金电铸工艺与中空金饰品

金电铸工艺与中空金饰品金电铸工艺（ＥｌｅｃｔｒｏＦｏｒｍｉｎｇ）是当今世界首饰制作的最新Ｌ艺技术，分为石腊模型工艺和金属模型工艺，以采用石腊模型的熔模铸造法之模型成型方式最为标准。加工分为１０个工艺过程，简单来说，就是在模型表面进行厚度为０．ｌ～０·...

电感耦合等离子体发射光谱法测定电铸硬金饰品中铊

3D硬金饰品制备过程中可能引入Tl元素,分析3D硬金饰品中Tl元素含量具有重要意义。实验采用电感耦合等离子体发射光谱法直接测定王水溶解后的3D硬金饰品金液,无需其他前处理操作。方法对3D硬金饰品中Tl元素的检出限为2.13 mg/kg,定量限为7.08 mg/kg。采用本方法测定市场上30批3D硬金饰品中的Tl,发现绝大多数样品未检出Tl元素,只有1批样品有Tl元素检出,且Tl元素含量较低。本方法的建立可为GB/T 28021—2011《饰品有害元素的测定光谱法》中有害元素Tl检测方法的建立提供参考。

电铸硬金的性质研究

为对电铸硬金产品的有关性质有更全面的认识,采集了3家公司的3件样品,采用ICP-MS、ICP-AES、显微硬度计、金相显微镜、扫描电子显微镜等对样品进行了测试与分析。结果显示:各样品的含金量均大于99.9%,其主要的微量元素为Ag,Cu。3件样品的维氏硬度分别为68.74,71.16,74.97,达不到145。在结构方面,各样品的晶粒尺寸非常细小,以致在扫描电子显微镜下无法分辨,这是其硬度较高的结构基础。表面微形貌起伏不平,有较多孔洞,结构较疏松。内部含有尺寸0.2～3.5μm的夹杂物,样品1的夹杂物主要是CaO和Na2O,样品2和样品3的夹杂物主要是SiO2和Na2O,这与电铸时样品所处的溶液介质有关。样品1热处理前的维氏硬度为68.74,处理后减小为25.94,这与热处理后发生了晶粒的"长大"有关。

银电铸金饰品的成分和硬度测定

采用硝酸溶解分银-重量法测定了银电铸金饰品中的金量,差减法得到银量;测定了饰品的维氏硬度。批量样品测定的统计表明,大部分送检饰品中金、银的含量和纯度符合饰品质量要求,电镀条件控制不当可能是少量饰品金含量或纯度不足的原因。在硬度检测中,采用景深法,引入不规则曲面偏差的修正系数,批量结果表明,银电铸金饰品的表面维氏硬度为100~145HV0.1。

足金首饰的硬化机制与维氏硬度试验

在保持黄金较高纯度的同时提高足金首饰的硬度以满足市场消费者和加工两方面需求,一直都是黄金首饰行业内一个重要的研究内容。本文综述并借鉴了传统金属材料的强化机制,从组织、位错的角度,分析了目前足金硬化工艺所蕴含的硬化机制。同时为更好地对硬度性能进行表征,选用维氏硬度试验进行测量,并针对电铸硬金试样测试难度大的问题进行了探索。另外,还统计了目前市场中硬金产品的硬度值,并就工艺对其硬度产生的影响进行了研究。

Heat transfer behavior of AZ80-1%Y alloy during low-frequency electromagnetic casting

Heat transfer behaviors of AZ80?1%Y alloy during low frequency electromagnetic casting (LFEC) and direct chilling casting were studied by in-situ temperature measurement. The results demonstrated that the low frequency electromagnetic field (EM) caused forced convection in the melt during LFEC. The forced convection led to uniform solidification velocity and temperature field. EM frequency, excitation current intensity and casting temperature could control the heat transfer behavior. The forced convection could improve the microstructure and degrade the difference in microstructure between the edge and center of billet. Appropriate parameters of low frequency EM for casting Mg alloy are 20 Hz of frequency and 60 A of electric current intensity.

