Optimization of pressurization process in low-pressure casting of a 5.4-ton gigantic C95800 copper alloy casting

During the low-pressure casting of extra-large size C95800 copper alloy components,traditional linear pressurization technique leads to a rapid surge of liquid metal inlet velocity at the regions where the mold cavity cross-section enlarges.This rapid increasement of liquid metal inlet velocity causes serious entrapment of gas and oxide films,and results in various casting defects such as the bifilm defects.These defects detrimentally deteriorate mechanical properties of the castings.To address this issue,an innovative nonlinear pressurization strategy timely matching to the casting structure was proposed.The pressurization rate decreases at sections where the cross-section widens,but it gradually increases as the liquid metal level rises.By this way,the inlet velocity remains below a critical threshold to prevent the entrapment of gas and oxide films.Comparative analyses involving numerical simulations and casting verification illustrate that the nonlinear pressurization technique,compared to the linear pressurization,effectively diminishes both the size and number of bifilm defects.Furthermore,the nonlinear pressurization method enhances the casting yield strength by 10%,tensile strength by 14%,and elongation by 10%.Examination through scanning electron microscopy highlights that the bifilm defects arising from the linear pressurization process result in the reduction of the castings’mechanical properties.These observations underscore the efficacy of nonlinear pressurization in enhancing the quality and reliability of gigantic castings,as exemplified by a 5.4-ton extra-large sized C95800 copper alloy propeller hub with complex structures in the current study.

A new vacuum-assisted low-pressure investment casting process for K446 alloy

Non-metallic inclusions and zyglo indications frequently occur in the superalloy castings produced through the traditional vacuum gravity investment casting process,particularly in components with thin-walled and complex structural features.The vacuum-assisted low-pressure casting(VLC),a type of counter-gravity casting(CGC)method,has been developed to minimize non-metallic inclusions and zyglo indications in superalloy castings.Rectifying frames for gas turbines made from K446 alloy were produced semi-continuously using the VLC process and subsequently evaluated through tensile testing,chemical composition analysis,X-ray diffraction,and zyglo penetrant inspection.The results indicate a roughly 10%improvement in tensile strength at 800℃ compared to gravity casting.Moreover,no significant changes are observed in the chemical composition of the alloys from the beginning to the end of a casting campaign,indicating that the developed VLC process is viable for the engineering-scale production of superalloy castings.Compared to traditional vacuum gravity casting(GC)method,the application of VLC can reduce the numbers of non-metallic inclusions and Zyglo indications in the castings by over 80%.At the same time,it significantly shortens the production time by 3 to 5 days.

Effect of process parameters on density of magnesium alloy parts by low-pressure expendable pattern casting

The combination of magnesium alloys with the low-pressure expendable pattern casting(LP-EPC) process would bright future for application of magnesium alloys. The researches are focused on the effect of process parameters on the internal casting quality of magnesium alloy parts. AZ91D magnesium alloy castings were produced for different combinations of the LP-EPC process parameters. Specifically,pouring temperature,vacuum,filling velocity and coupling action of these factors were manipulated to observe their effect on the casting porosity and density distribution. The results indicate that the pouring temperature with LP-EPC process is lower than it in gravity casting. The selected process parameters,such as vacuum,filling velocity and coupled modes of them,must ensure melt metal flowing front profile exhibiting smooth and convex shape. The optimal process parameters for the castings are pouring temperature 983-1 023 K,vacuum 0.02-0.03 MPa,filling velocity 60-95 mm/s,and simultaneous filling with sucking.

Process Optimization for AZ91 Mg-alloy Low-pressure EPC Process

The influence of a key process variable on the mold filling characteristics of AZ91 Mg-alloy was studied in the low pressure EPC process.The applied flow quantity of insert gas from 1 to 5 m~3/h associated with the pressurizing rate in the low pressure EPC casting process was considered for rectangle and L-shape plate casting. The experimental results show that there is an optimal flow quantity of insert gas for good mold filling characteristics in AZ91 Mg-alloy low-pressure EPC process. The optimal flow quantity of insert gas for the specimens is 3 to 4 m~3/h. Either less or higher than the optimal flow quantity of insert gas would lead to misrun defects or folds, blisters and porosity defects. The practice of hub casting confirmed that the low-pressure EPC process with an optimal processing variable exemplified as 4 m~3/h gas flow quantity was capable of producing complicated magnesium castings without misrun defects.

