Study on the liquid metal flow field in FC-mold of slab continuous casting

The flow pattern and the velocity distribution of a liquid metal in the flow control mold(FC-mold) were investigated with a mercury model by analogy to the molten steel during continuous casting.The velocity measurement was conducted by the ultrasonic Doppler velocimeter(UDV)under various magnetic distributions and flux densities.The impingement intensity and the scouring intensity of the liquid metal to the narrow wall of the mold were calculated based on the measured data,and the influence of the magnetic flux density on the liquid metal flow in the mold was analyzed.The results showed that the surface of the liquid metal became more active when only the lower magnet was assembled,and the surface fluctuation was suppressed when further applying the upper magnetic field.It was indicated that when the upper and lower magnetic flux densities were 0.18 T and 0.5 T,respectively,the optimum conditions could be obtained,under which the free surface fluctuation could be suppressed,and a flow recirculation could rapidly form.     

Two‐phase thermo‐mechanical and macrosegregation modelling of binary alloys solidification with emphasis on the secondary cooling stage of steel slab continuous casting processes

As an approach towards a better modelling of solidification problems, we introduce a thermo‐mechanical and macrosegregation model that considers a solidifying alloy as a binary mixture made of a liquid and a solid phase. Macroscopic conservation laws for mass, momentum and solute are obtained by spatial averaging of the respective microscopic conservation equations. Assuming local thermal equilibrium, a single equation for the conservation of the mixture energy is then written. A single equation can be obtained for the solute as well by invoking a proper microsegregation rule. The numerical implementation in a two‐dimensional finite element code is then detailed. Lastly, some examples of simulations of academic tests as well as industrial applications for continuous casting of steel slabs are discussed. They particularly enlighten the ability of the formulation to describe the formation of central macrosegregation during the secondary cooling of slab continuous casting processes. Copyright © 2006 John Wiley & Sons, Ltd.     

电磁场对7050铝合金凝固组织和元素分布影响

为了研究中频电磁场对7050铝合金凝固组织和元素分布的影响,在未施加电磁场,施加1000Hz、6000A电磁场和1000Hz、4000A电磁场下进行7050铝合金凝固试验.利用金相显微镜和电子背散射衍射分析技术分析了锭坯微观组织,利用化学分析方法测定溶质元素沿锭坯边部到中心的分布情况.结果表明:外加中频电磁场有效地细化晶粒,影响溶质元素分布.未施加电磁场下,锭坯晶粒最大,发生反偏析;1000Hz、4000A电磁场下,锭坯晶粒次之,发生反偏析;1000Hz、6000A电磁场下,锭坯晶粒最细,发生正偏析.     

热变形参数对LD7铝合金流动应力的影响

在Gleeble-1500热模拟试验机上对LD7铝合金试样在变形程度为60％，变形温度为360－480℃、变形速率为0.01-1s^-1的条件下进行等温压缩试验，得到了不同应变、不同变形温度和应变速率下材料的真实应力，并利用古布金公式对实验结果进行了摩擦修正。研究结果表明：LD7铝合金是动态回复型合金；合金的流动应力随温度的升高而降低，最佳变形温度是400－450℃；该材料对应变速率具有很高的敏感性。     

Effects of heat treatment on the microstructure and mechanical properties of AA2618 DC cast alloy

Direct chill (DC) cast ingot plates of AA2618 alloy have been increasingly used for large-mold applications in the plastics and automotive industries. The effects of different heat treatments on the microstructure and mechanical properties of AA2618 DC cast alloy were investigated using scanning electron microscopy (SEM), transmission electron microscopy (TEM) and hardness and tensile testing. The as-cast microstructure contained a considerable amount of coarse intermetallic phases, including Al₂CuMg, Al₂Cu, Al₇Cu₄Ni, Al₇Cu₂(Fe,Ni) and Al₉FeNi, resulting in poor mechanical properties. Solution treatment at 530 °C for 5 h dissolved the first three phases into the solid solution and consequently improved the mechanical properties of the alloy. By utilizing the appropriate aging temperature and time, different combinations of strength and ductility could be obtained to fulfill the design requirements of large-mold applications. The strengthening of AA2618 DC cast alloy under the aging conditions studied was caused by GPB zones and S′ precipitates. The evolution of both precipitates in terms of their size and density was observed to have a significant effect on the mechanical properties of the alloy.     

pH值对7050铝合金膜致应力和应力腐蚀敏感性的影响

采用慢应变速率拉伸法和流变应力差值法研究了7050铝合金在3.5%(质量分数)NaCl水溶液中膜致应力和应力腐蚀敏感性随pH值的变化规律。结果表明:当pH≤7时,随着pH值的增大,膜致应力和应力腐蚀敏感性均下降,当pH7时,膜致应力和应力腐蚀敏感性随着pH值的增大而提高;而当pH=1,14时,腐蚀的类型为剥蚀,合金基体发生剥落,表面没有钝化膜产生。pH值在6~9之间时,膜致应力随pH的变化比较平缓,而pH在2~5和10~13之间时,膜致应力变化则较为剧烈,整体的变化曲线呈山谷形。膜致应力和应力腐蚀敏感性具有很强的相关性。XPS研究表明,膜致应力值与钝化膜的成分有关。     

Influence of pulsed deformation on the redistribution of the components and mechanical properties on the surface and in the bulk of the welds in plates of 2024 T3-51 aluminum alloy

We perform the durometric and x-ray investigations of the welds in specimens of 2024 T3-51 alloy subjected to pulsed loading at different temperatures, establish the parameters of the most promising deformation treatment, and confirm the role of hydrodynamic plastic flow in the formation of controlled structures and mechanical properties. __________ Translated from Problemy Prochnosti, No. 4, pp. 128–136, July–August, 2007.     

