Effect of multi-step slow shot speed on microstructure of vacuum die cast AZ91D magnesium alloy

Two multi-step （two-step and three-step） slow shot speeds were used in the vacuum die casting process of AZ91D magnesium alloy. The vacuum pressure variation in the die cavity before mold filling was monitored by using a pressure sensor. The microstructures of the produced castings were analyzed with optical microscope and image analysis software. The experimental results demonstrate that, the vacuum pressure in the die cavity at the beginning of mold filling is significantly reduced by using three-step slow shot speed, resulting in a low gas porosity level in the produced castings. At an appropriate multi-step slow shot speed, the dwell time of the liquid metal in the shot sleeve before mold filling can be reduced and the flow of the liquid metal in the shot sleeve at the later stage of the slow shot process can be restrained, which cause a low externally solidified crystal content in the produced castings.

Grain refinement of gravity die cast secondary AlSi7Cu3Mg alloys for automotive cylinder heads

The effects of AITi5B1 grain refinement and cooling rate on the microstructure and mechanical properties of a secondary AlSi7Cu3Mg alloy were reported. Metallographic and image analysis techniques have been used to quantitatively examine the macrostructural and microstructural changes occurring with the addition of grain-refining agent at different cooling rates by using a step casting die. The results indicate that the addition of AlTi5B1 produces a fine and uniform grain structure throughout the casting and this effect is more pronounced in the slowly solidified regions. Increasing the cooling rate, lower amount of grain refiner is necessary to produce a uniform grain size throughout the casting. On the other hand, the initial contents of Ti and B, present as impurity elements in the supplied secondary alloy, are not sufficient to produce an effective grain refinement. The results from the step casting geometry were applied to investigate a gasoline 16V cylinder head, which was produced by gravity semi-permanent mould technology. The grain refinement improves the plastic behaviour of the alloy and increases the reliability of the casting, as evidenced by the Weibull statistics.

Effect of ultrasonic degassing on performance of Al-based components

The effect of high intensity ultrasound based on the novel multi-frequency multimode modulated technology on the final density, porosity, mechanical and fatigue properties of an AlSi9Cu3(Fe) alloy after different processing time was studied. Reduced pressure test was used to evaluate the density of alloys. The tensile and fatigue tests were used to evaluate the static and dynamic properties for the different time of ultrasonic degassing, respectively. It is found that ultrasonic degassing is effective in reduction porosity as well as to improve the final density of castings. Furthermore, the experimental results suggest that the porosity level does not have a substantial influence on the static properties contrary to what is observed on fatigue properties.

NO3- and HSO3- Induced Corrosion of Simulated Archaeological Iron in Humid-Acid Atmosphere

NO3- and HSO3- induced corrosion of simulated archaeological iron in humid-acid atmosphere was studied by using periodic wet-dry tests. Surface tension tests, electrochemical impedance measurement, stereoscopic microscopy and energy dispersive atomic X-ray analysis (EDAX) were used to investigate the corrosion processes and products. The results of mass loss measurement showed that the corrosion kinetics can be approximately described by △W - AtB. With the addition of NO3-, the value of B increases. NO3- acts as an inhibitor in the HSO3- bearing pollutant during the corrosion process. Both the electrochemical impedance measurement and surface tension test confirmed the result of mass loss measurement. In addition, we found that the attack of anions to the metal at the initial corrosion stage was in good agreement with their surface activity.

Microstructure characterization and mechanical properties of gas tungsten arc welded cast A356 alloy

The microstructure and mechanical properties of the gas tungsten arc welded cast A356 alloy were investigated with fillers ER1100,ER4043,ER4047 and ER5356 under the pulse frequencies of 1,3 and 5 Hz.Results showed that the filler metal and pulse frequency affected the grain structure of fusion zone considerably.The highest fraction of eutectic（44%） was formed with filler ER4047.Tensile fracture of all specimens indicated that fracture did not occur in the fusion zone.The greatest impact toughness（about 4 J） was achieved for the welds with filler ER4047 while the largest hardness（HV 90） was obtained with filler ER5356.

Microstructure and properties of rheo-HPDC Al-8Si alloy prepared by air-cooled stirring rod process

A new and effective semisolid slurry preparation process with air-cooled stirring rod(ACSR)is reported,in which the compressed air is constantly injected into the inner cavity of a stirring rod to cool the melt.The slurry of a newly developed high thermal conductivity Al?8Si alloy was prepared,and thin-wall heat dissipation shells were produced by the ACSR process combined with a HPDC machine.The effects of the air flow on the morphology ofα1-Al particles,mechanical properties and thermal conductivity of rheo-HPDC samples were studied.The results show that the excellent slurry of the alloy could be obtained with the air flow exceeding3L/s.Rheo-HPDC samples that were produced with the air flow of5L/s had the maximum UTS,YS,elongation,hardness and thermal conductivity of261MPa,124MPa,4.9%,HV99and153W/(m·K),respectively.Rheo-HPDC samples show improved properties compared to those formed by HPDC,and the increasing rates of UTS,YS,elongation,hardness and thermal conductivity were20%,15%,88%,13%and10%,respectively.

Simulation of mold filling and prediction of gas entrapment on practical high pressure die castings

Element parameters including volume filled ratio,surface dimensionless distance,and surface filled ratio for DFDM(direct finite difference method)were proposed to describe shape and location of free surfaces in casting mold filling processes.A mathematical model of the filling process was proposed specially considering the mass,momentum and heat transfer in the vicinity of free surfaces.Furthermore,a method for gas entrapment was established by tracking flow of entrapped gas.The model and method were applied to practical ADC1 high pressure die castings.The gas entrapment prediction was compared with the fraction and maximum size of porosities in the different casting parts.The comparison shows validity of the proposed model and method.The study indicates that final porosities in high pressure die castings are dependent on both gas entrapment during mold filling process and pressure transfer within solidification period.

Summer Extreme Temperatures over East China during 1984-2004 Simulated by LASG/IAP Regional Climate Model CREM

The authors examine extreme summer temperatures over East China during 19844004 using a regional climate model named CREM （the Climate version of Regional Eta-coordinate Model）, which was developed by LASG/IAP. The results show that the main features of the extreme summer temperatures over East China are reproduced well by CREM, and the skill for the minimum temperature is higher than that for the maximum tem- perature, especially along the Yangtze-Huai River Valley （YHV）. The simulated extreme temperatures are lower than those of observation, especially for the maximum temperature. The bias of extreme temperatures is consistent with the cold bias of the climatological mean summer surface air temperature. The skill of the model in simulating the interannual variability of extreme temperatures increases from north to south. The simulated interannual variation of the minimum temperature is more reasonable than the maximum temperature. The underestimation of net solar radiation at the surface leads to a cold bias of the climatological mean temperature. Furthermore, the model underestimates the light and moderate rain, while overestimates heavy rain. It causes the simulated minimum temperature more reasonable than the maximum temperature.