Recent research and development on forming for large magnesium alloy components with high mechanical properties

The lightweight of high-end equipment relies on high mechanical properties magnesium(Mg) alloy structural components, because it is the best way to improve equipment service performance and reduce energy consumption. This article summarizes the current progress and characteristics of large-scale high-performance Mg alloy components by analyzing the strengthening-toughening mechanisms, characteristics of plastic forming, and the preparation of large high mechanical properties forging blanks. Due to the lack of breakthroughs in the key technologies for forming large-scale Mg alloy components, their uniformity of mechanical properties and consistency are poor, the forming accuracy of components is low, and the production cost is high, which limit their engineering application and restrict the lightweight level of high-end equipment. In view of the above problems, the forming trends and research directions of large-scale and high mechanical properties Mg alloy components are proposed in this paper. It can provide help for the breakthrough of the key technology of large-scale Mg alloy components with high mechanical properties and expand the application of Mg alloy in high-end products.

Influence of alloy components on arc erosion morphology of Ag/MeO electrical contact materials

Arc erosion morphologies of Ag/MeO（10） electrical contact materials after 50000 operations under direct current of 19 V and 20 A and resistive load conditions were investigated using scanning electron microscope（SEM） and a 3D optical profiler（3DOP）. The results indicated that 3DOP could supply clearer and more detailed arc erosion morphology information. Arc erosion resistance of Ag/SnO_2（10） electrical contact material was the best and that of Ag/CuO（10） was the worst. Arc erosion morphology of Ag/MeO（10） electrical contact materials mainly included three different types. Arc erosion morphologies of Ag/ZnO（10） and Ag/SnO_2（10） electrical contact materials were mainly liquid splash and evaporation, and those of Ag/CuO（10） and Ag/CdO（10） were mainly material transfer from anode to cathode. Arc erosion morphology of Ag/SnO_2（6）In_2O_3（4） electrical contact materials included both liquid splash, evaporation and material transfer. In addition, the formation process and mechanism on arc erosion morphology of Ag/MeO（10） electrical contact materials were discussed.

Numerical simulation study on monoblock casting process of ultra-slender structural components and experimental validation

Substrate, a typical ultra-slender aluminum alloy structural components with a large aspect ratio and complex internal structure, was traditionally manufactured by re-assembly and sub-welding. In order to realize the monoblock casting of the substrate, the Pro/E software was utilized to carry out three-dimensional(3D) modeling of the substrate casting, and the filling and solidification processes were calculated, as well as the location and types of casting defects were predicted by the casting simulation software Anycasting. Results of the filling process simulation show that the metal liquid is distributed into each gap runner evenly and smoothly. There is no serious vortex phenomenon in the mold cavity, and the trajectory of the virtual particles is clear. Results of the solidification process simulation show that shrinkage cavities mainly appear at the junction of gap runners and the rail surface of the substrate. The average deformation is 0.6 mm in X direction, 3.8 mm in Y direction, and 8.2 mm in Z direction. Based on the simulation results, the casting process of the substrate was optimized, and qualified castings were successfully produced, which will provide a reference for the casting process design of other ultraslender aluminum alloy structural components.

INFLUENCES OF MICRO-ALLOY AND HEAT-TREATMENT PROCEDURE ON THE HARDENING OF DJ108TI ALLOY

The influences of micro alloy and heat treatment procedure on the hardening of DJ108Ti alloy, which is based on the electrolytic Al Si(2 05%) Ti(0 25%) Fe(0 30%) multi component alloy, have been investigated. The results indicate that the micro alloy based on the multi component alloy makes α Al dendrites in DJ108Ti alloy refined; that the improved heat treatment procedure makes the eutectic Si phases granulated , the Fe phase refined, and the strengthening phases of Mg2Si and Al2Cu fully precipitated. The micro alloy and the heat treatment procedure harden DJ108Ti alloy and benefit the abrasion resistance of the alloy

Microstructure and mechanical properties of multi-principal component AlCoCrFeNiCu_x alloy

By introducing Cu, AlCoCrFeNiCux （x values in molar ratio, x = 0, 0.1, 0.5, 1.0, 1.5, 2.0, and 2.5） alloys were designed and prepared. The effects of Cu on microstructure and properties of Al Co Cr Fe Ni alloy were investigated. The introduction of Cu results in the formation of Cu-rich FCC solid solution phase when Cu content is low.There are two FCC solid solution phases, i.e., Cu-rich FCC solid solution phase and phase transformation-induced FCC solid solution phase, when the Cu content is more than 1.0. Both the yield stress and plastic strain of alloy show a turning point when the Cu content is 0.5. Among the seven alloys, Cu0.5 alloy exhibits the largest yield stress of 1187 MPa and the lowest plastic strain of 16.01 %.

