During the solidification of the AZ91D-alloys, the Al8(Mn, Fe)5 phase is generally precipitated in the melt in advance of the precipitation of the primary α-Mg. The basic principle for manufacturing AZ91D-alloy slurr...During the solidification of the AZ91D-alloys, the Al8(Mn, Fe)5 phase is generally precipitated in the melt in advance of the precipitation of the primary α-Mg. The basic principle for manufacturing AZ91D-alloy slurries for semi solid forming is to use the Al8(Mn, Fe)5 precipitates as the heterogeneous nucleation sites for primary α-Mg phases. Microscopic analysis for the location of the Al8(Mn, Fe)5 precipitate explains that the Al8(Mn, Fe)5 precipitate is the effective heterogeneous nucleation site for the primary α-Mg phase. It was also observed that increase of the Mn content in the melt and the cooling rate below to the solid/liquid two-phase region resulted in smaller and more globular primary α-Mg due to the increase of heterogeneous nucleation sites. It was found that the average α-Mg diameter grew as a function of t0.278, where t is the holding time at the solid/liquid two-phase region. This would be attributed to the Ostwald type ripening and coalescence between primary α-Mg phases. The cooling rate below to the solid/liquid two-phase region, Mn content in AZ91D alloy, and the holding time and temperature affected on the quality of slurry.展开更多
In the present study, Al-5.5Fe-4Cu-2Zn-0.4Mg-0.5Mn al oy samples were prepared by electromagnetic stirring and semi-solid forming processing, and then the effects of T6 and T1 heat treatments on the microstructures an...In the present study, Al-5.5Fe-4Cu-2Zn-0.4Mg-0.5Mn al oy samples were prepared by electromagnetic stirring and semi-solid forming processing, and then the effects of T6 and T1 heat treatments on the microstructures and mechanical properties of the semi-solid forming samples were investigated. The results indicate that after semi-solid forming, the mechanical properties of the sample improved significantly compared to that of the merely electromagnetically stirred sample. The grains of semi-solid forming alloy became almost fine equiaxed; big long strip-shaped Al3 Fe phases became short rod-like morphology and distributed uniformly in the matrix. However, the mechanical properties of the T6-treated semi-solid forming sample decreased significantly instead of increasing and, with solution temperature rising, the tensile strength of the al oy decreased further. The results of EDS show that after high temperature solid-solution treatment, the Cu element in the semi-solid forming alloy sample is mainly concentrated at the boundaries of the Al3 Fe phases instead of being dissolved in the matrix. At the same time, the grains of the semi-solid forming sample grew slightly after solid-solution treatment. Therefore, the growth of the grains and the accumulation of Cu element at Al3 Fe phase boundaries during solution treatment of the semi-solid forming alloy were the main reasons for the mechanical properties decreasing after T6 treatment. The mechanical properties of the alloy were improved after T1 heat treatment due to aging strengthening phase being precipitated in the matrix.展开更多
A motorcycle component of damper housing was made by semi-solid forming process. This was used to investigate the effect of microstructures of feedstock on the formability of semisolid process. The soundness and micro...A motorcycle component of damper housing was made by semi-solid forming process. This was used to investigate the effect of microstructures of feedstock on the formability of semisolid process. The soundness and microstructures of casting parts made by dendritic and non-dendritic feedstock were investigated. Separating of liquid phase was found in the casting produced by dendritic feedstock, which might result in defects of porosity, while uniform microstructures were found in the casting produced by no...展开更多
In order to adapt to the trend of ＂energy saving and emission reduction＂ and impel the practical application of semi solid processing （SSP） in China, the progress and application of semi-solid theory in China have...In order to adapt to the trend of ＂energy saving and emission reduction＂ and impel the practical application of semi solid processing （SSP） in China, the progress and application of semi-solid theory in China have been reviewed briefly and systematically. It was emphasized on basic theories, such as formation of globular grains, theology, high pressure solidification and plastic deformation and applications, such as material design, preparation of semi-solid billets （slurries）, thixoforming and application status, which are based on the advantage of semi-solid processing. The results show that the gap of SSP between world level and China exists, especially in application technologies, including market recognition, application fields exploiting, developing of billets （slurries） preparation technologies with low cost and special equipments. The prospect of semi-solid forming development path in China is presented. And we hope that application of SSP has great new breakthrough and development and China wilt be changed from a large metal processing country to a powerful metal processing country.展开更多
The feasibility of semi solid processing of hypereutectic A390 alloys using a novel rheoforming process was investigated. A combination of the swirl enthalpy equilibration device （SEED） process, isothermal holding u...The feasibility of semi solid processing of hypereutectic A390 alloys using a novel rheoforming process was investigated. A combination of the swirl enthalpy equilibration device （SEED） process, isothermal holding using insulation and addition of solid alloy during swirling was introduced as a novel method to improve the processability of semi solid slurry. The effects of isothermal holding and the addition of solid alloy on the temperature gradient between the centre and the wall and on the formation of a（Al） particles were examined. In additional tests, phosphorus and strontium were added to the molten metal to refine the primary and eutectic silicon structure to facilitate semi solid processing. The results show that the combination of the SEED process with two additional processing steps can produce semi-solid A390 alloys that can be rheoprocessed. The microstructure reveals an adequate amount of non-dendritic a（Al） globules surrounded by liquid, which greatly improves the processability of semi-solid slurry.展开更多
The electronic packaging box with high silicon aluminum-base alloy was prepared by semi-solid thixoforming technique.The flow characteristic of the Si phase was analyzed.The microstructures of different parts of the b...The electronic packaging box with high silicon aluminum-base alloy was prepared by semi-solid thixoforming technique.The flow characteristic of the Si phase was analyzed.The microstructures of different parts of the box were observed by optical microscopy and scanning electron microscopy,and the thermophysical and mechanical properties of the box were tested.The results show that there exists the segregation phenomenon between the primary Si phase and the liquid phase during thixoforming,the liquid phase flows from the box,and the primary Si phase accumulates at the bottom of the box.The volume fraction of primary Si phase decreases gradually from the bottom to the walls.Accordingly,the thermal conductivities of bottom center and walls are 107.6 and 131.5 W/（m·K）,the coefficients of thermal expansion（CTE） are 7.9×10-6 and 10.6×10-6 K-1,respectively.The flexural strength increases slightly from 167 to 180 MPa.The microstructures and properties of the box show gradient distribution overall.展开更多
