摘要:The variation of hydrogen content in A356 aluminum alloy melt during holding, transferring and casting process was investigated. The influence of absolute water content of air, dew point temperature of compressed air, Sr content on the hydrogen absorption of aluminum melt was explored, and the pinhole defects under different hydrogen content condition were analyzed. The results indicate that transferring process leads to relatively serious hydrogen absorption, where absolute water content of air and Sr content are the main factors influencing the hydrogen absorption of aluminum melt. Under different hydrogen content conditions, the castings simultaneously contain dot pinholes and reticular pinholes distributed between dendrites, and the porosity is increased with the increase of hydrogen content in the melt. Under the premise of guaranteeing the modification effect, the decrease of the Sr addition is helpful to decline hydrogen content in the melt and reduce pinholes in the castings.
关键词:A356 Alloy;Hydrogen Content;Hydrogen Absorption of Melt;Pinholes
摘要:The influence of recycled material proportion on the size and content of inclusion in A356 aluminum alloy was investigated. Effects of recycled material addition on the stability of mechanical properties were analyzed by mechanical property test, and influence of rotary injection refining process parameters on density, inclusion size and content of aluminum melt were analyzed. The results indicate that with increase of recycled material proportion, the size and content of the inclusions in the alloy are increased, and the mechanical performance stability is decreased. The efficiency of degassing and impurity removal can be improved by properly increasing the rotation speed and gas flow or setting appropriate gas pressure. For A356 aluminum alloy melt with 30% recycled material, the optimized refining process parameters present as follows: Rotor speed of 500 r/min, gas pressure of 0.8 MPa and gas flow of 20 L/min. On this condition, the aluminum melt density can reach 2.657 g/cm~3, and the volume fraction of inclusions can be decreased to 0.08%, satisfying production requirement.
关键词:A356 Aluminum Alloy;Recycled Material;Melt Purification;Refining Process
摘要:Pulse current was applied to the solidification process of directionally solidified Ti-45.5 Al-4 Cr-2.5 Nb alloy. The effects of different pulse frequencies on the solidification microstructure and properties of TiAl-based alloy were investigated. The results indicate that when the pulse current density is 52.9 mA/mm~2, the lateral heat dissipation and the average deviation angle of dendrites are decreased with the increase of pulse frequency due to the skin effect and Joule heat effect of current. However, with the further increase of pulse frequency, the Lorentz force is increased, and the branch crystal is broken or remelted by electromagnetic stirring, resulting in the increase of grain deviation angle. The average width of grain is firstly increased and then reduced with the increase of pulse frequency. When the pulse current frequency is lower, the dendrites are remelted or broken due to the Joule heat effect of current and electromagnetic stirring. The length of melting zone is increased and temperature gradient is decreased, leading to the increase of average grain width instead. With the continuous increase of pulse frequency, Lorentz force is increased, and strong electromagnetic stirring can refine grains, resulting in the average width reduction of grains. Compared with the master alloy ingot, the tensile strength of TiAl alloy is increased by 70.7% under pulse current, and the elongation is increased by 129.5%.
摘要:The influence of extrusion temperature and extrusion speed on the equivalent strain, equivalent stress and extrusion pressure of 7 XXX series aluminum alloy bar was investigated by finite element simulation. The results indicate that the mean value and standard deviation of equivalent strain are decreased firstly and then increased with the increase of extrusion temperature, and increased with the increase of extrusion speed. The maximum equivalent stress is decreased with the increase of extrusion temperature and increased with the increase of extrusion speed. The extrusion pressure is decreased with the increase of extrusion temperature and increased with the increase of extrusion speed. Considering the bar performance and extrusion efficiency, it is suggested that the optimized extrusion temperature and the optimized extrusion speed are presented as 380 ℃ and 0.1 mm/s.
关键词:Aluminum Alloy;Finite Element Simulation;Equivalent Strain;Equivalent Stress;Extrusion Pressure
摘要:The Design-expert software was adopted to design the response surface test with the heat transfer coefficient of each die and die temperature as the test factor and the sum of all pore volumes of the castings as the response index. ProCAST software was applied to simulate the experimental forming process, and the experimental data was obtained. Finally, the response surface test data was analyzed to obtain the influence law of heat transfer coefficient between the lower die and liquid metal on the molding quality of the castings. Moreover, water-based graphite coating and changing the coating thickness were presented to adjust the heat transfer coefficient.
