To improve the service and machining performance of the workpiece, the tool wear mechanisms, surface machining quality, and wear resistance in conventional side milling(CSM)and longitudinal-torsional ultrasonic vibrat...To improve the service and machining performance of the workpiece, the tool wear mechanisms, surface machining quality, and wear resistance in conventional side milling(CSM)and longitudinal-torsional ultrasonic vibration side milling(LTUVSM) of GH4169 superalloy at different cutting lengths are investigated systematically. Tool wear mechanisms are revealed and the correlation between machined surface quality with tool wear is analyzed correspondingly. Tool wear patterns mainly include adhesive wear, diffusion wear, abrasive wear, and chipping sticking.Better surface quality is achieved in LTUVSM due to a maximum reduction of flank wear bandwidth and wear rate by 71.9% and 71.5%, respectively, compared to CSM. The friction coefficient,initial wear stage time, and wear volume of dry sliding wear were measured to evaluate the workpiece wear resistance. The maximum reductions in friction coefficient and wear volume in LTUVSM are 18.2% and 15.8% compared to CSM. The regular ultrasonic vibration textures suppress the friction and the growth of contact nodes in the contact area, decreasing the degree of surface wear, which is demonstrated by a 38.8% increase in initial wear stage time compared to CSM.In conclusion, the workpiece in LTUVSM exhibits higher wear resistance because of the improvement of tool wear and the guarantee of surface quality.展开更多
Al-Mg-Zn-based alloys are newly developed high-performance age-hardenable 5xxx series alloys.How-ever,they suffer from poor surface quality due to the Lüders bands and the Portevin-Le-Chatelier(PLC)effect during ...Al-Mg-Zn-based alloys are newly developed high-performance age-hardenable 5xxx series alloys.How-ever,they suffer from poor surface quality due to the Lüders bands and the Portevin-Le-Chatelier(PLC)effect during plastic deformation,and the elongation(EL)is impaired by the large constituent particles.In this work,various homogenization regimes combined with minor addition of Zr were employed to manipulate the microstructural evolution of Al-7Mg-2Zn-0.15Zr alloy and thus the deformation character-istics.The results demonstrate that a two-step homogenization treatment of 400℃/12 h+465℃/12 h can sufficiently dissolve the constituent phase and eliminate the micro-segregation,as well as achieve a fine and uniform distribution of Al_(3)Zr dispersoids,which results in the enhanced yield strength(YS)of 201 MPa and ultimate strength(UTS)of 376 MPa after rolling and annealing.Most importantly,it has been revealed that the dispersed Al_(3)Zr formed via two-step homogenization is favorable to impede the movement of dislocations,which extends the waiting time,increases the stress amplitude,and thus di-minishes the number of PLC bands.Moreover,the dislocation network induced by dispersed Al_(3)Zr can further inhibit the movement of active dislocations,which inhibits the formation of Lüders bands.This study provides a simple and effective homogenization regime to optimize the mechanical response and surface quality of alloys with high-Mg contents.展开更多
Cu-4.7%Sn （mass fraction） alloy plate was prepared by the self-developed two-phase zone continuous casting （TZCC） process. The relationship between process parameters of TZCC and surface quality of the alloy plate...Cu-4.7%Sn （mass fraction） alloy plate was prepared by the self-developed two-phase zone continuous casting （TZCC） process. The relationship between process parameters of TZCC and surface quality of the alloy plate was investigated. The microstructure and mechanical properties of the TZCC alloy plate were analyzed. The results show that Cu-4.7%Sn alloy plate with smooth surface can be obtained by means of reasonable matching the entrance temperature of two-phase zone mold and the continuous casting speed. The microstructure of the TZCC alloy is composed of grains-covered grains, small grains with self-closed grain boundaries, columnar grains and equiaxed grains. Compared with cold mold continuous casting Cu-4.7%Sn alloy plate, the room temperature tensile strength and ductility of the TZCC alloy plate are greatly improved.展开更多
Creep feed profile grinding of the fir-tree blade root forms of single crystal nickel-based superalloy was conducted using microcrystalline alumina abrasive wheels in the present study. The grinding force and the surf...Creep feed profile grinding of the fir-tree blade root forms of single crystal nickel-based superalloy was conducted using microcrystalline alumina abrasive wheels in the present study. The grinding force and the surface quality in terms of surface topography, subsurface microstructure,microhardness and residual stress obtained under different grinding conditions were evaluated comparatively. Experimental results indicated that the grinding force was influenced significantly by the competing predominance between the grinding parameters and the cross-sectional root workpiece profile. In addition, the root workpiece surface, including the root peak and valley regions, was produced with the large difference in surface quality due to the nonuniform grinding loads along the root workpiece profile in normal section. Detailed results showed that the surface roughness, subsurface plastic deformation and work hardening level of the root valley region were higher by up to25%, 20% and 7% in average than those obtained in the root peak region, respectively, in the current investigation. Finally, the superior parameters were recommended in the creep feed profile grinding of the fir-tree blade root forms. This study is helpful to provide industry guidance to optimize the machining process for the high-valued parts with complicated profiles.展开更多
Selective laser melting （SLM） is a powerful additive manufacturing （AM） technology, of which the most prominent advantage is the ability to produce components with a complex geometry. The service performances of t...Selective laser melting （SLM） is a powerful additive manufacturing （AM） technology, of which the most prominent advantage is the ability to produce components with a complex geometry. The service performances of the SLM-processed components depend on the microstructure and surface quality. In this work, the microstructures, mechanical properties, and fracture behaviors of SLM-processed Ti-6AI-4V alloy under machined and as-built surfaces after annealing treatments and hot isostatic pressing （HIP） were investigated. The microstructures were analyzed by optical microscope （OM）, scanning electron microscope （SEM） and transmission electron microscopy （TEM）. The mechanical properties were measured by tensile testing at room temperature. The results indicate that the as-deposited microstructures are characterized by columnar grains and fine brittle martensite and the as- deposited properties present high strength, low ductility and obvious anisotropy. After annealing at 800-900~C for 2-4 h and HIP at 920~C/100MPa for 2 h, the brittle martensite could be transformed into ductile lamellar （a＋~） microstructure and the static tensile properties of SLM-processed Ti-6AI-4V alloys in the machined condition could be comparable to that of wrought materials. Even after HIP treatment, the as-built surfaces could decrease the ductility and reduction of area of SLM-processed fi-6AI-4V alloys to 9.2% and 20%, respectively. The crack initiation could occur at the columnar grain boundaries or at the as-built surfaces. The lamellar （a＋13） microstructures and columnar grains could hinder or distort the crack propagation path during tensile tests.展开更多
