电磁场对铅黄铜水平连铸坯组织及偏析的影响

研究了铅黄铜在无磁场、低频交变电磁场下水平连铸得到的铸坯横截面宏观组织、微观组织形貌及合金元素Pb的分布,并对其机理进行了分析。试验结果表明,在铅黄铜水平连铸的过程中施加低频交变电磁场能有效地细化晶粒及影响合金元素在横截面上的分布,并且电磁场有效地抑制了在常规水平连铸过程中出现的铸坯横截面上中下部位组织分布不均匀的现象。表现在铸坯横截面的凝固组织由上方主要为细小柱状晶、下方为粗大柱状晶变为均为细小的等轴晶,铸锭上部凝固滞后的现象消除;合金元素Pb的宏观偏析得到抑制,并且电流为30Hz、100A的组织优于30Hz、80A的组织。     

电磁搅拌对BFe10-1-1白铜管坯的影响

采用试验的方法研究了在水平连铸过程中施加工频旋转电磁场对BFe10-1-1白铜管坯表面质量、凝固组织和力学性能的影响,并考察了电磁搅拌对管坯室温拉伸性能的影响.结果表明,采用水平电磁连铸短流程工艺能够制备出高质量的白铜管坯,电磁搅拌能够避免管坯表面热节瘤等缺陷的形成,同时促使粗大柱状晶发生细化,并使溶质元素宏观偏析得到了抑制;电磁搅拌能够提高管坯的抗拉强度和塑性,当线圈电流为100A时管坯抗拉强度较普通连铸坯提高了9%,而延伸率则提高了55%.     

连铸坯偏析对钢板氢致开裂的影响

按照YB/T 4003-1997《连铸钢板坯低倍组织缺陷评级图》对连铸坯进行了宏观低倍检验,并利用OPA-100型原位分析仪对连铸坯偏析进行了定量检测,然后按照NACE 0284-2003《管道、压力容器抗氢致开裂钢性能评价的试验方法》对经热机械控制工艺(TMCP)轧制成的钢板取样进行氢致开裂(HIC)腐蚀试验。结果表明:连铸坯中心偏析是钢板发生HIC的主要原因,偏析元素主要有硫、磷、碳、锰等;通过合理的成分设计和工艺控制,实现了连铸坯偏析的良好控制,所生产的连铸坯可满足抗HIC管线钢工业生产需求。     

Q550D钢拉伸试样断口分层原因

某Q550D钢拉伸试样在拉伸试验后出现拉伸断口分层现象。通过宏观观察、金相检验、硬度测试、能谱分析等方法,对拉伸断口的分层原因进行了分析。结果表明:Q550D钢板坯在连铸过程中采用了不适宜的连铸工艺,造成连铸钢坯在上、下1/4处出现成分正偏析,在连铸钢坯的1/2处存在负偏析、夹杂物,后续经轧制后在板材的1/4厚度处存在较严重的贝氏体偏析带,在心部区域有大量的B类夹杂物,最终导致拉伸试样断口出现分层现象。     

连铸坯中心偏析和疏松缺陷在轧制过程中的形态演化

连铸坯的中心偏析和疏松缺陷形态经轧制后会发生演化,合理选择轧制压缩比可以达到减轻或消除铸坯缺陷的效果。利用宏观检验、硬度测试、金相检验和密度测定等方法对典型的合金钢和普碳钢两种300mm厚连铸坯经不同压缩比轧制后其中心偏析和疏松缺陷的形态演化进行了分析。结果表明：在常规轧制工艺下,当轧制压缩比小于4时,连铸坯仅在板厚的上、下1／3厚度位置发生明显塑性变形,中心部位的偏析和疏松缺陷形态不会发生变化。压缩比达到5以上时,1．5级的中心疏松缺陷才得以轧合,但1．5级的中心偏析缺陷只能适度减轻。     

连铸10CrNi3MoV钢裂纹尖端张开位移(CTOD)试验研究

对电炉模铸及不同批转炉连铸 10CrNi3MoV钢进行了CTOD试验研究 ,并探讨了CTOD特征值与钢板中心偏析关系。结果表明 ,模铸钢板抵抗裂纹早期扩展的能力高于连铸板 ,但连铸板抵抗裂纹失稳扩展能力并不低于模铸板 ;钢板中心偏析使CTOD特征值降低 ;控制碳含量在较低水平 ,或碳含量达上限 (0 .11%C)时采取减轻偏析的有效措施 ,可使连铸 10CrNi3MoV钢具有较高的断裂韧性     

交变电磁场在晶体生长与凝固方面的应用

在合金凝固过程中施加时变电磁场,导电熔体在洛仑兹力的驱动下产生的强迫对流可有效控制合金溶质的再分配过程。在材料凝固与晶体生长过程中施加电磁场有助于深入研究其热物理性质、相平衡、亚稳态、组织形成、成分过冷和形核。人们对重力环境下合金的凝固过程已进行了大量深入详尽的实验探究,利用电磁场手段对凝固前沿进行有效干预并在晶体组织结构、成分偏析等方面取得了一定的进展。而微重力环境下浮力对流减少,为在宏观和微观尺度上获得成分更为均匀的半导体或合金材料提供了一个独特的平台,目前的研究表明在微重力环境下合金的凝固特征与在重力环境下的有所不同。从理论与实验的角度阐释了在微重力及重力环境下电磁场引起的强迫对流强度及方向对晶体生长过程中的宏观偏析、微观偏析、晶体形态以及金属间化合物的生长模式及空间分布的影响规律。     

