Flow characteristics and hot workability of a typical low-alloy high-strength steel during multi-pass deformation

Heavy components of low-alloy high-strength(LAHS) steels are generally formed by multi-pass forging. It is necessary to explore the flow characteristics and hot workability of LAHS steels during the multi-pass forging process, which is beneficial to the formulation of actual processing parameters. In the study, the multi-pass hot compression experiments of a typical LAHS steel are carried out at a wide range of deformation temperatures and strain rates. It is found that the work hardening rate of the experimental material depends on deformation parameters and deformation passes, which is ascribed to the impacts of static and dynamic softening behaviors. A new model is established to describe the flow characteristics at various deformation passes. Compared to the classical Arrhenius model and modified Zerilli and Armstrong model, the newly proposed model shows higher prediction accuracy with a confidence level of 0.98565. Furthermore, the connection between power dissipation efficiency(PDE) and deformation parameters is revealed by analyzing the microstructures. The PDE cannot be utilized to reflect the efficiency of energy dissipation for microstructure evolution during the entire deformation process, but only to assess the efficiency of energy dissipation for microstructure evolution in a specific deformation parameter state.As a result, an integrated processing map is proposed to better study the hot workability of the LAHS steel, which considers the effects of instability factor(IF), PDE, and distribution and size of grains. The optimized processing parameters for the multi-pass deformation process are the deformation parameters of 1223–1318 K and 0.01–0.08 s^(-1). Complete dynamic recrystallization occurs within the optimized processing parameters with an average grain size of 18.36–42.3 μm. This study will guide the optimization of the forging process of heavy components.

A highly sensitive LITES sensor based on a multi-pass cell with dense spot pattern and a novel quartz tuning fork with low frequency

A highly sensitive light-induced thermoelectric spectroscopy(LITES)sensor based on a multi-pass cell(MPC)with dense spot pattern and a novel quartz tuning fork(QTF)with low resonance frequency is reported in this manuscript.An erbi-um-doped fiber amplifier(EDFA)was employed to amplify the output optical power so that the signal level was further enhanced.The optical path length(OPL)and the ratio of optical path length to volume(RLV)of the MPC is 37.7 m and 13.8 cm^(-2),respectively.A commercial QTF and a self-designed trapezoidal-tip QTF with low frequency of 9461.83 Hz were used as the detectors of the sensor,respectively.The target gas selected to test the performance of the system was acetylene(C2H2).When the optical power was constant at 1000 mW,the minimum detection limit(MDL)of the C2H2-LITES sensor can be achieved 48.3 ppb when using the commercial QTF and 24.6 ppb when using the trapezoid-al-tip QTF.An improvement of the detection performance by a factor of 1.96 was achieved after replacing the commer-cial QTF with the trapezoidal-tip QTF.

Technique for Multi-Pass Turning Optimization Based on Gaussian Quantum-Behaved Bat Algorithm

The multi-pass turning operation is one of the most commonly used machining methods in manufacturing field.The main objective of this operation is to minimize the unit production cost.This paper proposes a Gaussian quantum-behaved bat algorithm(GQBA)to solve the problem of multi-pass turning operation.The proposed algorithm mainly includes the following two improvements.The first improvement is to incorporate the current optimal positions of quantum bats and the global best position into the stochastic attractor to facilitate population diversification.The second improvement is to use a Gaussian distribution instead of the uniform distribution to update the positions of the quantum-behaved bats,thus performing a more accurate search and avoiding premature convergence.The performance of the presented GQBA is demonstrated through numerical benchmark functions and amulti-pass turning operation problem.Thirteen classical benchmark functions are utilized in the comparison experiments,and the experimental results for accuracy and convergence speed demonstrate that,in most cases,the GQBA can provide a better search capability than other algorithms.Furthermore,GQBA is applied to an optimization problem formulti-pass turning,which is designed tominimize the production cost while considering many practical machining constraints in the machining process.The experimental results indicate that the GQBA outperforms other comparison algorithms in terms of cost reduction,which proves the effectiveness of the GQBA.

