Counter-gravity casting(CGC)is a widely adopted material processing technique in metals due to its notable benefits,including enhanced filling behavior,reduced defect occurrence,and elevated mechani-cal properties.It ...Counter-gravity casting(CGC)is a widely adopted material processing technique in metals due to its notable benefits,including enhanced filling behavior,reduced defect occurrence,and elevated mechani-cal properties.It plays a pivotal role in fabricating intricate,high-quality components.After its inception in the early 1900s,various CGC processes have emerged,such as low-pressure,counter-pressure,vac-uum suction,and adjusted pressure casting,which are explored in this discourse with an eye toward further advancements.Despite CGC’s superiority over traditional gravity casting and other manufacturing methodologies,specific issues and constraints persist within CGC.This paper endeavors to provide a com-prehensive overview of the historical progression of CGC,its recent developments,and the associated re-search aspects,encompassing topics like filling processes,solidification,microstructural transformations,and the resultant mechanical properties of the fabricated products.Additionally,this paper offers insights into the future challenges and opportunities of CGC.展开更多
Microstructure inhomogeneity and negative segregation have long been challenges for large-size alloy ingots,directly affecting the downstream processing and final performance of products.Here,we used2024 aluminum allo...Microstructure inhomogeneity and negative segregation have long been challenges for large-size alloy ingots,directly affecting the downstream processing and final performance of products.Here,we used2024 aluminum alloy as a model alloy to propose a technique,named double-cooling field casting,i.e.,one 2024 Al alloy rod(Φ20 mm)at room temperature was introduced into the melt along the central axis of the hot-top with the protection of a thermal-insulation tube during the direct chill(DC)casting process of aΦ300 mm 2024 Al alloy ingot.The results show that the introduction of the same alloy solid insert has a remarkable influence on refining grains in the center region of the ingot,reducing negative centerline segregation and decreasing the depth of the center part of the sump.With the application of the 2024 Al insert,the mean size of equiaxed grains at the center part of the ingot decreased from1204±132μm to 721±69μm.The relative deviation of the Cu and Mg main solutes reduced from-0.062 and-0.054 to-0.03 and-0.024,respectively,and the sump depth decreased from 280 mm to242 mm.Moreover,the shape of the solidification front was changed from‘V’-shaped to‘W’-shaped.The ingot quality was thus improved,mainly arising from the dissolution of the cold 2024 Al insert at a proper position of the hot-top counteracting some latent heat of solidification of the ingot,dissipating the heat of the central part of the hot-top by conducting the 2024 Al insert to the outside,and providing extra-nuclei from the unmoltenα-Al particles of the insert.展开更多
AZ31 alloy billets of 200 mm in diameter were produced by three different processes of conventional direct chill （DC） casting, low-frequency electromagnetic casting （LFEC） and low-frequency electromagnetic vibrati...AZ31 alloy billets of 200 mm in diameter were produced by three different processes of conventional direct chill （DC） casting, low-frequency electromagnetic casting （LFEC） and low-frequency electromagnetic vibration casting （LFEVC）, respectively. The effect of LFEC and LFEVC on the microstructures, macmsegregation and mechanical properties of AZ31 alloy billets was investigated. In conventional DC casting, the AZ31 alloy billets exhibited coarse grains （about 370 μa） and severe segregation of A1 and Zn. In the presence of a solo low-frequency alternating magnetic field or a low-frequency electromagnetic vibration field applied during DC casting of Ф200 mm AZ31 billets, grains in the AZ31 alloy billets were effectively reffmed （about 210 μa） and the macrosegregation of A1 and Zn in the billets was greatly decreased. Furthermore, the tensile strength, fracture elongation and hardness of the as-cast AZ31 alloy billets were improved by the processes of LFEC and LFEVC relative to that cast by the process of conventional DC casting.展开更多
In this work,the influences of surface layer slurry at different temperatures(10℃,14℃,18℃,22℃)on wax patterns deformation,shrinkage,slurry coating characteristics,and the surface quality of the casting were invest...In this work,the influences of surface layer slurry at different temperatures(10℃,14℃,18℃,22℃)on wax patterns deformation,shrinkage,slurry coating characteristics,and the surface quality of the casting were investigated by using a single factor variable method.The surface morphologies of the shell molds produced by different temperatures of the surface(first)layer slurries were observed via electron microscopy.Furthermore,the microscopic composition of these shell molds was obtained by EDS,and the osmotic effect of the slurry on the wax patterns at different temperatures was also assessed by the PZ-200 Contact Angle detector.The forming reasons for the surface cracks and holes of thick and large ZTC4 titanium alloy by investment casting were analyzed.The experimental results show that the surface of the shell molds prepared by the surface layer slurry with a low temperature exhibits noticeable damage,which is mainly due to the poor coating performance and the serious expansion and contraction of wax pattern at low temperatures.The second layer shell material(SiO_(2),Al_(2)O_(3))immerses into the crack area of the surface layer,contacts and reacts with the molten titanium to form surface cracks and holes in the castings.With the increase of the temperature of surface layer slurry,the damage to the shell surface tends to weaken,and the composition of the shell molds'surface becomes more uniform with less impurities.The results show that the surface layer slurry at 22℃is evenly coated on the surface of the wax patterns with appropriate thickness,and there is no surface shell mold rupture caused by sliding slurry after sand leaching.The surface layer slurry temperature is consistent with the wax pattern temperature and the workshop temperature,so there is no damage of the surface layer shell caused by expansion and contraction.Therefore,the shell mold prepared by the surface layer slurry at this temperature has good integrity,isolating the contact between the low inert shell material and the titanium liquid effectively,and the ZTC4 titanium alloy cylinder casting prepared by this shell mold is smooth,without cracks and holes.展开更多
Purpose–The precast concrete slab track(PST)has advantages of fewer maintenance frequencies,better smooth rides and structural stability,which has been widely applied in urban rail transit.Precise positioning of prec...Purpose–The precast concrete slab track(PST)has advantages of fewer maintenance frequencies,better smooth rides and structural stability,which has been widely applied in urban rail transit.Precise positioning of precast concrete slab(PCS)is vital for keeping the initial track regularity.However,the cast-in-place process of the self-compacting concrete(SCC)filling layer generally causes a large deformation of PCS due to the water-hammer effect of flowing SCC,even cracking of PCS.Currently,the buoyancy characteristic and influencing factors of PCS during the SCC casting process have not been thoroughly studied in urban rail transit.Design/methodology/approach–In this work,a Computational Fluid Dynamics(CFD)model is established to calculate the buoyancy of PCS caused by the flowing SCC.The main influencing factors,including the inlet speed and flowability of SCC,have been analyzed and discussed.A new structural optimization scheme has been proposed for PST to reduce the buoyancy caused by the flowing SCC.Findings–The simulation and field test results showed that the buoyancy and deformation of PCS decreased obviously after adopting the new scheme.Originality/value–The findings of this study can provide guidance for the control of the deformation of PCS during the SCC construction process.展开更多
