高速电弧喷涂再制造曲轴质量和效率优化研究

为提高自动化高速电弧喷涂再制造发动机曲轴的效率和涂层的性能,研究了一种新型的自动化高速电弧喷涂再制造发动机曲轴喷涂路径,利用扫描电镜(SEM)、X射线衍射仪(XRD)和材料力学性能试验设备分别测试了涂层的微观组织和结合强度.实验结果表明:涂层组织均匀、致密,为铁素体韧性相与固溶体、金属间化合物的复合组织,采用新喷涂工艺制备涂层性能较好,大大提高了喷涂效率和涂层在曲轴轴颈圆角处的结合强度,降低了再制造成本和喷涂时间,节能、节材及环保效果显著,应用前景广阔.     

自动化高速电弧喷涂锌铝基防腐涂层的耐蚀性研究

采用自动化高速电弧喷涂技术制备出Zn-Al及Zn-Al-Mg-RE涂层。通过浸泡实验考察涂层在3.5%NaCl溶液中的腐蚀行为,并结合扫描电镜(SEM)和X射线衍射仪(XRD)分析涂层的显微组织和相结构变化。结果表明,自动化高速电弧喷涂法制备的涂层均匀,与基体结合良好。浸泡试验两种锌基涂层均未出现红锈,能够对钢结构提供有效保护。     

高速电弧喷涂再制造曲轴用复合涂层的设计与研究

为提高再制造曲轴的涂层性能和使用寿命,设计了FeAlCrNi/3Cr13、Ni95Al/3Cr13和1Cr13/3Cr13的3种复合涂层和不喷涂过渡层的3Cr13涂层,利用扫描电镜、能谱仪和微动摩擦磨损设备等测试技术分析了4种涂层的微观组织和微区成分组成,研究了喷涂不同过渡层对复合涂层结合强度的影响,重点考察了FeAlCrNi/3Cr13复合涂层的耐磨性能.结果表明, FeAlCrNi/3Cr13复合涂层组织致密,孔隙率约3.2%,氧化物含量低,涂层平均结合强度达到46.6 MPa,复合涂层在高载荷油润滑摩擦条件下的耐磨性能远高于基体45钢.FeAlCrNi/3Cr13复合涂层可以应用到高速电弧喷涂再制造修复曲轴产业中.     

高速电弧喷涂FeNiCr/Ni包覆Cr3C2涂层组织和性能的研究

通过常温超声波辅助化学镀方法制备Ni包覆Cr3C2陶瓷粉体,以其作为增强相的粉芯材料通过高速电弧喷涂制备FeNiCr/Ni包覆Cr3C2涂层.采用光学显微分析、场发射扫描电镜分析(FE-SEM)、能谱分析(EDS)以及显微硬度测试方法,研究Ni包覆Cr3C2陶瓷粉体对涂层组织结构及性能的影响.试验结果表明:Ni包覆Cr3C2陶瓷粉体能改善涂层中各相之间的结合状态,显著减少涂层的氧化物和孔隙率,并提高涂层与基体的结合强度、抗热震性和抗高温冲蚀性能.     

Application of design of experiment on electrophoretic deposition of glass-ceramic coating materials from an aqueous bath

A process for application of abrasion- or corrosion-resistant glass-ceramic coating materials on metal substrate by electrophoretic deposition technique in an aqueous medium has been described. The effects of various process parameters, e.g. coating material concentration, time of deposition, applied current, pH of the suspension and concentration of the polymeric dispersant on the deposition efficiency have been studied. The process has been studied using a 2³-factorial design technique of three independent variables; i.e. coating material concentration, applied current, and the time taken to achieve the best combination. The regression equation obtained explains the experimental results satisfactorily.     

Numerical study on effect of external magnetic field, current profile, arc current and arc column radius on helical instabilities of arcs

This model differs from previous works in that the electrical conductivity (and the current profile) is approximated in a more realistic way (parabolic instead of flat profile). The magnetohydrodynamic equations in an electrostatic approximation serve as the starting point of the theory. The effects of the external axial magnetic field, current profile, arc current and arc column radius on the helical instabilities of arcs were numerically studied. Numerical results show that the short wavelength perturbation can be stabilized by positive direction magnetic field, whereas the long wavelength perturbation can be stabilized by reverse magnetic field when the current profile is the uniform distribution. In the short wavelength perturbation case, the effect of positive direction magnetic field on the arc stability is very small when the current profile has a parabolic distribution. However, its stabilizing effect is enhanced for the long wavelength perturbation. The intermediate and long wavelength perturbation can also be stabilized by reverse magnetic field. The low current is beneficial for stabilizing arcs.     

