For optimal design of a gating system,the setting of diagnosis parameters is very important.In this study,the permanent mold casting process was selected because most of the other casting processes have more complicat...For optimal design of a gating system,the setting of diagnosis parameters is very important.In this study,the permanent mold casting process was selected because most of the other casting processes have more complicated factors that influence the mold filling pattern compared to the permanent mold casting process,such as the surface roughness of mold,gas generation from the mold wash and binder of sand mold,and the gas permeability through a sand mold,etc.Two diagnosis parameters(flow rate difference and arrival time difference) of molten metal flow pattern in the numerical simulation are suggested for design of an optimum casting system with a permanent mold.The results show that the arrival time difference can be used as one important diagnosis parameter of the complexity of the runner system and its usefulness has been verified via making aluminum parts using permanent mold casting(Fig.9).展开更多
To design a power source system and mold for electromagnetic soft-contact continuous casting process and to theoretically estimate the heat losses from the charges and the system power, the effect of structure paramet...To design a power source system and mold for electromagnetic soft-contact continuous casting process and to theoretically estimate the heat losses from the charges and the system power, the effect of structure parameters on system power and magnetic flux density distribution was calculated using finite element method. The results show that as for electromagnetic soft-contact continuous casting system with partial-segment type mold, the power consumption is much more than that with a full-segment type mold; about 62% of electric power is dissipated in the mold, and the effective acting range of magnetic field is relatively narrow. Optimizing mold structure is a crucial measure of remarkably reducing mold power consumption and saving electric energy. Increasing slit number, width, and length can remarkably increase the magnetic flux density in the mold and can reduce the electric energy consumption. Among structure parameters, slit number and slit width are relatively more effective to reduce energy consumption. For a round billet electromagnetic continuous casting system with diameter of 178 ram, the reasonable slit number, width, and length are about 24--32, 0. 5--1.0 mm, and 160 mm, respectively.展开更多
Automation and intelligence have become the primary trends in the design of investment casting processes.However,the design of gating and riser systems still lacks precise quantitative evaluation criteria.Numerical si...Automation and intelligence have become the primary trends in the design of investment casting processes.However,the design of gating and riser systems still lacks precise quantitative evaluation criteria.Numerical simulation plays a significant role in quantitatively evaluating current processes and making targeted improvements,but its limitations lie in the inability to dynamically reflect the formation outcomes of castings under varying process conditions,making real-time adjustments to gating and riser designs challenging.In this study,an automated design model for gating and riser systems based on integrated parametric 3D modeling-simulation framework is proposed,which enhances the flexibility and usability of evaluating the casting process by simulation.Firstly,geometric feature extraction technology is employed to obtain the geometric information of the target casting.Based on this information,an automated design framework for gating and riser systems is established,incorporating multiple structural parameters for real-time process control.Subsequently,the simulation results for various structural parameters are analyzed,and the influence of these parameters on casting formation is thoroughly investigated.Finally,the optimal design scheme is generated and validated through experimental verification.Simulation analysis and experimental results show that using a larger gate neck(24 mm in side length) and external risers promotes a more uniform temperature distribution and a more stable flow state,effectively eliminating shrinkage cavities and enhancing process yield by 15%.展开更多
This study investigates the formation feasibility of the integrated bottom car body components with dual die casting injection molding technology.During the production of a die-cast super-large one-piece body part wei...This study investigates the formation feasibility of the integrated bottom car body components with dual die casting injection molding technology.During the production of a die-cast super-large one-piece body part weighing over 10,000 t,a thorough comparison and investigation were conducted on the arising issues,using both single and double injection systems.Particular attention was given to meticulously discussing the die casting filling problems and microstructural defects that originated from the filling process.The research findings indicate that the implementation of a double injection system can significantly minimize cold shuts and reduce the solidification time.The effectiveness of this die casting technique was further confirmed by the production of high-quality castings using a scaled model that replicated real casting conditions at a 1:3 ratio,thereby maintaining a one-to-one correspondence in essential aspects.This successful study offers both theoretical insights and practical applications for the production of integrated bottom car bodies utilizing die casting in conjunction with a dual injection system.展开更多
To address the current issues with the conventional slide gate system utilized in the steel teeming process,a unique electromagnetic induction controlled automated steel teeming(EICAST)technology has been developed.Co...To address the current issues with the conventional slide gate system utilized in the steel teeming process,a unique electromagnetic induction controlled automated steel teeming(EICAST)technology has been developed.Cooling means of spiral coil in this technology is directly related to its service life.Firstly,heat transfer processes of air cooling and spray cooling were compared and analyzed.Secondly,the impacts of water temperature,water flow rate and air flow rate were examined in order to maximize the spray cooling effect.To maintain coil temperature at a low value consistently throughout the entire thermal cycle process of the ladle,a combined cooling mode was finally employed.Numerical simulation was applied to examine the coil temperature variation with different cooling systems and characteristics.Before coil operation,spray cooling is said to be more effective.By controlling the water flow rate and air flow rate,the spray cooling effect is enhanced.However,water temperature has little or no impact when using spray cooling.Air cooling during the secondary refining process and spray cooling prior to coil operation are combined to further lower coil temperature.When the direction of the spray cooling is from bottom to top,the coil temperature is lowered below 165℃.A practical induction coil cooling plan was provided for the EICAST technology’s production process.展开更多
To develop a suitable production process for fiber reinforced investment casting shell mold,three methods were studied:the traditional method(M_(1)),the method of adding fiber into silica sol with mechanical stirring ...To develop a suitable production process for fiber reinforced investment casting shell mold,three methods were studied:the traditional method(M_(1)),the method of adding fiber into silica sol with mechanical stirring and ultrasonic agitation(M_(2)),and the method of adding fiber into slurry with mechanical stirring and ultrasonic agitation for durations of 3,15,30,and 45 min(M_(3)).The bending strength,high-temperature self-load deformation,and thermal conductivity of the shell molds were investigated.The results reveal that the enhancement of fiber dispersion through ultrasonic agitation improves the comprehensive performance of the shell molds.The maximum green bending strength of the shell mold by M_(2) reaches 3.29 MPa,which is 29% higher than that of the shell mold prepared by M_(1).Moreover,the high-temperature self-load deformation of the shell mold is reduced from 0.62% to 0.44%.In addition,simultaneous ultrasonic agitation and mechanical stirring effectively shorten the slurry preparation time while maintaining comparable levels of fiber dispersion.With the process M_(3)-45 min,the fillers are uniformly dispersed in the slurry,and the fired bending strength and the high-temperature self-load deformation reach 6.25 MPa and 0.41%,respectively.Therefore,the proposed ultrasonic agitation route is promising for the fabrication of fiber-reinforced shell molds with excellent fibers dispersion.展开更多
