).The results show that,with a given parameters,theα-Mg grain size exhibits more spherical with more uniform distribution in the extruded AZ80 magnesium alloy after SST,and the liquid phase in theα-Mg grain is generated from intracrystalline partial melting priority due to solution elements enrichment and high energy reserves,while the semi-continuous casting AZ80 magnesium alloy,the liquid phase in theα-Mg grain is caused by liquid phase entering inside the grain due to the dendrite arms coalescing.After SST with different parameters for extruded AZ80 magnesium alloy,theα-Mg grain sizes follows Gauss distribution.At 570℃for 20 min,the distribution of solid and liquid phase is relatively homogeneous,and the shape factor ofα-Mg grain size mainly concentrates in high coefficient area with relatively high average shape factor value of0.86.
摘要:The main problems existing in the design of carbon nanotubes(CNTs)reinforced magnesium matrix composites were presented such as the dispersed uniformity of CNTs in the magnesium matrix and effective interface bonding between the CNTs and magnesium matrix.The dispersed uniformity of CNTs,selection of preparation method and process,interface bonding between CNTs and magnesium matrix were analyzed to explore the effective method for solving the problems mentioned.Finally,the development trend of the design of CNTs reinforced magnesium matrix composites was surveyed.
摘要:Luk die casting housing used for special conditions taken high scrap rate and difficult product due to clamping forces of static container more than far away the moving container in die casting die design.So the die casting die was modified.Advanced preset pull rod for pressure rod was assembled on the mould to improve the deformation of the housing and reduce the housing soldering with the static container.In addition,drawing core mechanism for the static container was added and pendulum hinge was set between moving container and middle plate to eliminate the maximum clamping force from the static container,which taken release smoothly and eliminated the deformed scraps.
摘要:Based on CAE,solidification and filling process of aluminum alloy high-voltage switch housing were simulated.Through the analysis of temperature field and casting defects in the aluminum alloy housing during the solidification process,process was optimized.The results show that the aluminum metal alloy housing can eliminate the shrinkage porosity(holes)through adding feeding channel in the sand core for partial thick-wall position to realize the sequential solidification.
关键词:High Voltage Switchgear;Aluminum Alloy Housing;Numerical Simulation;Processing Design
摘要:Through hardness testing,metallographic microscope analysis,and other means,the origination of crack failure in the die casting die for aluminum alloy was analyzed.The results reveal that the crack failure of the mould is mainly attributed to the electrical discharge machining,the improper heat treatment process and the impact of liquid metal.Through the optimization of the heat treatment process,such as multi-staged heating at 480,700 and 850℃ +vacuum oild quenching at 1 050℃ +seconding tempering at 600℃,and proper preheating mould as well as annealing treatment to reduce design hardness to 4647(HRC),the service life of die is improved greatly.
关键词:Die Casting Die for Aluminum Alloy;Failure;Heat Treatment Process;Service Life
摘要:With the rapid development of technologies of mechanical automation,automatic units are widely used for pressure die casting.However,the production management capacity for the machine needs to be improved.The most efficient way is to develop remote monitor system for the die casting units.Combined with information management requirement,the development and application of remote monitor system was introduced,including communication mode between die casting machine and ancillary equipment,remote monitor system design proposal,software implementation and the application estimation.Remote monitor terminal can communicate with the device based on industrial Ethernet and OPC technology.The result indicates that the system can find the substandard products caused by unstable injection.
摘要:Aiming at die casting workstation using multi manipulator to improve the problems in production operating rate,production cycle and reasonable use of the production line layout to complete the die casting process at the domestic and foreign,a method of off-line programming of a full automatic die casting production system was developed.Based on the RobotStudio platform,a full automatic die casting production system workstation was established including development and production of system program,simulation robot,die casting machine,hydraulic machine automatic production process,the production system of off-line programming can be realized.The results show that the system can improve the flexibility of production,production efficiency and reproducibility,improving the utilization rate of equipment,and greatly shortening the production preparation time for equipment.