The investment on semi-solid die casting processes of AZ91D magnesium alloy brackets for generators in JH70-type motorbikes is introduced. The processes of low super-heat and cooling slope for the preparation of bille...The investment on semi-solid die casting processes of AZ91D magnesium alloy brackets for generators in JH70-type motorbikes is introduced. The processes of low super-heat and cooling slope for the preparation of billets with non-dendritic microstructure, the remelting of billets for thixoforming and the parameters in the process of semi-sohd thixoforming have been researched. The results show that primary billets with non-dendritical structures can be prepared by forming great amount of nuclei in melt via the process of low super heat. By optimizing the remelting process through adjusting the current of the induced equipment, semi-solid billets with a structure of spherical grains were obtained from the primary billets with non-dendritical structure. The range of 580℃ to 583℃ is the proper remelting temperatures by which the billets have an expected thixotropy and can be transferred to a die-casting machine. The optimized parameters of semi-solid forming in a die-casting machine are as follows： the area of the ingate in the die is 383.5 mm^2, the speed of the pierce of the machine 5 m/s, the shot pressure of the pierce 75 MPa, and the maintenance pressure of the pierce 350 MPa. The castings of brackets for supporting generators in JH70 type motorbikes were formed by adopting the optimized processes and parameters mentioned above.展开更多
To obtain new unconventional structures with specific mechanical and physical properties is possible not only by the development of new types of materials but also by treatment of conventional materials using unconven...To obtain new unconventional structures with specific mechanical and physical properties is possible not only by the development of new types of materials but also by treatment of conventional materials using unconventional innovative technological procedures.One of these technologies is the forming in semi-solid state involving rapid solidification of miniature components from steels.Production of such components is complicated by a number of technical problems.To explain phenomena of the process and structure development,the production of miniature components from the tool steel X210Cr12 difficult to form was experimentally tested.The structure of this originally ledeburite steel consisted of 95 % of metastable austenite after the treatment.Metastable austenite was located particularly in globular and polygonal grains while the remaining interspaces were filled by lamellar network.The detected high stability of extremely high fraction of metastable austenite was tested under different conditions of thermal exposition and mechanical loading.展开更多
The 6061 semi-solid aluminium alloy feedstocks prepared by near-liquidus casting were compressed in semi-solid state by means of Gleeble-3500 thermal-mechanical simulator.The relationship between the true stress and t...The 6061 semi-solid aluminium alloy feedstocks prepared by near-liquidus casting were compressed in semi-solid state by means of Gleeble-3500 thermal-mechanical simulator.The relationship between the true stress and the true strain at different temperatures and strain rates was studied with the deformation degree of 70%.The microstructures during the deformation process were characterized.The deformation mechanism and thixo-forming properties of the semi-solid alloys were analyzed.The results show that the homogeneous and non-dendrite microstructures of semi-solid 6061Al alloy manufactured by near-liquidus casting technology could be transformed into semi-solid state with the microstructure suitable for thixo-forming which are composed of near-spherical grains and liquid phase with eutectic composition through reheating process.The deformation temperature and strain rate affect the peak stress significantly rather than steady flow stress.The resistance to deformation in semi-solid state decreases with the increase of the deformation temperature and decrease of the strain rate.At steady thixotropic deformation stage, the thixotropic property is uniform, and the main deformation mechanism is the rotating or sliding between the solid particles and the plastic deformation of the solid particles.展开更多
In this paper the effect of pouring temperature of magnesium melt, preheating temperature of the barrel of screw mixer and shear rate on the solidified microstructures of semi-solid slurry was investigated by mechanic...In this paper the effect of pouring temperature of magnesium melt, preheating temperature of the barrel of screw mixer and shear rate on the solidified microstructures of semi-solid slurry was investigated by mechanical stirring method. The appropriate processing parameters of slurry preparation were obtained. The mold filling for thin walled casting was examined. Results indicated that the solid volume fraction of non-dendritic structure increased with decrease in pouring temperature of magnesium melt and the barrel preheating temperature of screw mixer. Also the grain size of primary α phase was reduced. Furthermore, the solid volume fraction of semi-solid non-dendritic structure decreased with the increase in shear rate. In the same time, grain size of primary α phase slightly changed. The fine-round granular solidified structure with 30～50 μm of prepared AZ91D magnesium semi-solid slurry was presented. Finally, it is successful to fabricate 1.0 mm extremely thin walled casting with clear contour and good soundness.展开更多
A new analytical model for geometric size and forming force prediction in incremental flanging(IF)is presented in this work.The complex deformation characteristics of IF are considered in the modeling process,which ca...A new analytical model for geometric size and forming force prediction in incremental flanging(IF)is presented in this work.The complex deformation characteristics of IF are considered in the modeling process,which can accurately describe the strain and stress states in IF.Based on strain analysis,the model can predict the material thickness distribution and neck height after IF.By considering contact area,strain characteristics,material thickness changes,and friction,the model can predict specific moments and corresponding values of maximum axial forming force and maximum horizontal forming force during IF.In addition,an IF experiment involving different tool diameters,flanging diameters,and opening hole diameters is conducted.On the basis of the experimental strain paths,the strain characteristics of different deformation zones are studied,and the stable strain ratio is quantitatively described through two dimensionless parameters:relative tool diameter and relative hole diameter.Then,the changing of material thickness and forming force in IF,and the variation of minimum material thickness,neck height,maximum axial forming force,and maximum horizontal forming force with flanging parameters are studied,and the reliability of the analytical model is verified in this process.Finally,the influence of the horizontal forming force on the tool design and the fluctuation of the forming force are explained.展开更多