The Cu-12Fe alloy has attracted significant attention due to its excellent electrical conductivity and electromagnetic shielding capability,high strength,cost-effectiveness,and recyclability.In the present work,the Cu...The Cu-12Fe alloy has attracted significant attention due to its excellent electrical conductivity and electromagnetic shielding capability,high strength,cost-effectiveness,and recyclability.In the present work,the Cu-12Fe alloy strip with the thickness of 2.4 mm was successfully produced by twin-roll strip casting.The microstructure and properties of the Cu-12Fe alloy were tailored by cold rolling and aging treatment.The tensile strength of the as-cast strip is approximately 328 MPa and its elongation is 25%.The Fe phase randomly dispersed in the matrix,and the average size of Fe-rich phase is 2μm.Besides,enrichment of Fe phase is observed in the central layer of the strip,results in the formation of the“sandwich structure”.Moreover,the as-cast strip of Cu-12Fe was directly cold-rolled from 2.4 to 0.12 mm.The directly cold-rolled sample after aging at 450℃for 16 h(ProcessⅠ)shows excellent electrical conductivity of 69.5%IACS,the tensile strength and elongation are 513 MPa and 3.8%,the saturation magnetic flux density is 20.1 emu·g^(-1),and the coercive force is 25.2 Oe.In ProcessⅡ,the as-cast strip firstly cold-rolled to 1.2 mm,then aged at 500℃for 1.5 h,followed by cold rolling to 0.12 mm,finally aged at 450℃for 16 h.The sample after ProcessⅡshows the electrical conductivity of 66.3%IACS,the tensile strength of 533 MPa,an elongation of 3.5%,saturation magnetic flux density of 21.4 emu·g^(-1),and the coercive force of 22.3 Oe.展开更多
The transient phenomena of re-oxidation and slag entrapment occurring in the tundish during the ladle change-over process have been proven detrimental to clean steel production.Therefore,an unsteady three-phase turbul...The transient phenomena of re-oxidation and slag entrapment occurring in the tundish during the ladle change-over process have been proven detrimental to clean steel production.Therefore,an unsteady three-phase turbulence model,coupling velocity,temperature,and phase field was established to study the effect of the ladle shroud immersion depth on the slag eye formation,slag entrainment,slag dragging,air dragging,and flow characteristics during the ladle change-over process of a two-strand tundish.The results showed that reducing the immersion depth decreases the high-velocity region area under the slag layer in the quasi-steady process.During the emptying stage,as the molten bath level gradually decreases,the outlet temperature exhibits a trend of initially decreasing and subsequently increasing across all three shroud immersion depths.However,under a 210 mm shroud immersion depth,molten slag and air are dragged into the shroud,forming slag droplets and causing significant fluctuations,with a maximum scalar velocity of 0.0764 m/s at the monitoring point.In the filling stage,air and molten slag are dragged into the molten bath,forming bubbles and slag droplets at an immersion depth of 210 mm.Bubbles are observed within the molten slag layer,which can readily cause an emulsification phenomenon,making it easier to be dragged as slag droplets.Additionally,the slag eye area measured under 210 mm immersion depth at 45 s is 0.303 m^(2),while the maximum scalar velocity of 2.4259 m/s is detected at 12 s.At an immersion depth of 360 mm,the average area of the slag eye is minimized to 0.06268 m2,with corresponding variances of 0.006753,representing the optimal immersion depth.展开更多
A full-sectional microstructure characterization method was developed to investigate the formation of coarse slag rims during the continuous casting of hypo-peritectic steel.The cross-sectional microstructural analysi...A full-sectional microstructure characterization method was developed to investigate the formation of coarse slag rims during the continuous casting of hypo-peritectic steel.The cross-sectional microstructural analysis of typical slag rims for two highly crystalline powders revealed that their formation was primarily driven by the solidification of the liquid slag.Distinct differences were observed in the microstructures of slag rims from the two powders.Powder A(characterized by a higher breaking temperature and viscosity)displayed alternating lamellar microstructures of coarse and fine phases,with the coarse phases composed of akermanite-gehlenite transition phases.In contrast,powder B(with a lower breaking temperature and viscosity)predominantly comprised regular akermanite-gehlenite crystals interspersed with a certain amount of glassy phases.Numerical simulations of a three-phase fluid flow coupled with heat transfer indicate that slag rim formation correlates with mold oscillation.Solidification of the liquid slag at the slag rim front predominantly occurs during the negative stroke of the mold oscillation.The average heating rate during the ascending stage of the mold reaches approximately 100 K·s^(−1),whereas the average cooling rate during the descending stage attains 400 K·s^(−1).This temperature variation leads to the formation of lamellar microstructures,whereas the ascending stage promotes the formation of coarse structures and thicker slag rims.Based on the powder properties,two distinct formation pathways exist for highly crystalline mold powders.For the powders with a higher breaking temperature,higher viscosity,and narrower solidification range(powder A),coarse microstructures and thicker slag rims were preferentially formed.For powders with lower breaking temperature and viscosity and wider solidification ranges(powder B),the liquid slag resisted rapid solidification,and the extended mushy zone allowed the partial liquid slag to persist at the slag rim front,promoting the formation of a thin slag rim.This study enhances the understanding of slag rim formation in highly crystalline mold powders and provides critical insights into the control of longitudinal surface cracks in hypo-peritectic steel.展开更多
The sub-rapid solidification(SRS)process associated with twin-roll strip casting(TRSC)is characterized by weakened elemental segregation and selective crystal growth,offering significant advantages compared with conve...The sub-rapid solidification(SRS)process associated with twin-roll strip casting(TRSC)is characterized by weakened elemental segregation and selective crystal growth,offering significant advantages compared with conventional casting methods.The interrelationship of the cooling rate,microstructure/texture evolution,and segregation behavior along the thickness direction of as-cast 18Ni–Mo–Co maraging steel strip produced by TRSC was investigated.The results revealed that the solidification microstructure of as-cast maraging steel strip exhibits the directional dendrite growth with preferred{001}texture under SRS condition.It was also found that the synchronous enrichment of Ni,Mo,and Ti elements appears in the as-cast strip to form microsegregation bands.The solidification path of the designed maraging steel strip involves the phase transformation from liquid→γ→α.Additionally,the presence of microsegregation bands of Ni and Mo allows a portion of the austenite(6–9 vol.%)to remain at room temperature after undergoing solid-state phase transformation.It could be observed that the microstructure of as-cast 18Ni–Mo–Co maraging steel strip consists of martensite and austenite,with the austenite distributed alternatively at the interdendritic positions.Ultimately,the interrelationship among solidification cooling rate,element segregation,and solidification microstructure evolution during the SRS process of 18Ni–Mo–Co maraging steel was clarified.展开更多
