Trend and Development of Semi-Solid Metal Processing

This paper reviewed the trend and development of semi-solid metal technique. The processes and mechanisms for producing slurry of SSM and its industrial applications have been summarized and discussed. Discussions on the basic rheological theory are presented for more applications. Further consideration of the development and application of SSM technique is also proposed.

South China University of fechnology Advanced Metallic Materials Research and Processing Technology Center

A dvanced Metallic Materials Research and Processing Technology Center was found in December 1998. As a unit under The College of Mechanical Engineering, the Center is an expansion of the former Cast and Composite Materials Research Group, which was found in the early eighties of last century. The Center is focusing in the basic and applied research, and development of advanced metallic materials and their processing technology. It also functions as an organization

Discussion on the Teaching of“Metallic Mineral Processing”for Mineral Processing Engineering

Social economic growth and the increasing demand for mineral resources have promoted the development of metallic mineral processing technology.Therefore,in order to satisfy the demands for development in mining,cultivating comprehensive mineral processing engineering professionals with strong innovative practical skills has become the top priority in current education.We have established a new course,“Metallic Mineral Processing,”for students majoring in mineral processing engineering in universities,with coal and other sources of energy as the main focus.This paper analyzes the purpose and significance of setting up this course and the exploration of the reform of the teaching mode,with the aim of improving the teaching quality and ensuring the cultivation of mineral processing engineering undergraduates.

Observation of interface of two kinds of bi-metal composite parts prepared by thixo-forging

Two kinds of bi-metal composite parts （Sn-15%Pb and Pb-22%Sn bi-metal system, and Al-7%Si and SiCp/6061 MMC bi-metal system） were prepared by the strain-induced melt activated thixo-forging. The interfaces of the bi-metal composites were observed by OM and SEM. The observations show that the semisolid metals keep independence during thixo-forging. The solid phases in the semisolid slurries maintain their original morphologies after thixo-forging. The liquid phases near the interface mix together and form a thin layer. The interfaces are bonded firmly with the metallurgical bonding. No oxide layers are found at the interfaces. Strengths of the interfaces were investigated by the micro-hardness test. The experimental results show that the composite interfaces have high strength. However, the agglomerated enhancing particles cause fine defect on the interface of the Al-7%Si and SiCr/6061 MMC bi-metal composite.

AN EXPERIMENTAL STUDY OF CO_2 LASER CUTTING OF METALLIC COATED SHEET STEELS

An experimental investigation is outlined for the CO 2 laser cutting process of metallic coated sheet steels, GALVABOND. It shows that by proper control of the cutting parameters, good quality cuts are possible at high cutting rate. Visual examination indicates that when increasing the cutting rate to as high as 5000 mm/min (about 100 times that suggested previously), kerfs of better quality can be achieved. Some kerf characteristics such as the width, heat affected zone and dross in terms of the process parameters are also discussed. A statistical analysis has arrived at a recommendatio on the optimum cutting parameters forprocessing GALVABOND.

Numerical Methodology for Metal Forming Processes Using Elastoplastic Model with Damage Occurrence

Ductile damage often occurs during metal forming processes due to the large thermo-elasto （visco） plastic flow Iocalisation. This paper presents a numerical methodology, which aims to virtually improve any metal forming processes. The methodology is based on elastoplastic constitutive equations accounting for nonlinear mixed isotropic and kinematic hardening strongly coupled with isotropic ductile damage. An adaptive remeshing scheme based on geometrical and physical error estimates including a kill element procedure is used. Some numerical results are presented to show the capability of the model to predict the damage initiation and growth during the metal forming processes.

Comparative evaluation of processes for heavy metal removal from municipal solid waste incineration fly ash

Hydrochloric acid leaching, chloride evaporation, acetic acid leaching, and biological leaching were evaluated and compared as processes of heavy metal removal for municipal solid waste incineration fly ash(MSWFA). Six factors, namely, energy consumption, process efficiency, process handling, process cost estimation, cost reduction potential, and study progress, were used in order to find out their advantages and disadvantages and to help develop a better recovery process of heavy metals from MSWFA in terms of treatment of the waste material. Hydrochloric acid leaching process was found to be most balanced among the evaluated processes. It showed superiority on energy consumption, process cost estimation, and study progress. On the other hand, despite of its excellency in process efficiency, chloride evaporation process was most unfavorable mainly due to heavy energy dependence. Biological process, with huge potential of cost reduction, was concluded to be the second best process.

