Effect of process parameters on sheath forming of continuous extrusion sheathing of aluminum

The effect of flow passage length in the die cavity and extrusion wheel velocity on the shape of aluminum sheath during the continuous extrusion sheathing process was analyzed by using finite element methods based on software DEFORM 3D and experimentally validated. The results show that by increasing the flow passage length, the velocity of metal at the cross-section of sheath tends toward uniformity, the values of the bending angles of sheath gradually approach the ideal value of zero and the cross-section exhibits a better shape. The extrusion wheel velocity has negligible effects on the bending shape and cross-section of the sheath product when a long flow passage is used.

Microstructure and properties of Al-0.70Fe-0.24Cu alloy conductor prepared by horizontal continuous casting and subsequent continuous extrusion forming

A novel process for manufacturing A1-0.70Fe-0.24Cu alloy conductor was proposed, which includes horizontal continuous casting and subsequent continuous extrusion forming （Conform）. The mechanical properties, electrical conductivity and the compressed creep behaviour of the alloy were studied. The results indicate that the Conform process induces obvious grain refinement, strain-induced precipitation of AI7CuzFe phase and the transformation of crystal orientation distribution. The processed alloy has good comprehensive mechanical properties and electrical conductivity. Moreover, a better creep resistance under the conditions of 90 ~C and 76 MPa is shown compared with pure A1 and annealed copper, and the relationship between primary creep strain and time may comply with the logarithmic law. The enhanced properties are attributed to the grain refinement as well as the fine and homogeneously distributed thermally stable A1Fe and A17Cu2Fe precipitation phases.

Analysis of Reservoir Forming Conditions and Prediction of Continuous Tight Gas Reservoirs for the Deep Jurassic in the Eastern Kuqa Depression,Tarim Basin

The exploration targets in the Kuqa Depression at present are mainly structure traps in Cretaceous-Tertiary.Due to the complexity of mountain distribution and reservoir forming conditions, the exploration of Jurassic in the eastern Kuqa Depression has been in a state of semi-stagnation since the discovery of the Yinan-2 gas reservoir.According to the concept and theory of 'continuous petroleum reservoirs' and the re-analysis of the forming conditions of the Yinan-2 gas reservoir and regional natural gas in the eastern Kuqa Depression,it is believed that the deep Jurassic has good natural gas accumulation conditions as well as geological conditions for forming continuous tight gas reservoirs.The boundary of the Yinan-2 gas reservoir is not controlled by a structural spillpoint.The downdip part of the structure is dominated by gas,while the hanging wall of the fault is filled by water and forming obvious inverted gas and water.The gas reservoir has the normal temperature and ultrahigh pressure which formed in the near source or inner-source.All of these characteristics indicate that the Yinan-2 gas reservoir is different from conventional gas reservoirs.The deep Jurassic in the eastern Kuqa Depression has multisets of source-reservoir-cap assemblages,which comprise interbedded sandstones and mudstones.These assemblages are characterized by a self-generation,self-preserving and self-coverage model.Reservoir sandstones and coal measure mudstones are interbedded with each other at a large scale.As the source rocks,Triassic-Jurassic coal measure mudstones distribute continuously at a large scale and can generate and expel hydrocarbon.Source rocks contact intimately with the overlying sandstone reservoirs.During the late stage of hydrocarbon expulsion,natural gas charged continuously and directly into the neighboring reservoirs.Petroleum migrated mainly in a vertical direction over short distances.With ultra-high pressure and strong charging intensity,natural gas accumulated continuously.Reservoirs are dominated by sandstones of braided delta facies.The sand bodies distribute continuously horizontal.With low porosity and low permeability,the reservoirs are featured by strong heterogeneity.It is hypothesized that the sandstones of the interior depression tend to be relatively tight with increasing depth and structure stress weakness.Thus,it is predicted that continuous tight gas reservoirs of ultra-high pressure may exist in the deep formations of the eastern and even the whole Kuqa Depression.So,it is worth evaluating the exploration potential.