Photoionization Mass Spectrometric and Kinetic Modeling of Low-pressure Pyrolysis of Benzene

Pyrolysis of benzene at 30 Torr was studied from 1360 K to 1820 K in this work. Synchrotron vacuum ultraviolet photoionization mass spectrometry was employed to detect the pyroly- sis products such as radicals, isomers and polycyclic aromatic hydrocarbons, and measure their mole fraction profiles versus temperature. A low-pressure pyrolysis model of benzene was developed and validated by the experimental results. Rate of production analysis was performed to reveal the major reaction networks in both fuel decomposition and aromatic growth processes. It is concluded that benzene is mainly decomposed via H-abstraction reaction to produce phenyl and partly decomposed via unimolecular decomposition reac- tions to produce propargyl or phenyl. The decomposition process stops at the formation of acetylene and polyyne species like diacetylene and 1,3,5-hexatriyne due to their high thermal stabilities. Besides, the aromatic growth process in the low-pressure pyrolysis of benzene is concluded to initiate from benzene and phenyl, and is controlled by the even carbon growth mechanism due to the inhibited formation of C5 and C7 species which play important roles in the odd carbon growth mechanism.

Low-pressure pneumoperitoneum with abdominal wall lift in laparoscopic total mesorectal excision for rectal cancer:initial experience

AIM To evaluate the safety and feasibility of a new technology combining low-pressure pneumoperitoneum(LPP) and abdominal wall lift(AWL) in laparoscopic total mesorectal excision(TME) for rectal cancer.METHODS From November 2015 to July 2017,26 patients underwent laparoscopic TME for rectal cancer using LPP(6-8 mm Hg) with subcutaneous AWL in Qilu Hospital of Shandong University,Jinan,China.Clinical data regarding patients' demographics,intraoperative monitoring indices,operation-related indices andpathological outcomes were prospectively collected.RESULTS Laparoscopic TME was performed in 26 cases(14 anterior resection and 12 abdominoperineal resection) successfully,without conversion to open or laparoscopic surgery with standard-pressure pneumoperitoneum.Intraoperative monitoring showed stable heart rate,blood pressure and paw airway pressure.The mean operative time was 194.29 ± 41.27 min(range:125-270 min) and 200.41 ± 20.56 min(range:170-230 min) for anterior resection and abdominoperineal resection,respectively.The mean number of lymph nodes harvested was 16.71 ± 5.06(range:7-27).There was no positive circumferential or distal resection margin.No local recurrence was observed during a median follow-up period of 11.96 ± 5.55 mo(range:5-23 mo).CONCLUSION LPP combined with AWL is safe and feasible for laparoscopic TME.The technique can provide satisfactory exposure of the operative field and stable operative monitoring indices.

THE PRODUCTION OF FOAM ALUMINIUM ALLOY BY LOW-PRESSURE INFILTRATION METHOD

The influence of technical parameters on the infiltrating height of the moltenmetal in the process of Producing aluminium alloy foam by low-pressure infiltration method were investigated.Experiments indicated that the height increases with the preheating temperature of granules,theexternal pressureand the pouring temperature of molten alloy,among which the action of pre heating temperature of granules is more effective.There exists a critical pre heating temperature for different size of granules.

Numerical simulation and analysis of lithium plasma during low-pressure DC arc discharge

Alkali metal DC arc discharge has the characteristics of easy ionization,low power consumption,high plasma temperature and ionization degree,etc,which can be applied in aerospace vehicles in various ways.In this paper,we calculate the physical property parameters of lithium vapor,one of the major alkali metals,and analyze the discharge characteristics of lithium plasma with the magnetohydrodynamic(MHD)model.The discharge effects between constant current and voltage sources are also compared.It is shown that the lithium plasma of DC arc discharge has relatively high temperature and current density.The peak temperature can reach tens of thousands of K,and the current density reaches 6 x 107 A m 2.Under the same rated power,the plasma parameters of the constant voltage source discharge are much higher than those of the constant current source discharge,which can be used as the preferred discharge mode for aerospace applications.

