Optimization of chemistry and process parameters for control of intermetallic formation in Mg sludges

Intermetallic formation in sludge during magnesium(Mg)melting,holding and high pressure die casting practices is a very important issue.But,very often it is overlooked by academia,original equipment manufacturers(OEM),metal ingot producers and even die casters.The aim of this study was to minimize the intermetallic formation in Mg sludge via the optimization of the chemistry and process parameters.The Al8Mn5 intermetallic particles were identified by the microstructure analysis based on the Al and Mn ratio.The design of experiment(DOE)technique,Taguchi method,was employed to minimize the intermetallic formation in the sludge of Mg alloys with various chemical compositions of Al,Mn,Fe,and different process parameters,holding temperature and holding time.The sludge yield(SY)and intermetallic size(IS)was selected as two responses.The optimum combination of the levels in terms of minimizing the intermetallic formation were 9 wt.%Al,0.15 wt.%Mn,0.001 wt.%(10 ppm)Fe,690℃ for the holding temperature and holding at 30 mins for the holding time,respectively.The best combination for smallest intermetallic size were 9 wt.%Al,0.15 wt.%Mn,0.001 wt.%(10 ppm)Fe,630℃ for the holding temperature and holding at 60 mins for the holding time,respectively.Three groups of sludge factors,Chemical Sludge(CSF),Physical Sludge(PSF)and Comprehensive Sludge Factors(and CPSF)were established for prediction of sludge yields and intermetallic sizes in Al-containing Mg alloys.The CPSF with five independent variables including both chemical elements and process parameters gave high accuracy in prediction,as the prediction of the PSF with only the two processing parameters of the melt holding temperature and time showed a relatively large deviation from the experimental data.The Chemical Sludge Factor was primarily designed for small ingot producers and die casters with a limited melting and holding capacity,of which process parameters could be fixed easily.The Physical Sludge Factor could be used for mass production with a single type of Mg alloy,in which the chemistry fluctuation might be negligible.In large Mg casting suppliers with multiple melting and holding furnaces and a number of Mg alloys in production,the Comprehensive Sludge Factor should be implemented to diminish the sludge formation.

Effects of processing parameters on fabrication defects,microstructure and mechanical properties of additive manufactured Mg–Nd–Zn–Zr alloy by selective laser melting process

Mg–3Nd–0.2Zn–0.4Zr(NZ30K,wt.%)alloy is a new kind of high-performance metallic biomaterial.The combination of the NZ30K Magnesium(Mg)alloy and selective laser melting(SLM)process seems to be an ideal solution to produce porous Mg degradable implants.However,the microstructure evolution and mechanical properties of the SLMed NZ30K Mg alloy were not yet studied systematically.Therefore,the fabrication defects,microstructure,and mechanical properties of the SLMed NZ30K alloy under different processing parameters were investigated.The results show that there are two types of fabrication defects in the SLMed NZ30K alloy,gas pores and unfused defects.With the increase of the laser energy density,the porosity sharply decreases to the minimum first and then slightly increases.The minimum porosity is 0.49±0.18%.While the microstructure varies from the large grains with lamellar structure inside under low laser energy density,to the large grains with lamellar structure inside&the equiaxed grains&the columnar grains under middle laser energy density,and further to the fine equiaxed grains&the columnar grains under high laser energy density.The lamellar structure in the large grain is a newly observed microstructure for the NZ30K Mg alloy.Higher laser energy density leads to finer grains,which enhance all the yield strength(YS),ultimate tensile strength(UTS)and elongation,and the best comprehensive mechanical properties obtained are YS of 266±2.1 MPa,UTS of 296±5.2 MPa,with an elongation of 4.9±0.68%.The SLMed NZ30K Mg alloy with a bimodal-grained structure consisting of fine equiaxed grains and coarser columnar grains has better elongation and a yield drop phenomenon.

Process Parameters Optimization of Laser Cladding for HT200 with 316L Coating Based on Response Surface Method

In order to improve the sealing surface performance of gray cast iron gas gate valves and achieve precise molding control of the cladding layer,as well as to reveal the influence of laser cladding process parameters on the morphology and structure of the cladding layer,we prepared the 316L coating on HT 200 by using Design-Expert software central composite design(CCD)based on response surface analysis.We built a regression prediction model and analyzed the ANOVA with the inspection results.With a target cladding layer width of 3.5 mm and height of 1.3 mm,the process parameters were optimized to obtain the best combination of process parameters.The microstructure,phases,and hardness variations of the cladding layer from experiments with optimal parameters were analyzed by the metallographic microscope,confocal microscope,and microhardness instrument.The experimental results indicate that laser power has a significant impact on the cladding layer width,followed by powder feed rate;scan speed has a significant impact on the cladding layer height,followed by powder feed rate.The HT200 substrate and 316L can metallurgically bond well,and the cladding layer structure consists of dendritic crystals,columnar crystals,and equiaxed crystals in sequence.The optimal process parameter combination satisfying the morphology requirements is laser power(A)of 1993 W,scan speed(B)of 8.949 mm/s,powder feed rate(C)of 1.408 r/min,with a maximum hardness of 1564.3 HV0.5,significantly higher than the hardness of the HT200 substrate.

