I-DCGAN and TOPSIS-IFP:A simulation generation model for radiographic flaw detection images in light alloy castings and an algorithm for quality evaluation of generated images

The intelligent detection technology driven by X-ray images and deep learning represents the forefront of advanced techniques and development trends in flaw detection and automated evaluation of light alloy castings.However,the efficacy of deep learning models hinges upon a substantial abundance of flaw samples.The existing research on X-ray image augmentation for flaw detection suffers from shortcomings such as poor diversity of flaw samples and low reliability of quality evaluation.To this end,a novel approach was put forward,which involves the creation of the Interpolation-Deep Convolutional Generative Adversarial Network(I-DCGAN)for flaw detection image generation and a comprehensive evaluation algorithm named TOPSIS-IFP.I-DCGAN enables the generation of high-resolution,diverse simulated images with multiple appearances,achieving an improvement in sample diversity and quality while maintaining a relatively lower computational complexity.TOPSIS-IFP facilitates multi-dimensional quality evaluation,including aspects such as diversity,authenticity,image distribution difference,and image distortion degree.The results indicate that the X-ray radiographic images of magnesium and aluminum alloy castings achieve optimal performance when trained up to the 800th and 600th epochs,respectively.The TOPSIS-IFP value reaches 78.7%and 73.8%similarity to the ideal solution,respectively.Compared to single index evaluation,the TOPSIS-IFP algorithm achieves higher-quality simulated images at the optimal training epoch.This approach successfully mitigates the issue of unreliable quality associated with single index evaluation.The image generation and comprehensive quality evaluation method developed in this paper provides a novel approach for image augmentation in flaw recognition,holding significant importance for enhancing the robustness of subsequent flaw recognition networks.

Effect of alloying elements W,Ti,Sn on microstructure and mechanical properties of gray iron 220

Experiments were carried out to observe the variation in microstructure and mechanical properties of gray cast iron by adding pearlite promoting alloying elements such as Ti,Sn and W.Results show that adding Sn,Ti,and W with different concentrations improve the microstructure,Brinell hardness and tensile strength of gray cast iron.With the increase of alloying element concentration,the average graphite length and graphite content increase linearly.At the same time,average cell size and the maximum graphite length also decrease linearly.Brinell hardness and tensile strength of gray cast iron also increase with an increase in alloying elements contents,and attain the maximum when Ti=0.561%,Sn=0.561%and W=0.945%.However,at higher concentrations of Ti=0.810%,Sn=0.631%and W=1.351%,the tensile strength decreases from 333 MPa to 297 MPa and the Brinell hardness decreases from 248 HB to 225 HB.The decrease in tensile strength and Brinell hardness at the higher concentration level is attributed to the formation of coarse and thick graphite flakes.

In situ monitoring methods for selective laser melting additive manufacturing process based on images-A review

Selective laser melting(SLM)has been widely used in the fields of aviation,aerospace and die manufacturing due to its ability to produce metal components with arbitrarily complex shapes.However,the instability of SLM process often leads to quality fluctuation of the formed component,which hinders the further development and application of SLM.In situ quality control during SLM process is an effective solution to the quality fluctuation of formed components.However,the basic premise of feedback control during SLM process is the rapid and accurate diagnosis of the quality.Therefore,an in situ monitoring method of SLM process,which provides quality diagnosis information for feedback control,became one of the research hotspots in this field in recent years.In this paper,the research progress of in situ monitoring during SLM process based on images is reviewed.Firstly,the significance of in situ monitoring during SLM process is analyzed.Then,the image information source of SLM process,the image acquisition systems for different detection objects(the molten pool region,the scanned layer and the powder spread layer)and the methods of the image information analysis,detection and recognition are reviewed and analyzed.Through review and analysis,it is found that the existing image analysis and detection methods during SLM process are mainly based on traditional image processing methods combined with traditional machine learning models.Finally,the main development direction of in situ monitoring during SLM process is proposed by combining with the frontier technology of image-based computer vision.

