计算机网络技术下的镁合金压铸工艺研究

科学技术的迅猛发展带动了计算机技术的发展,越来越多的计算机网络技术以及软件技术在工业生产中得到应用。本文利用网络技术Pro CAST软件对AZ91D镁合金的充型以及凝固过程进行了数值模拟计算,工艺参数对AZ91D镁合金压铸性能的一系列影响也被系统地分析,AZ91D镁合金性能以及与其相关的工艺参数数据库也被成功地建立。实验结果表明:AZ91D镁合金最好的流动性能以及充型性能的条件是充型时间为0.0030 s,凝固时间为2.9650 s。     

铈对铸造镁合金AZ91D显微组织与力学性能的影响

利用光学金相显微镜OM和XRD分析了分别加入0．1％，0．3％，0．5％，0．7％和1．0％Ce的AZ91D合金显微组织和相组成，测试了室温力学性能和硬度。结果表明，加入一定量Ce后的AZ91D合金形成杆状化合物Al4Ce，被推移到生长界面，阻碍枝晶的自由生长，从而细化合金显微组织；Ce能提高AZ91D合金室温抗拉强度和硬度，而对其屈服强度和延伸率影响不大；加入0．7％Ce的AZ91D合金晶粒细化效果好，其综合力学性能比较理想。     

Al_2Y/AZ91镁基复合材料流变成形数值模拟

在前期Al_2Y/AZ91镁基复合材料流变性能的研究基础上,将建立的Al_2Y/AZ91镁基复合材料表观粘度模型导入模拟软件,对Al_2Y/AZ91镁基复合材料液态及半固态充型及凝固过程进行了模拟,对压力场、速度场、固相分布和成形过程的缺陷进行了分析,结果表明,液态充型压力分布比较紊乱,熔体的流态为紊流,在型腔中容易产生涡流现象,在凝固过程中,铸件内部的冷却速度不一致,后续凝固的涡流区域在凝固过程中得不到有效的金属液的补充,进而容易产生缩孔缩松。半固态充型过程熔体内部压力传递相对比较平稳,速度分布均匀,熔体的流态表现为层流,不会产生涡流,铸件内外凝固速度相差不大,在整个凝固过程中不容易产生缩孔缩松等缺陷。为了验证模拟结果的正确性,进行了复合材料的流变成形实验,由实验可知,流变成形铸件显微组织以球状晶为主,没有孔洞缺陷,铸件成形质量较好。实验结果与模拟结果较吻合。     

稀土对AZ91镁合金组织和性能影响的研究进展

AZ91合金是实际使用最为普遍的一类镁合金,在现有压铸镁合金中AZ91约占90%。稀土元素的独特性质能够影响合金性能,因此在AZ91合金中添加稀土元素,以期改善其性能是目前研究的一个热点。综述了稀土元素对AZ91合金铸造过程中的净化作用,以及对AZ91合金组织的细化作用;论述了稀土元素对AZ91合金力学性能,摩擦磨损性能,耐腐蚀性能的影响。     

细晶Mg-Al-Ti-C中间合金的制备及其对AZ91D组织和性能的影响

采用两步法+铜模喷铸的方式制备具有颗粒增强和细晶强化作用的Mg-Al-Ti-C中间合金,并研究了其对AZ91D组织和性能的影响。通过OM、SEM、XRD、硬度及拉伸试验对中间合金和AZ91D的组织形貌和力学性能进行分析。结果表明,两步法制备得到了Mg-Al-Ti-C中间合金,经过铜模喷铸后,TiC颗粒尺寸大幅度减小,且弥散分布于Mg-Al-Ti-C中间合金中;用该细晶Mg-Al-Ti-C中间合金处理AZ91D,后者的抗拉强度提高了19.8%,硬度提高了64.9%;TiC颗粒既有颗粒增强作用,也能作为AZ91D凝固时的异质形核核心,起到细晶强化作用。     

稀土元素铈对镁合金AZ91D显微组织和力学性能的影响

利用光学显微镜、X射线衍射和扫描电镜等分析研究含铈镁合金AZ91D（0．25％Ce、0．7％Ce、0．95％Ce）的显微组织,并对其力学性能进行了测试,同时与不含铈镁合金AZ91D进行了比较。结果表明,加入一定量Ce后的镁合金AZ91D形成杆状化合物Al4Ce,被推移到生长界面,阻碍枝晶的自由生长,从而细化合金显微组织;Ce能提高镁合金AZ91D抗拉强度和硬度,而对其屈服强度和延伸率影响不大;加入0．7％Ce的AZ91D镁合金晶粒细化效果和综合力学性能比较理想。     