The northwestern margin of Junggar Basin is the region with the richest oil sand resources in China.For better understanding the enrichment rules and deployment of exploration and development of regional oil sand,it i...The northwestern margin of Junggar Basin is the region with the richest oil sand resources in China.For better understanding the enrichment rules and deployment of exploration and development of regional oil sand,it is of great scientific significance to study the accumulation conditions of oil sand in different strata and mining areas of the Junggar Basin.Through a large number of field investigations,drilling verification and sampling tests,it is found that the oil sand in the region covers an area of 2000 km^(2),with shallow and thick reservoir,and predicted resource of 180 million tons.The oil sand resources are mainly distributed in four geological strata,namely the Middle Triassic Karamay Formation,Early Jurassic Badaowan Formation,Late Jurassic Qigu Formation,and Early Cretaceous Qingshuihe Formation.The reservoir is mainly composed of sandstone with high porosity and permeability,and the reservoir space is mainly intergranular pores with a medium average oil content.The oil sand deposit in the region is a typical destructive oil reservoir.The crude oil in the oil sand layer is degraded and thickened from the deep to the shallow,the content of saturated hydrocarbon decreased,and the content of aromatic hydrocarbon,non-hydrocarbon and asphaltene increased.The oil source comes from the deep Permian hydrocarbon-generating depression.Unconformities,faults and marginal fan delta-braided river depositional systems constitute effective migration and storage systems.Caprocks of the Upper Triassic Baijiantan Formation,Lower Jurassic Sangonghe Formation and Lower Cretaceous Hutubihe Formation were formed by three large scale lake transgressions.The Indosinian,Yanshan and Late Yanshan movements are the main driving forces for the migration of deep oil and gas to the shallow edge to form oil sand deposits.It is considered that the oil sand in the northwestern margin of Junggar Basin is of a slope complex migration type.展开更多
The carcass layer is the innermost structure of flexible marine risers and is responsible for resisting external pressure.It has an“S”section with a spiral interlocking feature.After the multi-pass roll forming of a...The carcass layer is the innermost structure of flexible marine risers and is responsible for resisting external pressure.It has an“S”section with a spiral interlocking feature.After the multi-pass roll forming of a flat steel strip,a carcass layer is formed by lock forming.During roll forming,the steel strip undergoes significant plastic deformation,and its local area accumulates residual stress owing to multiple loading and unloading cycles.These phenomena complicate the design and analysis of the carcass layer multi-pass roll forming(CLMRF)process and cause issues in the carcass layer during manufacturing,such as strip fracture and low forming quality.Thus,herein,CLMRF was investigated to clarify the stress distribution,and a parameter analysis was performed.First,the CLMRF process was designed on the basis of classical roll-forming design theory.Second,a finite element model was established,and CLMRF was simulated.Third,the distributions of the forming stress and residual stress of the strip during CLMRF were investigated.Finally,the influences of the strip thickness,roll gap,roll distance,and angular increment were investigated.The conclusions of this study can be used to provide technical guidance in the manufacturing of flexible risers.展开更多
Spiral bevel gears are critical transmission components,and are widely used in the aerospace field.This paper proposes a new multi-DOF envelope forming process for fabricating spiral bevel gears.Firstly,the multi-DOF ...Spiral bevel gears are critical transmission components,and are widely used in the aerospace field.This paper proposes a new multi-DOF envelope forming process for fabricating spiral bevel gears.Firstly,the multi-DOF envelope forming principle of spiral bevel gears is proposed.Secondly,the design methods for the envelope tool geometry and movement are proposed based on the envelope geometry and movement relationships.Thirdly,the metal flow and tooth filling laws are revealed through 3D FE simulation of the multi-DOF envelope forming process of a typical spiral bevel gear.Fourthly,a new method for separating the envelope tool and the formed spiral bevel gear with back taper tooth is proposed to avoid their interference.Finally,experiments on multi-DOF envelope forming of this typical spiral bevel gear are conducted using new heavy load multi-DOF envelope forming equipment.The simulation and experimental results show the feasibility of the proposed multi-DOF envelope forming process for fabricating spiral bevel gears with back taper tooth and the corresponding process design methods.展开更多
The influence of geometric configuration on the friction characteristics during incremental sheet forming of AA5052 was analyzed by integrating surface morphology and its characteristic parameters,along with plastic s...The influence of geometric configuration on the friction characteristics during incremental sheet forming of AA5052 was analyzed by integrating surface morphology and its characteristic parameters,along with plastic strain,contact pressure,and area.The interface promotes lubrication and support when wall angles were≤40°,a 0.5 mm-thin sheet was used,and a 10 mm-large tool radius was employed.This mainly results in micro-plowing and plastic extrusion flow,leading to lower friction coefficient.However,when wall angles exceed 40°,significant plastic strain roughening occurs,leading to inadequate lubrication on the newly formed surface.Increased sheet thickness and decreased tool radius elevate contact pressure.These actions trigger micro-cutting and adhesion,potentially leading to localized scuffing and dimple tears,and higher friction coefficient.The friction mechanisms remain unaffected by the part’s plane curve features.As the forming process progresses,abrasive wear intensifies,and surface morphology evolves unfavorably for lubrication and friction reduction.展开更多
This article examines the influence of annealing temperature on fracture toughness and forming limit curves of dissimilar aluminum/silver sheets.In the cold roll bonding process,after brushing and acid washing,the pre...This article examines the influence of annealing temperature on fracture toughness and forming limit curves of dissimilar aluminum/silver sheets.In the cold roll bonding process,after brushing and acid washing,the prepared surfaces are placed on top of each other and by rolling with reduction more than 50%,the bonding between layers is established.In this research,the roll bonding process was done at room temperature,without the use of lubricants and with a 70%thickness reduction.Then,the final thickness of the Ag/Al bilayer sheet reached 350μm by several stages of cold rolling.Before cold rolling,it should be noted that to decrease the hardness created due to plastic deformation,the roll-bonded samples were subjected to annealing heat treatment at 400℃for 90 min.Thus,the final samples were annealed at 200,300 and 400℃for 90 min and cooled in a furnace to examine the annealing temperature effects.The uniaxial tensile and microhardness tests measured mechanical properties.Also,to investigate the fracture mechanism,the fractography of the cross-section was examined by scanning electron microscope(SEM).To evaluate the formability of Ag/Al bilayer sheets,forming limit curves were obtained experimentally through the Nakazima test.The resistance of composites to failure due to cracking was also investigated by fracture toughness.The results showed that annealing increases the elongation and formability of the Ag/Al bilayer sheet while reduces the ultimate tensile strength and fracture toughness.However,the changing trend is not the same at different temperatures,and according to the results,the most significant effect is obtained at 300℃and aluminum layers.It was also determined that by increasing annealing temperature,the fracture mechanism from shear ductile with small and shallow dimples becomes ductile with deep cavities.展开更多