This experiment obtained different laser energy density(LED) by changing SLM molding process parameters.The surface morphology, surface quality, and microstructure of as-fabricated samples were studied. The effects of...This experiment obtained different laser energy density(LED) by changing SLM molding process parameters.The surface morphology, surface quality, and microstructure of as-fabricated samples were studied. The effects of scanning speed, hatching space, and laser power on surface quality were analyzed, and the optimal LED range for surface quality was determined. The results show that pores and spherical particles appear on the sample’s surface when low LED is applied, while there are lamellar structures on the sides of the samples. Cracks appear on the sample’s surface,and the splash phenomenon increases when a high LED is taken. At the same time, a large amount of unmelted powder adhered to the side of the sample. The surface quality is the best when the LED is 150-170 J/mm^(3). The preferred hatch space is currently 0.05-0.09 mm, the laser power is 200-350 W, and the average surface roughness value is(15.1±3) μm.The average surface hardness reaches HV404±HV3, higher than the forging standard range of HV340-HV395.Increasing the LED within the experiment range can increase the surface hardness, yet an excessively high LED will not further increase the surface hardness. The microstructure is composed of needle-like α’-phases with a length of about 20μm, in a crisscross ‘N’ shape, when the LED is low. The β-phase grain boundary is not obvious, and the secondaryphase volume fraction is high;when the LED is high, the α’-phase of the microstructure is in the form of coarse slats, and the secondary-phase is composed of a small amount of secondary α’-phase, the tertiary α’-phase and the fourth α’-phase disappear, and the volume fraction of the secondary-phase becomes low.展开更多
In order to grind the ceramic blade surface with the Numerical Control contour evolution ultrasonic grinding method using the simple shape grinding wheel, primary comparative experiments of creep feed grinding with an...In order to grind the ceramic blade surface with the Numerical Control contour evolution ultrasonic grinding method using the simple shape grinding wheel, primary comparative experiments of creep feed grinding with and without ultrasonic vibration were carried out to grind Al2O3 ceramics so as to implore the effects of different process parameters on the machined surface quality. It can be concluded that when the direction of ultrasonic vibration is parallel to the direction of creep feed, the value of the surface roughness will be decreased; otherwise the surface quality will become worse. With the ultrasonic grinding method, the slower feed-rate, the smaller grinding depth, the higher grinding speed and the compound feed grinding method should be applied in order to improve the surface quality. The creep feed grinding meehanisms with and without ultrasonic vibration were analyzed theoretically from the experimental results. With the selected grinding parameters resulted from the experiments, the feasibility experiment of ultrasonic grinding ceramic blade surface was cartied out.展开更多
Electrochemical machining(ECM)has emerged as an important option for manufacturing the blisk.The inter-electrode gap(IEG)distribution is an essential parameter for the blisk precise shap-ing process in ECM,as it affec...Electrochemical machining(ECM)has emerged as an important option for manufacturing the blisk.The inter-electrode gap(IEG)distribution is an essential parameter for the blisk precise shap-ing process in ECM,as it affects the process stability,profile accuracy and surface quality.Larger IEG leads to a poor localization effect and has an adverse influence on the machining accuracy and surface quality of blisk.To achieve micro-IEG(<50 lm)blisk finishing machining,this work puts forward a novel variable-parameters blisk ECM strategy based on the synchronous coupling mode of micro-vibration amplitude and small pulse duration.The modelling and simulation of the blisk micro-IEG machining have been carried out.Exploratory experiments of variable-parameters blisk ECM were car-ried out.The results illustrated that the IEG width reduced with the progress of variable parameter pro-cess.The IEG width of the blade’s concave part and convex part could be successfully controlled to within 30 lm and 21 lm,respectively.The profile deviation for the blade’s concave surface and convex surface are 49 lm and 35 lm,while the surface roughness reaches R_(a)=0.149 lm and R_(a)=0.196 lm,respectively.The profile accuracy of the blisk leading/trailing edges was limited to within 91 lm.Com-pared with the currently-established process,the profile accuracy of the blade’s concave and convex profiles was improved by 50.5%and 53.3%,respectively.The surface quality was improved by 53.2%and 50.9%,respectively.Additionally,the machined surface was covered with small corrosion pits and weak attacks of the grain boundary due to selective dissolution.Some electrolytic products were dispersed on the machined surface,and their components were mainly composed of the carbide and oxide products of Ti and Nb elements.The results indicate that the variable-parameters strategy is effective for achieving a tiny IEG in blisk ECM,which can be used in engineering practice.展开更多
The unsatisfied surface quality seriously impedes the wide application of incremental sheet forming(ISF)in industrial field.As a novel approach,the interpolator method is a promising strategy to enhance the surface qu...The unsatisfied surface quality seriously impedes the wide application of incremental sheet forming(ISF)in industrial field.As a novel approach,the interpolator method is a promising strategy to enhance the surface quality in ISF.However,the mechanism for the improvement of surface quality and the influence of interpolator properties on surface roughness are not well understood.In this paper,the influences of process variables(i.e.tool diameter,step size and thickness of interpolators)on the forming process(e.g.surface roughness,forming force and geometric error)are investigated through a systematic experimental approach of central composite design(CCD)in two-point incremental sheet forming(TPIF).It is obtained that the increase in thickness of interpolators decreases the surface roughness in direction vertical to the tool path while increases the surface roughness in direction horizontal to the tool path.Nevertheless,the combined influence between thickness of interpolators and process parameters(tool diameter and step size)is limited.Meanwhile,the placement of interpolator has little influence on the effective forming force of blank.In addition,the geometric error enlarges with the increase of step size and thickness of interpolator while decreases firstly and then increase with an increase in tool diameter.Finally,the influencing mechanism of the interpolator method on surface quality can be attributed to the decrease of thecontact pressure due to the increase of contact area with the unchanged contact force.Meanwhile,the interpolator method eliminates the sliding friction on the surface of blank due to the stable relative position between the blank and the interpolator.展开更多
