反应合成银氧化锡电接触材料抗熔蚀性研究

采用反应合成技术和传统粉末冶金技术制备银氧化锡(AgSnO2)电接触材料，利用千瓦级CO2激光器模仿电弧作用在试样表面产生局部熔化。对AgSnO2块体材料进行抗熔蚀性测试，对块体材料及冷拉拔的AgSnO2线材进行显微组织分析(扫描电镜、透射电镜)。研究结果表明，采用反应合成技术可以在银基体中合成尺寸细小、界面新鲜的SnO2颗粒，制备AgSnO2电接触材料；用反应合成法制备的AgSnO2材料中，微米级的SnO2颗粒系由纳米级的SnO2颗粒聚集而成；用反应合成法制备的AgSnO2电接触材料由于改变了银和SnO2的结合状态使材料的抗熔蚀性得到改善和提高。     

AgSnO2电触点材料制备方法进展

综合评价了AgSnO2电触点材料的制备方法,对比分析了粉末冶金法、合金内氧化法、预氧化合金粉末法和反应合成法等几种制备方法的优缺点,简要介绍了AgSnO2电触点材料的应用进展及国内外差距,并展望了AgSnO2电触点材料的发展趋势.     

AgSnO2电接触材料研究概述

分析了AgSnO2电接触材料替代有毒的AgCdO材料进程中存在的主要问题.综述了国内外AgSnO2电接触材料的最新制造工艺及其优缺点.通过对目前国内外电接触材料行业发展状况的对比分析,探讨了AgSnO2电接触材料的研究和发展趋势.     

等离子弧焊接熔池和小孔形成过程数值分析

目的 研究等离子弧焊接穿孔过程中熔池内部的金属流动情况和小孔动态变化过程。方法 通过“传热-熔池流动-小孔”之间的相互耦合关系,建立了等离子弧焊接穿孔过程的数值分析模型,通过VOF方法追踪了小孔界面,采用FLOW-3D软件模拟了等离子弧焊接熔池和小孔的形成过程,定量计算了等离子弧焊接温度场、熔池流场及小孔形状;分析了等离子弧焊接熔池和小孔行为;并通过等离子弧焊接实验数据验证了模拟结果。结果 当焊接时间为0~1.0 s时,小孔深度曲线与熔深曲线几乎相同,小孔底部紧贴熔池底部;在2.8 s以后,小孔深度曲线与熔深曲线有一定距离,小孔深度曲线在一定范围内波动,等离子弧焊接电弧挖掘作用到达极限,电弧压力与其他力达到平衡状态。模拟的焊缝熔深为8.04 mm、熔宽为13.20 mm,实验测得的焊缝熔深为8.00 mm、熔宽为13.42 mm。结论 构建的随小孔动态变化的曲面热源模型和电弧压力模型可以描述等离子弧焊接过程中的电弧热-力分布;模拟出了等离子弧焊接熔池和小孔动态演变过程;模拟得到的等离子弧焊接焊缝形貌与实验测得的焊缝形貌基本吻合。     

低压继电器用AgSnO2触头材料的研究进展

简述了低压继电器用触头材料的工作状态、性能要求和AgSnO2材料的典型制备工艺.通过分析电弧侵蚀作用后的触头表面组织结构及其对电性能的影响,提出了降低接触电阻、增强界面结合强度和分散电弧的主要改善手段,并展望了AgSnO2材料的发展趋势.     

La掺杂AgSnO2触头材料的电性能

由于Cd有毒性,AgSnO2触头材料逐渐取代了 AgCdO 成为新型触头材料,但由于AgSnO2触头材料中的SnO2近乎绝缘,使得触头材料的接触电阻增大,故改善SnO2的导电性是急需解决的重大难题.本文提出了一种简单的、低成本的La掺杂AgSnO2触头材料的设计方法.采用模拟计算的方法,利用第一性原理的密度泛函理论平面波超软赝势法,建立了SnO2以及不同比例La掺杂的SnO2超晶胞模型,在对其进行几何优化之后分别研究了 La掺杂比为50%、25%、16. 67%、12. 5%、8.34% 的SnO2材料的电子结构,并研究了其晶格参数、能带结构和态密度等.结果表明,掺杂后材料晶胞体积变大. La的5d轨道进入导带,使得导带底向低能端移动,禁带宽度变小.最终得出La掺杂比为16.67% 时导电性最佳.最后进行了不同掺杂比下触头材料的电接触性能试验,得到了接触电阻和燃弧能量等电接触性能参数并验证了模拟结果.因此,本文的研究为触头材料的发展和应用提供了理论依据.     

