Effect of tin addition on microstructure and electrochemical properties of rolled AZ61-Sn magnesium anodic materials

Microstructure characterization, corrosion behavior, and electrochemical properties of magnesium anode materials containing 1-3 wt.% Sn in AZ61 alloy were studied by optical microscopy, X-ray diffraction （XRD）, scanning electron microscopy （SEM）, and energy-dispersive spec- troscopy （EDS）, constant current method, potential polarization, and drainage. The results showed that amount of Mg2Sn phase increased, and recrystallization ratio of Sn-contained Mg alloys during rolling process was improved with increasing of Sn content. This resulted in uniform and refined gains. The results also demonstrated that discharge potential was improved and hydrogen release rate was reduced with the addition of Sn. As the current density increased, the release hydrogen rate was rising, owing to negative variance effect of magnesium alloys. The current efficiency gets to 87% at 20 mA/cm2. The main components of the corrosion products are easy-to-peel-off MgO and Al2O3 that can lead to more negative and stable work potential and accelerate battery reaction continuously.

Microstructural evolution in Al-Zn eutectoid alloy by hot-rolling

The Al-Zn eutectoid alloy has been widely known as a typical superplastic metallic material, where fine-grained microstructure is usually obtained by heat treatment. Recently, thermo-mechanical controlled process has also been reported to provide a fine-grained microstructure. In the present study, Al-Zn alloy ingots of 20 mm in thickness were homogenized and hot-rolled to a thickness of 2 mm under three processes： 1） the specimen was air-cooled after homogenization and hot-rolled; 2） the specimen was water-quenched after homogenization and hot-rolled; 3） the specimen was immediately hot-rolled after homogenization. Microstructural observation showed that, in processes l and 3, lamellar microstructure was formed after homogenization, and became fragmented to fine-grained microstructure as the hot roiling process proceeded. In process 2, fine-grained microstructure without lamellar microstructure was attained throughout the hot-rolling process. A minimum grain size of 1.6 μm was obtained in process 3. Tensile tests at room temperature showed that the elongation to failure was the largest in process 3.

Finite Element Simulation of Flexible Roll Forming with Supplemented Material Data and the Experimental Verification

Flexible roll forming is a promising manufacturing method for the production of variable cross section products. Considering the large plastic strain in this forming process which is much larger than that of uniform deformation phase of uniaxial tensile test, the widely adopted method of simulating the forming processes with non-supplemented material data from uniaxial tensile test will certainly lead to large error. To reduce this error, the material data is supplemented based on three constitutive models. Then a finite element model of a six passes flexible roll forming process is established based on the supplemented material data and the original material data from the uniaxial tensile test. The flexible roll forming experiment of a B pillar reinforcing plate is carried out to verify the proposed method. Final cross section shapes of the experimental and the simulated results are compared. It is shown that the simulation calculated with supplemented material data based on Swift model agrees well with the experimental results, while the simulation based on original material data could not predict the actual deformation accurately. The results indicate that this material supplement method is reliable and indispensible, and the simulation model can well reflect the real metal forming process. Detailed analysis of the distribution and history of plastic strain at different positions are performed. A new material data supplement method is proposed to tackle the problem which is ignored in other roll forming simulations, and thus the forming process simulation accuracy can be greatly improved.

Applicability of discrete element method with spherical and clumped particles for constitutive study of granular materials

Discrete element method(DEM)has been intensively used to study the constitutive behaviour of granular materials.However,to what extent a real granular material can be reproduced by virtual DEM simulations remains unclear.This study attempts to answer this question by comparing DEM simulations with typical features of experimental granular materials.Three groups of models with spherical and clumped particles are investigated from four perspectives:(i)deviatoric stress and volumetric behaviour;(ii)critical state behaviour;(iii)stress-dilatancy relationship;and(iv)the evolution of principal stress ratio against axial strain.The results demonstrate that DEM with spherical or clumped particles is capable of qualitatively describing macroscopic deviatoric stress responses,volumetric behaviour,and critical state behaviour observed in experiments for granular materials.On the other hand,some qualitative deviations between experiments and the investigated DEM simulations are also observed,in terms of the stress-dilatancy behaviour and principal stress ratio against axial strain,which are proven to be critical for constitutive modelling.The results demonstrate that DEM with spherical or clumped particles may not necessarily fully capture experimental features of granular materials even from a qualitative perspective.It is thus encouraged to thoroughly validate DEM with experiments when developing constitutive models based on DEM observations.

