Hot spinning process has attracted significant attention because it can be used to manufacture complex parts, extend the forming limit of materials, decrease forming forces and reduce process chains. In this paper, we...Hot spinning process has attracted significant attention because it can be used to manufacture complex parts, extend the forming limit of materials, decrease forming forces and reduce process chains. In this paper, we review researches on lightweight metals spun at elevated temperatures since they are difficult to deform at room temperature. These metals include light alloys, such as titanium, magnesium and aluminum alloys, and metal composites. Then, the heating methods used in the hot spinning process and the treatment methods employed for the temperature boundary condition in finite element analyses for the process were discussed. Finally, the future development directions for the hot spinning process of lightweight but difficult-to-deform alloys were highlighted.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
The synthesis, processing and mechanical properties of the light metals, aluminum,magnesium and titanium Produced by advanced techniques are reviewed. Synthesis techniques to be addressed will include rapid solidifica...The synthesis, processing and mechanical properties of the light metals, aluminum,magnesium and titanium Produced by advanced techniques are reviewed. Synthesis techniques to be addressed will include rapid solidification, spray deposition, mechanical alloying, plasma Processing and vapor deposition.展开更多
Existing Metal Additive Manufacturing processes are fast approaching a matured stage in which a wide range of possibilities are available for the incorporation of the rapid fabrication technology to current industrial...Existing Metal Additive Manufacturing processes are fast approaching a matured stage in which a wide range of possibilities are available for the incorporation of the rapid fabrication technology to current industrial practices. In terms of design conventions, the limitless geometrical freedom allows complex structures including cellular internal grids and lattices to be formed without additional tooling. Repair parts and leveraging components can also be produced on demand when required especially for military assets where large volume of inventory is constantly maintained to ensure operational readiness. In this exemplary work, a feasibility study on using stainless steel material with integrated cellular design to manufacture a guide bracket found on a military vehicle via Selective Laser Melting process was conducted. The results showed appreciably better mechanical performance in using a stainless steel honeycomb as compared to the aluminum alloy used for the original component together with a faster production route through SLM.展开更多
纤维金属层板(fiber metal laminate,FML)是一种新型轻量化混杂材料,逐渐被应用于汽车等运载装备领域,但其成形过程受多种参数影响,成形过程中的应力应变分布规律尚不清楚。选用T300碳纤维铝合金复合层板为研究对象,利用ABAQUS有限元软...纤维金属层板(fiber metal laminate,FML)是一种新型轻量化混杂材料,逐渐被应用于汽车等运载装备领域,但其成形过程受多种参数影响,成形过程中的应力应变分布规律尚不清楚。选用T300碳纤维铝合金复合层板为研究对象,利用ABAQUS有限元软件对其冲压成形过程进行模拟,并进行了精度验证。主要研究了FML在预浸料种类、层板厚度和层板数等因素的影响下,应力分布及壁厚变化规律。结果表明,建立的FML冲压模型计算精度准确,预浸料种类主要影响纤维层的应力分布和壁厚变化,层板厚度和层板数对各层的壁厚变化产生影响,通过减薄层板厚度或增加层板数可以缓解过度减薄问题,层板厚度和层数也会影响铝合金层的应力分布,随着厚度和层数的增加,铝合金层的应力分布趋于均匀。展开更多
Lightweight sheet metals are highly desirable for automotive applications due to their exceptional strength-to-density ratio.An accurate description of the pronounced plastic anisotropy exhibited by these materials in...Lightweight sheet metals are highly desirable for automotive applications due to their exceptional strength-to-density ratio.An accurate description of the pronounced plastic anisotropy exhibited by these materials in finite element analysis requires advanced plasticity models.In recent years,significant efforts have been devoted to developing plasticity models and numeri-cal analysis methods based on the non-associated flow rule(non-AFR).In this work,a newly proposed coupled quadratic and non-quadratic model under non-AFR is utilized to comprehensively investigate the non-associated and non-quadratic characteristics during the yielding of three lightweight sheet metals,i.e.,dual-phase steel DP980,TRIP-assisted steel QP980,and aluminum alloy AA5754-O.These materials are subjected to various proportional loading paths,including uniaxial tensile tests with a 15°increment,uniaxial compressive tests with a 45°increment,in-plane torsion tests,and biaxial tensile tests using laser-deposited arm-strengthened cruciform specimens.Results show that the non-AFR approach provides an effective means for accurately modeling the yield behavior,including yield stresses and the direction of plastic strain rates,simultaneously,utilizing two separate functions and a simple calibration procedure.The introduction of the non-quadratic plastic potential reduces the average errors in angle when predicting plastic strain directions by the quadratic plastic potential function.Specifically,for DP980,the average error is reduced from 3.1°to 0.9°,for QP980 it is reduced from 6.1°to 3.9°,and for AA5754-O it is reduced from 7.0°to 0.2°.This highlights the importance of considering the non-quadratic characteristic in plasticity modeling,especially for aluminum alloys such as AA5754-O.展开更多
基金Project(51222509) supported by the National Science Fund for Excellent Young Scholars of ChinaProject(51175429) supported by the National Natural Science Foundation of ChinaProjects(97-QZ-2014,90-QP-2013) supported by the Research Fund of the State Key Laboratory of Solidification Processing(NWPU) of China
文摘Hot spinning process has attracted significant attention because it can be used to manufacture complex parts, extend the forming limit of materials, decrease forming forces and reduce process chains. In this paper, we review researches on lightweight metals spun at elevated temperatures since they are difficult to deform at room temperature. These metals include light alloys, such as titanium, magnesium and aluminum alloys, and metal composites. Then, the heating methods used in the hot spinning process and the treatment methods employed for the temperature boundary condition in finite element analyses for the process were discussed. Finally, the future development directions for the hot spinning process of lightweight but difficult-to-deform alloys were highlighted.