摘要:Modal tests were carried out to verify the accuracy of the aluminum alloy wheel model and then radial fatigue analysis was performed on the aluminum alloy wheel. The results indicate that the stress concentration area and the low life area are distributed at both ends of the weight reduction hole. On this basis, the response surface optimization method was utilized to optimize the hub structure. The error between the finite element simulation results of the optimized model and the predicted results of the response surface is within the acceptable range, which verifies the feasibility of the response surface optimization results. The optimization results reveal that the maximum stress of the hub is reduced by about 29.5 MPa, and the radial fatigue life is increased by about 3 times.
摘要:The simulation of casting process requires mesh generation of casting geometric model. The appropriate Delaunay triangulation of complex casting section can greatly simplify the operation. The quasi-growth point insertion triangulation method was adopted, proving that it strictly conforms to the Delaunay triangulation criterion. The triangular mesh obtained by the new triangulation method is similar to equilateral triangle. The algorithm has been successfully applied to the InteCAST CAE.
摘要:Due to its complex structure, air holes and other defects often occur at key positions in the actual production of automobile aluminum alloy rear longitudinal beam. The mold filling and solidification process of vacuum die casting aluminum alloy rear longitudinal beam was investigated based on the AnyCasting simulation software. The results indicate that serious air entrainment occurs at the loaded position of rear longitudinal beam during liquid metal filling. During the solidification of liquid metal, shrinkage porosity and other defects occur at the local wall thickness of the rear longitudinal beam. Based on the results of simulation analysis, the structure of the overflow system was optimized. By adding multiple overflow grooves at the position with serious gas volume, the casting defects at the loaded end of the rear longitudinal beam can be eliminated, and the integrated forming of the rear longitudinal beam can be realized.
关键词:Vacuum Die Casting;Rear Longitudinal Beam;AnyCasting;Overflow System
摘要:The free surface model of vertical centrifugal casting was analyzed. Based on the equivalent liquid surface descent method, a vacancy volume distribution method for numerical simulation of solidification process by vertical centrifugal casting based on the equivalent height interval was established, and the calculation results of solidification defects by vertical centrifugal casting was achieved. The defect calculation results of vertical centrifugal casting were verified by 山 shaped casting under gravity casting and centrifugal casting, respectively. The results indicate that the quantitative calculation of shrinkage porosity and cavity defects in centrifugal casting can be realized through vacancy volume distribution method for numerical simulation of solidification process by vertical centrifugal casting based on equivalent height interval.
摘要:Aiming at the problems of slow recognition and inability to achieve accurate prediction during the process of traditional BP neural network for breakout prediction, ACO algorithm was utilized to optimize the randomly selected weight threshold, and the optimization steps of ACO algorithm was introduced in detail. The neural network model was established based on the MATLAB software, and the optimized model was applied to breakout prediction. The historical data collected on the site was preprocessed, which was then input to the neural network model for training and testing. The result indicates that the recognition accuracy of ACO-BP breakout prediction model is significantly higher than that of traditional ones, where the forecast rate and reporting rate can reach 96.77% and 100%, respectively. The model not only speeds up the operation of the network model, but also ensures the global search ability and robustness of the model, which has desirable application prospects.
摘要:The GH3625 superalloy components were manufactured by selective laser melting(SLM), and multiple pores of different sizes were prefabricated in the interior. The pores of additive components were characterized in 2 D/3 D by X-ray digital radiography and micro-CT. The results indicate that for GH3625 superalloy SLM additive components with a diameter of 5 mm, prefabricated pores with a designed value of all diameters greater than or equal to 0.2 mm can be observed on DR images, and the minimum detectable pore size is 0.18 mm. CT data reveals that the pores with designed diameter of 0.05 mm and 0.1 mm are prefabricated to failure, while all the pores with designed diameter greater than 0.2 mm are successfully prefabricated. Among pores with design diameter of 0.2 mm, only the two are prefabricated to failure, and the rest are successfully prefabricated, and the minimum detected pore diameter is 0.05 mm. The results prove that the measured diameter value is greater than the designed one, with the maximum absolute error of 0.26 mm and the minimum of 0.03 mm. Finally, the pores at different positions were translated to the reference position, and the influence of the X-ray incident direction on the imaging of different pores was analyzed according to the penetration thickness difference combined with the three-dimensional morphology of the pores.
摘要:SiCp/A356 composites were prepared by stirring casting method, and the ventilated new energy vehicle brake disc was produced by vacuum suction casting. Based on ProCAST numerical simulation and defect prediction, optimal casting process parameters were determined to cast the qualified brake discs. Particle aggregation were observed by optical microscope, electron microscope and ultrasonic flaw detection analysis. Ultrasonic vibration assisting with mechanical agitation was used to improve the welability and depolymerization of ultrasonic melt infiltration into clusters. The SiC phase was extracted and the normal distribution curve of particles was fitted to confirm the dispersion distribution of particles without clusters in the disc layer by layer.