FEM simulation of flexible roll forming based on different material models

Flexible roll forming is a new roll forming process that produces parts with variable cross sections. This forming process is proposed to meet the demand of weight reduction of automobile industry. In order to study the mechanisms and material flow rules in this new forming process,the finite element mothod( FEM) model of a nine-step flexible roll forming of an ultra-high-strength steel bumper is established based on deep understanding and reasonable simplification of the process.Given that the material model is an important factor that influences the simulation accuracy,three material models which consist of different yield criteria and hardening models are adopted in the FEM models. Sheet thickness and springback amount calculated with three material models are studied comparatively. According to sheet thickness reduction and springback amounts,it is found that the MKi( Mises yield criterion and kinematic hardening law) model's result is larger than MI( Mises yield criterion and isotropic hardening law) model and HI( Hill's yield criterion and isotropic hardening law) model. Therefore,it is concluded that material models do have influences on the flexible roll forming simulation and need to be determined carefully.

Deformation Stability of GH4033 Superalloy in the Hot Continuous Rolling Process Based on Dynamic Material Model and Finite Element Model

The flow stress behavior of GH4033 superalloy was determined by the hot compression tests at the temperatures of 1223-1473 K and the total strains of 0.6 with the strain rates of 0.001-30.0 s^(-1) by using cylindrical samples.The processing maps based on the dynamic material model(DMM)combined with the corresponding microstructure observations indicate the reasonable processing domain locating at the strain rates of 0.1-1.0 s^(-1) and the deformation temperature of 1273-1423 K.Meanwhile,the numerical simulation based on finite element model(FEM)described the variation of the effective strain,effective strain rate and the temperature for the core node,and unveiled the influence of the hot rolling parameters considering the initial temperature(T_(0))range of 1223-1473 K and the first-stand biting velocity(v_(0))range of 0.15-0.35 m·s^(-1).Furthermore,the deformation stability of GH4033 superalloy in the round rod hot continuous rolling(HCR)process is described and analyzed by coupling the three-dimensional(3-D)processing map,and the spatial trajectory lines were determined by the numerically simulated temperatures,the strains and the strain rates.Finally,the results show that the hot deformation stability of GH4033 can be achieved by the rolling process parameters located at T_(0)=1423 K and v_(0)=0.25 m·s^(-1).Additionally,the practical HCR processes as T_(0)=1423 K and v_(0)=0.15,0.25,0.35 m·s^(-1) were operated to verify the influence of the hot rolling parameters on the hot deformation stability by the microstructure observation of the final products.

应用新结构、新材料开发配套低滚动阻力轮胎

应用新结构、新材料开发配套12R22.5 C600低滚动阻力轮胎。应用超高强度骨架材料,胎体采用0.17+5×0.215+10×0.235CCST钢丝帘线,带束层采用4+3×0.35ST钢丝帘线,钢丝包布采用0.17+5×0.215+10×0.235CCST钢丝帘线;优化配方设计,胎面胶采用低滚动阻力胶料,基部胶采用低滞后损失胶料;优化胎冠弧设计以及胎肩和胎圈部位材料分布。成品轮胎的充气外缘尺寸符合国家标准要求,耐久性能良好,滚动阻力达到欧盟标签C级,满足客户的需求,轮胎装车后行驶里程达到20万km,与普通轮胎相比,平均每百公里可节油1.13 L。

石墨烯/多孔聚酰亚胺自润滑保持架材料的制备及其性能

为提高航天长寿命轴承用多孔聚酰亚胺(PPI)保持架材料的自润滑性能,采用机械混合和原位聚合的方式分别制备了石墨烯(GP)改性多孔聚酰亚胺材料,通过扫描电镜、压汞仪、万能拉伸试验机及摩擦试验机等设备对其微孔性能、力学性能以及摩擦学性能进行分析,结果表明:原位聚合能形成“蜂窝状”多孔结构,有利于制备低孔隙率和小孔径的多孔聚酰亚胺材料;石墨烯含量0.5%时,机械混合和原位聚合工艺所制得复合材料的拉伸强度均最高,较未改性PPI分别提高了13.0%和42.3%;石墨烯含量0.5%和1.0%时,原位聚合试样具有更优异的耐磨性,磨损量较未改性PPI分别降低了73.3%和47.8%。

随动辊压型低应力精密断料教学实验平台开发

为了增强学生对先进成形装备及低应力精密断料技术的理解,开发了随动辊压型低应力精密断料教学实验平台。该实验平台综合利用机械设计、传感器技术及计算机控制技术,将应力集中效应和随动辊压技术引入管料的精密分离断料工序中,设计了管料断面质量评价方法,对带有V型槽的45#钢及304不锈钢管料进行了裂纹可控式低应力精密下料实验,验证了断料效果。该实验平台不仅使低应力断料过程更加直观,还提升了学生对低应力精密成形技术的认识,增强了学生对“机械制造工程基础”“切削原理与刀具”及“先进制造技术”等课程的学习兴趣。

