差压铸造薄壁铝硅合金铸件的位置效应

采用差压铸造工艺,研究垂直缝隙式浇注系统浇注的铝合金硅铸件不同位置的组织和力学性能变化.采用石英砂型、SiC砂型和冷铁,浇口处铸件的晶粒最细小,致密度高、力学性能最好;铸件冷端的组织和性能次之;位于两者之间的铸件的组织和性能最差.分析表明对于具有垂直缝隙式浇注系统,差压铸造凝固压力对金属的凝固作用具有位置效应,浇口处液态金属温度高,凝固时间长,凝固压力对浇口处金属的凝固作用显著;铸件冷端金属凝固时间短,凝固压力对该处金属的凝固作用不显著,铸型的冷却速度对铸件组织和性能的影响起显著作用.浇口处与冷端之间的金属液体的凝固受压力和冷却速度的影响小,铸件的晶粒尺寸最大、密度最小、性能最低.冷却速度提高,铸件的任意位置的组织和性能都相应得到提高.     

Effect of casting/mould interfacial heat transfer during solidification of aluminium alloys cast in CO2-sand mould

The ability of heat to flow across the casting and through the interface from the casting to the mold directly affects the evolution of solidification and plays a notable role in determining the freezing conditions within the casting, mainly in foundry systems of high thermal diffusivity such as chill castings. An experimental procedure has been utilized to measure the formation process of an interfacial gap and metal-mould interfacial movement during solidification of hollow cylindrical castings of Al-4.5 % Cu alloy cast in CO₂-sand mould. Heat flow between the casting and the mould during solidification of Al-4.5 % Cu alloy in CO₂-sand mould was assessed using an inverse modeling technique. The analysis yielded the interfacial heat flux (q), heat transfer coefficient (h) and the surface temperatures of the casting and the mould during solidification of the casting. The peak heat flux was incorporated as a dimensionless number and modeled as a function of the thermal diffusivities of the casting and the mould materials. Heat flux transients were normalized with respect to the peak heat flux and modeled as a function of time. The heat flux model proposed was to estimate the heat flux transients during solidification of Al-4.5 % Cu alloy cast in CO₂-sand moulds.     

Investigation of mechanical,electrical, and thermal properties of a Zn–1.26 wt% Al alloy

Zn–1.26 wt% Al alloy was directionally solidified upward with a constant growth rate (V = 16.6 μm/s) in a wide range of temperature gradients (1.94–5.15 K/mm) and with a constant temperature gradient (G = 5.15 K/mm) in a wide range of growth rates (8.3–500 μm/s) with a Bridgman-type directional solidification furnace. The microhardness (HV) and tensile strength (σ) of alloy were measured from directionally solidified samples. The dependency of the microhardness, tensile strength for directionally solidified Zn–1.26 wt% Al alloy on the solidification parameters (G, V) and microstructure parameters (λ₁, λ₂) were investigated and the relationships between them were experimentally obtained using regression analysis. According to present results, the microhardness and tensile strength of directionally solidified Zn–1.26 wt% Al alloy increase with increasing solidification processing parameters and decrease with the microstructure parameters. Variations of electrical resistivity (ρ) with the temperature in the range of 300–650 K were also measured using a standard dc four-point probe technique for cast samples. The enthalpy of fusion and specific heat for same alloy was also determined by means of differential scanning calorimeter (DSC) from heating trace during the transformation from solid to liquid.     

Influences of solute content, melt superheat and growth direction on the transient metal/mold interfacial heat transfer coefficient during solidification of Sn–Pb alloys

Several factors such as alloy composition, melt superheat, mold material, roughness of inner mold surface, mold coating layer, etc., can affect the transient metal/mold heat transfer coefficient, h_i. An accurate casting solidification model should be able to unequivocally consider these effects on h_i determination. After this previous knowledge on interfacial heat transfer, such models might be used to control the process based on thermal and operational parameters and to predict microstructure which affects casting final properties. In the present work, three different directional solidification systems were designed in such a way that thermal data could be monitored no matter what configuration was tested with respect to the gravity vector: vertical upward and downward or horizontal. Experiments were carried-out with Sn–Pb hypoeutectic alloys (5 wt.% Pb, 10 wt.% Pb, 15 wt.% Pb and 30 wt.% Pb) for investigating the influence of solute content, growth direction and melt superheat on h_i values. The experimentally obtained temperatures were used by a numerical technique in order to determine time-varying h_i values. It was found that h_i rises with decreasing lead content of the alloy, and that h_i profiles can be affected by the initial melt temperature distribution.     

