Production of super-high strength aluminum alloy billets by low frequency electromagnetic casting

The effects of low frequency electromagnetic field on the macro-physical fields in the semi-continuous casting process of aluminum alloys and the microstructure and crack in the billets were studied and analyzed by the numerical and experimental methods.Comparison of the results for the macro-physical fields in the low frequency electromagnetic casting（LFEC） process with the conventional DC casting process indicates the following characters due to the application of electromagnetic field：an entirely changed direction and remarkably increased velocity of melt flow;a uniform distribution and a decreased gradient of temperature;elevated isothermal lines;a reduced sump depth;decreased stress and plastic deformation.Further,the microstructure of the billets is refined remarkably and the crack in the billets is eliminated in LFEC process because of modification of the macro-physical fields induced by the application of low frequency electromagnetic field.

Efects of low frequency electromagnetic ield on surface quality, microstructure and hot-tearing tendency of semi-continuous casting ZK60 magnesium alloy billets

The low frequency electromagnetic field was applied during direct chill(DC) semi-continuous casting of the ZK60 magnesium alloy billets. Effects of low frequency electromagnetic field on surface quality, microstructure and hot-tearing tendency of Φ500 mm ZK60 magnesium alloy billets were investigated. The results showed that with the application of the low frequency electromagnetic field, the surface quality of the ZK60 magnesium alloy billets is markedly improved and the depth of cold fold is decreased. The microstructure of the billets is also significantly refined. Besides, the distribution of the grain size is relatively uniform from the billet surface towards its center, where the average grain size is 42 μm at surface and 50 μm at center. It also shows that the hot-tearing tendency of DC semi-continuous casting ZK60 magnesium alloy billets is significantly reduced under low frequency electromagnetic field.

Effect of Low Frequency Electromagnetic Field on Macrosegregation of Horizontal Direct Chill Casting Aluminum Alloys

The horizontal direct chill (HDC) casting process is a well-established production route for aluminum alloy ingot but the ingot may suffer from macrosegregation sometimes. In order to control the defect, a low frequency electromagnetic field has been applied in HDC casting process and the relevant influence has been studied. The results show that application of low frequency electromagnetic field can reduce macrosegregation in HDC casting process; and two main parameters of electromagnetic field density and frequency, have great influences on the solution distribution along the diameter of ingot. Moreover, the mechanisms of reduction of macrosegregation by electromagnetic field have been discussed.

Methods of de-noising the low frequency electromagnetic data

The quality of the low frequency electromagnetic data is affected by the spike and the trend noises.Failure in removal of the spikes and the trends reduces the credibility of data explanation.Based on the analyses of the causes and characteristics of these noises,this paper presents the results of a preset statistics stacking method(PSSM)and a piecewise linear fitting method(PLFM)in de-noising the spikes and trends,respectively.The magnitudes of the spikes are either higher or lower than the normal values,which leads to distortion of the useful signal.Comparisons have been performed in removing of the spikes among the average,the statistics and the PSSM methods,and the results indicate that only the PSSM can remove the spikes successfully.On the other hand,the spectrums of the linear and nonlinear trends mainly lie in the low frequency band and can change the calculated resistivity significantly.No influence of the trends is observed when the frequency is higher than a certain threshold value.The PLSM can remove effectively both the linear and nonlinear trends with errors around 1% in the power spectrum.The proposed methods present an effective way for de-noising the spike and the trend noises in the low frequency electromagnetic data,and establish a research basis for de-noising the low frequency noises.

Radiation of Ultra Low Frequency Electromagnetic Waves from Atmosphere under the Influence of Strong Shock Waves

We present preliminary results from the experimental investigation of the response of the atmosphere due to the impact of powerful shock waves. The response is evidenced as ultra low frequency electromagnetic wave radiation at frequency of 2-5 kHz and in duration of 3 7s. We hypothesize that this radiation appears due to the following process： the shock wave ionizes the neutral particles in the air and these charged and neutral particles continue their vertical motion, which forms in the trail of the shock wave. Such motion can cause the cyclotron-like radiation measured.