An Experimental and Numerical Study on the Cleaning of Pleated Bag Filters Using Low-Pressure Pulsed-Jets

Pulsed-jet cleaning is recognized as the most efficient method to regenerate bag dust collectors traditionally used in industrial processes to control the emission of particulates.In this study,non-woven needle felt filter bags with and without a film coating material have been analyzed considering different geometries(different number N of pairs of pleated filter bag sides)in the frame of dedicated low-pressure pulsed-jet cleaning experiments.The flow structure inside the bag and the response characteristics of its wall have also been analyzed numerically through a computational fluid-dynamics/structural-dynamics(CFD-CSD)unidirectional fluid-solid coupling method.As shown by the experiments,the peak pressure(P_(0))on the wall of the filter bag with N=8 and 12 is higher,which indicates dust can be removed more effectively in these cases.The peak pressure on the wall increases first and then decreases along the direction of the bag length,while the peak pressure of the pleated filter bag with nonwoven needled felt film coating is greater than that without film coating.A comprehensive analysis of the time variation of acceleration,deformation,strain,stress and other factors,has led to the conclusion that the pleated filter bag with N=12 would be the optimal choice.

The mechanism study of low-pressure air plasma cleaning on large-aperture optical surface unraveled by experiment and reactive molecular dynamics simulation

Low-pressure air plasma cleaning is an effective method for removing organic contaminants on large-aperture optical components in situ in the inertial confinement fusion facility.Chemical reactions play a significant role in plasma cleaning,which is a complex process involving abundant bond cleavage and species generation.In this work,experiments and reactive molecular dynamics simulations were carried out to unravel the reaction mechanism between the benchmark organic contaminants of dibutyl phthalate and air plasma.The optical emission spectroscopy was used to study the overall evolution behaviors of excited molecular species and radical signals from air plasma as a reference to simulations.Detailed reaction pathways were revealed and characterized,and specific intermediate radicals and products were analyzed during experiments and simulation.The reactive species in the air plasma,such as O,HO_(2)and O_(3)radicals,played a crucial role in cleaving organic molecular structures.Together,our findings provide an atomic-level understanding of complex reaction processes of low-pressure air plasma cleaning mechanisms and are essential for its application in industrial plasma cleaning.

Effect of Low-pressure Carbonation on the Heat Inactivation and Cytoplasmic Acidification of Saccharomyces cerevisiae

Effect of low-pressure carbonation （LPC） on heat inactivation of Saccharomyces cerevisiae was investigated. The cell suspension was carbonated at 1 MPa and 4℃ for 15 min and subsequently heated from 51 to 61 ℃ and 5 s to 5 min （heating with LPC）. As a control experiment, cell suspension was heat-treated under atmospheric pressure without LPC （heating）. The inactivation ratio of heating at 53℃ and 55℃ for l rain with LPC was approximately 1 log order higher than heating alone. Extending heating time to 5 min did not widen the difference in the inactivation ratio between heating with LPC and heating alone at both heating temperatures. At 57℃, the difference in inactivation ratio increased from 1 to 2.5 log order with extending treatment time from 5 to 15 s. The results suggested that the enhanced inactivation effect by LPC was obtained at the higher temperature with short time treatment than the lower temperature with longer time treatment. Under fluorescence microscope observation of LPC-treated cell stained with LysoSensor probe, it seemed that LPC was hardly able to acidify the cytoplasm ofS. cerevisiae. It is considered that the ability orS. cerevisiae ceils to keep their cytoplasmic pH during LPC resulted in the inferior increase in heat inactivation ratio by LPC as compared with bacteria in the previous studies.

