In this work the influence of the density of the molten metal on the emergence of the raining phenomenon in the horizontal centrifugal casting process is numerically studied. Transient 2D numerical simulations were ca...In this work the influence of the density of the molten metal on the emergence of the raining phenomenon in the horizontal centrifugal casting process is numerically studied. Transient 2D numerical simulations were carried out using Computational Fluid Dynamics software. Three molten metals with different density, namely aluminum, iron and lead, and three angular frequencies, namely 50, 66 and 77 rad/s were considered. It is found that the density of the molten metal significantly affects the emergence, transient or permanent, of the rain phenomenon. However, the magnitude and duration of the rain phenomenon depend on the angular frequency of the rotating mold. Likewise, since gravitational forces affect the metal according to its density, the value of the critical rotation speed of the mold is also affected.展开更多
In today’s manufacturing industries,hard competition between rival firms makes it compulsory for researchers to design lighter and cheaper machine components due to the megatrends of cost-effectiveness and anti-pollu...In today’s manufacturing industries,hard competition between rival firms makes it compulsory for researchers to design lighter and cheaper machine components due to the megatrends of cost-effectiveness and anti-pollution.At this point,aluminum syntactic foams(ASFs)are new-generation engineering composites and come into the upfront as a problem-solver.Owing to their features like low density,sufficient elongation,and perfect energy absorption ability,these advanced foams have been considerably seductive for many industrial sectors nowadays.In this study,an industrial-oriented automatic die casting technology was used for the first time to manufacture the combination of AA7075/porous expanded clay(PEC).Micro evaluations(optical and FESEM)reveal that there is a homogenous particle distribution in the foam samples,and inspections are compatible with the other ASF studies.Additionally,T6 aging heat treatment was operated on one half of the produced foams to explore the probable impact of aging on the compressive responses.Attained results show that PEC particles can be an alternative to expensive hollow spheres used in the previous works.Besides,a favorable relationship is ascertained between the aging treatment and mechanical properties such as compression strength and plateau strength.展开更多
To make high integrity lightweight metal castings,best practices are required in various stages of casting and heat treatment processes,including liquid metal composition and quality control,casting and gating/riser s...To make high integrity lightweight metal castings,best practices are required in various stages of casting and heat treatment processes,including liquid metal composition and quality control,casting and gating/riser system design,and process optimization.This paper presents best practices for liquid metal processing and quality assurance of molten metal in both melting and mold filling.Best practices for other aspects of lightweight metal casting will be published separately.展开更多
Heat transfer at the metal-die interface has a great influence on the solidification process and casting structure. As thin-wall components are extensively produced by high pressure die casting process(HPDC), the B390...Heat transfer at the metal-die interface has a great influence on the solidification process and casting structure. As thin-wall components are extensively produced by high pressure die casting process(HPDC), the B390 alloy finger-plate casting was cast against an H13 steel die on a cold-chamber HPDC machine. The interfacial heat transfer behavior at different positions of the die was carefully studied using an inverse approach based on the temperature measurements inside the die. Furthermore, the filling process and the solidification rate in different finger-plates were also given to explain the distribution of interfacial heat flux(q) and interfacial heat transfer coefficient(h). Measurement results at the side of sprue indicates that qmax and hmax could reach 9.2 MW·m^(-2) and 64.3 kW ·m^(-2)·K^(-1), respectively. The simulation of melt flow in the die reveals that the thinnest(T_1) finger plate could accelerate the melt flow from 50 m·s^(-1) to 110 m·s^(-1). Due to this high velocity, the interfacial heat flux at the end of T_1 could firstly reach a highest value 7.92 MW·m^(-2) among the ends of T_n(n=2,3,4,5). In addition, the q_(max) and h_(max) values of T_2, T_4 and T_5 finger-plates increase with the increasing thickness of the finger plate. Finally, at the rapid decreasing stage of interfacial heat transfer coefficient(h), the decreasing rate of h has an exponential relationship with the increasing rate of solid fraction(f).展开更多