摘要:Magnesium alloy was treated by compound Ca alloying addition and Nd modification,and then it was formed by squeezing casting at 100 MPa to understand effects of Nd on microstructure and mechanical properties of the alloy by XRD(X-ray diffraction)and EDS.The results reveal that grain size in the squeezing casting alloy is refined,and dislocation is easily generated with the uniform fine precipitation phase,greatly improving the mechanical properties of the alloy.With 0.4% Nd addition,the mechanical properties of the alloy exhibit desirable,where tensile strength,yield strength and elongation reach 230 MPa,121MPa and 4.8%,respectively,increased by 28%,61%and 78%,respectively.
摘要:Effects of electromagnetic stirring on equiaxial crystal ratio in 430 ferritic stainless steel、409L ferritic stainless steel and 2205 duplex stainless steel slab were analyzed under industry test.The results show that the equiaxial crystal ratios in slabs with electromagnetic stirring are obviously increased compared with no-EMS,and the equiaxial crystal ratios in slabs are all different,which is related to the characteristics of stainless steel grade.
摘要:In order to improve the strength of silicon sol shell for investment casting process,glass fiber was mixed into the slurries to prepare the sol silicate shell samples.The properties such as bending strength of green shell,fired strength and self-loaded deformation at elevated temperature were investigated,and the fracture surface of shell samples were observed by SEM(scanning electron microscopy).The results show that the green strength of shell specimens with glass fibers is increased,and the selfloaded deformation at elevated temperature is firstly increased and then decreased.The shell specimen reinforced with 0.6%fibers addition reaches the highest green strength of 4.61 MPa,and the self-loaded deformation at elevated temperature has a decrease of about 24% with the 1.0%fiber addition.The fired strength of shell sample with the concent of 0.2%1.0%glass fiber is increased more than 12%.It is found by SEM that the failure of the fiber-reinforced shell specimens at the applied load is attributed to breakdown of silicon sol films and pulling-out and debonding of fibers in the shell.
摘要:Taken full mold casting stamping die as samples,the basic procedure and key caution of bimetal casting process were described.Foamed pattern adopted EPS materials with 17kg/m3 in density with conventional graphite water-based coating and cold cured furan resin sand mould.Open gating system was designed,where the first package liquid iron(HT300with Cr and Mo)was poured into the mould at 1 360℃,and the second package liquid iron(HT300)was poured into the mould ahead of 23scompleting the first package pouring with 2times of the first package weight.The results show that the size,appearance and color of the castings produced meet the quality requirement.After heat treatment,the hardness of the bottom and upper working surface reaches 195(HBS)and 170(HBS),and tensile strength is more than 300 MPa.
摘要:The continuous casting for bismuth-bearing zinc-copper-nickel alloy substituted for lead-bearing zinc-copper-nickel alloy was conducted because of the toxicity of the lead element.Experimental results reveal that in the tradintional way,the coarse grains can be observed with radiation growth along heattransferring direction,resulting in the the poor plasticity.After improvements,compulsive heating and cooling equipments were installed at the exit of horizontal continuous casting furnace,and the growth of grain crystal in axial direction was promoted and grain size was refined.The elongation rate of bismuthbearing zinc-copper-nickel alloy continuous casting rod is increased more than 20%,after annealing and cutting detection,it could completely replace lead-bearing zinc-copper-nickel alloy.
摘要:The distribution of TiH2 particles foamed agent in the liquid aluminum alloy is related closely with the structure and properties of foamed aluminum.Dispersed behavior of TiH2 particles in the molten aluminum was simulated by the Fluent,especially effects of stirring blade parameters and stirring speed.The results show that dispersed uniformity of TiH2 particles is affected by radial and axial flow of molten aluminum,and it is related with stirring blade parameters and stirring speed.With 3layers of stirring blades with 30 cm in length,inclined angle of 30°and stirring velocity of 50r/s,distributed uniformity of TiH2 particles in molten aluminum exhibits desirable.