钛合金材料超声滚压加工的仿真分析与实验研究

采用普通滚压加工工艺对钛合金材料进行加工时,存在因低频冲击造成的工件残余应力分布不均匀和表面硬度低等问题,为此,开展了钛合金材料超声振动滚压工艺仿真及实验研究。首先,从理论层面分析了超声滚压加工的运动学及动力学特性,找出了影响超声滚压加工性能的相关因素;然后,采用ABAQUS有限元软件建立了钛合金材料的仿真模型,分析了超声滚压对残余应力的影响及强化机理;最后,设计了钛合金工件的超声滚压实验,研究了不同参数指标对工件加工质量的影响,并根据实验结果对仿真模型和残余应力结果进行了验证。研究结果表明:随着静载荷和超声振幅的增加,工件表面残余应力分布相对均匀且趋于平稳,表面粗糙度呈现先降低后增加的趋势,表面硬度随强化层深度的增加逐渐降低;在振幅为20μm时,工件表面质量和性能相对较好,此时残余应力均值为849 MPa,表面粗糙度均值为0.1μm。该实验结果与仿真分析结果一致,验证了所建模型的可靠性,可为滚压制造工艺参数的选取提供参考。

DC53钢连轧棒材退火工艺研究

为了满足DC53材料对加工硬度的特殊需求(硬度≤220 HB),对冷作模具钢DC53热轧材进行了不同退火工艺的试验。结果表明DC53的退火硬度与球化退火的工艺有很大关系,球化退火加热温度850℃、等温温度750℃为最佳退火工艺。在生产中应用该最佳退火工艺后,钢材的硬度均匀,平均硬度HB210左右,金相组织合格,满足用户标准要求。

采用大变形本构模型预测热轧AISI316不锈钢厚板的轧制力

采用热扭转实验数据,建立了一个AISI316钢大变形本构模型。根据建立的本构模型,采用三维有限元法模拟计算了AISI316钢热轧过程,并对计算的轧制力与实测的轧制力进行了分析。结果表明,在压下率30%~50%之间,计算值比实测值低约7%,在压下率为65%时,计算值比实测值低约12%,在工业应用范围内,采用确定的AISI316钢大应变本构模型计算的轧制力具有较高的预测精度。

基于LSTM模型的船舶材料成本滚动预测

船舶建造周期长、材料成本占比大,易受大宗商品价格指数和汇率等多个因素的影响,造成实际完工成本与报价估算存在较大误差的情况。采用灰色关联分析(Grey Correlation Analysis,GCA)方法识别材料成本的影响因素,基于长短期记忆网络(Long Short-Term Memory,LSTM)模型构建船舶材料成本滚动预测模型,并使用某造船企业53艘64000 t散货船63个月的材料成本数据和对应的影响因素数据进行试验分析。结果表明,预测数据与实际数据误差在可接受范围内,可证明所选择方法和构建模型的有效性。研究结果对制造过程的成本实时预测和控制具有现实意义。

面板堆石坝含特细砂砂砾石填筑料碾压特性研究

阿尔塔什水利枢纽工程大坝主堆石区填筑料以砂砾石料为主,该地区河滩砂砾石料颗粒级配中的砂为特细砂,其在砂的级配中缺少中粗砂、级配不连续、保水性较差等特殊性级配料的特点导致其在施工过程中势必会影响到碾压的压实效果,给施工过程的质量控制带来很大难度。阐述了施工中通过对含特细砂砂砾石填筑料进行的不同加水量、不同厚度、不同碾压遍数及碾压机械等不同的碾压工艺参数进行试验检测、综合统计分析研究,探索出适合该工程的相关碾压施工参数标准,优化了施工碾压参数,提升了施工现场试验检测控制的时效性,为大坝填筑建设提供了稳定、可靠的施工参数,增强了坝体整体填筑的可靠性,为减小坝体沉降变形、提高大坝抗震安全储备和控制大坝施工质量等提供了有利条件。

超声滚压金属材料的疲劳性能研究进展

超声滚压(ultrasonic surface rolling,USR)技术结合高能冲击和静载滚压的特点,处理后工件具有表面光洁度高、变形层深、残余压应力大和晶粒细化明显等优势;可通过适当的工艺参数设计,极大提高金属材料的疲劳强度,因而在制造业得到了广泛应用。自该技术应用至今,国内外学者做了大量有关USR工艺及性能方面的研究,并在多种重要金属材料及关键零部件中应用。截至目前,关于USR工艺参数对材料表面完整性和疲劳性能的研究,比较零散,缺乏系统总结。研究首先简要介绍了USR的工作原理和可控性;然后总结了不同USR工艺参数诱导的残余应力和微观组织,以及残余应力在疲劳加载过程中的释放规律;分析了不同工艺USR诱导的表面完整性对疲劳性能的影响及其潜在机理;阐述了与USR相关的复合强化方法的最新进展,并展望了USR金属材料的应用前景。

