The influence of stress and strain on the solid/liquid segregation formed in deformed semisolid metal was studied.Thecompression experiment at a low constant strain rate was conducted on a Gleeble 1500 thermo-mechanic...The influence of stress and strain on the solid/liquid segregation formed in deformed semisolid metal was studied.Thecompression experiment at a low constant strain rate was conducted on a Gleeble 1500 thermo-mechanical sireulator.The stress and strain fields of the samples were calculated by finite element method.The experiment results and themodeling results prove that the hydrostatic pressure gradient is the driving force for solid/liquid segregation.Thesegregated liquid phase usually agglomerates in the micropores and shear bands are created by sliding of equiaxeddendrite grains.The sliding among the grains is influenced by the solid fraction and grain size of the semisolid slurry,so as the solid fraction and grain size change,the morphology of the segregated liquid changes.展开更多
As a new attempt to recycle minute metal scraps, the possibility of manufacturing design materials by semisolid extrusion processing was shown.A design material with an intended shape, such as a character or petal sha...As a new attempt to recycle minute metal scraps, the possibility of manufacturing design materials by semisolid extrusion processing was shown.A design material with an intended shape, such as a character or petal shape, was manufactured using minute metal scraps.Similarly, a design material with an intended color pattern for each metal, such as red copper in a white aluminum matrix, resembling grainlike wood, was manufactured by mixing two or more types of minute metal scrap.In addition, secondary design materials, which have engraved patterns on the surface of the target metal made by an electric discharge machine using the above primary design material as an electrode, were manufactured.展开更多
The effect of the cooling slope on the structure of Zr-based metallic glass matrix composites was investigated by changing the cooling slope.The synthesis of bulk metallic glass composites was made by a process combin...The effect of the cooling slope on the structure of Zr-based metallic glass matrix composites was investigated by changing the cooling slope.The synthesis of bulk metallic glass composites was made by a process combining cooling slope casting and Cu mold casting for Zr66.4Nb6.4Cu10.5Ni8.7Al8 alloys.The results show that the semisolid slurry which consists of the spheroidal or rosette-type BCC crystals and the liquid phase which forms metallic glass phase can be formed by the cooling slope process in this alloy system.However,the semisolid slurry cannot reach to the mold.It is considered that higher viscosity of the liquid phase which forms metallic glass phase causes this result.Thus,parameters of the cooling slope have to be examined further.展开更多
To investigate the possibility of substituting the mechanical stirring system with electromagnetic stirring (EMS) system for aluminum rheo die-casting, the EMS under the different stirring cooling conditions was carri...To investigate the possibility of substituting the mechanical stirring system with electromagnetic stirring (EMS) system for aluminum rheo die-casting, the EMS under the different stirring cooling conditions was carried out. It was found that in the early period of solidification, the dendrite breakages led to a fine primary phase. When dendrites grew coarsely, the effect of ripening on grain size overwhelmed that of dendrite breakage. It was also found that the high cooling rate favored large nucleation rate, and led to a fine primary phase. But high cooling rate also made the growth rate of the dendrite arm, which prevented the dendrite arm from being sheared off. Therefore there were a suitable stirring time and suitable cooling rate to obtain the best rheo die-casting structure. Qualified semisolid A356 aluminum alloy was successfully manufactured with short time EMS.展开更多
Semisolid continuous casting (SSCC) is a new technology to produce billets for semisolid metal forming (SSMF). The effect of process factors, such as pouring temperature, stirring rate, preheating temperature and ther...Semisolid continuous casting (SSCC) is a new technology to produce billets for semisolid metal forming (SSMF). The effect of process factors, such as pouring temperature, stirring rate, preheating temperature and thermal conductivity of stirring chamber, on the microstructure of SSCC billets was studied by means of the factorial experimental method. The results show that the microstructure of SSCC billets can be controlled by the above-mentioned four process factors. In order to obtain fine and rounded granular grains in an SSCC billet, the pouring temperature, preheating temperature and stirring rate should be kept in a moderate range, and the thermal conductivity of stirring chamber should be high. The regression equations with the process factors connecting the microstructure was also set up based on experimental data.展开更多
