Optimization of degree of sphericity of primary phase during cooling slope casting of A356 Al alloy: Taguchi method and regression analysis

The present work presents the results of experimental investigation of semi-solid rheocasting of A356 Al alloy using a cooling slope. The experiments have been carried out following Taguchi method of parameter design (orthogonal array of L₉ experiments). Four key process variables (slope angle, pouring temperature, wall temperature, and length of travel of the melt) at three different levels have been considered for the present experimentation. Regression analysis and analysis of variance (ANOVA) has also been performed to develop a mathematical model for degree of sphericity evolution of primary α-Al phase and to find the significance and percentage contribution of each process variable towards the final outcome of degree of sphericity, respectively. The best processing condition has been identified for optimum degree of sphericity (0.83) as A₃, B₃, C₂, D₁ i.e., slope angle of 60°, pouring temperature of 650 °C, wall temperature 60 °C, and 500 mm length of travel of the melt, based on mean response and signal to noise ratio (SNR). ANOVA results shows that the length of travel has maximum impact on degree of sphericity evolution. The predicted sphericity obtained from the developed regression model and the values obtained experimentally are found to be in good agreement with each other. The sphericity values obtained from confirmation experiment, performed at 95% confidence level, ensures that the optimum result is correct and also the confirmation experiment values are within permissible limits.     

基于误差分离技术的圆度误差在位测量

总结了现有用于在位圆度误差测量的误差分离技术,并对经典频域三点法、时域三点法、频域三点法的近似实现方法和频域三点法的改进实现方法的测量特点进行了评述。针对球度误差没有实现在位测量的问题,将圆度误差分离技术引伸到球度误差分离技术,并在理论上进行了探讨。     

Microfluidic fabrication of ceramic microspheres with controlled morphologies

In this study, the diffusion‐induced external gelation is combined with a microfluidic technique to prepare monodisperse ZrO₂ ceramic microspheres. The gelation of sol droplets is traced by fluorescence visualization of the local pH, and it illustrates the effect of the external concentration of triggering agent (tetramethylethylenediamine, TMEDA) on the formation of the gel network, which results in 3 kinds of deformation of the gel particles. The deformation mechanism mainly lies in the imbalanced Laplace pressure exerted on the gel network during the competition between the gelation and the drying processes. By regulating the concentration of TMEDA, the monodisperse ZrO₂ ceramic microspheres with high sphericity can be readily fabricated.     

Evaluation of spherical form errors—Computation of sphericity by means of minimum zone method and some examinations with using simulated data

Because of the practical difficulties of measuring whole spherical surface form errors, no concrete three-dimensional (3-D) verification has yet been developed. This article deals with the calculation of the value of spherical form errors; that is, sphericity. The iterative least-squares method in which the problem is linearized and the minimum zone method in which the downhill simplex method, one of the nonlinear optimization techniques, is applied are considered. The data to be analyzed are not obtained by actual measurement of a spherical surface, because there is no such a measuring system in my laboratory, but simulated by applying surface harmonics (Laplace's spherical function) with a computer. Then, the application conditions for downhill simplex method are investigated. Furthermore, the roundness values of the spherical surface are compared with the sphericity by means of the minimum-zone method.     

Prediction of porosity characteristics of aluminium castings based on X-ray CT measurements

Porosity is a main factor limiting the fatigue performance of aluminium castings. Using micro X-ray computed tomography, size and morphology characteristics of porosity distributions are analysed for material from a cast Al–8Si–3Cu–(Sr) crankcase as well as from cast Al–8Si–3Cu–(Sr), Al–7Si–0·5Cu–Mg–(Sr) and Al–7Si–0·5Cu–Mg–(Na) cylinder heads. Correlations are developed between the porosity volume percentage and mean and maximum pore sizes. Two characteristic size measures of the porosity distribution are identified: the volume weighted spherical mean diameter and the volume weighted mean envelope diameter. Both correlate linearly with the corresponding diameters of the largest pore. The pore morphology is described by a volume weighted mean sphericity. This mean sphericity and the local amount of porosity are used to predict the mean and maximum pore sizes of the porosity distributions. These correlations will find applications in integrated computational materials engineering.     

直流电弧热等离子体球化处理TA1粉末工艺研究

采用直流电弧热等离子体对不规则TA1粉末进行球化处理。利用金相显微镜、扫描电子显微镜、粒度粒形分析仪、霍尔流速计、斯科特容量计及氧氮分析仪等分析测试手段,研究球化工艺对粉末组织形貌、粒度分布、球形度、流动性、松装密度及氧含量的影响。结果表明,球化处理可将不规则形状TA1粉末球化为表面附着亚微米颗粒的实心球形;球形粉末内部组织由等轴状α相转变为长条状α相。球化处理使TA1粉末平均粒径和氧含量降低,球形度升高。原料粉末粒度越小、等离子体发生器功率越高,球化后粉末平均粒径越小,球形度越高;但会导致球化后粉末中亚微米颗粒含量增加、粉末流动性变差、松装密度降低;去除亚微米颗粒可以提高粉末流动性,并进一步降低氧含量。     

经线法球度测量的评定方法研究

针对当前测量领域内球度差的超精密测量和评定这一薄弱环节，采用“经线法”球度误差测量技术，通过超精型圆度仪和相应的支承装置实现对外球面轮廓的测量，建立了采样数据的维数转换数学模型和球度误差最小二乘法评定数学模型，在最小区域法、最小外接球法、最大内接球法评定球度时，充分利用了最优化理论的单纯型法，为了验证该理论及软件的精度，作了大量仿真试验，并不同半径的球体、椭球、以及带有一定规律误差的球进行验证，通过分析可了“经线法”理论是正确的，该系统的设计方案是切实可行的，并且该算法精度较高，可达到0．1μm。     

三坐标法测量球度误差时最佳测点数目的确定

通过对不同测点数目对应的球度误差值进行数据处理,绘制出散点图和显著性拟合曲线,可确定应用三坐标法测量球度误差时的最佳测点数目。     

亚共析钢共析渗碳体相的快速球化

从奥氏体晶粒尺寸能够影响共析相变产物中渗碳体形状为基本出发点,研究了初轧－精轧两段式轧制中的精轧过程,以使奥氏体晶粒细化,生产时,将精轧至要求尺寸的钢材迅速送入轧机终端待料保持的退火炉中,进行短时间低于临界温度的退火,可获得渗优良球化,能承受大的冷塑性变形而不开裂的优良性能。