铸造铝合金汽缸体开裂分析

某汽车发动机在进行台架试验时,其铸铝合金的汽缸体出现漏油开裂,通过对开裂部位进行扫描电镜断口观察及金相检验分析,发现汽缸体熔体净化不好,内部存在密集的氧化物夹渣和夹杂物,并导致铝液吸氢,造成铝合金铸件中孔洞的形成.这些缺陷严重削弱铝合金铸件的力学性能,作为显微裂纹的发源地,使用时沿应力最大方向逐渐扩大发展,导致漏油失效.在分析基础上提出了改进措施.     

铸造铝合金用泡沫陶瓷过滤片及其对充型的影响

一、铸造铝合金用泡沫陶瓷过滤片铝合金在熔化和形成铸件的过程中,最突出的问题之一是产生一次夹杂和二次夹杂,使铸件的机械性能降低,加工性能变坏.铸件中的夹杂物往往还成为应力集中源,降低了零件寿命.人们为了去除这些夹杂物,在浇注系统中设置了各种挡渣系统;安放诸如带孔钢片、铁丝网,以及玻璃纤维等过滤器.但这些措施只能挡住大片夹杂物,并且还易引起铝液飞溅和紊流,产生二次夹杂,尤其当铝液高速充型时,无法避免铸件内夹杂缺陷的产生.     

铝合金中非金属夹杂物的测定

铝铸件中砂眼、气孔、分层以及其他缺陷,首先是由于非金属夹杂物和氢相互作用的结果.但是,夹杂物数量的增大并不能经常使含氢量也增大.看来,要弄清非金属夹杂物对气体吸附和析出过程的影响,不仅须确定非金属夹杂物的总量而且还须确定其大小.     

差压铸造铝合金汽车转向节的夹杂物分析

对差压铸造生产的A356铝合金转向节铸件进行了疲劳性能测试、疲劳断口扫描、XRF观察、金相组织观察与夹杂物统计、电解萃取夹杂物、XRD和EDS等试验。结果表明,铸件中夹杂物主要是氧化夹杂物,还包括少量的氮化物、碳化物和金属杂质等,而且铸件上部的夹杂物多于下部,右侧中Al_2O_3和SiO_2夹杂物的含量略高于左侧的铸件。     

铸造铝合金中典型夹杂物微观特征和成分研究

铝合金中的夹杂物是影响铸件质量的关键因素之一。采用IA500 T4铝渣检测仪进行压滤法实验，借助蔡司Axio Imager M2m金相显微镜和EVO18蔡司扫描电镜对铝合金中的氧化物、碳化物、氯化物、硼化物、碳化物、钛化物等夹杂物的灰度、形貌和成分进行了分析，并对其形成机制进行了讨论，对铝合金中夹杂物的准确定性定量有着重要的指导意义。     

AZ91D镁合金中的夹杂物

就镁合金铸件中夹杂物的形成过程以及它们对镁合金铸件质量的影响进行了分析。试验研究表明,在镁合金中,主要存在有氧化物夹杂、熔剂夹杂和外来夹杂等几种夹杂物,其中最主要的夹杂物是氧化物夹杂。通过适当工艺可以去除大部分夹杂物。     

铀铌合金铸件铸造过程中夹杂数值模拟研究

介绍了铸造过程中夹杂数值模拟的技术进展.基于氧化膜卷入机理,采用ProCAST软件中的粒子跟踪方法,对铀铌合金充型过程中夹杂物的运动轨迹进行了模拟.结果表明,当夹杂物的密度不大于15×103 kg/m3时,夹杂物最终位于铸件的顶部;当夹杂物的密度在(16～17)×103 kg/m3时,夹杂物在铸件的中部停留较长时间;当夹杂物的密度大于18×103 kg/m3时,夹杂物在铸件的底部.     

