The microstructure and properties of a 1030B Al strip were improved by applying ultrasonic melt treatment(UMT)in a Hazelett continuous casting direct rolling production line.The microstructure and properties of the 10...The microstructure and properties of a 1030B Al strip were improved by applying ultrasonic melt treatment(UMT)in a Hazelett continuous casting direct rolling production line.The microstructure and properties of the 1030B Al strip were investigated by scanning electron microscopy,electron backscatter diffraction,and tensile testing.Applying UMT reduced the average grain size of the as-cast sheet by more than 28.0%with respect to that of the normal samples without UMT.When UMT was applied,the rolled strip inherited the refined grains from the as-cast sheet with an average grain size smaller than 63.0μm.Meanwhile,the dislocation density was increased by the grain refinement,dynamic recovery,and recrystallization during rolling.Accordingly,the strain-hardening rates of the rolled samples after UMT were generally higher than those of the normal samples,and the strength of the rolled strip was also improved.Furthermore,the rolled strip exhibited better formability with higher strain-hardening exponents and Erichsen index values.展开更多
The research of carbon content along the casting direction of 82B cord steel billets is of great significance for improvingthe quality of cord products from subsequent processing.However,the traditional segregation an...The research of carbon content along the casting direction of 82B cord steel billets is of great significance for improvingthe quality of cord products from subsequent processing.However,the traditional segregation and billets quality evaluationmethods have certain limitations,such as sampling length and analysis area.which affect the accuracy of quality judgment.Thus.the statistics of extreme values(SEV)was introduced to predict the maximum value of carbon element contentalong the casting direction,which can quantitatively characterize the segregation degree.The size of the selected billet is150 mm×150 mm,and the sampling location is the centerline of the billet.The experiment was conducted by consideringthe effect of cooling intensity and casting speed on the maximum value of carbon element content.Firstly,the calculationresults show that the SEN method can predict the maximum value of carbon element content along the casting directionof 82B cord steel,and the SEV method is proved to be effective by analyzing the carbon distribution and fluctuation in billets.To some extent,the SEV method can break the limitations of the sampling length and analysis area by predicting themaximum value of carbon element on a larger range of continuous casting billets with few samples.During the continuouscasting process the increase in cooling intensity makes the surface shrinking rate increase,which can slow down the flowof solute-enriched liquid to the center,and the center segregation can be reduced.On the other hand,the function area ofthe final electromagnetic stirring can be expanded with the increase in the casting speed,which can reduce the concentration of carbon element in the center of the billets and reduce the maximum value of carbon element content.Ilt can providea new theoretical reference for the quantitative calculation of carbon content in continuous casting billets and the qualityevaluation of continuous casting billcts.展开更多
Central region coarse grains and centerline segregation are common defects in aluminum ingots fabricated by direct chill(DC)casting.A double cooling field was introduced into the DC casting process to reduce these def...Central region coarse grains and centerline segregation are common defects in aluminum ingots fabricated by direct chill(DC)casting.A double cooling field was introduced into the DC casting process to reduce these defects,whereby the external cooling was supplied by the mold and water jets,and intercooling was achieved by inserting a rod of the same alloy into the molten pool along the central axis of the ingot.Rather than forming a good metallurgical interface during solid-liquid compound casting,in the present work,the purpose of inserting the rod is to enforce internal cooling and consequently decrease the sump depth.Moreover,the insertion provides more nucleation sites with the unmoltenα-Al particles.The structure and the macrosegregation of 2024 Al alloy ingots prepared by DC casting with and without the inserts were investigated.Results show that when the inserting position is 50 mm above the upper edge of the graphite ring,significant grain refinement in the central region of the ingot and a reduced centerline segregation are achieved.展开更多
The influences of the low frequency electromagnetic field on the horizontal direct chill casting process were investigated experimentally. Ingots of 2024 aluminum alloy with a cross size of 40 mm× 200 mm were pro...The influences of the low frequency electromagnetic field on the horizontal direct chill casting process were investigated experimentally. Ingots of 2024 aluminum alloy with a cross size of 40 mm× 200 mm were produced by the conventional horizontal chill casting process and low frequency electromagnetic horizontal chill casting processre- spectively. The as-cast structures and the mechanical property of the ingots were examined. The results showed that the low frequency electromagnetic field could sub- stantially refine the microstructures and pronouncedly reduce the macrosegregation in the horizontal direct chill casting process. Moreover, the surface quality of the ingot was prominently improved by the low frequency electromagnetic field. The fracture strength and elongation percentage of the ingot was increased with the low frequency electromagnetic field.展开更多
