Metallurgical quality of CSP thin slabs

The casting structure, chemical composition segregation, dendrite arm space, inclusiona and during the CSP (compact strip production) rolling process were investigated. The results show that the CSP thin slab has a feature of uniform fine grains, more columnar crystals, less central porosity and segregation etc. There is no great difference in macrostructure between the CSP thin slab and conventional slab; however, the fine dendrite structure of the CSP slab is more uniform. Moreover, the central porosity and segregation are obviously improved after the first pass; and the dendrite is bent along the rolling direction rather than broken into pieces.Small inclusions with the diameter less than 10 p.m in the CSP slab are dominantly consisted of aluminates formed by A1 deoxidation and Ca treatment and not floating out of the melt. The large size inclusions found in the continuous casting slab are very few.     

非真空熔铸铍铜合金大规格铸锭的研究

在非真空熔铸铍铜合金大规格铸锭时,需要长时间的熔化和保温.由于铍在金属熔体中的氧化烧损量达到0.004 4%/min以上,熔体中的铍质量分数处于不断下降的状态,因而不同铸锭之间、同一铸锭头尾w（Be）偏差达到6%以上;铍及铍铜原料的大量烧损容易导致铸锭夹杂,进而影响铸锭的综合成品率;同时,由于铍具有强烈的脱氧作用,熔体极易吸气,铸锭内部容易出现气孔等铸造缺陷.通过上百炉次的试验,对熔铸工艺的每个细节深入研究和试验,确定了合理的熔铸工艺,在生产铍铜合金大规格铸锭时,铍及铍铜材料的烧损率分别降到6%及3%以下,铸锭化学成分偏差≤4%,铸锭综合成品率达到80%以上.     

Effects of Suspension Casting on Solidification Process of GCr15 Steel Ingot

The mechanism of inoculation in the case of suspension casting process has been studied through solidification kinetics. The effect of suspension casting process on temperature field, solidification rate, temperature gap of crystallization, effective distribution coefficient of solute and nucleation frequency during solidification process in steel ingot were discussed on the base of experiments. It has been found that the suspension casting process can increase both cooling at and solidification rate of steel ingot, improve the temperature field and solute distribution, narrow the temperature gap of crystallication, and increase the nucleation frequency. Thus, the solidification time can be shorten, the solute can be well distributied, the shrinkage porosity can be reduced and the grain of crystallization can be fined.     

硬铝合金半连续铸造过程数值模拟及裂纹倾向性研究

对凝固过程中流场、应力场、温度场及微观组织形态进行数值模拟,能帮助工艺设计人员分析不同时刻凝固过程的温度分布、金属流态、结晶晶粒尺寸、应力分布等重要物理参数,从而预测疏松、偏析、夹杂及热裂纹等缺陷.在结晶器下方设置区域冷却装置,控制区域冷却装置刮水板的作用位置,能够阻挡冷却水沿铸锭下流,实现区域冷却的效果.通过研究温度场、应力场分布规律,分析铸锭裂纹产生的原理,能够从宏观上阐明铸锭内部裂纹的形成原因及寻找有效的调节控制方法.     

过共晶Al-16%Si合金梯度功能材料的组织与性能

采用离心技术成功地制备了过共晶Al 1 6%Si合金梯度功能材料。采用金相及扫描电子显微镜、HV 5型小负荷维氏硬度计及销盘式ML 1 0 0型磨粒磨损试验机研究了该梯度功能材料的组织、硬度及耐磨性的分布规律。结果表明 ,由于Si的密度比Al液的密度稍低 ,在离心力场中初晶硅向试样内侧移动。Al 1 6%Si合金梯度功能材料的组织分布为 :最内层初晶硅含量最多、尺寸也最大 ,由内向外 ,初晶硅的体积分数及尺寸均逐渐减小 ,且呈梯度变化。在外层一定厚度内 ,完全不含初晶硅 ;硬度分布为内层硬度较高 ,由内向外硬度逐渐减小 ,呈梯度分布 ;耐磨性由内向外呈梯度下降趋势     

基于CAE技术铝合金支架压铸工艺优化

基于CAE技术研究了铝合金汽车支架压铸件的凝固过程,对可能出现的铸造缺陷进行预测,获得了零件成型过程的温度场分布和凝固时间与温度的关系。在有无水冷的两套方案中选择不同部位节点,研究不同节点凝固过程中的温度变化规律。结果表明：没有增设水冷的方案中,铸件凝固顺序混乱,温度梯度分布不合理,铸件成形过程容易产生铸造缺陷;增设水冷设置的方案中,铸件各节点冷却速度得到提高,同时保持良好的凝固顺序,铸造缺陷显著下降。     

