SPF model applications for aluminum

A closed-form, plane strain model (PS2) is compared with a finite element model (SUPFORM3) in analyzing the forming of rectangular pans from 2090-OE16 aluminum sheet. The errors introduced by improperly using a plane strain model are quantified. Some preliminary verification of SUPFORM3 is shown, and the effect of friction on the distribution of thickness in the superplastic forming (SPF) of a rectangular pan is presented. SUPFORM3 is used to predict thickness distribution of male formed access doors, selecting proper starting gauges, assessing producibility, estimating forming time, and developing pressure time cycles. SUPFORM3 will be used to form complex parts and flat-bottomed pans such that post-SPF properties samples can be cut from the flat areas of the flat-bottomed pans, yet have the same strain and strain rate history as the critical areas in the complex part. It is concluded that SUPFORM3 is a useful tool for predicting thickness distributions resulting from and pressurization schedules for superplastic forming.     

A dislocation-density-based 3D crystal plasticity model for pure aluminum

A dislocation-density-based crystal plasticity finite-element model (CPFEM) is developed in which different dislocation densities evolve. Based upon the kinematics of crystal deformation and dislocation interaction laws, dislocation generation and annihilation are modeled. The CPFEM model is calibrated for pure aluminum using experimental stress–strain curves of pure aluminum single crystal from the literature. Crystallographic texture predictions in plane-strain compression of aluminum are validated against experimental observations in the literature. The framework is implemented in ABAQUS with user interface UMAT subroutine.     

2A97铝锂合金蠕变本构模型的建立

对2A97新型铝锂合金在温度180℃不同应力水平条件下进行多组蠕变试验,通过数值拟合,建立了经典蠕变本构模型与基于双曲正弦函数的等温蠕变本构模型。结果表明,采用基于双曲正弦函数的等温蠕变本构模型得到的拟合曲线与试验值吻合较好,能准确描述蠕变时效成形过程。     

棕刚玉熔炼系统的新设计

介绍了国内首次实现的全机械化运行的刚玉分包接液新工艺,介绍了接液包的防爆措施;废除了传统的耐火砖拱顶而采用耐热混凝土天花板热保护,节约大量投资;采用了小巧的全保温炉缸,从而使冶炼炉具有较先进的节能效果。该设计在节能、节省电极材料消耗以及劳动保护方面显示出极大的优越性。     

Recrystallization model for hot-rolling of 5182 aluminum alloy

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A mathematical model for the distribution balance of extraction processes from waste batteries

The experiments of metal Cd extraction were carried out three times at oil phase/aqueous phase (O/A)=1 and pH 2.2 by using 1.3 mol/L di(2-ethylhexyl)phosphoric acid (DEHPA) as the agent,with an extraction rate of 99.5%.Experiments on metal Co extraction were done three times at O/A=0.5 and pH 4.7 by using 0.4 mol/L Cyanex 272 as the agent,with an extraction rate of 99.2%.By using equilibrium data and massive calculations to analyze and predict the interaction among the extraction systems,this paper came out with the polynomials of the empirical model as well as their parameter values for the equilibrium concentration of the above two extraction loops.     

Electrochemical etching model in aluminum foil for capacitor

A novel tunnel growth model is proposed to reveal how hydrogen is transported out of tunnels and explain the phenomena during etching process of aluminum foil for capacitor. Experimental results indicated that tunnel density increased and tunnel width decreased with temperature increasing at the temperature range of 70–80 °C. The pressure in electrolyte had an effect on the tunnel density. The tunnel density after etching at 0.2 atm was larger than that at 1 atm. A pulse electrochemical etching process is described according to the novel tunnel growth model. It considers that hydrogen bubble of nanometer dimension is absorbed on the tunnel’s walls surface during the pulse electrochemical etching process, and the saturated hydrogen at the end of the tunnel is accumulated to be a large bubble before hydrogen is transported out of the tunnel. The large bubble will emanate from the end of tunnel when the pressure in the bubble is equal to that outside. The wall surface passivation phenomena is explained by this model; the naturally corrugated texture with ripples of about 0.1 μm in tunnel’s walls surface is regarded to be produced by the potential periodical changes, which are caused by the large hydrogen bubble at the end of the tunnel. At the same time, the effect of temperature and pressure on the morphology of the tunnel is also investigated by use of the model. The pressure of the large hydrogen bubble in the tunnel is calculated according to the date in other references when the period of the pulse electrochemical etching is inferred to be 3 ms at their experimental conditions. The proposed process of pulse electrochemical etching could explain well the calculation results and the SEM images of etched tunnels under the same experimental conditions.     

