加热参数对表面温度信号的影响的建模与分析

为了研究加热参数（包括加热时间、热流密度和加热量）对表面温度信号的影响,使用有限元法对二维和三维模型进行了仿真分析,得出了以下结论：有缺陷区与无缺陷区的最大温差主要受加热量的影响,随加热量的增加而增大;最大温度对比度及其出现时间和有缺陷区与无缺陷区的最大温差出现时间对热流密度的改变不敏感,但是会受到加热时间的影响;对于碳纤维增强塑料,最大温度对比度表现出较强的稳定性,说明该参数更能够反映出缺陷本身的特征,有助于缺陷的定量计算;对于铝类热扩散率高的材料,高热流密度和短时加热是一种更为合适的加热方式。     

Inverse resolution of the heat-transfer equation with internal heat source: Application to the quenching of steels with phase transformations

A method is described for calculating the time dependence of the temperature and heat flux (on heating and cooling) at the surface of a solid body. For a given ambient temperature and a known time-temperature function of an interior point, the surface heat flux is computed through an inverse conduction algorithm taking into account the nonlinear nature of the problem. Moreover, this algorithm includes the enthalpy of phase transformations. The influence of space and time steps on inverse calculations (precision, stability) is investigated. The method is then applied to thermal cases involving different transformations in steels.     

基于持续加热的热波无损探伤参数优化

确定的加热时间和加热强度一直是持续加热方式的热波无损检测技术中的关键问题,利用仿真的方法,对带有缺陷的材料的热传导过程进行模拟。通过观察分析和计算结果,认为在假设条件下,加热对象任意点上升的温度与加热强度的比值为一常数;在持续加热一段时间后（该时间与加热强度无关）加热对象内任意一点温度上升的速度为相等的常数。这对红外热波无损探伤的定量检测和评估、加热强度的确定、加热参数的优化等奠定了理论基础。     

OD1422 mm的X80级管线钢SH-CCT曲线测定与分析

采用Gleeble3500热-力学模拟试验机,对外径为φ1422 mm的X80管线钢焊接热影响区(HAZ)在不同冷却速度下的热循环过程进行了模拟,利用热膨胀法绘制模拟焊接热影响区连续冷却组织转变曲线(SH-CCT);结合光学显微组织和硬度测试等分析手段,研究了φ1422 mm的X80管线钢在不同冷却速度条件下焊接热影响区的组织变化规律。结果表明,冷却速度对X80管线钢的相变行为和微观结构具有显著影响。当冷却速度为1 ℃/s时,组织转变为贝氏体;当冷却速度达到7 ℃/s时,开始产生马氏体组织;当冷却速度为20 ℃/s时,组织内较高位错密度的板条贝氏体较多,组织晶粒较小。当冷却速度在7~20 ℃/s之间时,X80管线钢热影响区的显微硬度和冲击性能都大于母材。     

Casting/mold thermal contact heat transfer during solidification of Al-Cu-Si alloy (LM 21) plates in thick and thin molds

Heat flow at the casting/mold interface was assessed and studied during solidification of Al-Cu-Si (LM 21) alloy in preheated cast iron molds of two different thicknesses, coated with graphite and alumina based dressings. The casting and the mold were instrumented with thermocouples connected to a computer controlled temperature data acquisition system. The thermal history at nodal locations in the mold and casting obtained during experimentation was used to estimate the heat flux by solving the one-dimensional inverse heat conduction problem. The cooling rate and solidification time were measured using the computer-aided cooling curve analysis data. The estimated heat flux transients showed a peak due to the formation of a stable solid shell, which has a higher thermal conductivity compared with the liquid metal in contact with the mold wall prior to the occurrence of the peak. The high values of heat flux transients obtained with thin molds were attributed to mold distortion due to thermal stresses. For thin molds, assumption of Newtonian heating yielded reliable interfacial heat transfer coefficients as compared with one-dimensional inverse modeling. The time of occurrence of peak heat flux increased with a decrease in the mold wall thickness and increase in the casting thickness.     

