连铸大方坯自然热收缩行为的有限元模拟分析

结合国内某钢厂360 mm×450 mm大方坯连铸的实际生产工艺,利用商用有限元软件MSC.MARC对连铸大方坯自然热收缩行为进行三维热力耦合模拟。本次有限元模拟采用热弹塑性模型,研究不同拉速下铸坯温度场与凝固收缩规律。研究结果表明：拉速越高,温度变化越慢,铸坯总收缩量越小;拉速越小,温度变化越快,铸坯总收缩量越大;铸坯在宽度方向和厚度方向表现出不同规律的自然热收缩行为。     

Effect of electromagnetic field on macrosegregation of continuous casting 7075 alloy

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Effects of continuous cast section size on torsion deformation and fatigue of induction hardened 1050 steel shafts

This study investigates the influence of continuous cast section size on the mechanical performance of induction hardened parts produced from steel bars. SAE 1050 steel from commercially produced Jumbo Blooms, Blooms, Rotary Round, and Billet were hot rolled into round bars with diameters of 37-44 mm. These bars were then normalized, machined into test specimens, the gauge sections were polished, and the specimens were case-hardened by induction hardening. Torsional monotonic and fully reversed cyclic fatigue tests were conducted to study the effect of the initial continuous cast section size on deformation and fatigue behaviors. Reduction ratios in this study ranged from a low of 20.4:1 for the Billet, up to a high of 142:1 for the Jumbo Bloom. Test results indicate that the continuous cast section size has only small effects on the torsion monotonic and cyclic deformation properties and negligible effect on the torsion fatigue performance. Small differences observed in deformation and fatigue properties between the four processes are attributed mostly to the variation in case and core hardness levels caused by small differences in chemistry, particularly carbon content. Variations in sulfur content also influence ductility and fatigue behavior. At high strains, the cracks initiated in shear as longitudinal cracks for all four materials. At low strains, the cracks initiated at the surface in tension as spiral cracks due to normal tensile stresses.     

HRB500E热轧带肋钢筋的制备及抗锈蚀性能研究

通过化学成分设计、转炉冶炼、连铸和热轧等成功地制备了1#～5#抗锈蚀钢筋试样,并测试其力学性能、工艺性能和抗锈蚀性能.结果表明,开发的1#～5#试样的力学性能和工艺性能均符合国家标准且优于普通钢筋,抗锈蚀性能也显著优与普通钢筋,当Al和V的质量比为1:1.5时抗锈蚀效果达到最好.     

High temperature composite forming limit diagrams of four magnesium AZ31B sheets obtained by pneumatic stretching

Formability of four magnesium AZ31B sheet materials, produced either by direct chill or twin roll continuous casting, was investigated at 400 °C and 5 × 10⁻³ s⁻¹ using pneumatic stretching. Sheet specimens were deformed through a series of four elliptical die inserts, with aspect ratios ranging between 1.0 and 0.4, producing ellipsoidal domes with different biaxial strain combinations. Testing was carried out in two scenarios, i.e. with the major strains aligned either along or across the rolling direction of the material. Circle grid analysis was then used to map the planar strains of the deformed specimens; the latter were used to generate comprehensive material forming limits curves (FLCs) that bound the safe, marginal and failure deformation zones. Orientation effects were quantified by constructing a “composite FLD” for each of the four sheets; the diagrams collectively showed that greater formability limits are achieved along the material's rolling direction. Furthermore, detailed comparisons between the four sheets were carried out based on formability limits, deformation uniformity, maximum dome height prior to failure, and fracture surface morphology and chemistry. Disparities in formability were linked to differences in grain structure and material inhomogeneities.     

Effect of vacuum on porosity and mechanical properties of high-pressure die-cast pure copper

Pure copper tensile bars were produced by conventional die casting(HPDC) and vacuum-assist die casting(VADC) processes. Porosity and mechanical properties were investigated by using optical microscopy(OM), scanning electron microscopy(SEM), energy dispersive spectroscopy(EDS), X-ray computed tomography(XCT) and tensile tester. Results show that porosities including gas porosity and shrinkage porosity could be observed in copper castings. Since the application of vacuum could reduce filling related gas entrapment and facilitate solidification due to the increased heat transfer between metal and die, both number and size of the entrapped gases, as well as shrinkage porosities were significantly reduced in vacuum-assist die castings of pure copper. The porosity fraction decreased from 2.243% to 0.875% compared with that of the conventional die casting. Besides, mechanical properties were improved significantly, i.e., by 15% for ultimate tensile strength and three times for elongation.     

