The electromagnetic-mechanical stirring technology was employed for preparing QTi4.3-4 graghite composite slurry,and QTi4.3-4 graghite composite with uniform distribution of graphite particles was prepared uring the ...The electromagnetic-mechanical stirring technology was employed for preparing QTi4.3-4 graghite composite slurry,and QTi4.3-4 graghite composite with uniform distribution of graphite particles was prepared uring the semi-solid casting technology successfully.The structure of this QTi4.3-4graphite composite was studied and the condition for uniform distribution of graphite particles was got.The experimental results show that there exists a linear relationship between the solid fraction and the stirring temperature of QTi4.3-4graphite slurry.With the decreasing of stirring temperature,the solid fraction of QTi4.3-4 graghite slurry increases constantly.In casting,with the increasing of solid fraction of QTi4.3-4 graphite slurry.the agglomeration of graphite particles is removed gradually.When the solid fraction is higher than 40%,graphite particles can distribute evenly in QTi4.3-4 graghite composite.展开更多
Semi-solid casting of M2 high speed steel ingots was investigated by inclined slope pre-crystallization method. Effects of casting temperature and slope length on the microstructure of M2 HSS ingots were investigated....Semi-solid casting of M2 high speed steel ingots was investigated by inclined slope pre-crystallization method. Effects of casting temperature and slope length on the microstructure of M2 HSS ingots were investigated. M2 cast ingots of non-dendritic primary austenite and fine eutectic ledeburite network carbide structure were obtained, with the casting temperature, slope length and angle of 1480 ℃, 500 mm and 60° respectively. Meanwhile, the microstructure of cast samples was quantitatively assessed by Image tool software. Results show that optimum mean equivalent diameter of primary austenite crystal grain is 50.8 μm, shape factor is 0.83, and mean thickness of network carbide is 5.21 μm.展开更多
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
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
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
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
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
In the foundry industries,process design has traditionally relied on manuals and complex theoretical calculations.With the advent of 3D design in casting,computer-aided design(CAD)has been applied to integrate the fea...In the foundry industries,process design has traditionally relied on manuals and complex theoretical calculations.With the advent of 3D design in casting,computer-aided design(CAD)has been applied to integrate the features of casting process,thereby expanding the scope of design options.These technologies use parametric model design techniques for rapid component creation and use databases to access standard process parameters and design specifications.However,3D models are currently still created through inputting or calling parameters,which requires numerous verifications through calculations to ensure the design rationality.This process may be significantly slowed down due to repetitive modifications and extended design time.As a result,there are increasingly urgent demands for a real-time verification mechanism to address this issue.Therefore,this study proposed a novel closed-loop model and software development method that integrated contextual design with real-time verification,dynamically verifying relevant rules for designing 3D casting components.Additionally,the study analyzed three typical closed-loop scenarios of agile design in an independent developed intelligent casting process system.It is believed that foundry industries can potentially benefit from favorably reduced design cycles to yield an enhanced competitive product market.展开更多
The crankshaft is subjected to complex rotational centrifugal force,periodic gas inertia force,and reciprocating inertia force during its working process.Consequently,the homogeneity requirement for crankshaft steel i...The crankshaft is subjected to complex rotational centrifugal force,periodic gas inertia force,and reciprocating inertia force during its working process.Consequently,the homogeneity requirement for crankshaft steel is exceptionally high.The distribution characteristics of center segregation and spot segregation of continuous casting bloom 42CrMoA crankshaft steel were analyzed by experiments,and the control mechanism of spot segregation by soft reduction zone and reduction amount was discussed.When the center solid fraction is between 0.61 and 1.00,an 8-mm soft reduction has a negligible impact on the flow of liquid steel at the end of solidification.Although it effectively improves center segregation,the improvement of spot segregation is limited.On the other hand,when the center solid fraction is between 0.31 and 1.00,a reduction of 10–12 mm,along with an expanded reduction zone and increased reduction amount,significantly promotes the flow of liquid steel at the end of solidification,reduces the size of equiaxed grains,mitigates the center negative segregation,and decreases the maximum size of spot segregation from 2954.29 to 1354.07μm.The number of spot segregations and the solutes enrichment degree of C,Cr,and Mn have also been significantly improved.An appropriate soft reduction zone and reduction amount can markedly ameliorate the semi-macro spot segregation of crankshaft steel blooms,thereby providing high-quality raw materials for subsequent products and enhancing the competitiveness of crankshaft products.展开更多