Effect of minor Sc and Zr addition on microstructure and properties of ultra-high strength aluminum alloy

The Al-9Zn-2.8Mg-2.5Cu-xZr-ySc alloys （x=0, 0.15%, 0.15%; y=0, 0.05%, 0.15%）, produced by low-frequent electromagnetic casting technology, were subjected to homogenization treatment, hot extrusion, solution and aging treatment. The effects of minor Sc and Zr addition on microstructure, recrystallization and properties of alloys were studied by optical microscopy （OM）, scanning electron microscopy （SEM） and transmission electron microscopy （TEM）. The results show that Sc and Zr addition can refine grains of the as-cast alloy by precipitation of primary Al3（Sc,Zr） particles formed during solidification as heterogeneous nuclei. Secondary Al3（Sc,Zr） precipitates formed during homogenization treatment strongly pin the movement of dislocation and subgrain boundaries, which can effectively inhibit the alloys recrystallization. Compared with the alloy without Sc and Zr addition, the Al-Zn-Mg-Cu-Zr alloy with 0.05%Sc and 0.15%Zr shows the increase in tensile strength and yield strength by 172 MPa and 218 MPa, respectively. Strengthening comes from the contributions of precipitation, substructure and grain refining.

Production of super-high strength aluminum alloy billets by low frequency electromagnetic casting

The effects of low frequency electromagnetic field on the macro-physical fields in the semi-continuous casting process of aluminum alloys and the microstructure and crack in the billets were studied and analyzed by the numerical and experimental methods.Comparison of the results for the macro-physical fields in the low frequency electromagnetic casting（LFEC） process with the conventional DC casting process indicates the following characters due to the application of electromagnetic field：an entirely changed direction and remarkably increased velocity of melt flow;a uniform distribution and a decreased gradient of temperature;elevated isothermal lines;a reduced sump depth;decreased stress and plastic deformation.Further,the microstructure of the billets is refined remarkably and the crack in the billets is eliminated in LFEC process because of modification of the macro-physical fields induced by the application of low frequency electromagnetic field.

Microstructure evolution of 3003/4004 clad ingots under diverse physical fields

In order to improve the quality of clad ingots, diverse physical fields including electromagnetic stirring, power ultrasonic and compound field of ultrasonic and electromagnetic stirring were attempted to prepare clad ingots of 3003/4004 alloys. The solidification structures near the interface in clad ingots were investigated. The experiment results indicate that the solidification structure of 4004 alloy changes from dendritic crystals to petal-like grains when the clad ingot is treated by electromagnetic stirring. With the effect of power ultrasonic, the solidified microstructure of 4004 alloy exhibits the refinement of both primary a（A1） and eutectic silicon. Under the compound field, the primary a（A1） is refined, the morphology of eutectic silicon has a transition from a coarse plate-like form without treatment or thin acicular-like form with power ultrasonic to fine coral-like form.

Fracture characteristics of notched investment cast TiAl alloy through in situ SEM observation

TiAl alloys were produced by investment casting method combined with induction skull melting （ISM） technique. In situ scanning electron microscopy （SEM） was utilized to study the fracture characteristics and crack propagation of a notched investment cast TiAl specimens in tension under incremental loading conditions. The whole process of crack initiation, propagation and failure during tensile deformation was observed and characterized. The results show that the fracture mechanism was sensitive to not only the microcracks near the notched area but also lamellar orientation to loading axis. The high tensile stress leads to the new microcracks nucleate along lamellar interfaces of grains with favorable orientation when local stress intensity reaches the toughness threshold of the material. Thus, both plasticity and high tensile stress are required to cause notched TiAl failure.

An Alternative Method for SU-8 Removal Using PDMS Technique

An alternative method for SU-8 removal is proposed.Instead of directly using SU-8 microstructure as the electroplating mold,a polydimethysiloxane (PDMS) replica is employed.The metallic micromold insert obtained through this method can be easily peeled off from the PDMS replica,meanwhile with high resolution and smooth surfaces.

