超声辅助磁性磨料光整加工工艺对钛合金表面完整性的影响

为了研究超声辅助磁性磨料光整加工工艺对钛合金表面完整性的影响,采用对比试验和建立切削力和材料去除模型理论分析相结合的方法,分析加工后的表面形貌、粗糙度、显微硬度、残余应力和亚表面组织,并讨论了加工中超声的作用机理。结果表明:在超声频率为21.91 kHz、振幅10μm,主轴转速1000 r/min,加工间隙1.5 mm,磁性磨料粒径300μm条件下,经过40 min加工后,表面粗糙度Ra降低到0.075μm,与普通磁性磨料光整加工相比降低近60%。超声的引入,增大了切削力和材料去除率,由于加工的尖点效应,使超声辅助磁性磨料光整加工的表面粗糙度快速降低;同时超声振动的碰撞作用使加工后的表面更加均匀光滑,在亚表面可形成一层近20μm的组织细化层,表面显微硬度可达到450.6 HV0.2,与普通磁性磨料光整加工相比提高了15%,表面残余应力由普通磁性磨料光整加工的+68 MPa的拉应力变为–34.1 MPa的压应力,可有效改善工件表面完整性,提高加工表面的综合性能。

切削液与产品内在质量关系的研究

当今世界先进金属加工技术中,功效寿命越来越为人们所关注,与之配套的精确制造工艺得到大力发展。为此东汽承担起国家973项目在切削液应用方面的研究课题《切削加工中切削液对金属构件微组织的作用机理》的研究任务。通过切削加工、静态浸泡等试验,并选择燃机、汽轮机和核电叶片常用的镍基、铬基和钛基材料为研究对象,进行切削液对金属微组织影响的试验研究。通过试验发现在切削加工条件下,不同配方的切削液对金属微组织和机械性能,特别是金属部件的抗疲劳性、表面防腐性能等多方面有较明显的作用和影响,并且发现和证明了粗糙度-检测数值和表面质量之间的颠覆性关系。证明了切削液和金属部件的如工质量存在十分密切的联系。

Surface modification of Cu-25Cr alloy induced by high current pulsed electron beam

A Cu-25Cr alloy prepared by vacuum induction melting method was treated by the high current pulsed electron beam （HCPEB） with pulse numbers ranging from 1 to 100. Surface morphologies and microstructures of the alloy before and after the treatment were investigated by scanning electron microscopy and X-ray diffraction. The results show that significant surface modification can be induced by HCPEB with the pulse number reaching 10. Craters with typical morphologies on the Cu-25Cr alloy surface are formed due to the dynamic thermal field induced by the HCPEB. Micro-cracks, as a unique feature, are well revealed in the irradiated Cu-25Cr specimens and attributed to quasi-static thermal stresses accumulated along the specimen surface. The amount of cracks is found to increase with the pulse number and a preference of these cracks to Cr phases rather than Cu phases is also noted. Another characteristic produced by the HCPEB is the fine Cr spheroids, which are determined to be due to occurrence of liquid phase separation in the Cu-25Cr alloy. In addition, an examination on surface roughness of all specimens reveals that more pulses will produce a roughened surface, as a result of compromising the above features.

Effect of deep surface rolling on microstructure and properties of AZ91 magnesium alloy

A solution-treated AZ91 bulk material was deep-surface-rolled at room temperature to investigate the effect of deep surface rolling on the microstructure and mechanical properties of the alloy. Microhardness and microstructure along the depth of the treated surface layer were characterized. The results show that the affected layer was up to 2.0 mm thick and consisted of three sublayers: a severe deformation layer with thickness of about 400 μm from the topmost surface, a medium deformation layer with thickness of around 600 μm and a small deformation layer up to 1000 μm thick. In addition to grain refinement in the deformation layer, strain-induced precipitation of β phase (Mg17Al12) was observed, particularly in the severe and medium deformation layers. It is believed that the cooperative effects of grain refinement, strain hardening and precipitation strengthening led to the significant increase in hardness of the AZ91 alloy after the deep surface rolling.