EFFECT OF LOW-FREQUENCY ELECTROMAGNETIC FIELD ON THE AS-CASTING MICROSTRUCTURES AND MECHANICAL PROPERTIES OF HDC 2024 ALUMINUM ALLOY

The influences of the low frequency electromagnetic field on the horizontal direct chill casting process were investigated experimentally. Ingots of 2024 aluminum alloy with a cross size of 40 mm× 200 mm were produced by the conventional horizontal chill casting process and low frequency electromagnetic horizontal chill casting processre- spectively. The as-cast structures and the mechanical property of the ingots were examined. The results showed that the low frequency electromagnetic field could sub- stantially refine the microstructures and pronouncedly reduce the macrosegregation in the horizontal direct chill casting process. Moreover, the surface quality of the ingot was prominently improved by the low frequency electromagnetic field. The fracture strength and elongation percentage of the ingot was increased with the low frequency electromagnetic field.

Coupled Modeling of Electromagnetic Fleld,Fluid Flow,Heat Transfer and Solidification During Conventional DC Casting and Low Ftequency Electrmagnetic Casting of 7xxx Aluminum Alloys

A comprehensive mathematical model has been developed to describe the interaction of the multiple physics fields during the conventional DC casting and LFEC (low frequency electromagnetic casting) process. The model is based on a combination of the commercial finite element package ANSYS and the commercial finite volume package FLUENT, with the former for the calculation of the electromagnetic field and the latter for the calculation of the magnetic driven fluid flow, heat transfer and solidification. Moreover, the model has been verified against the temperature measurements obtained from two 7XXX aluminum alloy billets of 200mm diameter, cast during the conventional DC casting and the LFEC casting processes. In addition, a measurement of the sump shape of the billets were carried out by using addition melting metal of Al-30%Cu alloy into the billets during casting process. There was a good agreement between the calculated results and the measured results. Further, comparison of the calculated results during the LFEC process with that during the conventional DC casting process indicated that velocity patterns, temperature profiles and the sump depth are strongly modified by the application of a low frequency electromagnetic field during the DC casting.

Direct-chilling casting of Mg alloy under electromagnetic and ultrasonic combined field

The effects of low frequency electromagnetic (LFEC) field and ultrasonic (US) field on the microstructures, macrosegregation of alloying elements and the mechanical properties of DC cast AZ80 alloy were studied. The results show that both LFEC and US fields can refine the grains of the billets, which results in the increase in mechanical properties and uniformity of alloying element distribution. The effective refinement takes place on the edge of ingots when LFEC field is applied, while in the center of billets when field US is adopted. Combined the characteristics of LFEC and US fields, a new process for direct-chilling (DC) casting of Mg-electromagnetic-ultrasonic (ECUS) casting is developed, by which the grains are refined significantly and are more uniform in the whole ingots, and the mechanical properties of the ingots are improved.

Effects of Different Electromagnetic Fields on Circadian Rhythms of Some Haematochemical Parameters in Rats

Objective To investigate the effects of different electromagnetic fields on some haematochemical parameters of circadian rhythms in Sprague-Dawley rats. Methods The study was carried out in 18 male and 18 female rats in good health conditions exposed to 50 Hz magnetic sinusoid fields at the intensity of 1000 μT, 100 μT, and 0 μT （control group） respectively, and in 18 male and 18 female rats in good health conditions exposed to 1.8 GHz electromagnetic fields at the intensity of 50 V/m, 25 V/m and 0 V/m （control group）, respectively. Following haematochemical parameters for glucose, triglycerides, and total cholesterol were measured. Results Different effects of electromagnetic fields on circadian rhythms of both male and female rats were observed. Different changes occurred in some haematochemical parameters for glucose, triglycerides, and total cholesterol （P〈0.05）. Conclusion Exposure to different electromagnetic fields is responsible for the variations of some haematochemical parameters in rats.

Analysis and Simulation of the Influence of Electromagnetic Fields on Living Beings near HV Power Lines Using the FDTD Method

Recent decades have seen rapid advances in the field of electrical engineering, such that our environment has become a sea of electrical and magnetic signals, raising questions about the possible effects of low-frequency electromagnetic fields on the environment and which are capable of modifying and destroying our ecosystem. Particular interest was given in this article due to a massive influx of population living near high voltage lines. The analysis and simulation of the influence of low frequency electromagnetic fields on living beings in the vicinity of high voltage sources 132 kV and 220 kV in urban areas in DR Congo is the subject of our research with a view to estimating the level of exposure of humans to low frequency electromagnetic fields. To carry out our research, we used the classic method of analyzing the field produced near a high voltage line based on Maxwell’s image theory, the Maxwell-Gauss theorem and Maxwell-Ampère theorem to model and quantify low-frequency electromagnetic fields in the vicinity of high-voltage lines. The 2D FDTD numerical formulation was developed from telegraphers’ equations and allowed us to obtain models of current and voltage induced by electromagnetic fields on living beings below and near HV lines. The different simulations carried out on the proposed models illustrate the effects of the electrical and geometric parameters of the pylons on the distribution of the electromagnetic field in the vicinity of the HV lines. The results obtained were compared to the safety limits recommended by the standards.