Mg-30Sr对AZ91D镁合金显微组织和力学性能的影响

为了开发低成本、高强度的新型镁合金．研究了微量Sr对AZ91D镁合金显微组织和力学性能的影响。研究结果表明：Sr加入AZ91D镁合金,能明显细化组织晶粒。从而改善合金的室温力学性能。当加入1％Sr（质量分数）时,合金晶粒细化效果较好。其室温力学性能和硬度比原来都有较大的提高。     

Al-Ti-B对AZ91D镁合金显微组织和力学性能的影响

研究了Al-Ti-B对AZ91D镁合金铸态显微组织和力学性能的影响，并探讨其化学成分与组织结构和力学性能之间的变化。研究结果表明：Al-Ti-B加入AZ91D镁合金，能明显细化组织晶粒，从而改善合金的室温力学性能。当加入Al-Ti-B时，合金晶粒细化效果较好，其室温力学性能和硬度比原来都有较大的提高。     

近液相线半连续铸造AZ91D镁合金微观组织研究

用近液相线半连续铸造法制备出具有球状和蔷薇状晶粒的AZ91D合金坯料。考察了铸造速度对合金微观组织的影响，以及对铸锭边部和中心组织差异的影响。实验结果表明，随铸造速度的增加，铸锭逐渐趋向枝晶化，边部和中心组织差异经历了由小到大，再由大到小的变化。并对铸造速度的影响机理进行了分析。     

铈镧混合稀土对AZ91D压铸镁合金显微组织和蠕变性能的影响

研究了不同含量Ce/La(x=0,0.1,0.5,1.0)对AZ91D镁合金显微组织及蠕变性能的影响。通过X射线衍射(XRD)、金相显微镜(OM)、扫描电镜(SEM)及能谱分析(EDX)观察与分析表明,压铸AZ91D镁合金中添加Ce/La后,除了α-Mg,β-Mg17Al12相之外,还生成了新的稀土化合物Al11RE3(RE=Ce/La)化合物,并且细化了合金显微组织、提高了合金室温和高温力学性能。生成的Al11RE3(RE=Ce/La)高温热稳定相使AZ91D+xCe/La(x=0,0.1,0.5,1.0)合金在150℃,50MPa下的蠕变抗力优于AZ91D镁合金,1%Ce/La的合金与AZ91D相比,蠕变延伸率低了0.2%,最小蠕变速率从2.30×10-8s-1降低到2.02×10-8s-1。蠕变试样的微观组织结构分析表明:AZ91D合金的蠕变机制主要以晶界滑移方式为主,Al11RE3(RE=Ce/La)热稳定相在晶界处延缓和阻碍了晶界断裂的过程。     

粉末注射成形充模过程凝固层形成规律研究

根据连续性、动量和能量守恒方程,以及固／液界面上能量平衡原理,建立了考虑凝固层后的一维流动模型,计算了模腔内壁上喂料凝固层厚度与工艺参数的关系,研究结果表明：模具入口附近凝固层厚度开始急剧增加,然后增加速率逐渐减缓;适当提高模具温度,可以减少凝固层厚度,有利于充模过程。     

异形坯连铸充型凝固过程数值模拟

利用CFD商用软件Flow-3d,对单双水口Q215钢750 mm×450 mm×120 mm异形坯连铸结晶器内钢水充型凝固过程进行数值模拟,得到了速度场、温度场的分布图和充填过程自由表面的位置和形状图。分析了单双水口模型对速度场及凝固的影响。结果表明,双水口模型可以减轻结晶器上部回流的强度,减小冲击深度,提高传热效率,加快结晶器内钢液的凝固速度,有助于提高铸坯的质量和提高拉速。     

Low-frequency pulsations of melt during lost foam casting process: Part I

An investigation into the process of the appearance of low-frequency pulsations of liquid metal in a mold is carried out on the basis of a mathematical model of kinetics of mold filling during the lost foam casting process (LFCP). The mold filling is shown to occur with a delay, when a gas space arises between the material of the lost pattern and liquid metal, which gets a mechanical impulse, causing fluctuations of its level in the riser and pressure in the gas space. The natural frequency of fluctuations in the gas space is shown to decrease (at first abruptly and then slowly) as the mold is filled by metal. At the same time, this depends weakly on the gas permeability of the mold, slightly increasing and then stabilizing as the feed speed of the liquid metal into the mold increases and decreases as the rarefaction in a flask increases.     