The impact of casting defects on the weldability of K4951 superalloy was investigated using tungsten inert gas(TIG)welding.The as-cast K4951 superalloy samples with prefabricated U-shaped grooves of varying depths and...The impact of casting defects on the weldability of K4951 superalloy was investigated using tungsten inert gas(TIG)welding.The as-cast K4951 superalloy samples with prefabricated U-shaped grooves of varying depths and widths were TIG welded,and the microstructures,cracks morphology,and precipitated phases were analyzed using optical microscope,scanning electron microscope,transmission electron microscope,and energy dispersive X-ray spectrometer.The results reveal that the dimensions of casting defects significantly affect the weldability of K4951.Deep defects(greater than 2 mm)lead to rapid crack propagation,while wider defects can moderate the propagation process of cracks.Elemental segregation and the formation of precipitated phases,such as MC carbides,are observed in the fusion zone,contributing to welding cracks.An optimal groove aspect ratio(depth-to-width)between 0.2 and 0.5 minimizes crack formation tendency and enhances tensile strength,resulting in a mixed brittle-ductile fracture mode of joint after high-temperature tensile testing.展开更多
The application of liquid core reduction(LCR)technology in thin slab continuous casting can refine the internal microstruc-tures of slabs and improve their production efficiency.To avoid crack risks caused by large de...The application of liquid core reduction(LCR)technology in thin slab continuous casting can refine the internal microstruc-tures of slabs and improve their production efficiency.To avoid crack risks caused by large deformation during the LCR process and to minimize the thickness of the slab in bending segments,the maximum theoretical reduction amount and the corresponding reduction scheme for the LCR process must be determined.With SPA-H weathering steel as a specific research steel grade,the distributions of tem-perature and deformation fields of a slab with the LCR process were analyzed using a three-dimensional thermal-mechanical finite ele-ment model.High-temperature tensile tests were designed to determine the critical strain of corner crack propagation and intermediate crack initiation with various strain rates and temperatures,and a prediction model of the critical strain for two typical cracks,combining the effects of strain rate and temperature,was proposed by incorporating the Zener-Hollomon parameter.The crack risks with different LCR schemes were calculated using the crack risk prediction model,and the maximum theoretical reduction amount for the SPA-H slab with a transverse section of 145 mm×1600 mm was 41.8 mm,with corresponding reduction amounts for Segment 0 to Segment 4 of 15.8,7.3,6.5,6.4,and 5.8 mm,respectively.展开更多
A suction casting experiment was conducted on Zr_(55)Cu_(30)Al_(10)Ni_(5)(at%)amorphous alloy.Using ProCAST software,numerical simulations were performed to analyze the filling and solidification processes.The velocit...A suction casting experiment was conducted on Zr_(55)Cu_(30)Al_(10)Ni_(5)(at%)amorphous alloy.Using ProCAST software,numerical simulations were performed to analyze the filling and solidification processes.The velocity field during the filling process and the temperature field during the solidification process of the alloy melt under different process parameters were obtained.Based on the simulation results,a Zr-based amorphous alloy micro-gear was prepared via casting.The results indicate that increasing the suction casting temperature enhances the fluidity of alloy melt but induces unstable flow rate during filling,which is detrimental to complete filling.Zr-based amorphous micro-gears with a module of 0.6 mm,a tooth top diameter of 8 mm,and 10 teeth were prepared through the suction casting.X-ray diffraction and differential scanning calorimetry analyses confirm that the fabricated micro-gear exhibits characteristic amorphous structural features,demonstrating well-defined geometrical contours and satisfactory forming completeness.展开更多
This study investigates the formation feasibility of the integrated bottom car body components with dual die casting injection molding technology.During the production of a die-cast super-large one-piece body part wei...This study investigates the formation feasibility of the integrated bottom car body components with dual die casting injection molding technology.During the production of a die-cast super-large one-piece body part weighing over 10,000 t,a thorough comparison and investigation were conducted on the arising issues,using both single and double injection systems.Particular attention was given to meticulously discussing the die casting filling problems and microstructural defects that originated from the filling process.The research findings indicate that the implementation of a double injection system can significantly minimize cold shuts and reduce the solidification time.The effectiveness of this die casting technique was further confirmed by the production of high-quality castings using a scaled model that replicated real casting conditions at a 1:3 ratio,thereby maintaining a one-to-one correspondence in essential aspects.This successful study offers both theoretical insights and practical applications for the production of integrated bottom car bodies utilizing die casting in conjunction with a dual injection system.展开更多
Deep learning has achieved great progress in image recognition,segmentation,semantic recognition and game theory.In this study,a latest deep learning model,a conditional diffusion model was adopted as a surrogate mode...Deep learning has achieved great progress in image recognition,segmentation,semantic recognition and game theory.In this study,a latest deep learning model,a conditional diffusion model was adopted as a surrogate model to predict the heat transfer during the casting process instead of numerical simulation.The conditional diffusion model was established and trained with the geometry shapes,initial temperature fields and temperature fields at t_(i) as the condition and random noise sampled from standard normal distribution as the input.The output was the temperature field at t_(i+1).Therefore,the temperature field at t_(i+1)can be predicted as the temperature field at t_(i) is known,and the continuous temperature fields of all the time steps can be predicted based on the initial temperature field of an arbitrary 2D geometry.A training set with 3022D shapes and their simulated temperature fields at different time steps was established.The accuracy for the temperature field for a single time step reaches 97.7%,and that for continuous time steps reaches 69.1%with the main error actually existing in the sand mold.The effect of geometry shape and initial temperature field on the prediction accuracy was investigated,the former achieves better result than the latter because the former can identify casting,mold and chill by different colors in the input images.The diffusion model has proved the potential as a surrogate model for numerical simulation of the casting process.展开更多