Role of processing parameters on relative density,microstructure and mechanical properties of selective laser melted titanium alloy

The relationships between the selective laser melting(SLM)processing parameters including laser power,scanning speed and hatch space,the relative density,the microstructure,and resulting mechanical properties of Ti-6Al-2Zr-1Mo-1V alloy were investigated in this work.The result shows that laser power acts a dominant role in determining the relative density in comparison with scanning speed and hatch space.The optimal SLM process window for fabricating relative density>99%samples is located in the energy density range of 34.72 J·mm^(-3)to 52.08 J·mm^(-3),where the laser power range is between 125 W and 175 W.An upward trend is found in the micro-hardness as the energy density is increased.The optimum SLM processing parameters of Ti-6Al-2Zr-1Mo-1V alloy are:laser power of 150 W,scanning speed of 1,600 mm·s^(-1),hatch space of 0.08 mm,and layer thickness of 0.03 mm.The highest ultimate tensile strength,yield strength,and ductility under the optimum processing parameter are achieved,which are 1,205 MPa,1,099 MPa,and 8%,respectively.The results of this study can be used to guide SLM production Ti-6Al-2Zr-1Mo-1V alloy parts.

Cookie Baking Process Optimization and Quality Analysis Based on Food 3D Printing

In order to obtain better quality cookies, food 3D printing technology was employed to prepare cookies. The texture, color, deformation, moisture content, and temperature of the cookie as evaluation indicators, the influences of baking process parameters, such as baking time, surface heating temperature and bottom heating temperature, on the quality of the cookie were studied to optimize the baking process parameters. The results showed that the baking process parameters had obvious effects on the texture, color, deformation, moisture content, and temperature of the cookie. All of the roasting surface heating temperature, bottom heating temperature and baking time had positive influences on the hardness, crunchiness, crispiness, and the total color difference(ΔE) of the cookie. When the heating temperatures of the surfac and bottom increased, the diameter and thickness deformation rate of the cookie increased. However,with the extension of baking time, the diameter and thickness deformation rate of the cookie first increased and then decreased. With the surface heating temperature of 180 ℃, the bottom heating temperature of 150 ℃, and baking time of 15 min, the cookie was crisp and moderate with moderate deformation and uniform color. There was no burnt phenomenon with the desired quality. Research results provided a theoretical basis for cookie manufactory based on food 3D printing technology.

Effects of process parameters on mechanical properties and microstructures of creep aged 2124 aluminum alloy

A series of tests were carried microstructures of 2124 aluminum alloy in increase of aging time, temperature and low-to-peak-to-low manner. No significant out to investigate the effects of process parameters on mechanical properties and creep aging process. The results show that creep strain and creep rate increase with the applied stress. The hardness of specimen varies with aging time and stress in a effect of temperature on hardness of material is seen in the range of 185-195 ℃. The optimum mechanical properties are obtained at the conditions of （200 MPa, 185 ℃, 8 h） as the result of the coexistence of strengthening S＂ and S＇ phases in the matrix by transmission electron microscopy （TEM）. TEM observation shows that applied stress promotes the formation and growth of precioitates and no obvious stress orientation effect is observed in the matrix.

Grain refinement of Mg-Al alloys by optimization of process parameters based on three-dimensional finite element modeling of roll casting

To study the influence of roll casting process parameters on temperature and thermal-stress fields for the AZ31 magnesium alloy sheets,three-dimensional geometric and 3D finite element models for roll casting were established based on the symmetry of roll casting by ANSYS software.Meshing method and smart-sizing algorithm were used to divide finite element mesh in ANSYS software.A series of researches on the temperature and stress distributions during solidification process with different process parameters were done by 3D finite element method.The temperatures of both the liquid-solid two-phase zone and liquid phase zone were elevated with increasing pouring temperature.With the heat transfer coefficient increasing,the two-phase region for liquid-solid becomes smaller.With the pouring temperature increasing and the increase of casting speed,the length of two-phase zone rises.The optimized of process parameters（casting speed 2 m/min,pouring temperature 640 ℃ and heat transfer coefficient 15 kW/（m2·℃） with the water pouring at roller exit was used to produce magnesium alloy AZ31 sheet,and equiaxed grains with the average grain size of 50 μm were achieved after roll casting.The simulation results give better understanding of the temperature variation in phase transformation zone and the formation mechanism of hot cracks in plates during roll casting and help to design the optimized process parameters of roll casting for Mg alloy.

