Magnesium alloy thin-walled cylindrical components with the advantages of high specific stiffness and strength present broad prospect for the lightweight of aerospace components.However,poor formability resulting from...Magnesium alloy thin-walled cylindrical components with the advantages of high specific stiffness and strength present broad prospect for the lightweight of aerospace components.However,poor formability resulting from the hexagonal close-packed crystal structure in magnesium alloy puts forwards a great challenge for thin-walled cylindrical components fabrication,especially for extreme structure with the thicknesschanging web and the high thin-wall.In this research,an ZK61 magnesium alloy thin-walled cylindrical component was successfully fabricated by two-step forging,i.e.,the pre-forging and final-forging is mainly used for wed and thin-wall formation,respectively.Microstructure and mechanical properties at the core,middle and margin of the web and the thin-wall of the pre-forged and final-forged components are studied in detail.Due to the large strain-effectiveness and metal flow along the radial direction(RD),the grains of the web are all elongated along RD for the pre-forged component,where an increasingly elongated trend is found from the core to the margin of the wed.A relatively low recrystallized degree occurs during pre-forging,and the web at different positions are all with prismatic and pyramid textures.During finalforging,the microstructures of the web and the thin-wall are almost equiaxed due to the remarkable occurrence of dynamic recrystallization.Similarity,except for few basal texture of the thin-wall,only prismatic and pyramid textures are found for the final-forged component.Compared with the initial billet,an obviously improved mechanical isotropy is achieved during pre-forging,which is well-maintained during final-forging.展开更多
The morphology and content of the divorced eutectic in the microstructure of high pressure die casting(HPDC) magnesium alloy have a great influence on the final performance of castings. Based on the previous work conc...The morphology and content of the divorced eutectic in the microstructure of high pressure die casting(HPDC) magnesium alloy have a great influence on the final performance of castings. Based on the previous work concerning simulation of the nucleation and dendritic growth of primary α-Mg during the solidification of magnesium alloy under HPDC process, an extension was made to the formerly established CA(Cellular Automaton) model with the purpose of modeling the nucleation and growth of Mg-Al eutectic. With a temperature field and solute field obtained during simulation of the primary α-Mg dendrites as the initial condition of the modified CA model, modeling of the Mg-Al eutectic with a divorced morphology was achieved. Moreover, the simulated results were in accordance with the experimental ones regarding the distribution and content of the divorced eutectic. Taking a "cover-plate" die casting with AM60 magnesium alloy as an example, the rapid solidification with a high cooling rate at the surface layer of the casting led to a fine and uniform grain size of primary α-Mg, while the divorced eutectic at the grain boundary revealed a more dispersed and granular morphology. Islands of divorced eutectic were observed at the central region of the casting, due to the existence of ESCs(Externally Solidified Crystals) which contributed to a coarse and non-uniform grain size of primary α-Mg. The volume percentage of the eutectic β-Mg_(17)Al_(12) phase is about 2%-6% in the die casting as a whole. The numerical model established in this study is of great significance to the study of the divorced eutectic in the microstructure of die cast magnesium alloy.展开更多
Cylindrical rings with thin wall and high web ribs(CRTWHWR)are widely used as the key load bearing structures such as rocket body and space station cabin in aerospace field.However,it is still difficult to efficiently...Cylindrical rings with thin wall and high web ribs(CRTWHWR)are widely used as the key load bearing structures such as rocket body and space station cabin in aerospace field.However,it is still difficult to efficiently manufacture CRTWHWR with high performance because of their extreme geometry with thin-walled skins,high web ribs and large size.In this paper,a novel radial envelope forming process is put forward to efficiently achieve the plastic forming of CRTWHWR with high performance.Firstly,the principle of radial envelope forming process is clarified.Then,an efficient design method for the tool motion and geometry is proposed based on the reverse envelope principle,i.e.,CRTWHWR is adopted to reversely envelope the tool and thus the tool which does not interfere with CRTWHWR can be efficiently obtained in a single operation.Finally,a reasonable 3D FE model of the radial envelope forming process of CRTWHWR is established and the radial envelope forming mechanism of CRTWHWR is comprehensively revealed.Through the FE simulation and experiments with material of plastic mud,a typical CRTWHWR with diameter of 300 mm,axial height of 192 mm,the maximum rib height of 25 mm,the minimum rib thickness of 3 mm and skin thickness of 5 mm is radial envelope formed,i.e.,the ratio of the maximum rib height to the minimum rib thickness reaches 8.33,the ratio of the maximum rib height to skin thickness reaches 5 and the ratio of diameter to the minimum rib thickness reaches 100.The above results verify that the proposed radial envelope forming process has great potentials in efficiently manufacturing CRTWHWR with extreme geometry.展开更多