Effect of extrusion wheel angular velocity on continuous extrusion forming process of copper concave bus bar

The continuous extrusion forming process for producing large section copper concave bus bar under different extrusion wheel angular velocities was studied by three-dimensional finite element technology based on software DEFORM-3D. The rigid-viscoplastic constitutive equation was employed in the model. The numerical simulation results show that the deformation body flow velocity in the die orifice increases gradually with the increase of the extrusion wheel angular velocity. But slippage between the rod and extrusion wheel occurs when the extrusion wheel angular velocity is high. The effective stress near the die orifice enhances gradually with increasing extrusion wheel angular velocity. High stress is concentrated in adjacent regions of the flash gap. The effective strain gradient is greater near the abutment than that near the die orifice. The effective strain of the product increases gradually with increasing extrusion wheel angular velocity. In the deformation process, the deformation body temperature increases remarkably due to friction and deformation. So the cooling is necessary in the region of the die and tools.

Theory and application research development of semi-solid forming in China

In order to adapt to the trend of ＂energy saving and emission reduction＂ and impel the practical application of semi solid processing （SSP） in China, the progress and application of semi-solid theory in China have been reviewed briefly and systematically. It was emphasized on basic theories, such as formation of globular grains, theology, high pressure solidification and plastic deformation and applications, such as material design, preparation of semi-solid billets （slurries）, thixoforming and application status, which are based on the advantage of semi-solid processing. The results show that the gap of SSP between world level and China exists, especially in application technologies, including market recognition, application fields exploiting, developing of billets （slurries） preparation technologies with low cost and special equipments. The prospect of semi-solid forming development path in China is presented. And we hope that application of SSP has great new breakthrough and development and China wilt be changed from a large metal processing country to a powerful metal processing country.

Semi-solid processing of hypereutectic A390 alloys using novel rheoforming process

The feasibility of semi solid processing of hypereutectic A390 alloys using a novel rheoforming process was investigated. A combination of the swirl enthalpy equilibration device （SEED） process, isothermal holding using insulation and addition of solid alloy during swirling was introduced as a novel method to improve the processability of semi solid slurry. The effects of isothermal holding and the addition of solid alloy on the temperature gradient between the centre and the wall and on the formation of a（Al） particles were examined. In additional tests, phosphorus and strontium were added to the molten metal to refine the primary and eutectic silicon structure to facilitate semi solid processing. The results show that the combination of the SEED process with two additional processing steps can produce semi-solid A390 alloys that can be rheoprocessed. The microstructure reveals an adequate amount of non-dendritic a（Al） globules surrounded by liquid, which greatly improves the processability of semi-solid slurry.

Preparation of AZ91D Slurries for Semi-Solid Forming Using Al8 ( Mn, Fe) 5 Precipitates

During the solidification of the AZ91D-alloys, the Al8(Mn, Fe)5 phase is generally precipitated in the melt in advance of the precipitation of the primary α-Mg. The basic principle for manufacturing AZ91D-alloy slurries for semi solid forming is to use the Al8(Mn, Fe)5 precipitates as the heterogeneous nucleation sites for primary α-Mg phases. Microscopic analysis for the location of the Al8(Mn, Fe)5 precipitate explains that the Al8(Mn, Fe)5 precipitate is the effective heterogeneous nucleation site for the primary α-Mg phase. It was also observed that increase of the Mn content in the melt and the cooling rate below to the solid/liquid two-phase region resulted in smaller and more globular primary α-Mg due to the increase of heterogeneous nucleation sites. It was found that the average α-Mg diameter grew as a function of t0.278, where t is the holding time at the solid/liquid two-phase region. This would be attributed to the Ostwald type ripening and coalescence between primary α-Mg phases. The cooling rate below to the solid/liquid two-phase region, Mn content in AZ91D alloy, and the holding time and temperature affected on the quality of slurry.

Structure of miniature components from steel produced by forming in semi-solid state

To obtain new unconventional structures with specific mechanical and physical properties is possible not only by the development of new types of materials but also by treatment of conventional materials using unconventional innovative technological procedures.One of these technologies is the forming in semi-solid state involving rapid solidification of miniature components from steels.Production of such components is complicated by a number of technical problems.To explain phenomena of the process and structure development,the production of miniature components from the tool steel X210Cr12 difficult to form was experimentally tested.The structure of this originally ledeburite steel consisted of 95 % of metastable austenite after the treatment.Metastable austenite was located particularly in globular and polygonal grains while the remaining interspaces were filled by lamellar network.The detected high stability of extremely high fraction of metastable austenite was tested under different conditions of thermal exposition and mechanical loading.