Optimization of steel casting feeding system based on BP neural network and genetic algorithm

The trial-and-error method is widely used for the current optimization of the steel casting feeding system, which is highly random, subjective and thus ineff icient. In the present work, both the theoretical and the experimental research on the modeling and optimization methods of the process are studied. An approximate alternative model is established based on the Back Propagation(BP) neural network and experimental design. The process parameters of the feeding system are taken as the input, the volumes of shrinkage cavities and porosities calculated by simulation are simultaneously taken as the output. Thus, a mathematical model is established by the BP neural network to combine the input variables with the output response. Then, this model is optimized by the nonlinear optimization function of the genetic algorithm. Finally, a feeding system optimization of a steel traveling wheel is conducted. No shrinkage cavities and porosities are induced through the optimization. Compared to the initial design scheme, the process yield is increased by 4.1% and the volume of the riser is decreased by 5.48×10~6 mm3.

Effects of hot isostatic pressing temperature on casting shrinkage densification and microstructure of Ti6Al4V alloy

The Ti6Al4V alloy castings were produced by the investment casting process, and the hot isostatic pressing(HIP) was used to remove shrinkage from castings. The processing pressure and holding time for HIP were 150 MPa and 20 min, respectively. Four different HIP temperatures were tested, including 750 ℃, 850 ℃, 920 ℃ and 950 ℃. To evaluate the effects of temperature on densification and microstructure of Ti6Al4V alloy treated by HIP, non-destructive testing and metallographic observation was performed. The experimental results show that the shrinkage was completely closed at 920 ℃ and 950 ℃. The densification of Ti6Al4V alloy increased as the HIP temperature increased below 920 ℃. The lamel ae were more uniform, the thickness of lamel ae was obviously broadened and the structure was coarsen. Besides, the Norton creep equation was used to simulate the effect of different temperatures on the densification of Ti6Al4V alloy during HIP. The simulation results were in good agreement with the experimental results. It was also found that 920 ℃ is a suitable temperature for HIP for Ti6Al4V alloy.

Extension of covariant derivative(Ⅰ): From component form to objective form

This paper extends the covariant derivative un der curved coordinate systems in 3D Euclid space. Based on the axiom of the covariant form invariability, the classical covariant derivative that can only act on components is ex tended to the generalized covariant derivative that can act on any geometric quantity including base vectors, vectors and tensors. Under the axiom, the algebra structure of the gen eralized covariant derivative is proved to be covariant dif ferential ring. Based on the powerful operation capabilities and simple analytical properties of the generalized covariant derivative, the tensor analysis in curved coordinate systems is simplified to a large extent.

Extension of covariant derivative(Ⅱ): From flat space to curved space

This paper extends the classical covariant deriva tive to the generalized covariant derivative on curved sur faces. The basement for the extension is similar to the pre vious paper, i.e., the axiom of the covariant form invariabil ity. Based on the generalized covariant derivative, a covari ant differential transformation group with orthogonal duality is set up. Through such orthogonal duality, tensor analy sis on curved surfaces is simplified intensively. Under the covariant differential transformation group, the differential invariabilities and integral invariabilities are constructed on curved surfaces.

Extension of covariant derivative(Ⅲ): From classical gradient to shape gradient

This paper further extends the generalized covari ant derivative from the first covariant derivative to the sec ond one on curved surfaces. Through the linear transforma tion between the first generalized covariant derivative and the second one, the second covariant differential transformation group is set up. Under this transformation group, the sec ond class of differential invariants and integral invariants on curved surfaces is made clear. Besides, the symmetric struc ture of the tensor analysis on curved surfaces are revealed.