Tapered ring with thin wall and three high ribs(TRTWTHR),showing complicated geometry(wall thickness is less than 4 mm and rib height exceeds 20 mm),is extensively utilized to fabricate the critical structural parts o...Tapered ring with thin wall and three high ribs(TRTWTHR),showing complicated geometry(wall thickness is less than 4 mm and rib height exceeds 20 mm),is extensively utilized to fabricate the critical structural parts of aerospace equipment such as spacecraft cabin,rocket body and fuel tank because of light weight and high carrying capacity.How to fabricate TRTWTHR with high performance is a critical problem that aerospace area needs to solve.In this work,constraining ring rolling(CRR)technique is first adopted to form TRTWTHR.However.unreasonable metal streamlines(UMS)and uncoordinated growth of three ribs easily occur in CRR of TRTWTHR,which makes the forming quality of TRTWTHR difficult to be controlled.Faced with this difficulty,an analytical model that can predict UMS and the height of three ribs in CRR of TRTWTHR is established so as to guide the process design of CRR.Subsequently,the reliability of the established analytical model and the feasibility of CRR of TRTWTHR are confirmed by FE simulation and experiment.Then,using the established analytical model,the window of UMS occurring relevant to the tapered angle of TRTWTHR and the location of the rib of middle end is developed.Finally,three uncoordinated growth modes among three ribs are found when the width of three ribs is identical and UMS do not occur,and the mechanisms of three uncoordinated growth modes are revealed.展开更多
Conical rings with thin sterna and high ribs(CRTSHR)are key bearing-load parts of aerospace equipment,which are required to be manufactured with high performance and efficiency.Traditional ring rolling is the most pre...Conical rings with thin sterna and high ribs(CRTSHR)are key bearing-load parts of aerospace equipment,which are required to be manufactured with high performance and efficiency.Traditional ring rolling is the most preferred method for manufacturing high-performance ring parts,but it can hardly achieve the forming of CRTSHR due to the extreme geometry of CRTSHR.To solve this difficulty,an innovative constraining ring rolling process(CRR)is proposed in this paper to manufacture CRTSHR.To evaluate the proposed CRR and reveal its deformation behaviors,a thermomechanical coupled FE model for CRR of CRTSHR is established.Then,the experiment for CRR of CRTSHR is performed on a modified ring rolling machine,which proves that CRR of CRTSHR is feasible and the established FE model is reliable.Based on the reliable FE model,the metal flow mode in deformed CRTSHR is analyzed,and the deformation characteristics such as the stress state,strain distribution and the evolution of power parameters in CRR of CRTSHR are revealed.Finally,the influences of key parameters such as the friction factor between ring and molds,the diameter of idle roll and the feed velocity of idle roll on CRR of CRTSHR are investigated by FE simulation.展开更多
High performance is of great importance to expand the application of magnesium alloys,and the inherent strength-plasticity synergic mechanism during a specific process should be unveiled.In this paper,a multi-degrees ...High performance is of great importance to expand the application of magnesium alloys,and the inherent strength-plasticity synergic mechanism during a specific process should be unveiled.In this paper,a multi-degrees of freedom(multi-DOF)forming process is conducted on initially extruded AZ91 magnesium alloy at different deformation degrees,including small deformation with deformation amounts of 10%and 20%,medium deformation with deformation amounts of 30%and 40%,and large deformation with deformation amounts of 60%and 70%.Simultaneous enhancement of ultimate tensile strength(UTS)and plasticity is achieved in all these multi-DOF processed alloys in comparison to the initially extruded one.As deformation degrees increase,both UTS and elongation of the multi-DOF processed alloy gradually increase in small and medium deformation and then slightly decrease in large deforma-tion,exhibiting a superior strength(401 MPa)and plasticity(16.3%)combination at deformation amount of 40%.The evolution of mechanical properties varying with deformation degrees is closely dependent on microstructure and texture characterization.The microstructures of multi-DOF processed AZ91 alloy are increasingly refined and heterogeneous as deformation degrees gradually increase,which consist of the predominant equiaxed coarse grains(CGs)and a few fine grains(FGs)in small deformation,some CGs(equiaxed or slightly elongated)and some FGs in medium deformation,and some remarkably elongated CGs and the predominant FGs in large deformation.The area fraction of basal texture gradually decreases while that of prismatic texture gradually increases with increasing deformation degrees,finally resulting in a complete disappearance of basal texture at a deformation amount of 70%.Thus,the strength-plasticity synergic mechanism related to increasingly obvious heterogeneous structure,gradually refined microstructure,and gradually decreased basal texture contribute to the constantly simultaneous improvement of UTS and plasticity until in medium deformation,and the remarkably elongated CGs play a significant role in the slight decrease of UTS and plasticity in large deformation even with further increasing grain refinement and decreasing basal texture.This research provides an efficient and novel way to achieve strength-plasticity synergic magnesium alloy via optimizing microstructure and texture.展开更多
