火焰调修工艺对转向架用钢SMA490BW性能的影响

采用火焰调修工艺对高速动车组转向架用钢SMA490BW材料进行了变形调修,并对不同加热温度后进行喷水冷却的材料组织和性能进行研究。结果表明:经火焰调修后,屈服强度、抗拉强度和延伸率都满足SMA490BW规定的要求,呈延性断裂特征,未改变材料断裂的特征属性。随着火焰加热温度的升高,材料的屈服强度、抗拉强度变化不大,断后伸长率有所降低。当火焰加热温度为750℃～850℃时,处于Ac1与Ac3的双相区,冷却后的组织为细化的铁素体、珠光体和少量粒状贝氏体以及少量的原始块状铁素体。当温度达到900℃时,加热温度超过Ac3,由于奥氏体快速冷却形成的贝氏体含量增加,导致材料冲击韧性降低。退火工艺对金相组织结构没有影响,但可以消除内应力,降低硬度,从而改善塑性和韧性。     

Damage evaluation regarding to contact zones of high-speed train wheel subjected to thermal fatigue

Repetitive high frictional forces, induced from braking, and running of a train during railway service, generate high frictional temperature increment at the contact surface, as a result, thermal fatigue damage occurs at the surface of the wheel. Microscopic deformation in the wheel surface due to repetitive fatigue damage causes an initiation and propagation of thermal crack. That is, if the microscopic deformation is accumulated beyond the tolerance of the material resistances including the hardening of material and residual stress, then the surface will be damaged and fractured. As a result, the derailment of railway vehicle may possibly happen.In the present paper, we study on the failure analyses at the tread of the thermally damaged wheel by doing the metallurgical transformation analysis, hardness analysis, and the residual stress analysis to understand the failure mechanism of thermal fatigue damaged wheel. For this purpose, the microstructure of tread surface was examined by applying non-destructive replication method, and the hardness along the tread surface was measured. Also, the change in residual stress in the tread surface of new and thermal-damaged wheels was investigated. Meanwhile, FE analyses were performed considering the heat treatment process of wheel manufacturing, and the braking process during railway service. From the analysis results, we understand that the degree of metallurgical transformation is not the same even in the same tread surface, and residual stress measured turns into tensile stress from the compressive stress in manufacturing in the magnitude of approximately 118 MPa in the thermal damaged surface wheel. The finite element analysis (FEA) data of residual stress considering heat treatment process of wheel is in good agreement with the experimental results measured in the wheel tread.     

Research on saggars of lightweight design used to prepare cathode materials for Li-ion batteries

The focus of lightweight refractory is equivalent volume replacement that uses lower-density raw materials to replace the original high-density raw materials. In this study, we employ porous mullite microspheres (PMM) to replace mullite particles to realize the weight-lighting of mullite–cordierite saggars used to prepare cathode materials for Li-ion batteries.To confirm that lightweight saggars satisfy the quality standards of production, we conducted various tests, including mechanical properties, thermal shock stability and corrosion resistance. Compared with samples with mullite particles, samples with PMM have a comparatively stable material structure and excellent performance. Furthermore, PMM reduce mullite consumption and enhance their resistance to prevent stress shedding in the corrosion process.     

Effects of ultrasonic treatment on the formation of iron-containing intermetallic compounds in Al-12%Si-2%Fe alloys

In general, the iron impurity is detrimental to the mechanical properties of Al–Si alloys. The α-phase and β-phase are the most important and common iron-containing intermetallic compounds (IMCs) in Al–Si alloys. During conventional casting, the acicular β-phase is stable, and considered to be harmful. In this paper, the Al-12%Si-2%Fe alloy was treated by power ultrasound and solidified under different cooling conditions. The effects of ultrasonic treatment (UST) and cooling rate on morphology and composition of IMCs were investigated. The results showed that UST can change the morphology and composition of iron-containing IMCs and promote the formation of metastable α-phase. When the ultrasound was applied at 720 °C, the amount of starlike α-phase increases and the acicular β-phase decreases with increasing applied time of UST. In addition, the polygonal α-phase is formed and substitutes for the β-phase when quenching after UST for 60 s and 120 s, suggesting that the formation of β-phase can be suppressed under this condition. For the case of UST at 610 °C which the β-phase has been nucleated, the β-phase transforms from an acicular shape to the rod-like morphology, indicating that the cavitation-induced fracture of β-phase.     