日本废钢业发展透视:废钢回收业如何实现“绿色重生”

<正>中国钢铁工业经历了数十年的快速发展,钢铁积蓄量不断增加,今后将有大量的废钢资源产生。如何有效利用、管理这些资源或将是未来中国钢铁工业需要解决的一个重大问题。相关资料显示,短流程炼钢比长流程炼钢可减少废气86%、废水76%和废渣97%,与长流程炼钢相比,用废钢炼1吨钢可减少近1.6吨碳排放,因此废钢生产更加清洁和有利于排废减量化,鼓励能耗低、污染小的电炉炼钢发展无疑有利于环境保护。日本钢铁业的发展与中国有很多类似之处,而且日     

A thermal model of friction stir welding in aluminum alloys

A thermal model of friction stir welding was developed that utilizes a new slip factor based on the energy per unit length of weld. The slip factor is derived from an empirical, linear relationship observed between the ratio of the maximum welding temperature to the solidus temperature and the welding energy. The thermal model successfully predicts the maximum welding temperature over a wide range of energy levels but under predicts the temperature for low energy levels for which heat from plastic deformation dominates. The thermal model supports the hypothesis that the relationship between the temperature ratio and energy level is characteristic of aluminum alloys that share similar thermal diffusivities. The thermal model can be used to generate characteristic temperature curves from which the maximum welding temperature in an alloy may be estimated if the thermal diffusivity, welding parameters and tool geometry are known.     

A mathematical model coupled to CALPHAD to predict precipitation kinetics for multicomponent aluminum alloys

A mathematical model was developed to simulate the precipitation kinetics during heat treatment of multicomponent aluminum alloys. The model is based on the general numerical framework proposed by Kampmann and Wagner, and features a full coupling with CALPHAD software for the evaluation of the Gibbs–Thomson effect. It also does not rely on the assumption that precipitate phase composition is stoichiometric or uniform, and is therefore applicable for predicting complex precipitation kinetics encountered in industrial practices. Applications of the model to various aging treatments of binary Al–Sc alloys and a ternary Al–Sc–Zr alloy were conducted. It was found that the model predictions for extended time coarsening kinetics are in good agreement with the analytical Lifshitz–Slyozov–Wagner coarsening theory. Its ability to reproduce the complex precipitation pathways in multicomponent alloys was demonstrated by simulation of the precipitation kinetics for an Al–0.09 at.% Sc–0.03 at.% Zr alloy. Comparison of the simulation results with experimental measurement has also highlighted research directions that require further effort.     

A material removal model for polishing glass–ceramic and aluminum magnesium storage disks

In this paper, a model is proposed to more closely describe the relationships between polishing parameters and the material removal rate for the commonly used storage disks in PC. Experiments were conducted to verify this model. It is shown that the proposed model predicts the material removal rate more accurately than existing models. The proposed model is expected to apply to different materials polished by similar processes. The FEM analysis of the applied polishing pressure well explained the current empirical results.     

An improved finite-element model for electromagnetic analysis in aluminum cells

This article presents the use of an improved finite-element model to calculate the static electromagnetic field for an aluminum reduction cell. Consisting of three solid cells and their surrounding bus bars, the model can evaluate the non-uniformity of the current distribution in the inside conductors and bus bar system and couple the current into the sequential magnetic analysis through a conversion routine. Voltage potential distribution in the molten aluminum was investigated based on one industrial 320 kA aluminum cell with two designed bus bar arrangements. Characteristics of magnetic components’ distributions were also given.     

铝合金薄板搅拌摩擦焊温度场模型

根据能量检测系统得出的搅拌摩擦焊接实时功率,结合M.Song等人提出的热输入模型,在此提出了简化的热输入模型.在深入考虑焊接过程的具体条件后,利用ANSYS有限元分析程序建立随热源一起移动的坐标系,模拟出瞬态温度场以及焊缝及母材区任何位置上的热循环曲线.通过模拟结果与热电偶测得的特征点温度曲线的比较,验证了热模型和模拟方法的正确性.     