A practical model for efficient anti-fatigue design and selection of metallic materials:Ⅱ.Parameter analysis and fatigue strength improvement

In the first paper,a Y-T-F model was proposed based on the restrictions of both strength and plasticity;the corresponding applications on the fatigue strength prediction have also been discussed.In this second paper,the emphasis will be put on the issues of fatigue strength improvement.Based on the primary form of the Y-T-F model,the parameters are further analyzed and quantified,to clarify the influences of various factors on fatigue strength.Firstly,the damage capacity C is proved to be sensitive to the elastic modulus E,which could change with the alloying components and nano-scaled grain boundaries;the increase of E would lead to the increasing C,thus increase the fatigue strength.Secondly,the microstructure characteristic coefficient a,as well as the yield strengthσ_(y) and tensile strengthσ_(b) in the crack initiation region could be influenced by the processing mode,grain size and microstructure uniformity of materials;the change of microstructure characteristics would affect the changing tendency of tensile strength--fatigue strength relation via varying the values of a,σ_(y) andσ_(b).Thirdly,the damage weight coefficientωis found to be a reflection of the fatigue strength declination induced by defects;the defect dimension D,the defect shape correlated stress concentration coefficient Kt,as well as the strengthening level of matrix materialsσ_(b) are all corresponding factors.Quantified correlations between the above parameters and corresponding factors are comprehensively built up,hence obtaining the influences of either a single factor or multiple factors on fatigue strength.This further developed Y-T-F model would be helpful to clarify the direction of fatigue strength improvement,and contribute to the anti-fatigue design optimization of metallic materials.

Science and technology in high-entropy alloys

As human improve their ability to fabricate materials, alloys have evolved from simple to complex compositions, accordingly improving functions and performances,promoting the advancements of human civilization. In recent years, high-entropy alloys（HEAs） have attracted tremendous attention in various fields. With multiple principal components, they inherently possess unique microstructures and many impressive properties, such as high strength and hardness, excellent corrosion resistance, thermal stability, fatigue,fracture, and irradiation resistance, in terms of which they overwhelm the traditional alloys. All these properties have endowed HEAs with many promising potential applications.An in-depth understanding of the essence of HEAs is important to further developing numerous HEAs with better properties and performance in the future. In this paper, we review the recent development of HEAs, and summarize their preparation methods, composition design, phase formation and microstructures, various properties, and modeling and simulation calculations. In addition, the future trends and prospects of HEAs are put forward.

Manufacturing of Long Products Made of Innovative Lightweight Materials

The processing of innovative lightweight materials to sheet metal components and assemblies with globally or locally defined properties is the object of this work. It takes a load-dependent design of components and assemblies, for example, based on the composition of different construction materials or a targeted setting of component areas with specified characteristics to fully exploit the lightweight potential when substituting conventionally used materials. Different process chains for the manufacturing of roll-formed long products made of magnesium alloys and high-strength steels with locally defined properties will be presented in this paper. Depending on the kind of material to be formed and the desired product characteristics, different temperature managements are needed for capable processes. Due to limited formability at room temperature, magnesium alloys require a heating of the forming zones above 200–225 °C throughout the bending process in order to activate additional gliding planes and to avoid any failures in the radii. The realization of local hardening effects requires at least one process-integrated heat treatment when roll forming manganese–boron steels. For both processes, it is imperative to realize a heating and cooling down or quenching appropriate for the manufacturing of long products with the required quality. Additionally, proper line speeds that allow a continuously operated economical production have to be considered. Research results including design, FEA, realization and experimentation of the mentioned process chains and strategies will be described in detail.