In this study,combining the single point diamond turning(SPDT)and spark plasma sintering(SPS),we achieved high-strength diffusion bonding of copper at an ultra-low temperature of 202℃(0.35 T_(m),T_(m):absolute temper...In this study,combining the single point diamond turning(SPDT)and spark plasma sintering(SPS),we achieved high-strength diffusion bonding of copper at an ultra-low temperature of 202℃(0.35 T_(m),T_(m):absolute temperature of the melting point).Additionally,the closure mechanism of interfacial micro-and nano-voids during the Cu-Cu SPS diffusion bonding is systematically revealed for the first time.For micro-voids,the pulsed current is found to induce additional diffusion flux and plastic deformation,thereby facilitating the void closure.Molecular dynamics(MD)simulation revealed that at the atomic scale,high-energy Cu atoms induced by the pulsed current can significantly promote the diffusion of low-energy atoms in their vicinity and accelerate the void closure.This study also proposes a novel“evaporation-deposition”nano-void closure mechanism for the previously unstudied nano-void closure process.The results show that the synergistic effect of the pulsed current and nanoscale surface rough-ness can significantly improve joint strength.At a low temperature of 405℃(0.5 T_(m)),on combining the computerized numerical control(CNC)turning and SPS diffusion bonding,the joint strength can reach 212 MPa,while that for the joint obtained by traditional hot pressing diffusion bonding at the same tem-perature is only 47 MPa.We obtained an ultra-high joint strength of 271 MPa using the combined process of SPDT and SPS diffusion bonding at an ultra-low temperature of 202℃(0.35 T_(m)),which is approximately 600℃ lower than the traditional diffusion bonding process temperature of 800℃(0.79 T_(m)).To sum up,this study provides a novel method and theoretical support for realizing low-temperature high-strength diffusion bonding.展开更多
Void closing from a spherical shape to a crack is investigated quantitatively in the present study. The constitutive relation of the Void-free matrix is assumed to obey the Norton power law. A representative volume el...Void closing from a spherical shape to a crack is investigated quantitatively in the present study. The constitutive relation of the Void-free matrix is assumed to obey the Norton power law. A representative volume element （RVE） which includes matrix and void is employed and a Rayleigh-Ritz procedure is developed to study the deformation-rates of a spherical void and a penny-shaped crack. Based on an approximate interpolation scheme, an analytical model for void closure in nonlinear plastic materials is established. It is found that the local plastic flows of the matrix material are the main mechanism of void deformation. It is also shown that the relative void volume during the deformation depends on the Norton exponent, on the far-field stress triaxiality, as well as on the far-field effective strain. The predictions of void closure using the present model are compared with the corresponding results in the literature, showing good agreement. The model for void closure provides a novel way for process design and optimization in terms of elimination of voids in billets because the model for void closure can easily be applied in the CAE analysis.展开更多
In order to reveal the mechanism and condition of void closure in large diameter steel rod during horizontal- vertical （H-V） groove rolling process, a three-dimensional thermomechanicaily coupled finite element mode...In order to reveal the mechanism and condition of void closure in large diameter steel rod during horizontal- vertical （H-V） groove rolling process, a three-dimensional thermomechanicaily coupled finite element model was es- tablished for 9-stand H-V groove rolling process aiming at a 4150 mm steel rod production line. A spherical hole with diameter from 2 to 10 mm was preset into the center of continuous casting billet with a rectangle cross section of 300 mmX 360 mm in this model to simulate the void defect, and then finite element analyses were carried out to observe and quantify the void shape evolution in each pass on the three orthogonal coordinate plane sections. The re- suits showed that the void was formed roughly in the reduction and extension directions, and crushed gradually from spherical shape to an approximate ellipsoid, micro-crack and finally to be closed. A quantitative analysis was carried out by using elliptic radii and closure ratio to describe this evolution process; it indicated that the longest axis of the ellipsoid coincided with the rolling line, and the second and third axes were alternatively ihorizontal and vertical on the exit cross section according to change of the reduction direction in H-V groove. The void closure behavior during H- V rolling was more complicated than that of common horizontal rolling, and the influence of groove type and the ex- tension coefficient on the void closure ratio was presented. Finally, a pilot rolling experiment was performed on a 5- stand H-V experimental mill to verify the numerical simulation results, and the experimental results are in good agree- ment with the numerical simulation results.展开更多