Inner-Sphere Reorganization Eneregy For Metal Ion-Benzene Complex in Electron-Transfer Process

Based on the capture force field potential model and the adiabatic invariant proposed by Bates, adopting improved average dipole orientation (IADO) theory, the force constants between transition metal ions and benzene (bz) and also a series of inner-sphere reoganization energy (REin) were calculated. The reasons for the differences between theoretical predictions and experimental results were discussed.

Conventional and micro scale finite element modeling for metal cutting process:A review

The metal cutting process is accompanied by complex stress field,strain field,temperature field.The comprehensive effects of process parameters on chip morphology,cutting force,tool wear and residual stress are complex and inter-connected.Finite element method(FEM)is considered as an effective method to predict process variables and reveal microscopic physical phenomena in the cutting process.Therefore,the finite element(FE)simulation is used to research the conventional and micro scale cutting process,and the differences in the establishment of process variable FE simulation models are distinguished,thereby improving the accuracy of FE simulation.The reliability and effectiveness of FE simulation model largely depend on the accuracy of the simulation method,constitutive model,friction model,damage model in describing mesh element,the dynamic mechanical behavior of materials,the tool-chip-workpiece contact process and the chip formation mechanism.In this paper,the FE models of conventional and micro process variables are comprehensively and up-to-date reviewed for different materials and machining methods.The purpose is to establish a FE model that is more in line with the real cutting conditions,and to provide the possibility for optimizing the cutting process variables.The development direction of FE simulation of metal cutting process is discussed,which provides guidance for future cutting process modeling.

Formation and Evolution of Non-dendritic Microstructures of Semisolid Alloys Prepared by Shearing/Cooling Roll Process

The shearing/cooling roll （SCR） process was adopted to prepare semi-solid A2017 alloy. The formation and evolution of non-dendritic microstructures in semi-solid A2017 alloy were studied. It is shown that the microstructures of semi-solid billets transform from coarse dendrites into fine equiaxed grains as the pouring temperature of molten alloy decreases o.r roll-shoe cavity height is reduced. From the inlet to the exit of roll-shoe cavity, microstructure of semi-solid slurry near the shoe surface is in the order of coarse dendrites, degenerated dendrites or equiaxed grains, but fine equiaxed grains are near the roll surface. Microstructural evolution of semi-solid slurry prepared by SCR process is that the molten alloy nucleates and grows into dendrite firstly on the roll and shoe＇s surface. Under the shearing and stirring given by the rotating roll, the dendrites crush off and disperse into the melt. Under the shearing and stirring on semi-solid slurry with high volume fraction of solid, the dendrite arms fracture and form equiaxed grain microstructures.

Cellular automaton modeling of semisolid microstructure formation

Computer modeling of semi-solid structure formation is of significance in both understanding the mechanisms of globular structure formation and determining the effect of solidification conditions on final microstructure.A modified cellular automaton(mCA) model has been developed,which is coupled with macroscopic models for heat transfer calculation and microscopic models for nucleation and grain growth.The mCA model is applied to A356 Al alloy-one of the most widely used semi-solid alloys,to predict grain morphology and grain size during semi-solid solidification,and determines the effects of pouring temperature on the final microstructure.The modeling results show that the lower the initial temperature,the finer grain size will be obtained.In addition,the model can be used to predict the solutal micro-segregation.

Grain Size Control of Semisolid A356 Alloy Manufactured by Electromagnetic Stirring

To investigate the possibility of substituting the mechanical stirring system with electromagnetic stirring (EMS) system for aluminum rheo die-casting, the EMS under the different stirring cooling conditions was carried out. It was found that in the early period of solidification, the dendrite breakages led to a fine primary phase. When dendrites grew coarsely, the effect of ripening on grain size overwhelmed that of dendrite breakage. It was also found that the high cooling rate favored large nucleation rate, and led to a fine primary phase. But high cooling rate also made the growth rate of the dendrite arm, which prevented the dendrite arm from being sheared off. Therefore there were a suitable stirring time and suitable cooling rate to obtain the best rheo die-casting structure. Qualified semisolid A356 aluminum alloy was successfully manufactured with short time EMS.

