Physical Simulation of Nonmetallic Particle Movement in Al Melt under Electromagnetic Field

Physical simulation is used to study the movement of nonmetallic particles in Al melt in electro- magnetic field. It is found that the terminal velocity of particles in different Reynolds number range has different functions. By confirming drag force coefficient of nonmetallic particles with Reynolds number in the range of 0.2-10 and 10-25 respectively, two functions of terminal ve- locity for spherical nonmetallic particles have been got accordingly, which provide a theoretical basis for separating nonmetallic inclusions from Al melt in electromagnetic field.

Separation efficiency of alumina particles in Al melt under high frequency magnetic field

The effects of separation time and magnetic induction intensity on the separation efficiency of alumina particles with diameters varying from 30 to 200 μm in aluminum melt were investigated. The experimental results show that the particle-accumulated layer is formed in the periphery of the solidified specimen when the diameter of the separated molten metal, the magnetic induction intensity and the separation time are 10 mm, 0.04 T and 1 s, respectively. When the separation time is 2 s, the particle-accumulated layer can be observed obviously and the separation efficiency is about 80%. There are few alumina particles in the inner of the solidified specimen when the separation time is 3 s. The separation efficiency higher than 85% can be achieved when the separation time is longer than 3 s. When the magnetic induction intensity is 0.06 T, the visible particle-accumulated layer can be formed in 1 s and the separation efficiency is higher than 95%. The experimental results were compared with the calculated results at last.

Kinetics of absorbing hydrogen of Al melt

The kinetics process of absorbing hydrogen of Al melt was analyzed and it was considered that the concentration of hydrogen in Al melt was determined by the concentration of water vapor in the interface of the oxide layer and Al melt. The change of the alloying composition will result in the change of compactability of oxide layer and affect the process of the water vapor gas penetrating the oxide layer and entering the interface of Al melt and oxide layer. Based on the above analysis, the kinetics equation of Al melt absorbing hydrogen was established, and compared with the test result. The results of calculation were elementally coincident with the test result. The curve of hydrogen concentration varying with reaction time in Al melt can be obtained from this equation. And scientific basis could be provided to select melting technology parameter properly and control the concentration of hydrogen in Al melt.

激光选区熔化Al-Mg-Sc-Zr合金各向组织与损伤容限性能

研究激光选区熔化(selective laser melting,SLM)技术成形Al-Mg-Sc-Zr合金材料不同取向的显微组织特征、拉伸和损伤容限性能。结果表明:YZ截面为细小的等轴晶和粗大的柱状晶组成的双峰组织,XY截面由细小的等轴晶组成;0°和90°方向屈服强度、抗拉强度均超过500 MPa,各向异性较小,但堆积层间存在的未熔合缺陷使得90°方向断裂伸长率明显低于0°方向;0°和90°CT试样K_(IC)分别为21.41 MPa·m^(1/2)和20.89 MPa·m^(1/2),在柱状晶区域裂纹扩展阻抗低,导致90°CT试样K_(IC)稍小;显微组织和缺陷是影响裂纹扩展性能各向异性的主要因素,在近门槛区未熔合缺陷起主导作用,当裂纹面平行于水平方向时裂纹扩展速率更快;在稳态扩展区显微组织的影响起主导作用,当裂纹面平行于水平方向时为穿晶断裂,裂纹扩展阻抗较高,裂纹扩展速率较低。

激光熔化沉积Al-Mg-Sc-Zr合金单熔道成形质量预测

本研究探讨了激光熔化沉积(LMD)工艺参数对Al-Mg-Sc-Zr合金单熔道成形质量的影响,并采用BP神经网络模型和改进的PSO-BP神经网络模型预测了不同工艺参数下的成形孔隙率。结果表明:Al-Mg-Sc-Zr合金的LMD单熔道成形孔隙率,随着激光线能量密度的增加呈现先上升后下降再上升的趋势,在175 J/mm^(2)时孔隙率达到最小值,仅为1.38%。在相同的送粉工艺参数下,LMD成形熔道宽度和熔道深度均与激光功率呈现出正相关性,而熔道高度和熔道深度均与扫描速率呈现出负相关性。相较于BP神经网络模型,改进的PSO-BP神经网络模型的平均绝对误差降低了29.69%,平均相对误差降低了19.42%,均方误差降低了19.02%,相关系数提升了63.44%。