Navier-Stokes equation and Lorentz force equation are used to calculate the fluid field of liquid metal of electromagnetic centrifugal casting (EMCC) in this paper. A field equation is given, which shows the azimuthal...Navier-Stokes equation and Lorentz force equation are used to calculate the fluid field of liquid metal of electromagnetic centrifugal casting (EMCC) in this paper. A field equation is given, which shows the azimuthal velocity closely relates to electrical conductivity, magnetic density, viscosity of liquid metal and radius of casting. The results show that the stationary magnetic field can effectively restrain the fluid flow and the relative velocity between liquid metal and casting mould and the velocity gradient at solid / liquid interface increases with rising magnetic density, which has a great effect on the solidification of liquid metal and crystal growth characteristics.展开更多
For the control of surface defects in interstitial-free(IF) steel, quantitative metallographic analyses of near-surface inclusions and surface liquid flow detection via the nail-board tipping method were conducted. Th...For the control of surface defects in interstitial-free(IF) steel, quantitative metallographic analyses of near-surface inclusions and surface liquid flow detection via the nail-board tipping method were conducted. The results show that, at casting speeds of 0.8 and 1.0 m/min, a thin liquid mold flux layer forms and non-uniform floating of argon bubbles occurs, inducing the entrainment and subsequent entrapment of the liquid flux; fine inclusion particles of Al_2O_3 can also aggregate at the solidification front. At higher casting speeds of 1.4 and 1.6 m/min, the liquid mold flux can be entrained and carried deeper into the liquid steel pool because of strong level fluctuations of the liquid steel and the flux. The optimal casting speed is approximately 1.2 m/min, with the most favorable surface flow status and, correspondingly, the lowest number of inclusions near the slab surface.展开更多
Metal mold micron scale precision casting technology was developed successfully,and three-dimension complicated microgear castings in micron scale were produced.Evolvement regularity of microgear castings were observe...Metal mold micron scale precision casting technology was developed successfully,and three-dimension complicated microgear castings in micron scale were produced.Evolvement regularity of microgear castings were observed by optical microscope and scanning electron microscope.Compared with conventional casting,microcasting is characterized by typical nonequilibrium solidification,for example,its grain size can be refined significantly,eutectic structure is transformed from lamellar morphology to rod eutectic,and the ratio of primary phase is increased.This kind of microstructure can promote mechanical properties of microcasting.展开更多
High pressure die casting copper is used to produce rotors for induction motors to improve efficiency.Experiments were carried out for a special"step-shape"casting with different step thicknesses.Based on th...High pressure die casting copper is used to produce rotors for induction motors to improve efficiency.Experiments were carried out for a special"step-shape"casting with different step thicknesses.Based on the measured temperature inside the die,the interfacial heat transfer coefficient(IHTC)at the metal/die interface during vacuum die casting was evaluated by solving the inverse problem.The IHTC peak value was 4.5×10^3-11×10^3 W·m^-2·K^-1 under the basic operation condition.The influences of casting pressure,fast shot speed,pouring temperature and initial die surface temperature on the IHTC peak values were investigated.Results show that a greater casting pressure and faster shot speed could only increase the IHTC peak values at the location close to the ingate.An increase of pouring temperature and/or initial die surface temperature significantly increases the IHTC peak values.展开更多
The reinforcement distribution of metal matrix composites (MMCs) plays an important role in low cycle fatigue. Thus, it is essential to study the effect of reinforcement clustering on the crack initiation mechanism of...The reinforcement distribution of metal matrix composites (MMCs) plays an important role in low cycle fatigue. Thus, it is essential to study the effect of reinforcement clustering on the crack initiation mechanism of MMCs. In this study, the effect of reinforcement clustering on the microcrack initiation mechanism in a cast hybrid MMC reinforced with SiC particles and Al2O3 whiskers was investigated experimentally and numerically. Experimental results showed that microcracks always initiated in the particle-matrix interface, located in the cluster of the reinforcements. The interface debonding occurred in the fracture which created additional secondary microcracks due to continued fatigue cycling. The microcrack coalesced with other nearby microcracks caused the final fracture. To validate the experimental results on the microcrack initiation, three dimensional unit cell models using finite element method (FEM) were developed. The stress distribution in both the reinforcement clustering and non-clustering regions was analyzed. The numerical analysis showed that high stresses were developed on the reinforcements located in the clustering region and stress concentration occurred on the particle-matrix interface. The high volume fraction reinforced hybrid clustering region experienced greater stresses than that of the SiC particulate reinforced clustering region and low volume fraction reinforced hybrid clustering region. Besides, the stresses developed on the non-clustering region with particle-whisker series orientation were reasonably higher than that of the non-clustering region with particle-whisker parallel orientation. The high volume fraction reinforced hybrid clustering region is found to be highly vulnerable to initiate crack in cast hybrid MMC during low cycle fatigue.展开更多