Corrosion behavior of Mg−Li alloys:A review

It has been known that the lack of excellent corrosion resistance is the key problem restricting the wide application of Mg−Li alloys.Based on a quantity of literature about corrosion behavior of Mg−Li alloys,this review elaborates the factors affecting the corrosion behavior of Mg−Li alloys and the processing methods for improving corrosion resistance.The corrosion characteristics of Mg−Li alloys are described firstly.Then,it is explained that the grain size,orientation,second phase,and surface film strongly influence corrosion performance,which can be tailored by alloying,plastic deformation,and heat treatment.Further in-depth discussion about the corrosion mechanisms for Mg−Li alloys was also presented.Finally,important points of improving corrosion resistance are suggested.

Fabrication of Al/Al_2Cu in situ nanocomposite via friction stir processing

The aim of present work is fabrication of Al/Al2Cu in situ nanocomposite by friction stir processing(FSP)as well asinvestigation of FPS parameters such as rotational speed,travel speed,number of FSP passes,and pin profile on the microstructure,chemical reaction,and microhardness of Al based nanocomposite.The Al2Cu particles were formed rapidly due to mechanicallyactivated effect of FSP as well as high heat generation due to Al?Cu exothermic reaction.The microstructure of the nanocompositesconsisted of a finer grained aluminium matrix(~15μm),unreacted Cu nanoparticles(~40nm),and reinforcement nanoparticles ofAl2Cu.Irregular morphology of Al2Cu is attributed to the local melting during FSP.Pin diameter has a higher effect on themicrostructure and hardness values.The hardness measurements exhibited enhancement by57%compared with the base metal.

DC casting of light alloys under magnetic fields

The working principle of LFEC（Low frequency electromagnetic casting） process developed in Northeastern University, China was introduced and the metallurgical results of LFEC were discussed according to the casting practices. The low frequency field around the mold produces Lorenz force, which can be divided into two parts： one is the potential force which will be balanced by a pressure gradient of the liquid and results in the formation of a convex surface meniscus and improves the surface quality; the other is the rotary force which stirs the liquid in the mold to refine the microstructures and homogenize the distribution of alloying elements. LFEC can refine microstructures remarkably, improve surface quality of the ingots, depress macrosegregation and eliminate cracks. Some new technologies, such as horizontal direct chill casting under low-frequency electromagnetic field （HLEC）, DC casting of hollow billets under electromagnetic fields （HBEC）, electromagnetic modifying of hypereutectic A1-Si alloys（EMM）, air film casting under static magnetic field （AFCM）, and multi-ingots casting under low-frequency magnetic field （MLFEC） were developed based on LFEC.

Fabrication of AA2024−TiO2 nanocomposites through stir casting process

Given the nonuse of TiO2 nanoparticles as the reinforcement of AA2024 alloy in fabricating composites by ex-situ casting methods,it was decided to process the AA2024−xTiO2(np)(x=0,0.5 and 1 vol.%)nanocomposites by employing the stir casting method.The structural properties of the produced samples were then investigated by optical microscopy and scanning electron microscopy;their mechanical properties were also addressed by hardness and tensile tests.The results showed that adding 1 vol.%TiO2 nanoparticles reduced the grain size and dendrite arm spacing by about 66%and 31%,respectively.Also,hardness,ultimate tensile strength,yield strength,and elongation of AA2024−1vol.%TiO2(np)composite were increased by about 25%,28%,4%and 163%,respectively,as compared to those of the monolithic component.The agglomerations of nanoparticles in the structure of nanocomposites were found to be a factor weakening the strength against the strengthening mechanisms.Some agglomerations of nanoparticles in the matrix were detected on the fractured surfaces of the tension test specimens.