To predict hot tearing susceptibility(HTS)during solidification and improve the quality of Al alloy castings,constitutive equations for AA6111 alloys were developed using a direct finite element(FE)method.A hot tearin...To predict hot tearing susceptibility(HTS)during solidification and improve the quality of Al alloy castings,constitutive equations for AA6111 alloys were developed using a direct finite element(FE)method.A hot tearing model was established for direct chill(DC)casting of industrial AA6111 alloys via coupling FE model and hot tearing criterion.By applying this model to real manufacture processes,the effects of casting speed,bottom cooling,secondary cooling,and geometric variations on the HTS were revealed.The results show that the HTS of the billet increases as the speed and billet radius increase,while it reduces as the interfacial heat transfer coefficient at the bottom or secondary water-cooling rate increases.This model shows the capabilities of incorporating maximum pore fraction in simulating hot tearing initiation,which will have a significant impact on optimizing casting conditions and chemistry for minimizing HTS and thus controlling the casting quality.展开更多
The low frequency electromagnetic field was applied during direct chill(DC) semi-continuous casting of the ZK60 magnesium alloy billets. Effects of low frequency electromagnetic field on surface quality, microstructur...The low frequency electromagnetic field was applied during direct chill(DC) semi-continuous casting of the ZK60 magnesium alloy billets. Effects of low frequency electromagnetic field on surface quality, microstructure and hot-tearing tendency of Φ500 mm ZK60 magnesium alloy billets were investigated. The results showed that with the application of the low frequency electromagnetic field, the surface quality of the ZK60 magnesium alloy billets is markedly improved and the depth of cold fold is decreased. The microstructure of the billets is also significantly refined. Besides, the distribution of the grain size is relatively uniform from the billet surface towards its center, where the average grain size is 42 μm at surface and 50 μm at center. It also shows that the hot-tearing tendency of DC semi-continuous casting ZK60 magnesium alloy billets is significantly reduced under low frequency electromagnetic field.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
The effects of two types of magnetic fields,namely harmonic magnetic field(HMF)and pulse magnetic field(PMF)on magnetic flux density,Lorentz force,temperature field,and microstructure of high purity Cu were studied by...The effects of two types of magnetic fields,namely harmonic magnetic field(HMF)and pulse magnetic field(PMF)on magnetic flux density,Lorentz force,temperature field,and microstructure of high purity Cu were studied by numerical simulation and experiment during electromagnetic direct chill casting.The magnetic field is induced by a magnetic generation system including an electromagnetic control system and a cylindrical crystallizer of 300 mm in diameter equipped with excitation coils.A comprehensive mathematical model for high purity Cu electromagnetic casting was established in finite element method.The distributions of magnetic flux density and Lorentz force generated by the two magnetic fields were acquired by simulation and experimental measurement.The microstructure of billets produced by HMF and PMF casting was compared.Results show that the magnetic flux density and penetrability of PMF are significantly higher than those of HMF,due to its faster variation in transient current and higher peak value of magnetic flux density.In addition,PMF drives a stronger Lorentz force and deeper penetration depth than HMF does,because HMF creates higher eddy current and reverse electromagnetic field which weakens the original electromagnetic field.The microstructure of a billet by HMF is composed of columnar structure regions and central fine grain regions.By contrast,the billet by PMF has a uniform microstructure which is characterized by ultra-refined and uniform grains because PMF drives a strong dual convection,which increases the uniformity of the temperature field,enhances the impact of the liquid flow on the edge of the liquid pool and reduces the curvature radius of liquid pool.Eventually,PMF shows a good prospect for industrialization.展开更多
The complex producing procedures and high energy-consuming limit the large-scale production and application of advanced high-strength steels(AHSSs).In this study,the direct strip casting(DSC)technology with unique sub...The complex producing procedures and high energy-consuming limit the large-scale production and application of advanced high-strength steels(AHSSs).In this study,the direct strip casting(DSC)technology with unique sub-rapid solidification characteristics and cost advantages was applied to the production of low-alloy Si-Mn steel with the help of quenching&partitioning(Q&P)concept to address these issues.Compared this method with the conventional compact strip production(CSP)process,the initial microstructure formed under different solidification conditions and the influence of heat treatment processes on the final mechanical properties were in-vestigated.The results show that the initial structure of the DSC sample is a dual-phase structure composed of fine lath martensite and bainite,while the initial structure of the CSP sample consists of pearlite and ferrite.The volume fraction and carbon content of retained austenite(RA)in DSC samples are usually higher than those in CSP samples after the same Q&P treatment.DSC samples typically demonstrate better comprehensive mechanical properties than the CSP sample.The DSC sample partitioned at 300℃ for 300 s(DSC-Pt300)achieves the best comprehensive mechanical properties,with yield strength(YS)of 1282 MPa,ultimate tensile strength(UTS)of 1501 MPa,total elongation(TE)of 21.5%,and product of strength and elongation(PSE)as high as 32.3 GPa·%.These results indicate that the excellent mechanical properties in low-alloy Si-Mn steel can be obtained through a simple process(DSC-Q&P),which also demonstrates the superiority of DSC technology in manufacturing AHSSs.展开更多
