MB15镁合金半固态压缩力学行为研究

通过MB15镁合金半固态等温压缩试验，研究了半固态材料的力学行为，提出了触变强度是半固态金属在稳态变形过程中触变点的应力，即半固态金属固体骨架所能承受的最大正应力，并分析了加热温度、应变速率、保温时间、固相晶粒大小、晶粒圆整度及材料本身的强度等因素对半固态触变强度的影响，提出了触变强度的存在条件。结果表明，半固态触变强度随着加热温度的升高、应变速率的降低及保温时间的延长而降低，随着固相晶粒的减小、晶粒圆整度的增加及材料本身强度的增加而增加；当半固态材料内部的固相颗粒相互连结形成固体骨架时，存在触变强度。     

高固相率MB15镁合金半固态压缩力学行为研究

通过MB15镁合金半固态等温压缩试验,研究了高固相率半固态材料的力学行为,提出了触变强度是高固相率半固态金属在稳态变形过程中的触变点的应力,即半固态金属固体骨架所能承受的最大正应力,并分析了加热温度、应变速率、保温时间、固相晶粒大小、晶粒圆整度及材料本身的强度等因素对半固态触变强度的影响,提出了触变强度的存在条件.结果表明,半固态触变强度随着加热温度的升高、应变速率的降低及保温时间的延长而降低,随着固相晶粒的减小、晶粒圆整度的增加及材料本身强度的增加而增加,当半固态材料内部的固相颗粒相互连结形成固体骨架时,存在触变强度.     

半固态镁合金AZ61压缩变形力学行为的研究

采用Gleeble1500热模拟试验机,通过对用应变诱发熔体激活法（SIMA）制备的AZ61半固态镁合金坯料进行单向、等温压缩试验,研究高固相率下半固态AZ61镁合金的力学特性,研究其主要热力参数应变速率ε′、固相率fS等与其应力之间的关系。得到了真实应力-应变关系曲线,分析了其应力-应变关系的力学行为意义和触变应力的力学意义。实验结果表明,当固相率较高,固相颗粒互相连接构成骨架时,存在触变应力,且触变应力随着加热温度的升高、应变速率的降低而降低。     

半固态金属触变塑性成形上限法

在高固相率时,半固态金属的力学模型可简化为连续多孔体力学模型。针对半固态金属触变塑性成形的特点,本文发展了上限法理论在半固态金属触变塑性成形分析中的应用。提出速度间断值不仅要包括切向分量,还要包括法向分量。速度间断的法向分量是由金属通过速度不连续面时,材料固相率的变化而引起的。由此建立了半固态金属触变塑性成形的上限分析模型和理论方法,导出了上限功率的计算公式。为在实际触变塑性成形工艺分析中的进一步应用奠定了理论基础。     

Mg-Al-Zn合金半固态坯的制备及触变成形研究

通过新SIMA法制备Mg-Al-Zn合金半固态坯的触变挤压和触变模锻试验以及借助金相显微镜、拉伸试验机等分析手段对Mg-Al-Zn合金半固态坯的制备及触变成形进行了研究.研究结果表明,新SIMA法中的等径道角挤压能使Mg-Al-Zn合金获得良好的应变诱导效果,即铸坯微观组织被大大细化,平均晶粒尺寸达到20μm,材料力学性能大幅度提高;该坯料在560℃保温20min制备的半固态坯料的固相晶粒细小,球化程度高,组织均匀,平均晶粒尺寸为25μm.通过触变挤压和触变模锻试验证明,新SIMA法制备的Mg-Al-Zn合金半固态坯料所触变成形的零件的力学性能很高.其中触变挤压的卫星角框零件的屈服强度、抗拉强度和伸长率分别为213.1MPa、312.6MPa和15.2%.触变模锻的托弹板零件的屈服强度、抗拉强度和伸长率分别为218.6MPa、320.9MPa和14.8%.     

半固态镁合金触变成形数值模拟及试验验证

利用DEFORM-3D塑性有限元软件,对半固态AZ61触变成形过程进行了数值模拟,分析了半固态坯料与常规态坯料成形过程中的应力、应变分布和温度场,并对此两种坯料进行了触变锻造试验.结果表明,半固态镁合金材料具有变形抗力小,应力、应变分布均匀,通过对触变锻造试验和模拟结果的对比可知,二者拟合较为理想.     