Mo microalloying effect on the glass-forming ability, magnetic, mechanical and corrosion properties of (Fe0.76Si0.096B0.084P0.06)100-xMox bulk glassy alloys

The effect of Mo addition on the glass-forming ability (GFA), magnetic properties, mechanical properties and corrosion resistance of (Fe_0.76Si_0.096B_0.084P_0.06)_100−xMo_x (x = 0, 2, 4 and 6 at.%) bulk glassy alloys (BGAs) with high Fe contents was investigated. The 2 at.% Mo addition makes the alloy composition approach towards a eutectic point, which could result in an increase in the GFA. The BGA rod with diameters up to 3.5 mm was produced by copper mold casting. These BGAs exhibit a rather high saturation magnetization of 0.98-1.51 T and lower coercive force of 1.7-2.1 A/m. A significant improvement in corrosion resistance was observed with microalloying Mo element in 1 N H₂SO₄ solution. Furthermore, these Fe-based BGAs show super-high strength of ∼3.3 GPa and Young's modulus of 200 GPa.     

Development of efficient production routes based on strip casting for advanced high strength steels for crash-relevant parts

Twin roll strip casting can be an effective alternative to produce high manganese TWIP steel, which provides extraordinary mechanical properties. In the work presented, 1.5–3 mm thin hot strips with up to 30 wt% manganese were produced directly from the melt and further processed to cold strip. An adapted thermo-mechanical treatment, consisting of cold rolling with or without subsequent annealing, enables to adjust different material states, such as recrystallised or strengthened state, and thus to tailor the mechanical properties. As an example for the superior crash behaviour of high manganese TWIP steels, dynamic crash tests were carried out using cold rolled Fe–29Mn–0.3C steel in different material states.     

应用连铸坯生产特厚钢板技术

鞍山钢铁股份有限公司通过合理的成分及工艺设计,解决了连铸坯生产特厚钢板因压缩比小所造成的偏析、疏松等同题.采用300mm铸坯可以生产最大厚度为150mm的特厚钢板,最小压缩比为2:1,生产的特厚钢板探伤合格、性能稳定,各项指标均符合国家标准.     

Enhanced mechanical properties of Mg-Gd-Y-Zr casting via friction stir processing

Mg-10Gd-3Y-0.5Zr casting was subjected to friction stir processing (FSP) at a tool rotation rate of 800 rpm and a traverse speed of 50 mm/min. FSP resulted in the fundamental dissolution of the coarse network-like β-Mg₅(Gd,Y) phase and remarkable grain refinement (∼6.1 μm), thereby significantly improving the strength and ductility of the casting. Post-FSP aging resulted in the precipitation of fine β′′ and β′ particles in a fine-grained magnesium matrix, producing an ultimate tensile strength of 439 MPa and a yield strength of 330 MPa. FSP combined with aging is a simple and effective approach to enhancing the mechanical properties of Mg-Gd-Y-Zr casting.     

Microstructure morphologies during the transient solidification of hypomonotectic and monotectic Al-Pb alloys

The solidification cooling rate (T), growth rate (v), temperature gradient (G), interphase spacing (λ) and diameter (d) of the Pb-rich phase have been experimentally determined for a hypomonotectic Al-0.9 wt%Pb and a monotectic Al-1.2 wt%Pb alloys directionally solidified under unsteady-state heat flow conditions. It is shown for both cases that, from the cooled bottom of the casting up to a certain position along the casting length, the microstructure was characterized by well-dispersed Pb-rich droplets in the aluminum-rich matrix, followed by a region of morphological transition (with the Pb-rich phase formed by droplets and fibers) and finally by a mixture of fibers and strings of pearls for positions closer to the top of the casting. It has been also observed that such microstructural transition was anticipated for the alloy with higher solute content. It is shown that the correlation between the morphology of the Pb-rich phase and the growth rate can be synthesized as follows: Al-0.9 wt%Pb alloy, droplets for v > 1.0 mm/s and fibers for v < 0.65 mm/s; Al-1.2 wt%Pb alloy, droplets for v > 1.1 mm/s and fibers for v < 0.87 mm/s. Experimental growth laws relating the interphase spacing to both G and v are proposed.     