Direct strip casting(DSC)is one of the cutting-edge technologies for the steel industry in the twenty-first century.Under the background of carbon peak and carbon neutrality,DSC technology has a bright future of appli...Direct strip casting(DSC)is one of the cutting-edge technologies for the steel industry in the twenty-first century.Under the background of carbon peak and carbon neutrality,DSC technology has a bright future of applications as it requires less production time and space with reduced energy consumption.Owing to its sub-rapid cooling rate during solidification and low reduction during hot rolling,DSC process exhibits a series of unique physical metallurgy characteristics.The process characteristics of DSC process and the microstructural evolution during the thermomechanical processing of low-carbon microalloyed steel are reviewed.The effects of hot rolling,cooling,coiling temperatures and microalloying elements on the microstructure and mechanical properties are then discussed.Finally,the future development orientations of DSC technology are suggested to fully utilize its unique features for the enhancement of its competitiveness and for the promotion of carbon neutrality of the steel industry.展开更多
High-quality Mg-Nd-Zn-Zr magnesium alloy billets with diameter of 200 mm were successfully prepared by direct chill(DC)casting.The results show that microstructures of the as-cast billet prepared by DC casting are mai...High-quality Mg-Nd-Zn-Zr magnesium alloy billets with diameter of 200 mm were successfully prepared by direct chill(DC)casting.The results show that microstructures of the as-cast billet prepared by DC casting are mainly composed of equiaxed a-Mg and Mg 12 Nd eutectic compound distributing along the grain boundaries.The average grain size decreases along the radius of the billet.And the alloying elements of Nd and Zn distribute homogeneously across the large billet.The optimum process parameters for DC casting of the Mg-Nd-Zn-Zr magnesium alloy billet with diameter of 200 mm have been experimentally determined as follows:casting temperature 710℃ and casting speed 80 mm/min.展开更多
To obtain the billet with homogeneous and spheroidized primary grains is the key step in the semi- solid forming process. Among the semi-solid billet preparation methods, the process of low-superheat direct chill （DC...To obtain the billet with homogeneous and spheroidized primary grains is the key step in the semi- solid forming process. Among the semi-solid billet preparation methods, the process of low-superheat direct chill （DC） casting is simpler and more effective. In this study, the billets of AISi7Mg alloy were prepared by low- superheat DC casting at various withdrawal rates. The effect of withdrawal rate on the surface quality of the billets was investigated, and the evolution mechanism of the microstructural morphology in the billets was analyzed. The results show that the periodic corrugations and a large quantity of fine shrinkage pits appear in the billet surface when the withdrawal rate is 100 mm.min-1, and the above defects in the billet surface can be eliminated completely when the withdrawal rate is above 150 mm.min-1. But when the withdrawal rate is too fast （250 mm.min-1）, the primary a grains, except the ones in the billet center, have not enough time for ripening due to the high silidification rate, and will solidify as the dendrite structure. When the withdrawal rate is between 150 - 200 mm.min-1, the dendritic growth of the primary a grains is effectively inhibited, and a billet of AISi7Mg alloy with a smooth surface and homogeneous, fine, non-dendritic grains can be obtained.展开更多
The horizontal direct chill (HDC) casting process is a well-established production route for aluminum alloy ingot but the ingot may suffer from macrosegregation sometimes. In order to control the defect, a low frequen...The horizontal direct chill (HDC) casting process is a well-established production route for aluminum alloy ingot but the ingot may suffer from macrosegregation sometimes. In order to control the defect, a low frequency electromagnetic field has been applied in HDC casting process and the relevant influence has been studied. The results show that application of low frequency electromagnetic field can reduce macrosegregation in HDC casting process; and two main parameters of electromagnetic field density and frequency, have great influences on the solution distribution along the diameter of ingot. Moreover, the mechanisms of reduction of macrosegregation by electromagnetic field have been discussed.展开更多
During direct chilling(DC)casting of ZK61 alloys,the primary and secondary cooling causes strong thermal gradients,which leads to the uneven crystallization rate and thermal contraction in different positions of the i...During direct chilling(DC)casting of ZK61 alloys,the primary and secondary cooling causes strong thermal gradients,which leads to the uneven crystallization rate and thermal contraction in different positions of the ingot.The consequences manifested appearance of heterogeneous grains,huge casting stresses,and even hot cracking flaws.In this paper,chemical and physical methods were integrated to produce large-scale magnesium(Mg)alloy ingots.A φ525 mm ZK61-RE alloy ingot that was refined,homogeneous,and free from hot cracking was obtained via the DC process coupled with a differential low frequency pulsed magnetic field(DLPM).The effects of rare earth(RE)and DLPM on