海外文献速报

20120901高木航,吉田诚.ADC12合金压铸时夹杂物的形成过程.铸造工学,2011,83(10):579-585.夹杂物会降低铝合金强度及伸长率,但夹杂物在压铸成形的整个工序中是如何变化的,迄今为止尚不明白。目前铝合金中夹杂物的测量方法是K模法,即将铝液浇入尺寸为36mm×6mm     

铝合金氧化夹杂物的炉前快速检测

铝合金氧化夹杂物的炉前快速检测第一汽车集团公司轻型发动机厂刘乃仑，渠晓东目前对铝合金氧化夹杂物的检测方法虽然很多，如金相法、熔剂法、减压凝固法、真空过滤取样法、综合分析法等，但都不能适用于炉前快速检测。氧化夹杂物作为衡量铝液冶金质量的重要对象之一，对...     

夹杂物对工业纯铝组织性能的影响

采用电化学分析、显微金相和图象分析、力学性能测量方法,研究了纯铝中夹杂物含量以及夹杂物形态对组织、电化学性能和力学性能的影响.得出腐蚀电位Econ、腐蚀电流密度Icon和纯铝中夹杂物含量的关系;测试了不同夹杂物含量的工业纯铝的硬度和延展性.试验结果表明:铝屑引入了大量的夹杂物,纯铝中夹杂物含量随着铝屑的增加而增多;试验材料的腐蚀电位逐渐向负方向移动,腐蚀电流密度变大,表明材料耐腐蚀性能随着夹杂物的增加而下降;材料的硬度有轻微增加,延展性降低,塑性变差.     

铸造铝合金洁净度-性能关系

综述了铸造铝合金熔体洁净度－疏松－力学性能三者之间的关系。指出溶解的氢和非金属夹杂通过与疏松的交互作用，对铸件的力学性能和可靠性产生极大损害。因此提高熔体洁净度水平已成为生产高质量铝铸件的关键。目前熔体洁净度－性能关系的研究以及与相应的熔体洁净度在线评定标准还有待深入探讨。     

Molten metal processing of advanced cast aluminum alloys

Premium quality aluminum alloy castings are used extensively in various applications requiring a high strength-to-weight ratio, such as aerospace, automotive and other structural components. The mechanical properties in these structure-sensitive alloys are determined primarily by the secondary dendrite arm spacing and the morphology of interdendritic phases. In addition, the amount of porosity in the casting and the inclusion concentration have a strong influence on fracture, fatigue and impact properties. During the production of the casting, various molten metal processing techniques can be implemented to control these microstructural parameters. These melt treatments include grain refinement with Ti-B, eutectic modification with strontium or sodium, degassing with purge gases and filtration of inclusions. The efficiency of these treatments determines the quality of the cast component.     

Al-Zn系高强铸造铝合金强韧化研究现状与展望

轻质高强铸造铝合金在航空航天、汽车轻量化等方面展现出独特的优势。对铸造铝合金成形性能和力学性能进一步优化,对拓宽其应用领域意义重大。本文综述了Al-Zn系高强铸造铝合金的研究现状与进展,重点归纳了高强铸造铝合金(微)合金化、晶粒细化、组织纯净化、热处理优化等方面的强化机制及现有研究成果,并对铸造铝合金目前研发中所存在的问题进行探讨,最后对高强铸造铝合金的发展方向进行了展望,对高强铸造铝合金的发展具有一定的实践和理论指导意义。     

Strengthening technology and mechanism for semi-solid die casting of aluminum alloy

Combined with theoretical evaluation,an optimized strengthening process for the semi-solid die castings of A356 aluminum alloy was obtained by studying the mechanical properties of castings solution treated and aged under different conditions in detail,then,the semi-solid die castings and liquid die castings were heat treated with the optimized process.The results show that the mechanical properties of semi-solid die castings of aluminum alloy are superior to those of the liquid die castings,especially the strengthening degree of heat treated semi-solid die castingsis much greater than that of liquid die castings with the tensile strength more than 330 MPa and the elongation more than 10％,and this is mainly contributed to the non-dendritic and more compact microstructure of semi-solid die castings.The strengthening mechanism of heat treatment for the semi-solid die castings of A356 aluminum alloy is due to the dispersive precipitation of the second phase(Mg2 Si) and formation of GP Zone.     