Metal foams are a new kind of materials with low densities and novel physical, mechanical, thermal, electrical and acoustic properties. They can be divided into closed and open cell structures. In this paper the open ...Metal foams are a new kind of materials with low densities and novel physical, mechanical, thermal, electrical and acoustic properties. They can be divided into closed and open cell structures. In this paper the open cell structures, called sponges, were treated. A new technique to manufacture sponges by plaster investment casting was described. Experimental results show that it is essential to make a sound plaster mould by casting plaster slurry into the polyurethane foams and infiltrate the open channels of the baked plaster mold by molten metal. The optimal processes include plaster slurry preparation, plaster mold baking, and molten metal infiltration. The sponge sample with porosity of 97% is presented.展开更多
An unsteady mathematical thermal model was developed for predicting the time,molten-steel weight,induction heating power,and temperature changes of the steel from the end of ladle refining to the end of the continuous...An unsteady mathematical thermal model was developed for predicting the time,molten-steel weight,induction heating power,and temperature changes of the steel from the end of ladle refining to the end of the continuous-casting process of a tundish. The calculations revealed that for a specific strip-casting process,the ladle tonnage should be controlled to about 90 t. If the ladle capacity reaches 130 t,the provision of a 1 500-kW tundish induction heating device is recommended. By comparing the measured and predicted molten-steel temperature values in the Ningbosteel-Baosteel strip casting industrialization demo project( NBS) of a tundish,it was determined that the prediction accuracy of the model could meet the forecasting accuracy requirements for the molten-steel temperature in the tundish during mass production. Simultaneously,the heat flux density on each surface of the tundish was found at about 50 min,which is entirely consistent with the values reported in the related literature,and the tundish had not reached a heat balance during the casting test period. This model can also be applied to calculate the suitable size of a tundish for a specific continuous-casting process,thereby providing a theoretical basis for the design of the continuous-casting tundish.展开更多
This paper presents a technique for controlling the pressure of a molten metal when using a new type of iron casting method called sand mold press casting to realize high productivity and obtain high-quality products....This paper presents a technique for controlling the pressure of a molten metal when using a new type of iron casting method called sand mold press casting to realize high productivity and obtain high-quality products.The past test results using this method showed a casting yield of 90% to 95%,while conventional methods only show a casting yield of 60% to 70%.Although the press casting method does not require a sprue cup or runner channel casting defects such as metal penetration are often caused by the high pressure in the high-velocity pressing part of this casting process.Therefore,we proposed a pressure control method with a mathematical model of molten metal pressure,and with it we achieved experimental confirmation of the successful production of brake drums at different pressing temperatures.Results show that the proposed pressing control method can realize sound,penetration-free casting production.However,the theoretical analysis and design of this pressing process had not previously been studied sufficiently,and therefore this paper presents the theoretical design algorithm for the process as well as its experimental confirmation.展开更多
SiCp/Gr/2024Al metal matrix composites were processed by squeeze casting technology. The microstructure of composites was observed by SEM and TEM, and the effects of graphite particulates and SiC particulates on the d...SiCp/Gr/2024Al metal matrix composites were processed by squeeze casting technology. The microstructure of composites was observed by SEM and TEM, and the effects of graphite particulates and SiC particulates on the damping behaviors of composites were also investigated. The results show that the microstructure of composites was dense and homogeneous, without any interfacial reactivity among reinforcement/matrix interfaces. Compared with the damping capacity of 2024A1, the damping capacity of composites was enhanced significantly by addition of SiC or graphite particulates. The main damping mechanisms of SiCp/Al composites were ascribed to the dislocation damping, and those of SiCp/Gr/2024Al were attributed to the intrinsic damping and interface damping.展开更多
