Recent progress in the research on magnesium and magnesium alloy foils:A short review

Magnesium and magnesium alloy foils have great potential for application in battery anodes,electromagnetic shielding,optics and acoustics,and biology because of their excellent specific damping,internal dissipation coefficients,magnetic and electrical conductivities,as well as high theoretical specific capacity.However,magnesium alloys exhibit poor deformation ability due to their hexagonal close-packed crystal structure.Preparing magnesium and magnesium alloy foils with thicknesses of less than 0.1 mm is difficult because of surface oxidation and grain growth at high temperatures or severe anisotropy after cold rolling that leads to cracks.Numerous methods have been applied to prepare magnesium alloy foils.They include warm rolling,cold rolling,accumulative roll bonding,electric plastic rolling,and on-line heating rolling.Defects of magnesium and magnesium alloy foils during preparation,such as edge cracks and breakage,are important factors for consideration.Herein,the current status of the research on magnesium and magnesium alloy foils is summarized from the aspects of foil preparation,defect control,performance characterization,and application prospects.The advantages and disadvantages of different preparation methods and defect(edge cracks and breakage)mechanisms in the preparation of foils are identified.

Preliminary discussion on the ignition mechanism of exploding foil initiators igniting boron potassium nitrate

Exploding foil initiator(EFI)is a kind of advanced device for initiating explosives,but its function is unstable when it comes to directly igniting pyrotechnics.To solve the problem,this research aims to reveal the ignition mechanism of EFIs directly igniting pyrotechnics.An oscilloscope,a photon Doppler velocimetry,and a plasma spectrum measurement system were employed to obtain information of electric characteristics,impact pressure,and plasma temperature.The results of the electric characteristics and the impact pressure were inconsistent with ignition results.The only thing that the ignition success tests had in common was that their plasma all had a relatively long period of high-temperature duration(HTD).It eventually concludes that the ignition mechanism in this research is the microconvection heat transfer rather than the shock initiation,which differs from that of exploding foil initiators detonating explosives.Furthermore,the methods for evaluating the ignition success of semiconductor bridge initiators are not entirely applicable to the tests mentioned in this paper.The HTD is the critical parameter for judging the ignition success,and it is influenced by two factors:the late time discharge and the energy of the electric explosion.The longer time of the late time discharge and the more energy of the electric explosion,the easier it is to expand the HTD,which improves the probability of the ignition success.

Purification of copper foils driven by single crystallization

High-purity copper(Cu) with excellent thermal and electrical conductivity, is crucial in modern technological applications, including heat exchangers, integrated circuits, and superconducting magnets. The current purification process is mainly based on the zone/electrolytic refining or anion exchange, however, which excessively relies on specific integrated equipment with ultra-high vacuum or chemical solution environment, and is also bothered by external contaminants and energy consumption. Here we report a simple approach to purify the Cu foils from 99.9%(3N) to 99.99%(4N) by a temperature-gradient thermal annealing technique, accompanied by the kinetic evolution of single crystallization of Cu.The success of purification mainly relies on(i) the segregation of elements with low effective distribution coefficient driven by grain-boundary movements and(ii) the high-temperature evaporation of elements with high saturated vapor pressure.The purified Cu foils display higher flexibility(elongation of 70%) and electrical conductivity(104% IACS) than that of the original commercial rolled Cu foils(elongation of 10%, electrical conductivity of ~ 100% IACS). Our results provide an effective strategy to optimize the as-produced metal medium, and therefore will facilitate the potential applications of Cu foils in precision electronic products and high-frequency printed circuit boards.

Investigation of Cavitation in NaCl Solutions in a Sonochemical Reactor Using the Foil Test Method

Ultrasonic baths and sonochemical reactors are widely used in industrial applications dealing with surface cleaningand chemical synthesis. The processes of erosion, cleaning and structuring of the surface can be typically controlledby changing relevant influential parameters. In particular, in this work, we experimentally investigate theeffect of NaCl concentration (0–5.5 mol/L) on the erosion of an aluminum foil under ultrasonic exposure at afrequency of 28 kHz. Special attention is paid to the determination of cavitation zones and their visualizationusing heat maps. It is found that at low NaCl concentration (0.3 mol/L), the foil destruction rate is higher thanin distilled water. At higher concentrations of salt, cavitation takes place mainly in the upper part of the container.

