NUMERICAL SIMULATION OF THE THERMO-MECHANICAL PROCESS FOR BEAM BLANK CONTINUOUS CASTING

The aim of this study was to simulate the solidification process of beam blank continuous casting, and then find the reasons for the typical defects of the beam blank. A two-dimensional transient coupled finite element model has been developed to compute the temperature and stress profile in beam blank continuous casting. The enthalpy method was used in the heat conduction equation. The thermo-mechanical property in the mushy zone was taken into consideration in this calculation. It is shown that at the mold exit the thickness of the shell had its maximum value at the flange tip and its minimum value at the fillet. The temperature had a great fluctuation on the surface of the beam blank in the secondary cooling zone. At the unbending point, the surface temperature of the web was in the brittleness temperature range under the present condition. To ensure the quality, it is necessary to weaken the intensity of secondary cooling. At the mold exit the equivalent stress and strain have higher values at the flange tip and at the web. From the spray 1 to the unbending point, the maximum values of stress and strain gradually moved to the internal section of the flange tip and the web. However, whenever, there were bigger stress and strain values near the flange tip and the web than in the other parts, it must be very easy to generate cracks at those positions. Now, online verification of this simulation has been developed, which has proved to be very useful and efficient to instruct the practical production of beam blank continuous casting.

IMPROVING THE MECHANICAL PROPERTIES OF COPPER ALLOYS BY THERMO-MECHANICAL PROCESSING

Systematic physical simulation of thermo-mechanical processing routes has been ap-plied on a Gleeble 1500 simulator to four copper alloys (mass %) Cu-0.57Co-0.32Si,Cu-0.55Cr-0.065P, Cu-0.22Zr-0.035Si and Cu-1.01Ni-0.43Si aimed at clarifying theinfluences of processing conditions on their final properties, strength and electricalconductivity. Flow curves were determined over wide temperature and strain rateranges. Hardness was used as a measure of the strength level achieved. High hard-ness was obtained as using equal amounts (strains 0.5) of cold deformation beforeand after the precipitation annealing stage. The maximum values achieved for theCu-Co-Si, Cu-Cr-P, Cu-Zr-Si and Cu-Ni-Si alloys were 190, 165, 178 and 193 HV5,respectively. A thermo-mechanical schedule involving the hot deformation-ageing-colddeformation stages showed even better results for the Cu-Zr-Si alloy. Consequently,the processing routes were designed based on simulation test results and wires of 5 and2mm in diameters have been successfully processed in the industrial scale.

NUMERICAL MODELING FOR COUPLED THERMO-HYDRO-MECHANICAL AND CHEMICAL PROCESSES (THMC) OF GEOLOGICAL MEDIA——INTERNATIONAL AND CHINESE EXPERIENCES

The coupled thermo-hydro-mechanical and chemical (THMC) processes of stress/deformation,fluid flow,temperature and geochemical reactions of the geological media,namely fractured rocks and soils,play an important role in design,construction,operation and environmental impact assessments of rock and soil engineering works such as underground nuclear waste repositories,oil/gas production and storage,geothermal energy extraction,landslides and slope stability,hydropower and water conservancy complexes,etc. This paper presents an overview of the international and Chinese experiences in numerical modeling of the coupled THMC processes for both the state-of-the-knowledge,remaining challenges and possible future prospects.

EVOLUTION OF MICROSTRUCTURES AND HARDNESS DURING CONTINUOUS THERMO-MECHANICAL PROCESSING OF 6201 ALUMINUM ALLOY

Continuous thermo-mechanical processing (CTMP) of 6201 aluminum alloy was simulated on Gleeble-1500. The deformed specimens were analyzed by the observation of TEM and the measurement of hardness. It was shown that rapid solid solution and aging treatment can be effectively combined in one procedure by the strain induced during CTMP. The deformation temperature is ranging from 540* C to 300* C, the hardness increases directly before the 6th pass followed by a slight drop, the amount of precipitates increases with the holding time after deformation. Uniformly distributed and stabilized Mg2Si precipitates, as well as dislocation substructure can be observed on deformed specimens which have been subsequently held at 300℃ for 60 seconds.