This study presents the development of a Magnesium Alloy Seat Frame(MASF),supported by case studies from automotive original equipment manufacturers.The process covers integrated design,simulation,manufacturing,and te...This study presents the development of a Magnesium Alloy Seat Frame(MASF),supported by case studies from automotive original equipment manufacturers.The process covers integrated design,simulation,manufacturing,and testing,aiming to boost industry confidence in Mg alloy applications.A novel structural design is developed that integrates the headrest with the backrest,achieving a balance between lightweight performance and safety.Structural optimization is guided by stress–strain simulations under diverse conditions within a complete forward development process.Casting simulations are conducted to analyze process characteristics,resulting in a verified MASF yield rate exceeding 90%.The final 9.88 kg MASF represents a 24.6%(3.23 kg)weight reduction versus a steel seat.This research contributes to advancements in defect control technology for large die casting magnesium alloy parts and has broad implications for their application in automotive manufacturing.展开更多
Mg-Gd based alloys are an important class of high-performance Mg alloys.In this study,three Mg-Gd alloys with different gadolinium(Gd)contents:Mg-9.54Gd-0.40Zr(wt.%,G10 K),Mg-15.11Gd-0.35Zr(wt.%,G15 K)and Mg-19.67Gd-0...Mg-Gd based alloys are an important class of high-performance Mg alloys.In this study,three Mg-Gd alloys with different gadolinium(Gd)contents:Mg-9.54Gd-0.40Zr(wt.%,G10 K),Mg-15.11Gd-0.35Zr(wt.%,G15 K)and Mg-19.67Gd-0.33Zr(wt.%,G20 K)were prepared by semicontinuous casting and subsequent solution and aging heat treatments.The role of Gd content on microstructures and mechanical properties of the Mg-Gd-Zr alloy is studied.All three as-cast alloys exhibit eutectic phases of Mg_(5)Gd,with the amount increasing as the Gd content rises.Mg_(5)Gd disappears after the solution heat treatment(the G10 K alloy solution-treated at 480℃ for 4 h,the G15 K alloy at 500℃ for 12 h and the G20 K alloy at 520℃ for 24 h,respectively).Aging heat treatment at 200℃ for 64 h after solution introduces numerous prismatic β' precipitates,with a significant increase in their area number density corresponding to increased Gd content.Additionally,the morphology of the β' precipitates exhibits distinct variations:the G10 K alloy is characterized by an enhanced aspect ratio.Consequently,the peak-aged G10 K alloy demonstrates superior strength-ductility synergy,with a yield strength(YS)of 216±1 MPa,an ultimate tensile strength(UTS)of 363±1 MPa,and an elongation(EL)of 8.7±0.6%.This study suggests that plasticity diminishes and precipitation strengthening is limited when the gadolinium content exceeds 15 wt.%.展开更多
A356/6061 bimetallic specimens were prepared by liquid-solid compound casting.The effects of various casting conditions on the interfacial microstructure and mechanical properties of the bimetallic specimens were stud...A356/6061 bimetallic specimens were prepared by liquid-solid compound casting.The effects of various casting conditions on the interfacial microstructure and mechanical properties of the bimetallic specimens were studied.Results demonstrate that a combination of chemical zinc deposition and electroplating can create a dense protective layer on the surface of the 6061 aluminum bar,achieving complete metallurgical bonding at the bimetallic interface.The interfacial microstructure is primarily characterized by equiaxed grain formation,with eutectic silicon distributed along the grain boundaries.Notably,the thickness of the zinc plating layer does not significantly influence the microstructure of the interface transition layer.Pouring temperature is critical for establishing metallurgical bonding at the bimetallic interface,with the thickness of the transition layer increasing as the pouring temperature rises.The hardness of the bimetallic composite interface falls between the hardness values of the two constituent materials.While the thickness of the galvanized layer has a minimal effect on interfacial shear strength,there is a slight decrease in shear strength with increasing pouring temperature,with a maximum value recorded at 68 MPa.展开更多
The billets of a new super-high strength Al-Zn-Mg-Cu alloy in 200mm diameter were produced by the processesof low frequency electromagnetic casting (LFEC) and conventional direct chill (DC) casting, respectively. The ...The billets of a new super-high strength Al-Zn-Mg-Cu alloy in 200mm diameter were produced by the processesof low frequency electromagnetic casting (LFEC) and conventional direct chill (DC) casting, respectively. The effects of lowfrequency electromagnetic field on temperature field of the melt in the hot-top were investigated by temperaturemeasurement method. Temperature curves were measured from the surface to the center of the billets by locating type Kthermocouples into the casting during the processes. The results show that during LFEC process the temperature field inthe melt applying the hot-top is very uniform, which is helpful to reduce the difference of thermal gradients between thesurface and the center, and then to reduce the thermal stress and to eliminate casting crack.展开更多
In the production of castings,intrusive gas pore represents a kind of common defects which can lead to leakage in high gas-tightness requirement castings,such as cylinder blocks and cylinder heads for engines.It occur...In the production of castings,intrusive gas pore represents a kind of common defects which can lead to leakage in high gas-tightness requirement castings,such as cylinder blocks and cylinder heads for engines.It occurs due to the intrusion of gases generated during the resin burning of the sand core into castings during the casting process.Therefore,a gas generation and flow constitution model was established,in which the gas generation rate is a function of temperature and time,and the flow of gas is controlled by the gas release,conservation,and Darcy's law.The heat transfer and gas flow during casting process was numerically simulated.The dangerous point of cores is firstly identified by a virtual heat transfer method based on the similarity between heat transfer and gas flow in the sand core.The gas pores in castings are predicted by the gas pressure,the viscosity and state of the melt for these dangerous points.Three distinct sand core structures were designed and used for the production of iron castings,and the simulated gas pore results were validated by the obtained castings.展开更多