<span style="font-family:Verdana;">It is numerically studied the influence of the angular velocity, the molten metal viscosity, and the mold wall roughness on the molten metal distribution in the mold ...<span style="font-family:Verdana;">It is numerically studied the influence of the angular velocity, the molten metal viscosity, and the mold wall roughness on the molten metal distribution in the mold of a horizontal centrifugal casting process. The undesirable raining phenomenon sometimes arises in horizontal centrifugal casting. It occurs when the molten metal rains or falls from the top of the mold to the bottom while the mold is rotating. Using Computational Fluid Dynamics simulations, the conditions for the emergence of the raining phenomenon were explored in this work. For the system considered, angular velocities less than 77 rad/s cause the emergence of the raining phenomenon and accumulation of the molten metal in the lower part of the mold, whereas angular velocities greater than 77 rad/s produce a constant thickness of the molten metal and prevent raining.</span>展开更多
In aluminum killed steels, the size, shape, quantity and formation of non-metallic inclusions in ladle steel (before and after RH vacuum treatment) and in tundish as well as in slabs were studied by EPMA (Electron Pro...In aluminum killed steels, the size, shape, quantity and formation of non-metallic inclusions in ladle steel (before and after RH vacuum treatment) and in tundish as well as in slabs were studied by EPMA (Electron Probe Microanalysis) and by analyzing the total oxygen. The results showed that in the slabs the total oxygen was quite low and the inclusions discovered were mainly small-sized angular alumina inclusions. This indicates that most inclusions have been removed by floating out during the continuous casting process. In addition, the countermeasures were discussed to decrease the alumina inclusions in the slabs further.展开更多
In order to know the behavior of non-metallic inclusions in centrifugal induction electroslag castings (CIESC), non-metallic inclusions in 5CrMnMo and 4Cr5MoSiV1 were qualitatively and quantitatively analyzed. The lar...In order to know the behavior of non-metallic inclusions in centrifugal induction electroslag castings (CIESC), non-metallic inclusions in 5CrMnMo and 4Cr5MoSiV1 were qualitatively and quantitatively analyzed. The largest size of inclusions in the casting and the thermodynamic possibility of TiN precipitation in steel were also calculated. The results show that sulfide inclusions are evenly distributed and the content is low. The amount of oxide inclusions in CIESC: 4Cr5MoSiV1 steel is close to the ESR steel and lower than that in the EAF steel, and there are some differences along radial direction. Nitride inclusions are fine and the diameter of the largest one is 3-1 mum. With the increase of the centrifugal machine's rotational speed, the ratio of round inclusions increases and the ratio of sharp inclusions decreases. According to the experiment and the calculation results, it is pointed out that the largest diameter of non-metallic inclusions in the CIESC 4Cr5MoSiV1 casting is only 6.6 mum, and [N%][Ti%] in 4Cr5MoSiV1 steel should be controlled less than 4.4x 10(-5) in order to further reduce the amount and size of TiN inclusions.展开更多
Aluminum based metal matrix composites were fabricated using stir casting where silicon carbide and alumina were the reinforcements. Different types of properties (physical-density, mechanical-tensile, hardness, chemi...Aluminum based metal matrix composites were fabricated using stir casting where silicon carbide and alumina were the reinforcements. Different types of properties (physical-density, mechanical-tensile, hardness, chemical-corrosion etc.) were measured and compared with base metals/alloys. The properties were significantly varied. The highest density was obtained for pure aluminium with 5% Al<sub>2</sub>O<sub>3</sub> whereas the lowest was obtained for AA-4032 alloy. The highest hardness was obtained for AA-4032 with 5% Al<sub>2</sub>O<sub>3</sub> whereas the lowest was obtained for pure Al with 5% Al<sub>2</sub>O<sub>3</sub>. The highest strength was obtained for AA-6061 with 5% coarse SiC whereas the lowest was obtained for pure Al. The highest impact strength was obtained for AA-4032 with 5% Al<sub>2</sub>O<sub>3</sub> whereas the lowest was obtained for AA-6061. The corrosion resistance of all composites was lower than that of the base materials.展开更多
文摘In this work the influence of the density of the molten metal on the emergence of the raining phenomenon in the horizontal centrifugal casting process is numerically studied. Transient 2D numerical simulations were carried out using Computational Fluid Dynamics software. Three molten metals with different density, namely aluminum, iron and lead, and three angular frequencies, namely 50, 66 and 77 rad/s were considered. It is found that the density of the molten metal significantly affects the emergence, transient or permanent, of the rain phenomenon. However, the magnitude and duration of the rain phenomenon depend on the angular frequency of the rotating mold. Likewise, since gravitational forces affect the metal according to its density, the value of the critical rotation speed of the mold is also affected.