Process optimization of Ti–Nb alloy coatings on a Ti–6Al–4V plate using a fiber laser and blended elemental powders

A fiber laser was used to modify the surface composition of a Ti–6Al–4V plate through deposition of the blown powder mixture of Ti–45 wt.%Nb. Scanning electron microscopy and energy dispersive spectroscopy (EDS) were employed to examine the clad sections microstructure and chemical composition. The optimized set of laser processing parameters, including the laser power of 1100 W, the laser scan speed of 350 mm/min (or ∼5.83 mm/s), the laser spot diameter of 2 mm and the powder feed rate of 0.1 g/s was found with the identification of combined parameters, the laser specific energy, the powder density and the newly defined laser supplied energy (i.e. representing the amount of energy given to the unit mass of the blown powder). It is shown that, with these parameters, continuous beads can be formed with pore-free sections and a homogeneous composition corresponding to that of β (Ti, Nb) solid solution phase. Furthermore, Al and V elements are thoroughly replaced with a more biocompatible element, Nb, in the second layer of a Ti–Nb cladding build-up on the surface of the Ti–6Al–4V plate (i.e. after ∼1 mm in clad thickness from the clad/substrate interface).     

Effect of interfacial oxidation occurring during the duplex process combining surface nanocrystallisation and co-rolling

This paper presents an investigation of the interface quality of nanocristallised 316 L stainless steel multilayer structures. They were produced by a duplex process, combining the Surface Mechanical Attrition Treatment (SMAT) and the co-rolling process at two different annealing temperatures (550 °C and 650 °C). Oxide layers were observed at the interfaces between the sheets and their morphology was characterised by optical microscopy. Their chemical composition was determined by Energy Dispersive X-ray spectrometry. The microstructure near the interfaces was analysed by Transmission Electron Microscopy (TEM). In the laminate co-rolled at 550 °C, the presence of ultrafine grains was demonstrated. Additional tensile tests have shown an influence of the annealing temperature on the yield strength, as well as on the resistance of the interfaces of the co-rolled multilayer structures.     

API5L BNS石油管用圆管坯的生产实践

山东钢铁股份有限公司莱芜分公司特钢事业部采用废钢＋铁水（70%~80%）-100 t UHP EAF-双工位120 t LF-VD-连铸-轧制的工艺开发了API5L BNS石油管用圆管坯,介绍了其冶炼、连铸、轧制的工艺控制关键点,批量生产的130、150、180、220 mm等规格圆钢的化学成分、气体含量、夹杂物级别、晶粒度、表面质量和高倍金相组织等均满足协议要求。     

Analysis of the non-uniform thermal behavior in slab continuous casting mold based on the inverse finite-element model

A full finite-element model of a mold, including four copper plates, nickel layer and water slots of different depths, was developed to reveal the complex thermal behavior of molds in slab continuous casting. An inverse algorithm was applied to calculate the heat flux and combined with the temperatures measured using thermocouples that were buried in different positions of the mold. The temperature distributions of the four copper plates are not symmetric, reflecting the non-uniform nature of heat transfer and the necessity of building a full model. The maximum hot surface temperature of the mold occurs in the region 70–100 mm below the meniscus. At heights 100 mm below the meniscus, the average temperature of the deep water slot root is higher than that of the shallow water slot by approximately 10 °C. In the off-corner regions, the hot surface temperature differences between the narrow face and wide face near the corners are approximately 20–30 °C 100 mm below the meniscus. It will provide a helpful tool for further improving the casting parameters and operations.     

