Influence of Plasma Instabilities in Ceramic Suspension Plasma Spraying

Direct current Suspension Plasma Spraying (SPS) allows depositing finely structured coatings. This article presents an analysis of the influence of plasma instabilities on the yttria-stabilized suspension drops fragmentation. A particular attention is paid to the treatment of suspension jet or drops according to the importance of voltage fluctuations (linked to those of the arc root) and depending on the different spray parameters such as the plasma forming gas mixture composition and mass flow rate and the suspension momentum. By observing the suspension drops injection with a fast shutter camera and a laser flash sheet triggered by a defined transient voltage level of the plasma torch, the influence of plasma fluctuations on jet or drops fragmentation is studied through the deviation and dispersion trajectories of droplets within the plasma jet. This article is an invited paper selected from presentations at the 2007 International Thermal Spray Conference and has been expanded from the original presentation. It is simultaneously published in Global Coating Solutions, Proceedings of the 2007 International Thermal Spray Conference, Beijing, China, May 14-16, 2007, Basil R. Marple, Margaret M. Hyland, Yuk-Chiu Lau, Chang-Jiu Li, Rogerio S. Lima, and Ghislain Montavon, Ed., ASM International, Materials Park, OH, 2007.     

AZ91镁合金的应变疲劳行为研究

研究了铸态和挤压态AZ91镁合金的室温应变疲劳行为。结果表明，铸态镁合金表现为循环应变硬化，而挤压态镁合金可呈现循环应变硬化、软化或循环稳定。与此同时，对两种状态的AZ91镁合金的应变寿命行为和循环应力-应变行为进行了分析测试，确定了相应的室温应变疲劳参数。此外，利用扫描电子显微镜观察分析了铸态和挤压态AZ91镁合金的疲劳裂纹萌生和扩展行为。     

二次喷丸42CrMo钢表面完整性的数值模拟研究

目的探究二次喷丸工艺参数对42CrMo钢零件表面完整性的影响规律。方法建立三维随机喷丸有限元模型,并通过实验验证有限元模型预测残余应力的准确性。将一次喷丸后零件的表面形貌和应力应变结果作为初始状态导入到二次喷丸模型中,构建出二次喷丸预测模型。分析二次喷丸参数对42CrMo钢零件表面残余应力场、表面粗糙度以及等效塑性形变场的影响情况。结果二次喷丸后,42CrMo钢零件近表层(0～100μm)的残余压应力值均比初始状态有所增加。增加二次喷丸覆盖率对表面残余应力的提升作用最为明显,最大可比初始状态提高63.3%,而增加二次喷丸直径对残余应力的改善效果最不明显。过度增加二次喷丸速度会导致表面粗糙度明显增加,提高二次喷丸覆盖率可显著降低表面粗糙度,覆盖率为300%时,粗糙度比初始状态减小了14.4%。表层PEEQ值随着二次喷丸速度、弹丸直径和覆盖率的增加而增加,但当二次喷丸速度、弹丸直径和覆盖率增加到一定程度后,表层PEEQ值会趋于饱和。结论二次喷丸预测模型揭示了二次喷丸参数与42CrMo钢零件表面完整性之间的影响规律,为二次喷丸的工业应用提供了一定的参考意义。     

电机换向器整体冷锻变形力的计算

采用主应力法推导了带台阶槽型换向器整体冷锻一次成形的变形力计算公式 ,用C ++语言实现了所推导计算公式的算法 ,并进行了电测实验验证。该研究可为其它复杂形状零件冷锻变形力的计算提供借鉴     

拉力法测量氧化膜的粘附力

利用拉力法测量了Ti-5621S及含1wt%Nd的Ti-5621S合金800℃空气中形成的氧化膜的粘附力,用膜/合金界面能表征的氧化膜的粘附力不仅与断裂载荷有关、而且还与膜内的残余应力有关.简化分析后得出它们间存在关系Ti-5621S合金中添加Nd能增强氧化膜粘附力,两种合金氧化膜的粘附力随厚度增加而降低.     

离心喷射沉积距离对TiAl基合金组织的影响

研究了γＴｉＡｌ基合金经离心喷射沉积成形时不同喷射距离对合金组织的影响。合金经等离子弧熔炼并重熔后，在真空条件下进行离心喷射沉积成形，喷射沉积距离分别为２００、３００、４００和５００ｍｍ。结果表明，经离心喷射沉积后的合金仍存在着孔隙，且随喷射距离的增加，孔隙率增加，孔隙越细密。成形后的组织结构为层片状组织，其形貌、层片大小也随成形距离的不同而变化     

车轮热处理过程中残余应力的分析

综合考虑了温度、相变及应力的耦合作用,运用有限元法分析了车轮热处理过程中残余应力的产生及分布,并进行了测试。在淬火开始阶段车轮踏面附近分布周向拉应力,深部受压,在淬火60 s时踏面拉应力达到最大,随后冷却过程中踏面附近拉应力逐渐减小并转化为压应力,通过测试和计算,KKD车轮踏面的最大残余压应力为120 MPa左右,压应力区深度达到45 mm。     

Corrosion behavior of wire-arc-sprayed stainless steel coating on mild steel

The corrosion characteristics of a wire-are-sprayed stainless steel coating on mild steel have been investigated in regards to atomizing gases and sealing treatment. Salt spray test was performed. The corrosion behavior of the coating was observed under a microscope succesively through a cycling test of wetting and drying in a salt solution. The sealing-treated coating was found to rust faster compared with the non-sealing-treated coating; it protected the mild steel substrate against corrosion, but even it deteriorated the coating itself due to the interruption of the substrate as an anode. The air-atomized coating ruste more heavily than the nitrogen-atomized one. Four different phases were observed in the coating in regards to corrosion behavior; namely, chromium-based oxide, iron-based oxide, chromium-depleted metallic phase, and stainless steel matrix phase. It was found that the chromium-depleted metallic phase and the iron-based oxide are non-corrosion-resistant, whereas the chromium-based oxide and the stainless steel matrix phase are corrosion-resistant.     

某航空发动机第三级涡轮叶片失效分析

本文对某型号航空发动机GH4033第三级涡轮叶片榫头裂纹及断裂失效进行了分析,确定了失效模式为两类,第一类为蠕变疲劳裂纹,第二类为起始应力较大的高低周复合疲劳断裂.研究发现GH4033合金屈服强度偏低、晶界强化能力不足是叶片发生蠕变疲劳开裂的主要原因.而叶片的高低周复合疲劳断裂则主要与个别相邻叶片的叶冠间隙偏大引发的高振动弯曲应力及R处加工刀痕引发的应力集中有关.最后提出了预防叶片发生该类失效的措施.     

回火过程对40Cr钢淬火残余应力的影响

使用40Cr钢偏心圆环试样,淬火后经不同温度和时间回火,用X-射线应力仪测定其不同部位的残余应力。对测定结果处理分析后认为,X-射线应力仪测出的残余应力值,其中有一部分是和该材料强度相对应的;回火过程中残余应力的变化,不仅与回火温度和时间有关,而且与组织转变中各相比容变化有着密切关系;同时发现,回火时也可能使残余应力增加。