Silicon steel is characterized by a high melting point,poor fluidity,and limited wettability,and the process window for the preparation of non-oriented silicon steel ribbons by planar flow casting(PFC)is limited.Durin...Silicon steel is characterized by a high melting point,poor fluidity,and limited wettability,and the process window for the preparation of non-oriented silicon steel ribbons by planar flow casting(PFC)is limited.During the production process,the melt puddle(MP)behavior is a key factor in determining the final quality of ribbons,and the influence mechanism of the airflow boundary layer on the MP behavior and the surface quality of ribbons is still unclear.The effects of wheel speed on the quality of PFC Fe–3.0%Si non-oriented silicon steel ultra-thin ribbons were systematically investigated.Combined with experiments and numerical simulations,the mechanism of different wheel speeds on the behavior of MP and the surface quality of ribbons was analyzed in depth.It is found that when the MP reaches a steady state,the upstream meniscus shows a C-shape,while the downstream meniscus exhibits a sloped shape.During the formation of the MP,the vortex phenomena occur both around and within the MP.With the increase in wheel speed,the thickness of the ribbons gradually decreases from 67 to 31μm.Furthermore,the air vortex on the upstream and downstream meniscus becomes more and more intense,which significantly increases the possibility of air entrapment in the MP and leads to a significant increase in the percentage of air pockets.When the wheel speed is 10–15 m/s,the surface of the ribbon is smooth,the thickness uniformity is better,and there are fewer defects.However,when the wheel speed is more than 15 m/s,the MP’s stability deteriorates,and the ribbons have obvious veining,wrinkles,and uneven thickness.展开更多
With the development of electronic components towards high frequency,high efficiency,and miniaturization,the demand for non-oriented silicon steel ultra-thin ribbons is increasing,which were usually prepared by multi-...With the development of electronic components towards high frequency,high efficiency,and miniaturization,the demand for non-oriented silicon steel ultra-thin ribbons is increasing,which were usually prepared by multi-pass rolling with complex processes and high cost.The ultra-thin non-oriented silicon steel ribbons with silicon content of 2–4.5 wt.%Si were prepared with the planar flow casting technology,and the microstructure and properties of ribbons were investigated.The results showed that as the silicon content increased,the grain size of the as-cast ribbons gradually decreased,and the dislocation density and internal stress were higher.The proportion of{100}oriented grains gradually increased from 29.3 to 37.3%,and the ratio of{110}and{111}oriented grains decreased.Meanwhile,the magnetic induction B50 showed a decline trend from 1.62 to 1.45 T with the increase in silicon content,while the iron loss P_(1.0/400) increased from 20.61 to 66.65 W/kg.This may be related to the silicon content affecting the wettability of melt and the wheel,thereby affecting the cooling capacity.The grains grew significantly after annealing,the internal stress was released and dislocations were eliminated.All this greatly improved the magnetic properties and decreased the hardness.B_(50) of ribbons with 2 wt.%Si reached 1.66 T and P_(1.0/400) of ribbons with 4.5 wt.%Si was reduced to 13.40 W/kg.The percentage of{110}fiber grains increased obviously while{100}fiber grains decreased slightly after heat treatment.展开更多
Maintaining constant mold level variations during the continuous casting process is essential to guarantee the effectiveness and quality of steel production. An unsupervised deep learning-based mold level anomaly dete...Maintaining constant mold level variations during the continuous casting process is essential to guarantee the effectiveness and quality of steel production. An unsupervised deep learning-based mold level anomaly detection (MLAD) model for real-time monitoring of mold level fluctuations under varying operating conditions was proposed. The MLAD framework employs a two-stage encoder-decoder structure with adversarial training to accurately reconstruct time-series mold level data. In the first stage, the model learns long-term trends by reconstructing input windows, while in the second stage, it employs reconstruction errors as focus scores to capture short-term anomaly patterns. A transformer-based architecture, incorporating multi-head attention mechanisms and positional encoding, enables MLAD to capture both local and global temporal dependencies. In addition, a novel multi-threshold strategy, based on extreme value theory, is implemented to enhance the model’s ability and to adapt to varying operating conditions, including startup, steady-state, and shutdown phases. The model was validated with over 240-h real data from a steel factory. The results demonstrate its superior performance in anomaly detection compared to popular methods, with a precision of 0.9937, recall of 0.9932, and a low false alarm rate of 0.0038. MLAD represents a significant advancement in the detection of nonlinear and nonstationary anomalies in industrial processes, offering an efficient solution for smart manufacturing systems. Therefore, the established model could be used for online anomaly detection of mold level with real-time data.展开更多
Manual inspection of onba earing casting defects is not realistic and unreliable,particularly in the case of some micro-level anomalies which lead to major defects on a large scale.To address these challenges,we propo...Manual inspection of onba earing casting defects is not realistic and unreliable,particularly in the case of some micro-level anomalies which lead to major defects on a large scale.To address these challenges,we propose BearFusionNet,an attention-based deep learning architecture with multi-stream,which merges both DenseNet201 and MobileNetV2 for feature extraction with a classification head inspired by VGG19.This hybrid design,figuratively beaming from one layer to another,extracts the enormity of representations on different scales,backed by a prepreprocessing pipeline that brings defect saliency to the fore through contrast adjustment,denoising,and edge detection.The use of multi-head self-attention enhances feature fusion,enabling the model to capture both large and small spatial features.BearFusionNet achieves an accuracy of 99.66%and Cohen’s kappa score of 0.9929 in Kaggle’s Real-life Industrial Casting Defects dataset.Both McNemar’s and Wilcoxon signed-rank statistical tests,as well as fivefold cross-validation,are employed to assess the robustness of our proposed model.To interpret the model,we adopt Grad-Cam visualizations,which are the state of the art standard.Furthermore,we deploy BearFusionNet as a webbased system for near real-time inference(5-6 s per prediction),which enables the quickest yet accurate detection with visual explanations.Overall,BearFusionNet is an interpretable,accurate,and deployable solution that can automatically detect casting defects,leading to significant advances in the innovative industrial environment.展开更多
The effects of the high pressure die casting(HPDC)processes on porosity,microstructure,and mechanical properties of heat-treatment-free aluminum silicon(Al-Si)alloys have long been a focal point in automotive die-cast...The effects of the high pressure die casting(HPDC)processes on porosity,microstructure,and mechanical properties of heat-treatment-free aluminum silicon(Al-Si)alloys have long been a focal point in automotive die-casting research.In this work,the combined effect of shot sleeve materials and slow shot speeds on porosity,microstructure and mechanical properties of a newly designed HPDC Al-Si alloy was investigated.Results show that employing a ceramic shot sleeve or increasing the slow shot speed significantly reduces both the average size and area fraction of externally solidified crystals(ESCs),as well as the average pore size and volume fraction.When the slow shot speed is increased from 0.05 m·s^(-1)to 0.1 m·s^(-1),the pore volume fraction decreases by 10.2%in steel-shot-sleeve samples,compared to a substantial 67.1%reduction in ceramic-shot-sleeve samples.At a slow shot speed of 0.1 m·s^(-1),castings produced with a ceramic shot sleeve exhibit superior mechanical properties:8.3%higher yield strength,17.4%greater tensile strength,and an 81.4%improvement in elongation,relative to those from a steel shot sleeve.These findings provide valuable insights for minimizing porosity and coarse ESCs in die castings,offering promising potential for broader industrial applications.展开更多