Additive manufacturing and foundry innovation

Additive manufacturing is expected to transform and upgrade the traditional foundry industry to realize the integrated manufacturing and rapid and low-cost development of high-performance components with complex shapes.The additive manufacturing technology commonly applied in casting mold preparation(fusible molds,sand molds/cores and ceramic cores)mainly includes selective laser sintering(SLS)and binder injection three-dimensional printing(3DP).In this work,the research status of SLS/3DP-casting processes on material preparation,equipment development,process optimization,simulation and application cases in aerospace,automotive and other fields were elaborated.Finally,the developing trends of the additive manufacturing technology in the future of foundry field are introduced,including multi-material sand molds(metal core included),ceramic core-shell integration and die-casting dies with conformal cooling runners.

Temperature field simulations during selective laser melting process based on fully threaded tree

Selective laser melting(SLM) is a promising technique for additive manufacturing. During SLM of metallic powder, the temperature field and thermal history are important to understand physical phenomena involved. The purpose of this study is to simulate the temperature field during the SLM process of a hollow cylinder shape part based on a fully threaded tree(FTT) technique, and to analyze the temperature variation with time in different regions of the part. A revised model for temperature field simulation in the SLM process was employed, which includes the transition of powder-to-dense sub-model and a moving volumetric Gaussian distribution heat source sub-model. The FTT technique is then adopted as an adaptive mesh strategy in the simulation. The simulation result shows that during the SLM process of cylinder part, the temperature of inner powder bed is obviously higher than external one. The temperature at the internal of the molten pool is also higher than external, which may lead to differences in microstructures and other properties between the two regions.

Pyrolysis characteristics and thermal kinetics of expanded polystyrene(EPS) and styrene-methyl methacrylate(St-MMA) copolymer in LFC process

The pyrolysis behaviors of foam patterns have critical influences on fluid morphology and defect formation in Lost Foam Casting(LFC). The pyrolysis behaviors of expanded polystyrene(EPS) and styrenemethyl methacrylate(St-MMA) foams were compared using synchronous thermal analysis(STA), which was performed under argon atmosphere at different heating rates(from 10 to 40 K·min^(^(-1))). The degradation heat was calculated by integrating DSC curves. Results show that the calculated degradation heat of St-MMA(605.28 J·g^(-1)) was significantly lower than that of EPS(706.71 J·g^(-1)). Furthermore, the non-isothermal iso-conversional method was used to determine the pyrolysis apparent activation energies of EPS and St-MMA, and results show that the activation energy of St-MMA(200.36 kJ·mol^(-1)) was apparently higher than that of EPS(167.92 kJ·mol^(-1)). These calculated results indicate that the weight loss rate of EPS is greater than St-MMA in the pyrolysis process. In addition, the apparent activation energies at various pyrolysis stages demonstrate that the pyrolysis reactions of EPS and St-MMA may involve physical and chemical changes in the decomposition layer of the LFC process.

Finite element simulation of real cavity closure in cast Ti6Al4V alloy during hot isostatic pressing

The healing behavior of shrinkage cavity inside the cast Ti6Al4V alloy during hot isostatic pressing(HIP)was investigated experimentally by interrupted hot isostatic pressing tests.The X-ray micro computed tomography was used to record the morphology changes before and after hot isostatic pressing.The two-dimensional geometry obtained by the microCT scan was used in simulation to study the evolution of the real shrinkage cavity during hot isostatic pressing.Shrinkage cavities,shrinkage porosity and small gas pores can be effectively eliminated under proper HIP conditions.The two-dimensional morphology in the simulation results agrees well with the experimental results.This study reveals that plastic deformation,creep and diffusion are the main mechanisms of cavity closure during hot isostatic pressing.In addition,the simplified elliptical pores with aspect ratios at different positions were used to replace the real pores to further study the factors affecting the position of dimples after HIP by simulation.It is found that the position of the dimples mainly depends on the aspect ratio of the elliptical pore and the distance between the pore surface and the external surface of the geometric model.

