Semisolid casting with ultrasonically melt-treated billets of Al-7mass%Si alloys

Abstract： The demand for high performance cast aluminum alloy components is often disturbed by increasing impurity elements, such as iron accumulated from recycled scraps. It is strongly required that coarse plate-like iron compound of β-Al5FeSi turns into harmless form without the need for applying refining additives or expensive virgin ingots. The microstructural modification of Al-7mass%Si alloy billets with different iron contents was examined by applying ultrasonic vibration during the solidification. Ultrasonically melt-treated billets were thixocast right after induction heating up to the semisolid temperature of 583 ℃, the microstructure and tensile properties were evaluated in the thixocast components. Globular primary reAl is required to fill up a thin cavity in thixocasting, so that the microstructural modification by ultrasonic melt-treatment was firstly confirmed in the billets. With ultrasonic melt-treatment in the temperature range of 630 ℃ to 605 ℃, the primary α-AI transforms itself from dendrite into fine globular in morphology. The coarse plate-like β-AIsFeSi compound becomes markedly finer compared with those in non-treated billets. Semisolid soaking up to 583 ℃, does not appreciably affect the size of β-AIsFeSi compounds; however, it affects the solid primary reAl morphology to be more globular, which is convenient for thixocasting. After thixocasting with preheated billets, eutectic silicon plates are extremely refined due to the rapid solidification arising from low casting temperature. The tensile strength of thixocast samples with different iron contents does not change much even at 2mass% of iron, when thixocast with ultrasonically melt-treated billets. However, thixocast AI-7mass%Si-2mass%Fe alloy with non-treated billets exhibits an inferior strength of 80 MPa, compared with 180 MPa with ultrasonically melt-treated billets. The elongation is also improved by about a factor of two in thixocastings with ultrasonically melt-treated billets for all iron contents of AI-7mass%Si alloys, for example, the elongation of 11% in thixocast of AI-7mass%Si-0.5mass%Fe alloy with ultrasonically melt-treated billets, 5% in that with non-treated billets.

Influences of acoustic field parameters on welding arc behavior in ultrasonic-MIG welding

By applying ultrasonic-MIG welding as research object, the behaviors of welding arc were analyzed with varied ultrasonic parameters in welding using arc images recorded by high-speed camera. The influences of the current by exciting ultrasonic and the height and shape of ultrasonic radiator on welding arc were studied. Results showed that when the current was 150 mA, ultrasonic showed most distinct compressive effect on arc. The compressive volumes of arc length at different heights were calculated by adjusting the height of ultrasonic radiator continuously from 10 mm to 35 mm, there were three maximum points. The compressive degrees of them reduced successively. By utilizing different shapes of ultrasonic radiator, it revealed that ultrasonic radiator with spherical crown surface showed better compressive effect in a larger welding standard scope. When radius of radiator increased, axial compressive volume of arc enlarged, while an increasing curvature radius led to mare distinct radial compression of arc.

Ultrasonic backward radiation profile on painted rough interface

Generalized Lamb surface waves are generated in a surface region when ultrasonic waves are incident to the layered substrates such as painted specimen in liquid. Then, backward radiated waves are returned to the direction of incidence by scattering and energy radiation of the surface waves. Hence, the backward radiation could be used in assessing the interracial state between layer and substrate because the surface wave is sensitive to the change of physical properties in a surface region. Painting surface treatment of commercial products and articles occasionally hide the surface region trouble such as roughness and crack. The evaluation of interfacial state under painting layer is very important in the prevention of great accidence, hence the evaluation technique should be nondestructive, fast and easy applicable to the fields. The backward radiations were measured for the painted glass with periodic interfacial roughness immersed in water tank. The effect of interfacial roughness on the angular pattern and frequency spectrum of the ultrasonic backward radiation was investigated to develop the nondestructive technique for interfacial roughness evaluation.

Measurement of acoustic field radiated by low frequency power ultrasonic transducer with laser-interferometer

Based on the piezo-optic effect of medium, the refractive index of medium is the function of its density, and so it's also the function of acoustic pressure. Therefore, acoustic pressure in the optical path everywhere can be determined absolutely by laser-interferometric technique and relative distribution of pressure in the middle and far acoustic field, which can be obtained from theory or experiment respectively. Theory and experiment of measurement of pressure in acoustic field with laser-interferometer are introduced. Distribution of pressure radiated by a power ultrasonic transducer is determined by laser interferometric technique. The theoretical and experimental results are in good agreement. The receiving sensitivity of a PVDF (Polyvinylidene fluoride) transducer in free field is also calibrated absolutely due to above results and its sensitivity is -118.5 dB.

Study on rectangular ultrasonic radiator of flexural resonant vibration in high modes

Based on the theory of coupling vibration and flexural vibration of thin rod of rectangular cross section, the flexural vibration of rectangular thin plate was studied. The frequency equation was derived under the condition of free boundaries. The normal modes and the relation between the normal modes and the resonant frequency were obtained. Experiments showed that the calculated resonant frequencies agree well with the measured results, and the rectangular thin plate in flexural vibration has abundant resonant frequencies. The radiator of flexural vibration used in ultrasonic cleaning and other techniques has the advantages of large acoustic radiating area, uniform acoustic field and easy adjustment of resonant frequencies, proving that it is a promising ultrasonic source.