Bearings are one of the most important components in modern industry.Rolling contact fatigue(RCF)initiating from surface and subsurface is the major failure mode.In this paper,a typical high speed thrust angular conta...Bearings are one of the most important components in modern industry.Rolling contact fatigue(RCF)initiating from surface and subsurface is the major failure mode.In this paper,a typical high speed thrust angular contact ball bearing was selected,and the machined surface quality and near-surface microstructure of the race-way and rolling ball were systematically characterized by using of a probe surface profiler,white light interferometer,optical microscopy(OM),scanning electron microscopy(SEM),electron backscatter diffraction(EBSD)and transmission electron microscopy(TEM)combined with focused ion beam(FIB).Two kinds of precursor,probably resulting in pitting or spalling during the following rolling contact,were detected.One is the defects on the surface of either the race-way or the rolling ball,such as heavy machining marks,scratches and slag-hole.The other is nano-crystalline layer due to machining,in the outermost layer around the surface of race-way.The results may well lay foundation for our further research on RCF with the real part of such typical rolling bearings.展开更多
7075 aluminum alloy ingot with the diameter izontal direct chill casting in different casting of 100 mm has been produced by horspeed. The effect of the casting speed on the ingot surface and subsurface layer was stud...7075 aluminum alloy ingot with the diameter izontal direct chill casting in different casting of 100 mm has been produced by horspeed. The effect of the casting speed on the ingot surface and subsurface layer was studied by surface observation and subsurface structure analysis. It was found that increasing the casting speed results in the adding of segregation knots in the ingot surface. The thickness of the dendrite microstrueture layer in the subsurface reduces with increasing the casting speed. And the elements of Zn, Cu and Mg enrich in the coarse dendrite microstructure layer of the ingot.展开更多
A ceramic matrix coating for minimizing steel loss of stainless steel at high temperatures was prepared by handled air-spraying technique, and the influence of coating on surface quality of stainless steel was mainly ...A ceramic matrix coating for minimizing steel loss of stainless steel at high temperatures was prepared by handled air-spraying technique, and the influence of coating on surface quality of stainless steel was mainly investiga ted in laboratory. Experimental results showed that the protective coating reduced the oxidation of stainless steel by more than 91% and minimized high temperature scaling and also enhanced steel surface quality. The scales of coated specimen were removed completely and the scales of uncoated specimen were partly residual on the surface after cool ing process. Mn-rich and Fe-rich zones were found in the oxides. The Cr2 O3 found in scales came from the underlying stainless steel and formed a Cr rich layer along the spalled surface.展开更多
To improve the quality of 7050 aluminum alloy ingots, low-frequency electromagnetic （LFE） field was applied during the conventional hot-top casting process. Macrostructures and microstructures of the ingots by the c...To improve the quality of 7050 aluminum alloy ingots, low-frequency electromagnetic （LFE） field was applied during the conventional hot-top casting process. Macrostructures and microstructures of the ingots by the conventional and LFE hot-top casting processes were studied. The experimental results show that when the LFE field is turn off during the hot-top casting process, cold folding appears, and the as-cast structure becomes very coarse. Additionally, the thickness of the shell zone is much thinner during the low-frequency electromagnetic hot-top casting process than that during the conventional hot-top casting process. Some reasons for low-frequency electromagnetic field improving the surface quality, refining the structure of the ingot, and minimizing the thickness of the shell zone have been studied.展开更多
For laser cladding a large temperature gradient easily weakened the surface quality by generating cracks and irregular coating surfaces,which in turn affected the bearing capacity and corrosion resistance of coatings ...For laser cladding a large temperature gradient easily weakened the surface quality by generating cracks and irregular coating surfaces,which in turn affected the bearing capacity and corrosion resistance of coatings in the rapid heating and cooling process.The response surface methodology(RSM)was used to predict coating cracks by changing the powder ratio,energy density,and preheating temperature,which obtained the relevant mathematical model.After that,the sensitivity of the crack length to process parameters was analyzed based on the sensitivity analysis method.The effect of Ni60/WC composite powder process parameters on the surface quality was revealed in laser cladding.The crack length first decreased and then increased,and the Smooth decreased with the increased powder ratio.The crack length and Smooth increased with the increased energy density.The crack length decreased and Smooth increased with the increased preheating temperature.Sensitivity analysis showed that the crack length and Smooth were the most sensitive to the powder ratio.Therefore,the process parameters were reasonably selected to control the surface quality.The mathematical model and sensitivity analysis method in the work could improve the surface quality,which provided a theoretical basis for the prediction and control of laser cladding cracks.展开更多
The mechanical characters of CdZnTe crystal were investigated by nanoscratch tests, and the effects of mechanical anisotropy on the material removal rate and surface quality were studied by polishing tests. There is a...The mechanical characters of CdZnTe crystal were investigated by nanoscratch tests, and the effects of mechanical anisotropy on the material removal rate and surface quality were studied by polishing tests. There is a peak of frictional coefficient at the early stage of scratch, and increasing the vertical force will result in the increase of peak value correspondingly. The fluctuation phenomenon of frictional coefficient is generated at high vertical force. The lateral forces show the apparent twofold and threefold symmetries on （110） and （111） planes, respectively. To obtain high surface quality, low polishing pressure and hard direction （〈 T10 〉 directions on （110） plane and 〈 112 〉 directions on （111） plane） should be selected, and to achieve high material removal rate, high polishing pressure and soft direction （〈001〉 directions on （110） plane and 〈 121 〉 directions on （111） plane） should be selected.展开更多