Optimal design of feeding system in steel casting by constrained optimization algorithms based on InteCAST

The traditional foundry industry has developed rapidly in recently years due to advancements in computer technology. Modifying and designing the feeding system has become more convenient with the help of the casting software, Inte CAST. A common method of designing a feeding system is to first design the initial systems, run simulations with casting software, analyze the feedback, and then redesign. In this work, genetic, fruit fly, and interior point optimizer(IPOPT) algorithms were introduced to guide the optimal riser design for the feeding system. The results calculated by the three optimal algorithms indicate that the riser volume has a weak relationship with the modulus constraint; while it has a close relationship with the volume constraint. Based on the convergence rate, the fruit fly algorithm was obviously faster than the genetic algorithm. The optimized riser was also applied during casting, and was simulated using Inte CAST. The numerical simulation results reveal that with the same riser volume, the riser optimized by the genetic and fruit fly algorithms has a similar improvement on casting shrinkage. The IPOPT algorithm has the advantage of causing the smallest shrinkage porosities, compared to those of the genetic and fruit fly algorithms, which were almost the same.

Global heat transfer model and dynamic ray tracing algorithm for complex multiple turbine blades of Nibased superalloys in directional solidification process

High-quality solidification microstructure during directional solidification relies on precise temperature gradient control, so accurate calculation of the temperature field is critical. In this study, a 3D transient global heat transfer model of directional solidification by the Bridgman method based on the finite difference method is developed. The radiation heat in this model is calculated by the discrete transfer method, and a modified method of external surface area for irregular geometric models is proposed to reduce the zigzag shape caused by finite difference grids. Considering the radiative heat transfer between any surface elements of all materials in the directional solidification furnace, a dynamic ray tracing algorithm is developed to simulate the entire process of directional solidification. Then, the simulated results are compared with the theoretical results and experimental results, respectively. Finally, based on the present model and method, the simulation program developed is applied to the directional solidification of actual castings. The simulated results are in good agreement with the experimental results, which indicate that the model and method developed in this study is effective and practical.

Multi-scale coupling simulation in directional solidification of superalloy based on cellular automaton-finite difference method

Casting microstructure evolution is difficult to describe quantitatively by only a separate simulation of dendrite scale or grain scale, and the numerical simulation of these two scales is difficult to render compatible. A three-dimensional cellular automaton model couplling both dendritic scale and grain scale is developed to simulate the microstructure evolution of the nickel-based single crystal superalloy DD406. Besides, a macro–mesoscopic/microscopic coupling solution algorithm is proposed to improve computational efficiency. The simulation results of dendrite growth and grain growth of the alloy are obtained and compared with the results given in previous reports. The results show that the primary dendritic arm spacing and secondary dendritic arm spacing of the dendritic growth are consistent with the theoretical and experimental results. The mesoscopic grain simulation can be used to obtain results similar to those of microscopic dendrites simulation. It is indicated that the developed model is feasible and effective.

Phase field study on crystal orientation effects in eutectoid phase transformation

In this present work, a multi-phase field model was used to simulate the eutectoid transformation process, and on the basis of the nucleation model that was previously proposed by our research team, anisotropic and orientation relationship models were introduced to study the growth mechanism of the pearlite lamellae with anisotropy. It was found that the growth direction of the pearlite lamellae is related to its orientation and spacing. In the process of lamellar growth, deflection growth of pearlite will appear along with the adjustment of lamellar spacing, and the deflection angle is equal to the orientation difference between the austenite and the pearlite. Comparison between experimental and numerical results indicates a good consistency in pearlite morphology.

Microstructure characteristics and mechanical properties of NbMoTiVWSix refractory high-entropy alloys