摘要:A6061 aluminum alloy and AZ31 B magnesium alloy were welded by resistance spot welding with a zinc interlayerof 60 μm thickness. The microstructure of the nugget zone was observed and analyzed by scanning electron microscopy. The effects of welding parameters on the nugget size and tensile shear load of the joint were investigated. The results indicate that Al12Mg17 layer with thickness of 20 μm is formed near aluminum alloy side, and the Al12Mg17+(Mg) layer with thickness of 10 μm is formed near magnesium alloy side of the joint. The tensile shear load and nugget diameter of A6061/Zn/AZ31 B joint are increased at first and then decreased with the increase of welding current, welding time and electrode force, and the maximum tensile shear load is 3.8 kN.
摘要:The diamond/Cu composites with different volume fractions of diamond(50%, 60%, 70%) were prepared by direct thermal powder thixoforming process. By measuring the thermal conductivity, bending strength and thermal expansion coefficient, the influence of diamond volume fraction on the microstructure and properties of diamond/Cu composites was analyzed. The results indicate that the increase of diamond volume fraction is adverse to the interfacial bonding between diamond and copper.When the diamond volume fraction is 50%, the thermal conductivity and bending strength of the composites reach the maximum, which are 200.028 W/(m·K) and 406.39 MPa, respectively, and the thermal expansion coefficient reaches 6.299×10-6 ℃-1 at 200 ℃.
摘要:FeCrMoCBY amorphous/phenolic resin composites were prepared by hot press forming, and the effects of different content of amorphous particles on the properties of composites were explored. The results indicate that the hardness of the composites is enhanced after the addition of amorphous particles, of which the specimens with an amorphous addition of 30% and 40% are 68 HRB and 74.3 HRB, respectively. With the increase of the amorphous content, the average friction coefficient is firstly increased and then decreased, and the volume wear rate is gradually decreased. The wear mechanism is transformed from abrasive wear to a mixed mechanism of adhesive wear and abrasive wear. As the test temperature increases, the average friction coefficient of the composite is gradually decreased, and the volume wear rate is gradually increased.
关键词:Amorphous Alloy;Phenolic Resin;High Temperature Friction;Micro Morphology
摘要:A large part porosity problems of aluminum alloy casting comes from the gas-evolution properties of precoated sand itself. In view of the specific casting process of precoated sand on a large amount of experimental study, a more general and quantitative method is to apply numerical simulation algorithm to the simulation of gas and core. However, accurate gas model of precoated sand is still lack of data support. Gas evolution curves of 5 kinds of precoated sand were measured at different temperatures by modifying the gas evolution instrument, and the relationship between volume of precoated sand and gas evolution rate or temperature was analyzed. The formula of the maximum gas volume and temperature of precoated sand were presented. It was confirmed that the gas reaction of precoated sand has two stages: low temperature zone and high temperature zone.
摘要:In order to obtain the fine globular grains in semi-solid recycled billets, Strain-Induced Melt Activation(SIMA) process was carried out for ZL205 A alloy chips. The effects of SIMA process on microstructure of semi-solid billets were investigated and verified.The results indicate that with the increase of isothermal temperature and isothermal time, the average grain size of semi-solid billet is firstly increased, then decreased and finally increased, while the grain shape is transformed from roundness to irregularity to roundness again. In conclusion, the optimal process parameters is 620 ℃×45 min, where the average grain size and shape factor of ZL205 A alloy semi-solid microstructure are 114 μm and 1.12, respectively, and the solid fraction is lower than 68%.
关键词:ZL205A Alloy;Semi-solid Recycled;Microstructure;Isothermal Process Parameter;SIMA Method
摘要:The effects of solid solution and aging treatment on the microstructure and mechanical properties of the Mg-10 Gd-2 Y-0.5 Zn-0.5 Zr experimental magnesium alloy were investigated. The results reveal that the microstructure of the as-cast alloy is mainly composed of α-Mg, Mg5(Gd, Y), Mg24(Y,Gd)5 and Mg12(Gd, Y)Zn phases, and the solid solution and aging treatment have no obvious effect on the type of the alloying phases, however the solid solution temperature has a great effect on the amount of the Mg12(Gd, Y)Zn phase, and the new Mg12(Gd, Y)Zn phase is precipitated during the aging treatment. In addition, after being solutionized at 480 ℃×24 h for the experimental alloy, the tensile strength, yield strength and elongation at room temperature are obviously improved, especially the elongation reaches 15.3%. Furthermore, after being aged at 200 ℃×24 h, the tensile strength, yield strength and elongation of the alloy at room temperature reach 278 MPa, 235 MPa and 5.5%, respectively.
