AZ31镁合金管材游动芯头拉拔有限元模拟

运用Deform软件模拟了AZ31镁合金管材游动芯头拉拔过程,并对比研究了模具锥角、定径带长度、变径带长度对拉拔管材成形性的影响。结果表明:在拉拔AZ31管材时,最大压应力出现在外模变径段与定径段过渡区,合适的模角配合不仅能降低拉拔力,还能提高尺寸精度。模具定径段长度对管材变形时的均匀性和拉拔力的影响较大,变径段长度对管材拉拔的影响较小。最终通过实验验证了模拟结果,制备出了尺寸精度高的AZ31镁合金管材。     

芯轴摩擦系数对推压-拉拔复合缩径的影响

推压-拉拔复合缩径工艺是管坯减径的新方法,芯轴外表面与管坯内表面之间摩擦系数对工艺有重要的影响。通过建立推压-拉拔复合缩径变形过程中变形管坯的力学模型,分析了芯轴外表面与管坯内表面之间摩擦系数对成形的影响规律。针对某载重6.5 t胀压成形汽车桥壳管件的第一道次推压-拉拔复合缩径,设定不同的芯轴摩擦系数,进行了有限元仿真,得到了芯轴摩擦系数对管坯变形的影响规律,并基于管坯传力区不失稳以及变形所需凹模推力和芯轴拉拔力较小,给出了芯轴摩擦系数的设定范围。进行了缩径实验,实验和有限元模拟的结果接近。较小的芯轴摩擦系数可能造成管坯起皱失稳,而较大的芯轴摩擦系数,有利于降低管坯轴向压应力、凹模推力和芯轴拉拔力,但可能造成管坯表面划伤。     

焊接用钢盘条断裂分析

采用低倍检验、金相检验及化学成分分析等方法,对焊接用钢盘条在拉拔过程中出现断裂失效的现象进行了分析。结果表明:钢盘条在拉拔过程中出现了严重的加工硬化,导致表面裂纹形成和断裂失效。     

多芯复合超导线拉拔的有限元模拟

利用商业有限元软件DEFORM-3D对多芯复合超导线材的拉拔过程进行有限元模拟,研究变形过程中复合超导线各亚组元的变形情况,以及拉拔速度对超导线成形的影响.分析超导线拉拔过程中等效应力、等效应变的分布规律;并且结合韧性断裂准则来预测不同位置开裂产生的可能性.总结出拉拔速度对拉拔过程的影响规律,确定了拉拔过程中的危险区域.     

基于模具创新设计的高强钛管小半径加热绕弯扁化控制

目的 发展小直径高强钛管小弯曲半径(R=1.5D)加热弯曲成形的截面扁化缺陷控制技术.方法 基于对管材弯曲前预变形和弯曲过程中施加有效约束的原理,设计变曲率型腔的反变形压力模结构、勺形芯模结构和带芯球的柔性芯模结构,结合有限元仿真分析,研究探索不同模具结构设计对弯管截面扁化的影响.结果 与"压力模+圆形芯棒"模具组合相...     

碳纤维/聚醚醚酮(PEEK)复合材料拉拔制管工艺设计和模拟

从太空制造角度出发,设计了一种碳纤维/聚醚醚酮(PEEK)预浸复合板料拉拔连续制管工艺.综合考虑了预浸复合板料的供料放卷过程、冲压、拉拔成形工步和超声焊接工序,并创造性的提出了卷曲拉挤成型方式.利用Johnson-Cook和Holzapfel-Gasser-Ogden模型构建了一种以PEEK为基体,以碳纤维编织布为增强体相互叠加的材料模型,通过实验数据确定材料参数.采用商业软件ABAQUS对各工序分步进行了地面条件下的有限元数值模拟,分析了预浸复合材料板材在供料放卷、冲压拉拔成形过程中的应力分布,并采用蔡-希尔最大变形能理论证明了本文设计的放卷模具和卷曲成形模具可以进行连续制管.在焊接过程中,分析了预浸料基体PEEK在焊接区域产生的Mises应力分布,证明了超声波焊接方案对管材表面质量的影响较小.模拟结果表明,所设计的连续拉拔制管工艺能够快速有效地生产出表面良好的管材.仿真结果可为后续复合材料在轨拉拔连续制管的工艺设计和制造提供借鉴.     

新型医用TLM钛合金管材加工工艺及性能研究

选择同样规格管坯进行了:①变形量ε分别为15%,28%,34%,40%的冷轧变形实验;②Q值为0.86,1.15,2.62的冷轧变形实验;③加热温度分别为680,715,730,820℃,均保温1 h的中间退火实验;④5种热处理工艺制度实验;⑤冷轧和拉拔2种不同加工方式实验.实验后用10%HF+30%HNO3+60%H2O酸洗液对管材表面进行处理,之后测试管材的力学性能.结果表明,该合金的变形量(ε)应选在30%～35%之间,Q值控制在2以下;中间退火温度应选在相变点以上,此时可获得最高的合金塑性,具有优良的冷加工性能;最终热处理应先在750℃固溶处理,然后再在510℃时效处理4 h可以得到塑性和强度匹配良好的管材.另外,采用轧制方法生产出的管材强度较高,塑性较低,表质量好,而采用拉拔方法生产出的管材塑性较高,强度略低,表面光洁度差.     