Al-Si-Cu-Mg alloy demonstrates a significant age-hardening effect,with its mechanical properties tunable by optimizing the aging parameters.To enhance this effect,the as-cast Al-8.5Si-2Cu-0.9Mg alloy was subjected to ...Al-Si-Cu-Mg alloy demonstrates a significant age-hardening effect,with its mechanical properties tunable by optimizing the aging parameters.To enhance this effect,the as-cast Al-8.5Si-2Cu-0.9Mg alloy was subjected to either single-stage aging at temperatures of 150℃,175℃,200℃,and 225℃for 0.5 h to 20 h;or double-stage aging:involving a first-stage aging treatment at 120℃for 1 h,3 h,5 h,or 7 h,followed by a second-stage aging treatment at 175℃ for 0.5 h to 20 h.The microstructure and mechanical properties were evaluated for samples aged at 175℃/7 h,175℃/10 h,120℃/5 h+175℃/5 h,and 120℃/5 h+175℃/8 h.XRD analysis reveals that the as-cast Al-8.5Si-2Cu-0.9Mg alloy consists of theα-Al,Si,θ-Al_(2)Cu,and Q-Al_(5)Cu_(2)Mg_8Si_6phases.The aging kinetics exhibit a double-peak behavior in both single-stage and double-stage aging processes.Under single-stage aging at 175℃/x h and double-stage aging(120℃/5 h+175℃/x h),the precipitates'size at the first peak is smaller than that at the second peak.Compared with single-stage aging(175℃/7 h),double-stage aging(120℃/5 h+175℃/5 h)produces a finer precipitate in the alloy.Theoretical calculations indicate that the number density and nucleation rate of both the Al_(5)Cu_(2)Mg_8Si_6 and Al_(2)Cu phases are higher during the double-stage aging(120℃/5 h+175℃/5 h)than those during the single-stage aging(175℃/7 h).Additionally,tensile tests at both room temperature and 250℃demonstrate that double-stage aging(120℃/5 h+175℃/5 h)significantly improves the mechanical properties of the alloy compared to single-stage aging(175℃/7 h),suggesting that double-stage aging is more effective for enhancing mechanical properties for this alloy.展开更多
The flow behavior of molten steel in the thin slab mold under high casting speed conditions was investigated,with a focus on the multi-mode continuous casting and rolling mold.A steel-slag two-phase flow model was est...The flow behavior of molten steel in the thin slab mold under high casting speed conditions was investigated,with a focus on the multi-mode continuous casting and rolling mold.A steel-slag two-phase flow model was established using large eddy simulation,the volume of fluid,and magnetohydrodynamics methods through numerical simulation.The maximum flow velocity and wave height at the steel-slag interface within the mold are critical evaluation criteria for analyzing asymmetric flow under varying casting speeds and electromagnetic braking.The results indicate that the asymmetric flows within the mold do not occur synchronously.The severity of the asymmetric flow correlates with the velocity difference across the steel-slag interface.A greater biased flow prolongs the time required to revert to a steady state.When the magnetic field intensity is set to 0.24 T and the magnetic pole position is at 390 mm from the steel-slag interface,this configuration can reduce the velocity of the steel-slag interface,thereby mitigating the asymmetric flow.Additionally,it can diminish the velocity,impact depth,and impact intensity on the narrow face of the jet,thus improving the distribution of velocity and turbulent kinetic energy within the mold.This configuration prolongs the time required for the steel-slag interface to transition from a stable state to its maximum velocity and shortens the time for the interface to return to stability from an unstable state.Moreover,it ensures the positional stability of the steel-slag interface,confining its position within−3 mm.展开更多
Airless tires are essential for enhancing the safety,reliability,and convenience of maintenance of electric bicycles.Polyurethane(PU)is considered a promising candidate for such applications owing to its versatile pro...Airless tires are essential for enhancing the safety,reliability,and convenience of maintenance of electric bicycles.Polyurethane(PU)is considered a promising candidate for such applications owing to its versatile properties.However,their use is limited by insufficient heat resistance and excessive dynamic heat generation under cyclic loading.In this study,star-shaped trifunctional polypropylene glycerol(PPG3)was incorporated into conventional poly(tetramethylene glycol)(PTMG)and 4,4'-methylenediphenyl diisocyanate(MDI)-based systems to construct microporous star-shaped casting polyurethanes(SCPU),with water serving as a green foaming agent.Unlike conventional small-molecule trifunctional crosslinkers that create junctions within hard segment domains,PPG3 introduces long flexible arms between the hard segments,anchoring the crosslinking points at its molecular core.The large steric hindrance of PPG3 effectively suppresses soft segment crystallization and lowers the degree of microphase separation,whereas the crosslinked network restricts chain mobility,thereby reducing dynamic heat generation.These structural features also enhance the heat resistance,yielding a softening temperature of 183℃,which is 30.9%higher than that of polyurethane without PPG3.When applied to airless tires by casting SCPU into rubber treads,the fabricated hybrid airless tires achieved a rolling distance of over 3000 km under a load of 65 kg at 25km/h without structural failure,satisfying practical performance requirements.This strategy offers a simple,solvent-free,and environmentally friendly process,underscoring the potential of SCPU for scalable production of high-performance airless tires.展开更多
In order to investigate the effect of die wall thickness on morphologies of defect band,a stepped mold with a wall thickness of 5 mm,4 mm,3 mm,2 mm,and 1 mm was designed to carry out high pressure die casting experime...In order to investigate the effect of die wall thickness on morphologies of defect band,a stepped mold with a wall thickness of 5 mm,4 mm,3 mm,2 mm,and 1 mm was designed to carry out high pressure die casting experiments with AlSi10 MgMn alloy.For castings with wall thickness of 2-4 mm,the ratio of the mean defect band width(w)and mean grain size(d)in the defect band(w/d)ranges 7-18,while it increases to 24.47 for the 5 mm-thick casting.This difference is related with the filling speed and the distribution of externally solidified crystals(ESCs).The mold flow analysis indicates that the filling speed decreases from 25.41 m·s^(-1)to 11.07 m·s^(-1)when wall thickness increases from 2 mm to 5 mm.Due to the decreasing filling speed along the wall thickness,ESCs gradually diffuse from the center to the defect band,which keep the shear strength in the defect band at a high-level during filling.Meanwhile,the shear strength generated during the filling also decreases as the shear rate drops.Finally,the defect bands in the 5 mm-thick region become widen and indistinct,and the porosity is as high as 5.25%.展开更多
The filling and solidification of a malleable iron pipe casting manufactured by DISA casting mold line with different design parameters were calculated by using software MAGMASOFT. Then the shrinkage porosity was pred...The filling and solidification of a malleable iron pipe casting manufactured by DISA casting mold line with different design parameters were calculated by using software MAGMASOFT. Then the shrinkage porosity was predicted by thermal criterion. Based on the simulation results, the influences of the runner ratio and feeder position on the porosity were discussed. The results show that synchronization of injection can be significantly influenced by the size of downsprue section, and an de-sign structure of DISA gating system was used to solve the problem of flow imbalance in the filling procegs. At the same time, the riser was designed on the hotspot for feeding shrinkage. At last, the optimizated gating system and feeding system were ac-complished to eliminate shrinkage porosity.展开更多
基金the international cooperative program between KITECH(Korea Institute of Industrial Technology)and SRIF(Shenyang Research Institute of Foundry)
文摘For optimal design of a gating system,the setting of diagnosis parameters is very important.In this study,the permanent mold casting process was selected because most of the other casting processes have more complicated factors that influence the mold filling pattern compared to the permanent mold casting process,such as the surface roughness of mold,gas generation from the mold wash and binder of sand mold,and the gas permeability through a sand mold,etc.Two diagnosis parameters(flow rate difference and arrival time difference) of molten metal flow pattern in the numerical simulation are suggested for design of an optimum casting system with a permanent mold.The results show that the arrival time difference can be used as one important diagnosis parameter of the complexity of the runner system and its usefulness has been verified via making aluminum parts using permanent mold casting(Fig.9).