Evaluation of Contact Pressure in Bending under Tension Test by a Pressure Sensitive Film

The contact pressure acting on the sheet/tools interface has been studied because of growing the concern about the wear of tools. Recent studies make use of numerical simulation software to evaluate and correlate this pressure with the friction and wear generated. Since there are many studies that determine the coefficient of friction in sheet metal forming by bending under tension (BUT) test, the contact pressure between the pin and the sheet was measured using a film that has the ability to record the applied pressure. The vertical force applied to pin was also measured. The results indicate that the vertical force is more accurate to set the contact pressure that using equations predetermined. It was also observed that the contact area between the sheet and the pin is always smaller than the area calculated geometrically. The friction coefficient was determined for the BUT test through several equations proposed by various authors in order to check if there is much variation between the results. It was observed that the friction coefficient showed little variation for each equation, and each one can be used. The material used was the commercially pure aluminum, alloy Al1100.

Chifeng City Creates NationalLevel Nonferrous Metals Smelting Processing Base

As'China’s hometown of nonferrous metals',Chifeng City is the biggest concentration zone in Inner Mongolia’s nonferrous metals industry.Copper resources accounts for 17% of the whole region,lead resource accounts for 35%,zinc resource accounts for 30%,tungsten resource accounts for 42%,tin resource accounts for 88%,molybdenum resource accounts for 15%,gold resource accounts

Mobility and sulfidization of heavy metals in sediments of a shallow eutrophic lake, Lake Taihu, China

The technique of DGT（diffusive gradients in thin films） using three diffusive gel thicknesses was applied to estimate the mobility and bioavailability of heavy metals in sediments and porewater of Lake Taihu, China. The DGT results showed significantly positive correlations between Co, Pb, Cd and Mn, and Ni and Fe concentrations in porewater. Cu and Zn showed a significantly negative correlation with Mn, due to Cu combination with carbonates and Zn derived from agricultural pollution, respectively. The rank order of average concentrations of Co, Ni and Cd at each station was DGT1.92〉DGT0.78〉 DGT0.39, suggesting stronger resupply from sediments to porewater when using thicker diffusive gels. Comparing centrifugation and DGT measurements, Co, Ni and Cd are highly labile; Mn and Fe are moderately labile; and Cu, Zn and Pb are slightly labile. The variations of AVS concentrations in sediment cores indicate that metal sulfides in deeper layers are easily diffused into surface sediments.

Interfacial engineering of printable bottom back metal electrodes for full-solution processed flexible organic solar cells

Printing of metal bottom back electrodes of flexible organic solar cells（FOSCs） at low temperature is of great significance to realize the full-solution fabrication technology. However, this has been difficult to achieve because often the interfacial properties of those printed electrodes, including conductivity, roughness, work function,optical and mechanical flexibility, cannot meet the device requirement at the same time. In this work, we fabricate printed Ag and Cu bottom back cathodes by a low-temperature solution technique named polymer-assisted metal deposition（PAMD） on flexible PET substrates. Branched polyethylenimine（PEI） and ZnO thin films are used as the interface modification layers（IMLs） of these cathodes. Detailed experimental studies on the electrical, mechanical, and morphological properties, and simulation study on the optical properties of these IMLs are carried out to understand and optimize the interface of printed cathodes. We demonstrate that the highest power conversion efficiency over 3.0% can be achieved from a full-solution processed OFSC with the device structure being PAMDAg/PEI/P3 HT：PC61BM/PH1000. This device also acquires remarkable stability upon repeating bending tests.