The effect of the microstructure of plates fabricated both in the traditional process, involving casting, hot rolling and cold rolling （HR）, and in the novel twin roll casting ＋ cold rolling （TRC） process on the ...The effect of the microstructure of plates fabricated both in the traditional process, involving casting, hot rolling and cold rolling （HR）, and in the novel twin roll casting ＋ cold rolling （TRC） process on the surface quality of presensitized （PS） plates was analyzed by optical microscopy （OM）, scanning electron microscopy （SEM）, and energy-dispersive X-ray spectroscopy （EDXS）. The formation of pores on the surface of the electrolyzed HR plate could be attributed to the presence of approximately 1-μm-sized large Al-Fe precipitates in the HR plate compared to the smaller precipitates in the TRC plate. Moreover, residual graphite lubricants used during the TRC process were entrapped on the surface of the TRC plate during the subsequent rolling process. The entrapped pollutants tended to further deteriorate the formation of pores on the surface of the TRC plate, and no residual carbon was detected on the surface of the HR plate. Furthermore, the surface quality of the TRC plate can be improved by surface cleaning before the cold rolling process, which could dramatically lower the residual graphite on the surface.展开更多
The relationships between the surface quality of a single crystal copper ingot and the process parameters of heated mould continuous casting method were studied experimentally using our own design of horizontal heated...The relationships between the surface quality of a single crystal copper ingot and the process parameters of heated mould continuous casting method were studied experimentally using our own design of horizontal heated mould continuous casting apparatus, and the mechanism by which process parameters affect the surface quality of a single crystal copper ingot is analyzed in the present paper. The results show that the process parameters affect the surface quality of a pure copper ingot by affecting the position of the liquid-solid interface in the mould. The position of the liquid-solid interface in the mould must be controlled carefully within an appropriate range, which is determined through a series of experiments, in order to gain a single crystal copper ingot with good surface quality.展开更多
5182 Al alloy ingots with the diameters of 100 mm are produced by conventional and combined electromagnetic fields （CEMF） horizontal direction chill （HDC） cast- ing process. The effect of CEMF on the ingot surface...5182 Al alloy ingots with the diameters of 100 mm are produced by conventional and combined electromagnetic fields （CEMF） horizontal direction chill （HDC） cast- ing process. The effect of CEMF on the ingot surface quality and floating grains is investigated. The results show that the CEMF is effective in reducing the segregation layer in both top and bottom sub-surfaces. Big floating grains with coarse dendrite arms mainly distribute in the crescent-shaped area near the bottom in the conven- tional HDC casting ingot. With the application of the CEMF, they disappear in the whole cross section of the HDC casting ingot and the equiaxed grains are significantly refined.展开更多
As a substitute for toxic cadmium coatings in the aerospace industry,zinc-nickel coatings have excellent application prospects,and their properties can be improved by adding molybdenum.In this study,laser-assisted ele...As a substitute for toxic cadmium coatings in the aerospace industry,zinc-nickel coatings have excellent application prospects,and their properties can be improved by adding molybdenum.In this study,laser-assisted electrodeposition is used to improve the surface quality and properties of Zn–Ni–Mo coatings,with investigation of how laser energy in the range of 0–21.1μJ affects their element content,surface morphology,crystal phase,microhardness,residual internal stress,and corrosion resistance.The laser irradiation accelerates the electrodeposition,refines the grain size,improves the hydrogen adsorption,and reduces the residual tensile stress,and a laser energy of 15.4μJ gives the highest Ni and Mo contents and the lowest Zn content,as well as the optimum surface morphology,microhardness,residual internal stress,and corrosion resistance of the coating.展开更多
Contour bevel gears have the advantages of high coincidence,low noise and large bearing capacity,which are widely used in automobile manufacturing,shipbuilding and construction machinery.However,when the surface quali...Contour bevel gears have the advantages of high coincidence,low noise and large bearing capacity,which are widely used in automobile manufacturing,shipbuilding and construction machinery.However,when the surface quality is poor,the effective contact area between the gear mating surfaces decreases,affecting the stability of the fit and thus the transmission accuracy,so it is of great significance to optimize the surface quality of the contour bevel gear.This paper firstly analyzes the formation process of machined surface roughness of contour bevel gears on the basis of generating machining method,and dry milling experiments of contour bevel gears are conducted to analyze the effects of cutting speed and feed rate on the machined surface roughness and surface topography of the workpiece.Then,the surface defects on the machined surface of the workpiece are studied by SEM,and the causes of the surface defects are analyzed by EDS.After that,XRD is used to compare the microscopic grains of the machined surface and the substrate material for diffraction peak analysis,and the effect of cutting parameters on the microhardness of the workpiece machined surface is investigated by work hardening experiment.The research results are of great significance for improving the machining accuracy of contour bevel gears,reducing friction losses and improving transmission efficiency.展开更多
基金supported by the National Natural Science Foundation of China Regional Innovation and Development Joint Fund (Hunan Province) (No. U22A20200)。
文摘To improve the service and machining performance of the workpiece, the tool wear mechanisms, surface machining quality, and wear resistance in conventional side milling(CSM)and longitudinal-torsional ultrasonic vibration side milling(LTUVSM) of GH4169 superalloy at different cutting lengths are investigated systematically. Tool wear mechanisms are revealed and the correlation between machined surface quality with tool wear is analyzed correspondingly. Tool wear patterns mainly include adhesive wear, diffusion wear, abrasive wear, and chipping sticking.Better surface quality is achieved in LTUVSM due to a maximum reduction of flank wear bandwidth and wear rate by 71.9% and 71.5%, respectively, compared to CSM. The friction coefficient,initial wear stage time, and wear volume of dry sliding wear were measured to evaluate the workpiece wear resistance. The maximum reductions in friction coefficient and wear volume in LTUVSM are 18.2% and 15.8% compared to CSM. The regular ultrasonic vibration textures suppress the friction and the growth of contact nodes in the contact area, decreasing the degree of surface wear, which is demonstrated by a 38.8% increase in initial wear stage time compared to CSM.In conclusion, the workpiece in LTUVSM exhibits higher wear resistance because of the improvement of tool wear and the guarantee of surface quality.