Ductile iron represents an optimal solution for saving material and costs in producing large heavy-section castings in the energy sector.It aimed to investigate the influence of very long solidification time(3,10 and ...Ductile iron represents an optimal solution for saving material and costs in producing large heavy-section castings in the energy sector.It aimed to investigate the influence of very long solidification time(3,10 and 20 h)in different casting zones(casting center and transition zone)on the microstructure and mechanical properties of non-standard heavy-section ferritic ductile iron(EN-GJS-400-15)castings.The different solidification conditions significantly influenced the microstructure(graphite and ferrous matrix).The extent of phenomena such as degenerate graphite,solidification defects,hard carbides,and intergranular pearlitic areas and the microstructural coarsening were proportional to the solidification time and attributable to the combined effect of limited undercooling,solid solution diffusion mechanisms,and segregation phenomena.For comparable solidification time,the transition zone was characterized by larger nodules,comparable nodularity,and lower nodule count than the casting center due to more effective diffusion phenomena during cooling.Moreover,the lower segregation phenomena in the transition zone reduced the amount of pearlite and carbides in the intercellular zones.Hardness was only slightly influenced by the different solidification conditions and did not represent a reliable indicator of the microstructural inhomogeneities.These results are essential to refine casting simulations for producing large ferritic ductile iron castings,considering the wide microstructural variability within non-standard heavy-section castings caused by significantly different solidification conditions.展开更多
Al-based TiC particle-reinforced composites with varying TiC concentrations were fabricated through semi-continuous casting.The effects of TiC particles on the alloys’microstructure,grain boundary segregation,and mec...Al-based TiC particle-reinforced composites with varying TiC concentrations were fabricated through semi-continuous casting.The effects of TiC particles on the alloys’microstructure,grain boundary segregation,and mechanical properties were systematically analyzed.Moreover,the mechanisms by which TiC particles contribute to grain refinement,suppression of grain boundary segregation,and enhancement of hardness and wear resistance were discussed.The results demonstrate that TiC particles act as heterogeneous nucleation sites forα-Al within the Al-Cu-Mn alloys,leading to a refinement of grain size.As the TiC particle’s content increases,the grain size of the alloy drops at first and then elevates,transitioning from coarse dendritic crystals to fine equiaxed grains.At a TiC content of 1.3wt.%,the alloy exhibits the smallest grain size,reducing from 139±42μm without TiC to 90±38μm.Beyond this concentration,grain coarsening is observed.The incorporation of TiC particles effectively mitigates Cu segregation at grain boundaries,thereby enhancing the homogeneity of the Al-Cu-Mn matrix alloys.Additionally,the addition of TiC particles promotes hardness and wear resistance.Both hardness and wear resistance exhibit an initial increase followed by a decrease with increasing TiC content from 0 to 1.8wt.%.展开更多
Precipitation of carbides, nitrides, and carbonitrides is an important factor influencing the formation of surface transverse cracks in the continuous casting of microalloyed steel, affecting the quality and yield of ...Precipitation of carbides, nitrides, and carbonitrides is an important factor influencing the formation of surface transverse cracks in the continuous casting of microalloyed steel, affecting the quality and yield of the final product. Based on previous investigation, the precipitation sequence and temperature, position and mode, as well as the size, morphology, and number of different types of precipitates were reviewed. The effects of C, N, Nb, Ti, and V on the precipitation behavior and surface transverse cracks in continuous casting slabs were summarized, with a particular emphasis on the new achievements concerning Ti addition. The critical amounts of different elements to avoid serious surface cracks during continuous casting were proposed. The control mechanisms and industrial effects of composition optimization, cooling design, and chamfered mold configuration to improve surface transverse cracks in continuous casting slabs were also illustrated, and the recent application of surface microstructure control technology was emphasized. The characteristics, advantages, and shortcomings of existing theoretical and experimental methods in investigating continuous casting surface cracks regarding precipitation are finally discussed, and a new setup with advanced functions is introduced.展开更多
Accurate retrieval of casting 3D models is crucial for process reuse.Current methods primarily focus on shape similarity,neglecting process design features,which compromises reusability.In this study,a novel deep lear...Accurate retrieval of casting 3D models is crucial for process reuse.Current methods primarily focus on shape similarity,neglecting process design features,which compromises reusability.In this study,a novel deep learning retrieval method for process reuse was proposed,which integrates process design features into the retrieval of casting 3D models.This method leverages the comparative language-image pretraining(CLIP)model to extract shape features from the three views and sectional views of the casting model and combines them with process design features such as modulus,main wall thickness,symmetry,and length-to-height ratio to enhance process reusability.A database of 230 production casting models was established for model validation.Results indicate that incorporating process design features improves model accuracy by 6.09%,reaching 97.82%,and increases process similarity by 30.25%.The reusability of the process was further verified using the casting simulation software EasyCast.The results show that the process retrieved after integrating process design features produces the least shrinkage in the target model,demonstrating this method’s superior ability for process reuse.This approach does not require a large dataset for training and optimization,making it highly applicable to casting process design and related manufacturing processes.展开更多
A mathematical model coupling flow,solidification,strain-stress,and interface failure was developed.Following identification of crack source type through thermal tensile experiment and validation by strain-stress comp...A mathematical model coupling flow,solidification,strain-stress,and interface failure was developed.Following identification of crack source type through thermal tensile experiment and validation by strain-stress comparison,the model was used to investigate slab cracking tendency near precipitated phases,considering various locations,sizes and shapes of them.The results show that the jet from submerged entry nozzle creates a“double roll”flow pattern during continuous casting,resulting in more uniform temperature distributions at slab corner and wide surface center compared with narrow surface center.Consequently,precipitated phases,particularly those located on the narrow surface,readily induce stress concentration and thus increase cracking tendency.A smaller precipitated phase size can reduce the stress concentration zone,while a more spherical shape can distribute surrounding stress along its surface and lower the internal stress within it,thereby decreasing the risk of slab cracking during continuous casting.The optimal precipitated phase exhibits a spherical or ellipsoidal shape with a major axis of less than 5µm,minimizing its potential to initiate cracks.展开更多
基金supported by the National Sci-ence and Technology Major Project of China(No.J2019-VI-0004-0117)the National Natural Science Foundation of China(Nos.52071205 and 51821001)+2 种基金the Aeronautical Science Fund of China(No.2023Z053057003)the Science and Technology Commission of Shanghai Municipality,China(No.23ZR1428800)the Shanghai Industrial Collaborative Innovation Project(No.XTCX-KJ-2022-41).