Al5A06 sheets by large cold plastic deformation usually have high strength but low plasticity,i.e.weak strength-plasticity matching,which may lead to their poor fatigue property.In this study,annealing treat-ments are...Al5A06 sheets by large cold plastic deformation usually have high strength but low plasticity,i.e.weak strength-plasticity matching,which may lead to their poor fatigue property.In this study,annealing treat-ments are applied on cold rotary forged Al5A06 sheets to regulate strength-plasticity matching and im-prove fatigue properties.The microstructures,tensile mechanical properties and fatigue properties un-der different annealing parameters were analyzed.The abnormal grain growth mechanism of cold rotary forged Al5A06 sheets during 300℃ annealing treatment was investigated,and the fatigue failure mech-anism of Al5A06 sheets with different annealing temperatures was also investigated.The abnormal grain growth during 300℃ annealing treatment is mainly due to the asynchronous recrystallization behavior with low recrystallization driving force,which leads to the early recrystallized regions directly absorb-ing adjacent grains along134crystal direction.The cold rotary forged Al5A06 sheets after 250℃-2 h annealing treatment exhibit the best fatigue property,which is mainly because the optimum strength-plasticity matching brings about coordinate plastic deformation throughout most grains,and the effective dislocation movement between adjacent grains can delay the appearance of strain localization and ac-commodate continuous fatigue cyclic loading.展开更多
基金supported by the National Natural Science Foundation of China(No.52405408,No.U21A20131,No.U2037204,No.52422510)the Natural Science Foundation of Hubei Province(No.2023AFB116)+1 种基金the State Key Laboratory of Materials Processing and Die&Mould TechnologyHuazhong University of Science and Technology(No.P2022-005)。
文摘Magnesium alloy thin-walled cylindrical components with the advantages of high specific stiffness and strength present broad prospect for the lightweight of aerospace components.However,poor formability resulting from the hexagonal close-packed crystal structure in magnesium alloy puts forwards a great challenge for thin-walled cylindrical components fabrication,especially for extreme structure with the thicknesschanging web and the high thin-wall.In this research,an ZK61 magnesium alloy thin-walled cylindrical component was successfully fabricated by two-step forging,i.e.,the pre-forging and final-forging is mainly used for wed and thin-wall formation,respectively.Microstructure and mechanical properties at the core,middle and margin of the web and the thin-wall of the pre-forged and final-forged components are studied in detail.Due to the large strain-effectiveness and metal flow along the radial direction(RD),the grains of the web are all elongated along RD for the pre-forged component,where an increasingly elongated trend is found from the core to the margin of the wed.A relatively low recrystallized degree occurs during pre-forging,and the web at different positions are all with prismatic and pyramid textures.During finalforging,the microstructures of the web and the thin-wall are almost equiaxed due to the remarkable occurrence of dynamic recrystallization.Similarity,except for few basal texture of the thin-wall,only prismatic and pyramid textures are found for the final-forged component.Compared with the initial billet,an obviously improved mechanical isotropy is achieved during pre-forging,which is well-maintained during final-forging.
基金financially supported by the Fundamental Research Funds for the Central Universities(WUT:2017IVA036)111 Project(B17034)State Key Laboratory of Materials Processing and Die&Mould Technology,Huazhong University of Science and Technology(P2018-003)
文摘The morphology and content of the divorced eutectic in the microstructure of high pressure die casting(HPDC) magnesium alloy have a great influence on the final performance of castings. Based on the previous work concerning simulation of the nucleation and dendritic growth of primary α-Mg during the solidification of magnesium alloy under HPDC process, an extension was made to the formerly established CA(Cellular Automaton) model with the purpose of modeling the nucleation and growth of Mg-Al eutectic. With a temperature field and solute field obtained during simulation of the primary α-Mg dendrites as the initial condition of the modified CA model, modeling of the Mg-Al eutectic with a divorced morphology was achieved. Moreover, the simulated results were in accordance with the experimental ones regarding the distribution and content of the divorced eutectic. Taking a "cover-plate" die casting with AM60 magnesium alloy as an example, the rapid solidification with a high cooling rate at the surface layer of the casting led to a fine and uniform grain size of primary α-Mg, while the divorced eutectic at the grain boundary revealed a more dispersed and granular morphology. Islands of divorced eutectic were observed at the central region of the casting, due to the existence of ESCs(Externally Solidified Crystals) which contributed to a coarse and non-uniform grain size of primary α-Mg. The volume percentage of the eutectic β-Mg_(17)Al_(12) phase is about 2%-6% in the die casting as a whole. The numerical model established in this study is of great significance to the study of the divorced eutectic in the microstructure of die cast magnesium alloy.