To overcome the shortage of complex equipment,large volume,and high energy consumption in space capsule manufacturing,a novel sliding pressure Joule heat fuse additive manufacturing technique with reduced volume and l...To overcome the shortage of complex equipment,large volume,and high energy consumption in space capsule manufacturing,a novel sliding pressure Joule heat fuse additive manufacturing technique with reduced volume and low energy consumption was proposed.But the unreasonable process parameters may lead to the inferior consistency of the forming quality of single-channel multilayer in Joule heat additive manufacturing process,and it is difficult to reach the condition for forming thinwalled parts.Orthogonal experiments were designed to fabricate single-channel multilayer samples with varying numbers of layers,and their forming quality was evaluated.The influence of printing current,forming speed,and contact pressure on the forming quality of the single-channel multilayer was analyzed.The optimal process parameters were obtained and the quality characterization of the experiment results was conducted.Results show that the printing current has the most significant influence on the forming quality of the single-channel multilayer.Under the optimal process parameters,the forming section is well fused and the surface is continuously smooth.The surface roughness of a single-channel 3-layer sample is 0.16μm,and the average Vickers hardness of cross section fusion zone is 317 HV,which lays a foundation for the subsequent use of Joule heat additive manufacturing technique to form thinwall parts.展开更多
Short process forming techniques for brazing and soldering materials can shorten the process,improve product quality,and increase production efficiency,which has received much attention from welding researchers.This r...Short process forming techniques for brazing and soldering materials can shorten the process,improve product quality,and increase production efficiency,which has received much attention from welding researchers.This review mainly summarized the research reports on short process forming techniques for brazing and soldering materials.Firstly,the traditional process and its shortcomings were presented.Secondly,the latest research of short process forming technologies,such as continuous casting technique,atomization powder technique,solder ball forming technique,and rapid solidification technique,was summarized,and the traditional forming performance of several brazing and soldering materials was introduced.Finally,the current restrictions and research trends of short process forming technique for brazing and solder materials were put forward,providing theoretical guidance and reference for related research and technique development in brazing and soldering field.展开更多
In the present study,numerical simulation method was used to analyze the conditions,resulting in the formation of blisters during solution heat treatment.Blister formation is considered to occur as the height of blist...In the present study,numerical simulation method was used to analyze the conditions,resulting in the formation of blisters during solution heat treatment.Blister formation is considered to occur as the height of blister reaches 5μm.The effects of process parameters on the magnitude of the forming temperatures of blister(Tb)were discussed.Two kinds of Al-Si alloys were used to analyze the effect of mechanical properties of the alloys on blister forming conditions.Simulation results show that decreasing the initial pressure in gas hole,the long-short axial ratio of gas hole and the size of gas hole,as well as increasing the depth of gas hole and the strength of alloy are helpful to increase the critical temperature of forming blister.These conclusions are helpful for casters to understand the conditions controlling blister formation during solution heat treatment and take actions to avoid the blister defects.展开更多
An analytical model for contact area and contact stress considering the loading history in incremental sheet forming(ISF)was established.Then,by integrating with the directional characteristics of friction force and h...An analytical model for contact area and contact stress considering the loading history in incremental sheet forming(ISF)was established.Then,by integrating with the directional characteristics of friction force and horizontal force in the process,a friction test method reflecting the forming characteristics of ISF was proposed.Friction coefficients during the forming processes of parts with different wall angles were measured under various plane curves,process paths,and lubrication conditions.Furthermore,the accuracy of the analytical model,as well as the measured friction coefficients and their variation trends,was verified through comparative analysis with experimental results,simulation data,and outcomes from other existing models.The results indicate that the influence of the plane curve characteristics and process paths of parts on the friction condition is not significant.Under the lubrication conditions of L-HM46 oil,MoS_(2)grease,graphite powder,and dry friction,the friction coefficient shows a gradually increasing trend.Notably,when the wall angle is≤40°,the friction coefficient remains relatively constant;however,when the wall angle exceeds 40°,the friction coefficient increases progressively.展开更多
文摘During the solidification of the AZ91D-alloys, the Al8(Mn, Fe)5 phase is generally precipitated in the melt in advance of the precipitation of the primary α-Mg. The basic principle for manufacturing AZ91D-alloy slurries for semi solid forming is to use the Al8(Mn, Fe)5 precipitates as the heterogeneous nucleation sites for primary α-Mg phases. Microscopic analysis for the location of the Al8(Mn, Fe)5 precipitate explains that the Al8(Mn, Fe)5 precipitate is the effective heterogeneous nucleation site for the primary α-Mg phase. It was also observed that increase of the Mn content in the melt and the cooling rate below to the solid/liquid two-phase region resulted in smaller and more globular primary α-Mg due to the increase of heterogeneous nucleation sites. It was found that the average α-Mg diameter grew as a function of t0.278, where t is the holding time at the solid/liquid two-phase region. This would be attributed to the Ostwald type ripening and coalescence between primary α-Mg phases. The cooling rate below to the solid/liquid two-phase region, Mn content in AZ91D alloy, and the holding time and temperature affected on the quality of slurry.