Effect of Zr content on crack formation and mechanical properties of IN738LC processed by selective laser melting

Two batches of commercial IN738LC alloy powders with different Zr contents were printed under the same parameters.The influences of Zr content(0.024 wt.% and 0.12 wt.%,respectively) in powders on crack density,distribution,formation mechanism and mechanical properties of selective laser melting(SLM)-treated parts were systematically studied.It was found that the crack density(area ratio) increases from 0.15% to 0.87% in the XOY plane and from 0.21% to 1.81% in the XOZ plane along with the Zr content increase from 0.024 wt.% to 0.12 wt.% in the original powders.Solidification cracks are formed along the epitaxially grown <001>-oriented columnar grain boundaries in molten pool center.The ultimate tensile strength of Sample 1(0.024 wt.% Zr) is 1113 MPa,and there are dimples in tensile fracture.With an increase in the Zr content to 0.12 wt.%(Sample 2),the ultimate tensile strength of Sample 2 decreases to 610 MPa,and there are numerous original cracks and exposed columnar grain boundaries in tensile fracture.The optimization of printing parameters of Sample 2 considerably increases the ultimate tensile strength by 55.2% to 947 MPa,and the plasticity is greatly improved.

Analysis of defects in clean fabrication process of friction stir welding

Striving for cleaner production is a sought-after manufacturing philosophy.Friction stir welding(FSW)is a joiningtechnique with par excellence and far less invasive to the environment than even best conventional welding processes.It is energyefficient and free from consumables,affluent and radiations.It is,thus,accepted as a clean welding process that can produceacceptable quality joints.It suffers from some major challenges of defects of its own kind that subject the process open toimprovements so as to prove itself a reliable production process.This study presents a holistic characterization of defects commonlyfound in FSW joints.The finding of the present study reveals that most defects are caused by inadequate heat generation,impropermaterial movement around the pin and inadequate material consolidation behind the pin.The amount of heat generation andmaterial stirring depends on several FSW parameters which may lead to the defect formation,if not selected properly.The resultsreported in this work are derived from sound literature support and experimentation.Prescriptions are made in the form ofcharacteristics of defects such as likelihood of their location,main responsible parameters along with the recommendations forminimizing them.

Thermodynamic simulation of complex Pb-Bi concentrate oxidative bath smelting process

The element partitioning in a Pb-Bi concentrate oxygen-rich bath smelting process was studied using thermodynamic equilibrium simulation method. Effects of oxygen to feed ratio(OFR) and sulfur dioxide partial pressure(pSO2) on the partitionings of Bi, Pb, As, Sb, Cu and Ag were analyzed and compared with industrial data. The results suggested that the optimal OFR was between 6.3 and 6.8 kmol/t to maximize Bi, Pb, Cu and Ag partitioning in the metal phase. Further increase of OFR led to the drop of metal partitioning and increase of slag liquidus temperature. High pSO2 led to high deportment of Bi and Pb in the gas phase mainly in the form of sulfides, suggesting that a low pSO2 was conducive for reducing the dust ratio.

Mesoscopic-Scale Numerical Investigation Including the Influence of Process Parameters on LPBF Multi-Layer Multi-Path Formation

As a typical laser additive manufacturing technology,laser powder bed fusion(LPBF)has achieved demonstration applications in aerospace,biomedical and other fields.However,how to select process parameters quickly and reasonably is still themain concern of LPBF production.In order to quantitatively analyze the influence of different process parameters(laser power,scanning speed,hatch space and layer thickness)on the LPBF process,the multilayer and multi-path forming process of LPBF was predicted based on the open-source discrete element method framework Yade and the open-source finite volume method framework OpenFOAM.Based on the design of experiments method,a four-factor three-level orthogonal test scheme was designed,and the porosity and surface roughness data of each calculation scheme were extracted.By analyzing the orthogonal test data,it was found that as the laser power increased,the porosity decreased,and as the scanning speed,hatch space,and layer thickness increased,the porosity increased.In addition,the influence of laser power and scanning speed on surface roughness showed a trend of decreasing first and then increasing,while the influence of scanning distance and layer thickness on surface roughness showed amonotonous increasing trend.The order of the influence of each process parameter on porosity was:scanning speed>laying thickness>laser power>hatch space,and the order of the influence of each process parameter on surface roughness was:hatch space>layer thickness>laser power>scanning speed.So the porosity of the part is most sensitive to scanning speed,and the surface roughness is the most sensitive to hatch space.The above conclusions are expected to provide process control basis for actual LPBF production of the 316L stainless steel alloy.