The effects of vibration and grain refiner on the microstructure of semisolid slurry of hypoeutectic Al-Si alloy were studied. The impact of vibration on the convection of liquid was conducted by using a system of wat...The effects of vibration and grain refiner on the microstructure of semisolid slurry of hypoeutectic Al-Si alloy were studied. The impact of vibration on the convection of liquid was conducted by using a system of water-particle tracer. The 356 melt at temperature of 630-660 ℃ with or without grain refiner Al-5%Ti-1%B was poured into a metal cup as the vibrating vessel, then it was cooled to 590-610 ℃ in the semisolid zone and kept for some time, subsequently vibration with different frequencies was applied. The results show that the primary α(Al) particles become finer and rounder with the increase of vibration frequency. The slurry with primary α(Al) equivalent particle diameter(EPD) of about 90 μm and average shape coefficient(ASC) of about 0.5 can be prepared under vibration of 20 Hz. With the combined action of vibration and grain refiner Al-5Ti-B, even smaller and rounder spheroids with EPD of about 85 μm and ASC of about 0.6 are obtained.展开更多
Two kinds of bi-metal composite parts (Sn-15%Pb and Pb-22%Sn bi-metal system, and Al-7%Si and SiCp/6061 MMC bi-metal system) were prepared by the strain-induced melt activated thixo-forging.The interfaces of the bi-me...Two kinds of bi-metal composite parts (Sn-15%Pb and Pb-22%Sn bi-metal system, and Al-7%Si and SiCp/6061 MMC bi-metal system) were prepared by the strain-induced melt activated thixo-forging.The interfaces of the bi-metal composites were observed by OM and SEM.The observations show that the semisolid metals keep independence during thixo-forging.The solid phases in the semisolid slurries maintain their original morphologies after thixo-forging.The liquid phases near the interface mix together and form a thin layer.The interfaces are bonded firmly with the metallurgical bonding.No oxide layers are found at the interfaces.Strengths of the interfaces were investigated by the micro-hardness test.The experimental results show that the composite interfaces have high strength.However, the agglomerated enhancing particles cause fine defect on the interface of the Al-7%Si and SiCp/6061 MMC bi-metal composite.展开更多
The major unsteady phenomena in semisolid continuous casting process are the breakage and breakout. The essential reasons for them are the passageway blocking or the solidified shell too thin to endure the withdrawal ...The major unsteady phenomena in semisolid continuous casting process are the breakage and breakout. The essential reasons for them are the passageway blocking or the solidified shell too thin to endure the withdrawal force because of the remained shell formed at the beginning and its developing afterwards. Through theoretically analyzing the crack filling and the remained shell developing, stability conditions were presented. The essential one of them is that the stress acted on the semisolid slurry must be larger than the yield stress of it. The condition without breakage is to build a balance between the increase of the remained shell resulted in solidifying and the decrease of it resulted in flowing of the semisolid slurry. The condition without breakout is to ensure the solidified thickness larger than the safe thickness. The corresponding mathematical formulas of these conditions were set up and the verification experiments show that these conditions are reliable in applications. [展开更多
A two-dimensional computational model coupling an annular electromagnetic stirring（A-EMS） with a macroscopic heat and fluid flow analysis in Al-alloys semisolid slurry preparation was developed.The dynamic evolution...A two-dimensional computational model coupling an annular electromagnetic stirring（A-EMS） with a macroscopic heat and fluid flow analysis in Al-alloys semisolid slurry preparation was developed.The dynamic evolutions of the electromagnetic field,flow field,and temperature field were presented successfully by commercial software ANSYS 10.0 with corresponding experimental verification.A horizontally rotational electromagnetic field and,thereby,a more intensive velocity field were uniformly distributed in the stirred melt even at commercial frequency,and thus,a lower temperature difference in the stirred melt and subsequent uniformly fine microstructures were obtained compared with the normal electromagnetic stirring.The simulation results were in good agreement with experimental ones.展开更多