Horizontal continuous casting process under electromagnetic field for preparing AA3003/AA4045 clad composite hollow billets

A modified horizontal continuous casting process under the electromagnetic field was proposed for preparing AA3003/ AA4045 clad composite hollow billets. To investigate the effect of electromagnetic field on this process, a comprehensive three-dimensional model was developed. Two cases with and without electromagnetic field were compared using the simulations. When rotating electromagnetic stirring is applied, the flow pattern of fluid melt is greatly modified; the mushy zone becomes much wider, the temperature profile becomes more uniform, and the solid fraction decreases for both the external and internal alloy melt layers. These modifications are beneficial for the formation of a bimetal interface and fine and uniform grain structure of the clad composite hollow billet. Experiments conducted using the same electrical and casting parameters as the simulations verify that under the electromagnetic field the microstructure of the clad composite hollow billet becomes fine and the diffusion of the elements at the interface is promoted.

Optimization of mechanical properties using D-optimal factorial design of experiment: Electromagnetic stir casting process of A357-SiC nanocomposite

Electromagnetic stir casting process of A357-Si C nanocomposite was discussed using the D-optimal design of experiment(DODOE) method. As the main objective, nine random experiments obtained by DX-7 software were performed. By this method, A357-Si C nanocomposites with 0.5, 1.0 and 1.5 wt.% Si C were fabricated at three different frequencies(10, 35 and 60 Hz) in the experimental stage. The microstructural evolution was characterized by scanning electron and optical microscopes, and the mechanical properties were investigated using hardness and roomtemperature uniaxial tensile tests. The results showed that the homogeneous distribution of Si C nanoparticles leads to the microstructure evolution from dendritic to non-dendritic form and a reduction of size by 73.9%. Additionally, based on DODOE, F-values of 44.80 and 179.64 were achieved for yield stress(YS) and ultimate tensile strength(UTS), respectively, implying that the model is significant and the variables(Si C fraction and stirring frequency) were appropriately selected. The optimum values of the Si C fraction and stirring frequency were found to be 1.5 wt.% and 60 Hz, respectively. In this case, YS and UTS for A357-Si C nanocomposites were obtained to be 120 and 188 MPa(57.7% and 57.9 % increase compared with those of the as-cast sample), respectively.

Purification technology of molten aluminum

Various purification methods were explored to eliminate the dissolved hydrogen and nonmetallic inclusions from molten aluminum alloys. A novel rotating impeller head with self-oscillation nozzles or an electromagnetic valve in the gas circuit was used to produce pulse gas currents for the rotary impeller degassing method. Water simulation results show that the size of gas bubbles can be decreased by 10%20% as compared with the constant gas current mode. By coating ceramic filters or particles with active flux or enamels, composite filters were used to filter the scrap A356 alloy and pure aluminum. Experimental results demonstrate that better filtration efficiency and operation performance can be obtained. Based on numerical calculations, the separation efficiency of inclusions by high frequency magnetic field can be significantly improved by using a hollow cylinder-like separator or utilizing the effects of secondary flow of the melt in a square separator. A multi-stage and multi-media purification platform based on these methods was designed and applied in on-line processing of molten aluminum alloys. Mechanical properties of the processed scrap A356 alloy are greatly improved by the composite purification.

Corrosion performance of high pressure die-cast Al-6Si-3Ni and Al-6Si-3Ni-2Cu alloys in aqueous NaCl solution

The corrosion performance of high pressure die-cast Al？6Si？3Ni （SN63） and Al-6Si-3Ni-2Cu （SNC632） alloys in 3.5%（mass fraction） NaCl solution was investigated. X-ray diffraction （XRD） and microstructural studies revealed the presence of singlephase Si and binary Al3Ni/Al3Ni2 phases along the grain boundary. Besides, the single Cu phase was also identified at the grainboundaries of the SNC632 alloy. Electrochemical corrosion results revealed that, the SNC632 alloy exhibited nobler shift incorrosion potential （φcorr）, lower corrosion current density （Jcorr） and higher corrosion resistance compared to the SN63 alloy.Equivalent circuit curve fitting analysis of electrochemical impedance spectroscopy （EIS） results revealed the existence of twointerfaces between the electrolyte and substrate. The surface layer and charge transfer resistance （Rct） of the SNC632 alloy was higherthan that of the SN63 alloy. Immersion corrosion test results also confirmed the lower corrosion rate of the SNC632 alloy andsubstantiated the electrochemical corrosion results. Cu addition improved the corrosion resistance, which was mainly attributed to theabsence of secondary Cu containing intermetallic phases in the SNC632 alloy and Cu presented as single phase.