预热温度对激光选区熔化成形30%SiC_(p)/AlSi10Mg复合材料力学性能的影响

基板常温工况下激光选区熔化成形中等体积分数SiC_(p)/Al复合材料存在孔洞、裂纹等冶金缺陷,从而导致成形零件致密度低、力学性能差等问题。首先研究了固定优化成形工艺参数时,基板预热温度(200~400℃)对45μm的30%(质量分数,下同)SiC_(p)/AlSi10Mg成形零件表观致密度和力学性能的影响;进一步提高SiC_(p)质量分数至50%,再次评价了上述基板预热温度对成形性能的影响。结果表明,当SiC_(p)质量分数为30%时,升高基板预热温度可以减少成形零件的孔洞和裂纹,成形零件的表观致密度及力学性能显著提高;当基板预热至400℃时,成形零件表观致密度最高达到97.98%,与此同时极限抗压强度和极限抗拉强度分别为578 MPa和56 MPa;随着SiC_(p)质量分数进一步增加至50%,基板预热温度对成形零件致密化和力学性能的强化效果逐步减弱。本研究证明高温预热基板能够有效抑制激光选区熔化成形中等体积分数SiC_(p)/Al复合材料的冶金缺陷,为增材制造SiC_(p)/Al复合材料提供了工程应用解决方案。

选区激光熔化成形TiB_(2)/Al-Si-Mg大尺寸复杂构件

选区激光熔化(SLM)成形大尺寸复杂构件厚度多样、成形高度较高、方向复杂,需要研究构件微观组织均匀性和力学性能稳定性。本文以SLM成形TiB_(2)/Al-Si-Mg复合材料为研究对象,分析复合材料多级微观组织,对比不同成形厚度、高度、方向下复合材料的力学性能。结果表明:复合材料表现出熔池特征结构,细小等轴晶粒组织均匀分布且随机取向,纳米TiB_(2)颗粒在材料内部弥散分布。随成形厚度增加,复合材料伸长率保持稳定,抗拉强度受本征热处理影响略微增大;在不同成形高度下,复合材料抗拉强度和伸长率保持稳定;在不同成形方向下,复合材料抗拉强度保持稳定,伸长率受熔池结构影响在水平方向略高。基于以上结果,成功制备大飞机舱门铰链臂(588 mm×318 mm×470 mm)复杂结构件。

Al-Mn-Sc合金的选区激光熔化工艺优化及室温与高温力学性能研究

通过探究能量密度对Al-4.5Mn-1.5Mg-0.6Sc-0.2Zr(wt.%)合金致密度的影响,优化其成形工艺,并进一步分析该合金在时效过程中组织变化及其室温与高温力学性能。结果表明:随着能量密度增大,合金致密度先增后减。当能量密度为77.6 J/mm^(3)时,即激光功率275 W、扫描速率985 mm/s、扫描间距0.12 mm、层厚0.03 mm,可获得致密的、缺陷少的合金材料。沉积态合金显微组织由等轴晶和柱状晶组成,周围分布着细小富Mn相;300℃/5 h时效后,晶内析出大量纳米Al_(3)(Sc,Zr)相。同时,时效后合金表现出优异的室温与高温力学性能,其室温屈服强度、抗拉强度和伸长率分别是500 MPa、536 MPa和12.3%,高温(250℃)屈服强度、抗拉强度和伸长率分别为224 MPa、299 MPa和11.5%。

The Combustion Synthesis Process of Al-Ti-C System in an Elevated-temperature Al-melt

One of the main disadvantages of combustion synthesis of ceramic/metal composite materials is the relatively high level of porosity present in the products. To synthesize TiC/Al composites with a dense structure, this paper proposes a novel application of an elevated-temperature Al-melt to directly ignite and simultaneously infiltrate Al-Ti-C preform dipped in the melt. The emphasis was placed on the combustion synthesis process and mi-crostructural evolution of the preform in the melt, by a liquid quenching test combined with the measurement of the temperature history of the dipped preform. The results show that the combustion synthesis process of the preform in the elevated-temperature melt involves a series of reactions, and that higher temperature of the melt is favourable for the formation of TiC. The synthesized TiC/Al composites exhibit a dense structure, which is attributed to the infiltration of the melt into the preform.

Preparation of TiC/Ni_3Al Composites by Upward Melt Infiltration

TiC/Ni_3Al composites have been prepared using upward infiltration method. The densification was performed by both Ni_3Al melt filling and TiC sintering during the infiltration. The dissolution of TiC in liquid Ni_3Al has been evidenced by finding Ni_3(Al,Ti)C after fast cooling in the TiC/Ni_3Al composites. The dissolution may be responsible for the infiltration and sintering. Compared with downward infiltration, the upward infiltration brought about higher strength and fracture toughness and shorter infiltration time. TiC/20 vol. pct Ni_3Al composite processed by upward infiltration had a flexural strength of 1476 MPa with a statistic Weibull modulus of 20.2 and a fracture toughness of 20.4 MPa . Better mechanical properties may be attributed to melt unidirectional movement in upward infiltration.