The low frequency electromagnetic casting(LFEC)was used to prevent hot cracking during the solidification process of GH4742 superalloy ingot.The effects of LFEC on the solidification macrostructure of the ingot were i...The low frequency electromagnetic casting(LFEC)was used to prevent hot cracking during the solidification process of GH4742 superalloy ingot.The effects of LFEC on the solidification macrostructure of the ingot were investigated through experiments and simulation.The results show that the average grain size decreases after application of LFEC.At the same time,the fraction of equiaxed grains increases compared with the ingots that without LFEC.In addition,the average grain size decreases and the fraction of equiaxed grains increases with increasing the current frequency.When the current frequency increases from 5 Hz to 20 Hz,the average grain size decreases from 5.39 mm to 4.74 mm,and the fraction of equiaxed grains increases from 41.21%to 55.24%.The distribution of Lorentz force,melt flow field and temperature field in the melt was simulated using COMSOL Multiphysics software.It is found that the Lorentz force increases and the forced convection is enhanced with increasing the current frequency,thus the melt flow velocity and heat transfer in the melt are promoted.It can facilitate the heterogenous nucleation in the melt,resulting in grain refinement,and further preventing hot cracking of large size ingots.展开更多
The Mg−1Zn−1Sn and Mg−1Zn−1Sn−0.2Ca alloy scaffolds were prepared via infiltration casting using 3D-printed Ti templates to achieve complete and accurate control of the pore structure.The results indicate that the act...The Mg−1Zn−1Sn and Mg−1Zn−1Sn−0.2Ca alloy scaffolds were prepared via infiltration casting using 3D-printed Ti templates to achieve complete and accurate control of the pore structure.The results indicate that the actual porosity and pore size of the prepared P model for each pore size are greater than the designed values.The addition of Ca changes the second phase of the alloy from Mg_(2)Sn to CaMgSn and refines its microstructure.The compressive yield strength and compressive modulus of the Mg−1Zn−1Sn−0.2Ca alloy scaffold reach 32.61 MPa and 0.23 GPa,respectively.The corrosion current density is measured at 14.64μA/cm^(2),with an instantaneous corrosion rate of 0.335 mm/a.Both scaffolds exhibit excellent biocompatibility and no cytotoxicity.Additionally,the antibacterial effects of both alloys on E.coli are greater than 97.81%.These results indicate that Mg alloy scaffolds have great potential for clinical applications.展开更多
文摘The electromagnetic-mechanical stirring technology was employed for preparing QTi4.3-4 graghite composite slurry,and QTi4.3-4 graghite composite with uniform distribution of graphite particles was prepared uring the semi-solid casting technology successfully.The structure of this QTi4.3-4graphite composite was studied and the condition for uniform distribution of graphite particles was got.The experimental results show that there exists a linear relationship between the solid fraction and the stirring temperature of QTi4.3-4graphite slurry.With the decreasing of stirring temperature,the solid fraction of QTi4.3-4 graghite slurry increases constantly.In casting,with the increasing of solid fraction of QTi4.3-4 graphite slurry.the agglomeration of graphite particles is removed gradually.When the solid fraction is higher than 40%,graphite particles can distribute evenly in QTi4.3-4 graghite composite.
基金Funded by the Science Foundation of Beijing Jiaotong University (No.230-12)
文摘Semi-solid casting of M2 high speed steel ingots was investigated by inclined slope pre-crystallization method. Effects of casting temperature and slope length on the microstructure of M2 HSS ingots were investigated. M2 cast ingots of non-dendritic primary austenite and fine eutectic ledeburite network carbide structure were obtained, with the casting temperature, slope length and angle of 1480 ℃, 500 mm and 60° respectively. Meanwhile, the microstructure of cast samples was quantitatively assessed by Image tool software. Results show that optimum mean equivalent diameter of primary austenite crystal grain is 50.8 μm, shape factor is 0.83, and mean thickness of network carbide is 5.21 μm.
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)+3 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)The authors are thankful to Prof.Diran Apelian(University of Cal-ifornia,Irvine),Prof.Enrique Lavernia(Texas A&M University),and Prof.Alan A.Luo(Ohio State University)for their constructive and helpful comments during manuscript preparation.
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.
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.
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.
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.
基金the financial support of the Natural Science Foundation of Hubei Province,China (Grant No.2022CFB770)。
文摘In the foundry industries,process design has traditionally relied on manuals and complex theoretical calculations.With the advent of 3D design in casting,computer-aided design(CAD)has been applied to integrate the features of casting process,thereby expanding the scope of design options.These technologies use parametric model design techniques for rapid component creation and use databases to access standard process parameters and design specifications.However,3D models are currently still created through inputting or calling parameters,which requires numerous verifications through calculations to ensure the design rationality.This process may be significantly slowed down due to repetitive modifications and extended design time.As a result,there are increasingly urgent demands for a real-time verification mechanism to address this issue.Therefore,this study proposed a novel closed-loop model and software development method that integrated contextual design with real-time verification,dynamically verifying relevant rules for designing 3D casting components.Additionally,the study analyzed three typical closed-loop scenarios of agile design in an independent developed intelligent casting process system.It is believed that foundry industries can potentially benefit from favorably reduced design cycles to yield an enhanced competitive product market.