Study on theoretical model for electrical explosion resistivity of Al/Ni reactive multilayer foil

Al/Ni reactive multilayer foil(RMF)possesses excellent comprehensive properties as a promising substitute for traditional Cu bridge.A theoretical resistivity model of Al/Ni RMF was developed to guide the optimization of EFIs.Al/Ni RMF with different bilayer thicknesses and bridge dimensions were prepared by MEMS technology and electrical explosion tests were carried out.According to physical and chemical reactions in bridge,the electrical explosion process was divided into 5 stages:heating of condensed bridge,vaporization and diffusion of Al layers,intermetallic combination reaction,intrinsic explosion,ionization of metal gases,which are obviously shown in measured voltage curve.Effects of interface and grain boundary scattering on the resistivity of film metal were considered.Focusing on variations of substance and state,the resistivity was developed as a function of temperature at each stage.Electrical explosion curves were calculated by this model at different bilayer thicknesses,bridge dimensions and capacitor voltages,which showed an excellent agreement with experimental ones.

Effect of Surface Roughness on Lubrication Performance of Bump-Type Gas Foil Bearings

Taking bump-type gas foil bearings as the research object,a deformation model of bump foil and a thin-plate finite element model of top foil were proposed.By solving Reynolds equation and energy equation,the pressure distribution and the temperature distribution of gas films in foil bearings were obtained.Further,a numerical method for calculating the lubrication performance of gas foil bearings with considering the surface roughness was proposed.With a specific example,effects of the surface roughness on the bearing lubrication performance were parametrically studied.The results indicate that rougher journal surface can lead to larger fluctuation of the lubrication performance,while surface roughness of top foil has few effects on the fluctuation.Moreover,the mean values of performance parameters almost remain constant at different values of surface roughness.

Methods of controlled formation of instabilities during the electrical explosion of thin foils

The results of a study of the electrical explosion of aluminum foils with an artificial periodic surface structure created by laser engraving are presented.Experiments were carried out on pulsed high-current generators BIN(270 kA,300 kV,100 ns)and KING(200 kA,40 kV,200 ns)with Al foil of thicknesses 16 and 4μm,respectively.Images of the exploded foils were recorded by point projection radiography in the radiation from hybrid X-pinches.It is found that the application of an artificial periodic structure to the foil leads to a much more uniform and well-defined periodic structure of the exploded foil.Images recorded in the UV range using a microchannel-plate-intensified detector show that the radiation from a surface-modified foil is more uniform along the entire length and width of the foil than that from a foil without modification.

Experimental and numerical studies of titanium foil/steel explosively welded clad plate

Ti/Fe clad plate had attracted extensive attention because of its important application. In order to reduce the titanium layer thickness, the explosive welding of TA1 titanium foil to Q235 steel plate was carried out. The interfacial bonding performance was analyzed by micromorphology analysis and mechanical property test, and the formation process of interfacial wave and molten block in the vortex was simulated by smoothed particle hydrodynamics(SPH) method. The results showed that salt as pressure transfer layer used in explosive welding could play a good buffer effect on the collision between flyer and base layers. Regular waveforms were formed on the bonding interface, and the titanium foil/steel clad plate exhibited good welding quality and bonding property. The crest of the observed interfacial wave moved 200 μm from the beginning to the final formation, and it was important of jet on the formation of interfacial waveform. The interface was mainly bonded in the form of molten layer, and the grains near the interface were streamlined. Molten block containing intermetallic compounds and metal oxides appeared in the vortex of wave crest.

基于流固耦合的箔片气体轴承动态特性分析

基于有限元软件ANSYS Workbench,建立箔片气体轴承在可压缩流体介质中运动的有限元模型,采用6DOF动网格计算方法对轴承的运动状态进行流固耦合数值模拟,探讨了不同转速和波箔片结构参数(波箔片的长度比、高度以及厚度)对轴承动态特性的影响规律。仿真结果表明:转速增加,轴承的承载能力增加,但稳定性有所下降,更容易发生失稳现象;选取波箔片的长度比在1~1.5之间、厚度为0.16 mm,既可以保证轴承具有较高的刚度,同时又能获得较大的阻尼;波箔片高度与轴承动态特性成反比关系。将仿真结果与试验结果进行对比,验证了仿真计算方法的正确性和有效性。同时本文的研究为优化波箔片结构,改善轴承动态特性,提高轴承运行稳定性提供理论依据。

电爆炸金属桥箔早期过程中电磁-热-力多物理场耦合建模与分析

金属桥箔的电爆炸过程对电炮、冲击片雷管等的性能影响极为关键。这一过程中物质性质变化、几何构型和动力学过程非常复杂,早期的大量理论模拟工作均采用极为简化的物理模型。为此,建立了描述爆炸箔早期行为的三维电磁-热-固体力学耦合求解全物理模型,模拟爆炸箔在大电流加载下的早期受热膨胀过程,并对早期膨胀过程中桥箔上的磁场、电流、温度等演化进行分析,观察到电流在构型和电阻率两种因素影响下的角扩散和线扩散现象,模拟得到的桥区温度场分布与参考文献中的实验图像及模拟结果定性符合。