基金Item Sponsored by National Natural Science Foundation of China(50274203)National High Technology Research and Development Program of China(2001AA337040)
文摘To design a power source system and mold for electromagnetic soft-contact continuous casting process and to theoretically estimate the heat losses from the charges and the system power, the effect of structure parameters on system power and magnetic flux density distribution was calculated using finite element method. The results show that as for electromagnetic soft-contact continuous casting system with partial-segment type mold, the power consumption is much more than that with a full-segment type mold; about 62% of electric power is dissipated in the mold, and the effective acting range of magnetic field is relatively narrow. Optimizing mold structure is a crucial measure of remarkably reducing mold power consumption and saving electric energy. Increasing slit number, width, and length can remarkably increase the magnetic flux density in the mold and can reduce the electric energy consumption. Among structure parameters, slit number and slit width are relatively more effective to reduce energy consumption. For a round billet electromagnetic continuous casting system with diameter of 178 ram, the reasonable slit number, width, and length are about 24--32, 0. 5--1.0 mm, and 160 mm, respectively.
基金financially supported by the National Key Research and Development Program of China (2022YFB3706802)。
文摘Automation and intelligence have become the primary trends in the design of investment casting processes.However,the design of gating and riser systems still lacks precise quantitative evaluation criteria.Numerical simulation plays a significant role in quantitatively evaluating current processes and making targeted improvements,but its limitations lie in the inability to dynamically reflect the formation outcomes of castings under varying process conditions,making real-time adjustments to gating and riser designs challenging.In this study,an automated design model for gating and riser systems based on integrated parametric 3D modeling-simulation framework is proposed,which enhances the flexibility and usability of evaluating the casting process by simulation.Firstly,geometric feature extraction technology is employed to obtain the geometric information of the target casting.Based on this information,an automated design framework for gating and riser systems is established,incorporating multiple structural parameters for real-time process control.Subsequently,the simulation results for various structural parameters are analyzed,and the influence of these parameters on casting formation is thoroughly investigated.Finally,the optimal design scheme is generated and validated through experimental verification.Simulation analysis and experimental results show that using a larger gate neck(24 mm in side length) and external risers promotes a more uniform temperature distribution and a more stable flow state,effectively eliminating shrinkage cavities and enhancing process yield by 15%.
基金supported by the National Natural Science Foundation of China(No.52175284)the National Key Research and Development Program of China(Grant No.2022YFB3404201).
文摘This study investigates the formation feasibility of the integrated bottom car body components with dual die casting injection molding technology.During the production of a die-cast super-large one-piece body part weighing over 10,000 t,a thorough comparison and investigation were conducted on the arising issues,using both single and double injection systems.Particular attention was given to meticulously discussing the die casting filling problems and microstructural defects that originated from the filling process.The research findings indicate that the implementation of a double injection system can significantly minimize cold shuts and reduce the solidification time.The effectiveness of this die casting technique was further confirmed by the production of high-quality castings using a scaled model that replicated real casting conditions at a 1:3 ratio,thereby maintaining a one-to-one correspondence in essential aspects.This successful study offers both theoretical insights and practical applications for the production of integrated bottom car bodies utilizing die casting in conjunction with a dual injection system.
基金supported by the Startup Foundation of Shenyang Agriculture University(No.X2023050)the Fundamental Research Funds for the Central Universities(No.N2209006)the National Natural Science Foundation of China(No.U22A20173).
文摘To address the current issues with the conventional slide gate system utilized in the steel teeming process,a unique electromagnetic induction controlled automated steel teeming(EICAST)technology has been developed.Cooling means of spiral coil in this technology is directly related to its service life.Firstly,heat transfer processes of air cooling and spray cooling were compared and analyzed.Secondly,the impacts of water temperature,water flow rate and air flow rate were examined in order to maximize the spray cooling effect.To maintain coil temperature at a low value consistently throughout the entire thermal cycle process of the ladle,a combined cooling mode was finally employed.Numerical simulation was applied to examine the coil temperature variation with different cooling systems and characteristics.Before coil operation,spray cooling is said to be more effective.By controlling the water flow rate and air flow rate,the spray cooling effect is enhanced.However,water temperature has little or no impact when using spray cooling.Air cooling during the secondary refining process and spray cooling prior to coil operation are combined to further lower coil temperature.When the direction of the spray cooling is from bottom to top,the coil temperature is lowered below 165℃.A practical induction coil cooling plan was provided for the EICAST technology’s production process.
基金supported by the National Natural Science Foundation of China (Grant No. 5186504)the University Science Foundation for Young Science and Technology Talents in Inner Mongolia Autonomous Region of China (Grant No. NJYT22078)+2 种基金the Basic Scientific Research Expenses Program of Universities directly under Inner Mongolia Autonomous Region (Grant No. JY20220059)the Inner Mongolia Autonomous Region ‘Grassland Talent’ project Young Innovative Talent Training Program Level ⅠBasic Research Expenses of Universities directly under the Inner Mongolia Autonomous Region (Grant No. ZTY2023040)。
文摘To develop a suitable production process for fiber reinforced investment casting shell mold,three methods were studied:the traditional method(M_(1)),the method of adding fiber into silica sol with mechanical stirring and ultrasonic agitation(M_(2)),and the method of adding fiber into slurry with mechanical stirring and ultrasonic agitation for durations of 3,15,30,and 45 min(M_(3)).The bending strength,high-temperature self-load deformation,and thermal conductivity of the shell molds were investigated.The results reveal that the enhancement of fiber dispersion through ultrasonic agitation improves the comprehensive performance of the shell molds.The maximum green bending strength of the shell mold by M_(2) reaches 3.29 MPa,which is 29% higher than that of the shell mold prepared by M_(1).Moreover,the high-temperature self-load deformation of the shell mold is reduced from 0.62% to 0.44%.In addition,simultaneous ultrasonic agitation and mechanical stirring effectively shorten the slurry preparation time while maintaining comparable levels of fiber dispersion.With the process M_(3)-45 min,the fillers are uniformly dispersed in the slurry,and the fired bending strength and the high-temperature self-load deformation reach 6.25 MPa and 0.41%,respectively.Therefore,the proposed ultrasonic agitation route is promising for the fabrication of fiber-reinforced shell molds with excellent fibers dispersion.
