Spatial interfacial heat transfer and surface characteristics during gravity casting of A356 alloy

As one of the key boundary conditions during casting solidification process, the interfacial heat transfer coefficient (IHTC) affects the temperature variation and distribution. Based on the improved nonlinear estimation method (NEM), thermal measurements near both bottom and lateral metal-mold interfaces throughout A356 gravity casting process were carried out and applied to solving the inverse heat conduction problem (IHCP). Finite element method (FEM) is employed for modeling transient thermal fields implementing a developed NEM interface program to quantify transient IHTCs. It is found that IHTCs at the lateral interface become stable after the volumetric shrinkage of casting while those of the bottom interface reach the steady period once a surface layer has solidified. The stable value of bottom IHTCs is 750 W/(m²·°C), which is approximately 3 times that at the lateral interface. Further analysis of the interplay between spatial IHTCs and observed surface morphology reveals that spatial heat transfer across casting-mold interfaces is the direct result of different interface evolution during solidification process.     

Study on interfacial heat transfer coefficient at metal/die interface during high pressure die casting process of AZ91D alloy

The high pressure die casting (HPDC) process is one of the fastest growing and most efficient methods for the production of complex shape castings of magnesium and aluminum alloys in today's manufacturing industry. In this study, a high pressure die casting experiment using AZ91D magnesium alloy was conducted, and the temperature profiles inside the die were measured. By using a computer program based on solving the inverse heat problem, the metal/die interfacial heat transfer coefficient (IHTC) was calculated and studied. The results show that the IHTC between the metal and die increases right after the liquid metal is brought into the cavity by the plunger, and decreases as the solidification process of the liquid metal proceeds until the liquid metal is completely solidified, when the IHTC tends to be stable. The interfacial heat transfer coefficient shows different characteristics under different casting wall thicknesses and varies with the change of solidification behavior.     

铝合金连续铸造喷水冷却的换热系数

基于边界条件替换法建立了铝合金连续铸造喷水冷却过程的换热系数计算模型.采用实验测量铸锭冷却过程的表面温度和温度场数值计算相结合的方法,确定了铸锭表面温度为100～500 ℃和喷水密度为11.3～27.8     

余热热处理对Al-Si-Cu合金铸件组织和性能的影响

研究了余热热处理工艺对Al-Si-Cu合金中Cu元素的固溶效果、共晶Si颗粒形貌及尺寸变化、以及该工艺对合金铸件力学性能的影响.结果表明,余热热处理工艺条件下,铸件可以在更短的时间内获得理想的固溶效果.通过分析铸件微观组织显微可知,余热热处理工艺可以通过缩短固溶处理时间有效地抑制共晶Si颗粒的粗化,在4h的固溶处理中Si颗粒平均尺寸持续减小且未出现粗化趋势.采用相同工艺参数,余热热处理工艺条件下制备的单铸试棒抗拉强度比传统T6热处理工艺提升约15%.     

铸型冷却速度对半固态镁合金浆料凝固组织的影响

采用不同直径型腔的铜质和铁质两种金属型,研究了铸型冷却速度对双螺杆机械搅拌法制备的半固态镁合金浆料凝固组织的影响.结果表明,随着铸型冷却速度的降低,半固态浆料的固相率升高,初生α-Mg相晶粒平均尺寸增大.采用铁质重力金属型不能制备直径大于φ25mm的半固态镁合金坯料,半固态浆料必须采用压铸或挤压成形的方法才能为触变成形工艺提供优质的半固态坯料.     

Determination of interfacial heat transfer coefficient and its application in high pressure die casting process

In this paper,the research progress of the interfacial heat transfer in high pressure die casting（HPDC）is reviewed.Results including determination of the interfacial heat transfer coefficient（IHTC）,influence of casting thickness,process parameters and casting alloys on the IHTC are summarized and discussed.A thermal boundary condition model was developed based on the two correlations：（a）IHTC and casting solid fraction and（b）IHTC peak value and initial die surface temperature.The boundary model was then applied during the determination of the temperature field in HPDC and excellent agreement was found.     