The effect of grain size of primary α phase on the bonding interface characteristic and shear strength of bond was investigated in the press bonding of Ti-6Al-4V alloy. The quantitative results show that the average ...The effect of grain size of primary α phase on the bonding interface characteristic and shear strength of bond was investigated in the press bonding of Ti-6Al-4V alloy. The quantitative results show that the average size of voids increases from 0.8 to 2.6 μm and the bonding ratio decreases from 90.9% to 77.8% with an increase in grain size of primary α phase from 8.2 to 16.4 μm. The shape of voids changes from the tiny round to the irregular strip. The highest shear strength of bond can be obtained in the Ti-6Al-4V alloy with a grain size of 8.2 μm. This is contributed to the higher ability of plastic flow and more short-paths for diffusion in the alloy with smaller grain size of primary α phase, which promote the void closure process and the formation of α/β grains across bonding interface.展开更多
The head of nuclear pressure vessel is a key component to guarantee the safety of nuclear power plant, so it is necessary to improve its mechanical properties during manufacturing. In the practical production,due to t...The head of nuclear pressure vessel is a key component to guarantee the safety of nuclear power plant, so it is necessary to improve its mechanical properties during manufacturing. In the practical production,due to the huge size of the ingots from which the head is manufactured, coarse grains and voids are common defects existing in the material. Furthermore, cracks may appear in the forming process. It is highly demanded that the forming process must be properly designed with suitable parameters to compact the voids, to refine and homogenize the grains and to avoid cracks. Therefore, the research on the evolution of internal voids, grain size and cracks is very important to determine the forming process of huge components. SA508-3 steel is the material to manufacture the head of pressure vessel in the nuclear island. In the previous studies, we have separately built models to evaluate the evolution of internal voids, grain size and cracks during the hot forming process for SA508-3 steel. This study integrates the models for multi-scale simulation of the forging process of the head of nuclear pressure vessel in order to control the quality of the forgings. Through the software development, the models are integrated with a commercial finite element code DEFORM. Then, the extended forging and final forging processes of the head are investigated, and some appropriate deformation parameters are recommended.展开更多
文摘In this study,combining the single point diamond turning(SPDT)and spark plasma sintering(SPS),we achieved high-strength diffusion bonding of copper at an ultra-low temperature of 202℃(0.35 T_(m),T_(m):absolute temperature of the melting point).Additionally,the closure mechanism of interfacial micro-and nano-voids during the Cu-Cu SPS diffusion bonding is systematically revealed for the first time.For micro-voids,the pulsed current is found to induce additional diffusion flux and plastic deformation,thereby facilitating the void closure.Molecular dynamics(MD)simulation revealed that at the atomic scale,high-energy Cu atoms induced by the pulsed current can significantly promote the diffusion of low-energy atoms in their vicinity and accelerate the void closure.This study also proposes a novel“evaporation-deposition”nano-void closure mechanism for the previously unstudied nano-void closure process.The results show that the synergistic effect of the pulsed current and nanoscale surface rough-ness can significantly improve joint strength.At a low temperature of 405℃(0.5 T_(m)),on combining the computerized numerical control(CNC)turning and SPS diffusion bonding,the joint strength can reach 212 MPa,while that for the joint obtained by traditional hot pressing diffusion bonding at the same tem-perature is only 47 MPa.We obtained an ultra-high joint strength of 271 MPa using the combined process of SPDT and SPS diffusion bonding at an ultra-low temperature of 202℃(0.35 T_(m)),which is approximately 600℃ lower than the traditional diffusion bonding process temperature of 800℃(0.79 T_(m)).To sum up,this study provides a novel method and theoretical support for realizing low-temperature high-strength diffusion bonding.
