Ti-6Al-4V电弧熔丝增材轧制复合制造的有限元模拟

增材制造过程中由于在凝固及随后的冷却阶段易产生残余应力,从而影响部件的成形和使用。在增材过程中引入轧制工序,可望降低宏观残余应力,从而降低部件的变形。本文通过建立Ti-6Al-4V钛合金电弧熔丝增材与层间轧制复合成形过程的有限元模型,研究圆柱形轧辊条件下不同压下量对部件温度、应力、应变及残余应力分布的影响规律。结果表明,层间轧制可显著降低沉积层金属中的残余宏观应力；同时降低对基板的整体应力。采用圆柱形轧辊并增加压下量可显著降低宏观残余应力,还可以通过塑性变形改变材料的微观组织,提高材料性能,为复合增材工艺的优化指明了方向。     

Effects of welding parameters and welding sequence on residual stress and distortion in Al6061-T6 aluminum alloy for T-shaped welded joint

The distribution of temperature and then the distribution of residual stress and distortion in the stiffened aluminum alloy Al6061-T6 plates under the metal inert gas (MIG) welding process were investigated by three dimensional thermo-mechanical coupled finite element model using Ansys software. The properties of materials were considered temperature-dependent and the filler metal was added to the workpiece by the element birth and death technique. In three modes of current, two different speeds and two various sequences, the distribution of residual stress and distortion were calculated and analyzed. The results showed that increase in welding speed decreased the vertical deflection in the plate, transverse shrinkage and angular distortion of plate and the lateral deflection of stiffener, but increased the maximum longitudinal tensile stress in the plate and stiffener. Furthermore, increase in current increased the residual stress and deformation in the plate and stiffener, and the change in the welding sequence changed the distribution of the distortion in the plate and the stiffener without significant change in the distribution of the longitudinal residual stress.     

金属薄板平面铣削形变分析与控制

由于初始残余应力的作用,金属薄板平面加工普遍存在加工难度大,加工变形严重等问题,难以保证板面的加工质量。以不锈钢薄板的平面加工为基础,通过理论分析、仿真模拟和实验验证的方式,对金属薄板的加工形变进行较为系统的研究,分析了金属薄板加工形变的关键因素,总结了金属薄板残余应力分布形式以及有效避免加工形变的工艺方法,为类似金属板材加工提供理论参考依据。     

近距离煤层煤柱下应力分布和巷道支护技术

针对和尚嘴煤业近距离煤层煤柱下掘进巷道变形大的问题,在介绍地质力学特征的基础上,采用数值模拟分析上部煤层不同方式采动后,采空区和煤柱在下部煤层的应力分布情况。分析煤柱下巷道变形特点和支护要点,结合高预应力强力锚杆支护理论,提出合理的锚网与锚索联合支护设计,现场试验效果明显。     

Measurement of residual stresses in dissimilar friction stir-welded aluminium and copper plates using the contour method

The longitudinal residual stresses in the friction stir-welded plates of 5A06 aluminium and pure copper were determined using the contour method. The results revealed the presence of high tensile and compressive residual stresses on the aluminium and copper sides, respectively. The residual stresses were detected on the weld zone as well as the thermo-mechanically affected zone (TMAZ) of the aluminium plate. In contrast, the compressive residual stresses in the copper plate had a much narrower width along the weld line. Peak tensile stresses up to 240?MPa were found in the TMAZ of the aluminium plate.     

Effects of stray AC on corrosion of 3-layer polyethylene coated X70 pipeline steel and cathodic delamination of coating with defects in 3.5 wt-% NaCl solution

In this work, the effects of stray alternating current (AC) on the corrosion of coated X70 pipeline steel and the delamination of 3-layer polyethylene (3PE) coatings with defects were investigated using COMSOL Multiphysics simulation, electrochemical impedance spectroscopy and three-dimensional (3D) digital microscope techniques. The results showed that under the same level of AC interference, pits with deeper maximum pit depth were observed at the smaller defect areas than those at larger defect areas. It was consistent with the simulation results that a greater corrosion current density was accompanied on samples with smaller defects. According to 3D digital images, the larger delamination of 3PE coatings was found on samples with smaller defects. With the increase of current density, the impedance of samples with small defects decreased, while that of samples with large defects increased. Additionally, with the same defect size, the maximum pit depth became deeper and the corrosion was more severe.     

