Integrated Behavior of Carbon and Copper Alloy Heat Sink Under Different Heat Loads and Cooling Conditions

An actively water-cooled limiter has been designed for the long pulse operation of an HT-7 device, by adopting an integrated structure-doped graphite and a copper alloy heat sink with a super carbon sheet serving as a compliant layer between them. The behaviors of the integrated structure were evaluated in an electron beam facility under different heat loads and cooling conditions. The surface temperature and bulk temperature distribution were carefully measured by optical pyrometers and thermocouples under a steady state heat flux of 1 to 5 MW/m^2 and a water flow rate of 3 m^3/h, 4.5 m^3/h and 6 m^3/h, respectively. It was found that the surface temperature increased rapidly with the heat flux rising, but decreased only slightly with the water flow rate rising. The surface temperature reached approximately 1200℃ at 5 MW/m^2 of heat flux and 6 m^3/h of water flow. The primary experimental results indicate that the integrated design meets the requirements for the heat expelling capacity of the HT-7 device. A set of numerical simulations was also completed, whose outcome was in good accord with the experimental results.

Influence of Cooling Conditions in Casting Cu-Ni Alloy Based on Numerical Simulation

The most common and serious defect in Cu-Ni alloy casting is porosity. To solve the problem, accurate casting design and proper design of gating system are necessary. It can be predicted and designed by means of computer simulation of casting solidification. Based on the casting process of the Cu-Ni alloy, the simulation software of diathermanous—flowing—stress coupling ProCAST was used to simulate the Cu-Ni alloy solidification process about the defects and temperature field. By combining experimental results with the simulation results, the quality of casting on some cooling conditions were analyzed. Furthermore, a better cooling condition for solidification process of the Cu-Ni alloy was chosen to improve the quality of the casting. The simulation results indicate that the quality of Cu-Ni alloy casting is the best when it is on the cooling condition of the permanent mold with the insulated riser system.

Coupling effect of micro-textured tools and cooling conditions on the turning performance of aluminum alloy 6061

Micro-texturing has been widely proven to be an effective technology for achieving sustainable machining.However,the performance of micro-textured tools under different cooling conditions,especially their coupling effect on machined surface integrity,was scarcely reported.In this paper,the non-textured,linear micro-grooved,and curvilinear micro-grooved inserts were used to turn aluminum alloy 6061 under dry,emulsion,and liquid nitrogen cryogenic cooling conditions.The coupling effects of different micro-textures and cooling conditions on cutting force,cutting temperature,and machined surface integrity,including the surface roughness,work hardening,and residual stress,were revealed and discussed in detail.Results indicated that the micro-grooved tools,especially the curvilinear micro-grooved tools,not only reduced the cutting force and cutting temperature,but also improved the machined surface integrity.In addition,the micro-grooved tools can cooperate with the emulsion or liquid nitrogen to reduce the cutting force,cutting temperature,and improve the machined surface integrity generally,although the combination of emulsion cooling condition and micro-grooved tools generated negative coupling effects on cutting forces and surface work hardening.Especially,the combination of curvilinear micro-grooved cutting tools and cryogenic cooling condition resulted in the lowest cutting force and cutting temperature,which generated the surface with low roughness,weak work hardening,and compressive residual stress.

Study on the reaming process of aluminum alloy 7050-T7451 under different cooling conditions

Aluminum alloy 7050 is widely used in the aeronautical industries.However,owing to their highly ductile property,chips created during high-speed machining cannot be naturally broken,and long continuous chips are unavoidably formed,impacting the machining stability and quality of the parts.Because a smaller cutting allowance is required compared with conventional machining operations,the behavior of the chips during reaming operation may be more complex and different from those determined in previous investigations.Therefore,studying the characteristics of chip formation and hole quality during the reaming process is essential to improve the machinability of aluminum alloy 7050.In this study,three different cooling conditions were applied to reaming aluminum alloy 7050-T7451 with polycrystalline diamond(PCD)reamers.The finite element models(FEMs)were established to simulate the chip formation.The macro-and micro-morphologies of chips under the three cooling conditions were compared to analyze the chip behaviors.The diameter,surface roughness,and micro-morphologies of the reamed holes were also analyzed to evaluate the hole quality.The results showed that the chip morphology was strongly influenced by the cutting parameters and cooling strategies.It was found that the desired chip morphologies satisfactory geometrical accuracy and surface quality during the reaming of aluminum alloy 7050-T7451 could be achieved using internal cooling at a spindle speed of 8000 r/min and a feed rate of 0.0l mm/z.This study also demonstrates the feasibility of an internal cooling strategy for breaking chips when reaming aluminum alloy 7050-T7451,which opens new possibilities for improving the chip-snarling that occurs during hole machining.

Natural Convective Heat and Mass Transfer of Water with Corrosion Products at Super-Critical Pressures under Cooling Conditions

A numerical study is reported of laminar natural convective heat and mass transfer on a vertical cooled plate for water containing metal corrosion products at super-critical pressures. The influence of variable properties at super-critical pressures on natural convection has been analyzed. The difference between heat and mass transfer under cooling or heating conditions is also discussed and some correlations for heat and mass transfer under cooling conditions are recommended.

Effect of cooling condition on microstructure of semi-solid AZ91 slurry produced via ultrasonic vibration process

The effects of cooling conditions on the microstructure of semi-solid AZ91 slurry produced via ultrasonic vibration process were investigated. AZ91 melts were subjected to ultrasonic vibration in different temperature ranges under different cooling rates. The results show that fine and spherical α-Mg particles are obtained under ultrasonic vibration at the nucleation stage, which is mainly attributed to the cavitation and acoustic streaming induced by the ultrasonic vibration. The reduction of lower limit of ultrasonic vibration temperature between the liquidus and solidus increases the solid volume fraction and average particle size. Increasing cooling rate increases the solid volume fraction and reduces the average shape factor of particles. The appropriate temperature range for ultrasonic vibration is from 605 °C to 595 °C or 590 °C, and the suitable cooling rate is 2-3 °C/min.