文摘Counter-gravity casting(CGC)is a widely adopted material processing technique in metals due to its notable benefits,including enhanced filling behavior,reduced defect occurrence,and elevated mechani-cal properties.It plays a pivotal role in fabricating intricate,high-quality components.After its inception in the early 1900s,various CGC processes have emerged,such as low-pressure,counter-pressure,vac-uum suction,and adjusted pressure casting,which are explored in this discourse with an eye toward further advancements.Despite CGC’s superiority over traditional gravity casting and other manufacturing methodologies,specific issues and constraints persist within CGC.This paper endeavors to provide a com-prehensive overview of the historical progression of CGC,its recent developments,and the associated re-search aspects,encompassing topics like filling processes,solidification,microstructural transformations,and the resultant mechanical properties of the fabricated products.Additionally,this paper offers insights into the future challenges and opportunities of CGC.
基金financially supported by the Fundamental Research Funds for the Central Universities(Nos.N2002025,N2109006 and N2109007)the Project of Promoting Talents in Liaoning Province(No.XLYC1808038)。
文摘Microstructure inhomogeneity and negative segregation have long been challenges for large-size alloy ingots,directly affecting the downstream processing and final performance of products.Here,we used2024 aluminum alloy as a model alloy to propose a technique,named double-cooling field casting,i.e.,one 2024 Al alloy rod(Φ20 mm)at room temperature was introduced into the melt along the central axis of the hot-top with the protection of a thermal-insulation tube during the direct chill(DC)casting process of aΦ300 mm 2024 Al alloy ingot.The results show that the introduction of the same alloy solid insert has a remarkable influence on refining grains in the center region of the ingot,reducing negative centerline segregation and decreasing the depth of the center part of the sump.With the application of the 2024 Al insert,the mean size of equiaxed grains at the center part of the ingot decreased from1204±132μm to 721±69μm.The relative deviation of the Cu and Mg main solutes reduced from-0.062 and-0.054 to-0.03 and-0.024,respectively,and the sump depth decreased from 280 mm to242 mm.Moreover,the shape of the solidification front was changed from‘V’-shaped to‘W’-shaped.The ingot quality was thus improved,mainly arising from the dissolution of the cold 2024 Al insert at a proper position of the hot-top counteracting some latent heat of solidification of the ingot,dissipating the heat of the central part of the hot-top by conducting the 2024 Al insert to the outside,and providing extra-nuclei from the unmoltenα-Al particles of the insert.
基金supported by the Major State Basic Research Development Program of China (Nos. 2007CB613701 and 2007CB613702)the National Natural Science Foundation of China (Nos. 50904018, 51004032 and 50974037)+2 种基金the Program for New Century Excellent Talents in Chinese Universities (No. NCET-08-0098)the Fundamental Research Funds for the Central Universities of China (Nos. N090409002 and N090209002)the China Postdoctoral Science Foundation (No. 20100471468)
文摘AZ31 alloy billets of 200 mm in diameter were produced by three different processes of conventional direct chill （DC） casting, low-frequency electromagnetic casting （LFEC） and low-frequency electromagnetic vibration casting （LFEVC）, respectively. The effect of LFEC and LFEVC on the microstructures, macmsegregation and mechanical properties of AZ31 alloy billets was investigated. In conventional DC casting, the AZ31 alloy billets exhibited coarse grains （about 370 μa） and severe segregation of A1 and Zn. In the presence of a solo low-frequency alternating magnetic field or a low-frequency electromagnetic vibration field applied during DC casting of Ф200 mm AZ31 billets, grains in the AZ31 alloy billets were effectively reffmed （about 210 μa） and the macrosegregation of A1 and Zn in the billets was greatly decreased. Furthermore, the tensile strength, fracture elongation and hardness of the as-cast AZ31 alloy billets were improved by the processes of LFEC and LFEVC relative to that cast by the process of conventional DC casting.
文摘In this work,the influences of surface layer slurry at different temperatures(10℃,14℃,18℃,22℃)on wax patterns deformation,shrinkage,slurry coating characteristics,and the surface quality of the casting were investigated by using a single factor variable method.The surface morphologies of the shell molds produced by different temperatures of the surface(first)layer slurries were observed via electron microscopy.Furthermore,the microscopic composition of these shell molds was obtained by EDS,and the osmotic effect of the slurry on the wax patterns at different temperatures was also assessed by the PZ-200 Contact Angle detector.The forming reasons for the surface cracks and holes of thick and large ZTC4 titanium alloy by investment casting were analyzed.The experimental results show that the surface of the shell molds prepared by the surface layer slurry with a low temperature exhibits noticeable damage,which is mainly due to the poor coating performance and the serious expansion and contraction of wax pattern at low temperatures.The second layer shell material(SiO_(2),Al_(2)O_(3))immerses into the crack area of the surface layer,contacts and reacts with the molten titanium to form surface cracks and holes in the castings.With the increase of the temperature of surface layer slurry,the damage to the shell surface tends to weaken,and the composition of the shell molds'surface becomes more uniform with less impurities.The results show that the surface layer slurry at 22℃is evenly coated on the surface of the wax patterns with appropriate thickness,and there is no surface shell mold rupture caused by sliding slurry after sand leaching.The surface layer slurry temperature is consistent with the wax pattern temperature and the workshop temperature,so there is no damage of the surface layer shell caused by expansion and contraction.Therefore,the shell mold prepared by the surface layer slurry at this temperature has good integrity,isolating the contact between the low inert shell material and the titanium liquid effectively,and the ZTC4 titanium alloy cylinder casting prepared by this shell mold is smooth,without cracks and holes.