the hot cracking tendency were investigated,and the mechanism of hot cracking formation and modification in largescale ingots was revealed.The findings indicate that the addition of moderate amounts of RE lessens the tendency of hot cracking in large-scale ZK61 alloy ingots.This is mainly attributed to the addition of RE increases the content of the second phase,thus enhancing the ability of the eutectic liquid phase to feed the cracking.With the introduction of DLPM,the grain sizes are significantly refined and homogenized,and there is no obvious hot cracking observed in the ingot.This is because the coupling of the DLPM provides a more homogeneous temperature field,leading to the synchronization of the solidification process,and the consequent reduction of the casting stress,thus reducing the driving force for the formation of hot cracking.In addition,the casting conditions are modified to enhance the ability of solidification feeding and the resistance to hot cracking.This work provides theoretical and practical references for the preparation of large-scale high-quality Mg alloy ingots.展开更多
As-cast alloys often require complex thermomechanical processing to obtain a hierarchical structure to achieve a good combination of strength and ductility.Here in this work,a novel hierarchical Fe_(27)Ni_(35)Cr_(18.2...As-cast alloys often require complex thermomechanical processing to obtain a hierarchical structure to achieve a good combination of strength and ductility.Here in this work,a novel hierarchical Fe_(27)Ni_(35)Cr_(18.25)Al_(13.75)Co_(2)Ti_(2)Mo_(2) high-entropy alloy(HEA)with ultra-high tensile strength and excellent ductility was fabricated by direct casting.The as-cast alloy exhibits hierarchical structure with an ul-trafine lamellar microstructure(ULM),ultrafine rhombus microstructure(URM),ultrafine vermicular mi-crostructure(UVM),nanosized precipitates and spinodal decomposition(SP)that develops during casting and cooling.The incompatibility of face-centered cubic(FCC)and body-centered cubic(BCC)phases in the deformation process leads to heterogeneous deformation-induced(HDI)hardening,which brings the alloy a tensile yield strength(YS)of~1056 MPa,an ultimate tensile strength(UTS)of~1526 MPa and a total elongation(El)of~15.6%.Additionally,the numerous interfaces generated by the hierarchical structure absorb the energy during deformation,effectively retarding the dislocation motion and causing strong work-hardening.展开更多
Engineered cementitious composites(ECC),also known as bendable concrete,were developed based on engineering the interactions between fibers and cementitious matrix.The orientation of fibers,in this regard,is one of th...Engineered cementitious composites(ECC),also known as bendable concrete,were developed based on engineering the interactions between fibers and cementitious matrix.The orientation of fibers,in this regard,is one of the major factors influencing the ductile behavior of this material.In this study,fiber orientation distributions in ECC beams influenced by different casting techniques are evaluated via numerical modeling of the casting process.Two casting directions and two casting positions of the funnel outlet with beam specimens are modeled using a particle-based smoothed particle hydrodynamics(SPH)method.In this SPH approach,fresh mortar and fiber are discretized by separated mortar and fiber particles,which smoothly interact in the computational domain of SPH.The movement of fiber particles is monitored during the casting simulation.Then,the fiber orientations at different sections of specimens are determined after the fresh ECC stops flowing in the formwork.The simulation results show a significant impact of the casting direction on fiber orientation distributions along the longitudinal wall of beams,which eventually influence the flexural strength of beams.In addition,casting positions show negligible influences on the orientation distribution of fibers in the short ECC beam,except under the pouring position.展开更多
Building high-performance aerogels with biomass-derived rather than fossil-derived polymers is an eco-friendlier option given the increasingly serious sustainability issues.Chitosan(CS)aero-gels with oriented pore str...Building high-performance aerogels with biomass-derived rather than fossil-derived polymers is an eco-friendlier option given the increasingly serious sustainability issues.Chitosan(CS)aero-gels with oriented pore structures exhibit broad application prospects owing to light weight,high porosity,and favorable bioactivity,but the dominating drawback in low mechanical strength greatly hinders their functional advantages.In this study,two types of silk microfibers with simi-lar diameter yet different aspect ratios(1-3(denoting as SmSF)and 50-100(denoting as LmSF))were used as fillers to reinforce CS aerogels prepared by directional freeze casting.The distinc-tion of SmSF and LmSF in size led to their notable variations in distribution pattern,as SmSF embedded within the individual CS lamellae while LmSF traversed throughout the adjacent CS lamellae,which in consequence significantly influence their mechanical reinforcing efficiency.The compressive strength values could be improved from 61.67 kPa(pure CS aerogel)to 82.13 kPa(SmSF/CS aerogel)and 165.03 kPa(LmSF/CS aerogel),respectively,attributing to the tran-sition in deformation mechanisms from a bending-to crumpling-dominated mode.In addition,the embedding or bridging structure could also change the liquid transportation property of CS aerogels.The results of this study demonstrated the feasibility of applying filler-size-mediated strategy for material structural optimization.展开更多
基金the National Natural Science Foundation of China(No.52004254)the Major Science and Technology Project of Henan Province,China(No.221100240300).