Refractory high-entropy alloys are considered as potential structural materials for elevated temperature applications.To obtain refractory high-entropy alloys with high strength,different amounts of Si were added into the NbMoTiVW refractory high-entropy alloys.The effects of Si on the phase constitution,microstructure characteristics and mechanical properties of NbMoTiVWSi_(x) alloys were investigated.Results show that when the addition of Si is 0,0.025 and 0.05(molar ratio),the alloys are consisted of primary BCC and secondary BCC in the intergranular area.When the addition of Si is increased to 0.075 and 0.1,eutectic structure including silicide phase and secondary BCC phase is formed.The primary BCC phase shows dendritic morphology,and is refined by adding Si.The volume fraction of intergranular area is increased from 12.22%to 18.13%when the addition of Si increases from 0 to 0.1.The ultimate compressive strength of the NbMoTiVW alloy is improved from 2,242 MPa to 2,532 MPa.Its yield strength is also improved by the addition of Si,and the yield strength of NbMoTiVWSi_(0.1) reaches maximum of 2,298 MPa.However,the fracture strain of the alloy is decreased from 15.31%to 12.02%.The fracture mechanism of the alloys is changed from mixed fracture of ductile and quasi-cleavage to cleavage fracture with increasing of Si.The strengthening of alloys is attributed to the refinement of primary BCC phase,volume fraction increment of secondary BCC phase,and formation of eutectic structure by addition of Si.

Effects of Ag,Co,and Ge additions on microstructure and mechanical properties of Be-Al alloy fabricated by investment casting

The effects of Ag,Co,and Ge additions on microstructure and mechanical properties of Be-35Al(wt.%)alloys fabricated by investment casting were studied.The results reveal that the trace metals 1.5wt.%Ag,0.7wt.%Co,and 0.8wt.%Ge additions do not change the nucleation temperature of Be phase.However,the nucleation temperature of the Al phase decreases from 642℃ to 630℃ by DSC due to the Ge addition.The strength of the alloys sharply increases due to the dissolution of the Ag and Ge solutes into the Al phase and the Co into the Be phase characterized by SEM and EDS.Obviously,the strength of Be-Al-Ag-Co-Ge alloy is improved by the solution strengthening.Furthermore,a few Ag_(3) Al particles contribute to the strength of the Al phase.Be-Fe-Al ternary intermetallic compounds which can effectively reduce the negative effect of an impurity element Fe on the mechanical properties of Be-Al alloys are also found by XRD and EDS.

Gas evolution characteristics of three kinds of no-bake resin-bonded sands for foundry in production

No-bake resin-bonded sand is commonly used in casting production.However,its air pollution is relatively serious,especially in the molding and pouring process.For this reason,it is necessary to study the gas evolution characteristics of no-bake resin-bonded sand from room temperature to high temperatures,and not only the amount of gaseous products,but also the composition of the gaseous products.No-bake furan resin-bonded sand(#1),phenolic urethane no-bake resin-bonded sand(#2),and alkaline phenolic no-bake resin-bonded sand(#3)are the three most common no-bake resin-bonded sands in casting.The gas evolution volume and rate of these three no-bake resin-bonded sands were studied.Thermogravimetry-mass spectrometer(TG-MS),headspace-gas chromatography/mass spectrometer(HS-GC/MS),and pyrolysis-gas chromatography/mass spectrometer(PY-GC/MS)were used to measure the composition of the gaseous products emitted from binders at room temperature and high temperatures.The differences between formaldehyde,heterocyclic aromatic compounds(HAC),monocyclic aromatic hydrocarbons(MAH),and polycyclic aromatic hydrocarbons(PAHs)gaseous products from the three types of no-bake resin-bonded sands during the molding and casting process were compared.From the perspective of environmental protection,alkaline phenolic no-bake resin-bonded sand and no-bake furan resin-bonded sand are better than phenolic urethane no-bake resin-bonded sand.

An acupoint-originated human interstitial fluid circulatory network

To the Editor:Since 1027,when the Tian Sheng Bronze Statue showing acupoints and meridians was first introduced for medical practitioners,it has evolved to the currently used acupoints and meridians atlas in traditional Chinese medicine(TCM).[1]To date,the acupoints represent defined areas on the body surface relative to certain landmarks.The acupoints in the extremity endings would connect anatomically with diverse associated visceral organs or tissues,forming a Meridian and Collateral network.Illustrated on the atlas,each main meridian is usually a virtual line connecting a group of adjacent acupoints that correlate with certain visceral organ.In modern medical science,the anatomical structures of main meridians remain largely unclarified.