火炮内膛表面粗糙度检测技术

本文介绍了火炮内膛表面粗糙度检测系统的组成、检测原理及图像处理的有关技术 ,利用了CCD器件作图像传感器 ,采用图像处理与识别技术来检测火炮内膛的表面粗糙度     

宽板坯凝固前沿轻压下率模型的研究

结合连铸坯凝固规律及轻压下技术改善铸坯中心偏析的冶金原理,建立宽板坯轻压下率理论模型。根据某厂连铸宽板坯实际生产条件,以传热模型计算的铸坯凝固温度数据作为轻压下率模型计算条件,分析拉速、浇注温度、坯壳凝固收缩特性对铸坯轻压下率的影响规律。结果表明,在相同的拉速和浇注温度条件下,铸坯轻压下率沿拉坯方向的分布总体呈减小趋势;拉速较高时的起始轻压下率小于拉速较低时对应的起始轻压下率;拉速与平均轻压下率呈线性递减关系：拉速每升高0.1m/min,平均轻压下率减小0.015mm/m;浇注温度越低,轻压下区起始轻压下率的值越高;浇注温度对平均轻压下率的影响较小,浇注温度每升高10℃,平均轻压下率仅减小0.002 5mm/m;铸坯外部凝固坯壳的收缩对整个轻压下区平均轻压下率的贡献量为20.4%～22.3%。     

基于球面展成原理的小球径内球面珩磨方法

基于球面的展成原理研究内球面珩磨过程中磨粒在工件上的空间运动轨迹,建立磨粒运动轨迹的数学模型,提出高硬度、高精度小球径内球面的珩磨方法.实际加工结果表明,提出的小球径内球面珩磨方法,可实现高硬度、高精度小球径内球面零件的精密珩磨加工.     

电熔爆加工机理的分析与研究

对电熔爆加工原理及加工蚀除金属的机理进行了分析.并指出:工具盘上的轮齿与工件间的脉冲放电可使工件表面熔化甚至汽化,从而达到加工蚀除金属的目的.工作液的喷淋作用在于降温和冲走金属碎屑.通过电学模拟电路的方法,指出电熔爆加工时,电路电阻应尽量的小.电熔爆加工的特点是不受工件硬度、粘度和机械性能的限制,是很有前途的加工方法.     

Microstructure and mechanical property of 2024／3003 gradient aluminum alloy

2024/3003 gradient aluminum alloy was prepared by semi-continuous casting using double-stream-pou-ring technique. The microstructures of the as-cast, pressed and heat-treated alloys were analyzed by scanning elec-tron microscope and transmission electron microscope. And the mechanical properties of the alloy in pressed and heat-treated states were studied. The results show that the ingots with diameter of 65 mm and external thickness about 5.5 mm are obtained when the temperatures of the melt in the internal and external ladles are 1 023 and 1 003 K, respectively, and the nozzle diameter is 2.0 mm. The microstructures of the as-cast alloy consist of α(AI) θ(CuAl2)q S(Al2CuMg) in the internal region and α(Al) MnAl6 in the external region. The phases found in the internal and external layers coexist in the transition zone. The transition layer is maintained after plastic deformation and heat treatment of the alloy. The tensile strength, yield strength and elongation of the alloy are 300 MPa,132 MPa and 16.0%, respectively, after T6 treatment. The tensile and yield strength are increased by 150.0% and 94.1%, respectively, compared with that of 3003 aluminum alloy. The maximum hardness in the internal region of 2024/3003 gradient aluminum alloy can be increased from HRF 55 in the pressed state to HRF 70 in the heat-treated state.     

部节流静压、动静压支承中节流腔新结构及其不同布置时的支承性能

本文提出了一种用于内部节流支承的节流腔新结构,给出了它在不同布置时支承的承载能力与刚度的简化公式并分析了主要参数对支承性能的影响,指出这种结构可明显地改善内部节流支承的性能,具有推广使用价值。     

Optimizing casting parameters of steel ingot based on orthogonal method

The influence and signification of casting parameters on the solidification process of steel ingot were discussed based on the finite element method (FEM) results by orthogonal experiment method. The range analysis, analysis of variance (ANOVA) and optimization project were used to investigate the FEM results. In order to decrease the ingot riser head and improve the utilization ratio of ingot, the casting parameters involved casting temperature, pouring velocity and interface heat transfer were optimized to decrease shrinkage pore and microporosity. The results show that the heat transfer coefficient between melt and heated board is a more sensitive factor. It is favor to decrease the shrinkage pore and microporosity under the conditions of low temperature, high pouring velocity and high heat transfer between melt and mold. If heat transfer in the ingot body is quicker than that in the riser, the position of shrinkage pore and microporosity will be closer to riser top. The results of optimization project show that few of shrinkage pore and microporosity reach into ingot body with the rational parameters, so the riser size can be reduced.     