Critical assessment of reduced pressure test. Part 1: Porosity phenomena

Abstract

During the production of aluminium ingots and castings, the surface oxide on the liquid may be folded into the bulk liquid to produce crack-like defects (bifilms) that are extremely thin, but can be extensive, and so constitute seriously detrimental defects. In this work, it has been found that bifilms are the initiator and hydrogen is only a contributor to the porosity formation process. For the first time, evidence is presented for the contribution of air (or perhaps more strictly, residual nitrogen from air) as an additional gas, adding to hydrogen in pores in cast Al alloys. The discriminating use of the RPT clearly reveals the existence of bifilms, and the effect of hydrogen on porosity formation. However, it seems that the RPT is of little use to evaluate the hydrogen content of the alloy. To investigate these effects, two alloys were studied in laboratory experiments LM0 (99.5%Al), LM4 (Al– 5Si–3Cu) and one in an industrial environment LM24 (Al–8Si–3Cu–Fe).     

Development and evaluation of a novel inclusion seeding methodology for Ti−6Al−4V castings

Hard alpha inclusions in titanium (Ti) investment castings are generally known to have detrimental effects on the mechanical properties of these castings. However, actual inclusions are infrequent and occur in random locations in castings. As a result, it is difficult to obtain tensile or fatigue test specimens of titanium castings with inclusions in the gage section. Quantifying the adverse influence of inclusions on the mechanical properties of castings is, therefore, extremely challenging. To address this problem, a novel artificial inclusion seeding methodology was developed to emulate actual Ti investment casting inclusions. Prefabricated inclusions were seeded into machined holes in cast Ti−6Al−4V plates, the holes were back-filled with plugs of the same Ti alloy and were then electron-beam (EB) welded closed. Hot isostatic pressing (HIP) was utilized to incorporate the inclusions fully into the cast titanium material. Finally, the plates were machined to create mechanical test specimens with inclusions centered in the gage region. Test specimens created by means of this novel artificial seeding methodology were evaluated and found to be equivalent to Ti casting specimens containing actual cast-in inclusions.     

Defects caused by precipitation of in liquid copper–nickel–aluminium–bronze alloys dissolved carbon and removal by treatment of melt

Castings made of copper–nickel–aluminium bronze (CuAl₁₀Fe₅Ni₅) alloys regularly show defects in the thick, slowly solidifying parts of the castings, which give rise to rejections. Metallographic examination has been made on material of scrap castings showing porosity accompanied with film-like inclusions located beside the iron rich κ_II phases. Investigations of large failed cast structures of copper–nickel–aluminium bronze show the same characteristic defects on which fatigue cracks initiate and grow. Investigation has been made to the nature and the cause of appearance of the film-like inclusions. Microanalysis indicates a high intensity of carbon at the place of the film-like inclusions. Hereafter, an investigation has been made into the solubility of carbon in liquid copper–nickel–aluminium bronze, and it is found that besides hydrogen, also carbon is soluble in copper–nickel–aluminium bronze alloys. The appearance of the carbon as flakes in the fracture surface of materials with defects does suspect there is a nucleating effect on the formation of microporosity causing the defects. To prevent the formation of the casting defects by the interaction between solved hydrogen and carbon, it is necessary to remove the carbon as far as possible by treatment of the melt.     

电解工艺对电解铝液质量的影响研究(上)

简介了铝电解机制对电解铝液中氢和Al2O3夹杂形成过程的影响,分析了铝液中Al2O3夹杂形成的机理,推算了CO2,对铝液扩散的质量传递方程,描述了效应处理期间铝液中氢和Al2O3夹杂的形成过程.利用Person-Waddington模型测算了铝液中可能形成的Al2O3夹杂最大值.电解液中的水份被电解成氢和氧,阴极析出的氢通过扩散和杂一气寄生机制进入铝液,是电解铝液中氢的主要来源.铝电解工艺对电解铝液具有一定的自净化作用.