连铸连轧10CrNiCu钢板厚度方向元素分布特征分析

采用激光原位分析技术,研究了连铸连轧10CrNiCu钢板中各元素在板厚方向的分布,结果表明:C在钢板下表面含量高,上表面含量低;P、S偏析微区弥散分布;Mn、Ni、Cr、Si基本沿板厚中心对称分布,为中心正偏析,Cu的分布最均匀。元素的偏析度基本与原子半径大小成反比关系,C的偏析度最大,P、S、Si偏析度居中,Mn、Cr、Ni、Cu的偏析度较小。     

热轧高强度钢板剪切开裂原因

采用化学成分分析、宏观和微观检验及试验验证等方法对某热轧高强度钢板剪切开裂原因进行了研究。结果表明：这种开裂并非由于连铸坯中心裂纹或偏析所造成的,而是中心马氏体带和基体上弥散分布较大的TiN（C）颗粒和晶界上富集的磷以及剪切加工工艺不合理所造成;并提出相应措施,解决了这一问题。     

电磁场对7050铝合金凝固组织和元素分布影响

为了研究中频电磁场对7050铝合金凝固组织和元素分布的影响,在未施加电磁场,施加1000Hz、6000A电磁场和1000Hz、4000A电磁场下进行7050铝合金凝固试验.利用金相显微镜和电子背散射衍射分析技术分析了锭坯微观组织,利用化学分析方法测定溶质元素沿锭坯边部到中心的分布情况.结果表明:外加中频电磁场有效地细化晶粒,影响溶质元素分布.未施加电磁场下,锭坯晶粒最大,发生反偏析;1000Hz、4000A电磁场下,锭坯晶粒次之,发生反偏析;1000Hz、6000A电磁场下,锭坯晶粒最细,发生正偏析.     

Contribution of forced centreline convection during direct chill casting of round billets to macrosegregation and structure of binary Al–Cu aluminium alloy

Abstract

Effects of upward or downward forced flow in the centre of the sump of an Al alloy billet on structure and macrosegregation were studied. The billet was cast at a pilot vertical direct chill caster and had dimensions of 195 mm diameter and 1400 mm length. Introduction of forced flow in the liquid part of the sump resulted in some changes in the structure and dramatic changes in macrosegregation. Upward flow coarsened the structure and increased negative centreline segregation. Downward flow made the structure finer and more uniform across the billet, and suppressed the macrosegregation. Strong downward flow produced positive macrosegregation in the billet. The experimental results are analysed using computer simulations of heat flow and solute transport, and discussed in terms of macrosegregation mechanisms.     

低熔点可切削微晶玻璃的组织与性能

不同的晶化温度和保温时间对低熔点可切削微晶玻璃的微观组织形貌、切削性能和力学性能有明显影响．试验表明,６００℃保温６～８ｈ与６５０℃保温１～２ｈ的晶化效果等同,具有最佳的切削性能和较高的抗弯强度．更高温度晶化可使强度进一步提高,但切削性能急剧下降．     

Macrosegregation in direct-chill casting of aluminium alloys

Semi-continuous direct-chill (DC) casting holds a prominent position in commercial aluminium alloy processing, especially in production of large sized ingots. Macrosegregation, which is the non-uniform chemical composition over the length scale of a casting, is one of the major defects that occur during this process. The fact that macrosegregation is essentially unaffected by subsequent heat treatment (hence constitutes an irreversible defect) leaves us with little choice but to control it during the casting stage. Despite over a century of research in the phenomenon of macrosegregation in castings and good understanding of underlying mechanisms, the contributions of these mechanisms in the overall macrosegregation picture; and interplay between these mechanisms and the structure formation during solidification are still unclear. This review attempts to fill this gap based on the published data and own results. The following features make this review unique: results of computer simulations are used in order to separate the effects of different macrosegregation mechanisms. The issue of grain refining is specifically discussed in relation to macrosegregation. This report is structured as follows. Macrosegregation as a phenomenon is defined in the Introduction. In “Direct-chill casting – process parameters, solidification and structure patterns” section, direct-chill casting, the role of process parameters and the evolution of structural features in the as-cast billets are described. In “Macrosegregation in direct-chill casting of aluminium alloys” section, macrosegregation mechanisms are elucidated in a historical perspective and the correlation with DC casting process parameters and structural features are made. The issue of how to control macrosegregation in direct-chill casting is also dealt with in the same section. In “Role of grain refining” section, the effect of grain refining on macrosegregation is introduced, the current understanding is described and the contentious issues are outlined. The review is finished with conclusion remarks and outline for the future research.     