Degradation of 09H2S steel under the conditions of petroleum refining

We study the changes in the properties of 09H2S + 08Kh13 bimetal from the K-6 and K-2 columns of the “LYNYK” Closed Joint-Stock Company after operation for 27 and 12 yr, respectively. At 20 and 200°C, the mechanical properties of 09H2S steel after operation are compared with the properties of the metal in the as-delivered state. It is shown that, the most informative parameters among the mechanical characteristics of the metal are σ_0.2, σ_u, and δ, and the complex quantity σ_0.2 /σ_u. The relative narrowing ψ and impact toughness are insufficiently informative due to the significant spread of the data of measurements. The long-term operation of the bimetal results in the pitting corrosion of the inner surface of the column, corrosion cracking in the heat-affected zone of welded joints, and knife-line corrosion. It is shown that the theory of dislocations adequately explains the causes and mechanism of hardening of steels operating in corrosive media.     

Influence of titanium admixtures on the structure and physicomechanical properties of niobium

On the basis of experimental investigations, we analyze the effect of temperature on the phase composition and microstructure of VN-10 alloy. We study some mechanical (σ_u, σ_0.2, and δ), including long-term strength, and tribological (mass wear) characteristics of a niobium-titanium alloy. We have established that alloys of the Nb-Ti system are characterized by the dispersion-soluble type of strengthening. In the course of oxidation of the alloy in air, oxides of complex structure and texture are formed. Under dry friction, the alloy is more wear resistant after oxidation than after annealing. __________ Translated from Fizyko-Khimichna Mekhanika Materialiv, Vol. 43, No. 2, pp. 65–70, March–April, 2007.     

Estimation of air gap and heat transfer coefficient at different faces of Al and Al–Si castings solidifying in permanent mould

Abstract

In the casting processes, the heat transfer coefficient at the metal/mould interface is an important controlling factor for the solidification rate and the resulting structure and mechanical properties. Several factors interact to determine its value, among which are the type of metal/alloy, the mould material and surface conditions, the mould and pouring temperatures, casting configuration, and the type of gases at the interfacial air gap formed. It is also time dependent. In this work, the air gap formation was computed using a numerical model of solidification, taking into consideration the shrinkage and expansion of the metal and mould, gas film formation, and the metallostatic pressure. The variation of the air gap formation and heat transfer coefficient at the metal mould interface are studied at the top, bottom, and side surfaces of Al and Al–Si castings in a permanent mould in the form of a simple rectangular parallelepiped. The results show that the air gap formation and the heat transfer coefficient are different for the different casting surfaces. The bottom surface where the metallostatic pressure makes for good contact between the metal and the mould exhibits the highest heat transfer coefficient. For the sidewalls, the air gap was found to depend on the casting thickness as the larger the thickness the larger the air gap. The air gap and heat transfer coefficient also depend on the surface roughness of the mould, the alloy type, and the melt superheat. The air gap is relatively large for low values of melt superheat. The better the surface finish, the higher the heat transfer coefficient in the first few seconds after pouring. For Al–Si alloys, the heat transfer coefficient increases with increasing Si content.     

Mold-filling characteristics and solidification behavior of magnesium alloy in vacuum suction casting process

A novel semi-solid processing technique, called new vacuum suction casting (NVSC), is used to manufacture high-quality components of AZ91D Mg alloy directly from a liquid metal. The resulting apparent morphologies and microstructures of castings are characterized in detail and linked to the corresponding mold-filling behavior and subsequent solidification behavior. It is revealed that the semi-solid metal (SSM) with higher viscosity can be caused to fill the mold with “solid-front fill”, as compared with the liquid metal “spraying” in the conventional vacuum suction casting (CVSC) process. The smooth filling achieved in the NVSC process diminishes some disadvantages inherent for the CVSC sheets, and generates castings with better surface finish and structures with high integrity. The microstructure of the CVSC sheet consists of the fine and homogeneous supersaturated α-Mg solid solution due to the extremely high cooling rate. In the NVSC microstructure, the “preexisting” primary solid particles, with the morphology of near-globules or rosettes, disperse in the homogeneous matrix consisting of fine near-equiaxed secondary α-Mg grains and fine precipitates of β-Mg₁₇Al₁₂ intermetallics. In addition, owing to rapid solidification, the volume fraction of the β phase in the sheets obtained by both the processes is much lower than that in the as-cast ingot.     