摘要:Effects of different RE addition and solid solution treatment on microstructure and tensile properties of as-cast and as-solution ZL301 alloy were investigated.The results indicate that tensile strength and elongation of the as-cast alloy can be improved with mixture RE addition,which are attributed to grain refinement and creation of Al-RE discontinuously distributed along grain boundary to strengthen grain boundary.The mechanical properties of ZL301 alloy exhibits desirable with 0.5% RE addition and solution treatment at 435℃for 16 h.With mixture RE addition more than 0.5%,the tensile strength and elongation of the alloy are deteriorated as a result of Al-RE phase continuously distributed along grain boundary decreasing bonding strength of grain boundary.
摘要:Hot compression test of the Al-Zn-Mg-Cu alloy with Zr addition was carried out on the Gleeble-1500 thermal simulation machine at 300450℃and the strain rates of 0.000 51.000s-1.The microstructure of the alloy under different deformation conditions was observed using optical microscopy(OM),electron back scattered diffraction(EBSD)and transmission electron microscopy(TEM).The results show that the dislocation density is decreased and the subgrain size is increased with increasing in deformation temperatures or decreasing in strain rates,leading to the decrease of peak stress.Under the given thermal deformation conditions,the microstructure is mainly controlled by low angle boundaries,and the main softening mechanism is characterized by dynamic recovery.Amounts of Al3 Zr particles with the size of 1025nm are generated after adding minor Zr in Al-Zn-Mg-Cu alloy,which can pin dislocations and subgrain boundaries to inhibit recrystallization during deformation,which are responsible for the alloy keeping dynamic recovery microstructure under the given hot deformation conditions.
摘要:Effects of grain refiner on microstructure and mechanical properties of the Al-Mg-Zr alloy were investigated by adding trace Sc or Ti elements and compound adding Ti and Sc.The results show that the addition of 0.15%Ti can positively refine microstructure of the alloy and improve mechanical properties obviously.And the combined addition of 0.2%Sc and 0.15%Ti exhibits the desirable grain refining effect,where average grain size of the alloy is refined to only about 43μm,and the strength and elongation are improved by about 70%and 16.4%,respectively,which is largely attributed to the formation of Al3 Ti,Al3Sc,Al3(Ti,Zr),Al3(Sc,Zr)and Al3(Sc,Ti)particles commonly to act as heterogeneous nuclei and to promote the grain refinement.
摘要:Influences of different Ce content on microstructure and mechanical properties of ZL107 alloy were investigation by scanning electron microscopy(SEM),tensile testing,wear resistance testing and corrosion resistance testing.The results show that morphology of eutectic Si in the ZL107 alloy is transformed from needle-flake shape to short bar shape with uniform distribution after modification,and the grains size is refined.The properties of ZL107 alloy with Ce modification are improved remarkably.The tensile strength and elongation of the alloy with 0.3% Ce modification reach up to 198.7 MPa and3.7%,respectively,and the wear resistance and corrosion resistance are increased by 61% and by70.8%,respectively.However,modification effect become worse with further Ce addition,decreasing the properties of the alloy.
摘要:The corrosion inhibition of AZ91 Dmagnesium alloy in 1g/L NaCl solution with sodium fluoride was detected by weightless,Tafel polarization curves,electrochemical impedance spectroscopy(E IS)and scanning electron microscopy(SEM).With adding sodium fluoride into salt solution,protective coating MgF2 is formed on AZ91 Dsurface,which prevents Cl-adsorption on the interface between the sample and corrosive medium,therefore inhibiting the corrosion.With the concentration of sodium fluoride from 1g/L to 3g/L,the inhibition efficiency is increased,and the depth and quantity of pits become shallow and less with the corrosion potential moving positively and the capacitive loop of electrochemical impedance spectroscopy increases.Sodium fluoride is the corrosion inhibition of anode inhibited type.The inhibition efficiency is more than 50%and the highest value reaches 85%in 1g/L NaCl with NaF for 168 h.