超声水浸法高精度测量玻璃材料声速的研究

材料的声速与其杨氏模量和密度有关,通过测量材料的声速可以评价材料的特性。相关研究表明,超低膨胀玻璃的声速是评价其热膨胀系数的关键参数,通过测量声速可以实现对超低膨胀玻璃热膨胀系数的间接无损测量。针对市售的超声声速测量仪器存在系统复杂且不易集成化的问题,结合高精度的数据采集卡设计了超声信号采集显示软件,并基于超声水浸脉冲反射法搭建了高精度的声速测量系统,系统结构简单,操作方便且较易集成化。采用该测量系统对制备的超低膨胀玻璃样品的声速进行了测量,结果表明该系统具有较高的声速测量分辨率,声速分辨率可达为0.2 m.s^-1,为使用超声声速法高精度测量超低膨胀玻璃的热膨胀系数奠定了研究基础。     

Preparation and characterization of dicalcium phosphate dihydrate coating on enamel

A coating of 60-80 μm in thickness had been prepared on the surface of enamel by rapid growth of highly crystalline dicalcium phosphate dihydrate crystal (DCPD). The DCPD coating was formed by conversion of calcium-deficient hydroxyapatite (CDHA) in strong acidic conditions. The characterization of the coating was performed using scanning electron microscopy (SEM), Fourier transform infrared spectroscopy (FT-IR), and X-ray diffraction (XRD). No obvious gap between the coating and the enamel was detected by SEM observation, which suggested that the coating adhered well to the enamel. Analysis of FT-IR and XRD revealed that the coating was a good match to DCPD. Moreover, the mean Vicker hardness number (VHN) of the coating was approximately 125, as measured by a microhardness tester.     

PH型改性高温防腐材料的研究与应用

PH型改性高温防腐涂料是一种耐高温、耐化学腐蚀的高分子材料,改性后的PH型高温防腐涂料是以有机硅化合物改性丙烯酸树脂,辅以偶联剂和增强剂等辅料,并经过科学工艺研制而成的新型耐高温防腐涂料,该新产品具有耐高温、耐腐蚀的性能,特别是耐高温性能高达800℃,超过了实验中对比测试的其它5种高温防腐涂料。     

电爆喷涂技术在材料表面制备涂层的研究进展

综述了电爆喷涂技术在材料表面制备涂层的研究进展和应用.给出了电爆喷涂技术的特点,喷涂设备的工作原理以及喷涂材料的种类;详细讨论了放电参数、喷涂材料与基体材料的几何尺寸、喷涂室气压、复合涂层等因素对涂层质量的影响;列举了电爆喷涂技术的实际应用;进一步分析了将来需要研究的问题.     

Numerical simulation on interaction between TIG welding arc and weld pool

The interface deformation between welding arc and weld pool is important in dynamic coupling numerical simulation on arc and pool. To reveal the interaction between welding arc and weld pool, unified mathematic model of TIG welding arc and pool was established in this paper. The moving interface was solved by updating the calculation region of arc and weld pool continually. Fluid flow and heat transfer of TIG welding arc and weld pool were analyzed basing on this model. The weld pool shape calculated by dynamic coupling welding arc and pool is more close to the experiment than that of non coupling calculation.     

复合材料纤维铺放自动编程技术研究

纤维铺放是近年来发展最快、最有效的复合材料构件成形技术之一。结合所研制的纤维铺放设备,研究复合材料纤维铺放自动编程技术。在已知芯模曲面和纤维铺放路径的基础上,运用机器人学原理建立了纤维铺放机构各杆件坐标系,设计了空间机构运动学逆问题的简化求解算法,针对纤维铺放路径上的每个控制点,得到纤维铺放机构各运动关节位置和姿态。根据传动机构的组成,计算出各驱动步进电机的转角,从而生成纤维铺放机运动控制指令代码。基于CATIA开发平台CAA,开发了复合材料纤维铺放仿真软件模块。     

Study on arc and laser powers in the hybrid welding of AA5754 Al-alloy

In this paper a new generation of fiber laser assisted by a MIG source was used to weld AA5754-H111 aluminum alloy in 3 mm thick butt configuration. The effects of laser and arc powers on the weld geometry and properties were studied. Weld geometry and porosity were measured. The microstructure was investigated by optical microscope and Vickers micro-hardness was taken. The residual stress close to the heat affected zone was measured by the incremental hole-drilling method. Eventually, the tensile test was conducted in order to compare the mechanical properties of the weld with those of the parent metal.For the first time the sensitiveness of the hybrid welding of the 5754 aluminum alloy to the arc and laser powers was demonstrated. Higher laser power favored the stability of the process and provided good structural and geometrical properties of the weld. Further investigation can be performed in order to optimize the weld soundness and the energy efficiency of hybrid welding an aluminum alloy using a fiber laser.     

快速高精度光电测速算法

研究基于光电编码器和四倍频电路的单片机速度测量系统的简化算法。该算法通过减少乘除运算缩短了测量时间,选用整数除法和分频电路避免了计算误差。作者编制了参数配置表,可使本文算法适配于不同当量系数的编码器。简化算法完成一次测量约需0.25s,可达1m/h的最小速度分辨力。该算法满足高精度、高分辨力和快速测量的要求,已成功用于作者研制的石油测井闭环速度控制。     

粉末状态对超音速喷涂合成TiC-Ni涂层组织和性能的影响

以Ti粉、Ni粉和石墨为原料通过PVA制粒和混合制粒制备两种喷涂粉末.研究表明:制粒方式在超音速火焰喷涂对涂层组织和耐磨性能有很大影响.PVA制粒粉末进行喷涂,涂层的相组成为TiC、Ni和少量Ti与Ni的氧化物,组织致密具有典型的层状涂层结构特征,涂层耐冲蚀磨损性能较强;混合制粒由于在火焰气流中缺乏SHS反应的条件,粉末喷涂后涂层中含有大量的Ti和Ni的氧化物和少量的粘结相Ni,具有较多的孔洞涂层组织疏松,耐冲蚀磨损性能较差.     