Effect of heat treatment on microstructure and mechanical properties of Ti-containing low alloy martensitic wear-resistant steel

Effects of quenching temperature and cooling conditions(water cooling and 10%NaCl cooling)on microstructure and mechanical properties of a 0.2%Ti low alloy martensitic wear-resistant steel used for die casting ejector plate were investigated.The results show that lath martensite can be obtained after austenitizing in the range of 860-980℃and then water cooling.With an increase in austenitizing temperature,the precipitate content gradually decreases.The precipitates are mainly composed of TiC and Ti4C2S2,and their total content is between 1.15wt.%and 1.64wt.%.The precipitate phase concentration by water-cooling is higher than that by10%NaCl cooling due to the lower cooling rate of water cooling.As the austeniting temperature increases,the hardness and tensile strength of both water cooled and 10%NaCl cooled steels firstly increase and then decrease.The experimental steel exhibits the best comprehensive mechanical properties after being austenitized at 900℃,cooled by 10%NaCl,and then tempered at 200℃.Its hardness,ultimate tensile strength,and wear rate reach551.4 HBW,1,438.2 MPa,and 0.48×10^(-2)mg·m^(-1),respectively.

Effects of moulding sands and wall thickness on microstructure and mechanical properties of Sr-modified A356 aluminum casting alloy

The effects of different cooling conditions on the mechanical properties and microstructures of a Sr-modified A356 （Al-7Si-0.3Mg） aluminum casting alloy were comparatively investigated using three moulding sands including quartz, alumina and chromite into multi-step blocks. The results show that the mechanical properties and microstructures using chromite sand are the best. As the cooling speed increases, the dendrite arm spacing （DAS） decreases significantly and the mechanical properties are improved, and the elongation is more sensitive to the cooling speed as compared with the tensile strength. The increase of the properties is primarily attributed to the decrease of the DAS and the increase of the free strontium atoms in the matrix. In particular, the regression models for predicting both the tensile strength and the elongation for Sr-modified A356 aluminum casting alloy were established based on the experimental data.

Convective Heat and Mass Transfer in Water at Super－Critical Pressures under Heating or Cooling Conditions in Vertical Tubes

Forced and mixed convection heat and mass transfer are studied numerically for water containingmetallic corrosion products in a heated or cooled vertical tube with variable thermophysical propertiesat super-critical pressures. The fouling mechanisms and fouling models are presented. The influenceof variable properties at super-critical pressures on forced or mixed convection has been analyzed.The differences between heat and mass transfer under heating and cooling conditions are discussed. Itis found that variable properties, especially buoyancy, greatly influence the fluid flow and heat masstransfer.

Microstructure and properties evolution of Nb-bearing medium Cr wear-resistant cast steel during heat treatment

The effect of quenching temperature and cooling conditions on the microstructure and mechanical properties of a 0.2%Nb medium chromium wear-resistant cast steel was investigated.The microstructure,carbides and volume fraction of retained austenite were characterized using the optical microscope,scanning electron microscope,transmission electron microscope and X-ray diffraction.The influence of heat treatment on hardness,impact toughness and tensile properties of test steel was studied.It can be observed that lath martensite can be obtained under the condition of air cooling and oil cooling upon austenitizing in the range of 900–1020℃.Total carbide content of 0.2–1.1 wt.%under air cooling is more than that under oil cooling due to the lower cooling rate.Nb6C5,M23C6 and M7C3 were found at lower austenitizing temperature,of which niobium carbide mostly located at grain boundaries,while chromium carbides were uniformly distributed in the matrix with the size of 20–50 nm.The chromium carbides are basically dissolved into the matrix in test steel austenitized at 1020°C.Meanwhile,the negligible growth of prior austenite grain size is achieved.Specimen austenitized at 1020℃ and cooled in air+tempered at 200℃ has a best combination of hardness,plasticity and tensile strength due to fine grain size and more amount of retained austenite.Under this condition,the hardness is 58 HRC,the impact toughness is 22.92 J/cm^(2),and the tensile strength is 1136.9 MPa.

Comparison of surface integrity for dry and wet drilling of 49Fe-49Co-2V alloy

Working performances of the components made out of 49Fe-49Co-2V alloy are closely related to the surface integrity of the drilled holes,which are influenced remarkably by the cooling conditions.The present study focuses on the surface integrity differences between wet and dry drilled 49Fe-49Co-2V alloy holes.The drilled hole surface roughness and topographies,metallurgical and mechanical properties,and the exit characterizations were obtained using optical microscopy(OM),scanning electron microscopy(SEM),electron backscatter diffraction microscopy(EBSD),transmission electron microscopy(TEM),energy dispersive spectroscopy(EDS)and Vickers hardness techniques,etc.The effects of cooling conditions on the surface integrity were concluded and the influence mechanisms were analyzed based on the force and temperature differences in drilling process with different cooling conditions.It is found that the surface roughness and the thickness of refined-grain region of the dry drilled holes are larger than those of wet drilled holes;work hardening induced by wet drilling is more serious than dry drilling;chippings occurred in the exits of the wet drilled holes due to the material brittleness,which could be avoided by dry drilling.The surface integrity differences of wet and dry drilled holes are closely related to the force and temperature differences in drilling process with different cooling conditions.