Milli-Joule pulses post-compressed from 14 ps to 475 fs in bulk-material multi-pass cell based on cylindrical vector beam

A cylindrical vector beam is utilized to enhance the energy scale of the pulse post-compressed in a bulk-material Herriott multi-pass cell(MPC).The method proposed here enables,for the first time to the best of our knowledge,pulse compression from 14 ps down to 475 fs with throughput energy beyond 1 mJ,corresponding to a compression ratio of 30,which is the highest pulse energy and compression ratio in single-stage bulk-material MPCs.Furthermore,we demonstrate the characteristic of the vector polarization beam is preserved in the MPC.

Microstructure Distribution Characteristics of High-Strength Aluminum Alloy Thin-Walled Tubes during Multi-Passes Hot Power Backward Spinning Process

The microstructure of the thin-walled tubes with high-strength aluminum alloy determines their final forming quality and performance. This type of tube can be manufactured by multi-pass hot power backward spinning process as it can eliminate casting defects, refine microstructure and improve the plasticity of the tube. To analyze the microstructure distribution characteristics of the tube during the spinning process, a 3D coupled thermo-mechanical FE model coupled with the microstructure evolution model of the process was established under the ABAQUS environment. The microstructure evolution characteristics and laws of the tube for the whole spinning process were analyzed. The results show that the dynamic recrystallization is mainly produced in the spinning deformation zone and root area of the tube. In the first pass, the dynamic recrystallization phenomenon is not obvious in the tube. With the pass increasing, the trend of dynamic recrystallization volume percentage gradually increases and extends from the outer surface of the tube to the inner surface. The fine-grained area shows the states of concentration, dispersion, and re-concentration as the pass number increases. .

Influence of laser intensity in second-harmonic detection with tunable diode laser multi-pass absorption spectroscopy

Tunable diode laser absorption spectroscopy （TDLAS） has been widely employed in atmospheric trace gases detection. The ratio of the second-harmonic signal to the intensity of laser beam incident to the multi-pass cell is proved to be proportional to the product of the path length and the gas concentration under any condition. A new calibration method based on this relation in TDLAS system for the measurement of trace gas concentration is proposed for the first time. The detection limit and the sensitivity of the system are below 110 and 31ppbv （parts-per-billion in volume）, respectively.

Numerical simulation of 80 ℃ temperature field distribution of thick plate multi-pass welding with SYSWELD

The PPG PITT-CHAR XP flame retardant system has been used by COOEC to preventing the thermal softening of steel in the high temperature,whose degradation temperature is 80 ℃.To prevent damage to PPG PITT-CHAR XP fire retardant paint from excessive heat during welding,it is necessary to get accurately reserved area near the welding joints prior to welding. For the foregoing reasons,the 80 ℃ temperature field distribution of thick plate multi-pass welding was analyzed with SYSWELD.The influence of welding groove form and time interval on welding temperature field was also analyzed. Results showed that the range of 80 ℃ welding temperature field increased with the increasing of weld layers at first and then it inclined to stable value. Interpass time setting was crucial to control the range of 80 ℃ welding temperature field. It was also found that double V groove had better thermal diffusivity than double-bevel groove.And double-bevel groove was better than single V groove.

Plastic Mechanism of Multi-pass Double-roller Clamping Spinning for Arc-shaped Surface Flange

Compared with the conventional single-roller spinning process, the double-roller clamping spinning（DRCS） process can effectively prevent the sheet metal surface wrinkling and improve the the production efficiency and the shape precision of final spun part. Based on ABAQUS/Explicit nonlinear finite element software, the finite element model of the multi-pass DRCS for the sheet metal is established, and the material model, the contact definition, the mesh generation, the loading trajectory and other key technical problems are solved. The simulations on the multi-pass DRCS of the ordinary Q235A steel cylindrical part with the arc-shaped surface flange are carried out. The effects of number of spinning passes on the production efficiency, the spinning moment, the shape error of the workpiece, and the wall thickness distribution of the final part are obtained. It is indicated definitely that with the increase of the number of spinning passes the geometrical precision of the spun part increases while the production efficiency reduces. Moreover, the variations of the spinning forces and the distributions of the stresses, strains, wall thickness during the multi-pass DRCS process are revealed. It is indicated that during the DRCS process the radical force is the largest, and the whole deformation area shows the tangential tensile strain and the radial compressive strain, while the thickness strain changes along the generatrix directions from the compressive strain on the outer edge of the flange to the tensile strain on the inner edge of the flange. Based on the G-CNC6135 NC lathe, the three-axis linkage computer-controlled experimental device for DRCS which is driven by the AC servo motor is developed. And then using the experimental device, the Q235A cylindrical parts with the arc-shape surface flange are formed by the DRCS. The simulation results of spun parts have good consistency with the experimental results, which verifies the feasibility of DRCS process and the reliability of the finite element model for DRCS.