基于ProCAST的一模多腔YL112铝合金压铸件数值模拟及工艺优化

针对YL112压铸铝合金一模多铸产品的组织性能均一性需求,采用ProCAST软件对典型一模多铸工艺进行模拟,比较了两种不同充型顺序的压铸方案。结果表明:基于顺序凝固一模多腔压铸件由于充型与凝固过程的温度场分布不均,导致近浇口端铸件出现明显缩松缩孔缺陷,造成铸件性能均一性差。后续采用等流程浇注系统,实现一模多腔铸件同时充型凝固过程,改善了铸件温度场分布,减少了工艺缺陷。经过实际生产验证,获得了组织性能均一性好的压铸件。

Neutrons in a nanosecond low-pressure discharge in deuterium

Stable neutron generation with a yield of ~1.2×10^(4) neutrons per pulse was obtained during d(d,n)^(3)He reaction initiated by the high-voltage nanosecond discharge in a gap with a potential tungsten cylinder(anode)and a grounded deuterated zirconium plate(cathode)filled with deuterium at a pressure of ~10^(2) Pa.Estimated duration of the neutron pulse was ~1.5 ns.Less intensive neutron emission was registered without deuterated plate.Splashing of material of the tungsten electrode was observed during the high-voltage nanosecond discharge in the deuterium,hydrogen,helium and argon at pressures of 10^(2)-10^(4) Pa.

Strength and elastic modulus enhancement in Mg-Li-Al matrix composites reinforced by ex situ TiB2 particles via stir casting

A novel Mg^(-1)0Li-3Al(wt.%,LA103)matrix composite reinforced by ex situ micron TiB_(2) particles was developed in the present study.The ball milling and cold pressing pretreatment of the reinforcements made it feasible to prepare this material under stir casting conditions with good dispersion.The microstructure and mechanical properties of the composites prepared by different pretreatment methods were analyzed in detail.The TiB_(2) particles in the Al-TiB_(2)/LA103 composite using the pretreatment process were uniformly distributed in the microstructure due to the formation of highly wettable core-shell units in the melt.Compared with the matrix alloys,the Al-TiB_(2)/LA103 composite exhibited effective strength and elastic modulus improvements while maintaining acceptable elongation.The strengthening effect in the composites was mainly attributed to the strong grain refining effect of TiB2.This work shows a balance of high specific modulus(36.1 GPa·cm^(3)·g^(-1))and elongation(8.4%)with the conventional stir casting path,which is of considerable application value.

A LOW-PRESSURE AND ONE-STEP METHOD FOR THE SYNTHESIS OF ALKYLIDYNETRICOBALT NONACARBONYL CLUSTERS:RCCo_8(CO)_9

Metal clusters RCCo_3(CO)_9(R-H,C1,Br,CH_3,Ph) were prepared in 18.8-57.3% yields from the reaction of cobalt(Ⅱ)salt and RCX_a under mild PTC conditions(latm CO,25℃).The cobalt salt was reduced to Co(CO)_4 in the presence of Na_3S_2O_4.

Data-driven casting defect prediction model for sand casting based on random forest classification algorithm

The complex sand-casting process combined with the interactions between process parameters makes it difficult to control the casting quality,resulting in a high scrap rate.A strategy based on a data-driven model was proposed to reduce casting defects and improve production efficiency,which includes the random forest(RF)classification model,the feature importance analysis,and the process parameters optimization with Monte Carlo simulation.The collected data includes four types of defects and corresponding process parameters were used to construct the RF model.Classification results show a recall rate above 90% for all categories.The Gini Index was used to assess the importance of the process parameters in the formation of various defects in the RF model.Finally,the classification model was applied to different production conditions for quality prediction.In the case of process parameters optimization for gas porosity defects,this model serves as an experimental process in the Monte Carlo method to estimate a better temperature distribution.The prediction model,when applied to the factory,greatly improved the efficiency of defect detection.Results show that the scrap rate decreased from 10.16% to 6.68%.

Simulation of propagation of the HPM in the low-pressure argon plasma

The propagation of the high-power microwave（HPM） with a frequency of 6 GHz in the lowpressure argon plasma was studied by the method of fluid approximation.The two-dimensional transmission model was built based on the wave equation,the electron drift-diffusion equations and the heavy species transport equations,which were solved by means of COMSOL Multiphysics software.The simulation results showed that the propagation characteristic of the HPM was closely related to the average electron density of the plasma.The attenuation of the transmitted wave increased nonlinearly with the electron density.Specifically,the growth of the attenuation slowed down as the electron density increased uniformly.In addition,the concrete transmission process of the HPM wave in the low-pressure argon plasma was given.