Process designing for laser forming of circular sheet metal

Laser forming is a new type of flexible manufacturing process that has become viable for the shaping of metallic components. Process designing of laser forming involves finding a set of process parameters, including laser power, laser scanning paths, and scanning speed, given a prescribed shape. To date, research has focused on process designing for rectangular plates, and only a few studies are presented for axis-symmetric geometries like circular plates. In the present study, process designing for axis-symmetric geometries--with focus on class of shapes--is handled using a formerly proposed distance-based approach. A prescribed shape is achieved for geometries such as quarter-circular and half-circular ring plates. Experimental results verify the applicability of the proposed method for a class of shapes.

Optical properties and dynamic process in metal ions doped on CdSe quantum dots sensitized solar cells

In recent years, the nanostructure for solar cells have attracted considerable attention from scientists as a result of a promising candidate for low cost devices. In this work, quantum dots sensitized solar cells with effective performance based on a co-sensitized Cd S∕Cd Se：Mn2＋（or Cu2＋） nanocrystal, which was made by successive ionic layer absorption and reaction, are discussed. The optical, physical, chemical, and photovoltaic properties of quantum dots sensitized solar cells were sensitized to Mn2＋and Cu2＋dopants. Therefore, the short current（JSC）of the quantum dot sensitized solar cells is boosted dramatically from 12.351 mA∕cm2 for pure Cd Se nanoparticles to 18.990 mA∕cm2 for Mn2＋ions and 19.915 mA∕cm2 for Cu2＋ions. Actually, metal dopant extended the band gap of pure Cd Se nanoparticles, reduced recombination, enhanced the efficiency of devices, and improved the charge transfer and collection. In addition, Mn2＋and Cu2＋dopants rose to the level of the conduction band of pure Cd Se nanoparticles, which leads to the reduction of the charge recombination, enhances the lightharvesting efficiency, and improves the charge diffusion and collection. The results also were confirmed by the obtained experimental data of photoluminescence decay and electrochemical impedance spectroscopy.

Microstructural Evolution of Solid-solution-treated Zn-22Al in the Semisolid State

The effect of solid-solution-treatment on the semisolid microstructure of Zn-22Al with developed dendrites was investigated. Forming Zn-22Al products by semisolid metal processing offers significant advantages, such as reductions in macro-segregation, porosity and forming costs. Thermal and rnicrostructural analyses of the formed Zn-22Al alloy were performed by differential scanning calorimetry, scanning electron microscopy and optical microscopy. The changes in the microstructures and phase transformation in response to various solid- solution-treatments were analysed. In this study, as-cast samples were held isothermally at 330 ℃ for 0.5- 5 h and then partially remelted at a semisolid temperature of 438 ℃ for 1 h to produce a solid-globular grain structure in a liquid matrix. A non-dendritic semisolid microstructure could not be obtained when the traditionally cast Zn 22Al alloy with developed dendrites was subjected directly to partial remelting. After solid-solution-treatment at 330 ℃, the black interdendritic eutectics were dissolved, and the dendritic structures gradually transformed into uniform β structures when the treatment time was increased. The coarsened and merged dendrites were separated as a result of penetration by the liquid phase and melting of the residual eutectic at sites along the former grain boundaries. The microstructure of the solid-solution- treated sample transformed into a small globular structure; the best shape factor of 0.9, corresponding to a particle size of 40 ± 16 μm, is achieved when the sample was treated for 3 h followed by direct partial remelting into its semisolid zone.

Effect of Welding Processes and Consumables on Tensile and Impact Properties of High Strength Quenched and Tempered Steel Joints

Quenched and tempered steels are prone to hydrogen induced cracking in the heat affected zone after welding. The use of austenitic stainless steel consumables to weld the above steel was the only available remedy because of higher solubility for hydrogen in austenitic phase. In this investigation, an attempt was made to determine a suitable consumable to replace expensive austenitic consumables. Two different consumables, namely, austenitie stain less steel and low hydrogen ferritic steel, were used to fabricate the joints by shielded metal are welding （SMAW） and flux cored arc welding （FCAW） processes. The joints fabricated by using low hydrogen ferritic steel consumables showed superior transverse tensile properties, whereas joints fabricated by using austenitic stainless steel consumables exhibited better impact toughness, irrespective of the welding process used. The SMAW joints exhibited superior mechanical and impact properties, irrespective of the consumables used, than their FCAW counterparts.