板中正交静应力与Lamb波波速关系探讨

在静应力产生的位移是有限位移,波产生的位移是无限小位移的假设前提下,用非线性声弹性理论,导出了正交静应力作用下的各向同性超弹性体的等效弹性常数．进而探讨了正交静应力与Lamb波波速的关系．得出了一些有实用价值的结论。可为Lamb波的应力测量提供理论基础。     

Effect of graphene oxide coating on bubble dynamics and nucleate pool boiling heat transfer

Materials coating has been proved to be an effective mean to increase the number of active nucleating sites, and therefore generate more vapor bubbles and lead to better pool boiling heat transfer performance. In this work, graphene oxide (GO) is coated on a boiling surface by self-assembly method, to enhance critical heat flux (CHF). The pool boiling is carried out on a smooth copper surface to study the effect of GO coating using distilled water as the working fluid along with bubble dynamic visualization. GO coating facilitates bubble nucleation by providing numerous microscale cavities. The visualization investigation of bubble dynamic behavior shows that the CO-coated surface exhibits a higher bubble departure frequency, a smaller bubble departure diameter and smaller bubble diameters in the pool, indicating greatly enhanced heat transfer effects. Meanwhile, the GO-coated surface exhibited a smaller contact angle than the copper surface, revealing that surface becomes more hydrophilic after GO coating. Consequently, GO-coated surface with a coating time of 4 h provides a CHF of 224.3 W/cm² and a heat transfer coefficient (HTC) of 8.79 W/(cm²·K), representing an improvement of 94.0% in CHF and 83.5% in HTC compared to smooth copper surface.     

Effect of Ti-Zr addition on the microstructure and the arc chopping current of melt-spun CuCr ribbon

The microstructure and the arc chopping current of melt-spun Cu₇₁Cr₂₉ ribbon added by Ti-Zr are studied in the article. The results reveal that the melt spinning could partly restrain the liquid phase separation of CuCr alloys because it has a high cooling rate (about 10⁶ K/s), the size of the Cr rich phase from liquid phase separation in the Cu₇₁Cr₂₉ microstructure can be decreased from the micron-scale to about 250 nm by using melt spinning. On the melt-spun base, alloying by Ti-Zr could further decrease the size of the Cr rich phase from 250 nm to about 100 nm. For nano-grained CuCr alloys, its lower arc chopping current is advantageous to the use of contact and the circuitry protect, its long arc trace route and high velocity of spot direction motion could mitigate the partial ablate of cathode surface and the lifetime of contact could be prolonged.     

Evaluation of thermal imaging system and thermal radiation detector for real-time condition monitoring of high power frequency converters

We have carried out at laboratory test to study the feasibility of using thermal radiation detectors for online thermal monitoring of electrical systems in wind
turbines. A 25 kW frequency converter is instrumented with a thermal camera, operating in the 8–14 lm wavelength range, and a single-pixel thermopile sensor, operating in the 4–8 lm wavelength range, to monitor the temperature development of the power electronics under various load sequences. Both systems performed satisfactorily with insignificant temperature deviations when compared to data from calibrated point contact sensor. With spatial averaging over a 7 mm 9 7 mm for the camera and temporal averaging over 60 s for the thermopile sensor, we reduce the root mean square noise to 45 mK
and 68 mK respectively. The low cost and simple operation of the thermopile sensor make it very attractive for condition monitoring applications, whereas the attractive feature of the camera is the possibility of multi-point or distributed temperature measurements.     

Microstructure,mechanical and tribological properties of high velocity oxy fuel thermal spray coating: A review

Iron alloy based amorphous coating materials have enormous potential in wide range of applications such as petrochemical, aerospace, ocean, and electronic communications due to their better mechanical properties, chemical properties, magnetic properties and tribological properties. The industrial applications of coating are increasing rapidly due to many advancements in the material development and coating deposition techniques. The present paper reviewed the recent progresses in deposition technologies, development of new high order alloys and composite based coating materials. In this regard, change in microstructure, elemental composition, mechanical and tribological properties on performance of iron alloy based coating properties were presented. It can be concluded that the tribological properties of coating is dependent on pre-coating and post-coating factors. Pre-coating factors include coating deposition techniques, coating layer thickness and coating parameters such as spray distance, oxygen flow rate etc. Post-coating factors include microstructure, hardness, fracture toughness and adhesion strength. Therefore, multi-criteria decision making techniques can be the best approach to find the optimum formulation of coating materials to achieve desired set of objectives under the conflicting criteria.