基金financially supported by the Natural Science Foundation of Liaoning Province of China(2022-MS-109)the Key Research and Development Program of Liaoning Province(2023JH2/101800045)the Ministry of Science and Technology of the Peoples Republic of China(ZZ2021006).
文摘The Cu-12Fe alloy has attracted significant attention due to its excellent electrical conductivity and electromagnetic shielding capability,high strength,cost-effectiveness,and recyclability.In the present work,the Cu-12Fe alloy strip with the thickness of 2.4 mm was successfully produced by twin-roll strip casting.The microstructure and properties of the Cu-12Fe alloy were tailored by cold rolling and aging treatment.The tensile strength of the as-cast strip is approximately 328 MPa and its elongation is 25%.The Fe phase randomly dispersed in the matrix,and the average size of Fe-rich phase is 2μm.Besides,enrichment of Fe phase is observed in the central layer of the strip,results in the formation of the“sandwich structure”.Moreover,the as-cast strip of Cu-12Fe was directly cold-rolled from 2.4 to 0.12 mm.The directly cold-rolled sample after aging at 450℃for 16 h(ProcessⅠ)shows excellent electrical conductivity of 69.5%IACS,the tensile strength and elongation are 513 MPa and 3.8%,the saturation magnetic flux density is 20.1 emu·g^(-1),and the coercive force is 25.2 Oe.In ProcessⅡ,the as-cast strip firstly cold-rolled to 1.2 mm,then aged at 500℃for 1.5 h,followed by cold rolling to 0.12 mm,finally aged at 450℃for 16 h.The sample after ProcessⅡshows the electrical conductivity of 66.3%IACS,the tensile strength of 533 MPa,an elongation of 3.5%,saturation magnetic flux density of 21.4 emu·g^(-1),and the coercive force of 22.3 Oe.
基金supported by the National Natural Science Foundation of China(Nos.52422408 and 52171031)the Liaoning Xingliao Talents-Top-notch Young Talents Project(No.XLYC2203064)+1 种基金the Excellent Youth Fund of Liaoning Natural Science Foundation(No.2023JH3/10200001)the Fundamental Research Funds for the Central Universities(No.N2425004).
文摘The transient phenomena of re-oxidation and slag entrapment occurring in the tundish during the ladle change-over process have been proven detrimental to clean steel production.Therefore,an unsteady three-phase turbulence model,coupling velocity,temperature,and phase field was established to study the effect of the ladle shroud immersion depth on the slag eye formation,slag entrainment,slag dragging,air dragging,and flow characteristics during the ladle change-over process of a two-strand tundish.The results showed that reducing the immersion depth decreases the high-velocity region area under the slag layer in the quasi-steady process.During the emptying stage,as the molten bath level gradually decreases,the outlet temperature exhibits a trend of initially decreasing and subsequently increasing across all three shroud immersion depths.However,under a 210 mm shroud immersion depth,molten slag and air are dragged into the shroud,forming slag droplets and causing significant fluctuations,with a maximum scalar velocity of 0.0764 m/s at the monitoring point.In the filling stage,air and molten slag are dragged into the molten bath,forming bubbles and slag droplets at an immersion depth of 210 mm.Bubbles are observed within the molten slag layer,which can readily cause an emulsification phenomenon,making it easier to be dragged as slag droplets.Additionally,the slag eye area measured under 210 mm immersion depth at 45 s is 0.303 m^(2),while the maximum scalar velocity of 2.4259 m/s is detected at 12 s.At an immersion depth of 360 mm,the average area of the slag eye is minimized to 0.06268 m2,with corresponding variances of 0.006753,representing the optimal immersion depth.
基金supported by the National Natural Science Foundation of China(No.52274318).
文摘A full-sectional microstructure characterization method was developed to investigate the formation of coarse slag rims during the continuous casting of hypo-peritectic steel.The cross-sectional microstructural analysis of typical slag rims for two highly crystalline powders revealed that their formation was primarily driven by the solidification of the liquid slag.Distinct differences were observed in the microstructures of slag rims from the two powders.Powder A(characterized by a higher breaking temperature and viscosity)displayed alternating lamellar microstructures of coarse and fine phases,with the coarse phases composed of akermanite-gehlenite transition phases.In contrast,powder B(with a lower breaking temperature and viscosity)predominantly comprised regular akermanite-gehlenite crystals interspersed with a certain amount of glassy phases.Numerical simulations of a three-phase fluid flow coupled with heat transfer indicate that slag rim formation correlates with mold oscillation.Solidification of the liquid slag at the slag rim front predominantly occurs during the negative stroke of the mold oscillation.The average heating rate during the ascending stage of the mold reaches approximately 100 K·s^(−1),whereas the average cooling rate during the descending stage attains 400 K·s^(−1).This temperature variation leads to the formation of lamellar microstructures,whereas the ascending stage promotes the formation of coarse structures and thicker slag rims.Based on the powder properties,two distinct formation pathways exist for highly crystalline mold powders.For the powders with a higher breaking temperature,higher viscosity,and narrower solidification range(powder A),coarse microstructures and thicker slag rims were preferentially formed.For powders with lower breaking temperature and viscosity and wider solidification ranges(powder B),the liquid slag resisted rapid solidification,and the extended mushy zone allowed the partial liquid slag to persist at the slag rim front,promoting the formation of a thin slag rim.This study enhances the understanding of slag rim formation in highly crystalline mold powders and provides critical insights into the control of longitudinal surface cracks in hypo-peritectic steel.
基金supported by National Key Research and Development Program of China(Nos.2023YFB3710203 and 2023YFB3710202)National Natural Science Foundation of China(Nos.52304361 and 52130408)Natural Science Foundation of Hunan Province(No.2023JJ40737).
文摘The sub-rapid solidification(SRS)process associated with twin-roll strip casting(TRSC)is characterized by weakened elemental segregation and selective crystal growth,offering significant advantages compared with conventional casting methods.The interrelationship of the cooling rate,microstructure/texture evolution,and segregation behavior along the thickness direction of as-cast 18Ni–Mo–Co maraging steel strip produced by TRSC was investigated.The results revealed that the solidification microstructure of as-cast maraging steel strip exhibits the directional dendrite growth with preferred{001}texture under SRS condition.It was also found that the synchronous enrichment of Ni,Mo,and Ti elements appears in the as-cast strip to form microsegregation bands.The solidification path of the designed maraging steel strip involves the phase transformation from liquid→γ→α.Additionally,the presence of microsegregation bands of Ni and Mo allows a portion of the austenite(6–9 vol.%)to remain at room temperature after undergoing solid-state phase transformation.It could be observed that the microstructure of as-cast 18Ni–Mo–Co maraging steel strip consists of martensite and austenite,with the austenite distributed alternatively at the interdendritic positions.Ultimately,the interrelationship among solidification cooling rate,element segregation,and solidification microstructure evolution during the SRS process of 18Ni–Mo–Co maraging steel was clarified.
基金supported by the National Key Research and Development Program of China(No.2021YFB3800501)Numerical calculation in this research is supported by the High-Performance Computing Center of Wuhan University of Science and Technology.