基金support from the National Natural Science Foundation of China(No.52201004)the Beijing Natural Science Foundation(No.2222095)+1 种基金S.W.Pan would acknowledge the support from the China Postdoctoral Science Foundation(No.2023M730234)the National Natural Science Foundation of China(No.52301005).
文摘Al-Mg-Zn-based alloys are newly developed high-performance age-hardenable 5xxx series alloys.How-ever,they suffer from poor surface quality due to the Lüders bands and the Portevin-Le-Chatelier(PLC)effect during plastic deformation,and the elongation(EL)is impaired by the large constituent particles.In this work,various homogenization regimes combined with minor addition of Zr were employed to manipulate the microstructural evolution of Al-7Mg-2Zn-0.15Zr alloy and thus the deformation character-istics.The results demonstrate that a two-step homogenization treatment of 400℃/12 h+465℃/12 h can sufficiently dissolve the constituent phase and eliminate the micro-segregation,as well as achieve a fine and uniform distribution of Al_(3)Zr dispersoids,which results in the enhanced yield strength(YS)of 201 MPa and ultimate strength(UTS)of 376 MPa after rolling and annealing.Most importantly,it has been revealed that the dispersed Al_(3)Zr formed via two-step homogenization is favorable to impede the movement of dislocations,which extends the waiting time,increases the stress amplitude,and thus di-minishes the number of PLC bands.Moreover,the dislocation network induced by dispersed Al_(3)Zr can further inhibit the movement of active dislocations,which inhibits the formation of Lüders bands.This study provides a simple and effective homogenization regime to optimize the mechanical response and surface quality of alloys with high-Mg contents.
基金Project(51374025) supported by the National Natural Science Foundation of ChinaProject(2014Z-05) supported by the State Key Laboratory for Advanced Metals and Materials,University of Science and Technology Beijing,ChinaProject(2152020) supported by the Beijing Natural Science Foundation,China
文摘Cu-4.7%Sn （mass fraction） alloy plate was prepared by the self-developed two-phase zone continuous casting （TZCC） process. The relationship between process parameters of TZCC and surface quality of the alloy plate was investigated. The microstructure and mechanical properties of the TZCC alloy plate were analyzed. The results show that Cu-4.7%Sn alloy plate with smooth surface can be obtained by means of reasonable matching the entrance temperature of two-phase zone mold and the continuous casting speed. The microstructure of the TZCC alloy is composed of grains-covered grains, small grains with self-closed grain boundaries, columnar grains and equiaxed grains. Compared with cold mold continuous casting Cu-4.7%Sn alloy plate, the room temperature tensile strength and ductility of the TZCC alloy plate are greatly improved.
基金financial support for this work by the National Natural Science Foundation of China (No. 51775275)the Funding of Jiangsu Innovation Program for Graduate Education of China (KYCX170245)+2 种基金the Funding for Outstanding Doctoral Dissertation in NUAA of China (BCXJ17-04)the Fundamental Research Funds for the Central University of China (No. NP2018110)the National Science and Technology Major Project and the Six Talents Summit Project in Jiangsu Province of China (No.JXQC-002)。
文摘Creep feed profile grinding of the fir-tree blade root forms of single crystal nickel-based superalloy was conducted using microcrystalline alumina abrasive wheels in the present study. The grinding force and the surface quality in terms of surface topography, subsurface microstructure,microhardness and residual stress obtained under different grinding conditions were evaluated comparatively. Experimental results indicated that the grinding force was influenced significantly by the competing predominance between the grinding parameters and the cross-sectional root workpiece profile. In addition, the root workpiece surface, including the root peak and valley regions, was produced with the large difference in surface quality due to the nonuniform grinding loads along the root workpiece profile in normal section. Detailed results showed that the surface roughness, subsurface plastic deformation and work hardening level of the root valley region were higher by up to25%, 20% and 7% in average than those obtained in the root peak region, respectively, in the current investigation. Finally, the superior parameters were recommended in the creep feed profile grinding of the fir-tree blade root forms. This study is helpful to provide industry guidance to optimize the machining process for the high-valued parts with complicated profiles.