文摘The microstructure and properties of a 1030B Al strip were improved by applying ultrasonic melt treatment(UMT)in a Hazelett continuous casting direct rolling production line.The microstructure and properties of the 1030B Al strip were investigated by scanning electron microscopy,electron backscatter diffraction,and tensile testing.Applying UMT reduced the average grain size of the as-cast sheet by more than 28.0%with respect to that of the normal samples without UMT.When UMT was applied,the rolled strip inherited the refined grains from the as-cast sheet with an average grain size smaller than 63.0μm.Meanwhile,the dislocation density was increased by the grain refinement,dynamic recovery,and recrystallization during rolling.Accordingly,the strain-hardening rates of the rolled samples after UMT were generally higher than those of the normal samples,and the strength of the rolled strip was also improved.Furthermore,the rolled strip exhibited better formability with higher strain-hardening exponents and Erichsen index values.
基金The authors are very grateful for support from United Funds between National Natural Science Foundation and Baowu Steel Group Corporation Limited from China(No.U1860101)Chongqing Fundamental Research and Cutting-Edge Technology Funds(No.cstc2017jcyjAX0019).
文摘The research of carbon content along the casting direction of 82B cord steel billets is of great significance for improvingthe quality of cord products from subsequent processing.However,the traditional segregation and billets quality evaluationmethods have certain limitations,such as sampling length and analysis area.which affect the accuracy of quality judgment.Thus.the statistics of extreme values(SEV)was introduced to predict the maximum value of carbon element contentalong the casting direction,which can quantitatively characterize the segregation degree.The size of the selected billet is150 mm×150 mm,and the sampling location is the centerline of the billet.The experiment was conducted by consideringthe effect of cooling intensity and casting speed on the maximum value of carbon element content.Firstly,the calculationresults show that the SEN method can predict the maximum value of carbon element content along the casting directionof 82B cord steel,and the SEV method is proved to be effective by analyzing the carbon distribution and fluctuation in billets.To some extent,the SEV method can break the limitations of the sampling length and analysis area by predicting themaximum value of carbon element on a larger range of continuous casting billets with few samples.During the continuouscasting process the increase in cooling intensity makes the surface shrinking rate increase,which can slow down the flowof solute-enriched liquid to the center,and the center segregation can be reduced.On the other hand,the function area ofthe final electromagnetic stirring can be expanded with the increase in the casting speed,which can reduce the concentration of carbon element in the center of the billets and reduce the maximum value of carbon element content.Ilt can providea new theoretical reference for the quantitative calculation of carbon content in continuous casting billets and the qualityevaluation of continuous casting billcts.
基金financially supported by the Natural Science Foundation of Liaoning Province(Nos.2019-ZD-0002,2019KF-0503)the Fundamental Research Funds for the Central Universities(Nos.N2002025,N2109006)the National Natural Science Foundation of China(No.51674078)。
文摘Central region coarse grains and centerline segregation are common defects in aluminum ingots fabricated by direct chill(DC)casting.A double cooling field was introduced into the DC casting process to reduce these defects,whereby the external cooling was supplied by the mold and water jets,and intercooling was achieved by inserting a rod of the same alloy into the molten pool along the central axis of the ingot.Rather than forming a good metallurgical interface during solid-liquid compound casting,in the present work,the purpose of inserting the rod is to enforce internal cooling and consequently decrease the sump depth.Moreover,the insertion provides more nucleation sites with the unmoltenα-Al particles.The structure and the macrosegregation of 2024 Al alloy ingots prepared by DC casting with and without the inserts were investigated.Results show that when the inserting position is 50 mm above the upper edge of the graphite ring,significant grain refinement in the central region of the ingot and a reduced centerline segregation are achieved.
文摘The influences of the low frequency electromagnetic field on the horizontal direct chill casting process were investigated experimentally. Ingots of 2024 aluminum alloy with a cross size of 40 mm× 200 mm were produced by the conventional horizontal chill casting process and low frequency electromagnetic horizontal chill casting processre- spectively. The as-cast structures and the mechanical property of the ingots were examined. The results showed that the low frequency electromagnetic field could sub- stantially refine the microstructures and pronouncedly reduce the macrosegregation in the horizontal direct chill casting process. Moreover, the surface quality of the ingot was prominently improved by the low frequency electromagnetic field. The fracture strength and elongation percentage of the ingot was increased with the low frequency electromagnetic field.
