Friction welding process of 5052 aluminium alloy to 304 stainless steel

Abstract

Type 5052 aluminium alloy was joined to type 304 austenitic stainless steel via a continuous drive friction welding process. The joint strength increased, and then decreased after reaching a maximum value, with increasing friction time. Joint strength depended on the size and shape of the tensile testpiece. Friction weldability could be estimated by electrical resistmetry. The process of friction welding between the aluminium alloy and the stainless steel is proposed to evolve as follows: welding progresses from the outer to the inner region; an unbonded region is retained at the centre of the weld interface with shorter friction time; longer friction time causes the formation of an intermetallic reaction layer at the weld interface; and the reaction layer grows as the friction time increases. When the thickness of the reaction layer increased above a critical value, the joint was brittle and fractured at the weld interface. The joint was sound when there was no unbonded region and a thin reaction layer formed along the entire weld interface.     

Aqueous tape casting of yttria stabilized zirconia

Tape casting process was used to produce yttria stabilized zirconia (YSZ) substrates in an aqueous system with poly(vinylalcohol) (PVA) and glycerine as binder and plasticizer, respectively. Various compositions of YSZ slips with different amounts of PVA and glycerine and consequently different solid/liquid ratios were prepared. The influence of the slip composition on the rheological properties of the slips was studied. In addition, the effect of the slip composition on the properties of the green and sintered tapes was investigated. PVA and glycerine did not affect the dispersion properties of the YSZ powder. Glycerine additions enhanced the flexibility of the green tapes but also produced a decrease in the tensile strength. The increase in the PVA content increased the tensile strength but resulted in a markedly decrease in the green density of the tapes. A correlation between the green and sintered density was found. The anisotropic sintering shrinkage parallel and perpendicular to the casting direction increased with increasing the PVA content. The slip compositions with 5 wt% PVA produced green tapes with satisfactory tensile strength. They had the highest sintered density, the lower sintering shrinkage and the lesser shrinkage anisotropy.     

Iron–phosphorus–carbon system: Part 2 – Metallographic behaviour of Oberhoffer's reagent

Abstract

An investigation of the microstructures found in phosphoric irons has been carried out as part of a larger archeomet allurgical investigation. Oberhoffer's reagent has been used traditionally to display the macroscopic distribution of phosphorus in steels but in order to determine the microscopic response of the reagent with certainty, a systematic study of its action has been undertaken. The reagent is in current use in the metallographic analysis of archeological iron artefacts and its action needed to be clarified before further use in the current work. A series of specimens with controlled microstructures and solute profiles has been examined when etched with nital and also with Oberhoffer's reagent. The solute distribution in some of the specimens has been confirmed using wavelength dispersive X-ray microanalysis. It has been shown that Oberhoffer's reagent responds to microstructural as well as macrostructural segregations of phosphorus and also to nickel and arsenic. The etch does not deposit copper at a significant rate on carbide or phosphide particles so that they remain bright after etching. In ferritic microstructures, there may be a slight response due to variation in grain orientation.     

Preparation and properties of W-SiC/Cu composites by tape casting and hot-pressing sintering

In this study, W-SiC/Cu composites were prepared by tape casting and vacuum hot-pressing sintering. The microstructures and properties of the composites were studied by means of X-ray diffraction, X-ray photoelectron spectroscopy, field emission scanning electron microscopy, Vickers hardness test, bending strength test and coefficient of thermal expansion (CTE) test. The results showed that W₂C, WC and WSi₂ formed in the composites. The effects of SiC particle size on the relative densities, Vickers hardness, bending strength and CTE of composites were investigated. Vickers hardness, bending strength and CTE of the composite with SiC particle size of 6?µm reached the optimal values, which were 445.2?HV, 726.1?MPa, 9.24?ppm?K^?1.     

流延法制备高热导率定向石墨/高分子复合片层材料(英文)

以天然鳞片石墨为原料,PVB为黏结剂,PEG和DBP混合物为增塑剂,通过流延工艺在室温下制备了定向排列的石墨/聚合物片层复合材料。系统分析了不同黏结剂用量和流延刀口高度下复合片层材料的定向排列状况,并探讨了定向排列程度对其热导率的影响。XRD和SEM的结果表明,石墨/聚合物复合片层材料显示了不同程度的定向排列。热导率测试结果表明,片层复合材料的热导率随着定向排列程度的提高而增大。通过优化黏结剂的用量和流延刀口高度制备了具有较高热导率的片层复合材料,其热导率最高可达490 W/(m.K)。     

Modeling of the interface behavior in tape casting of functionally graded ceramics for magnetic refrigeration parts

The main goal of this work is to study the multiple material flows in side-by-side (SBS) tape casting and analyze the influence of the different material properties, i.e. the density and the viscosity, on the interface between the fluids, since this is highly important for the efficiency of a graded configuration of the magnetocaloric materials. The Newtonian flow behavior with relatively high viscosity is assumed for each fluid and used in the simulation with a commercial CFD code (ANSYS FLUENT). The results show that the density difference does not affect the interface between the adjacent fluids, whereas the viscosity of the fluids plays the most important role in the behavior of the interface. Moreover, increasing the viscosity difference of the adjacent fluids, Δμ, leads to increasing the diffusive region between them. However, this can be counteracted by decreasing the velocity by the substrate.     