加氢反应器不锈钢堆焊熔合区氢剥离行为的分析

针对309L+347L双层不锈钢带极堆焊工艺,采用高温、高压釜试验方法进行了氢剥离试验研究,试验发现氢剥离裂纹萌生于紧靠熔合区硬化带的纯奥氏体晶界并沿平行于硬化带的奥氏体晶界扩展.结果表明,氢剥离的主要机制是H原子在硬化带与奥氏体不锈钢结合界面高度聚集,造成紧靠硬化带的纯奥氏体晶界脆化,在结合界面高剪应力的作用下,裂纹萌生和扩展.采用较小的焊接热输入,抑制309L堆焊层奥氏体晶粒过分长大并保证铁素体含量;采用合理的焊后热处理,减小硬化带厚度及控制加氢反应器停运的冷却速度是防止氢剥离的有效措施.     

排气阀壳体铸造工艺的数值模拟优化

为消除排气阀壳体的渗漏缺陷,利用ZCAST数值模拟软件对原铸造工艺方案进行模拟,发现产生渗漏的区域属于后凝固的区域。对封闭式和开放式两种新设计浇注系统模拟后,发现开放式浇注系统充型平稳、液面上升稳定,解决了铸件打压渗漏问题,通过采用铬矿砂砂芯解决了局部出现夹砂的问题。     

Quantitative characterization of porosity in Fe–Al dissimilar materials lap joint made by gas metal arc welding with different current modes

5052 Al alloy sheets and galvanized mild steel sheets were joined by gas metal arc welding with three different current modes, including direct-current pulse gas metal arc welding (DPG), alternate-current pulse gas metal arc welding (APG) and alternate-current double pulse gas metal arc welding (ADG). The effect of current mode on size, distribution and volume fraction of pores generated in Fe–Al dissimilar materials lap joint was quantitatively studied. EDS result showed that pores in Fe–Al joint were mainly caused by trapped zinc metal vapor from galvanized steel. Volume fraction of pores in joints made by APG and ADG processes was larger than that in joint resulted from DPG process. Moreover, pores in joints made by APG and ADG processes had smaller diameter, and tended to distribute in the middle of the weld seam. On the contrary, pores with large diameter were inclined to distribute close to upper weld surface of the joint resulted from DPG process. These results are attributed to the difference of arc stirring force and linear heat input in these three processes caused by different current modes.     

铝合金壳盖压铸工艺优化研究

通过对铝合金壳盖压铸件进行实体造型,采用铸造数值模拟软件Z-Cast对铝合金壳盖压铸过程的压力场、速度场和温度场进行数值模拟,根据模拟结果分析浇注系统和溢流槽尺寸的合理性,重新设计、优化浇注系统的形状和布置位置,得到合理的压铸方案。对于铝合金压铸件结构和压铸工艺设计有着重要的指导意义。     

Improved thermoelectric properties of SiC with TiC segregated network structure

A TiC segregated network structure (SNS) approach was utilised to improve the thermoelectric properties of SiC. Different amounts of TiC particles were dry coated on SiC granules to form electrically conductive SNS; then the powder mixtures were spark plasma sintered at 2200°C. The TiC-SNS simultaneously increased the electrical and decreased thermal conductivity of SiC but adversely affected the Seebeck coefficient. By adding 10 vol% TiC, an ≈ 800% increase in electrical conductivity and a ≈ 50% decrease in thermal conductivity were achieved, but the Seebeck coefficient deteriorated due to the metallic nature of the material. A maximum ZT of 5.04 × 10⁻³ was achieved at 923 K, by limiting the Seebeck coefficient's reduction by optimising TiC content to 1.5 vol% while simultaneously increasing the electrical conductivity by ≈ 100% and reducing thermal conductivity by ≈ 40%. This ZT value is almost 90% higher than any value recorded in the literature for SiC.     

Catalytic synthesis of long NbS2 nanowire strands

Large-scale of long NbS₂ nanowire strands were successfully synthesized by a catalyzed transport reaction involving C₆₀. The strands have a diameter of 1–2 μm and length up to 0.5 mm, which are composed of single nanowire. The diameter of single nanowire is 1.6–20 nm. The products were characterized by powder X-ray diffraction, transmission electron microscopy, selected area electron diffraction, high-resolution transmission electron microscopy, scanning electron microscopy, and X-ray photoelectron spectroscopy. Probable mechanisms for catalytic growth were proposed.