文摘In today’s manufacturing industries,hard competition between rival firms makes it compulsory for researchers to design lighter and cheaper machine components due to the megatrends of cost-effectiveness and anti-pollution.At this point,aluminum syntactic foams(ASFs)are new-generation engineering composites and come into the upfront as a problem-solver.Owing to their features like low density,sufficient elongation,and perfect energy absorption ability,these advanced foams have been considerably seductive for many industrial sectors nowadays.In this study,an industrial-oriented automatic die casting technology was used for the first time to manufacture the combination of AA7075/porous expanded clay(PEC).Micro evaluations(optical and FESEM)reveal that there is a homogenous particle distribution in the foam samples,and inspections are compatible with the other ASF studies.Additionally,T6 aging heat treatment was operated on one half of the produced foams to explore the probable impact of aging on the compressive responses.Attained results show that PEC particles can be an alternative to expensive hollow spheres used in the previous works.Besides,a favorable relationship is ascertained between the aging treatment and mechanical properties such as compression strength and plateau strength.
文摘To make high integrity lightweight metal castings,best practices are required in various stages of casting and heat treatment processes,including liquid metal composition and quality control,casting and gating/riser system design,and process optimization.This paper presents best practices for liquid metal processing and quality assurance of molten metal in both melting and mold filling.Best practices for other aspects of lightweight metal casting will be published separately.
基金financially supported by the class General Financial Grant from the China Postdoctoral Science Foundation(No.2015M580093)the National Nature Science Foundation of China(No.20151301587)the National Major Science and Technology Program of China(No.2012ZX04012011)
文摘Heat transfer at the metal-die interface has a great influence on the solidification process and casting structure. As thin-wall components are extensively produced by high pressure die casting process(HPDC), the B390 alloy finger-plate casting was cast against an H13 steel die on a cold-chamber HPDC machine. The interfacial heat transfer behavior at different positions of the die was carefully studied using an inverse approach based on the temperature measurements inside the die. Furthermore, the filling process and the solidification rate in different finger-plates were also given to explain the distribution of interfacial heat flux(q) and interfacial heat transfer coefficient(h). Measurement results at the side of sprue indicates that qmax and hmax could reach 9.2 MW·m^(-2) and 64.3 kW ·m^(-2)·K^(-1), respectively. The simulation of melt flow in the die reveals that the thinnest(T_1) finger plate could accelerate the melt flow from 50 m·s^(-1) to 110 m·s^(-1). Due to this high velocity, the interfacial heat flux at the end of T_1 could firstly reach a highest value 7.92 MW·m^(-2) among the ends of T_n(n=2,3,4,5). In addition, the q_(max) and h_(max) values of T_2, T_4 and T_5 finger-plates increase with the increasing thickness of the finger plate. Finally, at the rapid decreasing stage of interfacial heat transfer coefficient(h), the decreasing rate of h has an exponential relationship with the increasing rate of solid fraction(f).
文摘Navier-Stokes equation and Lorentz force equation are used to calculate the fluid field of liquid metal of electromagnetic centrifugal casting (EMCC) in this paper. A field equation is given, which shows the azimuthal velocity closely relates to electrical conductivity, magnetic density, viscosity of liquid metal and radius of casting. The results show that the stationary magnetic field can effectively restrain the fluid flow and the relative velocity between liquid metal and casting mould and the velocity gradient at solid / liquid interface increases with rising magnetic density, which has a great effect on the solidification of liquid metal and crystal growth characteristics.
基金financially supported by the National Natural Science Foundation of China (No. 51674069)the National Key R & D Program of China (No. 2017YFC0805100)
文摘For the control of surface defects in interstitial-free(IF) steel, quantitative metallographic analyses of near-surface inclusions and surface liquid flow detection via the nail-board tipping method were conducted. The results show that, at casting speeds of 0.8 and 1.0 m/min, a thin liquid mold flux layer forms and non-uniform floating of argon bubbles occurs, inducing the entrainment and subsequent entrapment of the liquid flux; fine inclusion particles of Al_2O_3 can also aggregate at the solidification front. At higher casting speeds of 1.4 and 1.6 m/min, the liquid mold flux can be entrained and carried deeper into the liquid steel pool because of strong level fluctuations of the liquid steel and the flux. The optimal casting speed is approximately 1.2 m/min, with the most favorable surface flow status and, correspondingly, the lowest number of inclusions near the slab surface.