半固态材料制备的研究现状和发展趋势

半固态加工的优越性完全依赖于半固态材料所需具备的特殊组织结构,即细小球状固态颗粒均匀悬浮于液态基体中而形成液固共存的半固态组织.对现有的半固态材料的制备工艺进行了总结,主要有机械搅拌法,电磁搅拌法,促进凝固过程形核,外加晶粒细化剂,SIMA工艺和雾化成型工艺.还结合半固态加工的工艺路径流变成形和触变成形,提出上述半固态材料制备方法的发展趋势.     

半固态金属触变挤压上限分析

运用半固态金属触变塑性成形上限法,对半固态金属触变挤压过程进行了上限分析。导出了半固态金属触变挤压上限功率的计算公式,获得了相对应力与摩擦因子、半锥角和断面缩减率等工艺参数的相互影响关系。对于某一固定的半锥角,摩擦因子的增加使相对应力增大,而增大的幅度随着断面缩减率的增大而增大。对于某一固定的断面缩减率,半锥角的增加,使相对应力下降后再度略有上升。因此存在着一个最佳半锥角,对应于最佳上限解,其相对应力为最小。而且摩擦因子越小,相对应力下降幅度越小。经实验验证,所获计算结果与实验值吻合,可用于指导半固态金属触变挤压工艺实践。     

预形变量和半固态等浊温度对触变组织的影响

研究了预形变量与固态等温温度对应力诱发熔化激活工艺所获得的触变组织的影响。结果表明，增加预形变量和半固态等温温度，都将促进合金中初生α相由树枝晶向颗粒状转化。但预形变量过大或半固态等温温度过高，都会使晶粒长大。     

预形变量和半固态等温温度对触为组织的影响

研究了预形变量与半固态等温温度对应力诱发熔化激活（Ｓｔｒａｉｎｉｎｄｕｃｅｄｍｅｌｔａｃｔｉｖａｔｅｄ）工艺所获得的触交组织的影响。结果表明，增加预形变量和半固态等温温度，都将促进合金中初生α相由树枝晶向颗粒状转化。但预形变量过大或半固态等温温度过高，都会使晶粒长大。因此，要获得均匀细小的触变组织，必须使预形变量和半固态等温温度有一个合理的匹配。     

AlSi7Mg合金坯料在固液两相区的初始结构对变形的影响

本文论述了Ａ１Ｓｉ７Ｍｇ合金在半固态下的初始结构对压缩变形行为的影响。结果表明：Ａ１Ｓｉ７Ｍｇ合鑫产的初妈显微结构的固想颗粒尺寸及分布、颗粒形貌、颗粒团聚化程度对兰固态合金坯料的表观粘度有重要的影响。具有初始细昌结构（蔷薇状结构）的合金应力水平较低,具有中等枝晶和粗枝晶结构的合金应力水平较高。非枝晶组织半固态合金变形时固相颗粒变形力的传递数学模型：σｓ＝α２λ１／λ２（Ｔ）ηｆε。     

半固态AZ91D镁合金的触变性

利用Couette型同轴双桶流变仪，对等温搅拌和重熔加热的半固态AZ91D镁合金浆料的触变性能进行了研究．实验结果表明：经过连续降温和等温搅拌，半固态浆料的表观粘度逐渐降低，并达到一个稳态值；此时，若停止搅拌剪切，并经过某一时段的等温静置，再次在某一剪切速率下搅拌时，半固态浆料的表观粘度会突然升高，然后再迅速降低，最后到达一个稳态值，呈现出典型的剪切变稀特性；延长静置时间、或增加固相分数、或降低剪切速率，再次剪切搅拌时，半固态浆料到达稳态表观粘度的时间随之增长，同时稳态表观粘度值也相应增大；重熔加热后的半固态浆料的稳态表观粘度比相同固相分数的等温搅拌的半固态浆料的稳态表观粘度低；随重熔加热保温时间的延长，半固态浆料的稳态表观粘度逐渐降低，当稳态表观粘度达到最低值后，随重熔加热保温时间的延长，稳态表观粘度又逐渐增大．     

Deformation mechanism and forming properties of 6061Al alloys during compression in semi-solid state