基金financially supported by the Natural Science Foundation of Liaoning Province(201202166)the Shenyang City Application Basic Research Foundation(F14-231-1-23)
文摘In the present study, Al-5.5Fe-4Cu-2Zn-0.4Mg-0.5Mn al oy samples were prepared by electromagnetic stirring and semi-solid forming processing, and then the effects of T6 and T1 heat treatments on the microstructures and mechanical properties of the semi-solid forming samples were investigated. The results indicate that after semi-solid forming, the mechanical properties of the sample improved significantly compared to that of the merely electromagnetically stirred sample. The grains of semi-solid forming alloy became almost fine equiaxed; big long strip-shaped Al3 Fe phases became short rod-like morphology and distributed uniformly in the matrix. However, the mechanical properties of the T6-treated semi-solid forming sample decreased significantly instead of increasing and, with solution temperature rising, the tensile strength of the al oy decreased further. The results of EDS show that after high temperature solid-solution treatment, the Cu element in the semi-solid forming alloy sample is mainly concentrated at the boundaries of the Al3 Fe phases instead of being dissolved in the matrix. At the same time, the grains of the semi-solid forming sample grew slightly after solid-solution treatment. Therefore, the growth of the grains and the accumulation of Cu element at Al3 Fe phase boundaries during solution treatment of the semi-solid forming alloy were the main reasons for the mechanical properties decreasing after T6 treatment. The mechanical properties of the alloy were improved after T1 heat treatment due to aging strengthening phase being precipitated in the matrix.
文摘A motorcycle component of damper housing was made by semi-solid forming process. This was used to investigate the effect of microstructures of feedstock on the formability of semisolid process. The soundness and microstructures of casting parts made by dendritic and non-dendritic feedstock were investigated. Separating of liquid phase was found in the casting produced by dendritic feedstock, which might result in defects of porosity, while uniform microstructures were found in the casting produced by no...
文摘In order to adapt to the trend of ＂energy saving and emission reduction＂ and impel the practical application of semi solid processing （SSP） in China, the progress and application of semi-solid theory in China have been reviewed briefly and systematically. It was emphasized on basic theories, such as formation of globular grains, theology, high pressure solidification and plastic deformation and applications, such as material design, preparation of semi-solid billets （slurries）, thixoforming and application status, which are based on the advantage of semi-solid processing. The results show that the gap of SSP between world level and China exists, especially in application technologies, including market recognition, application fields exploiting, developing of billets （slurries） preparation technologies with low cost and special equipments. The prospect of semi-solid forming development path in China is presented. And we hope that application of SSP has great new breakthrough and development and China wilt be changed from a large metal processing country to a powerful metal processing country.
基金the financial support provided by the Natural Sciences and Engineering Research Council of Canada (NSERC) and Rio Tinto Alcan through the NSERC Industrial Research Chair in Metallurgy of Aluminum Transformation at Université du Québec à Chicoutimi
文摘The feasibility of semi solid processing of hypereutectic A390 alloys using a novel rheoforming process was investigated. A combination of the swirl enthalpy equilibration device （SEED） process, isothermal holding using insulation and addition of solid alloy during swirling was introduced as a novel method to improve the processability of semi solid slurry. The effects of isothermal holding and the addition of solid alloy on the temperature gradient between the centre and the wall and on the formation of a（Al） particles were examined. In additional tests, phosphorus and strontium were added to the molten metal to refine the primary and eutectic silicon structure to facilitate semi solid processing. The results show that the combination of the SEED process with two additional processing steps can produce semi-solid A390 alloys that can be rheoprocessed. The microstructure reveals an adequate amount of non-dendritic a（Al） globules surrounded by liquid, which greatly improves the processability of semi-solid slurry.