Non-Newtonian fluid flow in annular pipes and entropy generation: Temperature-dependent viscosity

Non-Newtonian fluid flow in annular pipes is considered and the entropy generation due to fluid friction and heat transfer in them is formulated. A third-grade fluid is employed to account for the non-Newtonian effect, while the Reynolds model is accommodated for temperature-dependent viscosity. Closed-form solutions for velocity, temperature, and entropy fields are presented. It is found that entropy generation number increases with reducing non-Newtonian parameter, while it is the reverse for the viscosity parameter, which is more pronounced in the region close to the annular pipe inner wall.     

Electrical properties of La2Mo1.98Nb0.02O8.99 oxide ionic conductors prepared by tape casting

La₂Mo_2-xNb_xO_9-δ thick films have been successfully prepared by using a tape casting technique. Partial stabilization of the high temperature cubic phase is revealed in Nb doped La₂Mo₂O₉ (LMO) films. The sintering temperature is decreased to 925?°C as compared with that of 1150?°C in bulk ceramics. The grain exhibits an oxide ionic conductivity of 0.014?S?cm^?1 at 603?°C for La₂Mo_1.98Nb_0.02O_8.99, which is 39% higher than pure LMO. Additionally, the Nb doped LMO films present low grain boundary resistance showing the potential application as solid electrolytes.     

Fabrication of hybrid ceramic matrix composites

The desire to improve the transverse properties and microcracking stress of unidirectional continuous fiber reinforced ceramic matrix composites has led to development of the hybrid ceramic matrix composite (HCMC). This paper discusses the techniques we used in the fabrication of HCMC specimens used for mechanical characterization.     

Densification behavior,doping profile and planar waveguide laser performance of the tape casting YAG/Nd:YAG/YAG ceramics

The sintering behavior and doping concentration profile of the planar waveguide YAG/Nd:YAG/YAG ceramics by the tape casting and solid-state reaction method were investigated on the basis of densification trajectory, microstructure evolution, and Nd³⁺ ions diffusion. The porosity of the green body by tape casting and cold isostatic pressing is about 38.6%. And the green bodies were consolidated from 1100 °C to 1800 °C for 0.5–20 h to study the densification and the doping diffusion behaviors. At the temperature higher than 1500 °C, pure YAG phase is formed, followed by the densification and grain growth process. With the increase of temperature, two sintering stages occur, corresponding to remarkable densification and significant grain growth, respectively. The mechanism controlling densification at 1550 °C is grain boundary diffusion. The diffusion of Nd³⁺ ions is more sensitive to temperature than the sintering time, and the minimum temperature required for the obvious diffusion of Nd³⁺ ions is higher than 1700 °C. Finally, planar waveguide YAG/1.5 at.%Nd:YAG/YAG transparent ceramics with in-line transmittance of 84.8% at 1064 nm were obtained by vacuum-sintering at 1780 °C for 30 h. The fluorescence lifetime of ⁴F_3/2 state of Nd³⁺ in the specimen is about 259 μs. The prepared ceramic waveguide was tested in a laser amplifier and the laser pulse was amplificated from 87 mJ to 238 mJ, with the pump energy of 680 mJ.     

A two-scale model for fluid flow in an unsaturated porous medium with cohesive cracks

A two-scale model is developed for fluid flow in a deforming, unsaturated and progressively fracturing porous medium. At the microscale, the flow in the cohesive crack is modelled using Darcy’s relation for fluid flow in a porous medium, taking into account changes in the permeability due to the progressive damage evolution inside the cohesive zone. From the micromechanics of the flow in the cavity, identities are derived that couple the local momentum and the mass balances to the governing equations for an unsaturated porous medium, which are assumed to hold on the macroscopic scale. The finite element equations are derived for this two-scale approach and integrated over time. By exploiting the partition-of-unity property of the finite element shape functions, the position and direction of the fractures are independent from the underlying discretization. The resulting discrete equations are nonlinear due to the cohesive crack model and the nonlinearity of the coupling terms. A consistent linearization is given for use within a Newton–Raphson iterative procedure. Finally, examples are given to show the versatility and the efficiency of the approach. The calculations indicate that the evolving cohesive cracks can have a significant influence on the fluid flow and vice versa.     