Model for Periodic Analysis of the Quantity of Water Evaporated during Thermo-processing of Clay Designated for Production of Oven Refractory

A model has been derived for periodic analysis of the quantity of water evaporated during thermo-processing of clay designated for production of oven refractory. The model;γ = exp〔〔lnt/2.9206〕1.3〕 shows that the quantity of evaporated water during the drying process is dependent on the drying time, with the evaporating surface being constant. It was found that the validity of the model is rooted on the expression lnγ = (lnt/Logβ)N where both sides of the equation are correspondingly almost equal. The maximum deviation of the model-predicted quantity of evaporated water from the corresponding experimental value is less than 19% which is quite within the acceptable deviation range of experimental results. Water evaporation rate as obtained from experiment and derived model were evaluated to be 0.0536 and 0.0337g mins -1 respectively.

Evolution of Microstructure in a Cu-Cr in situ Composite Produced by Thermo-Mechanical Processing

This paper studied the microstructure evolution of a deformation-processed Cu-7Cr in situ composite prepared by thermo-mechanical processing. The longitudinal and transverse sectional microstructures were analyzed using an optical microscope and a scanning electronic microscope. In the longitudinal section, the initially randomly distributed Cr dendrites in the as-cast Cu-7Cr alloy were transformed into the fibres aligned parallel to the drawing axis;the Cr dendrites experienced breaking, flattening and rotating, lapping and merging, and homogenizing and refinement during thermo-mechanical processing. In the transverse section, the initially randomly distributed Cr dendrites in the as-cast Cu-7Cr alloy were changed into the curvy ribbon like fibres;the Cr dendrites underwent breaking, flattening and rotating, folding and twisting, and irregularizing and refinement during thermo-mechanical processing.

Modeling of Microstructure Evolution and Mechanical Properties of Steel Plates Produced by Thermo-Mechanical Control Process and Its On-line Application

An integrated metallurgical model was developed to predict microstructure evolution and mechanical properties of low-carbon steel plates produced by TMCP. The metallurgical phenomena occurring during TMCP and mechanical properties were predicted for different process parameters. In the later passes full recrystallization becomes difficult to occur and higher residual strain remains in austenite after rolling. For the reasonable temperature and cooling schedule, yield strength of 30 mm plain carbon steel plate can reach 310 MPa. The first on-line application of prediction and control of microstructure and properties (PCMP) in the medium plate production was achieved. The predictions of the system are in good agreement with measurements.

Thermo-Calc calculations and studies of the heating process of Fe_(83)Si_4B_(13) alloy

The microstructural changes of Fe83Si4B13 amorphous mother alloy during the heating process were investigated by Laser Scanning Confocal Microscopy （LSCM） ,and the phase transformation was determined by the Thermo-Calc calculations. The differences in the melting points measured by Differential Scanning Calorimetry （DSC） and LSCM, and those obtained by Thermo-Calc calculations were also discussed. It is found that the melting points measured by DSC and LSCM are relatively similar, whereas the onset and end of the melting temperatures calculated by Thermo-Calc software are higher than those measured by DSC and observed by LSCM.

Formation Mechanism in Alloy Steel Rolling Process Using Thermo-mechanical Coupling Method

Based on the theory of elastic-plastic finite element method, the high-speed hot continuous rolling process of a billet is simulated and analyzed in vertical and horizontal passes. The billet is dragged into the passes by contact friction force between the billet and rollers. The rollers and billet are represented by respectively rigid and deformable bodies, and three-dimensional models are developed for the billet and rollers. The distribution of deformation field, effective strain, rolling force and temperature field are accurately calculated for the whole rolling process （including unstable and stable stages）. In addition, the rolling pressure on the width symmetry center is compared with that in the in-situ experimental measurements. It is revealed that various heat exchange phenomena among the billet, rollers and surroundings can result in unbalanced temperature distribution on the cross section. Rolling force and strain can change significantly when the billet is moved towards or away from the roller gap, and keep almost invariable in the stable stage. It is expected that the simulation results would be useful for practical manufacture and provide the theoretical foundation for improvement of process planning and optimization of process parameters.