Fabrication of silica-based ceramic cores with internal lattice structures by stereolithography

Ceramic cores are widely used in investment casting, and ideal properties of cores are essential for high-quality castings. Under the circumstances requiring thick cores, solid cores are likely to encounter deformation and cracking defects due to the accumulation of shrinkage. Therefore, with the superiority of ceramic stereolithography in producing complex ceramic parts, hollow cores with lattice structures were designed and fabricated. The dimensional accuracy and properties of the green and sintered bodies were evaluated. Results show the dimensional accuracy of sintered cores is controlled within ±0.25 mm benefited from the precise green bodies. The mechanical properties are not obviously deteriorated. The bending strength reaches 11.94 MPa at room temperature and 12.87 MPa at 1,500 °C with a creep deformation of 0.345 mm. Furthermore, casting verifications prove that the hollow cores meet the requirements of investment casting. Smooth casting surfaces are obtained, at the same time, the core-removal efficiency is improved by over 3 times.

     

曲轴轮毂铸造生产工艺分析

原曲轴轮毂为锻造生产,现准备改用铸造生产。材质要求为QT450-10,铸件毛坯正火后硬度要求达到HBW170-240.综合分析认为用QT500-7高牌号进行生产可以不用正火处理即可达到硬度要求,通过对材质、铸件结构进行分析,对化学成分进行优化来确保铸件毛坯达到了铸件要求的硬度,及延伸率达到QT450-10的要求。由于铸件结构厚大,铸造易出现缩松、缩孔缺陷,通过对浇注系统和产品结构优化,保证了铸件内部无缩松、缩孔缺陷。     

A double control forming technology combining die casting and forging for the production of Mg alloy components with enhanced properties

A double control forming technology combining the die casting and forging was firstly proposed for the production of Mg alloy components with enhanced properties. In this technology, high-speed filling of liquid melt and high-pressure forging of partially solidified melt were performed by using injection and forging systems of a double control forming device. Some Mg alloy motorcycle wheel components were produced by die casting and double control forming to verify the improvement of the mechanical properties of components formed by double control forming. The results showed that double control forming was an alternative technology for producing the complex Mg alloy components with enhanced properties. Average tensile strength and elongation of Mg alloy components produced by double control forming were greatly improved in comparison with die casting. The average tensile strength was enhanced from 126.8 MPa to 213 MPa and elongation was improved from 3.5% to 7.2%. The optimal process parameters were obtained according to the results of orthogonal experiments, which involved pouring temperature of 675 °C, injection speed of 2 m/s and die temperature of 210 °C. The improved nucleation frequency in the melt caused by the forging pressure led to successful grain refinement of the microstructure of the component produced by double control forming. The defects were removed from the microstructure due to plastic deformation caused by the forging pressure. A refined and densified microstructure led to an enhancement of mechanical properties of Mg alloy component produced by double control forming.     

Microstructure evolution and properties of Mg-3Sn-1Mn (wt%) alloy strip processed by semisolid rheo-rolling

The high cooling rate caused by the sloping plate and stirring action caused by the vibration and metal flow lead to a high nucleation rate as well as two primary grain growth patterns, direct globular growth as well as dendrite growth and subsequent breakage, which causes the formation of fine spherical or rosette primary grains. The change of the primary grain shape is not obvious in the roll gap. However, solid fraction increases from the entrance to the exit of the roll gap. The spherical or rosette grains were remained eventually. When the casting temperature is 670 °C, and the vibrating amplitude is 1.5 mm, the strip with a cross section of 4 mm×160 mm was produced. Homogeneous microstructure was obtained. Mechanical properties of the present product were higher than that of Mg-3Sn-1Mn (wt%) alloy casting with the addition of 0.87 wt% Ce.     

Influence of chemical composition and holding time on austenite (γ) → ferrite (α) transformation in ductile iron occurring within the intercritical interval

This work focuses on the influence exerted by the chemical composition on the characteristics of the γ → α reaction occurring within the intercritical interval of the Fe-C-Si diagram, in order to produce a new “dual phase ADI” variant.Three ductile iron melts with different chemical compositions were used and several thermal cycles were performed. The results show a strong dependence between the alloy composition and the characteristics of the γ → α reaction, affecting the amount as well as the morphology of the precipitated allotriomorphic ferrite. Low alloy content promotes ferritic nucleation around graphite nodules and fast growth. Moreover, when the alloy content increases, the ferrite nucleates preferentially at the grain boundaries of the recrystallized austenite, and grows very slowly forming a continuous net. This novel microstructure is expected to enhance the mechanical properties of ductile cast iron.