不同冷却条件下Al-Si/SiC颗粒系统二维凝固过程数值模拟

本文采用多相流模型对不同冷却条件下Al-Si/SiC系统二维凝固过程进行了数值模拟,对顶面冷却、底面冷却、侧面冷却和四面冷却条件下,无颗粒、小颗粒和大颗粒的情况进行了研究。溶质分布表明:对于分凝系数小于1的合金,先凝固的地方出现负偏析,后凝固的地方出现正偏析。顶面冷却和底面冷却时会出现A型偏析,侧面冷却和四面冷却时出现V型偏析。共晶分布验证了Scheil方程,共晶的产生会受到宏观偏析的影响,而且大颗粒的堆积会抑止共晶的产生。     

Effect of a Rotating Magnetic Field on Convection Stability and Crystal Growth in Zero Gravity and on the Ground

A numerical study of the flows arising in a conducting liquid under the action of a rotating magnetic field as well as under its interaction with gravitational and thermocapillary convection has been made. The boundaries of the transition to the oscillating regime of convective flows have been determined. Regions of mixed flows, in which the impurity macrosegregation in crystals grown by the Bridgman and floating-zone methods decrease, have been revealed. It has been shown that regions of flows in which both a smooth increase in the impurity macrosegregation and a change in the form of a clearly defined extremum are observed also exist. The possibilities of mathematical modeling of geophysical problems with the use of a rotating magnetic field are discussed.     

Effect of Low Frequency Electromagnetic Field on Macrosegregation of Horizontal Direct Chill Casting Aluminum Alloys

The horizontal direct chill (HDC) casting process is a well-established production route for aluminum alloy ingot but the ingot may suffer from macrosegregation sometimes. In order to control the defect, a low frequency electromagnetic field has been applied in HDC casting process and the relevant influence has been studied. The results show that application of low frequency electromagnetic field can reduce macrosegregation in HDC casting process; and two main parameters of electromagnetic field density and frequency, have great influences on the solution distribution along the diameter of ingot. Moreover, the mechanisms of reduction of macrosegregation by electromagnetic field have been discussed.     

Effect of Cold Deformation on the Machinability of a Free Cutting Steel

The effect of cold deformation on the machinability of a free cutting steel has been investigated through characterization of the variation in size and morphology of the sulfide inclusions. The machinability has been indexed in terms of cutting force, surface roughness, and chip characteristics. The possible interrelations between inclusion characterizing parameters and machinability indices have been examined. Increased cold deformation was found to increase interinclusion spacing as well as aspect ratio of the inclusions. These variations in inclusion characteristics, in turn, were found to reduce the cutting forces and the chip length up to a critical amount of deformation. The results highlight the influence of inclusion characterizing parameters on machinability characteristics of free cutting steels.     

Comparative Study on the Machinability Aspects of Aluminium Silicon Carbide and Aluminium Graphite Composites

Aluminium matrix composites find wide applications in the present industrial scenario due to their desirable properties. Study of the effect of process parameters on machinability of aluminium matrix composites is of paramount importance in the field of manufacturing engineering. Machining of a composite depends on the properties and relative content of the reinforcement and the matrix materials as well as on its response to the machining process. In this article, investigations on the machinability aspects of aluminium-silicon carbide and aluminium-graphite composites are presented. Experiments have been carried out through the Design of Experiments technique and regression machinability models have been developed, which express the degree to which the resultant force depends upon the cutting parameters and the percentage of reinforcement present in the aluminium matrix composites machined. A comparative study of the effect of cutting parameters on the resultant force has been presented.     

Heat treatment effect on CNC turning of Incoloy 800H superalloy

Nuclear power plant components, high-temperature furnace, and most of the nuclear reactors are in need of high creep rupture which can be attained by Incoloy 800H superalloy. Based on this, the present research work is aimed to relate the microstructure, mechanical, and machinability of Incoloy 800H in various conditions, namely, solution treated, heat-treated with air cooling, and heat-treated with furnace cooling. The samples were initially heated till 975°C after solution treated and then subjected to the aforesaid heat treatments. The optical microstructures revealed that the fine grains’ structure was obtained in the air-cooled sample, whereas coarse grain structure was obtained in a furnace-cooled sample. The heat-treated samples were machined using CNC dry turning process and the machining parameter effects on the machinability aspects were studied, investigated, and reported. Experimental investigations explained clearly that the machinability aspects were significantly influenced by the cooling medium. Furnace-cooled sample had shown improvement in mechanical and machinability performances.     

Influence of an axial uniform magnetic field on the solid/liquid interface curvature and macrosegregation in directionally solidified the Al–0.85 wt.% Cu alloy

Effect of a uniform magnetic field on the solid/liquid interface curvature and macrosegregation in directionally solidified the Al–0.85 wt.% Cu alloy has been investigated. Results show that the interface curvature and macrosegregation increase to a maximum when B is about 0.1 T; and then decreases as B still increases. This is good agreement with the computed velocities of the thermoelectric magnetic convection. Above results reveal that the uniform magnetic field induces the new convection and further modifies the interface curvature and macrosegregation.