文摘The electronic packaging box with high silicon aluminum-base alloy was prepared by semi-solid thixoforming technique.The flow characteristic of the Si phase was analyzed.The microstructures of different parts of the box were observed by optical microscopy and scanning electron microscopy,and the thermophysical and mechanical properties of the box were tested.The results show that there exists the segregation phenomenon between the primary Si phase and the liquid phase during thixoforming,the liquid phase flows from the box,and the primary Si phase accumulates at the bottom of the box.The volume fraction of primary Si phase decreases gradually from the bottom to the walls.Accordingly,the thermal conductivities of bottom center and walls are 107.6 and 131.5 W/（m·K）,the coefficients of thermal expansion（CTE） are 7.9×10-6 and 10.6×10-6 K-1,respectively.The flexural strength increases slightly from 167 to 180 MPa.The microstructures and properties of the box show gradient distribution overall.
文摘The investment on semi-solid die casting processes of AZ91D magnesium alloy brackets for generators in JH70-type motorbikes is introduced. The processes of low super-heat and cooling slope for the preparation of billets with non-dendritic microstructure, the remelting of billets for thixoforming and the parameters in the process of semi-sohd thixoforming have been researched. The results show that primary billets with non-dendritical structures can be prepared by forming great amount of nuclei in melt via the process of low super heat. By optimizing the remelting process through adjusting the current of the induced equipment, semi-solid billets with a structure of spherical grains were obtained from the primary billets with non-dendritical structure. The range of 580℃ to 583℃ is the proper remelting temperatures by which the billets have an expected thixotropy and can be transferred to a die-casting machine. The optimized parameters of semi-solid forming in a die-casting machine are as follows： the area of the ingate in the die is 383.5 mm^2, the speed of the pierce of the machine 5 m/s, the shot pressure of the pierce 75 MPa, and the maintenance pressure of the pierce 350 MPa. The castings of brackets for supporting generators in JH70 type motorbikes were formed by adopting the optimized processes and parameters mentioned above.
基金the project 1M06032 Research Centre of Forming TechnologySlovak and Czech Project SK-CZ-0180-09
文摘To obtain new unconventional structures with specific mechanical and physical properties is possible not only by the development of new types of materials but also by treatment of conventional materials using unconventional innovative technological procedures.One of these technologies is the forming in semi-solid state involving rapid solidification of miniature components from steels.Production of such components is complicated by a number of technical problems.To explain phenomena of the process and structure development,the production of miniature components from the tool steel X210Cr12 difficult to form was experimentally tested.The structure of this originally ledeburite steel consisted of 95 % of metastable austenite after the treatment.Metastable austenite was located particularly in globular and polygonal grains while the remaining interspaces were filled by lamellar network.The detected high stability of extremely high fraction of metastable austenite was tested under different conditions of thermal exposition and mechanical loading.
基金Project(50874049) supported by the National Natural Science Foundation of ChinaProject(2008DFB50020) supported by International Science and Technology Cooperation of Ministry of Science and Technology of China
文摘The 6061 semi-solid aluminium alloy feedstocks prepared by near-liquidus casting were compressed in semi-solid state by means of Gleeble-3500 thermal-mechanical simulator.The relationship between the true stress and the true strain at different temperatures and strain rates was studied with the deformation degree of 70%.The microstructures during the deformation process were characterized.The deformation mechanism and thixo-forming properties of the semi-solid alloys were analyzed.The results show that the homogeneous and non-dendrite microstructures of semi-solid 6061Al alloy manufactured by near-liquidus casting technology could be transformed into semi-solid state with the microstructure suitable for thixo-forming which are composed of near-spherical grains and liquid phase with eutectic composition through reheating process.The deformation temperature and strain rate affect the peak stress significantly rather than steady flow stress.The resistance to deformation in semi-solid state decreases with the increase of the deformation temperature and decrease of the strain rate.At steady thixotropic deformation stage, the thixotropic property is uniform, and the main deformation mechanism is the rotating or sliding between the solid particles and the plastic deformation of the solid particles.
文摘In this paper the effect of pouring temperature of magnesium melt, preheating temperature of the barrel of screw mixer and shear rate on the solidified microstructures of semi-solid slurry was investigated by mechanical stirring method. The appropriate processing parameters of slurry preparation were obtained. The mold filling for thin walled casting was examined. Results indicated that the solid volume fraction of non-dendritic structure increased with decrease in pouring temperature of magnesium melt and the barrel preheating temperature of screw mixer. Also the grain size of primary α phase was reduced. Furthermore, the solid volume fraction of semi-solid non-dendritic structure decreased with the increase in shear rate. In the same time, grain size of primary α phase slightly changed. The fine-round granular solidified structure with 30～50 μm of prepared AZ91D magnesium semi-solid slurry was presented. Finally, it is successful to fabricate 1.0 mm extremely thin walled casting with clear contour and good soundness.
基金supported in part by financial support from the National Key R&D Program of China(No.2023YFB3407003)the National Natural Science Foundation of China(No.52375378).
文摘A new analytical model for geometric size and forming force prediction in incremental flanging(IF)is presented in this work.The complex deformation characteristics of IF are considered in the modeling process,which can accurately describe the strain and stress states in IF.Based on strain analysis,the model can predict the material thickness distribution and neck height after IF.By considering contact area,strain characteristics,material thickness changes,and friction,the model can predict specific moments and corresponding values of maximum axial forming force and maximum horizontal forming force during IF.In addition,an IF experiment involving different tool diameters,flanging diameters,and opening hole diameters is conducted.On the basis of the experimental strain paths,the strain characteristics of different deformation zones are studied,and the stable strain ratio is quantitatively described through two dimensionless parameters:relative tool diameter and relative hole diameter.Then,the changing of material thickness and forming force in IF,and the variation of minimum material thickness,neck height,maximum axial forming force,and maximum horizontal forming force with flanging parameters are studied,and the reliability of the analytical model is verified in this process.Finally,the influence of the horizontal forming force on the tool design and the fluctuation of the forming force are explained.