Microstructure and Properties of Low-pressure Cold Sprayed Al-based Composite Coatings on Magnesium Alloy Surface

Pure Al and Al-30%Al_(2)O_(3)composite coatings are prepared on the surface of AZ31B magnesium alloy by low-pressure cold spraying.The morphology and structure of the coatings are analyzed by scanning electron microscope (SEM),energy dispersive spectroscopy (EDS),and X-ray diffraction (XRD),and the effects of the addition of Al_(2)O_(3)on the microstructure of the Al-based coatings are discussed.The mechanical properties and corrosion resistance of the coatings are fully evaluated by the micro-hardness tester,electronic tensile machine,and electrochemical workstation.The results show that the coating structure is more uniform and denser,and the porosity is significantly reduced after the addition of Al_(2)O_(3).The interfaces between the coatings and the magnesium alloy substrate are distinct,and the coatings and the substrate are mechanically combined.Compared with the pure Al coating,the microhardness of the Al-Al_(2)O_(3)composite coating is increased to 61.1 HV_(0.2),and the bonding strength reaches above 53.1 MPa.The self-corrosion potential of the two coatings is higher than that of the magnesium alloy,and the self-corrosion current density is significantly lower than that of the magnesium alloy substrate.The Al-based coatings prepared by low-pressure cold spraying have high hardness,good bonding strength,and good corrosion resistance,which can be used for the repair and protection of magnesium alloy structural parts.

基于ProCAST仿真的型芯型壳一体化空心涡轮叶片反变形精度控制

目的针对空心涡轮叶片在定向凝固铸造过程中产生收缩扭转变形的问题,对叶片进行反变形补偿优化,控制叶片铸造过程中的型面精度,实现空心涡轮叶片的快速迭代。方法通过ProCAST仿真软件对某型号空心涡轮导叶进行定向凝固模拟浇铸及位移场偏差分析,根据分析结果采用分截面反变形法对叶片进行整体重构;基于光固化3D打印技术与凝胶注模技术制备型芯/型壳一体化的反变形重构叶片铸型;对铸型内部结构进行CT检测并使用高温合金DZ411完成浇铸验证。结果反变形后叶片铸件尾缘最大偏差值从0.435 mm降低为0.1206 mm,叶盆方向最大扭转值从0.134 mm降低为0.0971 mm,前缘最大偏差值由0.206 mm降低为0.085 mm,提高了浇铸叶片的型面精度;气动性能分析结果表明,反变形收缩扭转的叶型基本保持了原叶片性能。结论通过反变形优化后的空心涡轮导叶整体偏差降低,实现了空心涡轮叶片型面的精度控制;利用型芯/型壳一体化技术的快速性缩短了叶片型面精度优化周期,为未来新型空心涡轮叶片的快速制造奠定了一定的工艺基础。

基于ProCAST的铜合金通海阀铸造工艺优化

目的结合ZCuAl7-7-4-2合金的铸造特性,研究复杂薄壁铸件通海阀的铸造成形工艺,探究初始浇注方案下的充型、凝固规律,优化工艺并提出合理的铸造工艺方案。方法根据通海阀的结构特点,设计出底注雨淋式浇注系统,并利用流体力学理论和截面积比值法确定浇注系统的具体参数,使用ProCAST软件研究不同工艺参数、冒口尺寸对铸件质量的影响,以得到最优的浇注方案。结果在底注雨淋式浇注系统的充型过程中,金属液温度分布均匀、流速平稳,凝固顺序合理,所得铸件缺陷较少,其中疏松缩孔体积为0.63 mm3,且集中分布在阀盖处。优化浇注温度和浇注速度能够有效减少铸造缺陷,优化出的最佳浇注工艺参数组合如下:浇注温度为1180℃,浇注速度为3.5 kg/s。结合该模拟结果改进冒口尺寸后,彻底消除了铸件的铸造缺陷。结论优化工艺参数和浇注系统设计能够有效提高铸件的生产质量,便于铸件的一次成形,对实际生产提供指导。