镜面塑料模具失效表面的缺陷分析

针对1.2083镜面塑料模具在抛光过程中出现的表面疤状凸起缺陷进行了系统分析.综合运用光学显微镜、场发射扫描显微镜等分析技术对表面缺陷的形貌、组织、微区成分及其与非金属夹杂之间的联系进行研究,同时分别对失效模具产品和金相试样的表面粗糙度进行了对比测量.结果表明,由于该模具钢材内部多种非金属夹杂物的存在以及局部成分不均等因素,导致模具在抛光过程中基体的连续性遭到破坏,从而引起产品表面出现肉眼可见的疤状凸起缺陷,导致模具失效.     

冠脉支架用CoCr合金管材拉拔工艺与组织分析

对大变形轧制后的CoCr合金管坯在不同退火条件下进行热处理，通过金相显微镜、电子拉伸试验机等分析手段，检测成品管的显微组织及力学性能，分析热处理参数对试样拉伸性能和显微组织的影响，并研究拉拔变形量对试样拉伸性能和显微组织的影响。结果表明：温度为1 100℃、保温时间为10 min,管材的析出物较少，有很好的强塑性匹配，可保证管材的后续顺利拉拔。随着变形量增加，管材晶粒逐渐破碎，并被拉拔成平行于拉拔方向的纤维状，其抗拉强度增大，延伸率减小，变形量为15%时，管材屈服强度显著提高，后续趋于平缓。本研究为制备不同强塑性管材提供依据。     

冷拉拔管棒材的残余应力测试与分析

用电阻应变片法测试了管棒材拉拔、矫和退火过程中产品表面残余应力,了管棒材残余应力随工艺参数变化的规律,结果表明,用不同变形方法生产管材,其表面残佟尖力相差很大。对制品采用去应力低温退火,在金属内部完成回复过程是减小制品残余应力最有效的措施。     

Analysis of pitting corrosion failure of copper tubes in an apartment fire sprinkler system

Microscopical and structural analyses as well as visual inspection of copper tubes were used to investigate the cause of pitting corrosion failure of copper tubes in the wet pipe sprinkler system. Chemical analysis of the water in the copper tubing and XRF/XRD analysis of its sediments were also used to obtain hints on what was happening in the copper tubing during the progress of the pitting corrosion. It was found from the failed copper tube that a significant amount of pressurized air was present over the water in the copper tubing during operation and a series of corrosion pits were aligned adjacent to the water/air line. The waterline localized corrosion, a type of differential oxygen concentration cell corrosion, induced by pressurized air over the water in the copper tubing was identified as the cause of the pitting corrosion failure. A state of a very low oxygen concentration was maintained under the envelope of a dense layer of malachite, the corrosion byproduct, which was evidenced by the formation of Cu₂O crystalline particles inside the corrosion pit. CuO particles observed on the inside surface of the copper tube do not seem to help prevent local as well as general corrosion. Accelerated pitting corrosion of the copper tube in the wet fire sprinkler system was simulated using a differential aeration cell. Finally, measures for stopping or delaying the pitting corrosion of the copper tube in the wet sprinkler system are suggested.     

Failure analysis of a copper tube in a finned heat exchanger

This paper reports on the failure analysis of a finned heat exchanger which leaked in the pressure test during commissioning. The heat exchanger was composed of panels made of thin-walled copper tubes and aluminum fins, and the structure was typical of equipment used in the heating, ventilation and air-conditioning industry. The tube material was phosphorus deoxidized copper Cu–DHP. In the pressure test, one of the tubes was found to have three leakage points. The investigation showed that the failure was a consequence of ant-nest corrosion, as all the experimental findings, together with the copper grade and the tube dimensions, were typical of this corrosion mechanism. Corrosion had initiated from the outer surface of the tube. The paper presents the morphology of the failure using optical and scanning electron microscope (SEM) micrographs. The presence of a contaminating organic substance on the outer tube surface and inside the corrosion crack was verified by SEM/EDS analyses. The corrosion mechanism and the relevant chemical reactions given in the literature are summarized, and the conditions in which the failure may occur are presented. Ant-nest corrosion is a special form of local corrosion, and associated most often with deoxidized copper tubes used in heat transfer applications as in this study.     

Investigation of pitting corrosion of a copper tube in a heating system

Electrochemical tests, as well as surface and chemical analyses were used to examine the mechanism of pitting failure of a copper tube. Synthetic tap water simulating the hot water in a heating system and field-used heating water at 60 °C were used as electrolytes in these tests. The results showed that the presence of a Cu(I) oxide layer on the copper surface is essential for pitting corrosion of a copper tube in hot synthetic tap water. Moreover, the pitting corrosion of copper tubes is preferred in heating water containing higher concentrations of Fe species and under stagnant condition.     