A new approach for preparing SiC particle-reinforced aluminum matrix composites by applying electromagnetic field

A new method for preparing SiC particle-reinforced aluminum matrix composites was introduced. In order to improve the ingot surface and homogeneity of structure, low frequency electromagnetic field was applied during the direct chilling casting process. The experimental results show that the new method can be used to prepare SiC particle-reinforced aluminum matrix composites; under the effects of the low frequency electromagnetic field, the microstructure of ingot is refined and the distribution of SiC particles is improved.     

AlSi／AlMn双金属复合材料制备试验研究

在自行设计和制造的双金属复合材料连铸设备上,通过工艺参数的合理配置,成功制备出尺寸为150mm×120mm×100mm的A1Si／A1Mn双金属复合材料铸坯。分析了复合铸锭的宏观和显微组织、界面附近的元素成分以及界面结合强度和硬度分布。结果表明,复合界面为,台金结合,所制备复合材料的微观组织与化学成分分布及硬度之间有良好的对应关系。     

双流低频电磁连铸过程中磁场分布的数值模拟

采用数值模拟的方法研究了双流低频电磁连铸过程中磁场分布规律.建立了单、双流低频电磁连铸中包括铸锭、结晶器、线圈和屏蔽罩的二维轴对称有限元模型.利用ANSYS软件包进行划分网格及计算,模拟出了磁场在连铸结晶器区域的分布.研究了电流频率、电流强度、电流方向和线圈距离对金属熔体内磁感应强度的影响.计算结果表明：单流时,电流频率升高,磁感应强度降低;电流强度增大,磁感应强度升高.双流时,无论电流方向是同向还是反向,同一铸锭的远端磁场强度要大于其近端磁场强度,相邻线圈电流方向为反向时,铸锭内磁场强度高于相邻线圈电流方向为同向的情况;增大线圈之间的距离时,铸锭远端和近端的磁感应强度的差值降低.     

电磁水平连铸1560镍基合金的组织与性能研究

为提高1560镍基合金圆形铸锭的质量,采用电磁水平连铸方法对其进行生产实验,并对圆锭及其坯料再进一步轧制和冷拉所生产系列棒线材产品的组织与性能进行了研究。结果表明,该方法生产的1560镍基合金电磁铸锭的芯部由中心等轴晶组成,其溶质元素偏析程度明显降低,且常规水平连铸过程中常见的芯部裂纹、缩孔和疏松等缺陷也得到有效消除。该方法不仅取消了传统工艺中的铸坯退火、锻造及打磨等工序,而且还缩短了工艺流程,其产品成材率也由传统工艺时的70％提升到90％以上。     

铸铁合金熔体成分及性能热分析系统的研究

对热分析技术的特点进行了分析,提出了一种对铸造合金熔体成分及性能进行综合检测和预报的新的热分析技术.该技术可根据所测得的温度特征值及所回归的数学模型,预测灰铸铁和球铁的主要成分和性能.为了实现对所建数学模型的动态修正和更新,设计引用了对热分析模型自适应性分析软件模块.通过对冷却曲线形状的分析,实现对特征值的误判和预测值偏差的解释,将传统热分折技术从单纯的定量拓宽到了定量和定性相结合.在自动校正技术的基础上,设计开发了能对铸铁成分进行检测并预报其性能的微机热分析仪硬件电路系统和软件系统.     

Orthogonal tests of lead-clad tin bimetal continuous casting by air pressure core-filling

To provide theoretical basis and practical guidance for preparing composite rods of external diameter no larger than 12 mm by directly continuous casting, low melting point materials of lead and tin were selected to prepare composite rods of external diameter 12 mm and inner diameter 8 mm with air pressing core filled continuous casting process. The orthogonal tests consisting of three factors and three levels were designed to investigate the parameters of melting lead temperature, continuous casting speed and air pressure that affect the performance of the composite rods. The results show that melting lead temperature is the most important factor that influences the solid/liquid interface location; continuous casting speed is the most important factor that influences the surface quality and lead and tin inter-diffusion amount; air pressure can improve the surface quality obviously and make the rods easily drawn out, but the surface quality cannot get obvious improvement when the air pressure is above 0.03 MPa. The composite rods have excellent surface quality, obvious intermediate layer, even thick clad, and metallurgical bonding interface under the condition of melting lead temperature of 375 °C, continuous casting speed of 10 mm/min, and air pressure of 0.03 MPa.     

钢的固-液混合浇铸的试验研究

研究了固－液混合浇铸方法对钢锭温度场及其成分分布的影响,并对采用固－液混合浇铸方法所得钢锭的宏观铸态组织和热轧钢筋的力学性能进行了初步探讨。