基金granted by the Xinjiang Geological Exploration Fund。
文摘The northwestern margin of Junggar Basin is the region with the richest oil sand resources in China.For better understanding the enrichment rules and deployment of exploration and development of regional oil sand,it is of great scientific significance to study the accumulation conditions of oil sand in different strata and mining areas of the Junggar Basin.Through a large number of field investigations,drilling verification and sampling tests,it is found that the oil sand in the region covers an area of 2000 km^(2),with shallow and thick reservoir,and predicted resource of 180 million tons.The oil sand resources are mainly distributed in four geological strata,namely the Middle Triassic Karamay Formation,Early Jurassic Badaowan Formation,Late Jurassic Qigu Formation,and Early Cretaceous Qingshuihe Formation.The reservoir is mainly composed of sandstone with high porosity and permeability,and the reservoir space is mainly intergranular pores with a medium average oil content.The oil sand deposit in the region is a typical destructive oil reservoir.The crude oil in the oil sand layer is degraded and thickened from the deep to the shallow,the content of saturated hydrocarbon decreased,and the content of aromatic hydrocarbon,non-hydrocarbon and asphaltene increased.The oil source comes from the deep Permian hydrocarbon-generating depression.Unconformities,faults and marginal fan delta-braided river depositional systems constitute effective migration and storage systems.Caprocks of the Upper Triassic Baijiantan Formation,Lower Jurassic Sangonghe Formation and Lower Cretaceous Hutubihe Formation were formed by three large scale lake transgressions.The Indosinian,Yanshan and Late Yanshan movements are the main driving forces for the migration of deep oil and gas to the shallow edge to form oil sand deposits.It is considered that the oil sand in the northwestern margin of Junggar Basin is of a slope complex migration type.
基金financially supported by the National Natural Science Foundation of China(Grant Nos.U1906233 and 52201312)Dalian High-Level Talent Innovation Program(Grant No.2021RD16)the Natural Science Foundation of Liaoning Province of China(Grant No.2023-BSBA-052).
文摘The carcass layer is the innermost structure of flexible marine risers and is responsible for resisting external pressure.It has an“S”section with a spiral interlocking feature.After the multi-pass roll forming of a flat steel strip,a carcass layer is formed by lock forming.During roll forming,the steel strip undergoes significant plastic deformation,and its local area accumulates residual stress owing to multiple loading and unloading cycles.These phenomena complicate the design and analysis of the carcass layer multi-pass roll forming(CLMRF)process and cause issues in the carcass layer during manufacturing,such as strip fracture and low forming quality.Thus,herein,CLMRF was investigated to clarify the stress distribution,and a parameter analysis was performed.First,the CLMRF process was designed on the basis of classical roll-forming design theory.Second,a finite element model was established,and CLMRF was simulated.Third,the distributions of the forming stress and residual stress of the strip during CLMRF were investigated.Finally,the influences of the strip thickness,roll gap,roll distance,and angular increment were investigated.The conclusions of this study can be used to provide technical guidance in the manufacturing of flexible risers.
基金the National Science and Technology Major Project of China(No.2019-VII0017e0158)the National Natural Science Foundation of China(No.U21A20131)+1 种基金the Industry-University Research Cooperation Project,China(No.HFZL2020CXY025)the National Key Laboratory of Science and Technology on Helicopter Transmission,China(No.HTL-O-21G05).
文摘Spiral bevel gears are critical transmission components,and are widely used in the aerospace field.This paper proposes a new multi-DOF envelope forming process for fabricating spiral bevel gears.Firstly,the multi-DOF envelope forming principle of spiral bevel gears is proposed.Secondly,the design methods for the envelope tool geometry and movement are proposed based on the envelope geometry and movement relationships.Thirdly,the metal flow and tooth filling laws are revealed through 3D FE simulation of the multi-DOF envelope forming process of a typical spiral bevel gear.Fourthly,a new method for separating the envelope tool and the formed spiral bevel gear with back taper tooth is proposed to avoid their interference.Finally,experiments on multi-DOF envelope forming of this typical spiral bevel gear are conducted using new heavy load multi-DOF envelope forming equipment.The simulation and experimental results show the feasibility of the proposed multi-DOF envelope forming process for fabricating spiral bevel gears with back taper tooth and the corresponding process design methods.
基金the support of the Key Research and Development Program of Shaanxi Province,China(No.2021GXLH-Z-049)。
文摘The influence of geometric configuration on the friction characteristics during incremental sheet forming of AA5052 was analyzed by integrating surface morphology and its characteristic parameters,along with plastic strain,contact pressure,and area.The interface promotes lubrication and support when wall angles were≤40°,a 0.5 mm-thin sheet was used,and a 10 mm-large tool radius was employed.This mainly results in micro-plowing and plastic extrusion flow,leading to lower friction coefficient.However,when wall angles exceed 40°,significant plastic strain roughening occurs,leading to inadequate lubrication on the newly formed surface.Increased sheet thickness and decreased tool radius elevate contact pressure.These actions trigger micro-cutting and adhesion,potentially leading to localized scuffing and dimple tears,and higher friction coefficient.The friction mechanisms remain unaffected by the part’s plane curve features.As the forming process progresses,abrasive wear intensifies,and surface morphology evolves unfavorably for lubrication and friction reduction.