退火工艺对Cu/Al复层材料界面影响的研究

采用纯铜/纯铝和纯铜/铝合金进行400℃温轧和退火热处理,并对得到的Cu/Al复层材料进行界面结合强度测试、界面金相显微组织分析和界面扫描电镜分析。结果表明:Cu/Al复层材料界面处Cu/Al中间相的形成需要一定的孕育期,其形成过程为:形核→核长大→沿界面横向连片生长→沿界面法线方向纵向生长;纯铜/纯铝复层材料最佳退火工艺为300℃×1 h,最大界面结合强度可达2.4 N/mm;而纯铜/铝合金为300℃×3 h,界面结合强度最大值为3.1 N/mm,保证了材料的成型性能,同时防止金属间化合物的生成;经较高温度的长时退火(500℃×5 h),纯铜/铝合金比纯铜/纯铝复层材料界面更容易形成脆性金属间化合物相,导致界面结合强度的降低,造成界面在剥离条件下的脆性断裂。

自动换卷机构的纸带拼接刚柔耦合分析与试验研究

针对卷烟纸带拼接中压模纹理与拼接力设计不当,易发生纸带拼接松脱、错位和穿透的问题,基于自动换卷机构的纸带拼接原理,建立自动换卷机构刚柔耦合模型,采用数值模拟与试验测试方法,研究对辊材料、拼接力和压模纹理对纸带拼接效果的影响规律。结果表明,4种对辊材料(橡胶、尼龙、铝、钢)的纸带拼接力仿真值分别为177.1,3.50×104,1.29×106,4.45×106 MPa,仿真结果与理论值相符。设计不同压模纹理的纸带拼接试验,测算出菱形压模拼接后的纸带断裂应力为1.040 MPa,弹性模量为17.816 MPa;矩形压模拼接后的纸带断裂应力为1.802 MPa,弹性模量为28.001 MPa,菱形压模拼接质量优于矩形压模。研究为自动换卷机构的对辊材料和压模纹理设计,以及纸带拼接效果评价提供技术支撑。

双机架宽厚板轧机轧制效率提升措施及实践

针对莱钢4 300 mm粗轧机、精轧机间距离短对轧制节奏影响大的现状,通过辊道分组、辊道逻辑控制优化、缩短待温板坯间距等措施,最大限度增加了待温辊道的长度和批轧块数;通过优化辊道接钢、分钢优先权判断功能的开发、精轧机咬钢顺控优化等措施,减少了时间浪费;通过跟踪物料影像保持功能减少了物料跟踪错误导致的停机时间。以上措施的实施,使产线生产效率提升15%以上。

铁基粉末冶金材料表面滚压致密化效果及组织演变

采用不同滚压压力对不同密度的Fe–2Cu–0.6C粉末冶金材料进行表面滚压加工,研究材料密度和滚压压力对致密化效果的影响。结果表明:滚压压力和材料密度是影响表面致密化效果的主要因素。随着滚压压力的增加,致密层厚度和表面硬度显著增加。材料密度对表面致密化效果的影响随着滚压压力的增加而减弱。当滚压压力较小时,致密层厚度和表面硬度随着材料密度的增加而增加;当滚压压力较大时,不同密度材料表面硬度和致密层厚度接近。滚压后表面层珠光体沿滚压方向弯曲,靠近表面的层片间距变小,部分区域层片发生扭折,出现波浪形,甚至部分渗碳体破碎断裂;铁素体细化,沿着滚压方向弯曲,在铁素体晶粒边界存在大量位错纠缠和位错墙。铁素体细化和珠光体变形为表面强化提供了有利的条件。

建筑用高性能热轧钛-钢复合材料的力学性能研究

以钢板和钛板为原材料,经预处理、组胚、焊接、热轧等制备建筑用高性能热轧钛-钢复合材料。用万能试验机等设备测试不同变形量、不同钛含量、不同卷曲温度下该复合材料的抗拉强度、屈曲强度等力学性能。结果表明:变形量为30%时,热轧钛-钢复合材料的屈服强度、抗拉强度适宜,拉伸断口呈韧性断裂;钛的质量分数为0.6%时,复合材料的抗拉强度、屈曲强度均最高;卷曲温度为600℃时复合材料的力学性能最佳,继续升高卷曲温度,力学性能反而降低。