Corrosion Test of the Steel Plate in a WJ-8 Fastener for High Speed Rail

It was found that the steel plate in the composite plate in the WJ-8 fastener used in high speed rail is rusty. The objective of this study is to test the zinc coating of the steel plate. A literature review was conducted to identify the zinc coating techniques, and the companies that can provide different coating service was identified. A salt fog chamber was built that was in compliance with the ANSI B117 code, and the steel plates that were coated by the identified companies were tested using the salt fog chamber. The results indicated that the coating technique that had the best performance in preventing corrosion was the Greenkote plates with passivation. The galvanized option had the roughest coating layer, and it was the most reactive in the salt water solution. This makes it non-ideal for the dynamic rail environment because the increased friction of the plate could damage the supports, especially during extreme temperatures that would cause the rail to expand or contract. Greenkote with Phosphate and ArmorGalv also provided increased corrosion prevention with a smooth, strong finish, but it had more rust on the surface area than the Greenkote with ELU passivation. The ArmorGalv sample had more rust on the surface area than the Greenkote samples. This may not be a weakness in the ArmorGalv process;rather, it likely was the result of this particular sample not having the added protection of a colored coating.

High-temperature tribological properties of Ni-P alloy coatings deposited by electro-brush plating

High-temperature tribological properties of Ni-P alloy coatings processed by electro-brush plating on 20CrMo steel have been investigated. A baU-on-disc configuration was employed and 4 mm diameter Si3N4 balls were used as static counterpart. All the wear tests were carried out at 450℃ for 180 rain without lubricants. The electro-brush plating Ni-P coating is amorphous in as-deposited condition, and it becomes polycrystalline with the formation of Ni and Ni3P after heat treatment at 450℃for 1 h. The friction coefficient of the Ni-P coating is just 50% of that of the 20CrMo steel at the friction temperature of 450℃. A mild adhesive wear mechanism was found for the electro-brush plating Ni-P coating tested at 450℃, whereas for the 20CrMo steel at the same temperature a mixed adhesive and abrasive wear mechanism was observed.

Wear and Corrosion Resistance of Electroless Plating Ni-P Coating on P110 Steel

In order to improve the surface performance and increase the lifetime of P 110 oil casing tube steel during operation, electroless plating was conducted to form Ni-P coating onto its surface. The surface morphology/element distribution and phase constitution of the Ni-P coating were analyzed using scanning electron microscope （SEM） equipped with energy dispersive spectrometry （EDS） and X-ray diffraction （XRD）. Tribological and electrochemical measurement tests were applied to investigate the wear and corrosion resistance of P110 steel and the Ni-P coating. The results showed that a uniform and compact, high phosphorous Ni-P coating was formed. The obtained Ni-P coating indicated certain friction-reduction effect and lower mass loss during friction-wear tests. The Ni-P coating also exhibited higher corrosion resistance in comparison with bared P 110 steel. The obtained N i-P coating has significantly improved the surface performance of P110 steel.

Electrochemical behavior of Cu-Zn-Al shape memory alloy after surface modification by electroless plated Ni-P

The electrochemical behavior of Cu-Zn-Al shape memory alloy (SMA) with andwithout electroless plated Ni-P was investigated by electrochemical methods, in artificial Tyrode'ssolution. The results showed that Cu-Zn-Al SMA engendered dezincification corrosion in Tyrode'ssolution. The anodic active current densities as well as electrochemical dissolution sensitivity ofthe electroless plated Ni-P Cu-Zn-Al SMA increased with NaCl concentration rising, pH of solutiondecreasing and environmental temperature uprising. X-ray diffraction analysis indicated that aftersurface modification by electroless plated Ni-P, an amorphous plated film formed on the surface ofCu-Zn-Al SMA. This film can effectively isolate matrix metal from corrosion media and significantlyimprove the electrochemical property of Cu-Zn-Al SMA in artificial Tyrode's solution.