Electrical conductivity of Cu-Li alloys

The electrical conductivity of Cu-Li alloys was studied. And the distribution of electrons near Fermi surface was detected by synchrotron radiation instrument. The results show that the electrical conductivity of Cu-Li alloys decreases from 5.22 X 10(-9) S/m to 3.69 X 10(-9) S/m with the increase of Li content. Li can decrease the oxygen, sulfur and other impurities content in commercial Cu, but Li dissolved in Cu lattice leads to distortion of Cu lattice from 0.005%-0.050%, affects the valence band of Cu, increases the binding energy of surface electron, and decreases the electron density of Fermi surface simultaneously. So the electrical conductivity decreases gradually with the increase of Li content.

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.

Effect of T6I6 treatment on dynamic mechanical behaviour of Al-Si-Mg-Cu cast alloy and impact resistance of its cast motor shell

The effect of T6I6 treatment on the dynamic mechanical and microstructure behaviour of Al-Si-Mg-Cu cast alloy was investigated using split Hopkinson pressure bar(SHPB), transmission electron microscopy(TEM), and highresolution transmission electron microscopy(HRTEM). Besides, the impact resistances of T6I6 and T6 motor shells of new energy vehicles made of Al-Si-Mg-Cu cast alloy were compared using a trolley crash test. The results indicated that the main strengthening-phases of the T6 peak-aged and T6I6 peak-aged alloy were GP zone and β″ precipitates. T6I6treatment can increase the density and size of β″ precipitates in peak-aged alloy and enhance both its tensile strength(σb)and elongation(δ). The dynamic toughness values of T6I6 samples are 50.34 MJ/m^(3) at 2000 s^(-1) and 177.34 MJ/m^(3) at 5000 s^(-1) which are 20% and 12% higher than those of T6 samples, respectively. Compared with a T6 shell, the overall deformation of T6I6 shell is more uniform during the crash test. At an impact momentum of 3.5×10;kg·m/s, the T6I6shell breaks down at 0.38 s which is 0.10 s later than the T6 shell.

Numerical simulation of temperature distribution and heat transfer during solidification of titanium alloy ingots in vacuum arc remelting process

In order to get a better understanding of the vacuum consumable arc remelting(VAR) processes and thus to optimize them,a 3D finite element model was developed for the temperature fields and heat transfer of titanium alloy ingots during VAR process.The results show that the temperature fields obtained by the simulation are well validated through the experiment results.The temperature distribution is different during the whole VAR process and the steady-state molten pool forms at 329 s for d100 mm × 180 mm ingots.At the initial stage of remelting,the heat dissipation of crucible bottom plays an important role in the whole heat dissipation system.At the middle of remelting,the crucible wall becomes a major heat dissipation way.The effect of cooling velocity on the solidification structure of ingots was investigated based on the temperature fields and the results can well explain the macrostructure of titanium alloy ingots.

Manufacture of μ-PIM gear mold by electroforming of Fe-Ni and Fe-Ni W alloys

The micro gear mold for powder injection molding was made by electroforming process of Fe-Ni and Fe-Ni-W alloys using UV-lithography process. Kinetics and activation energies in electroplating of both alloys were investigated to determine the best process conditions. Fe content within electrodeposited Fe-Ni alloys increased with the increase of rotating disk speed and the decrease of temperature and it is considered from the calculated activation energy of iron content that the rate determining step is controlled by mass transfer. Iron content in Fe-Ni electrodeposit varied from 58.33% to 70.45% by increasing current density from 2 to 6 A/drn2. Also, iron content in Fe-Ni-W electrodeposit increased from 59.32% to 70.15%, nickel content decreased from 27.86% to 17.07% and the content of tungsten was almost consistent in the range of 12.78%-12.82% although the current density increases from 1.5 to 5 A/dm^2. For the electroforming of micro gear mold, SU-8 mandrel with 550 μm in diameter and 400 μm in height was prepared by UV-lithography processing. Subsequently, Fe-36Ni and Fe-20Ni-13W alloys micro gear molds were electroformed successfully. Surface hardness values of the electroformed micro molds were measured to be HV490 and HV645, respectively.