文摘Purpose–The precast concrete slab track(PST)has advantages of fewer maintenance frequencies,better smooth rides and structural stability,which has been widely applied in urban rail transit.Precise positioning of precast concrete slab(PCS)is vital for keeping the initial track regularity.However,the cast-in-place process of the self-compacting concrete(SCC)filling layer generally causes a large deformation of PCS due to the water-hammer effect of flowing SCC,even cracking of PCS.Currently,the buoyancy characteristic and influencing factors of PCS during the SCC casting process have not been thoroughly studied in urban rail transit.Design/methodology/approach–In this work,a Computational Fluid Dynamics(CFD)model is established to calculate the buoyancy of PCS caused by the flowing SCC.The main influencing factors,including the inlet speed and flowability of SCC,have been analyzed and discussed.A new structural optimization scheme has been proposed for PST to reduce the buoyancy caused by the flowing SCC.Findings–The simulation and field test results showed that the buoyancy and deformation of PCS decreased obviously after adopting the new scheme.Originality/value–The findings of this study can provide guidance for the control of the deformation of PCS during the SCC construction process.
基金National Natural Science Foundation of China(52201054,52175368)National Science and Technology Major Projects(J2019-VI-0018-0133)+2 种基金Liaoning Provincial Science and Technology Program(2023-BS-019,2023-MS-020)National Key R&D Program of China(2021YFB3700401)Key Specialized Research and Development Break-Through-Unveiling and Commanding the Special Project Program in Liaoning Province(2021JH15)。
文摘The impact of casting defects on the weldability of K4951 superalloy was investigated using tungsten inert gas(TIG)welding.The as-cast K4951 superalloy samples with prefabricated U-shaped grooves of varying depths and widths were TIG welded,and the microstructures,cracks morphology,and precipitated phases were analyzed using optical microscope,scanning electron microscope,transmission electron microscope,and energy dispersive X-ray spectrometer.The results reveal that the dimensions of casting defects significantly affect the weldability of K4951.Deep defects(greater than 2 mm)lead to rapid crack propagation,while wider defects can moderate the propagation process of cracks.Elemental segregation and the formation of precipitated phases,such as MC carbides,are observed in the fusion zone,contributing to welding cracks.An optimal groove aspect ratio(depth-to-width)between 0.2 and 0.5 minimizes crack formation tendency and enhances tensile strength,resulting in a mixed brittle-ductile fracture mode of joint after high-temperature tensile testing.
基金supported by the National Natural Science Foundation of China(No.52474355)the Liaoning Province Science and Technology Plan Joint Program(Key Research and Development Program Project),China(Nos.2022JH25/10200003 and 2023JH2/101800058).
文摘The application of liquid core reduction(LCR)technology in thin slab continuous casting can refine the internal microstruc-tures of slabs and improve their production efficiency.To avoid crack risks caused by large deformation during the LCR process and to minimize the thickness of the slab in bending segments,the maximum theoretical reduction amount and the corresponding reduction scheme for the LCR process must be determined.With SPA-H weathering steel as a specific research steel grade,the distributions of tem-perature and deformation fields of a slab with the LCR process were analyzed using a three-dimensional thermal-mechanical finite ele-ment model.High-temperature tensile tests were designed to determine the critical strain of corner crack propagation and intermediate crack initiation with various strain rates and temperatures,and a prediction model of the critical strain for two typical cracks,combining the effects of strain rate and temperature,was proposed by incorporating the Zener-Hollomon parameter.The crack risks with different LCR schemes were calculated using the crack risk prediction model,and the maximum theoretical reduction amount for the SPA-H slab with a transverse section of 145 mm×1600 mm was 41.8 mm,with corresponding reduction amounts for Segment 0 to Segment 4 of 15.8,7.3,6.5,6.4,and 5.8 mm,respectively.
基金National Natural Science Foundation of China(51971103)Key Research and Development Program in Gansu Province(20YF8GA052)。
文摘A suction casting experiment was conducted on Zr_(55)Cu_(30)Al_(10)Ni_(5)(at%)amorphous alloy.Using ProCAST software,numerical simulations were performed to analyze the filling and solidification processes.The velocity field during the filling process and the temperature field during the solidification process of the alloy melt under different process parameters were obtained.Based on the simulation results,a Zr-based amorphous alloy micro-gear was prepared via casting.The results indicate that increasing the suction casting temperature enhances the fluidity of alloy melt but induces unstable flow rate during filling,which is detrimental to complete filling.Zr-based amorphous micro-gears with a module of 0.6 mm,a tooth top diameter of 8 mm,and 10 teeth were prepared through the suction casting.X-ray diffraction and differential scanning calorimetry analyses confirm that the fabricated micro-gear exhibits characteristic amorphous structural features,demonstrating well-defined geometrical contours and satisfactory forming completeness.
基金supported by the National Natural Science Foundation of China(No.52175284)the National Key Research and Development Program of China(Grant No.2022YFB3404201).
文摘This study investigates the formation feasibility of the integrated bottom car body components with dual die casting injection molding technology.During the production of a die-cast super-large one-piece body part weighing over 10,000 t,a thorough comparison and investigation were conducted on the arising issues,using both single and double injection systems.Particular attention was given to meticulously discussing the die casting filling problems and microstructural defects that originated from the filling process.The research findings indicate that the implementation of a double injection system can significantly minimize cold shuts and reduce the solidification time.The effectiveness of this die casting technique was further confirmed by the production of high-quality castings using a scaled model that replicated real casting conditions at a 1:3 ratio,thereby maintaining a one-to-one correspondence in essential aspects.This successful study offers both theoretical insights and practical applications for the production of integrated bottom car bodies utilizing die casting in conjunction with a dual injection system.
