Numerical Simulation of Temperature Field of Die Casting Dies

In this study, the Solidworks was used as pre-processor, which performed the three- dimensional solid construction and automatic enmeshment. The COSMOS was adopted as post- processor to display the temperature distribution and further to simulate the thermal stress distribution of dies. A software package for three-dimensional temperature fields of complicated die casting and its dies was developed and the temperature distributions of a fan cover casting were simulated by the software.

Effects of Pouring Temperature on Interfacial Reaction between Ti-47-5Al-2-5V-1Cr Alloy and Mold during Centrifugal Casting

Pouring temperature and time are the most important influencing factors on interfacial reaction during the centrifugal casting. When cast at high temperatures, the crucible becomes brittle and prone to cracking, and shows a low stability. In this paper, we studied the centrifugal casting of Ti-47.5-Al-2.5V-1Cr alloy, and explored the effects of pouring temperature on the interfacial reaction. Castings at 1 600, 1 650, and 1 700 ℃ were obtained by controlling the other parameters constant in the experiments. The microstructure, elemental distribution, thickness of the reaction layer and phase composition of the castings at the interface were studied. The results show that the thickness at the interfacial reaction layer is increased by raising the pouring temperature. The elements in the mold and the matrix were double-diffused and reacted at the interface during the casting process, and formed solid solutions with the precipitation of many new phases such as AlOand TiO. The roughness of interface structure and layer thickness of reaction increase with the rise of temperature, and the interfacial reaction is more intense. There is a minimum layer thickness of the reaction layer that is 80 μm when the temperature is 1 600 ℃.

THE TEMPERATURE ANALYSIS OF THE BILLET WITH PHASE CHANGE DURING CONTINUOUS CASTING

In this paper,the problem of 3-D steady heat conduction including the influenceof phase change on billets is turned into the 2-D transient problem by a suitable transformation technique. The effective specific heat has been employed to substitutefor the effect of the phase ceange.The computational formulation of finite element has been presented. And the careful disposal of the phase change region has also beengiven.

Characteristics of High Temperature Rupture of a Cast Ni-Based Superalloy M963

The rupture behavior of a cast Ni-base superalloy M963 at high temperature has been investi- gated. The microstructure examination shows that there exists a large amount of the carbide and γ-γ' eutectic, which is very harmful to the mechanical properties of M963 superalloy. The tensile strength of M963 superalloy both at room temperature and at high temperatures is higher than that of K17G alloy, but the tensile ductility of the former is much lower than that of the latter. In tensile fracture process with the high strain rate, the open carbides are the initiation site and the carbide/matrix interface is the propagation path of cracks. But in fracture process with the low strain rate, the carbide/matrix interface and cast microvoids are the initiation sites, and the carbide/matrix interface is the propagation path of cracks. The effective ways to improve ductility of M963 superalloy are also suggested.

Microstructures and Properties of FeAl-Fe_3AlC_(0.5) Composites Prepared by SHS Casting

FeAl composites with 21, 37 and 50 wt pct Fe3AlC0.5 were fabricated by a self-propagating high temperature synthesis （SHS） casting. Phases and microstructures were analyzed by X-ray diffraction （XRD） and scanning electron microscopy （SEM）. Microhardness and bending strength of the composites were measured. The composites with 21 and 50 wt pct Fe3AlC0.5 mainly consisted of FeAl and FesAlC0.5 phases, whereas the composite with 37 wt pct Fe3AlC0.5 was composed of FeAl, Fe3AlC0.5 and graphite phases. The bonding of the reinforcement and the matrix was good. Hardness and bending strength of the composite with 37 wt pct Fe3AlC0.5 was lower than those of the 21 and 50 wt pct composites owing to the presence of the soft graphite phase.

Effects of Cr Content and Annealing Temperature on Microstructure and Wear Characteristics of Cast Ausferrite Nodular Iron

The effects of Cr content and annealing temperature on abrasive wear characteristics of cast ausferrite nodular iron were investigated with Suga type abrasive wear tester. The surface morphology and Vickers hardness of the tested samples were analyzed by scanning electron microscopy（SEM）, digital microscope and Vickers hardness tester. The results show that the cast ausferrite nodular iron could be obtained by alloying with Cr in the as-cast ductile cast iron and permanent mold casting, and the bainite content in the matrix increased with increasing Cr content. However, the decomposition of bainite took place during annealing at 500 °C to 800 °C; especially, at 800 °C, the bainite transformed into a mixture of fine lamellar pearlite and ferrite matrix structure. The wear loss of specimens was reduced with increasing Cr content in the cast ausferrite nodular iron. The wear loss of the sample cast ausferrite nodular iron with 0.4mass% Cr is the least. The wear loss began to increase while the Cr content is 0.6mass%. The wear loss of annealed ductile irons at different annealing temperatures was higher than that of as-cast samples. During the abrasive wear, the shear stress transformed austenite to martensite, and the hardness of specimens increased and the wear resistance of as-cast ductile cast iron was improved.

Thermo-elasto-visco-plastic finite element analysis on formation and propagation of off-corner subsurface cracks in bloom continuous casting

The formation and propagation of the popular off-corner subsurface cracks in bloom continuous casting were investigated through thermo-mechanical analysis using three coupled thermo-mechanical models. A two-dimensional thermo-elasto-visco-plastic finite element model was developed to predict the mould gap evolution, temperature profiles and deformation behavior of the solidified shell in the mould region. Then, a three-dimensional model was adopted to calculate the shell growth, tempera- ture history and the development of stresses and strains of the shell in the following secondary cooling zones. Finally, another three-dimensional model was used to analyze the stress distributions in the straightening region, The results showed that the off-corner cracks in the shell originated from the mould owing to the tensile strain developed in the crack sensitive regions of the solidification front, and they could be driven deeper by the possible severe surface temperature rebound and the extensive tensile stress in the secondary cooling zone, especially upon the straightening operation of the bloom casting. It is revealed that more homogenous shell temperature and thickness can be obtained through optimization of mould corner radius, casting speed and secondary cooling scheme, which help to decrease stress and strain concentration and therefore prevent the initiation of the cracks.

Preparation of an ultrafine-grained Fe-40Al intermetallic compound

An ultrafine grained Fe-40Al intermetallic compound is fabricated by a self- propagating high temperature synthesis （SHS） casting. The XRD result shows that the Fe-40Al intermetallic compound consists of the B2 FeAl phase. The Fe-40Al intermetallic compound presents ultrafine grain size in the range of 100-600 rim, leading from the high nucleation rate and the low growth rate. The Fe-40Al intermetallic compound exhibits high hardness （3.4 GPa） and high bending strength （830 MPa） and high compressive strength （2700 MPa）, which originate from the ultrafine-structure in the material. The effect of the load on dry-sliding wear rate of the material against AISI52100 steel was investigated. The wear rate increases with the increase of normal load. The dominated weax mechanism is microfracture.