A method for leaching or dissolving gold from ores or precious metal scrap

The hydrometallurgical leaching of native gold from gold-bearing ores or the dissolution of gold metal during the recycling of electronic and precious metal scrap is performed every day using hazardous chemicals such as sodium cyanide or aqua regia. These chemicals represent health and safety risks for workers and a serious threat for the environment. However, even if several other reagents are known to dissolve gold at the laboratory scale, none of these are used industrially. Hot mixtures of hydrochloric acid with strong oxidizing compounds are known to generate in-situ nascent chlorine which is capable of dissolving gold efficiently. In this study, the authors investigated the capability of a hot mixture of hydrochloric acid and ground manganese (IV) oxide to dissolve gold metal either under atmospheric or pressurized conditions. The best result was obtained under a pressure of 639 kPa at 90°C with a dissolution rate of 0.250 g·cm⁻²h⁻¹ and it was compared to that reported in the literature for other industrial reagents. For more information, contact Nicolas Geoffroy, McGill University, 3610 University Street, Montreal, (QC) PQ H3A 2B2, Canada; e-mail nicolas.geoffroy@mail.mcgill.ca.     

Thrust force model for vibration-assisted drilling of aluminum 6061-T6

Vibration assistance has increasing applications in metal removal processes. This method induces high-frequency and low-amplitude vibration in the feed direction during cutting, and has the potential to reduce cutting forces leading to improved surface quality and reduced tool wear. Note that this cutting process is distinct from ultrasonic machining. This paper presents a thrust force model to predict the thrust force during vibration-assisted drilling of aluminum 6061-T6. This model incorporates plowing force and strain rate-dependent shear strength to provide more accurate predictions than the existing model. The results of 72 drilling experiments with TiN-coated standard twist drills are reported. The predictions from the developed thrust force model are compared with the experimental results. The comparison demonstrates that the maximum deviation between the predictions and the averaged values of the experimental measurements is 20% using the existing model and only 7% using the proposed model.     

5A90铝锂合金真空熔炼工艺研究

采用真空精炼技术对自备的5A90铝锂合金进行处理,研究了不同真空度和熔炼时间对于合金中氢等杂质的去除效果,得出合理的真空熔炼参数。结果表明真空熔炼5A90铝锂合金的真空度在1000Pa,真空精炼时间为5min时．能够很好地保留合金元素并去除其中的氢和碱金属杂质。     

A conceptual model for the process variables related to heat generation in friction stir welding of aluminum

This paper seeks to describe relationships between the independent process variables and the dependent process outcomes related to heat generation and dissipation in friction stir welding. A conceptual model, proposed earlier, has been modified to specifically distinguish between plastic work and friction in the generation of heat. A case study is used to confirm and explore the relationships expressed in the conceptual model. Further, a method for expressing friction coefficient variation with respect to the key process variables is introduced.     

ZL205A铝合金淬火过程本构模型及数值模拟

通过等温压缩实验研究了ZL205A铝合金在宽温度范围(2～500℃)和宽应变速率范围(0.001～0.1 s-1)条件下的塑性变形行为.采用Arrhenius模型、Extended Ludwik-Hollomon(ELH)模型和BP人工神经网络模型描述ZL205A铝合金的流动应力,并应用在ZL205A工件淬火过程有限元...     

2A12硬铝合金热拉伸流变行为及本构建模

在变形温度350~500℃、应变速率0.01~1 s~(-1)条件下,利用Gleeble-3500热模拟实验机对2A12硬铝合金板进行热拉伸实验。结果表明:峰值应力随温度升高而减小,随应变速率提高而增大;随着应变速率减小,断裂总伸长率升高,而均匀伸长率降低;应变速率较低时,其断裂总伸长率在350~450℃时较高,升高到500℃时迅速降低,均匀伸长率则对温度变化不敏感;应变速率较高时,试样断裂总伸长率对温度变化不敏感,均匀伸长率随温度升高而降低。根据实验结果,采用Z参数建立的流变应力本构模型,能较好地描述2A12铝合金板材热拉伸变形下的流变行为。