Investigations in the compaction and sintering of large ceramic parts

In this study, a large ceramic part was successfully compacted and sintered using uniaxial die compaction technique. The effects of die design, compaction pressure, lubrication, sintering procedure and part orientation in the oven on the P/M part quality were investigated and the preferred process conditions were discussed and concluded. The main quality issues encountered were cracking and distortion. A finite element model for the powder compaction process was also developed and validated. Based on the model, the relationship between the cracking location and the density distribution predicted from finite element analysis (FEA) was discussed.     

T91与1Cr18Ni9Ti异种钢焊接

T91钢是国外为提高火力发电机组的效率而研制的一种高合金耐热钢,它是完成超临界发电机组主蒸气参数由566℃向593℃过渡的关键材料.针对马氏体耐热钢(T91)与奥氏体钢(1Cr18Ni9Ti)的物理化学性能,分析了该异种钢的焊接性.通过在湘潭电厂二期工程中具体应用表明,采取适当的焊前预热及焊后热处理的措施,选取合适的焊接材料和焊接工艺参数,能够获得性能优良的焊接接头.     

Direct laser fabrication of thin-walled metal parts under open-loop control

Direct laser fabrication (DLF) is an advanced manufacturing technology, which can build full density metal parts directly from CAD files without using any modules or tools. The investigation on the fabrication of thin-walled parts of nickel alloy using open-loop DLF process is introduced in this paper. The experimental setup consisted of a CO₂ laser, a 3-axis CNC table, a coaxial powder nozzle and a powder recycler. The 3D-CAD file of a thin-walled metal part was converted into the STL file format and imported into software HUST-RP to generate ‘pseudo-random’ scanning paths of laser beam. The influence of process parameters on the build height of thin-walled metal parts was studied by 1–10 layered single-bead stacks of nickel alloy. The result shows that the interference factors which affect the build height of thin-walled metal parts occur randomly during the process. For open-loop DLF process, thin-walled metal parts can achieve much better shape quality if the process parameters are suitable. Multilayer single-bead walls were built up with different scanning velocity to obtain the optimal process parameters of thin-walled parts of nickel alloy. It shows that thin walls of nickel alloy with uniform height can be built up layer by layer in a certain range of specific energy. However, it is difficult to control the build height of complex thin-walled metal parts in an accurate manner just using optimal parameters. A special coaxial powder nozzle was designed in this paper. In a certain range, the deposition thickness of the nozzle is nearly linearly increased with increase in the standoff distance between the powder focusing point of the nozzle and the deposition substrate. By means of the nozzle, a novel method to control the build height of thin-walled metal parts using open-loop DLF process was introduced. The difference in build height of a thin-walled part can be compensated automatically in one or several layers during the process. It is proved that the build height of a thin-walled metal part can be accurately controlled in theory using the nozzle. A complex single-bead part of nickel alloy whose geometry was designed to be the well-known Chinese ‘FU’ was fabricated and explained in this paper. The result shows that the shape quality of the sample is quite good, and actual build height of the sample is 53.54 mm while the designed value is 54 mm.     

热处理对Mg-Li-Zn-Zr系镁合金组织及性能影响

研究了Mg-Li-Zn-Zr镁合金和添加钇、镧错铈混合稀土的Mg-Li-Zn-Zr-Y-LPC镁合金的显微组织和力学性能特点．以及热处理对两种镁锂合金显微组织和力学性能的影响规律。结果表明：铸态Mg-7．13Li-3．92Zn-1Zr合金主要由α-Mg相．θ′相（MgLi2Zn）组成；添加混合稀土后，铸态Mg-8．16Li-4．10Zn-2．86Y-0.59Zr-2．14LPC合金主要由Li、Zn和RE在Mg中的固溶体和Mg-Li-Zn-RE块状化合物共同组成。对铸态Mg-Li-Zn-Zx合金均化处理后，合金的θ′相转变为更为稳定的θ相（MgLiZn），并且均化处理可以明显提高铸态Mg-7．13Li-3．92Zn-1Zt合金的力学性能。另外，氢化处理也可以明显提高铸态Mg-Li-Zn-Y-Zr-LPC合金的力学性能。     

管线钢多丝埋弧焊烧结焊剂焊接工艺性能研究

对管线钢用多丝埋弧焊烧结焊剂主要组分对焊接工艺性能的影响规律进行了试验研究．在此基础上研制出一种基于MgO-CaF2-Al2O3-SiO2-MnO-ZrO2渣系、碱度BⅡw在1．2～1．5之间的新型烧结焊剂。试验表明．该焊剂在多丝埋弧焊时具有良好的焊接工艺性能，焊接接头各项力学性能均能满足X70级管线钢的焊接要求。     

马鞍形板材件多点“三明治”成形实验研究

多点“三明治”成形是一种针对小批量多曲率板材工件制造而提出的新成形方法。用该方法成形时,上模采用聚氨酯模具,下模为型面可调节的多点模具。为了使多点模具型面连续化和消除工件表面的压痕,在成形过程中使用了金属护板和弹性垫板。由于工件板材两侧都和聚氨酯相接触,因此成形后工件的表面质量好。为了研究采用多点“三明治”成形复杂三维曲面工件的成形过程以及成形可能会出现的表面缺陷,文章选用马鞍面作为目标形面进行了实验研究,提出了用于提高工件的贴模程度,通过改变上模形状的分步成形方法,并得到了Q235B板材厚度和可成形马鞍形工件深度之间的关系曲线。     

板料成形数值模拟的关键技术及难点

本文结合国内外板料成形数值模拟的最新研究动态，从关键算法、屈服函数、本构方程、有限元列式、接触问题、破裂准则、回弹计算、起皱分析八个方面叙述了板料成形有限元计算的关键技术及主要难点。     

五轴开放式数控系统用户界面的研究

介绍了一种以基于DSP的五轴运动控制卡作为运动驱动与算法控制部件的数控系统用户界面。该界面运用VisualC 6．0语言，采用模块化结构方法设计而成。详细论述了功能模块的划分以及典型功能模块的实现。     

稳恒磁场下Ni-W合金镀膜的制备与耐蚀性

研究了施加稳恒磁场(0~1 T)对电镀Ni-W合金的影响。测定不同方向、不同强度稳恒磁场下的电流效率、合金组成及镀层的耐蚀性,并用扫描电镜和X射线衍射对镀层的微观形貌及结构进行了观察和分析。对实验结果进行了分析讨论,找出稳恒磁场对这些性能指标的影响规律。结果表明:与不施加磁场相比,施加磁场后镀层的表面更均匀、细致、平整;镀层的含钨量上升:当B⊥J,B=1.0 T时,含钨量上升了约7%;当B∥J,B=1.0 T时,含钨量上升了约9%;镀膜的非晶化程度增强;镀膜的耐蚀性提高;但Ni-W合金电镀的电流效率降低。     

7A04高强铝合金复合强韧化工艺

采用复合强韧化工艺，对7A04铝合金的组织和性能进行了研究。结果表明，通过熔体净化、晶粒细化、强化均匀化、锻造及分级固溶处理能明显改善和提高7A04高强铝合金的综合性能，而且可以大大减少均匀化处理的保温时间。