Experimental Research on Effects of Process Parameters on Servo Scanning 3D Micro Electrical Discharge Machining

Servo scanning 3D micro electrical discharge machining (3D SSMEDM) is a novel and effective method in fabricating complex 3D micro structures with high aspect ratio on conducting materials. In 3D SSMEDM process, the axial wear of tool electrode can be compensated automatically by servo-keeping discharge gap, instead of the traditional methods that depend on experiential models or intermittent compensation. However, the effects of process parameters on 3D SSMEDM have not been reported up until now. In this study, the emphasis is laid on the effects of pulse duration, peak current, machining polarity, track style, track overlap, and scanning velocity on the 3D SSMEDM performances of machining efficiency, processing status, and surface accuracy. A series of experiments were carried out by machining a micro-rectangle cavity (900 μm×600 μm) on doped silicon. The experimental results were obtained as follows. Peak current plays a main role in machining efficiency and surface accuracy. Pulse duration affects obviously the stability of discharge state. The material removal rate of cathode processing is about 3/5 of that of anode processing. Compared with direction-parallel path, contour-parallel path is better in counteracting the lateral wear of tool electrode end. Scanning velocity should be selected moderately to avoid electric arc and short. Track overlap should be slightly less than the radius of tool electrode. In addition, a typical 3D micro structure of eye shape was machined based on the optimized process parameters. These results are beneficial to improve machining stability, accuracy, and efficiency in 3D SSMEDM.

Optimization of extrusion process parameters of Incoloy028 alloy based on hot compression test and simulation

True stress?true strain curves of Incoloy028alloy at high temperature and strain rate were investigated by hot compression test.These curves show that the maximum flow stress decreases with the increase in temperature and the decrease in strain rate.FEM simulation was employed to investigate the influence of temperature,extrusion speed and friction coefficient on the extrusion load,stress,strain and strain rate in the extrusion process.The increase of extrusion temperature results in decrease of load and deformation resistance,but has little influence on strain and strain rate.When extrusion speed changes between200and350mm/s,no obvious change about extrusion load can be found.Sharp peak value up to42500kN emerges in the extrusion load curve and the extrusion process becomes unstable seriously when extrusion speed rises up to400mm/s.Both stress and strain rate increase with the raise of extrusion speed.When friction coefficient is between0.02and0.03,deformation resistance is about160MPa and the strain rate can be limited below70s?1.Successful production of Incoloy028tube verifies the optimized parameters by FEM simulation analysis,and mechanical tests results of the products meet the required properties.

Effects of Process Parameters on the Temperature Field in Ti-6Al-4V Alloy Blade Precision Forging Process

Blade precision forging is a high temperature and large plastic deformation process. Process parameters have a great effect on temperature distribution in billet, so in this paper, by taking a Ti-6Al-4V alloy blade with a tenon as an object, the influence of process parameters on the temperature distribution in precision forging process was investigated using 3D coupled thermo-mechanical FEM （finite element method） code developed by the authors. The results obtained illustrate that： （1） the gradient of temperature distribution increases with increasing the deformation degree; （2） with increasing the initial temperature of the billet, the zones of high temperature become larger, and the gradient of temperature distribution hardly has any increase; （3） friction factors have little effect on the distribution of temperature field; （4） with increasing upper die velocity, temperature of the billet increases while the temperature gradient in billet decreases. The results are helpful to the design and optimization of the process parameters in precision forging process of Ti-alloy blade.

Numerical analysis on the effect of process parameters on deposition geometry in wire arc additive manufacturing

Here we develop a two-dimensional numerical model of wire and arc additive manufacturing(WAAM)to determine the relationship between process parameters and deposition geometry,and to reveal the influence mechanism of process parameters on deposition geometry.From the predictive results,a higher wire feed rate matched with a higher current could generate a larger and hotter droplet,and thus transfer more thermal and kinetic energy into melt pool,which results in a wider and lower deposited layer with deeper penetration.Moreover,a higher preheat temperature could enlarge melt pool volume and thus enhance heat and mass convection along both axial and radial directions,which gives rise to a wider and higher deposited layer with deeper penetration.These findings offer theoretical guidelines for the acquirement of acceptable deposition shape and optimal deposition quality through adjusting process parameters in fabricating WAAM components.