Measurement of temperature inside die and estimation of interfacial heat transfer coefficient in squeeze casting

As an advanced near-net shape technology, squeeze casting is an excellent method for producing high integrity castings. Numerical simulation is a very effective method to optimize squeeze casting process, and the interfacial heat transfer coefficient (IHTC) is an important boundary condition in numerical simulation. Therefore, the study of the IHTC is of great significance. In the present study, experiments were conducted and a"plate shape" aluminum alloy casting was cast in H13 steel die. In order to obtain accurate temperature readings inside the die, a special temperature sensor units (TSU) was designed. Six 1 mm wide and 1 mm deep grooves were machined in the sensor unit for the placement of the thermocouples whose tips were welded to the end wall. Each groove was machined to terminate at a particular distance (1, 3, and 6 mm) from the front end of the sensor unit. Based on the temperature measurements inside the die, the interfacial heat transfer coefficient (IHTC) at the metal-die interface was determined by applying an inverse approach. The acquired data were processed by a low pass filtering method based on Fast Fourier Transform (FFT). The feature of the IHTC at the metal-die interface was discussed.     

22MnB5钢表面微观形貌对界面换热系数的影响

为了探究冲压压强和样件表面粗糙度对22MnB5钢板的界面换热系数(Interfacial heat transfer coefficient,以下简称IHTC)的影响,自主设计了圆台试验模型,利用Beck非线性估算法,求解热成形工艺中高温样件与低温模具间界面换热系数。实验中通过调整冲压压强和改变样件表面粗糙度的方式,进而改变模具与样件间接触表面微观形貌,探究其对IHTC的影响。研究表明:压强与IHTC存在高度近似的正幂函数关系;粗糙度也会对IHTC产生影响,并且当粗糙度大于1μm时,IHTC值会随粗糙度的增大而明显减小,当粗糙度小于1μm时,由于表面氧化皮的影响,IHTC将随粗糙度值的减小而增大放缓,甚至趋于定值而不再增加。     

Influences of pouring temperature and cooling rate on microstructure and mechanical properties of casting A1-Si-Cu aluminum alloy

This paper investigated the influences of pouring temperature and cooling rate on the microstructure development and mechanical properties for casting Al-Si-Cu aluminum alloy.The microstructure of the as-cast samples was characterized by an optical microscope.The results showed that the dendrite arm spacing(DAS,λ) is well refined by pouring at a higher temperature.The λ decreases with increasing pouring temperature due to the multiplication of the nucleation sites in the superheating liquid melt,and the mechanical properties,such as microhardness and ultimate tensile strength increase correspondingly,while the elongation decreases.The relationships between microhardness and λ for the samples cooled in metal mould and sand mould,are given as HV=118.9 1.246λ and HV=115.2 1.029λ,respectively.The effects of the cooling rate controlled by using permanent mould casting and sand mould casing processes(the cooling medium is air and sand,respectively) on the dendrite arm spacing and mechanical properties are similar to the effect of the pouring temperature.     

一种铝合金水冷界面换热系数反求方法的研究

针对水冷金属界面换热系数影响因素多,测量与求解难的问题,以温度场数学模型为基础,以实测温度曲线为基准,通过数值模拟迭代计算和自动寻优,实现了铝合金水冷界面换热系数随温度变化定量关系的反求.反求得到的铝合金换热系数结果表明:在浸入式水冷过程中,铝合金界面换热系数随表面温度由低到高呈现出先升后降的单峰形状特征,降低冷却水的温度会使换热系数的峰值点升高,但不会改变峰值点出现的温度范围,换热系数的最大值出现在200～230℃.金属与冷却水之间热交换的强度主要取决于界面温度,将界面温度控制在200～230℃会使强化传热效果达到最佳.     

Effect of mold oscillation on the metallurgical characterization and mechanical properties of A319 aluminum alloy casting

Effect of mold oscillation on metallurgical characterization and mechanical properties of the A319 alloy was investigated. Experimental results show that the microstructure of A319 alloy was significantly refined regarding α-Al grain refinement along with improved silicon particle morphology due to mold oscillations. Mechanical properties of casting such as tensile strength, yield strength, percentage elongation and micro-hardness improved by 39.05, 28.05%, 2.67 times and 27.02% respectively as compared to that of stationary casting. This investigation is an attempt to study the effect of mold frequency on mechanical and metallurgical properties of aluminum alloys.     