Synthesis of SiC/Al Co-Continuous Composite by Spontaneous Melt Infiltration

Investigation has been made on the process of synthesizing SiC/Al co-continuous composite by spontaneous melt infiltration. It is found that nitrogen atmosphere is an indispensable factor for spontaneous infiltration of melt Al into SiC preform with continuous porosity. The critical temperature for spontaneous infiltration occurrence can be lowered and spontaneous infiltration rate increased by doping a small amount of Mg into the Al alloy. Adding fine SiO2 powders into the ceramic preform can play the similar role as Mg-doping by increasing wetting through the chemical reaction of 3SiO2+4AI=2Al2O3+3Si at the infiltration front. Infiltration rate can also be increased by Si-doping to lower the viscosity of the molten Al alloy. In addition, sufficient Si content in the molten Al is also indispensable to avoid the formation of Al4C in the synthesized composite.

Specific heat of superheated Al-10Sr alloy melts

The specific heat of superheated Al 10Sr melts was determined at different heating rates between 1 K/min and 20 K/min using a differential scanning calorimeter(DSC). As a whole, the specific heat increases with increasing temperature. A hump is observed on the specific heat curve at the temperature corresponding to the phase boundary temperature dependent on heating rate. Moreover, the hump shifts to higher temperature in the measured temperature range from about 840 ℃ to 890 ℃ with increasing heating rate. At certain temperature in the higher superheated zone, the specific heat of the melt as a function of temperature shows a sharp rise . The result indicates that disorder zone fraction begins to increase while atom clusters fraction decreases at the breaking temperature. [

Thermodynamics of effect of modification on microstructure of Al-Si alloy melt

Thermodynamic law of interaction between modification element and alloy melt has been analyzed, and the effect of modification element on electrical resistivity of melt has been studied. It was found that, in a certain range of concentration, there exists a ‘node’ where the alloy melt reconstruction will occur. An extreme value appeared in the relationship curve of melt’s resistivity and modification element’s concentration corresponding to the ‘node’, where the solidified structure of the alloy changed remarkably.

TEMPERATURE DEPENDENCE OF VISCOSITY OF Al-Si ALLOY MELTS

The relationship between the viscosity and temperature of Al-Si alloy melts was investigated. The viscosity of three different types of Al-Si alloy melts was measured. It was showed that the relationship between the viscosity and temperature of hypoeutectic Al-5%Si and eutectic Al- 12.5%Si alloy melts is approximately exponential except for some special zones, but that of the hypereutectic melt is different. The paper discussed the correlation of the viscosity and atomic density, which is thought that the viscosity corresponds to the atomic density to some extent.

Microstructure and mechanical properties of melt-conditioned high-pressure die-cast Mg-Al-Ca alloy

A new shape casting process,melt-conditioned high-pressure die-casting(MC-HPDC) was developed.In this process,liquid metal was conditioned under intensively forced convection provided by melt conditioning with advanced shear technology(MCAST) unit before being transferred to a conventional cold chamber high-pressure die-casting(HPDC) machine for shape casting. The effect of melt conditioning was investigated,which was carried out both above and below the liquidus of the alloy,on the microstructure and properties of a Mg-Al-Ca alloy(AZ91D+2%Ca(mass fraction) ,named as AZX912) .The results show that many coarse externally-solidified crystals(ESCs) can be observed in the centre of conventional HPDC samples,and hot tearing occurs at the inter-dendritic region because of the lack of feeding.With the melting conditioning,the MC-HPDC samples not only have considerably refined size of ESCs but also have significantly reduced cast defects,thus provide superior mechanical properties to conventional HPDC castings.The solidification behaviour of the alloy under different processing routes was also discussed.

In-situ synthesized (Al_3Zr+Al_2O_3)_p /A356 composites by direct melt reaction in Al-Zr-O system

A novel in situ reaction system Al Zr O was developed. In situ Al 3Zr and Al 2O 3 particulate reinforced A356 alloy matrix composites have been fabricated by direct melt reaction method. The results show that the maximum sizes of Al 3Zr and Al 2O 3 particulates synthesized in the system ZrOCl 2 A356 are 1 μm and 3 μm respectively, and they are well distributed in the matrix. The investigation shows that the Al 3Zr crystal is in the shape of polyhedron and rectangle. There is a faceted growth phenomenon on Al 3Zr crystal surface. It is firstly found that the Al 3Zr crystal grows in the mechanism of twinning. The twinning plane is (1 1 4), and the twinning direction is [2 2 1] . The crystal morphology of in situ α Al 2O 3 particulate is rectangle or sphere. Furthermore, (Al 3Zr+Al 2O 3) p/A356 composites have not only higher tensile strength at room temperature (376.2 MPa) but also higher yield strength (319.4 MPa) and higher tensile strength at elevated temperature (200 ℃) than those of the A356 alloy. The dry sliding wear test shows that the wear resistance of the (Al 3Zr+Al 2O 3) p/A356 composites is greatly enhanced with increasing particulate volume fraction.