Relationships between the surface quality of a single crystal copper ingot and the process parameters of a heated mould continuous casting method

The relationships between the surface quality of a single crystal copper ingot and the process parameters of heated mould continuous casting method were studied experimentally using our own design of horizontal heated mould continuous casting apparatus, and the mechanism by which process parameters affect the surface quality of a single crystal copper ingot is analyzed in the present paper. The results show that the process parameters affect the surface quality of a pure copper ingot by affecting the position of the liquid-solid interface in the mould. The position of the liquid-solid interface in the mould must be controlled carefully within an appropriate range, which is determined through a series of experiments, in order to gain a single crystal copper ingot with good surface quality.

Head Curvature of Pure Titanium Sheet Influenced by Process Parameters and Controlling in Hot Rolling Process

We investigated the influences of process parameters on the head curvature of pure titanium sheet in hot rolling process and proposed the controlling means. First, the thermal simulation experiments for pure titanium TA1 were carried out to investigate the hot deformation behaviors of pure titanium in the temperature range of 700-800 ℃ with strain rate range of 1-20 S-1, and the processing map was established to determine optimized deformation parameters. Then, the finite element model has been constructed and used to analyze the effect of process parameters on the direction and severity of head curvature of pure titanium sheet. The process parameters considered in the present study include workpiece temperature, work roll diameter, pass reduction, oxide scale thickness of workpiece surface, and interface friction coefficient. The simulation results show that the workpiece temperature and the interface friction coefficient are the two main factors. The proposed controlling means was carried out on a hot rolling production line and solved the head curvature problem effectively. The rolling practices indicate that the rolling yield is improved greatly.

Review of Design of Process Parameters for Squeeze Casting

Squeeze casting(SC)is an advanced net manufacturing process with many advantages for which the quality and properties of the manufactured parts depend strongly on the process parameters.Unfortunately,a universal efficient method for the determination of optimal process parameters is still unavailable.In view of the shortcomings and development needs of the current research methods for the setting of SC process parameters,by consulting and analyzing the recent research literature on SC process parameters and using the CiteSpace literature analysis software,manual reading and statistical analysis,the current state and characteristics of the research methods used for the determination of SC process parameters are summarized.The literature data show that the number of pub-lications in the literature related to the design of SC process parameters generally trends upward albeit with signifi-cant fluctuations.Analysis of the research focus shows that both“mechanical properties”and“microstructure”are the two main subjects in the studies of SC process parameters.With regard to materials,aluminum alloys have been extensively studied.Five methods have been used to obtain SC process parameters:Physical experiments,numeri-cal simulation,modeling optimization,formula calculation,and the use of empirical values.Physical experiments are the main research methods.The main methods for designing SC process parameters are divided into three categories:Fully experimental methods,optimization methods that involve modeling based on experimental data,and theoreti-cal calculation methods that involve establishing an analytical formula.The research characteristics and shortcomings of each method were analyzed.Numerical simulations and model-based optimization have become the new required methods.Considering the development needs and data-driven trends of the SC process,suggestions for the develop-ment of SC process parameter research have been proposed.

Influence of processing parameters on coating surface roughness of aluminum alloy

The influence of processing parameters on the coating surface roughness of LD10 aluminum alloy treated by the power source with positive and negative pulse in the alkaline electrolyte was discussed.Lots of experiments were done with different processing parameters including the positive final voltage,the negative final voltage,the frequency,the duty ratio,the processing time and electrolyte temperature.And the surface roughness tester TR200 was used to measure the coating surface roughness.The influence of the processing time on the surface roughness is the smallest,less than 0.2μm.The surface roughness decreases gradually with the duty ratio decreasing or the frequency increasing;it decreases gradually with each of the other parameters increasing,and then increases gradually after achieving the minimum value.Appropriately by selecting processing parameters,the coating with Ra 0.6 can be obtained.

Process parameter effects on microstructure and mechanical properties of tubes processed via friction assisted tube straining method

This paper investigates process parameter effects on microstructure and mechanical properties of the tubes processed via recently developed friction assisted tube straining(FATS)method.For this purpose,design of experiment was used to arrange finite element analyses and experimental tests.Numerical and experimental tests were executed by changing rotary speed,feed rate and die angle.Taguchi design results show that increasing feed rate and decreasing rotary speed enhance Zener-Hollomon(Z)parameter and decrease average grain size,while die angle has no considerable effect.Increasing Z value reduces grain size and enhances flow stress of the processed samples,while the experiment with the highest Z value refines initial microstructure from 40 to 8μm and increases flow stress by 5 times.