文摘To predict hot tearing susceptibility(HTS)during solidification and improve the quality of Al alloy castings,constitutive equations for AA6111 alloys were developed using a direct finite element(FE)method.A hot tearing model was established for direct chill(DC)casting of industrial AA6111 alloys via coupling FE model and hot tearing criterion.By applying this model to real manufacture processes,the effects of casting speed,bottom cooling,secondary cooling,and geometric variations on the HTS were revealed.The results show that the HTS of the billet increases as the speed and billet radius increase,while it reduces as the interfacial heat transfer coefficient at the bottom or secondary water-cooling rate increases.This model shows the capabilities of incorporating maximum pore fraction in simulating hot tearing initiation,which will have a significant impact on optimizing casting conditions and chemistry for minimizing HTS and thus controlling the casting quality.
基金financially supported by the Major State Basic Research Development Program of China(Grant No.2013CB632203)the Liaoning Provincial Natural Science Foundation of China(Grant No.201202072)+1 种基金the Program for Liaoning Excellent Talents in University(Grant No.LJQ2012023)the Fundamental Research Foundation of Central Universities(Grant Nos.N120509002 and N120309003)
文摘The low frequency electromagnetic field was applied during direct chill(DC) semi-continuous casting of the ZK60 magnesium alloy billets. Effects of low frequency electromagnetic field on surface quality, microstructure and hot-tearing tendency of Φ500 mm ZK60 magnesium alloy billets were investigated. The results showed that with the application of the low frequency electromagnetic field, the surface quality of the ZK60 magnesium alloy billets is markedly improved and the depth of cold fold is decreased. The microstructure of the billets is also significantly refined. Besides, the distribution of the grain size is relatively uniform from the billet surface towards its center, where the average grain size is 42 μm at surface and 50 μm at center. It also shows that the hot-tearing tendency of DC semi-continuous casting ZK60 magnesium alloy billets is significantly reduced under low frequency electromagnetic field.
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financially supported by the National Key Research and Development Program of China(Grant No.2017YFB0305504)。
文摘The effects of two types of magnetic fields,namely harmonic magnetic field(HMF)and pulse magnetic field(PMF)on magnetic flux density,Lorentz force,temperature field,and microstructure of high purity Cu were studied by numerical simulation and experiment during electromagnetic direct chill casting.The magnetic field is induced by a magnetic generation system including an electromagnetic control system and a cylindrical crystallizer of 300 mm in diameter equipped with excitation coils.A comprehensive mathematical model for high purity Cu electromagnetic casting was established in finite element method.The distributions of magnetic flux density and Lorentz force generated by the two magnetic fields were acquired by simulation and experimental measurement.The microstructure of billets produced by HMF and PMF casting was compared.Results show that the magnetic flux density and penetrability of PMF are significantly higher than those of HMF,due to its faster variation in transient current and higher peak value of magnetic flux density.In addition,PMF drives a stronger Lorentz force and deeper penetration depth than HMF does,because HMF creates higher eddy current and reverse electromagnetic field which weakens the original electromagnetic field.The microstructure of a billet by HMF is composed of columnar structure regions and central fine grain regions.By contrast,the billet by PMF has a uniform microstructure which is characterized by ultra-refined and uniform grains because PMF drives a strong dual convection,which increases the uniformity of the temperature field,enhances the impact of the liquid flow on the edge of the liquid pool and reduces the curvature radius of liquid pool.Eventually,PMF shows a good prospect for industrialization.
基金supported by the National Natural Science Foundation of China(No.52130408)the Natural Science Foundation of Hunan Province,China(No.2022JJ10081).
文摘The complex producing procedures and high energy-consuming limit the large-scale production and application of advanced high-strength steels(AHSSs).In this study,the direct strip casting(DSC)technology with unique sub-rapid solidification characteristics and cost advantages was applied to the production of low-alloy Si-Mn steel with the help of quenching&partitioning(Q&P)concept to address these issues.Compared this method with the conventional compact strip production(CSP)process,the initial microstructure formed under different solidification conditions and the influence of heat treatment processes on the final mechanical properties were in-vestigated.The results show that the initial structure of the DSC sample is a dual-phase structure composed of fine lath martensite and bainite,while the initial structure of the CSP sample consists of pearlite and ferrite.The volume fraction and carbon content of retained austenite(RA)in DSC samples are usually higher than those in CSP samples after the same Q&P treatment.DSC samples typically demonstrate better comprehensive mechanical properties than the CSP sample.The DSC sample partitioned at 300℃ for 300 s(DSC-Pt300)achieves the best comprehensive mechanical properties,with yield strength(YS)of 1282 MPa,ultimate tensile strength(UTS)of 1501 MPa,total elongation(TE)of 21.5%,and product of strength and elongation(PSE)as high as 32.3 GPa·%.These results indicate that the excellent mechanical properties in low-alloy Si-Mn steel can be obtained through a simple process(DSC-Q&P),which also demonstrates the superiority of DSC technology in manufacturing AHSSs.