电容屏破损缺陷局部放电过程规律特征及仿真分析

油纸电容式变压器套管因性能好、成本低而被广泛采用。当电容屏存在边缘破损工艺缺陷时易发生局部放电,进而会改变油纸绝缘性能,缩短套管使用寿命,严重时危及电网设备安全运行。为研究电容屏破损局部放电过程变化规律,明确放电发展阶段,该文搭建了缺陷套管放电实验模型分析局放过程中相位谱图、放电量等参数发展规律,并基于实验规律及流体漂移扩散理论、固体双极电荷传输理论,建立了末屏缺陷针板沿面放电过程仿真模型,结合仿真中电荷形态变化、放电时间及油纸界面电荷密度分布对电容屏破损放电过程进行阶段划分:放电初始阶段,铝箔尖端电荷聚集发生电晕放电;放电发展阶段,尖端处带电粒子在电场作用下向油纸发展,小部分达到油纸界面产生沿面放电;放电破坏阶段,经过长时间沿面放电进入油纸发生预击穿,电场强度更大使带电粒子能量更高,冲击油纸表面造成油纸表面纤维素断裂炭化形成通道。仿真结果与实验结论相对应,证明了仿真的有效性。该文的研究成果进一步阐明了油纸套管电容屏工艺缺陷局部放电的过程及机理。

自然环境老化ETFE薄膜单轴拉伸力学性能研究

ETFE薄膜在自然环境老化后的力学性能是ETFE结构长期使用性能评价的基础。选取在室外自然环境长期使用后的ETFE薄膜,开展了微观形貌表征和宏观力学性能试验,采用能量法确定了自然环境老化ETFE薄膜的屈服点及弹性模量,基于数理统计分析了材料力学参数标准值。研究结果表明,自然环境老化作用使ETFE薄膜材料表面微观形貌粗糙,截面褶皱纹理密集,晶粒尺寸增大了7.8%。老化ETFE薄膜破断强度下降显著,屈服应力及弹性模量降低较大,其标准值为11.73、703.2 MPa,降低了14.9%、13.5%。研究扩展了ETFE薄膜材料力学的研究范畴,可为准确评估ETFE结构长期使用性能提供重要的力学参数。

金属桥箔电爆炸驱动飞片过程数值模拟研究

为研究金属桥箔电爆炸等离子体驱动飞片全过程中飞片的性能特征和影响规律,建立了金属桥箔电爆炸驱动飞片全过程的多相流数值计算模型,并进行了数值模拟计算.计算中,利用了相变分数描述金属桥箔由固相到等离子体相的相态转变,采用了考虑粒子数目变化及粒子间库仑作用的高温高压等离子体状态方程描述电爆炸等离子体的形成和运动行为,采用了动网格模型描述飞片的运动.将计算结果与实验结果进行对比分析,计算得到的飞片速度值与实验值的误差小于5%,表明计算模型的准确性较好.基于该计算模型,对总面积相同的双体阵列桥箔和单体桥箔电爆炸等离子体驱动飞片过程进行了数值模拟,计算结果表明,由于阵列桥箔电爆炸过程中等离子体和冲击波的叠加汇聚作用,提高了能量转化效率,使得等离子体及冲击波流场对飞片的驱动力增加,从而提高了飞片的速度.等离子体流场对飞片表面的烧蚀厚度约为0.1μm,飞片的完整性较好.

深低温氢气润滑箔片气体动压轴承特性研究

针对实际工程运用中氢气润滑箔片气体动压轴承出现的湍流效应,结合氢气润滑箔片气体动压轴承所处的深低温状态,利用壁面定律修正经典气体雷诺方程,耦合Link-Spring力学模型后求解并获得了以深低温氢气作为润滑介质的箔片气体动压轴承静动态特性;对比箔片气体动压轴承在深低温氢气与其他润滑气体介质时的静态特性,分析偏心率、环境压力、宽径比和名义间隙等参数对箔片气体动压轴承静动态特性的影响.结果表明,相较于常温常压空气和低温高压氮气,以低温高压氢气为润滑介质的箔片气体动压轴承的承载力相对较低,但可通过增大轴承的偏心率、工作环境压力、宽径比、动力黏度和减小轴承的名义间隙等方式增大承载力;轴承的直接动态刚度系数随环境压力的增大而增大,随名义间隙的增大而减小.