MOCVD-derived GdYBCO tapes with smooth surface and low Rs based on a new self-heating technology

The metal organic chemical vapor deposition (MOCVD) method was used to prepare GdYBCO films on LaMnO₃/ homo epitaxial-MgO/ ion-beam-assisted-deposition-MgO/ solution-deposition-planarization-Y₂O₃ buffered Hastelloy tapes. By adopting a simple self-heating technique, the substrates were heated by the joule effect after applying a heating current (I_h) through Hastelloy metal tapes. The effects of substrate temperature and (Gd, Y)/Ba ratio (r_c) in the precursor on the biaxial texture, surface morphology and superconducting performance of GdYBCO films were systematically investigated by varying the values of I_h and r_c. Needle-like outgrowths formed on the substrate surface were characterized using a scanning electron microscope, energy dispersive spectrometer and X-ray diffraction system. The results show that a high I_h or r_c leads to the formation of needle-like outgrowths. Therefore, I_h and r_c are crucial process parameters that control the growth of needle-like outgrowths on the surface of GdYBCO films. Three hundred nanometer thick GdYBCO films were prepared at different I_h and r_c by the MOCVD process. At an I_h of 27.0?A and an r_c of 0.6, the surface of the GdYBCO film was very smooth and dense, which can provide a good template for multiple depositions of GdYBCO films. The critical current density of the deposited 300?nm-thick GdYBCO film was 4.4 MA/cm² (77?K, 0?T), which is attributed to good biaxial texture and appropriate film composition. Furthermore, the microwave surface resistance (77?K, 10?GHz) of the GdYBCO film was merely 0.581?mΩ.     

Effects of chemical etching on structure and properties of Y0.5Gd0.5Ba2Cu3O7-z coated conductors

Corrosion resistance is a crucial property to achieve successful superconducting joints of Y_0.5Gd_0.5Ba₂Cu₃O_7-z (YGdBCO) coated conductors (CCs). Cu and Ag metallic layers need to be fully removed from the area of conductor to be joint to allow for a superconducting path across the joint. Therefore, when using a wet etching process to remove the metallic layers, the joint performance can be significantly influenced by the etching conditions. The effects of chemical etching with ammonia water and hydrogen peroxide mixture on crystal structure, surface microstructure and critical current (I_c) of YGdBCO CCs were systematically investigated. We found the set of etching parameters that does not affect conductor performance, leaving the I_c of the YGdBCO conductor unchanged upon etching. However, when the etching conditions are not optimal, decrease in I_c was found and the underlying reasons driving the degradation were investigated. Raman spectroscopy and XRD analysis indicated that the reduced I_c is mainly due to oxygen deficiency in the YGdBCO crystal lattice.     

Numerical modeling assessment of mechanical effect in bovine leather drying process

Leather manufacturing involves a crucial energy-intensive drying stage in the finishing process to remove its residual moisture and generates important heat gradients. The numerical model presented in this study has been developed to describe the drying process of porous medium: bovine leather that undergoes deformation due to shrinkage. The mathematical formulation of fundamental heat, mass and momentum transfers’ phenomena during drying summarizes a two-dimensional model considering elastic behavior of bovine leather. The evolution of moisture content, temperature, and mechanical stresses during drying was discussed. The model was validated with experimental results. Numerical simulations show good agreement with experimental results. The study shows that the elastic model keeps the stress sign at the final stage of drying. The deformations induce tensional stresses near the surface equilibrated by compressive stresses within the product. They reached their maximum for normal stresses equal to 5.97 and 3.52?MPa at around 2145 and 868?s, respectively, for normal stresses along x and y directions and then decrease.