Thermo-Calc和DICTRA软件系统在高性能钢研制中的应用

介绍了Thermo Calc和DICTRA软件系统及其在高性能钢研制中的最新应用。结果表明 ,采用该软件系统可对奥氏体转变 ,碳化物溶解与粗化以及渗氮层形成等钢中相变过程进行模拟 ,为准确制定热处理工艺参数提供参考 ,同时还可预测钢中各组元对相变的影响并据此进行成分优化设计 ,说明该软件系统在高性能钢的研制与开发方面具有良好的发展前景。

Recent process in special steel,heat treatment and surface modification of automotive components

Demand of improving the mechanical properties and productivity of automotive components while minimizing environmental impact makes the development of special steel combined with advance heat treatment and surface modification technologies become an important research area. Recently,to reduce CO_2 emissions by saving the manufacturing time,the following new special steel and advance heat treatment methods were developed: (1 ) An anti-coarsening extra-fine case hardening steel for automobile gear was developed,whose carburizing temperature can be improved for conventional 930 - 950℃to 1 050℃without coarsening,and the carburizing time can be reduced by maximum 75%. (2) Various microalloyed steels for fracture splitting connecting rod were developed.By using the above-mentioned steel combined with Thermo Mechanical Control Process(TMCP) method,the manufacturing time can be reduced by 30%-40%. (3) Vacuum carburizing and mild carburizing combined with induction quenching are being developed to replace the traditional gas carburizing,and the CO_2 emissions can be reduced by 20%-40%. (4) Intensive quenching is another new quenching technology which can be defined as cooling usually with pure water quenchant or low concentration water/salt solutions at a rate several times higher than the rate of ' normal' or conventional quenching,and the conventional effective case hardening depth can be reduce greatly and carburizing time can reduced. In addition,the high pressure gas quenching for reducing the quenching distortion and dual shot-peening for improving fatigue strength of gear will also be discussed. In a word,the present paper will focus on how to use the interaction among the development of special steel, advance heat treatment and surface modification to improve the strength of automotive components while reducing the manufacturing cost and impact to environment.

Existence results for unilateral contact problem with friction of thermo-electro-elasticity

This work studies a mathematical model describing the static process of contact between a piezoelectric body and a thermally-electrically conductive foundation. The behavior of the material is modeled with a thermo-electro-elastic constitutive law. The contact is described by Signorini＇s conditions and Tresca＇s friction law including the electrical and thermal conductivity conditions. A variational formulation of the model in the form of a coupled system for displacements, electric potential, and temperature is de- rived. Existence and uniqueness of the solution are proved using the results of variational inequalities and a fixed point theorem.

Simulations of THM processes in buffer-rock barriers of high-level waste disposal in an argillaceous formation

The main objective of this paper is to investigate and analyse the thermo-hydro-mechanical（THM） coupling phenomena and their influences on the repository safety.In this paper,the high-level waste（HLW） disposal concept in drifts in clay formation with backfilled bentonite buffer is represented numerically using the CODE BRIGHT developed by the Technical University of Catalonia in Barcelona.The parameters of clay and bentonite used in the simulation are determined by laboratory and in situ experiments.The calculation results are presented to show the hydro-mechanical（HM） processes during the operation phase and the THM processes in the after-closure phase.According to the simulation results,the most probable critical processes for the disposal project have been represented and analyzed.The work also provides an input for additional development regarding the design,assessment and validation of the HLW disposal concept.