Investigation on a Non-cyanide Plating Process of Ni-P Coating on Magnesium Alloy AZ91D

In this research we presented a non-cyanide plating process of Ni-P alloy coating on Mg alloy AZ91D. By applying a new process flow of electroless nickel plating in which zinc coating is used as transition of Ni-P coating on Mg alloy AZ91D, the process of copper transition coating plated in the cyanides bath can be replaced. A new bath composed of NiSO4 was established by orthogonal test. The results show that zinc transition coating can increase the adhesion and protect the Mg alloy substrate from the bath corrosion. The optimal plating bath composition is NiSO4·6H2O 20 g/L, NaH2PO2·H2O20g/L and C6H8O7·H2O 2.5 g/L, and optimal bath acidity and optimal plating temperature are pH 4.0 and 95℃, respectively. The present process flow is composed of ultrasonic cleaning→alkaline cleaning→acid pickling→activation→double immersing zinc→electroplating zinc→electroless nickel plating→passivation treatment. The present non-cyanide process of electroless nickel plating is harmless to our surroundings and Ni-P coating on Mg alloy AZ91D produced by present process possesses good adhesion and corrosion resistance.

Kinematical Analysis and Simulation of High-Speed Plate Carrying Manipulator Based on Matlab

In order to construct the more effective kinematics method for industry, by taking a high-speed plate handing robot as an example, the structure and parameters of the robot linkages are analyzed, and the standard Denavit-Hartenberg method is applied to establish the coordinates and the kinematic equation of the linkages. Depending on the graphics and matrix calculation ability of Matlab especially including the Robotics Toolbox, the handling robot has been modeled and its kinematics, inverse kinematics and the trajectory planning have been simulated. Therefore, the correctness of kinematic equation has been verified, meanwhile, the functions of displacement, velocity, acceleration and trajectory of all the joints are also obtained. In a further step, this has verified the validity of all the structure parameters and pro- vided a reliable basis for the theoretical research on the design, dynamics analysis and trajectory planning of the ma- nipulator control system.

Settlement Characteristics of Cement Fly-Ash GravelPile-Plate Composite Foundation of High-Speed Railway

Field tests on settlement characteristics were carried out on the cement fly-ash gravel （CFG） pile-plate composite foundation on Beijing-Xuzhou section of Beijing-Shanghai high-speed railway. The settlements of the piles and the soil between pries were measured and analyzed. The results show that the settlement-time dependency experienced three phases： rapid development phase, stable development phase and stable phase. Therefore, surcharge preloading was necessary to reduce the settlement after construction. The finite element software Plaxis was used to calculate the deformations of the pile top and the soil between piles at the embankment center, as well as the settlements of CFG pile reinforcement area and the underlying stratum under surcharge preloading. The calculation results and the field test results were compared and analyzed. Both the results show that the settlement of the composite foundation mainly occured in underlying stratum. The settlement characteristics of pile-plate composite foundation under high embankment are also concluded.

Analysis of strain variation in cross shear zone of plate during snake hot rolling

In order to study the distribution of equivalent and shear strain of aluminum alloy plate during snake hot rolling, several coupled thermo-mechanical finite element models(FEM) are established. Effects of speed ratio and offset distance on strain distribution of the plate are analyzed. The length of cross shear zone is defined to have a better understanding of the deformation characteristic in cross shear zone, which is the essential difference from symmetrical rolling in deformation zone. The results show that the equivalent strain and shear strain of lower part both increase with the increase of speed ratio, while the upper part decreases; the equivalent strain through the whole thickness decreases with ascending offset distance, while the shear strain of lower part increases. The length of cross shear zone quickly increases with ascending speed ratio and slightly decreases with ascending offset distance. The "positive" and "negative" cross shear zones are formed with the increase of speed ratio and offset distance, respectively. The value of the sensitivity coefficient of speed ratio is an order of magnitude bigger than the offset distance. However, the shear strain at center point increases with the ascending speed ratio and offset distance for different mechanism. As speed ratio increases, the asymmetry of the distribution of equivalent is becoming larger and the shear strain is generated in the same direction in cross shear zone. The FEM results agree well with experimental results.