直流电弧对工业硅埋弧炉内传热过程影响的数值模拟

为优化直流埋弧炉工业硅冶炼过程,建立二维轴对称等离子体电弧的磁流体动力学模型,运用有限元分析软件,计算得到了等离子体电弧的形态特征分布,并与已有的实验测量结果进行了比较。通过计算不同电流、弧长条件下电弧的温度、速度变化以及熔池表平面的热通量组成分布,分析了电弧的形态变化规律和电弧的传热方式,由此计算不同电流值、不同电弧弧长的条件时,电弧向阳极熔池表面传热的效率。结果表明:弧长越长,向熔池表面传热的效率越小;电流越大,向熔池表面传热的效率越高。基于结果分析,工业硅生产应采用长电弧低电流高电压的冶炼模式。     

碳纳米管和TiB2混杂增强铜复合材料的电弧侵蚀行为

采用放电等离子烧结（SPS）工艺制备出不同混杂比例碳纳米管（CNTs）和TiB₂混杂增强铜（CNTs-TiB₂/Cu）复合材料,对复合材料致密度、硬度、导电率、导热率和显微组织进行了对比和分析。同时对复合材料进行了电接触试验,研究了不同电流条件下CNTs与TiB₂混杂比例对CNTs-TiB₂/Cu复合材料电弧侵蚀行为的影响。结果表明:随着CNTs与TiB₂混杂比例的增加,CNTs-TiB₂/Cu复合材料的密度、硬度、导电率和导热率逐渐降低,铜基体晶界分离现象越来越明显;在特定电流条件下,合适的CNTs-TiB₂混杂比例可提高CNTs-TiB₂/Cu复合材料的抗电弧侵蚀性能;当电流为5 A和10 A时,CNTs与TiB₂混杂比例为4∶1的平均燃弧能量、平均燃弧时间和材料转移量达到最低,而电流为15 A时,CNTs与TiB₂混杂比例为1∶4的平均燃弧能量、平均燃弧时间和材料转移量达到最低。电弧侵蚀后阴极出现熔池、气孔及熔融金属铺展等特征,且随着CNTs与TiB₂混杂比的增加,CNTs-TiB₂/Cu复合材料熔池面积减小,气孔数量变少,熔融金属铺展的特征减弱。      

ZnO含量对AgCuOIn2O3SnO2ZnO材料电接触性能的影响

实验采用原位反应合成法制备了4种ZnO含量不同的AgCuO(10)In₂O₃(2)SnO₂(2)ZnO(x),(x=0.5、1、1.5、1.8)电接触材料并制成电触头铆钉，通过XRD、SEM、JR04C触点测试机等测试手段，分析了ZnO含量对材料电接触性能的影响。结果表明：电流电压的同时增大，材料电弧侵蚀现象更为明显；ZnO含量对接触电阻、熔焊力、阳极损耗及材料转移有着不同规律的影响，ZnO含量为1.8%(质量分数)的触头具有相对稳定且较低的接触电阻，当ZnO含量为1.0%(质量分数)时平均熔焊力最低，随着ZnO含量的增大，阳极损耗及质量转移质量呈现先减小后增大的趋势，但ZnO含量对于燃弧能量的影响不明显；电弧侵蚀后的阳极表面形成凹坑，阴极表面形成凸峰，ZnO含量的不同，阳极表面侵蚀面积及侵蚀形貌略有不同。对比发现，添加一定含量的ZnO对于AgCuO(10)In₂O₃(2)SnO₂(2)材料的电接触性能有所提升。     

银金属氧化物触点材料电弧侵蚀退化机制研究进展

本文简述了银金属氧化物触点材料的发展历程,综述回顾了典型材料在服役过程中的电弧光谱特性、表面侵蚀结构演化、材料性能参数以及电弧侵蚀退化机制等方面的研究。结果表明：电弧持续时间、材料转移(或材料质量损失)、接触电阻等特征参数是导致电接触材料失效的关键因素,对电接触材料性能退化起到了决定性作用;优化灭弧室构造、非对称性配对、掺杂改性或引入磁性相等技术手段可以降低电弧持续时间,减轻表面烧蚀程度;借助电弧光谱学、数值计算与模拟仿真等技术,构建了触点材料的失效模式,包括“蒸发-分解-熔桥-喷溅”侵蚀模式、颗粒飞溅-沉积、常量k值模型等,在此基础上归纳了触点材料的设计原理与关键影响因素,为原创性研发全面替代Ag/CdO的高性能电接触材料奠定理论与应用研究基础。     