Simultaneous determination of trap depth and the ratio of the rate of recombination to that of capture from thermo-luminescence

Thermo-luminescence （TL） is a kind of luminescence decay measured with varying temperature. In the process of TL the decay parameter itself involves the temperature effect of traps. Thus the trap depth is inseparable from the decay parameter. There are two separate peaks in the TL curve of ZnS：Cu,Co if the measurement starts from liquid nitrogen temperature. In the experiment we started from zero Celsius temperature to isolate the deeper traps. We have proposed and realized three methods for simultaneous determination of trap depth and decay parameter based on the quasi-equilibrium model and experimental data. If we treat the case of kinetic order a = 1 as a = 2, the error might be as large as 100%.

IMPROVED PROCESSING FOR MICROSTRUCTURES AND MECHANICAL PROPERTIES OF A COMMERCIAL PIPELINE STEEL

The transformation productions of hot-deformation simulation experiments were investigated using a Gleeble-1500 hot simulator for a commercial pipeline steel. Based on the investigation results, the improved thermo-mechanical control processing (TMCP) schedules containing a two stage multi-pass controlled rolling coupled with moderate cooling rates were applied to hot rolling experiments and acicular ferrite dominated microstructure was obtained. Microstructures and mechanical properties of hot rolled plates were related to TMCP processing, and regression equations describing the relation between processing parameters and mechanical properties in the current TMCP were developed, which could be used to predict mechanical properties of the experimental steel during commercially processing. It was found that with an increase in cooling rate after hot rolling, grain size in the microstructure became smaller, the amount of polygonal ferrite decreased and acicular ferrite increased, and accordingly mechanical properties increased.

三维纺织复合材料热-力学性能研究进展

三维纺织复合材料具有优异的力学性能、可设计性强和耐极端环境等优点,在航空航天领域有着广泛应用。为深入了解应用于高温环境中三维纺织复合材料的结构体系和力学行为,本文从三维纺织结构出发,综述了三维纺织复合材料结构类型及其在航空航天领域上的应用;总结了三维纺织复合材料成型工艺和结构特征;分析了三维纺织复合材料热-力学性能的研究进展情况;提出了未来的研究重点和需解决的关键问题,以期为新一代三维纺织复合材料的耐高温/承载设计、制造和应用提供依据。

聚乙烯管道的微波无损检测技术研究

非金属聚乙烯材料在燃气管道中的应用日益增加,由于加工工艺问题,其热熔焊接接头容易出现过焊和冷焊等焊接缺陷。在服役和运行过程中,存在缺陷的管道焊接接头易损坏,导致较高的安全风险。传统无损检测方法(例如超声检测和射线检测)难以对该类缺陷进行有效检测。针对该问题,对聚乙烯焊接工艺和微波检测原理进行了详细分析和说明,从理论上证实了微波检测方法在检测聚乙烯焊接接头缺陷方面的有效性。采用微波检测新技术对聚乙烯管道热熔接头中的夹杂缺陷进行了检测,检测结果验证了微波检测方法在聚乙烯管道缺陷检测中的可行性。

某组件多芯连接器气密焊接热力可靠性分析

针对毫米波收发组件盒体上多芯连接器气密焊接可靠性问题,开展组件级工艺仿真。分析了多芯连接器、盒体与焊料在焊接过程中热力水平及随时间变化趋势;对比了不同焊料材料与不同焊料量的影响。分析结果可有效支撑焊料材料选择与多芯连接器安装孔位的结构设计。

TMCP态桥梁钢与316L不锈钢制备的爆炸复合板热处理工艺研究

介绍了研究控轧控冷(TMCP)生产的Q370qD桥梁钢和316L不锈钢制备的爆炸复合板热处理性能与组织演变过程。结果表明:316L/Q370qD(TMCP)爆炸焊接复合板低温退火后强度偏高延伸率较低,900℃高温退火后强度不合格、冲击值离散性大;优化热处理方案进行630~710℃退火,最终确认适宜的热处理温度区间为650~680℃、时间为1.5~2 h,大规格复合板退火(680℃/1.5 h退火后空冷)验证测试性能合格,后续生产处理效果良好,表明TMCP状态的Q370qD桥梁钢与316L不锈钢制备爆炸复合板具有可行性。