Effect of cooling rate on eutectic cell count, grain size, microstructure, and ultimate tensile strength of hypoeutectic cast iron

This article describes a series of microstructural and strength studies performed on hypoeutectic cast iron, which was sand cast using a variety of end chills (metallic, nonmetallic, water-cooled, and subzero, respectively). The effects of cooling rate on the eutectic cell count (ECC), grain size, and the ultimate tensile strength (UTS) were evaluated. Attempts were also made to explain these effects and to correlate the UTS with ECC. It was found that subzero chilled and water-cool, chilled cast iron exhibit severe undercooling compared to normal sand cast iron. It was concluded from this investigation that nucleation conditions are completely altered but growth conditions prevail as usual. Therefore, undercooling during solidification is considered to be responsible for variation in ECC, grain size, microstructure, and tensile strength.     

热处理冷却速度对IN792合金显微组织及持久性能的影响

研究了热处理冷却速度对IN792合金显微组织及760 ℃/662 MPa持久性能的影响。结果表明,热处理冷却速度对γ′相的析出有显著影响：与炉冷相比,空冷和油冷条件下较快的冷却速度细化了合金二次γ′相尺寸,同时促进三次γ′相的析出,获得了尺寸、形貌不同的两种γ′相相匹配的双态组织。这种组织特点使合金760 ℃/662 MPa的持久寿命由炉冷条件下的118 h提高到空冷条件下的216 h和油冷条件下的245 h,使伸长率由炉冷条件下的8.5%下降到空冷条件下的4.0%和油冷条件下的3.3%。合金经1185 ℃×2 h,AC+1121 ℃×2 h,AC+843 ℃×24 h,AC时效处理,可获得较好的综合性能。     

Zr-4合金与模具钢的界面换热行为研究

界面换热系数是锆合金塑性成形模拟的重要边界条件之一。本文测定了界面有、无玻璃润滑剂条件下Zr-4合金和H13模具钢的界面接触温度随接触时间的变化曲线,在此基础上分析了界面换热特征,获得了界面换热系数随初始界面温度变化的函数式。结果表明,玻璃润滑剂可有效减缓Zr-4合金与H13钢的界面传热,当Zr-4合金和H13钢的初始界面温度分别为700℃和470℃时,有玻璃润滑剂时Zr合金表面温度达到稳定的时间约为16.3s,该时间段内相应的界面换热系数随实验时间的延长由226 W/( m₂?℃)增大到2166 W/( m₂?℃),无润滑剂时Zr合金表面温度达到稳定的时间约为7.7s,该时间段内界面换热系数由250 W/( m₂?℃)增大到2700 W/( m₂?℃)。采用本文确定的换热系数随温度变化的关系式进行热交换模拟可以获得较高的模拟精度,模拟与实验结果的最大误差约为4.5%。     

凝固速度和时效处理对高强高导Cu-3.2Ni-0.7Si合金组织与性能的影响*

通过单辊旋淬快速凝固技术制备Cu-3.2Ni-0.7Si（wt%）合金薄带。研究了不同旋淬速度（凝固速度）和时效处理对合金微观组织、导电率和力学性能的影响。结果表明,随着凝固速度的增大,铸态合金的晶粒明显细化,导电率降低,显微硬度和拉伸强度升高。铸态合金在同一温度进行时效处理,随着时效时间的增加,合金的电导率呈升高趋势,而合金的显微硬度和拉伸强度先升高后降低。铸态合金的导电率随凝固速度的增大而降低是基体晶格畸变程度增大所致;合金时效处理后导电率升高是由于第二相析出明显消除晶格畸变的结果。铸态合金显微硬度和拉伸强度随凝固速度增大而升高是细晶强化的结果;时效处理后,合金的显微硬度和抗拉强度明显提高是第二相强化的结果,而过度时效导致显微硬度和拉伸强度降低的主要原因是第二相的粗化团聚所致。     

Effect of superheat,mold, and casting materials on the metal/mold interfacial heat transfer during solidification in graphite-lined permanent molds

