Numerical modelling of the structural behaviour of thin-walled cast magnesium components using a through-process approach

A through-process methodology for numerical simulations of the structural behaviour of thin-walled cast magnesium components is presented. The methodology consists of casting process simulations using MAGMAsoft, mapping of data from the process simulation onto a FE-mesh (shell elements) and numerical simulations using the explicit FE-code LS-DYNA. In this work, generic High Pressure Die Cast (HPDC) AM60 components have been studied using axial crushing, 3-point bending and 4-point bending tests. The experimental data are applied to obtain a validated methodology for finite element modelling of thin-walled cast components subjected to quasi-static loading. The cast magnesium alloy is modelled using a user-defined material model consisting of an elastic–plastic model based on a modified J2-flow theory and the Cockcroft–Latham fracture criterion. The fracture criterion is coupled with an element erosion algorithm available in LS-DYNA. The constitutive model and fracture criterion are calibrated both with data from material tests and data from the process simulation using MAGMAsoft.     

Corrosion failure of Zn–Al detonator housing

Some batches of detonator housings made up of Chromium plated Zn–Al alloy were found in an extensively cracked condition after few months of storage at room temperature. An analysis of the failure showed that the cracks were due to intergranular corrosion facilitated by segregation of lead at the grain boundaries. Improper chromium plating further aggravated the corrosion problem. This failure case emphasises the need for strict control of chemical composition for components made from Zn–Al alloy and the process of Cr plating of the components.     

Finding feasible mold parting directions using graphics hardware

We present new programmable graphics hardware accelerated algorithms to test the 2-moldability of geometric parts and assist with part redesign. These algorithms efficiently identify and graphically display undercuts as well as minimum and insufficient draft angles. Their running times grow only linearly with respect to the number of facets in the solid model, making them efficient subroutines for our algorithms that test whether a tessellated CAD model can be manufactured in a two-part mold. We have developed and implemented two such algorithms to choose candidate directions to test for 2-moldability using accessibility analysis and Gauss maps. The efficiency of these algorithms lies in the fact that they identify groups of candidate directions such that if any one direction in the group is undercut-free, all are, or if any one is not undercut-free, none are. We examine trade-offs between the algorithms' speed, accuracy, and whether they guarantee that an undercut-free direction will be found for a part if one exists.     

Epitaxial growth of GaN on (0001) Al<Subscript>2</Subscript>O<Subscript>3</Subscript> via solution-cast seed layer formation process using Ga(mDTC)<Subscript>3</Subscript>

This paper reports an alternative method for the growth of GaN epitaxial layer on (0001) Al₂O₃ substrate by hot-wall vapor phase epitaxy technique. Tris (N,N-dimethyldithiocarbamato)-gallium (III), Ga(mDTC)₃ was introduced as a precursor material for the seed layer formation in the growth of GaN. Optimal growth conditions with seed layers formed by the Ga(mDTC)₃ concentration of 0.047 mol/L were identified: Growth temperature was found to be 850 °C, and optimal distance between the reactant outlet and substrate was determined to be 12.5 cm. Characterization results showed that this growth method produce high-crystallinity GaN epitaxial layers at a relatively lower growth temperature compared to the existing growth techniques and simplify the growth process.     

高强度船板纵裂纹的成因及预防

针对高强度船板纵裂纹轧后退废过高的现状，分析原因并优化冶炼、连铸工艺及操作，有效地降低高强度船板的退废率。     

转炉冶炼20管坯钢生产实践

介绍了20#管坯钢的生产试验工艺，采取了拉碳法脱碳、钢包底吹氩及喂丝、保护浇铸、合理控制拉速等有效措施，解决了生产中存在的质量问题，为下一步的生产提供了理论和实践依据。     

精铸件结构优化设计实践

以6种典型的精密铸件为例，利用“6个千方百计”原则对产品结构进行优化设计，同时辅助有限元分析对优化结果进行再验证。通过减少大平面、避免深长孔、采用加强筋等优化措施，有效地避免了夹砂、鼓包、跑火、缩孔、裂纹等铸造缺陷，实现了少无切削和减轻铸件质量。     

Determining the Castability of Simple Polyhedra

A polyhedron P is castable if its boundary can be partitioned by a plane into two polyhedral terrains. Castable polyhedra can be manufactured easily using two cast parts, where each cast part can be removed from the object without breaking the cast part or the object. If we assume that the cast parts are each removed by a single translation, it is shown that for a simple polyhedron with n vertices, castability can be decided in time and linear space using a simple algorithm. A more complicated algorithm solves the problem in time and space, for any fixed ε > 0. In the case where the cast parts are to be removed in opposite directions, a simple O(n ² )-time algorithm is presented. Finally, if the object is a convex polyhedron and the cast parts are to be removed in opposite directions, a simple algorithm is presented. Received June 1, 1994; revised May 25, 1995.     

铸造Al-5Cu合金准固态断裂行为的研究

采用SEM观察手段并结合EDX分析 ,在合金的准固态区 ,通过观察Al 5Cu Mn合金准固态拉伸和热裂应力测试试样的断口形貌 ,研究了Ti、Ce等合金元素及其交互作用对Al 5Cu Mn合金准固态断裂行为的影响及其影响机理。通过对试验合金准固态力学性能的测试和大量SEM断口的观察分析研究 ,结果表明 ,Al 5Cu Mn中添加Ti元素可明显提高合金抗热裂能力 ,主要是由于其良好的细化晶粒效果 ;适量Ce元素的加入 ,不仅可细化晶粒 ,而且其在晶间富集形成的化合物还可有效改善低熔点共晶反应在准固态区的力学行为 ,对减小热裂倾向非常有利 ;Ti和Ce的综合作用对合金抗热裂水平的提高比单一元素更有效 ;热裂的产生首先表现为枝晶枝臂的屈服 ,其后的扩展则表现为脆性断裂占优的穿晶、沿晶混合型特征     

水平连铸带坯QSn6.5-0.1的组织与性能

讨论了锡磷青铜QSn6.5-0.1水平连铸带坯的宏观组织特点、反偏析行为和显微缩孔。结果表明：横断面以柱状晶为主，结晶中心线普遍上移，大面出现结晶角，上下表面和侧边出现反偏析，紧临偏析区出现低Sn区，显微缩松是主要组织缺陷．是冷加工报废的主要原因，同时通过热处理试验，分析了热处理规范对锭坯性能及组织的影响，并制订出合理的热处理规范。