The application of semisolid process was investigated on Pb-Sb alloys that are normally used for metallic parts in car batteries, in order to increase their mechanical properties and corrosion resistance.The semisolid...The application of semisolid process was investigated on Pb-Sb alloys that are normally used for metallic parts in car batteries, in order to increase their mechanical properties and corrosion resistance.The semisolid behaviour of a Pb-4%Sb alloy was analysed by means of rheological and calorimetry differential scanning experiments.The alloy was melted, treated by ultrasound to obtain the semisolid state and then poured into permanent moulds.Some of these samples were also heated in semisolid temperature range and injected in thixo-casting apparatus.Both poured and injected samples were characterized by metallographic analysis, mechanical test and electrochemical corrosion experiments.The results show an improvement of mechanical and corrosion resistance with respect to samples obtained by conventional casting technique.展开更多
文摘The influence of stress and strain on the solid/liquid segregation formed in deformed semisolid metal was studied.Thecompression experiment at a low constant strain rate was conducted on a Gleeble 1500 thermo-mechanical sireulator.The stress and strain fields of the samples were calculated by finite element method.The experiment results and themodeling results prove that the hydrostatic pressure gradient is the driving force for solid/liquid segregation.Thesegregated liquid phase usually agglomerates in the micropores and shear bands are created by sliding of equiaxeddendrite grains.The sliding among the grains is influenced by the solid fraction and grain size of the semisolid slurry,so as the solid fraction and grain size change,the morphology of the segregated liquid changes.
文摘As a new attempt to recycle minute metal scraps, the possibility of manufacturing design materials by semisolid extrusion processing was shown.A design material with an intended shape, such as a character or petal shape, was manufactured using minute metal scraps.Similarly, a design material with an intended color pattern for each metal, such as red copper in a white aluminum matrix, resembling grainlike wood, was manufactured by mixing two or more types of minute metal scrap.In addition, secondary design materials, which have engraved patterns on the surface of the target metal made by an electric discharge machine using the above primary design material as an electrode, were manufactured.
文摘The effect of the cooling slope on the structure of Zr-based metallic glass matrix composites was investigated by changing the cooling slope.The synthesis of bulk metallic glass composites was made by a process combining cooling slope casting and Cu mold casting for Zr66.4Nb6.4Cu10.5Ni8.7Al8 alloys.The results show that the semisolid slurry which consists of the spheroidal or rosette-type BCC crystals and the liquid phase which forms metallic glass phase can be formed by the cooling slope process in this alloy system.However,the semisolid slurry cannot reach to the mold.It is considered that higher viscosity of the liquid phase which forms metallic glass phase causes this result.Thus,parameters of the cooling slope have to be examined further.
文摘To investigate the possibility of substituting the mechanical stirring system with electromagnetic stirring (EMS) system for aluminum rheo die-casting, the EMS under the different stirring cooling conditions was carried out. It was found that in the early period of solidification, the dendrite breakages led to a fine primary phase. When dendrites grew coarsely, the effect of ripening on grain size overwhelmed that of dendrite breakage. It was also found that the high cooling rate favored large nucleation rate, and led to a fine primary phase. But high cooling rate also made the growth rate of the dendrite arm, which prevented the dendrite arm from being sheared off. Therefore there were a suitable stirring time and suitable cooling rate to obtain the best rheo die-casting structure. Qualified semisolid A356 aluminum alloy was successfully manufactured with short time EMS.
基金This work was financed by the NatUral Science Research Fotmdation of Hebei Province, China and the NatUral Science Researc
文摘Semisolid continuous casting (SSCC) is a new technology to produce billets for semisolid metal forming (SSMF). The effect of process factors, such as pouring temperature, stirring rate, preheating temperature and thermal conductivity of stirring chamber, on the microstructure of SSCC billets was studied by means of the factorial experimental method. The results show that the microstructure of SSCC billets can be controlled by the above-mentioned four process factors. In order to obtain fine and rounded granular grains in an SSCC billet, the pouring temperature, preheating temperature and stirring rate should be kept in a moderate range, and the thermal conductivity of stirring chamber should be high. The regression equations with the process factors connecting the microstructure was also set up based on experimental data.