摘要:Double gradient porous HA/Mg composites where both porosity and HA exhibited gradient distribution were prepared by powder metallurgy method.Effects of the content and distribution of the pore former and HA on the porosity and compressive strength of the composites were analyzed.The microstructure of the sintered composites was observed,and corrosion resistance of the composites was examined.The results show that with the increase of the pore former in the inner layer of double gradient porous Mg/HA materials,the porosity of the composites is increased and compressive strength is decreased.With the increase of the HA content in the outer layer of double gradient porous HA/Mg composites,the compressive strength of the composites is decreased and the porosity of the composites is increased.The corrosion resistance measurement shows that with the increase of the porosity,the corrosion resistance of the composites is weaken.Double gradient porous HA/Mg composites is superior to gradient porous Mg material in corrosion resistance.With the increase of HA content in the outer layer of the composites,the corrosion rate of the composites is decreased and pH of solution is increased slowly.
关键词:HA/Mg Composites;Gradient Porosity;Gradient HA Phase;Compressive Strength
摘要:In order to improve the forming quality and production efficiency of superplastic forming Zn-5Al alloy drum winder,the super plastic forming process was analyzed.Based on principle of superplastic gas forming,basic principle of the parameters of superselective plastic forming process for aluminum alloy drum were presented according to the structure and technical features.Calculation method of the forming die design were given,and the key points of design and the use of die forming were described.The results show that tube blank by superplastic forming exhibits the features of precision shape with Ra≤6.3,which can be directly carried out polishing to meet the process requirements.Meanwhile,cost was reduced and the production cycle was shorten.
摘要:The wear testing of Cu-Ag alloy for Cu cladding Al composite contact wire with the 45#steel and bronze alloy as friction pair was conducted,and the wear surface morphology of the sample at different loads and sliding speeds was observed.The results show that the main mechanisms of Cu-Ag alloy sliding wear are abrasive wear and adhesive wear.With the 45 # steel as friction pair,there exist a large amount of plastic deformation on the wear surface,and obvious furrows and cutting traces in the sliding direction occur,meanwhile,copper oxide in the wear surface is generated,which plays not only the abrasive in the process of wear but also lubrication role.With the bronze alloy as friction pair,the wear surface has serious peeling pit and adhesion,and the wear rate of bronze alloy friction pair is obviously more than steel friction pair.
关键词:Cu Cladding Al Contact Wire;Cu-Ag Alloy;Sliding Wear
摘要:Grain size and mechanical properties of H62 brass without treatment,with pulsed magnetic field treatment,mechanical vibration treatment and compound treatment of pulsed magnetic field and mechanical vibration were investigated comparatively by using optical microscope,tensile testing machine and scanning electron microscope.In addition,influences of pulse voltage,pulse frequency and mold temperature on grain size and mechanical properties of the alloy with compound treatment were investigated.The results show that the compound treatment of pulsed magnetic field and mechanical vibration can not only refine the grains,but also improve the mechanical properties of H62 brass,which is more efficient than pulsed magnetic field treatment or mechanical vibration treatment.Tensile strength and elongation of the alloy with compound treatment are increased by up to 9.7%and 14.6%,respectively.With the increase of the pulsed voltage or pulsed frequency,grain size of the alloy is refined,and mechanical properties are improved gradually.
关键词:Pulsed Magnetic Field;Mechanical Vibration;Compound Treatment;Grain Size
摘要:Microstructure and properties of nickel-aluminum bronze before and after heat treatment were investigated by using SEM,OM,XRD and mechanical property testing.The results show that the microstructure of as,cast nickel aluminum bronze is composed ofαphase andκphase,and increasing the solution temperature from 850℃to 1 000℃for 2h,the hardness of the alloy is increased firstly and then decreased.Meanwhile,theαphase andκphase are reduced and the martensiteβ′phase is generated.Aging hardening exhibits obvious with aging temperature from 300 to 700℃after solution at 900℃for 2h,where the hardness reaches the peak with aging for 1h,and the phenomenon of aging hardening disappears with aging temperature more than 500℃.
摘要:A new type of tooling was designed including mosaic cavity,modular abutment,the cooled abutment and the cooled extrusion wheel for copper working,which could save copper materials and cost,and improve the service life and efficiency of the tool.