Effect of additives on nickel-phosphorus deposition obtained by electroless plating:Characterization and corrosion resistance in 3%(mass)sodium chloride medium

Nichel-phosphorus(Ni-P)coatings are deposited on mild steel by using an electroless plating process.The effect of three calix[4]arene derivatives,namely tetra methyl ester-P-tertbutyl calix[4]arene(Calix1),tetra acid-P-tert-butyl calix[4]arene(Calix2)and tetra methyl P-tert-butyl-thicalix[4]arene ester(Calix3)on the deposition rate,the deposit composition,and the morphological surface was investigated and the study of growth mechanisms has delivered useful information about the surface properties of deposit.It is found that these additives modify the deposition rate and the nickel crystallization process.In fact,the Calix1 and Calix3 act as an accelerator,while Calix2 acts as an inhibitor for the nickel electroless.Furthermore,it is shown that the chemical bath is more stable with calix[4]arene derivatives addition and the obtained deposits are compact and adherent.It is observed also that the nickel content increases with additives.On the other hand,the X-ray diffraction showed that the orientation peaks are intensified at{111}in the presence of Calix2,confirming obtained results of EDAX spectrum.The cyclic voltammetry revealed that the tested additives strongly influence the cathodic process and slightly affect the hypophosphite oxidation.Finally,it is found that these compounds improve the anticorrosion efficiency of Ni-P coating on the mild steel substrate in 3%(mass)NaCl,where its polarization resistance increases with Calix2 and Calix3 addition.

金刚石微粉电镀镍品质影响因素研究

金刚石微粉在镀液中易漂浮导致电镀镍困难,为获得金刚石微粉电镀镍工艺,本文研究了镀瓶转速和电镀电流对金刚石微粉电镀镍品质的影响。通过对金刚石微粉颗粒在不同镀瓶转速时运动状态进行理论分析,得到了镀瓶转速调节方法,并通过实验确定了不同电镀电流时镀瓶转速的调节范围。采用单因素实验,研究了电镀电流对镀层增重率、形貌和密度的影响。结果表明:镀瓶转速在1~7 r/min范围内,从小到大逐步提高,同时电镀电流不超过3.0 A条件下,能够实现金刚石微粉电镀镍。电镀电流在0.5 A时镀层失重,出现明显退镀现象,在1.0 A时镀层有少部分漏镀现象,在1.5~2.5 A时镀层包裹完整,基本无漏镀;电镀电流在1.0~2.5 A范围时,随着电镀电流增大,镀层增重率逐渐增大,镀层密度逐渐减小。采用低转速低电流、逐步提高镀瓶转速的方法对金刚石微粉进行电镀镍,镀瓶转速在1~7 r/min,电镀电流在1.5~2.5 A时金刚石微粉电镀镍品质较好。

圆形抗滑桩-拱形挡土板支挡性能与参数分析

为规避当前施工方法的不足,发展安全、高效和可靠的施工方法。依托东北地区某高速铁路路堑边坡工程,采用适于机械钻孔的圆形抗滑桩代替现行矩形抗滑桩,预制拱形挡土板,本文提出一种新型拱形板-桩墙支挡体系;并构建有限元模型,分析桩长、桩径、桩间距以及拱形挡土板矢跨比对新型拱形板-桩墙支挡体系支护性能的影响;揭示不同参数下桩顶水平位移与桩身内力的变化规律。研究结果表明:桩长与桩身弯矩和剪力大小呈正相关关系,与桩顶水平位移呈负相关关系。桩长超过14 m时,其对桩顶水平位移、桩身弯矩和剪力的影响效应明显减弱;随着桩间距增大,桩顶水平位移增大但变化幅度逐渐减小。拱形挡土板矢跨比增大时,桩顶水平位移、桩身弯矩和剪力均减小。影响拱形板-桩墙体系支挡性能的因素依次为桩间距、桩长、桩径和矢跨比。研究结果为圆形抗滑桩-拱形挡土板支挡体系在实际工程中的应用提供新思路。