A novel method to improve interfacial bonding of compound squeeze cast Al/Al-Cu macrocomposite bimetals:Simulation and experimental studies

A facile and innovative method to improve bonding between the two parts of compound squeeze cast Al/Al-4.5 wt.%Cu macrocomposite bimetals was developed and its effects on microstructure and mechanical properties of the bimetal were investigated.A special concentric groove pattern was machined on the top surface of the insert(squeeze cast Al-4.5 wt.%Cu) and its effects on heat transfer,solidification and distribution of generated stresses along the interface region of the bimetal components were simulated using ProCAST and ANSYS softwares and experimentally verified. Simulation results indicated complete melting of the tips of the surface grooves and local generation of large stress gradient fields along the interface. These are believed to result in rupture of the insert interfacial aluminum oxide layer facilitating diffusion bonding of the bimetal components. Microstructural evaluations confirmed formation of an evident transition zone along the interface region of the bimetal. Average thickness of the transition zone and tensile strength of the bimetal were significantly increased to about 375 μm and 54 MPa, respectively, by applying the surface pattern.The proposed method is an affordable and promising approach for compound squeeze casting of Al-Al macrocomposite bimetals without resort to any prior cost and time intensive chemical or coating treatments of the solid insert.

Improving tribological behavior of friction stir processed A413/SiC_p surface composite using MoS_2 lubricant particles

The effect of MoS2 lubricant particles on the microstructure, microhardness and tribological behavior of A413/SiCp surface composite, fabricated via friction stir processing （FSP）, was studied. For this purpose, the FSP was carried out with tool rotational speed of 1600 r/min, tool travel speed of 25 mm/min and tool tilt angle of 3° through only a “single pass”. The optical and scanning electron microscopies, microhardness and reciprocating wear tests were used to characterize the samples. The results showed that the addition of MoS2 lubricant particles to A413/SiCp surface composite leads to the decrease of friction coefficient and mass loss. In fact, the generation of mechanically mixed layer （MML） containing MoS2 lubricant particles in A413/SiCp/MoS2p surface hybrid composite results in the reduction of metal-to-metal contact and subsequently leads to the improvement of tribological behavior.

Evolution of surface microstructure of Cu-50Cr alloy treated by high current pulsed electron beam

A Cu-50Cr alloy was treated by the high current pulsed electron beam(HCPEB)at 20 and 30 ke V with pulse numbers ranging from 1 to 100.Surface morphologies and microstructures of specimens before and after the treatments were investigated by employing scanning electron microscopy and X-ray diffraction.Results show that the HCPEB technique is able to induce remarkable surface modifications for the Cu-50Cr alloy.Cracks in Cr phases appear even after one-pulse treatment and their density always increases with the pulse number.Formation reason for these cracks is attributed to quasi-static thermal stresses accumulated along the specimen surface.Craters with typical morphologies are formed due to the dynamic thermal field induced by the HCPEB and they are found to prefer the sites near cracks or boundaries between neighboring Cr phases.Another microstructural characteristic produced by the HCPEB is the fine Cr spheroids,which are determined to be due to occurrence of liquid phase separation in the Cu-50Cr alloy.Finally,a general microstructural evolution profile that incorporates various HCPEB-induced surface features is tentatively outlined.

Impact of the CoFe microstructure etched surface oxidation on Co spin and orbital moment

Patterned ferromagnetic thin film shows promising applications in ultra-high density magnetic storage,magnetoresistive transducer,magnetic random access memory and many other devices.Since the performance of these devices is closely associated with the magnetic properties of the etched patterns,it is necessary to study the effects of freshly etched surface oxidation on the magnetic properties of the patterned microstructures.In the current work,were carried out an X-ray Magnetic Circular Dichroism(XMCD) study on a 50 nm Co 0.9 Fe 0.1 continuous thin film and a related patterned Co 0.9 Fe 0.1 grating structure etched with a 2 μm period.Based on the sum rules,the spin and orbital moments were calculated for these two samples,respectively.The results indicated that the spin and orbital moments of grating structure(1.34μ B and 0.24μ B,respectively) decreased 17.3% compared with the corresponding continuous film(1.62μ B and 0.29μ B,respectively).We proposed that the moment decreasing of the patterned grating structure was mainly caused by the etched surface oxidation during the pattern manufacture process.The oxidation ratio of Co element in the patterned grating structure is 14.4% calculated from X-ray absorption spectroscopy(XAS) measurement.Considering the oxidation ratio,we amend the spin and orbital moment of Co and the amended result is basically in accordance with that of continuous film,demonstrating that the difference of the spin and orbital moments between the sub-micron grating unit and the continuous film is really caused by the oxidation.