空气介质中电火花表面强化的温度场有限元模拟分析

通过选取合适的热源模型、边界条件,建立了空气介质中电火花表面强化的热传导模型;通过分析其温度场的特点,建立了空气介质中电火花表面强化的二维温度场模型;借助ANSYS有限元分析软件对空气介质中电火花表面强化的温度场进行了模拟,分析了工件在不同时间、不同位置的热流密度矢量和随温度矢量的变化规律,以及电火花强化时温度随深度方向的变化历程。结果显示:电火花表面强化层的放电凹坑主要是由于热量在材料中不同方向的热传导存在差异引起的;电火花表面强化具有骤冷骤热的特点;在相同的加工速度下,节点的温度随着离表面距离的增大而减小。     

强流脉冲离子束辐照WC-Ni硬质密封材料表面改性研究

利用离子能量为300 keV,束流密度为300 A/cm~2,功率密度为10~8W/cm~2,脉冲宽度为70 ns的强流脉冲离子束(HIPIB)对用于核主泵轴密封的WC-Ni硬质合金材料进行了表面辐照处理,辐照次数分别为1,5.10次.利用XRD,SEM和EPMA研究了HIPIB辐照前后WC-Ni硬质合金表层相组成,表面形貌和元素分布的变化.借助显微硬度计和环一块式靡损仪测试了辐照前后硬质合金表层的性能.结果表明,HIPIB辐照硬质合金表层发生由六方碳化物WC向fcc碳化物β-WC_(1-x)转变,转变量随着辐照次数的增加而增加.HIPIB辐照引发硬质合金表层快速重熔和Ni黏结相的择优烧蚀,形成了许多丘状表面凸起,且随着辐照次数的增加,丘状凸起的尺寸增大,当辐照次数增加至10次,形成了网状峰-谷起伏结构的重熔烧蚀表面形貌,且具有微区光滑致密化特征.由于HIPIB辐照应力波的显著作用,辐照后硬质合金表层沿深度方向显著硬化.10次辐照后硬化层深度可达160μm,表面摩擦系数降低38%,耐磨性提高近3倍.     

镀锌板激光钎焊温度场的数值模拟

以镀锌钢板为母材，以CuSi3焊丝为钎料，进行了单、双光束激光钎焊实验．在分析单、双光束激光填丝钎焊传热行为的基础上，采用有限元方法对激光钎焊温度场进行了数值模拟，提出了激光填丝钎焊热源模型．采用体热源来模拟熔化钎料铺展流动引起的传热，模型考虑了热物性参数随温度的变化带来的非线性影响以及潜热、辐射和对流对传热的影响．对典型激光钎焊工艺参数下的温度场进行计算，结果表明：单光束激光钎焊有较高的温度梯度，而2mm焦点间距的双光束钎焊接头峰值温度和温度梯度低，高温区域宽，更适合于获得良好的钎焊接头．     

Inverse Resolution of the Heat- Transfer Equation: Application to Steel and Aluminum Alloy Quenching

Two applications of the numerical method for the inverse heat conduction problem are presented. This numerical method calculates the surface temperature and heat flux using an internal experimental temperature evolution. In the case of aluminum alloys, the question of stability and sensitivity to error measurements is investigated and applied to actual quench cooling. For steel application (high heating and cooling rates), a new calculation procedure is developed to solve the problem of solution stability due to the nonmonotonous initial temperature profile generated by the superficial heating. This new calculation procedure allows the martensite tempered zones to be explained and localized.     

高温喷丸强化Ti6Al4V合金的热力耦合数值模拟

发展一种连接喷丸强化与高温加载传热的热力耦合有限元方法,模拟高温喷丸强化Ti6Al4V合金的过程。首先建立一圆盘模型模拟待喷材料的高温加载传热过程。然后将圆盘模型的受热部分取出一小块建立对称胞元喷丸模型,并且将高温加载所致的温度场和热应力场通过解析场的方式导入到对称胞元喷丸模型,模拟高温喷丸强化过程。最后通过回弹计算获得稳定的残余应力场和温度场。创建4种模拟工况：常温喷丸、单独导入温度场的喷丸、单独导入热应力场的喷丸和高温喷丸,探究高温喷丸的残余压应力强化机理。结果表明：在常温环境下,对称胞元喷丸模型模拟的Ti6Al4V表层残余应力与试验结果具有很好的一致性。在高温加载作用下,随着热流密度的增加,受喷材料表层残余压应力有所减小,材料亚表层的残余压应力逐渐增大。影响高温喷丸强化的残余压应力的主要因素是高温加载所致的温度场,热应力场对残余压应力强化起次要作用。     