基金Project(4013311)supported by the National Science Foundation of Iran(INSF)。
文摘This article examines the influence of annealing temperature on fracture toughness and forming limit curves of dissimilar aluminum/silver sheets.In the cold roll bonding process,after brushing and acid washing,the prepared surfaces are placed on top of each other and by rolling with reduction more than 50%,the bonding between layers is established.In this research,the roll bonding process was done at room temperature,without the use of lubricants and with a 70%thickness reduction.Then,the final thickness of the Ag/Al bilayer sheet reached 350μm by several stages of cold rolling.Before cold rolling,it should be noted that to decrease the hardness created due to plastic deformation,the roll-bonded samples were subjected to annealing heat treatment at 400℃for 90 min.Thus,the final samples were annealed at 200,300 and 400℃for 90 min and cooled in a furnace to examine the annealing temperature effects.The uniaxial tensile and microhardness tests measured mechanical properties.Also,to investigate the fracture mechanism,the fractography of the cross-section was examined by scanning electron microscope(SEM).To evaluate the formability of Ag/Al bilayer sheets,forming limit curves were obtained experimentally through the Nakazima test.The resistance of composites to failure due to cracking was also investigated by fracture toughness.The results showed that annealing increases the elongation and formability of the Ag/Al bilayer sheet while reduces the ultimate tensile strength and fracture toughness.However,the changing trend is not the same at different temperatures,and according to the results,the most significant effect is obtained at 300℃and aluminum layers.It was also determined that by increasing annealing temperature,the fracture mechanism from shear ductile with small and shallow dimples becomes ductile with deep cavities.
基金Shaanxi Province Qin Chuangyuan“Scientist+Engineer”Team Construction Project(2022KXJ-071)2022 Qin Chuangyuan Achievement Transformation Incubation Capacity Improvement Project(2022JH-ZHFHTS-0012)+1 种基金Shaanxi Province Key Research and Development Plan-“Two Chains”Integration Key Project-Qin Chuangyuan General Window Industrial Cluster Project(2023QCY-LL-02)Xixian New Area Science and Technology Plan(2022-YXYJ-003,2022-XXCY-010)。
文摘To overcome the shortage of complex equipment,large volume,and high energy consumption in space capsule manufacturing,a novel sliding pressure Joule heat fuse additive manufacturing technique with reduced volume and low energy consumption was proposed.But the unreasonable process parameters may lead to the inferior consistency of the forming quality of single-channel multilayer in Joule heat additive manufacturing process,and it is difficult to reach the condition for forming thinwalled parts.Orthogonal experiments were designed to fabricate single-channel multilayer samples with varying numbers of layers,and their forming quality was evaluated.The influence of printing current,forming speed,and contact pressure on the forming quality of the single-channel multilayer was analyzed.The optimal process parameters were obtained and the quality characterization of the experiment results was conducted.Results show that the printing current has the most significant influence on the forming quality of the single-channel multilayer.Under the optimal process parameters,the forming section is well fused and the surface is continuously smooth.The surface roughness of a single-channel 3-layer sample is 0.16μm,and the average Vickers hardness of cross section fusion zone is 317 HV,which lays a foundation for the subsequent use of Joule heat additive manufacturing technique to form thinwall parts.
基金National Key Research and Development Program(2021YFB3401101)。
文摘Short process forming techniques for brazing and soldering materials can shorten the process,improve product quality,and increase production efficiency,which has received much attention from welding researchers.This review mainly summarized the research reports on short process forming techniques for brazing and soldering materials.Firstly,the traditional process and its shortcomings were presented.Secondly,the latest research of short process forming technologies,such as continuous casting technique,atomization powder technique,solder ball forming technique,and rapid solidification technique,was summarized,and the traditional forming performance of several brazing and soldering materials was introduced.Finally,the current restrictions and research trends of short process forming technique for brazing and solder materials were put forward,providing theoretical guidance and reference for related research and technique development in brazing and soldering field.
基金financially supported by the National Key Research and Development Program of China (No.2016YFB0301003)Shenzhen Science and Technology Innovation Commission under Projects (Nos.JCYJ20170307110223452,KQJSCX20170328155402991 and KQTD20170328154443162)。
文摘In the present study,numerical simulation method was used to analyze the conditions,resulting in the formation of blisters during solution heat treatment.Blister formation is considered to occur as the height of blister reaches 5μm.The effects of process parameters on the magnitude of the forming temperatures of blister(Tb)were discussed.Two kinds of Al-Si alloys were used to analyze the effect of mechanical properties of the alloys on blister forming conditions.Simulation results show that decreasing the initial pressure in gas hole,the long-short axial ratio of gas hole and the size of gas hole,as well as increasing the depth of gas hole and the strength of alloy are helpful to increase the critical temperature of forming blister.These conclusions are helpful for casters to understand the conditions controlling blister formation during solution heat treatment and take actions to avoid the blister defects.
基金the National Key R&D Program of China(No.2023YFB3407003)the National Natural Science Foundation of China(No.52375378).
文摘An analytical model for contact area and contact stress considering the loading history in incremental sheet forming(ISF)was established.Then,by integrating with the directional characteristics of friction force and horizontal force in the process,a friction test method reflecting the forming characteristics of ISF was proposed.Friction coefficients during the forming processes of parts with different wall angles were measured under various plane curves,process paths,and lubrication conditions.Furthermore,the accuracy of the analytical model,as well as the measured friction coefficients and their variation trends,was verified through comparative analysis with experimental results,simulation data,and outcomes from other existing models.The results indicate that the influence of the plane curve characteristics and process paths of parts on the friction condition is not significant.Under the lubrication conditions of L-HM46 oil,MoS_(2)grease,graphite powder,and dry friction,the friction coefficient shows a gradually increasing trend.Notably,when the wall angle is≤40°,the friction coefficient remains relatively constant;however,when the wall angle exceeds 40°,the friction coefficient increases progressively.