ESTABLISHMENT OF 3D FEM MODEL OF MULTI-PASS SPINNING

In order to improve the computational accuracy and efficiency,it is necessary to establish a reasonable 3D FEM model for multi-pass spinning including not only spinning process but also springback and annealing processes.A numerical model for multi-pass spinning is established using the combination of explicit and implicit FEM,with the advantages of them in accuracy and efficiency. The procedures for model establishment are introduced in detail,and the model is validated.The application of the 3D FEM model to a two-pass spinning shows the following：The field variables such as the stress,strain and wall thickness during the whole spinning process can be obtained,not only during spinning process but also during springback and annealing processes,and the trends of their distributions and variations are in good agreement with a practical multi-spinning process.Thus the 3D FEM model for multi-pass spinning may be a helpful tool for determination and optimization of process parameters of multi-pass spinning process.

H2 Stimulated Raman Scattering in a Multi-pass Cell with a Herriott Configuration

Stimulated raman scattering （SRS） is an effective method for expanding the spectral range of high power lasers, especially in the regime of near IR and middle IR. We report the SRS of high pressure H2 with a multiple-pass cell configuration. The SRS with the multiple-pass cell configuration is found to be very efficient for reduction of threshold of the first Stokes （S1）. Due to the coherent SRS （CSRS） process, the multiple-pass cell configuration is more effective for reduction of the threshold for the second Stokes （S2） SRS and for increasing the conversion efficiency of S2. This contributes to the relatively low conversion efficiency of S1 for the multiple-pass cell configuration. Multiple-pass cell SRS is also found to be very effective for improving the beam quality and the stability of S1.

Transient out-of-plane distortion of multi-pass fillet welded tube to pipe T-joints

The out-of-plane distortion induced in a multi-pass circumferential fillet welding of tube to pipe under different weld sequences and directions was studied using Finite Element Method(FEM) based Sysweld software and verified experimentally. The FEM analyses consisted of thermal and mechanical analyses.Thermal analysis was validated with experimental transient temperature measurements. In the mechanical analysis, three different weld sequences and directions were considered to understand the mechanism of out-of-plane distortion in the tube to pipe T-joints. It was learnt that the welding direction plays a major role in minimizing the out-of-plane distortion. Further, during circumferential fillet welding of the tube to pipe component, the out-of-plane distortion generated in the x direction was primarily influenced by heat input due to the start and stop points, whereas the distortion in the z direction was influenced by time lag and welding direction. The FEM predicted distortion was compared with experimental measurements and the mechanism of out-of-plane distortion was confirmed.

Machining Parameters Optimization of Multi-Pass Face Milling Using a Chaotic Imperialist Competitive Algorithm with an Efficient Constraint-Handling Mechanism

The selection of machining parameters directly affects the production time,quality,cost,and other process performance measures for multi-pass milling.Optimization of machining parameters is of great significance.However,it is a nonlinear constrained optimization problem,which is very difficult to obtain satisfactory solutions by traditional optimization methods.A new optimization technique combined chaotic operator and imperialist competitive algorithm(ICA)is proposed to solve this problem.The ICA simulates the competition between the empires.It is a population-based meta-heuristic algorithm for unconstrained optimization problems.Imperialist development operator based on chaotic sequence is introduced to improve the local search of ICA,while constraints handling mechanism is introduced and an imperialist-colony transformation policy is established.The improved ICA is called chaotic imperialist competitive algorithm(CICA).A case study of optimizing machining parameters for multi-pass face milling operations is presented to verify the effectiveness of the proposed method.The case is to optimize parameters such as speed,feed,and depth of cut in each pass have yielded a minimum total product ion cost.The depth of cut of optimal strategy obtained by CICA are 4 mm,3 mm,1 mm for rough cutting pass 1,rough cutting pass 1 and finish cutting pass,respectively.The cost for each pass are$0.5366 US,$0.4473 US and$0.3738 US.The optimal solution of CICA for various strategies with at=8 mm is$1.3576 US.The results obtained with the proposed schemes are better than those of previous work.This shows the superior performance of CICA in solving such problems.Finally,optimization of cutting strategy when the width of workpiece no smaller than the diameter of cutter is discussed.Conclusion can be drawn that larger tool diameter and row spacing should be chosen to increase cutting efficiency.