基金sponsored by Tsinghua-Toyota Joint Research Fund
文摘Deep learning has achieved great progress in image recognition,segmentation,semantic recognition and game theory.In this study,a latest deep learning model,a conditional diffusion model was adopted as a surrogate model to predict the heat transfer during the casting process instead of numerical simulation.The conditional diffusion model was established and trained with the geometry shapes,initial temperature fields and temperature fields at t_(i) as the condition and random noise sampled from standard normal distribution as the input.The output was the temperature field at t_(i+1).Therefore,the temperature field at t_(i+1)can be predicted as the temperature field at t_(i) is known,and the continuous temperature fields of all the time steps can be predicted based on the initial temperature field of an arbitrary 2D geometry.A training set with 3022D shapes and their simulated temperature fields at different time steps was established.The accuracy for the temperature field for a single time step reaches 97.7%,and that for continuous time steps reaches 69.1%with the main error actually existing in the sand mold.The effect of geometry shape and initial temperature field on the prediction accuracy was investigated,the former achieves better result than the latter because the former can identify casting,mold and chill by different colors in the input images.The diffusion model has proved the potential as a surrogate model for numerical simulation of the casting process.
基金supported in part by the project is supported partly by National Key Research and Development Program of China(no.2022YFB2503504)Chongqing Technology Innovation and Application Development Project(no.CSTB2022TIAD-DEX0011)China Scholarship Council.
文摘This study presents the development of a Magnesium Alloy Seat Frame(MASF),supported by case studies from automotive original equipment manufacturers.The process covers integrated design,simulation,manufacturing,and testing,aiming to boost industry confidence in Mg alloy applications.A novel structural design is developed that integrates the headrest with the backrest,achieving a balance between lightweight performance and safety.Structural optimization is guided by stress–strain simulations under diverse conditions within a complete forward development process.Casting simulations are conducted to analyze process characteristics,resulting in a verified MASF yield rate exceeding 90%.The final 9.88 kg MASF represents a 24.6%(3.23 kg)weight reduction versus a steel seat.This research contributes to advancements in defect control technology for large die casting magnesium alloy parts and has broad implications for their application in automotive manufacturing.
基金supported by the National Key Research and Development Program of China (No.2021YFB3701000)the National Natural Science Foundation of China (Nos. 52401158, U21A2047, 52201129, 51821001,U2037601)+1 种基金the China Postdoctoral Science Foundation (No.2023M742219)the Postdoctoral Fellowship Program(Grade B) of CPSF (No. GZB20240419)
文摘Mg-Gd based alloys are an important class of high-performance Mg alloys.In this study,three Mg-Gd alloys with different gadolinium(Gd)contents:Mg-9.54Gd-0.40Zr(wt.%,G10 K),Mg-15.11Gd-0.35Zr(wt.%,G15 K)and Mg-19.67Gd-0.33Zr(wt.%,G20 K)were prepared by semicontinuous casting and subsequent solution and aging heat treatments.The role of Gd content on microstructures and mechanical properties of the Mg-Gd-Zr alloy is studied.All three as-cast alloys exhibit eutectic phases of Mg_(5)Gd,with the amount increasing as the Gd content rises.Mg_(5)Gd disappears after the solution heat treatment(the G10 K alloy solution-treated at 480℃ for 4 h,the G15 K alloy at 500℃ for 12 h and the G20 K alloy at 520℃ for 24 h,respectively).Aging heat treatment at 200℃ for 64 h after solution introduces numerous prismatic β' precipitates,with a significant increase in their area number density corresponding to increased Gd content.Additionally,the morphology of the β' precipitates exhibits distinct variations:the G10 K alloy is characterized by an enhanced aspect ratio.Consequently,the peak-aged G10 K alloy demonstrates superior strength-ductility synergy,with a yield strength(YS)of 216±1 MPa,an ultimate tensile strength(UTS)of 363±1 MPa,and an elongation(EL)of 8.7±0.6%.This study suggests that plasticity diminishes and precipitation strengthening is limited when the gadolinium content exceeds 15 wt.%.
基金financially supported by the National Natural Science Foundation of China(Grant No.52275370)the Key R&D Program of Hubei Province,China(Grant No.2024BAB072)the Research Fund of the State Key Laboratory of Intelligent Agricultural Power Equipment(Grant No.SKLIAPE2023014).
文摘A356/6061 bimetallic specimens were prepared by liquid-solid compound casting.The effects of various casting conditions on the interfacial microstructure and mechanical properties of the bimetallic specimens were studied.Results demonstrate that a combination of chemical zinc deposition and electroplating can create a dense protective layer on the surface of the 6061 aluminum bar,achieving complete metallurgical bonding at the bimetallic interface.The interfacial microstructure is primarily characterized by equiaxed grain formation,with eutectic silicon distributed along the grain boundaries.Notably,the thickness of the zinc plating layer does not significantly influence the microstructure of the interface transition layer.Pouring temperature is critical for establishing metallurgical bonding at the bimetallic interface,with the thickness of the transition layer increasing as the pouring temperature rises.The hardness of the bimetallic composite interface falls between the hardness values of the two constituent materials.While the thickness of the galvanized layer has a minimal effect on interfacial shear strength,there is a slight decrease in shear strength with increasing pouring temperature,with a maximum value recorded at 68 MPa.
文摘The billets of a new super-high strength Al-Zn-Mg-Cu alloy in 200mm diameter were produced by the processesof low frequency electromagnetic casting (LFEC) and conventional direct chill (DC) casting, respectively. The effects of lowfrequency electromagnetic field on temperature field of the melt in the hot-top were investigated by temperaturemeasurement method. Temperature curves were measured from the surface to the center of the billets by locating type Kthermocouples into the casting during the processes. The results show that during LFEC process the temperature field inthe melt applying the hot-top is very uniform, which is helpful to reduce the difference of thermal gradients between thesurface and the center, and then to reduce the thermal stress and to eliminate casting crack.
基金funded by the Beijing Nature Sciences Fund Haidian Originality Cooperation Project (Grant No. L212002)。
文摘In the production of castings,intrusive gas pore represents a kind of common defects which can lead to leakage in high gas-tightness requirement castings,such as cylinder blocks and cylinder heads for engines.It occurs due to the intrusion of gases generated during the resin burning of the sand core into castings during the casting process.Therefore,a gas generation and flow constitution model was established,in which the gas generation rate is a function of temperature and time,and the flow of gas is controlled by the gas release,conservation,and Darcy's law.The heat transfer and gas flow during casting process was numerically simulated.The dangerous point of cores is firstly identified by a virtual heat transfer method based on the similarity between heat transfer and gas flow in the sand core.The gas pores in castings are predicted by the gas pressure,the viscosity and state of the melt for these dangerous points.Three distinct sand core structures were designed and used for the production of iron castings,and the simulated gas pore results were validated by the obtained castings.