基金Project(50775086) supported by the National Natural Science Foundation of ChinaProject (2007AA03Z557) supported by the Hi-tech Research and Development Program of China
文摘The effects of vibration and grain refiner on the microstructure of semisolid slurry of hypoeutectic Al-Si alloy were studied. The impact of vibration on the convection of liquid was conducted by using a system of water-particle tracer. The 356 melt at temperature of 630-660 ℃ with or without grain refiner Al-5%Ti-1%B was poured into a metal cup as the vibrating vessel, then it was cooled to 590-610 ℃ in the semisolid zone and kept for some time, subsequently vibration with different frequencies was applied. The results show that the primary α(Al) particles become finer and rounder with the increase of vibration frequency. The slurry with primary α(Al) equivalent particle diameter(EPD) of about 90 μm and average shape coefficient(ASC) of about 0.5 can be prepared under vibration of 20 Hz. With the combined action of vibration and grain refiner Al-5Ti-B, even smaller and rounder spheroids with EPD of about 85 μm and ASC of about 0.6 are obtained.
基金Project(1343-71333000469) supported by the Funding of Graduate Student Training of Central South University,China
文摘Two kinds of bi-metal composite parts (Sn-15%Pb and Pb-22%Sn bi-metal system, and Al-7%Si and SiCp/6061 MMC bi-metal system) were prepared by the strain-induced melt activated thixo-forging.The interfaces of the bi-metal composites were observed by OM and SEM.The observations show that the semisolid metals keep independence during thixo-forging.The solid phases in the semisolid slurries maintain their original morphologies after thixo-forging.The liquid phases near the interface mix together and form a thin layer.The interfaces are bonded firmly with the metallurgical bonding.No oxide layers are found at the interfaces.Strengths of the interfaces were investigated by the micro-hardness test.The experimental results show that the composite interfaces have high strength.However, the agglomerated enhancing particles cause fine defect on the interface of the Al-7%Si and SiCp/6061 MMC bi-metal composite.
基金Project (5 992 81)supportedbytheNaturalScienceFoundationofHebeiProvince P .R .China
文摘The major unsteady phenomena in semisolid continuous casting process are the breakage and breakout. The essential reasons for them are the passageway blocking or the solidified shell too thin to endure the withdrawal force because of the remained shell formed at the beginning and its developing afterwards. Through theoretically analyzing the crack filling and the remained shell developing, stability conditions were presented. The essential one of them is that the stress acted on the semisolid slurry must be larger than the yield stress of it. The condition without breakage is to build a balance between the increase of the remained shell resulted in solidifying and the decrease of it resulted in flowing of the semisolid slurry. The condition without breakout is to ensure the solidified thickness larger than the safe thickness. The corresponding mathematical formulas of these conditions were set up and the verification experiments show that these conditions are reliable in applications. [
基金supported by the Major State Basic Research Development Program of China (No.2006CB605203)the National High-Tech Research and Development Program of China (No.2009AA03Z534)
文摘A two-dimensional computational model coupling an annular electromagnetic stirring（A-EMS） with a macroscopic heat and fluid flow analysis in Al-alloys semisolid slurry preparation was developed.The dynamic evolutions of the electromagnetic field,flow field,and temperature field were presented successfully by commercial software ANSYS 10.0 with corresponding experimental verification.A horizontally rotational electromagnetic field and,thereby,a more intensive velocity field were uniformly distributed in the stirred melt even at commercial frequency,and thus,a lower temperature difference in the stirred melt and subsequent uniformly fine microstructures were obtained compared with the normal electromagnetic stirring.The simulation results were in good agreement with experimental ones.
文摘The application of semisolid process was investigated on Pb-Sb alloys that are normally used for metallic parts in car batteries, in order to increase their mechanical properties and corrosion resistance.The semisolid behaviour of a Pb-4%Sb alloy was analysed by means of rheological and calorimetry differential scanning experiments.The alloy was melted, treated by ultrasound to obtain the semisolid state and then poured into permanent moulds.Some of these samples were also heated in semisolid temperature range and injected in thixo-casting apparatus.Both poured and injected samples were characterized by metallographic analysis, mechanical test and electrochemical corrosion experiments.The results show an improvement of mechanical and corrosion resistance with respect to samples obtained by conventional casting technique.