关键词:Magnesium Alloys;Mg-Gd-Y Based Alloys;Heat Treatment;Microstructure;Mechanical Properties
摘要:Al-2.5 Ni-0.1 Co alloys with different Zr contents were prepared by super-gravity field solidification technology, and the effects of Zr contents on the microstructure and high-temperature mechanical properties of as-cast and direct aged alloys were investigated. The results indicate that Zr is dissolved in α-Al and refines the eutectic colony structure of the alloys, and the microhardness of the as-cast alloys is increased by the effect of solid solution and refinement. With Zr content of 0.1%, the hardness of the alloy reaches a peak of about 65 HV, and the Zr-rich phase is formed when Zr content is over 0.3%. After direct aging, the secondary Al3Zr phase is precipitated in the Al-Ni-Co-Zr alloy, improving the hardness and high-temperature mechanical properties of the alloy. When Zr content is 0.3%, the hardness of the alloy reaches up to about 87 HV, where the high-temperature tensile strength, yield strength and elongation of the Al-Ni-Co alloy at 300 ℃ reach 93.2 MPa, 62.5 MPa and 25.4%, respectively.
摘要:The dual-phase Ta-TaCr2 alloy was prepared by mechanical alloying with vacuum hot pressing sintering. The microstructure and room temperature mechanical properties of dual-phase Ta-TaCr2 alloys with different Ta contents were investigated with holding at 1 350 ℃ for 180 min. The results indicate that when the Ta content is increased from 50% to 85%(molar fraction), the density, fracture toughness, compressive strength and plastic strain of the alloy are gradually increased. When the Ta content is increased to 85%, the compressive strength and plastic strain are 3 753 MPa and 28.57%, respectively, fully achieving the dual-phase toughening effect.
关键词:TaCr2;Mechanical Alloying;Dual-phase Toughening;Room Temperature Mechanical Properties;Ta-TaCr Alloy
摘要:The Mg-6 Al-2 Nd-xCa alloys(x=0, 0.5, 1.0, 1.5, 2.0, 2.5, 3.0,%) were prepared, and the solidification curves were measured and analyzed, and then the microstructure was observed and analyzed by XRD, OM, SEM, EDS and remelting-isothermal liquid quenching experiment method. The influence of Ca on the phase formation and solidification path of Mg-6 Al-2 Nd alloy was investigated. The experimental results indicate that with the increase of Ca content, the content of Al11Nd3 and β-Mg17Al12 phases is decreased, and the content of the Al2Ca phase is increased. The precipitation temperature of α-Mg, Al2Nd, and Al11Nd3 phases is decreased with the increase of Ca content. The precipitation temperature of α-Mg is decreased from 620 ℃ to 606 ℃, and the precipitation temperature of Al2Nd phase is decreased from 630 ℃ to 610 ℃, while the precipitation temperature of Al2Ca phase is increased from 504 ℃ to 529 ℃. The solidification path of Mg-6 Al-2 Nd-xCa(x=0, 0.5,%) alloy is L→Al2Nd, L→α-Mg, LAl+Al2Nd→Al11Nd3, L→α-Mg+β-Mg17Al12. The solidification path of Mg-6 Al-2 Nd-xCa alloy(x=1.0, 1.5, 2.0, 2.5, 3.0,%) is L→Al2Nd, L→α-Mg, L→α-Mg+Al2Ca. The experimental results of the remelting-isothermal liquid quenching shows that the results of the isothermal liquid quenching experiment are consistent with those of the solidification curve analysis.
摘要:Microstructures and corrosion resistance of the Mg-9 Al-1 Zn-2 Ca alloy with trace rare earth Ce and solution treatment were investigated by scanning electron microscopy(SEM), energy dispersive spectroscopy(EDS), X-ray diffraction(XRD), optical microscopy(OM), immersion test and electrochemical test. The results reveal that the addition of Ce can reduce the grain size and improve the uniformity of microstructure. The volume fraction of the second phase in the alloy is decreased, and factors such as Al and Ce melting into the matrix can increase the potential of the matrix, weakening the microgalvanic corrosion and effectively improving the corrosion resistance of the alloy after solution treatment. The solution treated Mg-9 Al-1 Zn-2 Ca-0.5 Ce alloy sample exhibits excellent corrosion resistance.