INFLUENCES OF EDGING ROLL SHAPE ON THE PLASTIC STRAIN DISTRIBUTION OF SLAB DURING MULTI-PASS V-H ROLLING PROCESS

Multi-pass slab vertical-horizontal （V-H） rolling process with variable edging roll shape have been simulated with explicit dynamic finite element method and updating geometric method. The distributions of plastic strain contour in slab daring rolling process with different edging roll and under different rolling stage have been obtained. The results show that there exist two thin strain assembling zones in slab when the flat edging roll is used, and there just exist one strain assembling zone in slab when the edging roll with groove is used. And compared the deformation equality between flat edging roll and edging roll with groove, the lateris better than the former, which supplies the theory prove to the slab deformation distribution during V-H rolling process and is helpful for predicting the slab texture.

Effect of Multi-pass Compression on the Microstructure of 7 085 Aluminum Alloy

The isothermal compression tests of 7085 aluminum alloy were carried out on Gleeble-3800 thermal simulator by two-pass(30%per-pass)and three-pass(20%per-pass)at 300-400℃and the strain rate of 0.01 s^(-1).The effect of compression strategy on microstructure evolution of 7085 aluminum alloy was analyzed by optical microscopy(OM)and electron backscattering diffraction(EBSD).The results show the softening mechanism of 7085 aluminum alloy is mainly recovery,the recrystallization degree is sluggish when the samples deform at 300℃.The fraction of recrystallized grains just reaches 23.2%at a higher deformation temperature of 400℃,while a large amount of sub-grains with equiaxed morphology are formed inside the deformed grains.Different deformation paths have a significant effect on the microstructure evolution of the 7085 aluminum alloys,and more uniform and fine microstructures are obtained at the three-pass deformation.In addition,a short holding time of 5 s is not enough to trigger the static recrystallization.When the holding time reaches 120 s,the dislocations rearrange and a large number of recrystallized grains and regular sub-grains appear inside the original grain.In a word,more uniform and fine microstructures are obtained at three-pass deformation at 400℃and 120 s of 7085 aluminum alloy.

Continuous FEM simulation of multi-pass plate hot rolling suitable for plate shape analysis

In order to continuously simulate multi-pass plate rolling process,a 3-D elastic hollow-roll model was proposed and an auto mesh-refining module with data passing was developed and integrated with FE software,Marc.The hollow-roll model has equivalent stiffness of bending resistance and deformation to the real solid and much less meshes,so the computational time is greatly reduced.Based on these,the factors influencing plate profile,such as the roll-bending force,initial crown,thermal crown and heat transfer during rolling and inter-pass cooling can be taken into account in the simulation.The auto mesh-refining module with data passing can automatically refine and re-number elements and transfer the nodal and elemental results to the new meshes.Furthermore,the 3-D modeling routine is parametrically developed and can be run independently of Marc pre-processing program.A seven-pass industrial hot rolling process was continuously simulated to validate the accuracy of model.By comparison of the calculated results with the industrial measured data,the rolling force,temperature and plate profile are in good accordance with the measured ones.

Thermal Fission Rate Calculated Numerically by Particles Multi-passing over SaddlePoint

Langevin simulation of the particles multi-passing over the saddle point is proposed to calculate thermal fission rate.Due to finite friction and the corresponding thermal flutuation,a backstreaming exists in the process of the particle descent from the saddle to the scissio.This leads to that the diffusion behind the saddle point has influence upon the stationary flow across the saddle point.A dynamical correction factor,as a ratio of the flows of multi-and firstoverpassing the saddle point,is evaluated analytically.The results show that the fission rate calculated by the particles multi-passing over the saddle point is lower than the one calculated by the particle firstly passing over the saddle point,and the fomer approaches the results at the scission point.