基金financially supported by the National Program on Key Basic Research Project of China(973 Program)under Grant(No.613281)the National Natural Science Foundation of China(No.51505451)+3 种基金the Natural Science Foundation of Beijing(No.3172042)supported by EMUSIC which is part of an EU-China collaborationthe European Union’s Horizon 2020 research and innovation programme under Grant Agreement No.690725MIIT under the programme number MJ-2015-H-G-104
文摘Selective laser melting （SLM） is a powerful additive manufacturing （AM） technology, of which the most prominent advantage is the ability to produce components with a complex geometry. The service performances of the SLM-processed components depend on the microstructure and surface quality. In this work, the microstructures, mechanical properties, and fracture behaviors of SLM-processed Ti-6AI-4V alloy under machined and as-built surfaces after annealing treatments and hot isostatic pressing （HIP） were investigated. The microstructures were analyzed by optical microscope （OM）, scanning electron microscope （SEM） and transmission electron microscopy （TEM）. The mechanical properties were measured by tensile testing at room temperature. The results indicate that the as-deposited microstructures are characterized by columnar grains and fine brittle martensite and the as- deposited properties present high strength, low ductility and obvious anisotropy. After annealing at 800-900~C for 2-4 h and HIP at 920~C/100MPa for 2 h, the brittle martensite could be transformed into ductile lamellar （a＋~） microstructure and the static tensile properties of SLM-processed Ti-6AI-4V alloys in the machined condition could be comparable to that of wrought materials. Even after HIP treatment, the as-built surfaces could decrease the ductility and reduction of area of SLM-processed fi-6AI-4V alloys to 9.2% and 20%, respectively. The crack initiation could occur at the columnar grain boundaries or at the as-built surfaces. The lamellar （a＋13） microstructures and columnar grains could hinder or distort the crack propagation path during tensile tests.
基金Projects(51975006, 51505006) supported by the National Natural Science Foundation of China。
文摘This experiment obtained different laser energy density(LED) by changing SLM molding process parameters.The surface morphology, surface quality, and microstructure of as-fabricated samples were studied. The effects of scanning speed, hatching space, and laser power on surface quality were analyzed, and the optimal LED range for surface quality was determined. The results show that pores and spherical particles appear on the sample’s surface when low LED is applied, while there are lamellar structures on the sides of the samples. Cracks appear on the sample’s surface,and the splash phenomenon increases when a high LED is taken. At the same time, a large amount of unmelted powder adhered to the side of the sample. The surface quality is the best when the LED is 150-170 J/mm^(3). The preferred hatch space is currently 0.05-0.09 mm, the laser power is 200-350 W, and the average surface roughness value is(15.1±3) μm.The average surface hardness reaches HV404±HV3, higher than the forging standard range of HV340-HV395.Increasing the LED within the experiment range can increase the surface hardness, yet an excessively high LED will not further increase the surface hardness. The microstructure is composed of needle-like α’-phases with a length of about 20μm, in a crisscross ‘N’ shape, when the LED is low. The β-phase grain boundary is not obvious, and the secondaryphase volume fraction is high;when the LED is high, the α’-phase of the microstructure is in the form of coarse slats, and the secondary-phase is composed of a small amount of secondary α’-phase, the tertiary α’-phase and the fourth α’-phase disappear, and the volume fraction of the secondary-phase becomes low.
基金Jiangsu Natural Science Fund of China (BK2001048)
文摘In order to grind the ceramic blade surface with the Numerical Control contour evolution ultrasonic grinding method using the simple shape grinding wheel, primary comparative experiments of creep feed grinding with and without ultrasonic vibration were carried out to grind Al2O3 ceramics so as to implore the effects of different process parameters on the machined surface quality. It can be concluded that when the direction of ultrasonic vibration is parallel to the direction of creep feed, the value of the surface roughness will be decreased; otherwise the surface quality will become worse. With the ultrasonic grinding method, the slower feed-rate, the smaller grinding depth, the higher grinding speed and the compound feed grinding method should be applied in order to improve the surface quality. The creep feed grinding meehanisms with and without ultrasonic vibration were analyzed theoretically from the experimental results. With the selected grinding parameters resulted from the experiments, the feasibility experiment of ultrasonic grinding ceramic blade surface was cartied out.
基金sponsored by the National Science and Tech-nology Major Project(Grant No.2017-VII-0004-0097)National Natural Science Foundation of China for Creative Research Groups(Grant No.51921003)the Postgraduate Research&Practice Innovation Program of Jiangsu Province(Grant No.KYCX21_0191).
文摘Electrochemical machining(ECM)has emerged as an important option for manufacturing the blisk.The inter-electrode gap(IEG)distribution is an essential parameter for the blisk precise shap-ing process in ECM,as it affects the process stability,profile accuracy and surface quality.Larger IEG leads to a poor localization effect and has an adverse influence on the machining accuracy and surface quality of blisk.To achieve micro-IEG(<50 lm)blisk finishing machining,this work puts forward a novel variable-parameters blisk ECM strategy based on the synchronous coupling mode of micro-vibration amplitude and small pulse duration.The modelling and simulation of the blisk micro-IEG machining have been carried out.Exploratory experiments of variable-parameters blisk ECM were car-ried out.The results illustrated that the IEG width reduced with the progress of variable parameter pro-cess.The IEG width of the blade’s concave part and convex part could be successfully controlled to within 30 lm and 21 lm,respectively.The profile deviation for the blade’s concave surface and convex surface are 49 lm and 35 lm,while the surface roughness reaches R_(a)=0.149 lm and R_(a)=0.196 lm,respectively.The profile accuracy of the blisk leading/trailing edges was limited to within 91 lm.Com-pared with the currently-established process,the profile accuracy of the blade’s concave and convex profiles was improved by 50.5%and 53.3%,respectively.The surface quality was improved by 53.2%and 50.9%,respectively.Additionally,the machined surface was covered with small corrosion pits and weak attacks of the grain boundary due to selective dissolution.Some electrolytic products were dispersed on the machined surface,and their components were mainly composed of the carbide and oxide products of Ti and Nb elements.The results indicate that the variable-parameters strategy is effective for achieving a tiny IEG in blisk ECM,which can be used in engineering practice.