Microstructure,phase evolution and corrosion behaviour of the Zn–Al–Mg–Sb alloy coating on steel

ABSTRACT

In the present work, the influence of antimony (Sb) addition in Zn–Al–Mg alloy on the microstructure, phase characteristic, solidification behaviour and corrosion resistance of hot dipped Zn–0.5Al–0.5Mg–xSb (x?=?0, 0.1, 0.3 and 0.5?wt-%) coated steel wires were evaluated. Thermal analysis revealed that cooling rate of the liquid metal using the steel mould (5.3°C?s^–1) was higher than using ceramic mould (0.3°C?s^–1). Based on the phase analysis and verified by thermodynamic calculations, it was revealed that Zn₁₁Mg₂ and Zn₂Mg phases appeared for Zn–Al–Mg alloy at slow and fast cooling rates while, the Mg₃Sb₂ phase was observed after addition of Sb at both cooling rates. Corrosion behaviour of the alloys determined through electrochemical measurements shows that Zn–Al–Mg alloy with 0.3?wt-%Sb has the lowest corrosion rate indicating an excellent corrosion resistance.     

Characterization of Al–Mn particles in AZ91D investment castings

Manganese is currently added to Mg–Al alloys in order to improve the corrosion behavior of cast components. A part of this manganese is dissolved in the magnesium matrix and the balance is found as fine Al(Mn,Fe) particles dispersed within castings. For AZ91D specimens prepared using the plaster mould investment casting process, these particles were observed in very large quantity at the surface of castings. These particles were characterized by scanning electron microscopy and electron probe microanalysis. It was found that they consist of Al₈Mn₅ phase and that their morphology and size depend on local solidification conditions. Their presence at the surface of the castings is related to low solidification rates and reduced thermal gradients at the mould/metal interface.     

Influence of atomized powder size on microstructures and mechanical properties of rapidly solidified Al–Cr–Y–Zr aluminum alloys

Rapidly solidified powders of Al–5.0Cr–4.0Y–1.5Zr (wt%) were prepared by using a multi-stage atomization-rapid solidification powder-making device. The atomized powders were sieved into four shares with various nominal diameter level and were fabricated into hot-extruded bars after cold-isostatically pressing and vaccum degassing process. Influence of atomized powder size on microstructures and mechanical properties of the hot-extruded bars was investigated by optical microscopy, X-ray diffraction, transmission electronic microscopy with EPSX and scanning electron microscopy. The results show that the fine atomized powders of rapidly solidified Al–5.0Cr–4.0Y–1.5Zr aluminum alloy attains supersaturated solid solution state under the exist condition of multi-stage rapid solidification. With the powder size increasing, there are Al₂₀Cr₂Y (cubic, a = 1.437 nm) and Ll₂ Al₃Zr (FCC, a = 0.407 nm) phase forming in the powders, and even lumpish particles of Al₂₀Cr₂Y appearing in the coarse atomized powders, as can be found in the as-cast master alloy. Typical microstructures of the extruded bars of rapidly solidified Al–5.0Cr–4.0Y–1.5Zr aluminum alloy can be characterized by fine grain FCC α-Al matrix with ultra-fine spherical particles of Al₂₀Cr₂Y and Al₃Zr. But a small quantity of Al₂₀Cr₂Y coarse lumpish particles with micro-twin structures can be found, originating from lumpish particles of the coarse powders. The extruded bars of rapidly solidified Al–5.0Cr–4.0Y–1.5Zr aluminum alloy by using the fine powders eliminated out too coarse powders have good tensile properties of σ_0.2 = 403 MPa, σ_b = 442 MPa and δ = 9.4% at room temperature, and σ_0.2 = 153 MPa, σ_b = 164 MPa and δ = 8.1% at high temperature of 350 °C.     

Phase characterization in as-cast F-75 Co–Cr–Mo–C alloy

Microstructural characterization of a cast acetabulum of ASTM F-75 alloy has been carried out in order to clarify conflicting reports from the literature. The present investigation revealed that although sigma (σ) and M₂₃C₆ carbide were the only secondary phases formed in the face centered cubic cobalt-base alpha matrix (Co-α), as identified by X-ray diffraction, the observed microstructure was quite complex. Scanning and transmission electron microscopy indicated the presence of coarse and fine lamellar cellular colonies, grain boundary film carbide, and different types of coarse blocky particles, including single-phase σ, dual-phase σ/M₂₃C₆, a binary eutectic comprised of σ and Co-α phases, and a three-phase feature comprising the binary eutectic and solid state formed M₂₃C₆. The carbide has probably formed during cooling from casting due to σ metastability. While it is proposed that the some lamellar cellular colonies were formed by discontinuous precipitation, it is not clear whether all lamellar structures present in the as-cast alloy occurred due to the same mechanism. The results obtained for the tensile properties are discussed in view of the observed microstructure.     