文摘Direct strip casting(DSC)is one of the cutting-edge technologies for the steel industry in the twenty-first century.Under the background of carbon peak and carbon neutrality,DSC technology has a bright future of applications as it requires less production time and space with reduced energy consumption.Owing to its sub-rapid cooling rate during solidification and low reduction during hot rolling,DSC process exhibits a series of unique physical metallurgy characteristics.The process characteristics of DSC process and the microstructural evolution during the thermomechanical processing of low-carbon microalloyed steel are reviewed.The effects of hot rolling,cooling,coiling temperatures and microalloying elements on the microstructure and mechanical properties are then discussed.Finally,the future development orientations of DSC technology are suggested to fully utilize its unique features for the enhancement of its competitiveness and for the promotion of carbon neutrality of the steel industry.
基金supported by National Natural Science Foundation of China(Grant No.51775329 and 51605280)the Foundation of Shanghai youth teacher training scheme(Grant No.ZZSHOU16016)the Doctoral Scientific Re-search Foundation of Shanghai Ocean University(Grant No.A2-0203-17-100325).
文摘High-quality Mg-Nd-Zn-Zr magnesium alloy billets with diameter of 200 mm were successfully prepared by direct chill(DC)casting.The results show that microstructures of the as-cast billet prepared by DC casting are mainly composed of equiaxed a-Mg and Mg 12 Nd eutectic compound distributing along the grain boundaries.The average grain size decreases along the radius of the billet.And the alloying elements of Nd and Zn distribute homogeneously across the large billet.The optimum process parameters for DC casting of the Mg-Nd-Zn-Zr magnesium alloy billet with diameter of 200 mm have been experimentally determined as follows:casting temperature 710℃ and casting speed 80 mm/min.
基金supported by the Postdoctoral Foundation of Northeastern University and the National High Technology Research and Development Program of China(Grant No.2009BAE80B01)
文摘To obtain the billet with homogeneous and spheroidized primary grains is the key step in the semi- solid forming process. Among the semi-solid billet preparation methods, the process of low-superheat direct chill （DC） casting is simpler and more effective. In this study, the billets of AISi7Mg alloy were prepared by low- superheat DC casting at various withdrawal rates. The effect of withdrawal rate on the surface quality of the billets was investigated, and the evolution mechanism of the microstructural morphology in the billets was analyzed. The results show that the periodic corrugations and a large quantity of fine shrinkage pits appear in the billet surface when the withdrawal rate is 100 mm.min-1, and the above defects in the billet surface can be eliminated completely when the withdrawal rate is above 150 mm.min-1. But when the withdrawal rate is too fast （250 mm.min-1）, the primary a grains, except the ones in the billet center, have not enough time for ripening due to the high silidification rate, and will solidify as the dendrite structure. When the withdrawal rate is between 150 - 200 mm.min-1, the dendritic growth of the primary a grains is effectively inhibited, and a billet of AISi7Mg alloy with a smooth surface and homogeneous, fine, non-dendritic grains can be obtained.
基金This research was supported by the Major State Basic Research Project of China,Grant No.G1999064905the National Natural Science Foundation of China,No.59974009.
文摘The horizontal direct chill (HDC) casting process is a well-established production route for aluminum alloy ingot but the ingot may suffer from macrosegregation sometimes. In order to control the defect, a low frequency electromagnetic field has been applied in HDC casting process and the relevant influence has been studied. The results show that application of low frequency electromagnetic field can reduce macrosegregation in HDC casting process; and two main parameters of electromagnetic field density and frequency, have great influences on the solution distribution along the diameter of ingot. Moreover, the mechanisms of reduction of macrosegregation by electromagnetic field have been discussed.
基金Project supported by the Jiangxi Province Key Laboratory of Light Alloy(2024SSY05031)the National Natural Science Foundation of China(52061028)+1 种基金the National Key Research and Development Program of China(2021YFB3501001)the Major Research and Development Projects of Jiangxi Province(20223BBE51021,20213AAE02014)。
文摘During direct chilling(DC)casting of ZK61 alloys,the primary and secondary cooling causes strong thermal gradients,which leads to the uneven crystallization rate and thermal contraction in different positions of the ingot.The consequences manifested appearance of heterogeneous grains,huge casting stresses,and even hot cracking flaws.In this paper,chemical and physical methods were integrated to produce large-scale magnesium(Mg)alloy ingots.A φ525 mm ZK61-RE alloy ingot that was refined,homogeneous,and free from hot cracking was obtained via the DC process coupled with a differential low frequency pulsed magnetic field(DLPM).The effects of rare earth(RE)and DLPM on the hot cracking tendency were investigated,and the mechanism of hot cracking formation and modification in largescale ingots was revealed.The findings indicate that the addition of moderate amounts of RE lessens the tendency of hot cracking in large-scale ZK61 alloy ingots.This is mainly attributed to the addition of RE increases the content of the second phase,thus enhancing the ability of the eutectic liquid phase to feed the cracking.With the introduction of DLPM,the grain sizes are significantly refined and homogenized,and there is no obvious hot cracking observed in the ingot.This is because the coupling of the DLPM provides a more homogeneous temperature field,leading to the synchronization of the solidification process,and the consequent reduction of the casting stress,thus reducing the driving force for the formation of hot cracking.In addition,the casting conditions are modified to enhance the ability of solidification feeding and the resistance to hot cracking.This work provides theoretical and practical references for the preparation of large-scale high-quality Mg alloy ingots.