Abnormal mechanical property evolution induced by heat treatment for a semi-solid forming hypereutectic Al-Fe base alloy

In the present study, Al-5.5Fe-4Cu-2Zn-0.4Mg-0.5Mn al oy samples were prepared by electromagnetic stirring and semi-solid forming processing, and then the effects of T6 and T1 heat treatments on the microstructures and mechanical properties of the semi-solid forming samples were investigated. The results indicate that after semi-solid forming, the mechanical properties of the sample improved significantly compared to that of the merely electromagnetically stirred sample. The grains of semi-solid forming alloy became almost fine equiaxed; big long strip-shaped Al3 Fe phases became short rod-like morphology and distributed uniformly in the matrix. However, the mechanical properties of the T6-treated semi-solid forming sample decreased significantly instead of increasing and, with solution temperature rising, the tensile strength of the al oy decreased further. The results of EDS show that after high temperature solid-solution treatment, the Cu element in the semi-solid forming alloy sample is mainly concentrated at the boundaries of the Al3 Fe phases instead of being dissolved in the matrix. At the same time, the grains of the semi-solid forming sample grew slightly after solid-solution treatment. Therefore, the growth of the grains and the accumulation of Cu element at Al3 Fe phase boundaries during solution treatment of the semi-solid forming alloy were the main reasons for the mechanical properties decreasing after T6 treatment. The mechanical properties of the alloy were improved after T1 heat treatment due to aging strengthening phase being precipitated in the matrix.

Semi-solid Forming of a Damper Housing with Dendritic and Non-dendritic Al-Si-Mg Alloy

A motorcycle component of damper housing was made by semi-solid forming process. This was used to investigate the effect of microstructures of feedstock on the formability of semisolid process. The soundness and microstructures of casting parts made by dendritic and non-dendritic feedstock were investigated. Separating of liquid phase was found in the casting produced by dendritic feedstock, which might result in defects of porosity, while uniform microstructures were found in the casting produced by no...

Effects of technical parameters of continuous semisolid rolling on microstructure and mechanical properties of Mg-3Sn-1Mn alloy

A sloping semisolid rheo-rolling process of Mg-3Sn-1Mn alloy was developed, and the effects of process parameters on the microstructure and mechanical properties of Mg-3Sn-lMn alloy strip were studied. The results show that the primary grain average diameter of the strip increases with the increase of the roll speed. The primary grain average diameter decreases firstly and then increases with the increase of the vibration frequency, and the tensile strength and elongation of the strip increase firstly and then decrease with the increase of the vibration frequency. The primary grain average diameter increases with the increase of casting temperature, and the tensile strength and elongation of the strip decrease correspondingly. When the casting temperature is 670℃, the roll speed is 52 mm/s, and the vibration frequency is 60 Hz, Mg-3Sn-1Mn alloy strip with good properties is produced. The mechanical properties of the present product are higher than those of Mg-3Sn-lMn alloy casting with the addition of 0.87% Ce （mass fraction）.

Study on Multiple Electromagnetic Continuous Casting of Aluminum Alloy

To obtain semi-solid Al alloy billet with high quality, an investigation was carried out by imposing a multiple magnetic field from the outside of a copper mold in the continuous casting. AISi6Mg2 alloy designed for semi-solid metal （SSM） processing was continuously cast through a submerged entry nozzle under various conditions. Effects of multiple magnetic field on meniscus motion, temperature distribution and billet quality were examined. The experimental results showed that meniscus disturbance caused by electromagnetic stirring could be controlled effectively and the surface quality of semi-solid AI alloy billet was improved greatly, and an uniformly fine, globular microstructure across the transverse section of the billet was achieved by optimizing the distribution of multiple magnetic field.

Isothermal grain growth of reactive spray formed 7075 alloys in semi-solid state

The grain growth behavior in reactive spray formed 7075+2.91 vol percent TiCAl alloy was studied and compared with that of spray formed 7075 Al alloy at semi-solid state. Theeffects of in-situ TiC particles on the microstructure of spray formed 7075 Al alloy were alsoinvestigated. The specimens were heat-treated isothermally at various temperatures between thesolidus and liquidus of 7075 Al alloy for times in the range of 10-60 min, then quenched in water.The microstructure of reheated specimens was characterized using scanning electron microscopy andoptical microscopy. The grain size was measured using a mean linear intercept method. Results showthat the in-situ TiC particles can effectively retard grain growth and refine the grain at a limitedsize. The grain growth exponent in Arrhenius equation increases from 2 to 3, which indicates thatthe in-situ TiC particles have the significant pinning effect on grain coarsening in the semi-solidstate.