三维热耦合刚粘塑性有限元数值模拟技术的开发和应用

刚塑性有限元法是模拟热塑性变形的有效手段。本文介绍了可在工作站和微机上运行的三维热刚粘塑性有限元软件及其功能与特色，讨论了软件主要的理论依据和微机化过程。该软件可以进行加热和冷却过程中的温度场模拟，高温下金属塑性成形的速度场和温度场（包括上、下模具）的耦合计算、非稳态塑性成形过程分析；还可模拟和预测金属在热加工中的再结晶过程和内部组织的变化规律。应用所开发的软件，对中心压实法、高温镦粗、拔长、扩孔等三维锻造工艺进行了数值模拟。文章最后实验测定了ＪＴＳ锻造工艺的温度场和三维镦粗试件的晶粒度分布，实验值与模拟值的对比结果表明，数值模拟的结果是可靠的。     

Determination of Average Heat Conduction in Simulation of Thermal Processes in Discontinuous Charges

Computer simulation is used for determining the average heat conduction under the conditions of heating of a discontinuous charge in a heat-treatment furnace. The effect of such factors as the sizes, shape, surface of contact of metallic components and their packing density on the average heat conduction in a discontinuous charge is investigated. A dependence is suggested for determining the average thermal conductivity for various kinds of discontinuous charges of brass articles. An example of practical use of the method for computing the heating of a bundle of thin-wall tubes in a chamber electric resistance furnace under commercial conditions is presented.     

Heat Flux Estimation of a Flame Thermal Spray Process Using a Thermally Thin Composite Calorimeter

Temperature measurements take on prime importance in the field of the thermal spray coating since the temperature variation greatly affects the formation of splat morphology and also the coating properties and qualities. The evaluation of the heat flux is therefore essential since temperature variation comes from the energy transfer and conduction of the thermal system. The aim of this study is to estimate the heat flux of a flame thermal spray by solving an inverse heat conduction problem. Firstly, the substrate material and geometry are well designed so that the Biot number is small enough to conform to the lumped capacitance conditions. A lumped capacitance model of a substrate with its coating subjected to a uniform echelon heat flux is evaluated by solving a heat balance equation in the Laplace domain. Then, a thermally thin calorimeter is designed and the experimental thermogram is obtained by embedding a thin-wire micro-thermocouple onto the front and rear faces of the substrate. The forced convective heat transfer coefficient as well as the net incident heat flux density brought to the substrate during the thermal spray process are estimated. The theoretical composite surface temperature is compared to the experimental recording, the result showing a good agreement.     

Temperature and Thermal Expansion Analysis of the Cooling Roller Based on the Variable Heat Flux Boundary Condition

Planar flow casting (PFC) is a primary method for preparing an amorphous ribbon. The qualities of the amorphous ribbon are significantly influenced by the temperature and thermal expansion of the cooling roller. This study proposes a new approach to analyze the three-dimensional temperature and thermal expansion of the cooling roller using variable heat flux that acted on the cooling roller as a boundary condition. First, a simplified two-dimensional model of the PFC is developed to simulate the distribution of the heat flux in the circumferential direction with the software FLUENT. The resulting heat flux is extended to be three-dimensional in the ribbon’s width direction. Then, the extended heat flux is imported as the boundary condition by the CFX Expression Language, and the transient temperature of the cooling roller is analyzed in the CFX software. Next, the transient thermal expansion of the cooling roller is simulated through the thermal–structural coupling method. Simulation results show that the roller’s temperature and expansion are unevenly distributed, reach the peak value in the middle width direction, and the quasi-steady state of the maximum temperature and thermal expansion are achieved after approximately 50 s and 150 s of casting, respectively. The minimum values of the temperature and expansion are achieved when the roller has a thickness of 45 mm. Finally, the reliability of the approach proposed is verified by measuring the roller’s thermal expansion on the spot. This study provides theoretical guidance for the roller’s thermal expansion prediction and the gap adjustment in the PFC.     