基金Project(50475028)supported by the National Natural Science Foundation of China
文摘Metal mold micron scale precision casting technology was developed successfully,and three-dimension complicated microgear castings in micron scale were produced.Evolvement regularity of microgear castings were observed by optical microscope and scanning electron microscope.Compared with conventional casting,microcasting is characterized by typical nonequilibrium solidification,for example,its grain size can be refined significantly,eutectic structure is transformed from lamellar morphology to rod eutectic,and the ratio of primary phase is increased.This kind of microstructure can promote mechanical properties of microcasting.
文摘High pressure die casting copper is used to produce rotors for induction motors to improve efficiency.Experiments were carried out for a special"step-shape"casting with different step thicknesses.Based on the measured temperature inside the die,the interfacial heat transfer coefficient(IHTC)at the metal/die interface during vacuum die casting was evaluated by solving the inverse problem.The IHTC peak value was 4.5×10^3-11×10^3 W·m^-2·K^-1 under the basic operation condition.The influences of casting pressure,fast shot speed,pouring temperature and initial die surface temperature on the IHTC peak values were investigated.Results show that a greater casting pressure and faster shot speed could only increase the IHTC peak values at the location close to the ingate.An increase of pouring temperature and/or initial die surface temperature significantly increases the IHTC peak values.
文摘The reinforcement distribution of metal matrix composites (MMCs) plays an important role in low cycle fatigue. Thus, it is essential to study the effect of reinforcement clustering on the crack initiation mechanism of MMCs. In this study, the effect of reinforcement clustering on the microcrack initiation mechanism in a cast hybrid MMC reinforced with SiC particles and Al2O3 whiskers was investigated experimentally and numerically. Experimental results showed that microcracks always initiated in the particle-matrix interface, located in the cluster of the reinforcements. The interface debonding occurred in the fracture which created additional secondary microcracks due to continued fatigue cycling. The microcrack coalesced with other nearby microcracks caused the final fracture. To validate the experimental results on the microcrack initiation, three dimensional unit cell models using finite element method (FEM) were developed. The stress distribution in both the reinforcement clustering and non-clustering regions was analyzed. The numerical analysis showed that high stresses were developed on the reinforcements located in the clustering region and stress concentration occurred on the particle-matrix interface. The high volume fraction reinforced hybrid clustering region experienced greater stresses than that of the SiC particulate reinforced clustering region and low volume fraction reinforced hybrid clustering region. Besides, the stresses developed on the non-clustering region with particle-whisker series orientation were reasonably higher than that of the non-clustering region with particle-whisker parallel orientation. The high volume fraction reinforced hybrid clustering region is found to be highly vulnerable to initiate crack in cast hybrid MMC during low cycle fatigue.
文摘Metal foams are a new kind of materials with low densities and novel physical, mechanical, thermal, electrical and acoustic properties. They can be divided into closed and open cell structures. In this paper the open cell structures, called sponges, were treated. A new technique to manufacture sponges by plaster investment casting was described. Experimental results show that it is essential to make a sound plaster mould by casting plaster slurry into the polyurethane foams and infiltrate the open channels of the baked plaster mold by molten metal. The optimal processes include plaster slurry preparation, plaster mold baking, and molten metal infiltration. The sponge sample with porosity of 97% is presented.
文摘An unsteady mathematical thermal model was developed for predicting the time,molten-steel weight,induction heating power,and temperature changes of the steel from the end of ladle refining to the end of the continuous-casting process of a tundish. The calculations revealed that for a specific strip-casting process,the ladle tonnage should be controlled to about 90 t. If the ladle capacity reaches 130 t,the provision of a 1 500-kW tundish induction heating device is recommended. By comparing the measured and predicted molten-steel temperature values in the Ningbosteel-Baosteel strip casting industrialization demo project( NBS) of a tundish,it was determined that the prediction accuracy of the model could meet the forecasting accuracy requirements for the molten-steel temperature in the tundish during mass production. Simultaneously,the heat flux density on each surface of the tundish was found at about 50 min,which is entirely consistent with the values reported in the related literature,and the tundish had not reached a heat balance during the casting test period. This model can also be applied to calculate the suitable size of a tundish for a specific continuous-casting process,thereby providing a theoretical basis for the design of the continuous-casting tundish.