Effect of TiB2 particle size on the material transfer behaviour of Cu–TiB2 composites

Cu-5.8vol.-%TiB₂ composites reinforced with different sized TiB₂ particles were prepared by spark plasma sintering (SPS). The arc erosion resistance was examined using a JF04C electrical contact instrument. The results indicate that the TiB₂ particle size and contact currents have important effects on the material transfer mode. Both lower mass loss and relative mass transfer was observed in the Cu-5.8vol.-%TiB₂ composites reinforced with fine TiB₂ particles (10?um, 30?um) compared to those with coarse TiB₂ particles (70?um, 110?um). The investigation and analysis of the microstructure and arc erosion mechanism show uniform distribution of fine TiB₂ particles in the copper matrix can significantly improve the viscosity of the molten pool and decrease the splashing of molten Cu.     

Arc erosion behavior of Ag/Ni electrical contact materials

Ag/Ni electrical contact materials tend to be weld together under high current and/or high temperature, which was a key problem to restrict the usage of Ag/Ni electric contact materials. Arc erosion characteristics of Ag/12Ni electrical contact material after 50,000 operations under direct current 19 V, 20 A and resistive load conditions were investigated. The result indicated that the probability distribution and change trend of arc energy and arc time during 50,000 operations were similar and the relationship between arc time and arc energy followed exponential function. On the one hand, “Crater” type erosion pit, island-like melted silver, pore, crack and coral-like structure spitting were observed on erosion surface of Ag/Ni contact materials. On the other hand, distribution of Ag and Ni element on molten pool of movable contact was different from that of stationary contact. For movable contact, element Ni mainly distributed on melted pool root, whereas element Ag mainly distributed inside of melted pool. For stationary contact, however, element Ni and Ag distributed layer by layer. Furthermore, arc erosion of stationary contact is more serious than that of movable contact.     

Influence of gravity state upon bubble flow in the deep penetration molten pool of vacuum electron beam welding

The governing equations of two-dimensional bubble flow model for gas–liquid two-phase system in deep penetration molten pool of vacuum electron beam welding were developed according to the laws of mass and momentum conservation. The separation models of gas and liquid convections in bubble flow were formed by regarding the gas phase in molten pool as a particle phase, and the vacuolar fraction, velocity slip, pressure gradient and other factors were introduced into the models. The influences of the gravity state upon the convection of bubble flow and the distribution of cavity-type defects in molten pool of AZ91D magnesium alloy were studied by the method of numerical simulation based on the mathematical models. The results showed that the gravity is an important factor to drive the convection of the bubble flow in the deep penetration molten pool during vacuum electron beam welding. The gravity has an impact on the gas distribution in molten pool, thus affects the distribution of cavity-type defects in weld. Because of the gravity contributing to driving the convection of bubble flow, it is conducive to the escape of gas phase in molten pool and reducing the air rate. A larger convection velocity of gas phase is helpful to the escape of gas phase, thus reduce the tendency of cavity-type defects.     

Investigation on Cracking in the Surfacing Welding Layer of Ni_3Al Based Alloy

Investigation has been made into the causes of cracking in the Surfacing welding layer of Ni3Al based alloy by analysing both the liqu id-to-solid transformation in the molten pool and the distribution of thermal stress within the surfacing welding layer. The results show that cracking in the surfacing welding layer is directly related to the producing of eutectic phase β' (NiAl) in the interdendritic region and high thermal stress within the surfacing welding layer. When the process of electric arc surfacing welding is changed from along straight line to along" Z" pattern, cracking in the surfacing welding layer of Ni3Al based alloy is prevented due to being reduced of both the cooling rate of liquid in the molten pool and the moving speed of the heat source. Reducing the melting volume of the substrate material by lowering the output power of electric arc welding would make the content of iron atoms in the molten pool decrease. and this also can reduce the trend of the eutectic reaction in the interdendfitic region and is helpful to Suppress cracking in the surfacing welding layer.     