基金support from the National Natural Science Foundation of China(51575028)National Natural Science Foundation of China(51605258)the Fundamental Research Funds for the Central Universities of China(YWF-18-BJ-J-75)。
文摘The unsatisfied surface quality seriously impedes the wide application of incremental sheet forming(ISF)in industrial field.As a novel approach,the interpolator method is a promising strategy to enhance the surface quality in ISF.However,the mechanism for the improvement of surface quality and the influence of interpolator properties on surface roughness are not well understood.In this paper,the influences of process variables(i.e.tool diameter,step size and thickness of interpolators)on the forming process(e.g.surface roughness,forming force and geometric error)are investigated through a systematic experimental approach of central composite design(CCD)in two-point incremental sheet forming(TPIF).It is obtained that the increase in thickness of interpolators decreases the surface roughness in direction vertical to the tool path while increases the surface roughness in direction horizontal to the tool path.Nevertheless,the combined influence between thickness of interpolators and process parameters(tool diameter and step size)is limited.Meanwhile,the placement of interpolator has little influence on the effective forming force of blank.In addition,the geometric error enlarges with the increase of step size and thickness of interpolator while decreases firstly and then increase with an increase in tool diameter.Finally,the influencing mechanism of the interpolator method on surface quality can be attributed to the decrease of thecontact pressure due to the increase of contact area with the unchanged contact force.Meanwhile,the interpolator method eliminates the sliding friction on the surface of blank due to the stable relative position between the blank and the interpolator.
基金funded by the Strategic Priority Research Program of the Chinese Academy of Sciences,China through Projects No.XDC04030400。
文摘Bearings are one of the most important components in modern industry.Rolling contact fatigue(RCF)initiating from surface and subsurface is the major failure mode.In this paper,a typical high speed thrust angular contact ball bearing was selected,and the machined surface quality and near-surface microstructure of the race-way and rolling ball were systematically characterized by using of a probe surface profiler,white light interferometer,optical microscopy(OM),scanning electron microscopy(SEM),electron backscatter diffraction(EBSD)and transmission electron microscopy(TEM)combined with focused ion beam(FIB).Two kinds of precursor,probably resulting in pitting or spalling during the following rolling contact,were detected.One is the defects on the surface of either the race-way or the rolling ball,such as heavy machining marks,scratches and slag-hole.The other is nano-crystalline layer due to machining,in the outermost layer around the surface of race-way.The results may well lay foundation for our further research on RCF with the real part of such typical rolling bearings.
基金supported by Introducing Talents of Discipline to Universities (No.B07015)the Ministry of Education New Teachers Fund Project (No.20090042120001)Central University Basic R&D Operating Expenses (No.N100409006)
文摘7075 aluminum alloy ingot with the diameter izontal direct chill casting in different casting of 100 mm has been produced by horspeed. The effect of the casting speed on the ingot surface and subsurface layer was studied by surface observation and subsurface structure analysis. It was found that increasing the casting speed results in the adding of segregation knots in the ingot surface. The thickness of the dendrite microstrueture layer in the subsurface reduces with increasing the casting speed. And the elements of Zn, Cu and Mg enrich in the coarse dendrite microstructure layer of the ingot.
基金Item Sponsored by National Natural Science Foundation of China(51202249)Key Projects in National Science and Technology Pillar Program in the Twelfth Five-year Plan of China(2012BAB08B04)
文摘A ceramic matrix coating for minimizing steel loss of stainless steel at high temperatures was prepared by handled air-spraying technique, and the influence of coating on surface quality of stainless steel was mainly investiga ted in laboratory. Experimental results showed that the protective coating reduced the oxidation of stainless steel by more than 91% and minimized high temperature scaling and also enhanced steel surface quality. The scales of coated specimen were removed completely and the scales of uncoated specimen were partly residual on the surface after cool ing process. Mn-rich and Fe-rich zones were found in the oxides. The Cr2 O3 found in scales came from the underlying stainless steel and formed a Cr rich layer along the spalled surface.
基金supported by the Major State Basic Research and Development Project of China (No.2005CB623707)the Innovative Research Team Project of Northeastern University (No.N090109001)
文摘To improve the quality of 7050 aluminum alloy ingots, low-frequency electromagnetic （LFE） field was applied during the conventional hot-top casting process. Macrostructures and microstructures of the ingots by the conventional and LFE hot-top casting processes were studied. The experimental results show that when the LFE field is turn off during the hot-top casting process, cold folding appears, and the as-cast structure becomes very coarse. Additionally, the thickness of the shell zone is much thinner during the low-frequency electromagnetic hot-top casting process than that during the conventional hot-top casting process. Some reasons for low-frequency electromagnetic field improving the surface quality, refining the structure of the ingot, and minimizing the thickness of the shell zone have been studied.
基金supported by Science and Technology Major Project of Fujian Province(Grant No.2020HZ03018).
文摘For laser cladding a large temperature gradient easily weakened the surface quality by generating cracks and irregular coating surfaces,which in turn affected the bearing capacity and corrosion resistance of coatings in the rapid heating and cooling process.The response surface methodology(RSM)was used to predict coating cracks by changing the powder ratio,energy density,and preheating temperature,which obtained the relevant mathematical model.After that,the sensitivity of the crack length to process parameters was analyzed based on the sensitivity analysis method.The effect of Ni60/WC composite powder process parameters on the surface quality was revealed in laser cladding.The crack length first decreased and then increased,and the Smooth decreased with the increased powder ratio.The crack length and Smooth increased with the increased energy density.The crack length decreased and Smooth increased with the increased preheating temperature.Sensitivity analysis showed that the crack length and Smooth were the most sensitive to the powder ratio.Therefore,the process parameters were reasonably selected to control the surface quality.The mathematical model and sensitivity analysis method in the work could improve the surface quality,which provided a theoretical basis for the prediction and control of laser cladding cracks.