某直列式点火器双路瞎火故障分析与改进

针对某直列式点火器在低温点火试验中出现的双路冲击片点火管瞎火问题,进行了故障定位及原因分析,提出了改进措施并对其有效性进行了试验验证。结果表明:造成双路瞎火故障的原因是点火器转接件焊点异常处的气体间隙弧光放电;提出将2个回路的触发信号时间间隔调整为50μs,按照HB 7262航空产品电装工艺的相关规定细化电装工艺,增加对能量传输通道的介质耐压检测等改进措施。验证试验表明采取改进措施后,消除了弧光放电现象,点火器内的2个爆炸箔表面均有明显的电爆炸痕迹。

硫脲对电解高性能双面光锂电铜箔性能的影响

为研究硫脲质量浓度对铜箔表面形貌、结构、性能以及电解液电化学行为的影响,以磷铜板为阳极,以硫脲(TU)、羟乙基纤维素(HEC)、聚乙二醇(PEG-1000)和聚二硫二丙烷磺酸钠(SPS)作为组合添加剂,采用自制旋转电镀装置以直流电沉积法在TAl钛辊上制备电解铜箔,并利用扫描电子显微镜、铜箔拉伸强度试验仪以及电化学分析等方法,重点考察了组合添加剂中TU对铜箔表面形貌和物理性能的影响。结果表明:在组合添加剂体系中TU具有较强的极化作用,可以抑制铜核的生长,使铜箔结晶更细致,有效地起到光亮和整平作用并提高铜箔力学性能,且组合添加剂间表现出较好的协同效应。在高性能锂电铜箔的制备过程中,可通过适当调整电解液中硫脲的加入量来改善电解铜箔的各项性能。

融合设备状态和产品要求的电解铜箔制造工艺参数优化

针对当前电解铜箔制造工艺参数的优化仅考虑产品要求的问题,提出了一种融合设备状态和产品要求的电解铜箔制造工艺参数优化方法。首先,为辨识铜箔制造中工艺、设备与产品参数之间的非线性关系,建立了基于神经网络的“工艺-设备”与产品参数的映射模型,并通过构建当前生产模式与历史生产模式的相似性度量方法,确定当前工艺参数的优化初始点;然后,基于所建立的映射模型、设备状态和产品要求构建多目标约束函数,并利用遗传算法优化工艺参数,获得同时满足设备状态和产品要求的最佳工艺参数。企业的生产验证表明:相较于仅考虑产品要求的工艺优化方法,所提方法优化后的工艺参数能在相同的设备状态下获得质量更好的产品,在常温/高温抗拉强度、常温/高温延伸率和树脂剥离强度这5项关键指标上,分别提升了6.1 MPa、6.1 MPa、1.9%、0.7%和0.22 N/mm,生箔制备和表面处理的生产效率也提高了2.65%和7.5%,能够有效保证并提高铜箔的质量和生产效益。

TA1箔力学性能和断裂行为的尺寸效应

对不同晶粒尺寸的100μm厚TA1箔进行单轴拉伸试验,研究其力学性能和断裂行为的尺寸效应,并构建基于尺寸效应的微尺度本构方程。结果表明,随着晶粒尺寸增大,钛箔的拉伸应力及强度呈现增大的趋势,伸长率先缓慢下降至25%,随后快速降低。拉伸过程中颈缩阶段和平缓阶段不断缩短,除晶粒尺寸为56.88μm的试样外,其余试样断口夹角处于50°~60°,为典型的剪切型断裂。晶粒尺寸超过21.08μm后,断口表面的撕裂棱和韧窝数量不断减少,断裂模式由塑性断裂转变为准解理断裂,晶粒尺寸大于36.14μm后,钛箔基体从HCP-Ti结构转变为FCC-Ti结构,位错密度降低,断口表面出现明显的解理断裂特征,断裂模式完全转变为解理断裂。基于表面层模型构建考虑尺寸效应的本构模型,可精确预测微尺度钛箔拉伸过程中的力学特性。

基于铁锈红和废锂箔制备LiFePO_(4)/C正极材料的储锂性能

磷酸铁锂电池的需求大、市场垄断而导致原材料价格日益高涨。以铁锈红和废锂箔为原材料,采用磷酸铁工艺制备了LiFePO_(4)/C粉末,并测试其电化学储锂性能。结果表明:LiFePO_(4)/C粉末由粒径尺寸为110~400nm的颗粒组成,在1.0C循环350圈后的可逆比容量和容量保持率分别为129.7mAh/g和98.0%,与商业LiFePO_(4)正极材料性能相当。可见,该结果降低了LiFePO 4的制备成本,有利于循环经济和可持续发展。

低压发火环境下爆炸箔电爆炸性能测试

针对直列式安全起爆系统中冲击片雷管充电电压高且不易满足常规武器使用要求等问题,设计了一种多功能电爆炸起爆及测试仪器,建立了爆炸箔模型进行仿真,开展了在低压发火环境下三种相同形状不同材料爆炸箔的爆发电压、爆发电流测试试验,利用高速摄影机和电子显微镜观察电爆炸过程,仿真结果与试验结果相互印证得出:Al箔在低压起爆环境下的能量利用率更高在1000 V可达到28.6%、峰值功率更大,电爆炸性能更好。以低压发火为试验条件,起爆仪器验证了不同材料的爆炸箔的电爆炸特性,为冲击片雷管低能化的电爆性能研究提供一定的参考价值。