基金the National Natural Science Foundation of China(No.U2037204)the 111 Project(B17034)+1 种基金Innovative Research Team Development Program of Ministry of Education of China(No.IRT17R83)the National Natural Science Foundation of China(No.52005375)for the support given to this research。
文摘Cylindrical rings with thin wall and high web ribs(CRTWHWR)are widely used as the key load bearing structures such as rocket body and space station cabin in aerospace field.However,it is still difficult to efficiently manufacture CRTWHWR with high performance because of their extreme geometry with thin-walled skins,high web ribs and large size.In this paper,a novel radial envelope forming process is put forward to efficiently achieve the plastic forming of CRTWHWR with high performance.Firstly,the principle of radial envelope forming process is clarified.Then,an efficient design method for the tool motion and geometry is proposed based on the reverse envelope principle,i.e.,CRTWHWR is adopted to reversely envelope the tool and thus the tool which does not interfere with CRTWHWR can be efficiently obtained in a single operation.Finally,a reasonable 3D FE model of the radial envelope forming process of CRTWHWR is established and the radial envelope forming mechanism of CRTWHWR is comprehensively revealed.Through the FE simulation and experiments with material of plastic mud,a typical CRTWHWR with diameter of 300 mm,axial height of 192 mm,the maximum rib height of 25 mm,the minimum rib thickness of 3 mm and skin thickness of 5 mm is radial envelope formed,i.e.,the ratio of the maximum rib height to the minimum rib thickness reaches 8.33,the ratio of the maximum rib height to skin thickness reaches 5 and the ratio of diameter to the minimum rib thickness reaches 100.The above results verify that the proposed radial envelope forming process has great potentials in efficiently manufacturing CRTWHWR with extreme geometry.
基金the National Natural Science Foundation of China (No. U2037204)the 111 Project (No. B17034)+1 种基金Innovative Research Team Development Program of Ministry of Education of China (No. IRT17R83)the National Natural Science Foundation of China (No. 52005375)
文摘Tapered ring with thin wall and three high ribs(TRTWTHR),showing complicated geometry(wall thickness is less than 4 mm and rib height exceeds 20 mm),is extensively utilized to fabricate the critical structural parts of aerospace equipment such as spacecraft cabin,rocket body and fuel tank because of light weight and high carrying capacity.How to fabricate TRTWTHR with high performance is a critical problem that aerospace area needs to solve.In this work,constraining ring rolling(CRR)technique is first adopted to form TRTWTHR.However.unreasonable metal streamlines(UMS)and uncoordinated growth of three ribs easily occur in CRR of TRTWTHR,which makes the forming quality of TRTWTHR difficult to be controlled.Faced with this difficulty,an analytical model that can predict UMS and the height of three ribs in CRR of TRTWTHR is established so as to guide the process design of CRR.Subsequently,the reliability of the established analytical model and the feasibility of CRR of TRTWTHR are confirmed by FE simulation and experiment.Then,using the established analytical model,the window of UMS occurring relevant to the tapered angle of TRTWTHR and the location of the rib of middle end is developed.Finally,three uncoordinated growth modes among three ribs are found when the width of three ribs is identical and UMS do not occur,and the mechanisms of three uncoordinated growth modes are revealed.