316L不锈钢选区激光熔化单道熔池几何尺寸演变规律

目的 探究激光功率(P)和扫描速度(v)对单熔道熔池几何特征尺寸的影响规律,以及P–v组合工艺参数对熔池从成形到稳定状态经历的扫描距离的影响规律。方法 以316L为材料,通过单熔道数值仿真分析,建立P–v变量与研究目标之间的影响关系。结果 不同P–v参数组合对熔池几何尺寸的影响规律明显,熔池几何参数达到稳定状态需要经历一定的激光扫描距离(小于1 mm)。随着激光功率增大,熔池长度达到稳定状态所经历的激光扫描距离随之增大,而熔池深度尺寸随之减小。扫描速度增大到400 mm/s时,熔池达到稳定经历的扫描长度缩短了6.7%,扫描速度对熔池稳定性的影响效果不显著。结论 在SLM单道成形过程中,激光功率、扫描速度越大,成形熔池平均长度尺寸也越大;激光功率越大、扫描速度越小,成形熔池深度及平均宽度越大。模拟试验获得重熔效果较好的P–v参数组合为P=200 W、v=800 mm/s,重熔率达到94%。在熔池成形过程中,激光功率对熔池稳定性的影响起主导作用。为了减少成形件的边界翘曲,在打印试件初始成形阶段应在合理激光功率范围内选择较高的激光功率。     

超薄铝合金胶粘接及激光焊接工艺研究

目的 为了解决厚度为0.05 mm的铝合金在激光焊接过程中,材料发生变形导致的焊穿或者虚焊问题.方法 采用在下层铝合金材料表面均匀涂覆粘胶剂,将上下2层铝合金材料进行预固定,然后采用激光焊接,形成焊缝.通过控制涂覆粘胶剂的次数,得到胶层厚度为11.2μm,对涂覆粘胶剂的铝合金进行激光焊接实验.结果 当激光平均功率为150 W,焊接速度为100 mm/s,离焦量为2 mm时,焊缝剪切强度最大,为124 MPa,达到母材剪切强度的82％.结论 通过粘胶剂预固定后,在激光加热过程中,可以很好地克服材料的变形,让上下材料形成熔池,熔池冷却凝固后熔合在一起形成焊缝,可以解决材料发生变形导致的焊穿或者虚焊问题.     

镁合金冷金属过渡熔池动态行为数值模拟

为研究冷金属过渡焊(CMT)的周期性能量输入及焊丝抽送行为对镁合金熔池动态行为的影响,在FLUENT软件中建立了焊丝-熔滴-熔池多相流数值分析模型。提出一种在流体体积法(VOF)多相流计算域中划分熔滴与熔池区域并判断其接触状态的方法,结合动网格技术实现自动响应的焊丝抽送,在熔池区域加载间歇性的热源、电弧力,采用镁合金CMT堆焊实验所得参数进行数值模拟。结果表明,在CMT能量输入周期的短路阶段,由于焊丝的回抽,熔池被向上提拉并在焊丝端部形成了液桥,内部液态金属在马兰戈尼力的作用下,由边缘流向中间,由下方流向上方,焊丝持续回抽至脱离熔池后,熔池受到液桥断裂的反作用力,液态金属快速向后方流动使熔池形状发生改变,可知焊丝回抽与马兰戈尼力是熔池动态行为的主导作用力,此外,焊缝熔深的模拟结果为0.53 mm,与实际成形焊缝的熔深存在3.47 %的误差,验证了模型的有效性。     

Effects of quenching treatment on the structure and electrical property in doped V2O3 system

The effects of quenching treatment are examined in terms of the phase present, microstructure and electrical properties for doped V2O3 system, in this paper. The results indicate that the specimens transform to the PM phase and show microcracks in the structure after quenching. The room temperature (RT) resistivities become low and the resistivity ratios increase remarkably. There are optimum values for the RT resisitivity and resisitivity ratio under a certain quenching time. The electrical properties of quenched specimens containing Fe metal phase become stable after subsequent thermal cycles. This revised version was published online in November 2006 with corrections to the Cover Date.     

40Cr轴面激光熔覆Ni60数值模拟

目的 针对激光熔覆过程中熔池内部复杂的传热和对流现象,分析激光功率和扫描速度对熔池内部温度场、流场演变和分布的影响.方法 采用双椭球热源模型,建立了40Cr轴面基体激光熔覆Ni60粉末过程的三维温度场流场数值模型,并进行试验验证.结果 熔覆过程形成了近似椭球体的熔池,最高温度位于移动光斑中心偏后方,达到了2080.4 ...