文摘This paper presents a technique for controlling the pressure of a molten metal when using a new type of iron casting method called sand mold press casting to realize high productivity and obtain high-quality products.The past test results using this method showed a casting yield of 90% to 95%,while conventional methods only show a casting yield of 60% to 70%.Although the press casting method does not require a sprue cup or runner channel casting defects such as metal penetration are often caused by the high pressure in the high-velocity pressing part of this casting process.Therefore,we proposed a pressure control method with a mathematical model of molten metal pressure,and with it we achieved experimental confirmation of the successful production of brake drums at different pressing temperatures.Results show that the proposed pressing control method can realize sound,penetration-free casting production.However,the theoretical analysis and design of this pressing process had not previously been studied sufficiently,and therefore this paper presents the theoretical design algorithm for the process as well as its experimental confirmation.
文摘SiCp/Gr/2024Al metal matrix composites were processed by squeeze casting technology. The microstructure of composites was observed by SEM and TEM, and the effects of graphite particulates and SiC particulates on the damping behaviors of composites were also investigated. The results show that the microstructure of composites was dense and homogeneous, without any interfacial reactivity among reinforcement/matrix interfaces. Compared with the damping capacity of 2024A1, the damping capacity of composites was enhanced significantly by addition of SiC or graphite particulates. The main damping mechanisms of SiCp/Al composites were ascribed to the dislocation damping, and those of SiCp/Gr/2024Al were attributed to the intrinsic damping and interface damping.
文摘<span style="font-family:Verdana;">It is numerically studied the influence of the angular velocity, the molten metal viscosity, and the mold wall roughness on the molten metal distribution in the mold of a horizontal centrifugal casting process. The undesirable raining phenomenon sometimes arises in horizontal centrifugal casting. It occurs when the molten metal rains or falls from the top of the mold to the bottom while the mold is rotating. Using Computational Fluid Dynamics simulations, the conditions for the emergence of the raining phenomenon were explored in this work. For the system considered, angular velocities less than 77 rad/s cause the emergence of the raining phenomenon and accumulation of the molten metal in the lower part of the mold, whereas angular velocities greater than 77 rad/s produce a constant thickness of the molten metal and prevent raining.</span>
文摘In aluminum killed steels, the size, shape, quantity and formation of non-metallic inclusions in ladle steel (before and after RH vacuum treatment) and in tundish as well as in slabs were studied by EPMA (Electron Probe Microanalysis) and by analyzing the total oxygen. The results showed that in the slabs the total oxygen was quite low and the inclusions discovered were mainly small-sized angular alumina inclusions. This indicates that most inclusions have been removed by floating out during the continuous casting process. In addition, the countermeasures were discussed to decrease the alumina inclusions in the slabs further.
文摘In order to know the behavior of non-metallic inclusions in centrifugal induction electroslag castings (CIESC), non-metallic inclusions in 5CrMnMo and 4Cr5MoSiV1 were qualitatively and quantitatively analyzed. The largest size of inclusions in the casting and the thermodynamic possibility of TiN precipitation in steel were also calculated. The results show that sulfide inclusions are evenly distributed and the content is low. The amount of oxide inclusions in CIESC: 4Cr5MoSiV1 steel is close to the ESR steel and lower than that in the EAF steel, and there are some differences along radial direction. Nitride inclusions are fine and the diameter of the largest one is 3-1 mum. With the increase of the centrifugal machine's rotational speed, the ratio of round inclusions increases and the ratio of sharp inclusions decreases. According to the experiment and the calculation results, it is pointed out that the largest diameter of non-metallic inclusions in the CIESC 4Cr5MoSiV1 casting is only 6.6 mum, and [N%][Ti%] in 4Cr5MoSiV1 steel should be controlled less than 4.4x 10(-5) in order to further reduce the amount and size of TiN inclusions.
文摘Aluminum based metal matrix composites were fabricated using stir casting where silicon carbide and alumina were the reinforcements. Different types of properties (physical-density, mechanical-tensile, hardness, chemical-corrosion etc.) were measured and compared with base metals/alloys. The properties were significantly varied. The highest density was obtained for pure aluminium with 5% Al<sub>2</sub>O<sub>3</sub> whereas the lowest was obtained for AA-4032 alloy. The highest hardness was obtained for AA-4032 with 5% Al<sub>2</sub>O<sub>3</sub> whereas the lowest was obtained for pure Al with 5% Al<sub>2</sub>O<sub>3</sub>. The highest strength was obtained for AA-6061 with 5% coarse SiC whereas the lowest was obtained for pure Al. The highest impact strength was obtained for AA-4032 with 5% Al<sub>2</sub>O<sub>3</sub> whereas the lowest was obtained for AA-6061. The corrosion resistance of all composites was lower than that of the base materials.