An investigation of the effect of high-temperature cyclic straining and creep loading on tensile mechanical properties of GH4145/SQ alloy

The effect of the reverse cyclic straining and the creep loading on the resultant tensile mechanical properties, such as the strength parameter (σ_0.2 and σ_b), the ductile parameter (δ and ϕ_f) and the composite parameter of the strength and ductility, the static toughness (U_t), for the precipitation-strengthened nickel-based superalloy GH4145/SQ used for high-temperature turbine and valve studs/bolts in power plant was investigated systematically at a temperature of 538°C. The experimental results show that in the case of the reverse cyclic straining both σ_0.2 and σ_b increases at early stages of cyclic straining and, after reaching their saturated values, σ_0.2 remains relatively constant until about 90% of fatigue life, while σ_b exhibits continuous reduction up to a level equal to the maximum applied stress amplitude. With the increasing number of straining cycles, both δ and ϕ_f as well as U_t decrease significantly until final fracture. In the case of creep loading the strength parameters (σ_0.2 and σ_b) tend to increase, as a whole, while the ductile parameters (δ and ϕ_f) and the static toughness (U_t) exhibit continuous decrease characterization as the amount of the creep deformation increases. The variation of the aforementioned various tensile mechanical properties during cyclic straining and creep loading of the alloy was further discussed by means of the observations of the deformation microstructures as well as the examinations of the fracture features of the specimens.     

Analysis of fracture limit curves and void coalescence in high strength interstitial free steel sheets formed under different stress conditions

Void formation, which is a statistical event, depends on inhomogeneities present in the microstructure. The analysis on void nucleation, their growth and coalescence during the fracture of high strength interstitial free steel sheets of different thicknesses is presented in this article. The analysis shows that the criterion of void coalescence depends on the d-factor, which is the ratio of relative spacing of the ligaments (δd) present between the two consecutive voids to the radius of the voids. The computation of hydrostatic stress (σ_m), the dominant factor in depicting the evolution of void nucleation, growth and coalescence and the dimensional analysis of three different types of voids namely oblate, prolate and spherical type, have been carried out. The ratio of the length to the width (L/W) of the oblate or prolate voids at fracture is correlated with the mechanical properties, microstructure, strains at fracture, Mohr’s circle shear strains and Triaxiality factors. The Lode angle (θ) is determined and correlated with the stress triaxiality factor (T), ratio of mean stress (σ_m) to effective stress (σ_e). In addition, the Void area fraction (V _a), which is the ratio of void area to the representative area, is determined and correlated with the strain triaxiality factor (T_o).     

Effects of Nd on microstructures and properties of extruded Mg-2Zn-0.46Y-xNd alloys for stent application

The microstructures, mechanical and corrosion properties of three extruded Mg-2Zn-0.46Y-xNd alloys (x = 0.0, 0.5, 1.0 wt%) were studied by optical microscopy, scanning electronic microscopy (SEM), electrochemical measurements and tensile tests. Microstructural observations indicated that Nd led to the uniformity and the variation of morphology of major second phase; tensile tests showed that Nd can improve the ductility at moderate amount (0.5 wt%) and will be detrimental up to 1.0%; Mg-2Zn-0.46Y-0.5Nd alloy exhibited excellent mechanical properties (σ_b, 269.0 MPa, σ_0.2, 165.6 MPa and elongation, 24%); electrochemical tests revealed that Nd can enhance the corrosion resistance and Mg-2Zn-0.46Y-1.0Nd alloy had lowest corrosion current density, which was reasoned that the line-shape and rodlike NdZn₂ phase might serve as corrosion barriers and the dissolved Nd can raise the electrode potential of the matrix.     

Corrosion study of single crystal Ni–Mn–Ga alloy and Tb<Subscript>0.27</Subscript>Dy<Subscript>0.73</Subscript>Fe<Subscript>1.95</Subscript> alloy for the design of new medical microdevices

Once placed in a magnetic field, smart magnetic materials (SMM) change their shape, which could be use for the development of smaller minimally invasive surgery devices activated by magnetic field. However, the potential degradation and release of cytotoxic ions by SMM corrosion has to be determined. This paper evaluates the corrosion resistance of two SMM: a single crystal Ni–Mn–Ga alloy and Tb_0.27Dy_0.73Fe_1.95 alloy. Ni–Mn–Ga alloy displayed a corrosion potential (E _corr) of −0.58 V/SCE and a corrosion current density (i _corr) of 0.43 μA/cm². During the corrosion assay, Ni–Mn–Ga sample surface was partially protected; local pits were formed on 20% of the surface and nickel ions were mainly found in the electrolyte. Tb_0.27Dy_0.73Fe_1.95 alloy exhibited poor corrosion properties such as E _corr of −0.87 V/SCE and i _corr of 5.90 μA/cm². During the corrosion test, this alloy was continuously degraded, its surface was impaired by pits and cracks extensively and a high amount of iron ions was measured in the electrolyte. These alloys exhibited low corrosion parameters and a selective degradation in the electrolyte. They could only be used for medical applications if they are coated with high strain biocompatible materials or embedded in composites to prevent direct contact with physiological fluids.     