Structural evolution of spray-formed Al-70wt.%Si alloys during iso-thermal holding in the semi-solid state

The grain growth behavior of spray-formed Al-70wt.%Si alloys was studied in the semi-solid state. The specimens were isothermally heat-treated at various temperatures between the solidus and liquidus of Al-Si alloys and then quenched in water. The microstructure of reheated specimens was characterized using optical and scanning electron microscopies. The isothermal holding experiment was carried out to investigate grain growth behavior as a function of holding time and temperature in the semi-solid state. The coarsening mechanism and the effect of porosity on microstructure were also studied.

基于Simufact Forming的细长轴连续径向锻造数值仿真

针对细长轴刚性较差、变形较大及加工难度较大的问题,对某轴连续多次径向锻造工艺进行分析。运用专业锻造有限元软件Simufact Forming建立了连续多次径向锻造数值仿真模型,对其在不同径向锻造次数下的等效应力、等效应变进行了数值计算,得到不同径向锻造次数下锻件的形状变化及最大等效应力、最大等效应变的变化规律。结果表明:通过连续多次径向锻造能获得综合性能优良及表面精度较高的细长轴;随着径向锻造次数增加,最大等效应力、最大等效应变逐渐增加。

A SURFACE DEFECT PREDICTION METHOD FOR METAL FORMING PROBLEM

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The Convergence of 1-Periodic Branched Continued Fraction of the Special Form in Parabolic Regions

Branched continued fractions are one of the multidimensional generalization of the continued fractions. Branched continued fractions with not equivalent variables are an analog of the regular C-fractions for multiple power series. We consider 1-periodic branched continued fraction of the special form which is an analog fraction with not equivalent variables if the values of that variables are fixed. We establish an analog of the parabola theorem for that fraction and estimate truncation error bounds for that fractions at some restrictions. We also propose to use weight coefficients for obtaining different parabolic regions for the same fraction without any additional restriction for first element.

Unveiling the planar deformation mechanisms for improved formability in pre-twinned AZ31 Mg alloy sheet at warm temperature

To investigate the role of pre-twins in Mg alloy sheets during warm planar deformation,the stretch forming is conducted at 200℃.Results suggest the formability of the pre-twinned AZ31 Mg alloy sheet is enhanced to 11.30 mm.The mechanisms for the improved formability and the deformation behaviors during the planar stretch forming are systematically investigated based on the planar stress states.The Schmid factor for deformation mechanisms are calculated,the results reveal that planar stress states extremely affect the Schmid factor for{10-12}twinning.The detwinning is activated and the prismatic slip is enhanced in the pre-twinned sheet,especially under the planar extension stress state in the outer region.Consequently,the thickness-direction strain is accommodated better.The dynamic recrystallization(DRX)type is continuous DRX(CDRX)regardless of the planar stress state.However,the CDRX degree is greater under the planar extension stress state.Some twin lattices deviate from the perfect{10-12}twinning relation due to the planar compression stress state and the CDRX.The basal texture is weakened when the planar stress state tends to change the texture components.

美国及日本浸渍成型（Dig Forming）设备概况

详细介绍了美国及日本生产无氧铜杆的浸渍成型设备及工艺流程。该法整个过程均封闭在保护气氛中进行，采用自动控制。优点是设备占地面积小，投资小，生产能力达３．６～１０ｔ／ｈ，产品表面光亮，拉丝断裂少，质量高。

嵌套加强的LQ550高强冷弯薄壁C型钢连续檩条受力性能研究

为提高LQ550级高强冷弯薄壁C型钢连续檩条的承载能力,采用在支座处嵌套的方法来加强连续檩条。对未加强和采用两种嵌套方式加强的檩条共7组试件进行三点受弯试验,得到了试件的承载性能和破坏形态,试验结果表明加强后的试件出现跨中局部屈曲和嵌套端部局部屈曲两种破坏形态。采用ABAQUS软件建立了非线性有限元模型对嵌套加强的檩条进行数值模拟,有限元分析得到的承载力和破坏形态与试验结果吻合良好,验证了有限元模型的准确性。基于验证的有限元模型,分析了两种嵌套方式和不同嵌套长度对檩条承载力的提升,且表明嵌套檩条的长度宜取为连续檩条跨度的1/5~1/4。