Influence of left ventricular filling profile during preceding control beats on the occurrence of pulse deficit caused by ventricular premature contractions

This study was designed to investigate whether the left ventricular filling profile during preceding control beats significantly affects the pulse deficit caused by ventricular premature contractions (VPCs). The study group consisted of 18 patients (10 men, eight women, 15-85 years old) who underwent electrophysiological catheterization because of sinus bradycardia. Using a temporary pacing lead inserted in the right ventricular apex, isolated VPCs with various coupling intervals were produced by electrical stimulation of the right ventricle. During the production of the VPCs, the mitral filling flow velocity using pulsed wave Doppler echocardiography, the femoral arterial pressure curve and the electrocardiogram were simultaneously recorded. The right ventricle was stimulated 800, 750, 700, 650, 600, 550, 500, 450 and 400 ms after the triggered control beat QRS complex. Pulse pressures during VPCs gradually decreased in relation to the shortening of the extrasystolic beat coupling interval. The longest coupling interval for each subject, which caused complete abolition of the pressure pulse during the VPC, was defined as the pulse deficit coupling interval. The early to late diastolic velocity-time integral ratio (Ei/Ai ratio) of the mitral filling flow velocity during the control beats which precede the VPC was obtained as an index expressing the left ventricular filling profile. The Ei/Ai ratio of the mitral filling flow velocity ranged from 0.7 to 4.5 (1.8 +/- 1.0). The pulse deficit coupling interval ranged from 440 to 640 ms (510 +/- 60 ms).(ABSTRACT TRUNCATED AT 250 WORDS)     

Uphill Teeming Utilizing TurboSwirl to Control Flow Pattern in Mold

The flow pattern has widely been recognized to have an impact on the exogenous non‐metallic inclusion generation in the gating system and mold flux entrapment in the mold in the uphill teeming process. The possible solutions of the flow pattern control are required to be reliable and practical in order to improve the yield and the ingot quality in the steel production. In this work, a mathematical model of a new novel swirling flow generation component, TurboSwirl, was studied to investigate the flow pattern of steel in the gating system and molds based on the authors' previous study. The same calculation method and boundary conditions were adopted. The results show that a much calmer initial filling condition with less fluctuations is achieved in the mold with a swirling flow by using the TurboSwirl compared to previous studies. In addition, the initial position of the mold powder bags can further be lowered in the mold due to a decreased hump height. Moreover, the difference between the hump height and the surface height in the present model has a maximum value of 83 mm, which gives a lower risk of mold flux entrapment. Furthermore, the maximum wall shear stress value can generally be lowered with less fluctuations after the first hump formation in the mold at 2.5 s from the teeming start. In conclusion, the initial filling conditions can be substantially improved by the use of TurboSwirl flow pattern control.     

Metal flow in the mold of a continuous-casting machine

Analysis of the flow of liquid metal in the mold during continuous casting is a challenging mathematical problem. Nevertheless, precise solutions have bene found for some cases. Such analytical solutions may be used to verify numerical solutions. In the present work, the melt flow in the mold is studied numerically on the basis of the finite-difference approximation of the initial system of equations. This method is relatively universal: it has been successfully used in continuum mechanics, in mathematical modeling of the stress–strain state of shells in casting, and in other industrial contexts. In the present work, it is applied to the hydrodynamic and thermal fluxes of liquid metal in steel casting in a rectangular mold in a continuous-casting machine. The three-dimensional mathematical model that is obtained describes the liquid-metal fluxes in the mold. The processes that accompany the filling of the mold with melt are simulated by means of Odissei software. The calculations are based on the fundamental hydrodynamic equations, a formula from mathematical physics (the heat-conduction equation with allowance for mass transfer), and a familiar numerical method. The resulting system of differential equations is solved numerically. The region investigated is divided into finite elements. For each element, the system of equations is written in finite-difference form. Solution yields the field of flow velocities of the metal and the temperature field within the mold. The algebraic equations obtained by this means are solved by means of numerical algorithms. On that basis, a program is written in Fortran-4. The mathematical model permits variation of the mold dimensions and the cross section of the metal outlet from the submersible nozzle. It may also assist in understanding the motion of the cast metal, which affects the heat transfer by the mold walls, and in finding the optimal parameters of the liquid metal as it leaves the submersible nozzle. As an example, steel casting in a rectangular mold (height 100 cm) is considered. In casting, the metal leaves the submersible nozzle symmetrically on both sides, in the horizontal plane. The results are graphically displayed. The motion of the metal flux is shown in different cross sections of the mold. Regions of circular flow are identified, as well as regions of vertical motion in the mold. The magnitude and intensity of these regions are determined. The temperature field indicates a local hot zone at the mold wall. That may be attributed to the direct flux of hot metal from the aperture in the submersible nozzle.     