Effects of pH on the electrochemical behaviour of titanium alloys for implant applications

The electrochemical behaviour of two commercial titanium alloys Ti-6Al-4 V (ASTM F136) and Ti-13Nb-13Zr (ASTM F1713) was investigated in Ringer physiological solution at two pH values (5.5 and 7.0). The corrosion properties were examined by using electrochemical techniques: Potentiodynamic anodic polarization, cyclic polarization and electrochemical impedance spectroscopy (EIS). The electrochemical corrosion properties of both alloys at different conditions were measured in terms of corrosion potential (E _corr), corrosion current density (i _corr) and passivation current density (i _pass). Equivalent electrical circuits were used to modulate EIS data, in order to characterize alloys surface and better understanding the pH effect on the interface alloy/solution.     

Acoustic investigations on PbO-Al2O3-B2O3 glasses doped with certain rare earth ions

Elastic moduli (Y, η), Poisson’s ratio (σ), microhardness (H) and some thermodynamical parameters such as Debye temperature (θ_D), diffusion constant (D _i),latent heat of melting (ΔH _m) etc of PbO-Al₂O₃-B₂O₃ glasses doped with rare earth ions viz. Pr³⁺, Nd³⁺, Sm³⁺, Eu³⁺, Tb³⁺, Dy³⁺, Ho³⁺, Er³⁺ and Yb³⁺, are studied as functions of temperatures (in the temperature range 30–200°C) by ultrasonic techniques. All these parameters are found to increase with increasing atomic numberZ of the rare earth ions and found to decrease with increasing temperature of measurement. From these results (together with IR spectra of these glasses), an attempt is made to throw some light on the mechanical strength of these glasses.     

T4 热处理对石膏型 AZ91 铸造镁合金组织和性能的影响

用石膏型熔模铸造技术,成功制备了AZ91镁合金铸件.用金相显微镜(OM)、扫描电镜(SEM)、能谱(EDS)以及电子万能实验机等,研究了AZ91镁合金铸态及T4热处理态的显微组织演变和力学性能.结果表明,分布在铸态AZ91镁合金晶界的网状β-Mg17Al12相在T4热处理过程中逐渐溶解,铸态和T4热处理态中均存在大量的A18Mn5化合物,T4处理后,其力学性能显著提高.     

Analytical technique for the determination of solidification rates during the inward freezing of cylinders

An analytical/experimental approach which permits the determination of solidification rates during the inward solidification of cylinders is proposed. The technique is based on a previous analytical solution that treats the generalized problem of solidification of slabs. This solution is modified by a geometric correlation to compensate for the cylindrical geometry. A number of experiments have been carried out with a special experimental set-up, designed to simulate the inward solidification of cylinders in a water-cooled mould. A series of comparisons of experimental results, numerical predictions and calculations furnished by the proposed technique were made, showing good agreement for any case examined.Nomenclature a _s Thermal diffusivity of solid metal = k _s/c _s d _s (m² sec^–1) - A _i Internal surface area of the mould (m²) - b _s Heat diffusivity of solid metal = (k _s c _s d _s ^1/2(J m^–2 sec^–1/2 K^–1) - c _s Specific heat of solid metal (J kg^–1 K^–1) - d _s Density of solid metal (kg m^–3) - h Newtonian heat transfer coefficien (W m^–2 K^–1) - H Latent heat of fusion (J kg^–1) - k _s Thermal conductivity of solid metal (W m^–1 K^–1) - q Heat flux (W m^–2) - r Radial position (m) - r _o Radius of cylinder (m) - r _f Radius of solid/liquid interface (m) - S Thickness of solidified metal (m) - S _o Thickness of metal side adjunct (m) - t Solidification time (sec) - T Temperature (K) - T _i Surface temperature (K) - T _f Freezing temperature of metal (K) - T _o Temperature of the coolant (K) - T _s Temperature at any point in the solidified metal (K) - V ₁ Volume of remaining liquid metal during the solidification (m³) - V _s Volume of solidified metal (m³) - V _T Total volume of metal in the mould (m³) - x Distance from metal/mould interface (m) - Dimensionless solidification constant.