摘要:The microstructure evolution of electromagnetic stirred Mg-4 Zn-0.3 Zr alloy and the effect of the initial microstructure of the alloy on the microstructure and mechanical properties of extruded Mg-4 Zn-0.3 Zr alloy tubes were investigated. The results reveal that the grains of the Mg-4 Zn-0.3 Zr alloy after electromagnetic stirring can be refined and more uniform, and the average grain size is reduced from 91.3 μm to 85.7 μm. The quantities of MgZn phases are decreased, with twins formed inside the grains, and there exists more low-angle grain boundaries. The tensile strength and yield strength of the alloy reach up to 189 MPa and 105 MPa, respectively, and the elongation is increased to 17.3%. Due to the existence of twins and low-angle grain boundaries in the electromagnetic stirred alloy, the dynamic recrystallization degree of the electromagnetic stirred Mg-4 Zn-0.3 Zr alloy after hot extrusion presents higher and the grain size is the finer. The tensile strength, yield strength and elongation of the alloy reach 241 MPa, 178 MPa and 25.2%, respectively.
摘要:Al-15 Bi composite water-reactive materials were prepared by hot pressing sintering with mechanically mixed powder of Al and Bi as raw materials. The microstructure, water-reactive properties and reaction products of the materials were analyzed and characterized. The effects of temperature and KCl concentration on the reaction rate between Al-15 Bi and water were analyzed, meanwhile the water reaction mechanism of Al-15 Bi was explored, and the reaction model was established. The results indicate that the Al-Bi composite material with dense and uniform structure can be prepared at 550 ℃ and 40 MPa for 1 h. Bi in the material is distributed in a network at the interface of Al particles. The hydrogen production rate can be improved greatly by increasing the temperature. Al and Bi can form micro-galvanic cells in water, thereby promoting the reaction of Al and water.
关键词:Al-15Bi;Water-reactive Materials;Microstructure;Hydrogen Production Performance
摘要:The casting box lifting, iron inclusion and forming reasons of lost foam casting 140 flywheel shell were analyzed. Through changing the negative pressure value, film coating, pressure holding, and other process measures and optimizing the combined process, the effective solutions to solve the 140 flywheel housing lifting box and iron clamping were proposed combined with production practice.
摘要:Effects of pre-furnace pouring temperature on the size and rate of shrinkage porosities and cavities during the production of investment casting stainless steel parts were analyzed. The modification of pouring temperature was added to Henkin formula to calculate the inner gate modulus, and the actual inner gate modulus was obtained, which was verified to be reasonable. Reasonable pouring temperature was determined, and the empirical data of pouring temperature for reducing shrinkage porositie and cavities were presented.
关键词:Precision Casting;Stainless Steel;Shrinkage Porosities;Pouring Temperature
摘要:In order to solve the problem of shrinkage porosity defects in the casting process of bracket with large wall thickness difference, the filling and solidification process of indirect squeeze casting process were simulated by the ProCAST software, and the positions of defects were predicted and the casting process was optimized.The results show that the defects of air entrainment, slag inclusion and shrinkage at the through-hole can be eliminated by using large-size gate and low pouring speed. However, the defects are concentrated in the boss with the extrusion pressure of 75 MPa, which can not be eliminated by feed system. Localized squeezing process was designed, and the optimal activation time of squeeze pin was simulated to be 1.1 s and removal time was 9.5 s at 75 MPa, a pouring temperature of 700 ℃ and a die temperature of 200 ℃. The experiment results indicate that the defects of the boss are eliminated after local extrusion.
摘要:In the continuous low-pressure casting process of aluminum alloy water-cooled shell of electric vehicle, the change of spiral sand core in the mold cavity after mold closing is not visible, and the casting defects caused by spiral sand core damage are difficult to be tracked and controlled. A low pressure casting product quality control tracking system based on intelligent information technology was proposed, which were composed of three parts: character recognition and two-dimensional bar code generation, spiral sand core process record control and spiral sand core quality tracking. Through information technology, a unique bar code was set in the sand core manufacturing stage, and the manufacturing process of spiral sand core was recorded and controlled in real time based on the bar code information data. The performance parameters of sand core molding were connected with low-pressure casting parameters such as mold filling pressure and pressurization speed during low-pressure casting to form a closed-loop quality tracking system in order to optimize and improve the production processes with hidden dangers in the quality of low-pressure casting products in time, aiming to improve the overall quality of low-pressure casting products.