文摘Silicon steel is characterized by a high melting point,poor fluidity,and limited wettability,and the process window for the preparation of non-oriented silicon steel ribbons by planar flow casting(PFC)is limited.During the production process,the melt puddle(MP)behavior is a key factor in determining the final quality of ribbons,and the influence mechanism of the airflow boundary layer on the MP behavior and the surface quality of ribbons is still unclear.The effects of wheel speed on the quality of PFC Fe–3.0%Si non-oriented silicon steel ultra-thin ribbons were systematically investigated.Combined with experiments and numerical simulations,the mechanism of different wheel speeds on the behavior of MP and the surface quality of ribbons was analyzed in depth.It is found that when the MP reaches a steady state,the upstream meniscus shows a C-shape,while the downstream meniscus exhibits a sloped shape.During the formation of the MP,the vortex phenomena occur both around and within the MP.With the increase in wheel speed,the thickness of the ribbons gradually decreases from 67 to 31μm.Furthermore,the air vortex on the upstream and downstream meniscus becomes more and more intense,which significantly increases the possibility of air entrapment in the MP and leads to a significant increase in the percentage of air pockets.When the wheel speed is 10–15 m/s,the surface of the ribbon is smooth,the thickness uniformity is better,and there are fewer defects.However,when the wheel speed is more than 15 m/s,the MP’s stability deteriorates,and the ribbons have obvious veining,wrinkles,and uneven thickness.
基金supported by the financial support from National Key Research and Development Program of China(No.2021YFB3800501)。
文摘With the development of electronic components towards high frequency,high efficiency,and miniaturization,the demand for non-oriented silicon steel ultra-thin ribbons is increasing,which were usually prepared by multi-pass rolling with complex processes and high cost.The ultra-thin non-oriented silicon steel ribbons with silicon content of 2–4.5 wt.%Si were prepared with the planar flow casting technology,and the microstructure and properties of ribbons were investigated.The results showed that as the silicon content increased,the grain size of the as-cast ribbons gradually decreased,and the dislocation density and internal stress were higher.The proportion of{100}oriented grains gradually increased from 29.3 to 37.3%,and the ratio of{110}and{111}oriented grains decreased.Meanwhile,the magnetic induction B50 showed a decline trend from 1.62 to 1.45 T with the increase in silicon content,while the iron loss P_(1.0/400) increased from 20.61 to 66.65 W/kg.This may be related to the silicon content affecting the wettability of melt and the wheel,thereby affecting the cooling capacity.The grains grew significantly after annealing,the internal stress was released and dislocations were eliminated.All this greatly improved the magnetic properties and decreased the hardness.B_(50) of ribbons with 2 wt.%Si reached 1.66 T and P_(1.0/400) of ribbons with 4.5 wt.%Si was reduced to 13.40 W/kg.The percentage of{110}fiber grains increased obviously while{100}fiber grains decreased slightly after heat treatment.
基金supported by the Key Science and Technology Project of HBIS Materials Institute(No.HG2022328)the Innovation Group Project of Southern Marine Science and Engineering Guangdong Laboratory(Zhuhai)(No.311021013).
文摘Maintaining constant mold level variations during the continuous casting process is essential to guarantee the effectiveness and quality of steel production. An unsupervised deep learning-based mold level anomaly detection (MLAD) model for real-time monitoring of mold level fluctuations under varying operating conditions was proposed. The MLAD framework employs a two-stage encoder-decoder structure with adversarial training to accurately reconstruct time-series mold level data. In the first stage, the model learns long-term trends by reconstructing input windows, while in the second stage, it employs reconstruction errors as focus scores to capture short-term anomaly patterns. A transformer-based architecture, incorporating multi-head attention mechanisms and positional encoding, enables MLAD to capture both local and global temporal dependencies. In addition, a novel multi-threshold strategy, based on extreme value theory, is implemented to enhance the model’s ability and to adapt to varying operating conditions, including startup, steady-state, and shutdown phases. The model was validated with over 240-h real data from a steel factory. The results demonstrate its superior performance in anomaly detection compared to popular methods, with a precision of 0.9937, recall of 0.9932, and a low false alarm rate of 0.0038. MLAD represents a significant advancement in the detection of nonlinear and nonstationary anomalies in industrial processes, offering an efficient solution for smart manufacturing systems. Therefore, the established model could be used for online anomaly detection of mold level with real-time data.
基金funded by Multimedia University,Cyberjaya,Selangor,Malaysia(Grant Number:PostDoc(MMUI/240029)).
文摘Manual inspection of onba earing casting defects is not realistic and unreliable,particularly in the case of some micro-level anomalies which lead to major defects on a large scale.To address these challenges,we propose BearFusionNet,an attention-based deep learning architecture with multi-stream,which merges both DenseNet201 and MobileNetV2 for feature extraction with a classification head inspired by VGG19.This hybrid design,figuratively beaming from one layer to another,extracts the enormity of representations on different scales,backed by a prepreprocessing pipeline that brings defect saliency to the fore through contrast adjustment,denoising,and edge detection.The use of multi-head self-attention enhances feature fusion,enabling the model to capture both large and small spatial features.BearFusionNet achieves an accuracy of 99.66%and Cohen’s kappa score of 0.9929 in Kaggle’s Real-life Industrial Casting Defects dataset.Both McNemar’s and Wilcoxon signed-rank statistical tests,as well as fivefold cross-validation,are employed to assess the robustness of our proposed model.To interpret the model,we adopt Grad-Cam visualizations,which are the state of the art standard.Furthermore,we deploy BearFusionNet as a webbased system for near real-time inference(5-6 s per prediction),which enables the quickest yet accurate detection with visual explanations.Overall,BearFusionNet is an interpretable,accurate,and deployable solution that can automatically detect casting defects,leading to significant advances in the innovative industrial environment.
基金the National Key Research and Development Program of China(Grant No.2022YFB3404201)the National Natural Science Foundation of China(Grant Nos.52175335,52405342)+1 种基金the Natural Science Foundation Joint Foundation of Liaoning province(Grant No.2023-B SB A-108)the Fundamental Research Funds for the Central Universities(Grant No.N2402005)。
文摘The effects of the high pressure die casting(HPDC)processes on porosity,microstructure,and mechanical properties of heat-treatment-free aluminum silicon(Al-Si)alloys have long been a focal point in automotive die-casting research.In this work,the combined effect of shot sleeve materials and slow shot speeds on porosity,microstructure and mechanical properties of a newly designed HPDC Al-Si alloy was investigated.Results show that employing a ceramic shot sleeve or increasing the slow shot speed significantly reduces both the average size and area fraction of externally solidified crystals(ESCs),as well as the average pore size and volume fraction.When the slow shot speed is increased from 0.05 m·s^(-1)to 0.1 m·s^(-1),the pore volume fraction decreases by 10.2%in steel-shot-sleeve samples,compared to a substantial 67.1%reduction in ceramic-shot-sleeve samples.At a slow shot speed of 0.1 m·s^(-1),castings produced with a ceramic shot sleeve exhibit superior mechanical properties:8.3%higher yield strength,17.4%greater tensile strength,and an 81.4%improvement in elongation,relative to those from a steel shot sleeve.These findings provide valuable insights for minimizing porosity and coarse ESCs in die castings,offering promising potential for broader industrial applications.
