基于遗传算法的低压铸造铝合金车轮工艺优化

为解决低压铸造铝合金车轮质量控制难度大的问题,采用遗传算法对工艺参数进行优化.基于铸造数值模拟结果,利用BP人工神经网络建立了铸造工艺参数与质量控制目标缩松缺陷和凝固时间的非线性关系,采用遗传算法实现了铸造工艺参数的优化.以某型低压铸造A356铝合金车轮为例,对浇注温度、上模温度、下模温度、侧模温度、模芯温度5个参数进行优化,得到的最佳工艺组合,可有效控制缩松缺陷和凝固时间.利用数值模拟结果、建立神经网络模型,采用遗传算法优化的方法,获得近似最优解,有助于优化低压铸造工艺.     

Effect of processing parameters on the microstructure and mechanical properties of Al–steel composite foam

Al–steel composite foams comprise of steel hollow spheres embedded in an aluminum matrix and are processed using a gravity casting technique. The effect of processing parameters such as casting temperature and cooling rate on the microstructure and mechanical behavior was studied to establish structure–property relationships. Results show that the amount and composition of intermetallic phases present in the foam microstructure is directly related to casting temperature and cooling rate. Highest strength and energy absorption were obtained from Al–steel foams with fast solidification rates that minimize the growth of intermetallic phases.     

The effect of die geometry on the microstructure of indirect squeeze cast and gravity die cast 7050 (Al-6.2Zn-2.3Cu-2.3Mg) wrought Al alloy

The indirect squeeze casting process has been used to cast a 7050 (Al-6.2Zn-2.3Cu-2.3Mg) wrought Al alloy to near-net shape with excellent die replication. Defects which occur with gravity casting, in particular (1) shrinkage pipe, (2) macro-porosity and (3) hot-tearing, are largely removed by squeeze casting, although regions of macro-porosity can re-appear when thick sections are fed through substantially thinner sections. Squeeze casting results in a considerable refinement of microstructure compared to gravity casting due to a marked decrease in solidification time. The decrease in solidification time is caused by intimate contact between the pressurised melt and the die, which leads to an increase in the heat transfer coefficient. Decreasing the section thickness also results in a refinement of the microstructure due to a reduction in solidification time. This revised version was published online in September 2006 with corrections to the Cover Date.     

多孔铝合金的铸造工艺研究

采用加压铸造工艺，制备出了多孔铝合金。系统地研究了预制块的制备工艺过程及影响因素。利用所制备的预制块，研究了多孔铝合金的加压铸造工艺。研究表明，预制块孔隙大小及其初始温度、金属液浇注温度、外加压力等影响了金属液在预制块中的充型长度。采用合理的工艺，就可以获得大尺寸的多孔制品。     

铝合金压铸工艺数值模拟分析

采用压铸工艺成形铝合金薄壁长轴类零件。首先根据压铸模具浇注系统的设计原则,对铝合金件压铸模的浇注系统进行了设计计算;其次运用procast软件对铝合金压铸成形工艺进行数值模拟,根据压铸过程中的温度场云图,进行了压铸模具的热平衡分析和压铸件的充型凝固分析;最后针对模拟的结果进行了压铸模具的设计。     

AN EXPERIMENTAL STUDY OF THE STRIP CASTING PROCESS OF ALUMINUM ALLOY BY THE TWIN ROLL METHOD

Experimental studies on the twin roll casting process in order to produce thin aluminum alloy strips are presented in this paper. A new twin roll caster was developed as an effective experimental tool. The caster is equipped with a complete casting system incorporating a control and measuring system using multiple sensors and various actuators. The data acquisition system of the caster can measure various process parameters including meniscus, casting speed, and temperature as well as roll gap and pressure. With this system, aluminum alloy thin strips were manufactured and the process parameters such as strip temperature, casting velocity, and pressing force of roll were investigated. Furthermore, the crystallizability, microstructure, and mechanical properties of the strip are evaluated by X-ray diffractometer, scanning electron microscope, and tensile test. The results revealed the ability of the twin roll caster to produce directly the thin strip of aluminum alloy with improved mechanical strength.     

Mold-Filling Ability of Aluminum Alloy Melt during the Two-Step Foaming Process

For the two-step foaming method,one of the most cost-effective ways to fabricate three-dimensional shaped aluminum alloy foams with dense outer surface skin,it is crucial to describe and predict the moldfilling behavior of the shaped aluminum alloy foams with a favorable pore-distribution accurately.In this paper,a mold-filling model for semi-solid aluminum alloy foams was initially established and subsequently employed to predict the filling height,which represents the mold-filling ability of semi-solid aluminum alloy foams in a specially designed tube-like mold.Our results indicate that the proposed model can be applied to characterize the mold-filling property of aluminum alloy melts in a quantitative manner.Theoretically,our findings actually provide a guideline for mass-production of the shaped aluminum alloy foams by using the two-step foaming process.     

