合金液雾燃烧过程中反应速率与温度场

影响合金液雾燃烧工艺过程中氧化燃烧反应速率的关键因素是金属或者合金液雾滴径大小；液雾滴径越小，氧化燃烧反应速率越大，也越有利于金属或者合金液雾的完全氧化，燃烧室流场可分为内回流区，旋转射流区和外回流区3大场区。液雾燃烧系统的温度场为一以燃烧“核心”为球心的等温球面，球面半径越大，温度越低，而至封围其雾化燃烧室的周壁处温度最低。     

液雾滴径及雾场形态对合金液雾燃烧质量的影响

分析了合金液雾滴径及雾场形态对雾化燃烧质量的影响,指出合金熔体被雾化得越细,越有利于有关火燃烧,而合金液雾的燃烧所出现的高温使得合金雾滴沸腾并挥发而形成气相,气相的燃烧是获得纳米级金属氧化物的根本原因,采用旋涡式雾化燃烧器有利于合金液雾与氧气的充分混合,从而有利于合金液雾的完全氧化。     

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 通过建立圆管状燃烧室内甲烷气体燃烧的数学模型,对燃烧室回流区的温度场、速度场、流场以及甲烷、氧气、二氧化碳以及氮氧化合物的质量分数进行了数值模拟。通过改变入口高温空气的预热温度,数值模拟了以上变量的分布规律。研究结果表明,提高空气的预热温度,燃烧室内的反应进行越彻底,温度分布更均匀。研究结果对燃烧室的设计和燃烧室工况分析具有指导意义,所建立的数学模型为燃烧室几何和结构设计和燃烧过程操作中进行定量分析的有效手段。     

轴承衬套离心铸造凝固过程的数值模拟

应用ANSYS软件对油膜轴承衬套巴氏合金层离心铸造凝固过程温度场和应力场进行了数值模拟,分析研究了不同的浇注温度和铸型预热温度对凝固过程的影响。结果表明,随着金属液浇注温度和铸型预热温度的升高,金属液凝固速率降低,铸型内部产生的热应力增大,越靠近合金层的地方,热应力越大;铸型预热温度越高,铸型的冷却能力越差;在离心铸造凝固过程中铸型预热温度的影响比浇注温度的影响更大;分析并得出了最佳工艺参数。模拟结果与实际生产相符合。     

铝合金轮毂压铸模温度场数值分析

运用有限元分析软件ProCAST对压铸模进行了压铸过程模具温度场分析,研究了模具预热温度、浇注温度对模具温度场的影响。结果表明,模具型腔表面温度受金属液充填的影响较大,距型腔表面距离超过20mm后,模具温度受金属液的影响较小。模具预热温度影响模具内的温度梯度和升温速率,预热温度越高,型腔表面升温速率越小,模具内的温度梯度越小。浇注温度越高,模具型腔表面的升温幅度和升温速率越大。     

AZ31B镁合金热压缩变形的组织变化与变形机制

对铸态AZ31B镁合金在温度280℃～440℃、应变速率0.001s-1～0.1s-1条件下进行热压缩实验,分析变形程度、应变速率和加热温度对其微观组织变化的影响,探讨合金的热压变形机制。实验结果表明,该合金热变形时发生了动态再结晶。变形温度越高、变形速率越小和变形量越大时,动态再结晶进行的越充分;变形温度越低、变形速率越大和变形量越大时,动态再结晶晶粒越细小。该合金的热变形机制是滑移孪晶联合机制。     

三氯化铁溶液中影响铁镍合金蚀刻速率的因素

采用浸渍蚀刻的方法,研究了影响Fex(x=56～59)Ni1-x合金箔在三氯化铁溶液中蚀刻速率的几个因素,并对蚀刻液的有效蚀刻能力及失效蚀刻液的除镍和再生进行了初步的研究.研究结果表明:氧化还原电位随蚀刻液浓度的增大而升高,氧化还原电位越高,蚀刻反应趋势越大;蚀刻速率随浓度的增加先增大,再下降,且在浓度为40%左右出现极大值;蚀刻液温度越高、pH值越小,蚀刻速率越大;除镍后的失效蚀刻液经再生后能达到新鲜蚀刻液的90%以上,基本达到再生利用的要求.     