激光焊焊接速度对DC06超深冲钢板接头组织和性能的影响

研究了脉冲激光焊焊接速度对DC06超深冲钢板焊缝显微组织和力学性能的影响。金相组织、硬度检测结果显示:随着焊接速度的增加,焊接热输入减小,冷却速度变快,焊缝和热影响区的铁素体晶粒有所减小;同时,焊接速度增加,高温停留时间缩短,合金元素烧损减少,焊缝和热影响区固溶强化作用增强,显微硬度有所升高。

400 km/h高速列车转向架底板的阻力影响数值模拟研究

采用数值仿真方法研究明线运行400 km/h高速列车转向架底板包覆结构的气动阻力影响规律,揭示不同包覆形式及安装高度、缝隙间距这两类关键构型参数的阻力影响特性及流动结构的作用特征。研究结果表明:全封一体式及分体式底板包覆方案对整体均有明显的减阻效果,最优减阻率达9.76%,以头车转向架区域为主要减阻部件,但中间车阻力有所增加,且头车包覆越完整,中间车阻力增加越明显;在不同安装高度下,底板减阻效果呈非单调变化,头车底板适当下移有利于提高整车减阻效果,其原因主要是降低了中间车的转向架阻力;当底板缝隙间距维持在一定范围内时,整车减阻效果变化不大,继续增大缝隙会导致减阻效果变差,因为过大的缝隙将显著增强气流对转向架及舱体的冲击,导致整车减阻效果降低。

水下非接触爆炸下冲击波载荷与速度场等效关系研究

对于平板在水下非接触爆炸下的结构响应问题,学界目前常采用仿真和试验手段开展研究。但目前的仿真手段主要采用任意拉格朗日欧拉(arbitrary Lagrange-Euler, ALE)方法进行,计算效率低且在中远场计算中难以得到真实的结果,而试验手段成本较高。基于能流密度公式和TAYLOR板理论对平板水下非接触爆炸冲击波载荷与速度场等效关系展开研究,提出了冲击波载荷和等效初速度场的等效换算方法,建立了平板初速度场与水下爆炸参数的等效关系并开展试验验证。结果表明,基于能流密度的冲击波等效初速度场具有更好的计算精度和效率,这一方法可作为研究平板或者简单板架在水下爆炸冲击波作用下结构响应的一个重要的等效计算方法。

基于一维计算模型的斜盘式柱塞泵流动特性分析

斜盘式柱塞泵广泛应用在直升机疲劳试验的液压系统中,其流动特性对液压系统稳定性有着至关重要的作用。文中使用立体几何方法分析了斜盘式柱塞泵柱塞运动轨迹,基于图形解析法推导了过流面积公式,并编写相应Matlab程序实现吸排油过流面积自动化计算;构建了考虑流量倒灌及泄漏的单柱塞流动模型,结合AMESim软件实现柱塞泵三维计算模型向一维计算模型的转变;依据初始工况计算结果分析了柱塞泵的流动特性及其产生流量脉动的原因,并使用基于计算流体力学(CFD)方法的三维模型所获得的流量脉动计算结果验证了一维计算模型的准确性。在此基础上分析了不同运行工况(包含运行温度、工作压力及柱塞泵调节参数)对出口流量脉动率的影响,从降低流量脉动率进而提高直升机疲劳试验精度的角度分析了试验中柱塞泵调节控制要点。文中提出的一维计算模型可显著提高柱塞泵仿真计算速率,便于后续柱塞泵的改进设计以及将其作为子系统添加到虚拟数字试验平台中。

稀土La对电沉积Ni-P合金镀层工艺的影响

研究了添加稀土La电沉积电磁屏蔽N i-P合金镀层的工艺。在正交试验的基础上分析了镀液组成及电流密度对沉积速率的影响,综合考察了镀层表面质量及镀层与基体的结合力。结果表明:在镀液中加入微量稀土La,金属离子的沉积速率,镀层与基体的结合力,镀液的分散能力,镀层的表面质量都有不同程度的提高,并由此得出工艺的最佳镀液组成和操作条件。