Doppler estimation of left ventricular filling pressure in sinus tachycardia. A new application of tissue doppler imaging

BACKGROUND: Doppler echocardiography is frequently used to predict filling pressures in normal sinus rhythm, but it is unknown whether it can be applied in sinus tachycardia, with merging of E and A velocities. Tissue Doppler imaging (TDI) can record the mitral annular velocity. The early diastolic velocity (Ea) behaves as a relative load-independent index of left ventricular relaxation, which corrects the influence of relaxation on the transmitral E velocity. METHODS AND RESULTS: We evaluated 100 patients 64+/-12 years old with simultaneous Doppler and invasive hemodynamics. Mitral inflow was classified into 3 patterns: complete merging of E and A velocities (pattern A), discernible velocities with A dominance (B), or E dominance (C). The Doppler data were analyzed at the mitral valve tips for E, acceleration and deceleration times of E, and isovolumic relaxation time. In patterns B and C, the A velocity, E/A ratio, and atrial filling fraction were derived. Pulmonary venous flow velocities were also measured, and TDI was used to acquire Ea and Aa. Weak significant relations were observed between pulmonary capillary wedge pressure (PCWP) and sole parameters of mitral flow, pulmonary venous flow, and annular measurements. These were better for patterns A and C. E/Ea ratio had the strongest relation to PCWP [r=0.86, PCWP=1.55+1.47(E/Ea)], irrespective of the pattern and ejection fraction. This equation was tested prospectively in 20 patients with sinus tachycardia. A strong relation was observed between catheter and Doppler PCWP (r=0.91), with a mean difference of 0.4+/-2.8 mm Hg. CONCLUSIONS: The ratio of transmitral E velocity to Ea can be used to estimate PCWP with reasonable accuracy in sinus tachycardia, even with complete merging of E and A velocities.     

Formation Mechanism of Surface Crack in Low Pressure Casting of A360 Alloy

A surface crack defect is normally found in low pressure castings of Al alloy with a sudden contraction structure. To further understand the formation mechanism of the defect, the mold filling process is simulated by a two-phase flow model. The experimental results indicate that the main reason for the defect deformation is the mismatching between the height of liquid surface in the mold and pressure in the crucible. In the case of filling, a sudden contraction structure with an area ratio smaller than 0.5 is obtained, and the velocity of the liquid front increases dramatically with the influence of inertia. Meanwhile, the pressurizing speed in the crucible remains unchanged, resulting in the pressure not being able to support the height of the liquid level. Then the liquid metal flows back to the crucible and forms a relatively thin layer solidification shell on the mold wall. With the increasing pressure in the crucible, the liquid level rises again, engulfing the shell and leading to a surface crack. As the filling velocity is characterized by the damping oscillations, surface cracks will form at different heights. The results shed light on designing a suitable pressurizing speed for the low pressure casting process.     

多孔水口对轴承钢280 mm x325 mm铸坯结晶器钢液流场和温度场的影响

采用数值模拟的方法对比分析了直通式、四孔式以及五孔式水口对GCr15轴承钢280 mm×325 mm坯连铸结晶器内钢液流场和温度场的影响。结果表明,当前常用的直通式水口对坯壳无冲刷,利于坯壳均匀生长,但钢液冲击深度大,在弯月面处速度小,不利于大方坯质量的提高。当采用四孔水口时,钢液热中心上移,钢液面处温度可提高8℃,钢液向上漩流增强,有利于降低结晶器内钢水过热及保护渣的熔化,但由于钢液对结晶器宽、窄面坯壳的冲刷致使冲击区域附近坯壳出现不同程度的零增长区域。当采用五孔水口时,除了钢液热中心上移,钢液向上漩流增强,由于侧孔钢液流速减小,对坯壳的冲刷减小,有利于保护渣的快速熔化、过热度的快速降低,坯壳的均匀生长,显著提高大方坯的质量。