基金supported by the National Basic Research Program of China (973 Program)(No.2006CB705401)
文摘Void closing from a spherical shape to a crack is investigated quantitatively in the present study. The constitutive relation of the Void-free matrix is assumed to obey the Norton power law. A representative volume element （RVE） which includes matrix and void is employed and a Rayleigh-Ritz procedure is developed to study the deformation-rates of a spherical void and a penny-shaped crack. Based on an approximate interpolation scheme, an analytical model for void closure in nonlinear plastic materials is established. It is found that the local plastic flows of the matrix material are the main mechanism of void deformation. It is also shown that the relative void volume during the deformation depends on the Norton exponent, on the far-field stress triaxiality, as well as on the far-field effective strain. The predictions of void closure using the present model are compared with the corresponding results in the literature, showing good agreement. The model for void closure provides a novel way for process design and optimization in terms of elimination of voids in billets because the model for void closure can easily be applied in the CAE analysis.
基金Sponsored by National Natural Science Foundation of China(51005197,51101136)
文摘In order to reveal the mechanism and condition of void closure in large diameter steel rod during horizontal- vertical （H-V） groove rolling process, a three-dimensional thermomechanicaily coupled finite element model was es- tablished for 9-stand H-V groove rolling process aiming at a 4150 mm steel rod production line. A spherical hole with diameter from 2 to 10 mm was preset into the center of continuous casting billet with a rectangle cross section of 300 mmX 360 mm in this model to simulate the void defect, and then finite element analyses were carried out to observe and quantify the void shape evolution in each pass on the three orthogonal coordinate plane sections. The re- suits showed that the void was formed roughly in the reduction and extension directions, and crushed gradually from spherical shape to an approximate ellipsoid, micro-crack and finally to be closed. A quantitative analysis was carried out by using elliptic radii and closure ratio to describe this evolution process; it indicated that the longest axis of the ellipsoid coincided with the rolling line, and the second and third axes were alternatively ihorizontal and vertical on the exit cross section according to change of the reduction direction in H-V groove. The void closure behavior during H- V rolling was more complicated than that of common horizontal rolling, and the influence of groove type and the ex- tension coefficient on the void closure ratio was presented. Finally, a pilot rolling experiment was performed on a 5- stand H-V experimental mill to verify the numerical simulation results, and the experimental results are in good agree- ment with the numerical simulation results.
基金Project(2014M562447) supported by the China Postdoctoral Science FoundationProject(51275416) supported by the National Natural Science Foundation of China+1 种基金Project(BP201503) supported by the Research Fund of the State Key Laboratory of Solidification Processing(NWPU)China
文摘The effect of grain size of primary α phase on the bonding interface characteristic and shear strength of bond was investigated in the press bonding of Ti-6Al-4V alloy. The quantitative results show that the average size of voids increases from 0.8 to 2.6 μm and the bonding ratio decreases from 90.9% to 77.8% with an increase in grain size of primary α phase from 8.2 to 16.4 μm. The shape of voids changes from the tiny round to the irregular strip. The highest shear strength of bond can be obtained in the Ti-6Al-4V alloy with a grain size of 8.2 μm. This is contributed to the higher ability of plastic flow and more short-paths for diffusion in the alloy with smaller grain size of primary α phase, which promote the void closure process and the formation of α/β grains across bonding interface.
基金the National Science and Technology Major Project of China(No.2012ZX04012-011)the National Natural Science Foundation of China(No.51675335)
文摘The head of nuclear pressure vessel is a key component to guarantee the safety of nuclear power plant, so it is necessary to improve its mechanical properties during manufacturing. In the practical production,due to the huge size of the ingots from which the head is manufactured, coarse grains and voids are common defects existing in the material. Furthermore, cracks may appear in the forming process. It is highly demanded that the forming process must be properly designed with suitable parameters to compact the voids, to refine and homogenize the grains and to avoid cracks. Therefore, the research on the evolution of internal voids, grain size and cracks is very important to determine the forming process of huge components. SA508-3 steel is the material to manufacture the head of pressure vessel in the nuclear island. In the previous studies, we have separately built models to evaluate the evolution of internal voids, grain size and cracks during the hot forming process for SA508-3 steel. This study integrates the models for multi-scale simulation of the forging process of the head of nuclear pressure vessel in order to control the quality of the forgings. Through the software development, the models are integrated with a commercial finite element code DEFORM. Then, the extended forging and final forging processes of the head are investigated, and some appropriate deformation parameters are recommended.