工业燃气轮机涡轮叶片用铸造高温合金研究及应用进展

工业燃气轮机具有热效率高、污染低等突出优点,成为未来发电机组与大型水面舰船动力的首选设备。铸造高温合金是工业燃气轮机涡轮叶片等热端部件的关键材料,其性能和制备水平在一定程度上决定了先进燃气轮机的功率、效率、寿命等性能。本文重点综述了工业燃气轮机及其涡轮叶片用铸造高温合金材料的研究及应用现状,并对工业燃气轮机涡轮叶片用铸造高温合金及涡轮叶片制造技术的发展趋势进行了展望。未来,先进定向凝固,“材料基因工程”等技术将逐渐应用到工业燃气轮机涡轮叶片用铸造高温合金的研制中;此外,先进工业燃气轮机上定向/单晶高温合金的应用将越来越广泛。     

Entropy generation in a pipe due to non-Newtonian fluid flow: Constant viscosity case

Non-Newtonian fluid flow in a pipe system is considered and a third grade non-Newtonian fluid is employed in the analysis. The velocity and temperature distributions across the pipe are presented. Entropy generation number due to heat transfer and fluid friction is formulated. The influences of non-Newtonian parameter and Brinkman number on entropy generation number are examined. It is found that increasing the non-Newtonian parameter reduces the fluid friction in the region close to the pipe wall. This in turn results in low entropy generation with increasing non-Newtonian parameter. Increasing Brinkman number enhances the fluid friction and heat transfer rates; in which case, entropy number increases with increasing Brinkman number.     

Mg-Cu密度梯度材料的流延法制备

当密度分布指数p=2时, 根据密度分布函数设计的材料密度和厚度要求, 叠层不同组分不同厚度流延膜烧结制备了Mg-Cu密度梯度材料。通过XRD、光学显微镜、SEM、超声波扫描显微镜等对材料显微结构、不同层间结合及平整性、密度进行了表征。结果表明: 所制备的Mg-Cu密度梯度材料整体致密, 中间层的平整性和平行度较好, 结合紧密, 不存在明显的界面扩散, 密度和厚度方向的分布满足密度分布函数(p=2)要求。     

固体氧化物燃料电池阳极材料的流延制备和电池性能研究

利用流延法制备NiO-YSZ阳极，采用磁控溅射、多层流延法制备YSZ电解质薄膜，丝网印刷制备BSCF-YSZ阴极，制备出Ni-YSZ／YSZ／BSCF-YSZ单电池。阳极制备中探索了浆料配比对生坯性能的影响；研究了不同造孔剂得到的流延阳极的微结构形貌差异。考察了双层流延、磁控溅射制备YSZ薄膜的微观结构，并测试评价了电池性能。     

Dispersion and rheological studies of Y-PSZ tape casting slurry

Different solvent systems in combination with three different dispersants were tried to find out the suitable solvent-dispersant combination, which give optimum dispersion of PSZ. Based on sedimentation, viscosity and rheology characteristics, zeotropic ethanol : xylene with a ratio of 50 : 50 along with 0.5 wt% phosphate ester was found to be the best solvent and dispersant combination. Optimized tape casting slurry was prepared using PEG 600 and BBP as plasticizers and PVB as the binder. Cyclohexanone was used as the homogenizer. The optimized slurry composition with 58% solid loading exhibited shear-thinning pseudoplastic rheological behaviour. Y-PSZ tapes of ∼ 50 Μm thickness free from visible defects were cast with a green tape density of 55%.     

非牛顿幂律流体圆管湍流的新速度分布式

本文通过考察Spalding[1]提出的牛顿流体速度分布式，提出一种新的非牛顿幂律流体在光滑圆管中的湍流流动速度分布的统一关系式．此关系式的优点在于对任意n值下都可使管中心的速度梯度为零且适用于管壁附近，计算结果与1963年Bogue和Metzner[2]的数据吻合．     

Open-cell porous metals for thermal management applications: fluid flow and heat transfer

Porous metals are produced by a wide range of industrially applied techniques, and the resulting porous structure is a characteristic of the manufacturing method chosen. This review firstly provides an overview of the different techniques to manufacture open-cell porous metals, highlighting the distinction between the resulting porous structures. The effects of the structural parameters on the fluid flow properties and heat transfer in porous metals are also discussed. It was evident from literature that there exist optimum structural parameters which offered maximum thermal exchange performance. Therefore, the last part of this review outlines the current research on porous metals for thermal management applications, which focuses on optimising the design of the porous metal structure to improve the heat transfer performance.

This review was submitted as part of the 2016 Materials Literature Review Prize of the Institute of Materials, Minerals and Mining run by the Editorial Board of MST. Sponsorship of the prize by TWI Ltd is gratefully acknowledged     

充型凝固过程数值模拟在铜型铸件中的应用

考虑到大部分铸件充型过程均处于湍流状态 ,将工程湍流模式用于液态金属的流动和传热计算 ,并与层流计算结果、基准试验以及铜型压缩机灰铁铸件试验结果进行了对比 ,分析了计算结果之间产生差异的主要原因 .简要介绍了相应的数值算法以及在流体自由表面处理方法上与传统方法的不同之处 ,对铸件充型之后的凝固过程也进行了模拟计算且与现场试验作了对比 .     

钛合金精密铸造陶瓷型壳性能的研究

获得高质量精密铸造钛合金铸件的关键是制备出高质量的陶瓷型壳 .本文对Y/Y、ZY/ZY和TJ/ZC等三种面层材料的性能进行了研究 ,主要包括TG/DTA测试、型壳强度测试以及热膨胀性能测试 .实验表明 ,TJ/ZC材料是钛合金精密铸造理想的面层材料 .