用液雾氧化燃烧工艺制备SnO2／In2O3纳米粉

将Ｓｎ和Ｉｎ先熔炼成合金，然后通过气雾喷粉工艺，由高压富氧气体使合金熔体雾化成微细的金属雾滴，并随即在燃烧道中直接氧化燃烧而生成ＳｎＯ２／Ｉｎ２Ｏ３纳米级复合的陶瓷粉末，其粒度≤２５ｎｍ。     

镁铝钆合金在空气中的氧化与燃烧

研究了在镁铝质量比为20:80的镁铝合金中加入稀土金属钆后,合金在空气中的氧化与燃烧特性。借助TG-DSC,SEM,XRD,EDS以及高速摄像仪等仪器对Mg-Al-Gd合金的氧化、燃烧过程及产物进行分析。结果表明:相对于不含钆的Mg-Al合金,Mg-Al-Gd合金在空气中的点火温度较低,约为487.6℃。在TG-DSC实验中,镁铝钆合金的氧化分为2个阶段,第1个阶段为镁的氧化反应,第2个阶段为氧化镁、铝以及氧气的反应,反应生成MgAl_2O_4。当Mg-Al-Gd合金在空气中燃烧时,合金粒子表面会形成一层薄的致密的氧化层,氧化层限制了合金粒子固相或液相的氧化,促进其气相燃烧,同时也导致燃烧出现喷射现象。燃烧没有生成MgAl_2O_4,而是形成了一种新的产物AlN。     

钛建材及表面处理技术

采用直流电弧激发燃烧法（DCSB法）测试Ti40,AlloyC和TC4合金在3种气氛条件下的相对质量燃烧速度。结果表明：与TC4合金相比，Ti40和AlloyC均具有较好的阻燃性能，用氮气来稀释空气能够降低钛合金的燃烧速率。用扫描电镜（SEM）与X射线能谱（EDAX）观察分析了合金的燃烧产物、界面与基体，发现：当Ti40和AlloyC燃烧时，V优先迁移至表层，因而燃烧区表层氧化层为富V贫Cr，而燃烧产物与基体界面附近氧化层则为富Cr贫V。Ti40与AlloyC界面的富Cr贫V混合氧化层非常致密，既可抑制氧扩散入基体，又可阻碍基体中的V扩散进入燃烧区。TC4燃烧时，虽然Al优先迁移至表面与氧反应生成Al2O3，但该氧化层不连续不能有效降低燃烧速度，Cr,V元素均对合金燃烧时界面氧化层的致密化有重要作用。     

Effect of the Shape Factor on the Cold-Spraying Dynamic Characteristics of Sprayed Particles

Silicon powder was chosen to be deposited by cold spraying for the consideration of possible applications in lithium ion batteries. The influence of the silicon particle shapes other than spherical on the impact velocity and temperature for different working parameters of the gas streams have been numerically investigated by using computational fluid dynamics modeling. The results show that, for same equivalent diameter, the particle impact velocities increase to a maximum velocity when the shape factor increases to a certain value and then decreases to the impact velocity of spherical particles. In the cold-spraying process, the particle velocity profile for smaller shape factors is much closer to that of the gas stream due to the larger particle surface area. Furthermore, the particle impact velocity increment for smaller shape factors is much more remarkable with a higher main propulsion gas temperature and higher carrier gas pressure. The effect of raising the main propulsion gas pressure on the impact velocity of the particles with very smaller shape factors is negligible. The particle impact velocity and temperature can be altered by not only the change of the working parameters of the gas steams but also the change of the sizes and shapes of the sprayed particles.     

双级雾化快凝磁性磨料制备工艺系统的研制

为了获得混粉雾化快凝中的工艺参数,制备性能优良的球形磁性磨料,提高制备工艺系统的稳定性。通过对雾化快凝工艺的分析,设计了双级雾化器、设计了气力送混粉装置与控制系统、设计了雾化水冷室的结构与冷却供水系统。通过FLUENT流体分析软件,对双级雾化器在不同压力配比下的数值分析,模拟出在上级雾化压力为1.2MPa、下级雾化压力为2.5MPa时得到均匀的速度流场,保证雾化过程的持续性。在现有设计的基础上,通过实验验证了上述设备与工艺参数准确性,制备出了陶瓷硬质磨料颗粒牢固地镶嵌在铁基体表层的球形磁性磨料。     

Development of advanced research reactor fuels using centrifugal atomization technology

Rotating disk centrifugal atomization technology has been utilized to fabricate uranium silicide (U₃Si, U₃Si₂) and U-Mo nuclear fuel powders having high uranium content per unit volume for high performance research reactor fuels. Atomized nuclear fuel powders have characteristics of a spherical shape with narrow size distribution, small specific surface area and high purity. The heat treatment time for the formation of U₃Si by a peritectoid reaction was reduced from about 72 hours for comminuted powders to about 6 hours for atomized powders due to more rapid solidification of atomized powder with a finer microstructure. The homogeneity of fuel particles in fuel meats was improved by mixing atomized fuel powders with Al powders using a V-shaped tumbler mixer. The atomized powders with a spherical shape and smooth surface were extruded under lower force than the comminuted powders with angular rough surfaces. The dispersed fuel meat with atomized powders resulted in an increased fuel powder loading density and higher thermal conductivity in the heat flow direction. The thermal swelling of dispersed fuel meat decreased due to the reduced specific surface area of spherical atomized nuclear powder. The atomized U-10wt.%Mo dispersion fuel showed less bubble formation than the comminuted fuel after an irradiation test with 40% burnup.     