浇注温度对定向凝固Al－Cu合金热裂的影响

针对空心叶片类定向凝固铸件存在的热裂问题，开展了定向凝固热裂规律的研究。本文选择凝固参数较全的Ａｌ－Ｃｕ系合金，研究了定向凝固工艺参数之一的浇注温度对Ａｌ－０．６ｗｔ％Ｃｕ和Ａｌ－２．０ｗｔ％Ｃｕ合金热裂的影响。定向凝固热裂试验表明，提高浇注温度可以降低Ａｌ－０．６ｗｔ％Ｃｕ合金的热裂程度，但对Ａｌ－２．０ｗｔ％Ｃｕ则无作用。理论分析认为，合金在不可补缩区的冷却速率变化是改变合金热裂程度的重要因素。     

基于数值模拟的杆状钛合金铸件熔模铸造工艺研究

根据杆状钛合金铸件的结构特点,分别采用顺序凝固理论和均衡凝固理论设计浇注系统,并利用数值模拟方法对两种浇注系统进行了仿真,分析了杆状钛合金铸件的温度场、应力场情况,确定了利用均衡凝固理论的铸造方案适合生产该铸件,根据模拟结果,对铸造工艺方案进行优化模拟。采用优化后的铸造工艺方案生产铸件,获得了合格的符合客户需求的杆状钛合金铸件。      

EPS bead fusion effects on fold defect formation in lost foam casting of aluminum alloys

The effects of bead fusion in the polymer pattern on fold defect formation in castings produced by the lost foam process have been investigated. Castings of aluminum alloy 319.1 were produced with commercial patterns that were molded with varying levels of bead fusion. Each casting was broken into over 40 pieces to identify the fold defect on the fracture surface. The results indicate that castings produced with patterns with high bead fusion exhibit a greater number and a larger area of folds than parts obtained by using foams with low bead fusion.     

Technique of Aluminum Alloy Composite by Inversion Casting

The influence of the temperature of liquid aluminum alloy,the dipping time in liquid alloy and the thickness of base strips on the solidified layer was studied during the process of producing aluminum alloy composite strips used in automobile radizator with inversion casting.It is concluded that there is welding as well as diffusion of alloying elements between the base strip and the coating.Experiments proved that the interface has a good bonding.     

Characterization of close-celled cellular aluminum alloys

The deformation behaviour of two different types of aluminium alloy foam are studied under tension, compression, shear and hydrostatic pressure. Foams having closed cells are processed via batch casting, whereas foams with semi-open cells are processed by negative pressure infiltration. The influence of relative foam density, cell structure and cell orientation on the stiffness and strength of foams is studied; the deformation mechanisms are analysed by using video imaging and SEM (scanning electronic microscope). The measured dependence of stiffness and strength upon relative foam density are compared with analytical predictions. The measured stress versus strain curves along different loading paths are compared with predictions from a phenomenological constitutive model. It is found that the deformations of both types of foams are dominated by cell wall bending, attributed to various process induced imperfections in the cellualr structure. The closed cell foam is found to be isotropic, whereas the semi-open cell foam shows strong anisotropy.     

Dynamical Solidification Behaviors and Metal Flow during Continuous Semisolid Extrusion Process of AZ31 Alloy

In this paper, a novel near-net-shape forming process, continuous semisolid extrusion process (CSEP) of AZ31alloy was proposed, and the dynamical solidification behaviors and metal flow during the process were firstly investigated.During casting AZ31 alloy by this process, non-uniform microstructure distributions and nonequilibrium solidification region near the roll surface were found in the roll-shoe gap.Microstructural evolution from dendrite to rosette and spherical grains was observed during the casting by CSEP.Casting temperature,roll-shoe gap width and cooling ability have great effect on casting process and metal flow, so these factors should be carefully controlled, a proper casting temperature of 710-750℃ is suggested.The white a phases were strongly stretched during the processing, and the remnant liquids are correspondingly distributes along the solid phase boundaries and also show stripped lines.     