基金funded by the National Natural Science Foundation of China(NSFC)(Grant No.U1860111)Weifang Science and Technology Development Plan Project(Project No.2023ZJ1166).
文摘The crankshaft is subjected to complex rotational centrifugal force,periodic gas inertia force,and reciprocating inertia force during its working process.Consequently,the homogeneity requirement for crankshaft steel is exceptionally high.The distribution characteristics of center segregation and spot segregation of continuous casting bloom 42CrMoA crankshaft steel were analyzed by experiments,and the control mechanism of spot segregation by soft reduction zone and reduction amount was discussed.When the center solid fraction is between 0.61 and 1.00,an 8-mm soft reduction has a negligible impact on the flow of liquid steel at the end of solidification.Although it effectively improves center segregation,the improvement of spot segregation is limited.On the other hand,when the center solid fraction is between 0.31 and 1.00,a reduction of 10–12 mm,along with an expanded reduction zone and increased reduction amount,significantly promotes the flow of liquid steel at the end of solidification,reduces the size of equiaxed grains,mitigates the center negative segregation,and decreases the maximum size of spot segregation from 2954.29 to 1354.07μm.The number of spot segregations and the solutes enrichment degree of C,Cr,and Mn have also been significantly improved.An appropriate soft reduction zone and reduction amount can markedly ameliorate the semi-macro spot segregation of crankshaft steel blooms,thereby providing high-quality raw materials for subsequent products and enhancing the competitiveness of crankshaft products.
基金financially supported by the Major Projects in Aviation Engines and Gas Turbines (Grant No.2019-VI-0020-0136)the National Key Research and Development Program of China (Grant Nos.2022YFB3705101&2022YFB3705102)+1 种基金the National Natural Science Foundation of China (Grant No.U1708253)the Fundamental Research Funds for the Central Universities,China (Grant No.N2302005)。
文摘The low frequency electromagnetic casting(LFEC)was used to prevent hot cracking during the solidification process of GH4742 superalloy ingot.The effects of LFEC on the solidification macrostructure of the ingot were investigated through experiments and simulation.The results show that the average grain size decreases after application of LFEC.At the same time,the fraction of equiaxed grains increases compared with the ingots that without LFEC.In addition,the average grain size decreases and the fraction of equiaxed grains increases with increasing the current frequency.When the current frequency increases from 5 Hz to 20 Hz,the average grain size decreases from 5.39 mm to 4.74 mm,and the fraction of equiaxed grains increases from 41.21%to 55.24%.The distribution of Lorentz force,melt flow field and temperature field in the melt was simulated using COMSOL Multiphysics software.It is found that the Lorentz force increases and the forced convection is enhanced with increasing the current frequency,thus the melt flow velocity and heat transfer in the melt are promoted.It can facilitate the heterogenous nucleation in the melt,resulting in grain refinement,and further preventing hot cracking of large size ingots.
基金the financial support for this work from the National Natural Science Foundation of China(Nos.52171241,52373251,52201301,51801137)Natural Science Foundation of Tianjin City,China(No.22JCQNJC00750)Tianjin University of Technology Graduate Research Innovation Project,China(No.YJ2235)。
文摘The Mg−1Zn−1Sn and Mg−1Zn−1Sn−0.2Ca alloy scaffolds were prepared via infiltration casting using 3D-printed Ti templates to achieve complete and accurate control of the pore structure.The results indicate that the actual porosity and pore size of the prepared P model for each pore size are greater than the designed values.The addition of Ca changes the second phase of the alloy from Mg_(2)Sn to CaMgSn and refines its microstructure.The compressive yield strength and compressive modulus of the Mg−1Zn−1Sn−0.2Ca alloy scaffold reach 32.61 MPa and 0.23 GPa,respectively.The corrosion current density is measured at 14.64μA/cm^(2),with an instantaneous corrosion rate of 0.335 mm/a.Both scaffolds exhibit excellent biocompatibility and no cytotoxicity.Additionally,the antibacterial effects of both alloys on E.coli are greater than 97.81%.These results indicate that Mg alloy scaffolds have great potential for clinical applications.