The 6061 semi-solid aluminium alloy feedstocks prepared by near-liquidus casting were compressed in semi-solid state by means of Gleeble-3500 thermal-mechanical simulator. The relationship between the true stress and the true strain at different temperatures and strain rates was studied with the deformation degree of 70%. The microstructures during the deformation process were characterized. The deformation mechanism and thixo-forming properties of the semi-solid alloys were analyzed. The results show that the homogeneous and non-dendrite microstructures of semi-solid 6061Al alloy manufactured by near-liquidus casting technology could be transformed into semi-solid state with the microstructure suitable for thixo-forming which are composed of near-spherical grains and liquid phase with eutectic composition through reheating process. The deformation temperature and strain rate affect the peak stress significantly rather than steady flow stress. The resistance to deformation in semi-solid state decreases with the increase of the deformation temperature and decrease of the strain rate. At steady thixotropic deformation stage, the thixotropic property is uniform, and the main deformation mechanism is the rotating or sliding between the solid particles and the plastic deformation of the solid particles.     

Thixotropic behavior of semi-solid AZ91D magnesium alloy

The thixotropie behavior of semi-solid AZ91D slurry was studied through a Couette type viseometer.The results show that the apparent viscosity of semi-solid AZ91D magnesium alloy slurry increases after being isothermally held, but the apparent viscosity quickly falls down to a steady state value after being stirred again and it takes on a sharp shear-thinning behavior. With the same shearing rate and the rest time increasing, the steady apparent viscosity increases because of the agglomeration of the solid particles, and the time required for the slurry to reach the steady state also becomes longer. If the solid fraction increases, it takes longer time for the slurry to reach the steady apparent viscosity with the same shearing rate and the same rest time. If the solid fraction and the rest time are the same, but the shearing rate rises, it takes shorter time for the slurry to reach the steady apparent viscosity and the final steady apparent viscosity also decreases.     

变形程度对7A04合金半固态触变组织的影响

获得具有触变特性的均匀的、近球形的显微组织是半固态触变成形工艺的基础和关键。以挤压态7A04合金SIMA法生成触变组织为例．研究变形程度对其半固态触变组织的影响。结果表明：在加热前的变形程度对显微组织的影响很大，随着变形程度的增加，晶粒尺寸减小，晶粒形状越趋于球形；当变形程度超过0．3时，晶粒尺寸及其球形化速度逐渐减慢并趋于稳定值。此外，经过冷变形后，晶粒内及晶粒间的偏析减小，晶界易被低熔点液相浸润．更易获得均匀的、近球形的触变组织。     

A three-phase simulation of the effect of microstructural features on semi-solid tensile deformation

A direct finite-element microstructure model for prediction of the deformation behavior of semi-solid metallic alloys is presented. The 2D model geometry is based on a modified Voronoi tessellation, and includes rounded corners to approximate an equiaxed-globular grain structure, liquid surrounding the grains, and micro-porosity. An elasto-plastic empirical constitutive equation is derived for the solid grains, while the liquid is approximated as a perfectly plastic material with a very low yield stress. The resulting three-phase model was used to investigate the effects of fraction solid, porosity, and grain size on the constitutive behavior of a semi-solid aluminum alloy, AA5182. The model predictions were validated against experimental data at high fraction solid. These simulations reveal a strong correlation between semi-solid grain size and yield stress, and between porosity and strain localization. The application of direct finite-element simulations is shown to be an effective technique for examining the effects of microstructure phenomena on the macro constitutive behavior of semi-solid materials.     

Conception of tooling adapted to thixoforging of high solid fraction hot-crack-sensitive aluminium alloys

Thixoforging is a type of semi-solid metal processing at high solid fraction (0.7<?_s<1), which involves the processing of alloys in the semi-solid state. Tooling has to be adapted to this particular process to benefit shear thinning and thixotropic behaviour of such semi-solid material. Tooling parameters, such as the forming speed and tool temperature, have to be accurately controlled because of their influence on thermal exchanges between material flow and tool. These thermal exchanges influence the high-cracking tendency and the rheology of the semi-solid material during forming, which affects parts properties and therefore their quality. Extrusion tests show how thermal exchanges influence quality of thixoforged parts made of 7075 aluminium alloys at high solid fraction by modifying process parameters like forming speed, tool temperature and tool thermal protector. Thus an optimum in terms of thermal exchanges has to be found between surface quality and mechanical properties of the part. A direct application is the evaluation of surface quality of thixoforged thin wall parts made of 7075 aluminium alloy.