高速磁浮列车泡沫三明治板在冲击载荷下的吸能特性与参数优化

建立模拟高速磁浮列车泡沫三明治裙板冲击的有限元模型,基于搭建的钢球冲击试验装置验证模型的有效性,研究冲击速度、前后金属面板厚度和支撑间距对泡沫三明治板吸能量和冲击载荷的影响。采用响应面法建立泡沫三明治板内能和初始峰值载荷的代理模型,基于遗传算法提出冲击速度、前后面板厚度和支撑间距等参数的优化方法。研究结果表明:在低速(8 m/s)冲击下,泡沫三明治板具有更好的吸能效率,吸能效率能达到90%以上;随着冲击速度增加,吸能效率显著下降;增加冲击间距不仅能延长冲击作用时间,也能显著降低冲击载荷峰值力,降幅达到13.59%;针对高速磁浮列车泡沫三明治板的吸能设计要求,通过调整前、后金属面板的厚度可有效改善其吸能效果。内能和峰值力的预测值与其真实值之间的最大相对误差分别为4.14%和0.96%,满足高速磁浮列车泡沫三明治板吸能特性预测的精度要求。

混合稀土对Ni-P化学镀工艺的影响

研究了混合稀土氧化物对Ni-P化学镀工艺的影响。结果表明,镀液中加入适量的稀土氧化物能提高镀速、稳定镀液;稀土能与Ni、P粒子共沉积,起微合金化作用,形成含RE的化学镀层。

复合材料蜂窝夹芯板抗鸟弹高速冲击性能研究

为了研究复合材料蜂窝夹芯板在鸟弹高速冲击下的抗冲击性能,以及蜂窝夹芯材料在机械结构轻量化设计上的运用。通过有限元仿真软件LS-DYNA建立了模拟明胶鸟弹冲击含玻璃纤维增强复合材料和碳纤维增强复合材料面板、等效化NOMEX芳纶纸蜂窝芯的仿真模型。研究了芳纶纸和铝合金两种蜂窝材料、蜂窝芯胞元壁厚、复合材料面板和铝合金两种面板材料对蜂窝夹芯板的抗冲击性能影响。结果表明组件中蜂窝芯厚度和面板厚度对复合材料蜂窝夹芯结构抗冲击性能都有较大影响。同等结构参数下,铝蜂窝、铝面板对抗鸟弹高速冲击性能更好。等质量不同厚度时,复合材料面板和芳纶纸蜂窝抗冲击性能更好,更适合用于机械结构的轻量化设计。

400 km/h高速列车车下带格栅裙板区域气动噪声机理及影响因素分析

位于高速列车车体下部区域的通风口格栅与设备舱壁面构成格栅–空腔结构,列车高速运行时,该结构的流声耦合问题较为突出,有必要深入分析其流声耦合机理。将位于车体下部区域的带格栅裙板简化为带格栅的二维空腔模型(格栅–空腔结构),采用延迟分离涡数值模型(Delayed Detached Eddy Simulation,DDES)研究其气动噪声产生机理、流场和声场特性等。研究结果表明:当列车以400 km/h速度运行时,格栅–空腔结构开口处的剪切振荡较为剧烈,特别是空腔冲击边缘附近区域;基于总声压级的空间、频域分布和湍流压力波数–频率谱,发现形格栅–空腔结构的流场始终处于自激振荡的过渡状态,且各位置的总声压级和波数域上的振荡幅值始终低于V形格栅–空腔结构和半圆环形格栅–空腔结构;对目前常用的半圆环形带格栅裙板考虑通风口的出风作用后,观察到空腔内部的涡团演化明显减缓,直接导致格栅附近的总声压级大幅下降约15 d B,表明出风作用能够显著降低带裙板格栅的近场噪声。