Heat transfer during the solidification of an Al-Cu-Si alloy (LM4) and commercial pure tin in single steel, graphite, and graphite-lined metallic (composite) molds was investigated. Experiments were carried out at three different superheats. In the case of composite molds, the effect of the thickness of the graphite lining and the outer wall on heat transfer was studied. Temperatures at known locations inside the mold and casting were used to solve the Fourier heat conduction equation inversely to yield the casting/mold interfacial heat flux transients. Increased melt superheats and higher thermal conductivity of the mold material led to an increase in the peak heat flux at the metal/mold interface. Factorial experiments indicated that the mold material had a significant effect on the peak heat flux at the 5% level of significance. The ratio of graphite lining to outer steel wall and superheat had a significant effect on the peak heat flux in significance range varying between 5 and 25%. A heat flux model was proposed to estimate the maximum heat flux transients at different superheat levels of 25 to 75 °C for any metal/mold combinations having a thermal diffusivity ratio (α _R) varying between 0.25 and 6.96. The heat flow models could be used to estimate interfacial heat flux transients from the thermophysical properties of the mold and cast materials and the melt superheat. Metallographic analysis indicated finer microstructures for castings poured at increased melt superheats and cast in high-thermal diffusivity molds.     

热处理对Cu/Al-3.25Si合金冷压焊接复合带界面组织与性能的影响

利用金相显微镜、扫描电镜、万能材料实验机等,研究了Cu/Al-3.25Si合金冷压焊接复合带热处理工艺,讨论了界面层厚度、界面结合强度、铜铝金属间化合物生成规律等问题. 结果表明,随着热处理温度的升高和保温时间的增加,扩散层厚度的增长呈现先快再慢的趋势,动力学曲线时间指数在0.5~1之间;界面的结合强度随着热处理温度和保温时间的增加呈先升高后降低的趋势;界面金属间化合物有Cu₉Al₄,CuAl,CuAl₂等;最佳热处理温度宜控制在200~300 ℃,保温时间在2 h以内.     

Effect of electromagnetic parameters on melt flow and heat transfer of AZ80 Mg alloy during differential phase electromagnetic DC casting based on numerical simulation

Based on multi-physical field coupling numerical simulation method, magnetic field distribution, melt flow, and heat transfer behavior of a Φ300 mm AZ80 alloy billet during differential phase electromagnetic DC casting (DP-EMC) with different electromagnetic parameters were studied. The results demonstrate that the increase in current intensity only changes the magnitude but does not change the Lorentz force’s distribution characteristics. The maximum value of the Lorentz force increases linearly followed by an increase in current intensity. As the frequency increases, the Lorentz force’s r component remains constant, and the z component decreases slightly. The change in current intensity correlates with the melt oscillation and convection intensity positively, as well as the liquid sump temperature uniformity. It does not mean that the higher the electric current, the better the metallurgical quality of the billet. A lower frequency is beneficial to generate a more significant melt flow and velocity fluctuation, which is helpful to create a more uniform temperature field. Appropriate DP-EMC parameters for a Φ300 mm AZ80 Mg alloy are 10–20 Hz frequency and 80–100 A current intensity.

     

热处理对挤压铸造TiB2P/6061Al复合材料组织与性能的影响

采用挤压铸造法制备了不同体积分数的TiBzv／6061Al复合材料，利用扫描电镜、透射电镜、硬度计、三点弯曲等手段对复合材料的组织与力学性能进行了研究，分析了热处理工艺对其组织性能的影响。结果表明：不同的热处理条件下TiB2P／6061Al复合材料的组织不同：退火态时观察到再结晶晶粒和少量位错：时效态时观察到大量的位错和析出相，界面产物尺寸比退火态时相对大些，且在界面附近的基体中存在明显的无析出区。热处理状态对弹性模量的影响不大，但对材料的硬度和抗弯强度影响较大。45％TiB2v／6061Al复合材料时效处理后硬度和抗弯强度分别比退火态时提高了40％和23％。     

Effect of annealing and heating/cooling rate on the transformation temperatures of NiFeGa alloy

In this work, Ni₅₅Fe₁₈Ga₂₇ ferromagnetic shape memory alloy was prepared through a suck-casting method. The effects of annealing and heating/cooling rate on the martensitic transformation temperatures were investigated by differential scanning calorimetry (DSC). The results showed that the phase transformation temperatures increase with increasing the annealing temperature, upon the heating and cooling process. However, the start and the finish temperatures (M_s and M_f) of martensitic phase transformation increased firstly and then decreased upon the cooling process with the increase the annealing time at 300 °C. The start and the finish temperatures (A_s and A_f) of inverse phase transformation increased slightly upon the heating process with the increase of the annealing time. The results can be explained by the evolution of the microstructure after heat treatment. It was also found that the phase temperatures show great dependence on the heating/cooling rate of the DSC test, A_s and A_f increased and M_s and M_f decreased with the increase of the heating/cooling rate.