基金J.C.Niu and Z.Q.Fu acknowledge the financial support from the National Natural Science Foundation of China(No.52103360)from the Pearl River Talent Program(No.2021QN02C766)+1 种基金from the Basic and Applied Basic Research Foundation of Guangdong Province(No.2020A1515111104)W.P.Chen thanks the financial support from the Key-Area Research and Development Program of Guangdong Province(No.2018B090905002)。
文摘As-cast alloys often require complex thermomechanical processing to obtain a hierarchical structure to achieve a good combination of strength and ductility.Here in this work,a novel hierarchical Fe_(27)Ni_(35)Cr_(18.25)Al_(13.75)Co_(2)Ti_(2)Mo_(2) high-entropy alloy(HEA)with ultra-high tensile strength and excellent ductility was fabricated by direct casting.The as-cast alloy exhibits hierarchical structure with an ul-trafine lamellar microstructure(ULM),ultrafine rhombus microstructure(URM),ultrafine vermicular mi-crostructure(UVM),nanosized precipitates and spinodal decomposition(SP)that develops during casting and cooling.The incompatibility of face-centered cubic(FCC)and body-centered cubic(BCC)phases in the deformation process leads to heterogeneous deformation-induced(HDI)hardening,which brings the alloy a tensile yield strength(YS)of~1056 MPa,an ultimate tensile strength(UTS)of~1526 MPa and a total elongation(El)of~15.6%.Additionally,the numerous interfaces generated by the hierarchical structure absorb the energy during deformation,effectively retarding the dislocation motion and causing strong work-hardening.
基金This work belongs to the project No.T2021-97TD in 2021 funded by Ho Chi Minh City University of Technology and Education,Vietnam.
文摘Engineered cementitious composites(ECC),also known as bendable concrete,were developed based on engineering the interactions between fibers and cementitious matrix.The orientation of fibers,in this regard,is one of the major factors influencing the ductile behavior of this material.In this study,fiber orientation distributions in ECC beams influenced by different casting techniques are evaluated via numerical modeling of the casting process.Two casting directions and two casting positions of the funnel outlet with beam specimens are modeled using a particle-based smoothed particle hydrodynamics(SPH)method.In this SPH approach,fresh mortar and fiber are discretized by separated mortar and fiber particles,which smoothly interact in the computational domain of SPH.The movement of fiber particles is monitored during the casting simulation.Then,the fiber orientations at different sections of specimens are determined after the fresh ECC stops flowing in the formwork.The simulation results show a significant impact of the casting direction on fiber orientation distributions along the longitudinal wall of beams,which eventually influence the flexural strength of beams.In addition,casting positions show negligible influences on the orientation distribution of fibers in the short ECC beam,except under the pouring position.
基金supported by National Natural Science Foundation of China(No.52103149)State of Sericulture Industry Tech-nology System(No.CARS-18-ZJ0501)+2 种基金Zhejiang Provincial Science and Technology Plans(No.2021C02072-6)China Postdoctoral Science Foundation(No.2023M743064)Zhejiang University Start-up Fund.
文摘Building high-performance aerogels with biomass-derived rather than fossil-derived polymers is an eco-friendlier option given the increasingly serious sustainability issues.Chitosan(CS)aero-gels with oriented pore structures exhibit broad application prospects owing to light weight,high porosity,and favorable bioactivity,but the dominating drawback in low mechanical strength greatly hinders their functional advantages.In this study,two types of silk microfibers with simi-lar diameter yet different aspect ratios(1-3(denoting as SmSF)and 50-100(denoting as LmSF))were used as fillers to reinforce CS aerogels prepared by directional freeze casting.The distinc-tion of SmSF and LmSF in size led to their notable variations in distribution pattern,as SmSF embedded within the individual CS lamellae while LmSF traversed throughout the adjacent CS lamellae,which in consequence significantly influence their mechanical reinforcing efficiency.The compressive strength values could be improved from 61.67 kPa(pure CS aerogel)to 82.13 kPa(SmSF/CS aerogel)and 165.03 kPa(LmSF/CS aerogel),respectively,attributing to the tran-sition in deformation mechanisms from a bending-to crumpling-dominated mode.In addition,the embedding or bridging structure could also change the liquid transportation property of CS aerogels.The results of this study demonstrated the feasibility of applying filler-size-mediated strategy for material structural optimization.