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.
文摘The synthesis, processing and mechanical properties of the light metals, aluminum,magnesium and titanium Produced by advanced techniques are reviewed. Synthesis techniques to be addressed will include rapid solidification, spray deposition, mechanical alloying, plasma Processing and vapor deposition.
文摘Existing Metal Additive Manufacturing processes are fast approaching a matured stage in which a wide range of possibilities are available for the incorporation of the rapid fabrication technology to current industrial practices. In terms of design conventions, the limitless geometrical freedom allows complex structures including cellular internal grids and lattices to be formed without additional tooling. Repair parts and leveraging components can also be produced on demand when required especially for military assets where large volume of inventory is constantly maintained to ensure operational readiness. In this exemplary work, a feasibility study on using stainless steel material with integrated cellular design to manufacture a guide bracket found on a military vehicle via Selective Laser Melting process was conducted. The results showed appreciably better mechanical performance in using a stainless steel honeycomb as compared to the aluminum alloy used for the original component together with a faster production route through SLM.
文摘纤维金属层板(fiber metal laminate,FML)是一种新型轻量化混杂材料,逐渐被应用于汽车等运载装备领域,但其成形过程受多种参数影响,成形过程中的应力应变分布规律尚不清楚。选用T300碳纤维铝合金复合层板为研究对象,利用ABAQUS有限元软件对其冲压成形过程进行模拟,并进行了精度验证。主要研究了FML在预浸料种类、层板厚度和层板数等因素的影响下,应力分布及壁厚变化规律。结果表明,建立的FML冲压模型计算精度准确,预浸料种类主要影响纤维层的应力分布和壁厚变化,层板厚度和层板数对各层的壁厚变化产生影响,通过减薄层板厚度或增加层板数可以缓解过度减薄问题,层板厚度和层数也会影响铝合金层的应力分布,随着厚度和层数的增加,铝合金层的应力分布趋于均匀。
基金support of the BK21 Four program(SNU Materials Education/Research Division for Creative Global Leaders)support from the Science and Technology Commission of Shanghai Municipality(grant number:21170711200)+2 种基金MGL appreciates the grant from NRF(No.2022R1A2C2009315)supported by the KEIT(1415185590,20022438)funded by the Ministry of Trade,Industry&Energy(MOTIE,Korea).
文摘Lightweight sheet metals are highly desirable for automotive applications due to their exceptional strength-to-density ratio.An accurate description of the pronounced plastic anisotropy exhibited by these materials in finite element analysis requires advanced plasticity models.In recent years,significant efforts have been devoted to developing plasticity models and numeri-cal analysis methods based on the non-associated flow rule(non-AFR).In this work,a newly proposed coupled quadratic and non-quadratic model under non-AFR is utilized to comprehensively investigate the non-associated and non-quadratic characteristics during the yielding of three lightweight sheet metals,i.e.,dual-phase steel DP980,TRIP-assisted steel QP980,and aluminum alloy AA5754-O.These materials are subjected to various proportional loading paths,including uniaxial tensile tests with a 15°increment,uniaxial compressive tests with a 45°increment,in-plane torsion tests,and biaxial tensile tests using laser-deposited arm-strengthened cruciform specimens.Results show that the non-AFR approach provides an effective means for accurately modeling the yield behavior,including yield stresses and the direction of plastic strain rates,simultaneously,utilizing two separate functions and a simple calibration procedure.The introduction of the non-quadratic plastic potential reduces the average errors in angle when predicting plastic strain directions by the quadratic plastic potential function.Specifically,for DP980,the average error is reduced from 3.1°to 0.9°,for QP980 it is reduced from 6.1°to 3.9°,and for AA5754-O it is reduced from 7.0°to 0.2°.This highlights the importance of considering the non-quadratic characteristic in plasticity modeling,especially for aluminum alloys such as AA5754-O.