Uniformity and continuity of effective strain in AZ91D processed by multi-pass equal channel angular extrusion

AZ91D magnesium alloy was processed by equal channel angular extrusion(ECAE).The influence of extrusion temperature,extrusion pass and extrusion route on the ultimate strength of the extruded billet was analyzed.The process of multi-pass extrusion was simulated with the method of finite element analysis,and the continuity and uniformity of effective strain in multi-pass extrusion were investigated.The results show that extrusion pass plays the most important role in improving the ultimate strength of AZ91D magnesium alloy,the extrusion route is the second,and the extrusion temperature is the last.From the numerical simulation,there exists the continuity of the accumulated deformation in multi-pass extrusion and the effective strain increases linearly.The tendency of the strain uniformity is different in multi-pass extrusion with extrusion routes.The results of experiment agree with those of numerical simulation.

Influence of welding consumables on tensile and impact properties of multi-pass SMAW Armox 500T steel joints vis-a-vis base metal

In this investigation, comparative study of tensile and impact properties of multi-pass SMAW Armox500 T steel joints fabricated by austenitic stainless steel(ASS) and low hydrogen ferritic steel(LHF)consumables vis-a-vis base metal was carried out. The tensile tests were conducted on computer controlled Walter t Bai Ag UTM at a nominal strain rate of 10à3 sà1. Subsequently, charpy impact tests were carried out on an instrumented Zwick-Roell test setup to obtain load vs. displacement and maximum energy absorbed vs. displacement of the specimen. It was observed that, the joint efficiency of weldment processed by LHF consumable was 41.7% and weldment processed by ASS was 30.6% of its base metal indicating the influence of electrode consumable on tensile properties of the joints. On the contrary, impact toughness of weldment processed by ASS was 20% more and weldment processed by LHF was 12% less than that of base metal. Microstructural studies also revealed that, ASS can be considered as a candidate welding consumable for good strain hardening and toughness of the welding joint in impact applications. However, LHF steel consumable is recommended for welding joints that requires higher joint efficiency under tensile loading conditions.

Insight into deformation allocation in the multi-pass roll forming of a double-walled brazed tube

Deformation allocation is an important factor that affects 720°curling forming from copper-coated steel strips to double-walled brazed tubes(DWBTs).In this study,four schemes of deformation allocation,considering different weights of the total feed distance,are proposed,and a 3D finite element(FE)model of the multi-pass roll forming process for DWBT is developed and verified to investigate the cross-sectional evolution and deformation features.The results show the following.(i)In the 720°curling forming process from the steel strip into double-walled tubes,the curvature of the formed circular arc initially increases and then remains stable with roll forming,and the inner and outer tubes of the DWBT are formed in the third and fifth forming passes.Size forming can eliminate the gap between the double walls and improve the overall roundness.(ii)For different deformation allocations,the cross-sectional profiles of the roll-formed parts exhibit a discrepancy,and the deformation amount varies with the roll-forming process.The deformation amount in Scheme three is the maximum,and the cross-sectional profile deviates significantly from the ideal shape and fails to form a DWBT,which indicates that the deformation allocation is unsuitable.(iii)The roundness of the outer tube is better than that of the inner tube.Therefore,the roundness of the inner tube is the key to restricting the forming accuracy of the DWBT.Compared with Schemes one and two,Scheme four with a linear allocation of the total feed distance exhibits the best roundness,and the deformation allocation is reasonable;i.e.,when the contact points between the rollers and steel strip are in a straight line,the roundness of the DWBT is in good agreement with the ideal condition.

Thickness-Dependent Microstructure and its Effect on Anisotropic Mechanical Properties of Duplex Stainless Steel 2205 Multi-pass Welded Joints

In this study,the thickness-dependent microstructural characteristics of duplex stainless steel 2205 multi-pass welded joints were first investigated by the combination of optical microscope and electron back-scattered diffraction observation.Subsequently,a series of tensile tests of miniature samples cut from different passes and directions were performed to analyze the thickness-dependent and anisotropic mechanical properties.The results demonstrate that the microstructure changed with the welded passes,i.e.,a large number of grain boundary austenite,Widmanstätten austenite and a small number of tiny intragranular austenite existed at the surface passes,while a mass of intragranular austenite were found at the middle passes.Meanwhile,the Kurdjumov–Sachs orientation relationship was widespread at the welded zone.In addition,the yield and tensile strengths of the middle passes were greater than that of the surface passes due to the grain-boundary strengthening by tiny intragranular austenite.Furthermore,due to the existence of Kurdjumov–Sachs orientation relationship,the longitudinal yield and tensile strength were greater than transverse values,particularly for the middle passes.