基于第一性原理的金属导热性能研究

基于第一性原理提出了一种纯金属热导率的高效计算方法。引入常弛豫时间近似,应用密度泛函理论(DFT)与最大局域化Wannier函数(MLWFs)方法求解金属材料的电子热导率,简化了电子热导率的计算流程;在计算声子热导率时,将Birch-Murnaghan状态方程与Debye模型引入Slack方程,提高了声子热导率的计算效率。采用本方法计算了Al、Mg、Zn 3种材料在300~700 K温度范围内的电导率和热导率,计算值与实测值吻合良好,验证了计算方法的准确性。结果表明,材料的电子和声子的结构是影响热导率的关键因素,在金属材料的导热过程中,电子始终发挥着主要的输运作用,并且随着温度的升高,电子热导率占总热导率的比率也逐渐上升。     

Applied mechanics in grinding-V. Thermal residual stresses

The objective of this part of the series research is to investigate the correlation between the thermal residual stresses and conditions of surface grinding. The heat generated in grinding was modelled by a moving band heat source with a triangular profile. The effect of a coolant was simulated by heat convection. To obtain a reliable figure of thermal residual stresses induced by grinding, temperature-dependent properties of work materials were taken into account and a non-uniform convection model with an effective cooling factor was introduced. A thorough analysis using the finite element method showed that the predictions based on the temperature-independent properties always underestimate thermal deformation, that the effective cooling factor in the grinding zone should be maintained beyond a critical value, and that the Peclet number has a significant effect on the selection of critical grinding conditions. The paper offers an insight into the mechanism understanding of thermal residual stresses induced by surface grinding.     

孔隙密度对化学气相沉积泡沫金刚石导热性能的影响

选择不同孔隙密度的泡沫铜为沉积衬底,通过化学气相沉积(chemical vapor deposition, CVD)技术在其表面沉积连续金刚石膜,借助有限元模拟阐释泡沫骨架的孔隙密度对金刚石膜整体传热效果的影响,并通过扫描电镜、拉曼光谱及红外热成像仪等对不同孔隙密度的泡沫金刚石微观形貌、膜层成分以及热扩散性能进行对比与分析。结果表明:高孔隙密度泡沫衬底更有利于热量传递,但其极小的泡沫孔径会限制自由基在孔隙内部流动,CVD沉积的金刚石晶粒尺寸明显减小,仅有2～3 μm,晶粒质量也略逊于中、低孔隙密度样品的。在相同加热时间内的红外热成像中,中孔隙密度泡沫金刚石的表面升温速率相比低、高孔隙密度样品的升温速率分别提升43.4%与12.7%。综上所述,兼具良好三维连通特性与优异金刚石质量的中孔隙密度泡沫金刚石表现出更为优异的导热性能,是更理想的导热增强体选择。      

Solid Solubility in Laser Cladding

Laser cladding techniques have recently enjoyed attention in preparing in-situ novel surface clad alloys with extended solid solution. Mass transport involved in this process is rather intriguing since it plays the major role in producing new materials without being restricted by equilibrium phase diagram. Although earlier work has identified convection as the dominant factor for homogeneous liquid metal composition, very little is understood about the solute redistribution at the solid-liquid interface under such non-equilibrium conditions. In this paper, a mathematical model is presented for determining the composition of extended solid solution formed due to rapid cooling in laser cladding. This model considers a diffusion mechanism for mass transport in a one-dimensional semi-infinite molten pool of the cladding material from which heat is removed by conduction through a one-dimensional semi-infinite solid substrate. The rate of solidification was obtained by modeling the cooling process as a composite medium heat transfer problem, and the discontinuity of the concentration field was simulated using a nonequilibrium partition coefficient. A non-similar exact solution for the mass transport equation was obtained using a set of similarity variables derived using Lie group theory.     

药芯焊丝的加热数学模型与加热动力学

建立了药芯焊丝伸出长度上的加热数学模型,对不同焊接工艺参数下药芯焊丝伸出长度上的温度进行了测量和理论计算。对于直径为φ１．２ｍｍ的细直径药芯焊丝,电阻热使药芯焊丝的伸出长度被加热,电弧热的主要作用是使焊丝熔化和熔滴过热,药芯粉的分流作用和电弧热对药芯焊丝的加热灵堂模型的影响很小,故药芯粉的分流作用、电弧热可以忽略不计。用差热、热重法分析了药芯焊丝伸出长度的加热动力学,在加热阶段,电阻热主要使氟化物     

激光相变硬化过程中温度场及马氏体相变的数值分析

以相变理论、热弹塑性理论为基础 ,根据激光热处理加热、冷却速度快的特点 ,建立了考虑热物性系数及相变过程的非线性热传导方程。该方程能较好地反映马氏体相变特征。应用有限单元法和有限差分的混合解法对平板材料激光淬火过程的瞬态温度场进行了计算。在计算温度的同时 ,计算了马氏体量的分布 ,进而确定激光硬化区的形貌。计算结果与实验结果对比表明 ,此项理论研究有一定实用价值