基金supported by the Key Project of the National Natural Science Foundation of China (No. 50535020)the Fund of the State Key Laboratory of Solidification Processing in Northwestern Polytechnical University (No. SKLSP200902)
文摘The mechanical characters of CdZnTe crystal were investigated by nanoscratch tests, and the effects of mechanical anisotropy on the material removal rate and surface quality were studied by polishing tests. There is a peak of frictional coefficient at the early stage of scratch, and increasing the vertical force will result in the increase of peak value correspondingly. The fluctuation phenomenon of frictional coefficient is generated at high vertical force. The lateral forces show the apparent twofold and threefold symmetries on （110） and （111） planes, respectively. To obtain high surface quality, low polishing pressure and hard direction （〈 T10 〉 directions on （110） plane and 〈 112 〉 directions on （111） plane） should be selected, and to achieve high material removal rate, high polishing pressure and soft direction （〈001〉 directions on （110） plane and 〈 121 〉 directions on （111） plane） should be selected.
基金financially supported by the National Natural Science Foundation of China (No. 51074117)the International Scientific and Technological Cooperation Projects of China (No. 2013DFG12750)+1 种基金the Beijing Natural Science Foundation (No. 3142007)the Great Wall Scholar Program (No. CIT&TCD20140301)
文摘The effect of the microstructure of plates fabricated both in the traditional process, involving casting, hot rolling and cold rolling （HR）, and in the novel twin roll casting ＋ cold rolling （TRC） process on the surface quality of presensitized （PS） plates was analyzed by optical microscopy （OM）, scanning electron microscopy （SEM）, and energy-dispersive X-ray spectroscopy （EDXS）. The formation of pores on the surface of the electrolyzed HR plate could be attributed to the presence of approximately 1-μm-sized large Al-Fe precipitates in the HR plate compared to the smaller precipitates in the TRC plate. Moreover, residual graphite lubricants used during the TRC process were entrapped on the surface of the TRC plate during the subsequent rolling process. The entrapped pollutants tended to further deteriorate the formation of pores on the surface of the TRC plate, and no residual carbon was detected on the surface of the HR plate. Furthermore, the surface quality of the TRC plate can be improved by surface cleaning before the cold rolling process, which could dramatically lower the residual graphite on the surface.
文摘The relationships between the surface quality of a single crystal copper ingot and the process parameters of heated mould continuous casting method were studied experimentally using our own design of horizontal heated mould continuous casting apparatus, and the mechanism by which process parameters affect the surface quality of a single crystal copper ingot is analyzed in the present paper. The results show that the process parameters affect the surface quality of a pure copper ingot by affecting the position of the liquid-solid interface in the mould. The position of the liquid-solid interface in the mould must be controlled carefully within an appropriate range, which is determined through a series of experiments, in order to gain a single crystal copper ingot with good surface quality.
基金supported by the National Natural Science Foundation of China(Nos.51204053 and 51074048)Research Fund for the Doctoral Program of Higher Education of China(No.20090042120001)+2 种基金Central University Basic R&D Operating Expenses(No.N100409006)China Postdoctoral Science Foundation(No.20110491518)National Basic Research Program of China(973Program)(No.2012CB619506)
文摘5182 Al alloy ingots with the diameters of 100 mm are produced by conventional and combined electromagnetic fields （CEMF） horizontal direction chill （HDC） cast- ing process. The effect of CEMF on the ingot surface quality and floating grains is investigated. The results show that the CEMF is effective in reducing the segregation layer in both top and bottom sub-surfaces. Big floating grains with coarse dendrite arms mainly distribute in the crescent-shaped area near the bottom in the conven- tional HDC casting ingot. With the application of the CEMF, they disappear in the whole cross section of the HDC casting ingot and the equiaxed grains are significantly refined.
基金supported by the National Natural Science Foundation of China(Grant Nos.51905226,52075227,and 52105449)the Natural Science Foundation of Jiangsu Province(Grant No.BK20210755)the Postdoctoral Foundation of Jiangsu Province(Grant No.2021K264B).
文摘As a substitute for toxic cadmium coatings in the aerospace industry,zinc-nickel coatings have excellent application prospects,and their properties can be improved by adding molybdenum.In this study,laser-assisted electrodeposition is used to improve the surface quality and properties of Zn–Ni–Mo coatings,with investigation of how laser energy in the range of 0–21.1μJ affects their element content,surface morphology,crystal phase,microhardness,residual internal stress,and corrosion resistance.The laser irradiation accelerates the electrodeposition,refines the grain size,improves the hydrogen adsorption,and reduces the residual tensile stress,and a laser energy of 15.4μJ gives the highest Ni and Mo contents and the lowest Zn content,as well as the optimum surface morphology,microhardness,residual internal stress,and corrosion resistance of the coating.
基金National Key R&D Program of China(Grant No.2019YFE0121300)Yancheng Hali Power Transmission and Intelligent Equipment Industrial Research Institute Project。
文摘Contour bevel gears have the advantages of high coincidence,low noise and large bearing capacity,which are widely used in automobile manufacturing,shipbuilding and construction machinery.However,when the surface quality is poor,the effective contact area between the gear mating surfaces decreases,affecting the stability of the fit and thus the transmission accuracy,so it is of great significance to optimize the surface quality of the contour bevel gear.This paper firstly analyzes the formation process of machined surface roughness of contour bevel gears on the basis of generating machining method,and dry milling experiments of contour bevel gears are conducted to analyze the effects of cutting speed and feed rate on the machined surface roughness and surface topography of the workpiece.Then,the surface defects on the machined surface of the workpiece are studied by SEM,and the causes of the surface defects are analyzed by EDS.After that,XRD is used to compare the microscopic grains of the machined surface and the substrate material for diffraction peak analysis,and the effect of cutting parameters on the microhardness of the workpiece machined surface is investigated by work hardening experiment.The research results are of great significance for improving the machining accuracy of contour bevel gears,reducing friction losses and improving transmission efficiency.