基金supported by the Key R&D Projects in Heilongjiang Province(GA23A901)。
文摘Al-Si-Cu-Mg alloy demonstrates a significant age-hardening effect,with its mechanical properties tunable by optimizing the aging parameters.To enhance this effect,the as-cast Al-8.5Si-2Cu-0.9Mg alloy was subjected to either single-stage aging at temperatures of 150℃,175℃,200℃,and 225℃for 0.5 h to 20 h;or double-stage aging:involving a first-stage aging treatment at 120℃for 1 h,3 h,5 h,or 7 h,followed by a second-stage aging treatment at 175℃ for 0.5 h to 20 h.The microstructure and mechanical properties were evaluated for samples aged at 175℃/7 h,175℃/10 h,120℃/5 h+175℃/5 h,and 120℃/5 h+175℃/8 h.XRD analysis reveals that the as-cast Al-8.5Si-2Cu-0.9Mg alloy consists of theα-Al,Si,θ-Al_(2)Cu,and Q-Al_(5)Cu_(2)Mg_8Si_6phases.The aging kinetics exhibit a double-peak behavior in both single-stage and double-stage aging processes.Under single-stage aging at 175℃/x h and double-stage aging(120℃/5 h+175℃/x h),the precipitates'size at the first peak is smaller than that at the second peak.Compared with single-stage aging(175℃/7 h),double-stage aging(120℃/5 h+175℃/5 h)produces a finer precipitate in the alloy.Theoretical calculations indicate that the number density and nucleation rate of both the Al_(5)Cu_(2)Mg_8Si_6 and Al_(2)Cu phases are higher during the double-stage aging(120℃/5 h+175℃/5 h)than those during the single-stage aging(175℃/7 h).Additionally,tensile tests at both room temperature and 250℃demonstrate that double-stage aging(120℃/5 h+175℃/5 h)significantly improves the mechanical properties of the alloy compared to single-stage aging(175℃/7 h),suggesting that double-stage aging is more effective for enhancing mechanical properties for this alloy.
基金support from the National Natural Science Foundation of China(Grant Nos.52174313 and 52304350)thank all members of the Hebei High Quality Steel Continuous Casting Engineering Technology Research Center at North China University of Science and Technology,Tangshan,China.
文摘The flow behavior of molten steel in the thin slab mold under high casting speed conditions was investigated,with a focus on the multi-mode continuous casting and rolling mold.A steel-slag two-phase flow model was established using large eddy simulation,the volume of fluid,and magnetohydrodynamics methods through numerical simulation.The maximum flow velocity and wave height at the steel-slag interface within the mold are critical evaluation criteria for analyzing asymmetric flow under varying casting speeds and electromagnetic braking.The results indicate that the asymmetric flows within the mold do not occur synchronously.The severity of the asymmetric flow correlates with the velocity difference across the steel-slag interface.A greater biased flow prolongs the time required to revert to a steady state.When the magnetic field intensity is set to 0.24 T and the magnetic pole position is at 390 mm from the steel-slag interface,this configuration can reduce the velocity of the steel-slag interface,thereby mitigating the asymmetric flow.Additionally,it can diminish the velocity,impact depth,and impact intensity on the narrow face of the jet,thus improving the distribution of velocity and turbulent kinetic energy within the mold.This configuration prolongs the time required for the steel-slag interface to transition from a stable state to its maximum velocity and shortens the time for the interface to return to stability from an unstable state.Moreover,it ensures the positional stability of the steel-slag interface,confining its position within−3 mm.
基金financially supported by the National Natural Science Foundation of China(No.52303063)Hubei Provincial Department of Education Guided Scientific Research Project(No.B2024056)。
文摘Airless tires are essential for enhancing the safety,reliability,and convenience of maintenance of electric bicycles.Polyurethane(PU)is considered a promising candidate for such applications owing to its versatile properties.However,their use is limited by insufficient heat resistance and excessive dynamic heat generation under cyclic loading.In this study,star-shaped trifunctional polypropylene glycerol(PPG3)was incorporated into conventional poly(tetramethylene glycol)(PTMG)and 4,4'-methylenediphenyl diisocyanate(MDI)-based systems to construct microporous star-shaped casting polyurethanes(SCPU),with water serving as a green foaming agent.Unlike conventional small-molecule trifunctional crosslinkers that create junctions within hard segment domains,PPG3 introduces long flexible arms between the hard segments,anchoring the crosslinking points at its molecular core.The large steric hindrance of PPG3 effectively suppresses soft segment crystallization and lowers the degree of microphase separation,whereas the crosslinked network restricts chain mobility,thereby reducing dynamic heat generation.These structural features also enhance the heat resistance,yielding a softening temperature of 183℃,which is 30.9%higher than that of polyurethane without PPG3.When applied to airless tires by casting SCPU into rubber treads,the fabricated hybrid airless tires achieved a rolling distance of over 3000 km under a load of 65 kg at 25km/h without structural failure,satisfying practical performance requirements.This strategy offers a simple,solvent-free,and environmentally friendly process,underscoring the potential of SCPU for scalable production of high-performance airless tires.
基金supported by the National Natural Science Foundation of China(No.52474396 and 52175284)the National Key Research and Development Program of China(Grant No.2022YFB3404201)。
文摘In order to investigate the effect of die wall thickness on morphologies of defect band,a stepped mold with a wall thickness of 5 mm,4 mm,3 mm,2 mm,and 1 mm was designed to carry out high pressure die casting experiments with AlSi10 MgMn alloy.For castings with wall thickness of 2-4 mm,the ratio of the mean defect band width(w)and mean grain size(d)in the defect band(w/d)ranges 7-18,while it increases to 24.47 for the 5 mm-thick casting.This difference is related with the filling speed and the distribution of externally solidified crystals(ESCs).The mold flow analysis indicates that the filling speed decreases from 25.41 m·s^(-1)to 11.07 m·s^(-1)when wall thickness increases from 2 mm to 5 mm.Due to the decreasing filling speed along the wall thickness,ESCs gradually diffuse from the center to the defect band,which keep the shear strength in the defect band at a high-level during filling.Meanwhile,the shear strength generated during the filling also decreases as the shear rate drops.Finally,the defect bands in the 5 mm-thick region become widen and indistinct,and the porosity is as high as 5.25%.
文摘The filling and solidification of a malleable iron pipe casting manufactured by DISA casting mold line with different design parameters were calculated by using software MAGMASOFT. Then the shrinkage porosity was predicted by thermal criterion. Based on the simulation results, the influences of the runner ratio and feeder position on the porosity were discussed. The results show that synchronization of injection can be significantly influenced by the size of downsprue section, and an de-sign structure of DISA gating system was used to solve the problem of flow imbalance in the filling procegs. At the same time, the riser was designed on the hotspot for feeding shrinkage. At last, the optimizated gating system and feeding system were ac-complished to eliminate shrinkage porosity.