Continuous semisolid extending extrusion process for producing AA2017 aluminium alloy flat bar

Abstract

A novel testing machine for a continuous semisolid extending extrusion process (CSEP) has been designed and used to produce AA2017 alloy flat bar. Fine and homogeneous grains of AA2017 slurries with rosette structures were obtained at suitable casting temperatures. During preparation of semisolid AA2017 alloy by the proposed process, rosette grain formation was observed during the application of the large force provided by the rough roll. By controlling casting temperature, AA2017 products were produced with fine surfaces and rectangular transections of 14 × 25 mm. A casting temperature range of 710–750°C was suggested. The microstructure of the product is fine and even with striped appearance and is composed mainly of θ and α phases. The fracture strength of AA2017 product produced by the semisolid extending extrusion process is improved by 100 MPa, and elongation by 29%.     

The dependence of damping property of fly ash reinforced closed-cell aluminum alloy foams on strain amplitude

Closed-cell aluminum alloy foams with 1.5, 3.0 wt.% fly ash particles have been manufactured by molten body transitional foaming process. The room temperature damping properties of fly ash reinforced aluminum alloy foams were measured at different strain amplitude in two directions using the forced vibration mode. The results show that the damping properties of fly ash reinforced aluminum alloy foams increase with FA content. A critical strain amplitude ε_crit was observed and ε_crit decreases with increasing FA content. Moreover, the damping property in the transverse direction is higher than that in the longitudinal direction. The related mechanism has been discussed.     

基于数值模拟的大型复杂灰铁铸件工艺设计

为防止某大型复杂铸件产生缩孔缺陷并降低铸造成本,采用数值模拟方法对其铸造工艺参数进行定量化设计.应用Pro CAST软件对铸件进行凝固分析,通过提取凝固结果中的各参数(温度场、固相温度的密度、焓变化等)对模数进行求解,定量得到铸件的高模数分布区域,而后通过分析模数分布区域并结合均衡凝固理论设计了冒口、冷铁与浇注系统,运用Pro CAST软件对铸件的充型及凝固过程进行模拟.研究表明:该大型铸件应采用底注式浇注系统为宜,对铸件中部与底部模数达到2.5 cm的热节处采用冷铁和铬铁矿砂处理热节,对铸件顶部模数达到2.5 cm的部位采用飞边冒口进行补缩;提取凝固模拟结果中热节处的平均模数和金属液体积,即可对冒口尺寸进行定量化设计;通过观察模拟结果中浇口杯金属液水平高度的变化,可得出浇注系统进行液态补缩的时段.     

铝(镁)合金消失模铸造近净成形技术研究进展

阐述了铝(镁)合金消失模铸造技术的研究现状,着重介绍了铝(镁)合金消失模铸造在金属液充型、振动凝固、压力凝固以及消失模壳型铸造等技术方面的最新研究进展。研究表明,铝(镁)合金在消失模铸造过程中,需重点解决针孔、缩松等缺陷,提高液态合金的充型能力和铸件的力学性能;通过采用振动凝固和压力凝固的手段,可以提高金属液充型能力、细化组织、提高组织致密性,明显提高铸件力学性能。真空低压消失模壳型铸造技术,可以解决普通消失模铸造易于出现的孔洞和夹杂等缺陷以及浇不足和浇注温度高等问题,是一种生产复杂薄壁高质量铝、镁合金精密铸件的新方法。     

Investigation and characterisation of aluminium alloy foams with TiH2 as a foaming agent

This article presents an account of experiments used to produce aluminium alloy foams by the melt route process using titanium hydride as a foaming agent. Powdered titanium hydride with content of 0.4–1.4% (mass fraction) was added to the molten pure aluminium and the foaming condition was controlled at 690°C (1274°F). In the process, homogeneous aluminium foams were produced with a calcium amount of 1.0–3.0% (mass fraction). The mechanical properties of the aluminium foams with diverse relative density were tested. The result indicates that the foaming agent is suitable for making small aperture aluminium foams with an average pore diameter of 1.2?mm.     

空心管坯电磁离心过程的数值模拟

用有限元法模拟了铸造合金的流动和热量传输过程中瞬态速度场和温度场的分布,研究了电磁场强度和离心机转速对电磁铸造空心管坯的影响.结果表明,电磁搅拌引起的熔体相对运动是凝固过程中晶粒细化的主要原因.最优的电磁搅拌条件:转速1200 r/min,磁场强度为0.08 T,磁场持续加载25 s.在一定的转速和磁场强度条件下电磁离心铸造的温度场和凝固时的温度梯度对凝固组织有重要的的影响.合金液的外层,温度梯度达到最大值,铸件的温度下降得快,容易形成细小的等轴晶.