An integrated,finite element‐based process model for the analysis of flow,heat transfer,and solidification in a continuous slab caster

An integrated, finite element‐based process model is presented for the prediction of full three‐dimensional flow, heat transfer, and solidification occurring in a continuous caster. Described in detail are the basic models for the analysis of turbulent flow and heat transfer in the liquid steel zone, in the zone of mixture of the liquid steel and solidified steel, and in the solidified zone. Then, the models are integrated to form a process model which can take into account the strong interdependence between the heat transfer behaviour and the flow behaviour. The capability of the process model to reveal the detailed aspects of turbulent flow, heat transfer, and solidification occurring in a continuous caster is demonstrated through a series of process simulations. Copyright © 2003 John Wiley & Sons, Ltd.     

A study of elastic aftereffect in injection casting of thermoplastic feedstocks based on SiC,AlN, WC powders and its influence on mechanical properties of the workpiece material

The paper addresses the changes in dimensions of products prepared from thermoplastic feedstocks based on SiC, AlN, WC powders and paraffin by injection molding. The authors study the influence of the process pressure, temperature, and powder particle size on the elastic aftereffect in the product material as well as the influence of the injection casting variables (pressure and temperature) on the ultimate bending strength of the product material.     

拉压弹性模量差异对泡沫铝夹芯板三点弯曲模拟的影响

泡沫铝材料是一种典型的拉压双模量材料,即受拉与受压时弹性模量不同。使用ABAQUS有限元软件对泡沫铝夹芯板的三点弯曲行为进行了模拟。首先,对泡沫铝芯层采用可压缩泡沫模型,通过对芯层的受拉区和受压区采用不同的弹性模量来讨论拉压弹性模量差异对夹芯板三点弯曲行为的影响。同时,在泡沫铝压缩响应一致的情况下,对可反映拉压弹性模量差异的孔洞模型和未考虑拉压弹性模量差异的可压缩泡沫模型的夹芯板三点弯曲模拟结果进行了比较。研究表明,泡沫铝芯层的弹性模量对夹芯板的三点弯曲行为模拟有较大影响。若不考虑泡沫铝拉压弹性模量的差异,得到的夹芯板三点弯曲情况下的加载刚度和屈服荷载明显偏低。     

Impact of tool profile on mechanical behavior and material flow in friction stir welding of dissimilar aluminum alloys

The tool pin geometry used in friction stir welding of any material affects the transportation and mixing of the materials at the joint interface during the welding process. This further affects the mechanical properties of the joint. Tapered threaded and unthreaded tool pin profiles were investigated in this research work. The relationship between the material mixing characteristics and mechanical properties of each pin profile were evaluated. The results indicate that more materials mixing occurred in the nugget zone of the welds at lower rotational speed with the threaded tool pin than the unthreaded tool pin. However, at medium rotational speed, more volume of materials was swept into each other better in the unthreaded tool pin than the threaded pin. The tensile strengths of welds with the threaded tool pin were higher than the unthreaded tool pin. Although the two tool pins exhibit similarities in hardness variations across the weld zones however, higher average values of hardness were obtained at the nugget zone for welds performed with the tapered threaded tool pin. These could be as a result of better material mixing and higher opposition to grain dislocations across the dividing lines in the welds from the threaded tool pin.     

The effect of flow rate, accelerometer location and temperature in acoustic chemometrics on liquid flow: Spectral changes and robustness of the prediction models

Prediction of chemical composition of flowing liquids using passive acoustic measurements and multivariate regression (acoustic chemometrics) has been reported as a promising in-line measurement method. However, the passive acoustic measurement results are also affected directly or indirectly by other factors than composition of the liquid, i.e. physical conditions of the flow and equipment/pipe properties. The present study focuses on the effects of flow rate, accelerometer location and temperature on the acoustic spectra and prediction of composition of liquids. The studied liquids were two-component mixtures of sucrose and water, and three-component mixtures of ethanol, sucrose and water. Multivariate models were estimated using both local and global calibration on full spectra, and augmented frequency and amplitude matrices derived from full spectra. Flow rate and accelerometer location had the most pronounced effect on acoustic spectra and prediction results from recalibrated local models. Temperature had a minor effect on the acoustic spectra and prediction results. The prediction error for determination of ethanol, sucrose and water increased with increasing flow rate. Changes in flow rate resulted in considerable spectral variations, causing the resultant local calibration model to perform poorly predicting the new samples taken at other flow conditions. Global models performed well on prediction of liquid composition at all studied flow and temperature levels. The global models, however, needed higher number of PLS factors and led to higher prediction errors compared to local models. Using the augmented frequency and amplitude matrices in PLS/PPLS global regression models led to higher prediction errors compared to full spectra models. However, the augmented frequency and amplitude models were more parsimonious (4–6 PLS factors) compared to the full spectra models (10–12 PLS factors).