文摘Ductile iron represents an optimal solution for saving material and costs in producing large heavy-section castings in the energy sector.It aimed to investigate the influence of very long solidification time(3,10 and 20 h)in different casting zones(casting center and transition zone)on the microstructure and mechanical properties of non-standard heavy-section ferritic ductile iron(EN-GJS-400-15)castings.The different solidification conditions significantly influenced the microstructure(graphite and ferrous matrix).The extent of phenomena such as degenerate graphite,solidification defects,hard carbides,and intergranular pearlitic areas and the microstructural coarsening were proportional to the solidification time and attributable to the combined effect of limited undercooling,solid solution diffusion mechanisms,and segregation phenomena.For comparable solidification time,the transition zone was characterized by larger nodules,comparable nodularity,and lower nodule count than the casting center due to more effective diffusion phenomena during cooling.Moreover,the lower segregation phenomena in the transition zone reduced the amount of pearlite and carbides in the intercellular zones.Hardness was only slightly influenced by the different solidification conditions and did not represent a reliable indicator of the microstructural inhomogeneities.These results are essential to refine casting simulations for producing large ferritic ductile iron castings,considering the wide microstructural variability within non-standard heavy-section castings caused by significantly different solidification conditions.
基金supported by the Advanced Materials-National Science and Technology Major Project(Grant No.2025ZD0611400).
文摘Al-based TiC particle-reinforced composites with varying TiC concentrations were fabricated through semi-continuous casting.The effects of TiC particles on the alloys’microstructure,grain boundary segregation,and mechanical properties were systematically analyzed.Moreover,the mechanisms by which TiC particles contribute to grain refinement,suppression of grain boundary segregation,and enhancement of hardness and wear resistance were discussed.The results demonstrate that TiC particles act as heterogeneous nucleation sites forα-Al within the Al-Cu-Mn alloys,leading to a refinement of grain size.As the TiC particle’s content increases,the grain size of the alloy drops at first and then elevates,transitioning from coarse dendritic crystals to fine equiaxed grains.At a TiC content of 1.3wt.%,the alloy exhibits the smallest grain size,reducing from 139±42μm without TiC to 90±38μm.Beyond this concentration,grain coarsening is observed.The incorporation of TiC particles effectively mitigates Cu segregation at grain boundaries,thereby enhancing the homogeneity of the Al-Cu-Mn matrix alloys.Additionally,the addition of TiC particles promotes hardness and wear resistance.Both hardness and wear resistance exhibit an initial increase followed by a decrease with increasing TiC content from 0 to 1.8wt.%.
基金supported by the Fundamental Research Funds for the Central Universities(No.FRF-TP-19-017A3)National Natural Science Foundation of China(No.51874026).
文摘Precipitation of carbides, nitrides, and carbonitrides is an important factor influencing the formation of surface transverse cracks in the continuous casting of microalloyed steel, affecting the quality and yield of the final product. Based on previous investigation, the precipitation sequence and temperature, position and mode, as well as the size, morphology, and number of different types of precipitates were reviewed. The effects of C, N, Nb, Ti, and V on the precipitation behavior and surface transverse cracks in continuous casting slabs were summarized, with a particular emphasis on the new achievements concerning Ti addition. The critical amounts of different elements to avoid serious surface cracks during continuous casting were proposed. The control mechanisms and industrial effects of composition optimization, cooling design, and chamfered mold configuration to improve surface transverse cracks in continuous casting slabs were also illustrated, and the recent application of surface microstructure control technology was emphasized. The characteristics, advantages, and shortcomings of existing theoretical and experimental methods in investigating continuous casting surface cracks regarding precipitation are finally discussed, and a new setup with advanced functions is introduced.
基金supported by the National Natural Science Foundation of China(Nos.52074246,52275390,52375394)the National Defense Basic Scientific Research Program of China(No.JCKY2020408B002)the Key R&D Program of Shanxi Province(No.202102050201011).
文摘Accurate retrieval of casting 3D models is crucial for process reuse.Current methods primarily focus on shape similarity,neglecting process design features,which compromises reusability.In this study,a novel deep learning retrieval method for process reuse was proposed,which integrates process design features into the retrieval of casting 3D models.This method leverages the comparative language-image pretraining(CLIP)model to extract shape features from the three views and sectional views of the casting model and combines them with process design features such as modulus,main wall thickness,symmetry,and length-to-height ratio to enhance process reusability.A database of 230 production casting models was established for model validation.Results indicate that incorporating process design features improves model accuracy by 6.09%,reaching 97.82%,and increases process similarity by 30.25%.The reusability of the process was further verified using the casting simulation software EasyCast.The results show that the process retrieved after integrating process design features produces the least shrinkage in the target model,demonstrating this method’s superior ability for process reuse.This approach does not require a large dataset for training and optimization,making it highly applicable to casting process design and related manufacturing processes.
基金supported by National Natural Science Foundation of China(Nos.52325406 and 52374330)Fundamental Research Funds for the Central Universities(No.N2225046).
文摘A mathematical model coupling flow,solidification,strain-stress,and interface failure was developed.Following identification of crack source type through thermal tensile experiment and validation by strain-stress comparison,the model was used to investigate slab cracking tendency near precipitated phases,considering various locations,sizes and shapes of them.The results show that the jet from submerged entry nozzle creates a“double roll”flow pattern during continuous casting,resulting in more uniform temperature distributions at slab corner and wide surface center compared with narrow surface center.Consequently,precipitated phases,particularly those located on the narrow surface,readily induce stress concentration and thus increase cracking tendency.A smaller precipitated phase size can reduce the stress concentration zone,while a more spherical shape can distribute surrounding stress along its surface and lower the internal stress within it,thereby decreasing the risk of slab cracking during continuous casting.The optimal precipitated phase exhibits a spherical or ellipsoidal shape with a major axis of less than 5µm,minimizing its potential to initiate cracks.