空调器用翅片管式蒸发器铜管点蚀分析及预防措施

针对空调器用翅片管式蒸发器铜管点蚀泄漏故障,结合铜管点蚀失效机制,从使用环境及蒸发器结构方面进行分析。研究发现,空气中含有的氯气或氯化物、氨气等溶解于冷凝水中形成腐蚀性离子,蒸发器相邻翅片叠加位置存在明显的孔洞状间隙,使冷凝水长期积存引起腐蚀性离子对铜管表面的腐蚀破坏作用,是导致蒸发器铜管点蚀泄漏的根本原因,鉴于此,提出避开腐蚀源、采用高耐腐蚀铜管、在铜管表面涂覆缓蚀剂、优化蒸发器翅片与铜管接触结构等预防措施。     

蒸发器亲水性对空调性能影响的试验研究

采用平衡环境型房间量热计测试了亲水性不同的三组铜翅片蒸发器在不同含湿量下空调制冷性能,测试结果显示,在低湿时,除湿量较小,凝结水排除能力足够,亲水性改善空调制冷性能作用不大,在高湿时,除湿量较大,需要较强的凝结水排出能力,亲水性改善空调制冷性能作用明显。     

T3铜管的腐蚀及其分析

T3铜管衬套在冷挤压成型前的软化退火、酸洗后其表面产生严重腐蚀，造成整批产品报废。对该产品及其腐蚀产物进行了金相检验、化学分析等检验，综合各项检验结果并采用模拟试验的方法详细分析了产生铜腐蚀的原因和机理。试验证实，在潮湿条件下铜与氯化物、铁等金属氧化物接触时的化学和电化学腐蚀，退火加热使衬套产生了严重腐蚀。     

TP2铜管退火后起皮原因分析

采用化学成分分析、金相检验、扫描电镜和能谱仪分析等方法对TP2铜铸锭及其挤制管坯起皮的原因进行了分析。结果表明,在TP2铜铸锭和挤制管坯均分布着Cu2O颗粒。当挤制管在还原性气氛下退火时,因还原反应产生的气体而造成管坯表面起皮。采取了相应措施解决了起皮问题。     

Corrosion of a copper U-shaped heating element: Some morphological and microstructural observations

In this work, observations of the corrosion on a failed copper U-shaped tube, of 1 mm nominal thickness, are presented. This tube was subjected to severe corrosion and subsequent cracking after a month of operation as the heating element of an electrical boiler. Morphological and microstructural observations of the failure area as well as cross sections of the corroded copper tube are presented. Moreover, the chemical composition of the material and the principal physicochemical characteristics of the tap water used for boiler operation were determined in the context of the failure investigation. The quality of the water used for boiler operation was a significant factor influencing the heating element efficiency and reliability. Hard water with high electrical conductivity accelerated salt precipitation and led to the corrosion and premature failure of the components.     

采用铜铝复合管的翅片管换热器换热性能数值模拟与实验研究

提出采用一种铜铝复合管,用来替代传统的空调室外机换热器用铜管,可降低成本27.8%。首先通过数值模拟研究了Φ7管径的铜铝复合管与铜管翅片管换热器空气侧的传热与流动性能,计算结果表明,在入口风速为2.5m/s的情况下,与采用铜管的换热器相比,采用铜铝复合管的换热器空气侧的压力分布几乎不变,换热量降低3.12%,对性能影响较小。另一方面,对采用该模型的铜铝复合管换热器进行了性能测试,实验结果表明:铜铝复合管换热器换热量为8775W,与铜管换热器9101W相比降低3.58%,满足换热器标准要求。实验结果与数值模拟结果基本吻合,均证明这种新型铜铝复合管对换热器性能的影响不大,可用于空调的制造中。     

Analysis of helium II thermal links for instrument cooling in low gravity

The Low Temperature Microgravity Physics Facility (LTMPF) is a reusable, cryogenic facility that will accommodate a series of low temperature experiments to be conducted at the International Space Station. The facility will use a He II cryostat to cool the instruments. Some configurations of the science instruments in the cryostat will require an enhanced thermal link between the He II bath and parts of the instruments. Such an enhanced link can be made with plumbing filled with He II. This paper reports the results of analysis that was performed using the BATC proprietary helium flow software called SUPERFLO, on four different concepts for this link. The four concepts analyzed were: a simple tube with the heated end closed, a closed end tube with a porous plug at its entrance, a closed end tube filled with capillary tubes, and a porous plug driven flow loop. It was found that the concepts that used a porous plug were more robust since they were much less prone to boiling. This is due to the low gravity which causes all of the liquid in helium tank and plumbing to be very close to saturated conditions unless a porous plug is used to create a thermomechanical pressure. The effects of varying system parameters such as a acceleration, heat flux, pore size and tube size were also investigated and the results are reported.