LFEC and LFEVC of AZ80 magnesium alloy

The effects of a low frequency electromagnetic field and a low frequency electromagnetic vibration field applied during DC casting of AZ80 Mg on microstructures and alloying element distribution in ingots were investigated.The experiments were performed both in absence and in the presence of the magnetic fields.In DC casting,the ingot exhibited coarse microstructure and severe segregation of Al.In the presence of solo low frequency alternating magnetic field,namely LFEC,the grains of the ingot was effectively refined and the segregation of Al was significantly decreased.In LFEVC,namely low frequency electromagnetic vibration casting,the ingot were significantly refined and the segregation was suppressed.With increasing the vibration intensities,the grain refinement and segregation suppression were increased.

DC casting of light alloys under magnetic fields

The working principle of LFEC（Low frequency electromagnetic casting） process developed in Northeastern University, China was introduced and the metallurgical results of LFEC were discussed according to the casting practices. The low frequency field around the mold produces Lorenz force, which can be divided into two parts： one is the potential force which will be balanced by a pressure gradient of the liquid and results in the formation of a convex surface meniscus and improves the surface quality; the other is the rotary force which stirs the liquid in the mold to refine the microstructures and homogenize the distribution of alloying elements. LFEC can refine microstructures remarkably, improve surface quality of the ingots, depress macrosegregation and eliminate cracks. Some new technologies, such as horizontal direct chill casting under low-frequency electromagnetic field （HLEC）, DC casting of hollow billets under electromagnetic fields （HBEC）, electromagnetic modifying of hypereutectic A1-Si alloys（EMM）, air film casting under static magnetic field （AFCM）, and multi-ingots casting under low-frequency magnetic field （MLFEC） were developed based on LFEC.

Microstructures and constituents of super-high strength aluminum alloy ingots made through LFEC process

Ingots of a new super-high strength Al-Zn-Mg-Cu-Zr alloy were produced respectively by low frequency electromagnetic casting(LFEC)and by conventional direct chill(DC)casting process.Microstructure and constituents of the ingots were studied.The results indicated that the LFEC process significantly refines microstructure and constituents of the alloy,and to some extent,decreases the area(or volume)fraction of constituents and eutectic structure precipitated at grain boundaries.But,no difference in the type of constituents was observed between LFEC and DC ingots.The results also showed LFEC process can improve the as-cast mechanical properties.

Study on the Grain Refinement of an Al-Zn-Mg-Cu Alloy Prepared by LFEC Process

Low frequency electromagnetic casting(LFEC)process has been developed for years with the application of an induction coil outside the conventional direct chill(DC)casting mould.It has been demonstrated that the LFEC process has a significant grain refining effect on aluminium alloys.However,how it refines the microstructure is still not clearly understood.In the present work,the temperature measurement were carried out to study the temperature field during casting and to understand the mechanism of the grain refining effect of the LFEC process.The results showed that in contrast to the conventional DC casting process,during the LFEC process,the liquid melt flowing from the launder into the mould is cooled with very high cooling rate directly to 3-6 ℃ below the liquidus and the temperature field of the entire melt in the mould and the hot top is quite uniform,which results in enhanced heterogeneous nucleation and improved survival rate of the nuclei.This is believed to be the main reason why the LFEC process can significantly refine the grain size of aluminium alloys.

Localization technique research of a pipeline robot based on the magnetic-dipole model

The magnetic field distribution of an emission antenna is studied in this paper.When the slenderness ratio of the emission antenna is high,the emission antenna can be simplified as a magnetic dipole for practical application.The numerical results of the magnetic dipole magnetic field show that the magnetic magnitude distribution has a hump-shape,whose direction is perpendicular with the antenna axis direction.A localization method based on the hump-shape signal detection is presented.The experimental result shows that the precision can reach a value of±5 cm.The method can be used to localize a pipeline robot working in a metal pipe.