Physical Properties and Solidification Structure of Al－SiEutectic Alloy Melt with Cerium Modification

Relationship between physical property change of melt and solidification structure has been investigated by measuring the density, viscosity and electrical resistivity of the Al-Si eutectic alloy melt with different Ce contents. The results show that there exists corresponding relation between the turning points of physical properties change and eutectic Si shape change.

Change law of real vapor pressure of Al element in Ti-xAl (x=25～50) melt during ISM process

A new model was established to calculate the real vapor pressure of the Al element in the molten Ti x Al ( x = 25 ～ 50, mole fraction, %) alloy. The effects of the holding time, chamber pressure, mole fraction of Al and melting temperature on the real vapor pressure of Al element in the vacuum chamber were analyzed. Because of the impeding effect of the real vapor pressure on the evaporation loss rate, within a short time (less than 10?s), the real vapor pressure tends to a constant value. When the chamber pressure is less than the saturated vapor pressure of the Al component, the real vapor pressure of Al is equal to the chamber pressure. While when the chamber pressure is larger than the saturated vapor pressure, the real vapor pressure is equal to the saturated vapor pressure of the Al element of the same condition.

扫描速度对选区激光熔化高强Al-Mg-Sc-Zr合金组织与性能的影响

采用选区激光熔化(SLM)技术在不同扫描速度工艺条件下制备了高强Al-Mg-Sc-Zr合金,采用了光学显微镜(OM)、扫描电子显微镜(SEM)、室温拉伸实验、室温摩擦磨损实验等方法,研究了激光扫描速度对合金微观组织和力学性能的影响。结果表明:当激光功率不变,扫描速度在1250~1850 mm/s时,随着扫描速度从1250 mm/s升至1850 mm/s,合金致密度和力学性能均呈现先升高后降低的趋势。当扫描速度达到1850 mm/s时,由于能量密度低导致粉末无法充分熔化,层间润湿不充足,形成大量不规则孔隙,降低了材料力学性能。选区激光熔化成形合金在不同扫描速度下均可以完成冶金结合,且致密度均高于98.9%,当扫描速度为1450 mm/s时,合金成形性能达到最优,致密度为99.87%,其屈服强度、抗拉强度和断后延伸率分别为379 MPa、420 MPa和17.0%,摩擦磨损实验表明其磨损量和磨损速度均为最低,耐磨性能显著优于其他参数。

Melt Infiltration Ability and Microstructural Evolution of Fe40Al/ TiC Composites System

Pressureless melt infiltration is an economic route f or preparation of high-density ceramic/melt composites. In this study, the Fe40 Al iron aluminide intermetallic, a low cost material of excellent oxidation and corrosion resistance, was used as binder for fabricating Fe40Al/TiC composites b y pressureless melt infiltration. The wetting ability of liquid Fe40Al in porous TiC pre-form was studied by in-situ monitoring the melting and infiltration p rocess. The infiltration ability was investigated by observing the distance of l iquid Fe40Al intrusion in porous TiC pre-forms at different infiltration temper atures and times by using optical microscope. Porous TiC per-forms with density of 60%～88%TD (theoretical density), prepared under pre-defined sintering temp e rature cycles, were used for fabricating Fe40Al/TiC composites in the range of 1 2%～40% metal content by volume. Almost full dense Fe40Al/TiC composites were su c cessfully fabricated by this technique. Liquid Fe40Al exhibited excellent infilt ration ability, the distance of complete intrusion of liquid Fe40Al in the TiC s intered pre-form with density of 88%TD was over 7 mm after 5 min at the inf iltration temperature of 1 450 ℃. Microstructural observation by SEM and TEM also showed that liquid Fe40Al filled the very narrow gaps among TiC particles, the interfaces of TiC particles and F e40Al plastic ligaments being metallurgical bonded. TEM revealed that high densi ty of dislocations formed in Fe40Al ligaments during solidification, which favor the mechanical properties. Ti decomposed from TiC particles and dissolved into Fe40Al during infiltration. According to the compositional analysis of TEM-EDS, the concentration of Ti in Fe40Al ranges at 1at%～4at% depending on composite f a bricating conditions and the distance from the measuring point to the closest Ti C particles. XRD analysis indicated that the composites were composed of two pha ses, the original TiC and Fe 0.4Al 0.6 intermetallic. No new phase formed during infiltration, but the lattice parameter of Fe 0.4Al 0.6 was expended due to the Ti in the solid solution.