Modeling of particles impacting on a rigid substrate under plasma spraying conditions

Finite-element methods have been applied for the spreading process of a ceramic liquid droplet impacting on a flat cold surface under plasma spraying conditions. The goals of the present investigation are to predict the geometrical form of the splat as a function of process parameters, such as initial temperature and velocity, and to follow the thermal field developing in the droplet up to solidification. A nonlinear finite-element procedure has been extended to model the complex physical phenomena involved in the impact process. The dynamic motion of the viscous melt in the drops as constrained by elastic surface tensions and in interaction with the developing contact with the target has been coupled to transient thermal phenomena to account for the solidification of the material. A model is used to study the impact of spherical particles of liquid ceramic of given temperature and velocity on a flat, cool rigid surface. The deformation of the splat geometry as well as the evolution of the thermal field within the splat are followed up to the final state and require adaptive discretization techniques. The proposed model can be used to correlate flattening degrees with the initial process parameters.     

基于空气动力学的环缝气流雾化制粉喷嘴设计

气流雾化制粉技术在生产冶金粉末领域应用非常广泛,为了提高气流对金属流的剪切作用,根据压缩空气膨胀所形成的高速气流动力学原理,设计了一种环缝气流雾化制粉喷嘴,并对影响环缝气流雾化制粉喷嘴粉末破碎过程中的参数进行了分析。推导出了压缩空气在进气管内流动时不产生紊流的管径计算式;分析了R_0/re及pe/p_0比值对环缝出口处气流速度的影响,通过增加R_0/re比值或降低pe/p_0比值,将提高粉末的破碎效果;建立了雾化锥角设计计算的函数关系式。通过仿真得到喷嘴内部流场分成4个区域:涡流区、回流区、分离区和混合区。仿真效果验证了参数选取的准确性,为环缝气流雾化制粉喷嘴的设计提供了理论依据。     

Heat transfer analysis of atomized droplets during high velocity arc spraying

The heat transfer problem of the atomized droplets during high velocity arc spraying (HVAS) was modeled and solved by a numerical method using a Fe-Al alloy, and the influences of several important process parameters on the heat transfer behaviors of the atomized droplets were analyzed. The results show that the initial cooling rates of different size droplets range from 105 to 107 K/s, thus producing the coating microstructure with the features of rapid solidification. The droplet size, atomization gas pressure and droplet superheat have great influences on the heat transfer behavior of the droplet. The droplet temperature and cooling rate are much sensitive to the droplet sizes, but insensitive to the atomization gas pressure and droplet superheat. It can be predicted that the properties of HVAS coatings will be improved by decreasing droplet size as well as increasing atomization gas pressure and droplet superheat in certain extents.     

Numerical modeling of a low temperature high velocity air fuel spraying process with injection of liquid and metal particles

An analysis of a low temperature high velocity air fuel (LTHVAF) thermal spray process is presented using computational fluid dynamics (CFD). The originality of the process lies in the injection of liquid (water) upstream of the powder injection to control to gas temperature and, therefore, the heat transfer to the injected particles. First, computation fluid dynamic techniques are implemented to solve the mass, momentum, and energy conservation equations in the gas phase. A turbulence model based on the renormalized group theory (RNG) is used for the turbulent flow field. The gas dynamic data are, then, used to model the behavior of the liquid droplets and particles in the gas flow field. The calculated results show that the liquid flow rate should range between 20 and 30 kg/h to achieve the optimal gas characteristics for particle treatment. They also show that particle velocity and temperature are strongly affected by particle size. At the gun exit, the particle velocity and temperature range between 700 and 300 m/s and between 900 and 400 K, respectively, for Cu and Ni particles with size distributions of 1 to 50 μm. As expected, the smaller particles have higher velocity and temperature. The metal coatings (Nickel and copper) produced by the LTHVAF spray process are characterized by low oxide content, low residual stresses, high deposition rates, and good bonding to the substrate.