基金the National Natural Science Foundation of China(No.U2037204)the Natural Science Foundation of Hubei Province(No.2019CFA041)+1 种基金the National Key Research and Development Program of China(No.2019YFB1704502)the Fundamental Research Funds for the Central Universities(No.2019-YB-016)for the support。
文摘Conical rings with thin sterna and high ribs(CRTSHR)are key bearing-load parts of aerospace equipment,which are required to be manufactured with high performance and efficiency.Traditional ring rolling is the most preferred method for manufacturing high-performance ring parts,but it can hardly achieve the forming of CRTSHR due to the extreme geometry of CRTSHR.To solve this difficulty,an innovative constraining ring rolling process(CRR)is proposed in this paper to manufacture CRTSHR.To evaluate the proposed CRR and reveal its deformation behaviors,a thermomechanical coupled FE model for CRR of CRTSHR is established.Then,the experiment for CRR of CRTSHR is performed on a modified ring rolling machine,which proves that CRR of CRTSHR is feasible and the established FE model is reliable.Based on the reliable FE model,the metal flow mode in deformed CRTSHR is analyzed,and the deformation characteristics such as the stress state,strain distribution and the evolution of power parameters in CRR of CRTSHR are revealed.Finally,the influences of key parameters such as the friction factor between ring and molds,the diameter of idle roll and the feed velocity of idle roll on CRR of CRTSHR are investigated by FE simulation.
基金supported by the Natural Science Foundation of China(No.U21A20131)the Natural Science Foundation of Hubei Province(No.2023AFB116)+2 种基金the State Key Laboratory of Materials Processing and Die&Mould Technology,Huazhong University of Science and Technology(No.P2022-005)the 111 Project(No.B17034)Innovative Research Team Development Program of Ministry of Education of China(No.IRT17R83).
文摘High performance is of great importance to expand the application of magnesium alloys,and the inherent strength-plasticity synergic mechanism during a specific process should be unveiled.In this paper,a multi-degrees of freedom(multi-DOF)forming process is conducted on initially extruded AZ91 magnesium alloy at different deformation degrees,including small deformation with deformation amounts of 10%and 20%,medium deformation with deformation amounts of 30%and 40%,and large deformation with deformation amounts of 60%and 70%.Simultaneous enhancement of ultimate tensile strength(UTS)and plasticity is achieved in all these multi-DOF processed alloys in comparison to the initially extruded one.As deformation degrees increase,both UTS and elongation of the multi-DOF processed alloy gradually increase in small and medium deformation and then slightly decrease in large deforma-tion,exhibiting a superior strength(401 MPa)and plasticity(16.3%)combination at deformation amount of 40%.The evolution of mechanical properties varying with deformation degrees is closely dependent on microstructure and texture characterization.The microstructures of multi-DOF processed AZ91 alloy are increasingly refined and heterogeneous as deformation degrees gradually increase,which consist of the predominant equiaxed coarse grains(CGs)and a few fine grains(FGs)in small deformation,some CGs(equiaxed or slightly elongated)and some FGs in medium deformation,and some remarkably elongated CGs and the predominant FGs in large deformation.The area fraction of basal texture gradually decreases while that of prismatic texture gradually increases with increasing deformation degrees,finally resulting in a complete disappearance of basal texture at a deformation amount of 70%.Thus,the strength-plasticity synergic mechanism related to increasingly obvious heterogeneous structure,gradually refined microstructure,and gradually decreased basal texture contribute to the constantly simultaneous improvement of UTS and plasticity until in medium deformation,and the remarkably elongated CGs play a significant role in the slight decrease of UTS and plasticity in large deformation even with further increasing grain refinement and decreasing basal texture.This research provides an efficient and novel way to achieve strength-plasticity synergic magnesium alloy via optimizing microstructure and texture.
基金financially supported by the National Natural Science Foundation of China(no.U21A20131)the Innovative Research Team Development Program of Ministry of Education of China(no.IRT17R83)for the support given to this research.
文摘Al5A06 sheets by large cold plastic deformation usually have high strength but low plasticity,i.e.weak strength-plasticity matching,which may lead to their poor fatigue property.In this study,annealing treat-ments are applied on cold rotary forged Al5A06 sheets to regulate strength-plasticity matching and im-prove fatigue properties.The microstructures,tensile mechanical properties and fatigue properties un-der different annealing parameters were analyzed.The abnormal grain growth mechanism of cold rotary forged Al5A06 sheets during 300℃ annealing treatment was investigated,and the fatigue failure mech-anism of Al5A06 sheets with different annealing temperatures was also investigated.The abnormal grain growth during 300℃ annealing treatment is mainly due to the asynchronous recrystallization behavior with low recrystallization driving force,which leads to the early recrystallized regions directly absorb-ing adjacent grains along134crystal direction.The cold rotary forged Al5A06 sheets after 250℃-2 h annealing treatment exhibit the best fatigue property,which is mainly because the optimum strength-plasticity matching brings about coordinate plastic deformation throughout most grains,and the effective dislocation movement between adjacent grains can delay the appearance of strain localization and ac-commodate continuous fatigue cyclic loading.
