可分式无飞边模锻的研发与应用

在介绍实现闭式无飞边模锻技术的基础上,阐述了闭式无飞边模锻工艺原理及特点,研发不同合模机构组成的可分凹模模锻装置,与相应的通用模锻设备构成专用的无飞边闭式模锻装备系统,实现多种中小型复杂锻件的精密模锻生产.应用效果表明,可分式无飞边模锻能够实现复杂锻件的精密成形,产品精度高、力学性能好,材料利用率高。

Influence of high pressure and manganese addition on Fe-rich phases and mechanical properties of hypereutectic Al-Si alloy with rheo-squeeze casting

The influence of high pressure and manganese addition on Fe-rich phases(FRPs)and mechanical properties of Al-14Si-2Fe alloy with rheo-squeeze casting(RSC)was investigated.The semi-solid alloy melt was treated by ultrasonic vibration(UV)firstly,and then formed by squeeze casting(SC).Results show that the FRPs in as-cast SC alloys are composed of coarseβ-Al5(Fe,Mn)Si,δ-Al4(Fe,Mn)Si2 and bone-shapedα-Al15(Fe,Mn)3Si2 phases when the pressure is 0 MPa.With RSC process,the FRPs are first refined by UV,and then the solidification under pressure further causes the grains to become smaller.The peritectic transformation occurs during the formation ofαphase.For the alloy with the same composition,the ultimate tensile strength(UTS)of RSC sample is higher than that of the SC sample.With the same forming process,the UTS of Al-14Si-2Fe-0.8Mn alloy is higher than that of Al-14Si-2Fe-0.4Mn alloy.

Correspondence between low-energy twin boundary density and thermal-plastic deformation parameters in nickel-based superalloy

To deeply understand and even describe the evolutions of the low-energy twin boundary density(BLDΣ3n)in a thermal-plastic deformation process,an improved twin density model as a function of average grain size and stored energy is developed.For Nimonic 80A superalloy,the model is solved based on the EBSD statistical results of grain size and BLDΣ3n in the specimens compressed at temperatures of 1273−1423 K and strain rates of 0.001−10 s−1.The corresponding relationships of BLDΣ3n with stored energy and grain size varying with temperature and strain rate are clarified by the superimposed contour plot maps.It is summarized that BLDΣ3n increases with increasing stored energy and decreasing grain size,and higher BLDΣ3n with finer grains corresponds with lower temperatures and higher strain rates.Such relationships are described by the improved twin density model,and the prediction tolerance of the solved model is limited in 2.8%.

Processing map and hot deformation behavior of squeeze cast 6082 aluminum alloy

The hot deformation behavior and microstructure evolution of 6082 aluminum alloy fabricated through squeeze casting(SC)under different pressures were studied.The alloy was subjected to hot compression tests and 3D hot processing maps were established.The microstructure evolution was studied by optical microscope(OM),scanning electron microscope(SEM),and electron backscattered diffraction(EBSD).It is found that more dynamic recrystallization(DRX)grains are generated during the deformation of the specimen fabricated under higher SC pressure.At high temperature the effect of SC pressure on microstructure evolution weakens due to the dissolution of second phase particles.In addition,uneven second phase particles in specimens fabricated under higher SC pressure compressed with low temperature and middle strain rate would result in flow localization instability.Finally,the optimum deformation conditions for the 6082 aluminum alloy fabricated by SC were obtained at the temperatures of 430−500℃ and the strain rates of 0.01−1 s^(−1).

Effect of solution treatment time on plasticity and ductile fracture of 7075 aluminum alloy sheet in hot stamping process

The effect of solution treatment time on the post-formed plasticity and ductile fracture of 7075 aluminum alloy in the hot stamping process was studied.Tensile tests were conducted on the specimens subjected to the hot stamping process with different solution treatment time.The digital image correlation(DIC)analysis was used to obtain the strain of the specimen.Based on the experiments and modeling,the Yld2000-3d yield criterion and the DF2014 ductile fracture criterion were calibrated and used to characterize the anisotropy and fracture behavior of the metal,respectively.Furthermore,the microstructure of specimens was studied.The experimental and simulation results indicate that the 7075 aluminum alloy retains distinct anisotropy after the hot stamping process,and there is no obvious effect of extending the solution treatment time on the material anisotropy.However,it is found that a longer solution treatment time can increase the fracture strain of the aluminum alloy during the hot stamping process,which may be related to the decrease of the second-phase particles size.

Effects of nano-SiC_p content on microstructure and mechanical properties of SiC_p/A356 composites assisted with ultrasonic treatment

nano-SiCp/A356 composites with different nano-SiCp contents were prepared by squeeze casting after ultrasonic treatment（UT）. The effects of SiCp content on the microstructure and mechanical properties of the nanocomposites were investigated. Theresults show that with the addition of nano-SiCp, the microstructure of nanocomposites is obviously refined, the morphology of theα（Al） grains transforms from coarse dendrites to rosette crystals, and long acicular eutectic Si phases are shortened and rounded. Themechanical properties of 0.5%, 1% and 2% （mass fraction） SiCp/A356 nanocomposites are improved continuously with the increaseof nano-SiCp content. Especially, when the SiCp content is 2%, the tensile strength, yield strength and elongation are 259 MPa,144 MPa and 5.3%, which are increased by 19%, 69% and 15%, respectively, compared with those of the matrix alloy. Theimprovement of strength is attributed to mechanisms of Hall？Petch strengthening and Orowan strengthening.

3D modeling and deformation analysis for electromagnetic sheet forming process

Electromagnetic forming （EMF） is a high-speed forming method which can be quite effective in increasing the forming limits of metal sheet. However, the EMF process is complicated due to magnetic-structure coupling analysis. Numerical simulation offers an opportunity to overcome the problem. Nevertheless, most present models for EMF process are limited to 2D axisymmetric model. So, a three-dimensional （3D） finite element model was established to analyze the electromagnetic sheet bulging. The contact between the sheet and the die and the effect of sheet deformation on the magnetic field analysis were both taken into consideration during the forming process. The simulation results of deflection at the sheet center and 20 mm away from the center were in agreement with the experimental ones. The plastic strain energy and plastic strain were analyzed.

Calibration of anisotropic yield function by introducing plane strain test instead of equi-biaxial tensile test

The equi-biaxial tensile test is often required for parameter identification of anisotropic yield function and it demands thespecial testing technique or device. Instead of the equi-biaxial tensile test, the plane strain test carried out with the traditional uniaxialtesting machine is suggested to provide the experimental data for calibration of anisotropic yield function. This simplified method byusing plane strain test was adopted to identify the parameters of Yld2000-2d yield function for 5xxx aluminum alloy and AlMgSialloy sheets. The predicted results of yield stresses, anisotropic coefficients and yield loci by the proposed method were very similarwith the experimental data and those by the equi-biaxial tensile test. It is validated that the plane strain test is effective to provideexperimental data instead of equi-biaxial tensile test for calibration of Yld2000-2d yield function.

Formation mechanism of basin-like depression defect in electric upsetting process of Ni80A superalloy

A kind of surface instability,basin-like depression defect companied by mixed grain structure at the bottom of large-scale valve during electric upsetting process,would significantly influence the microstructures and mechanical properties of components.In order to analyze the forming process of the basin-like depression defect,a finite element model for the electric upsetting process of Ni80A superalloy was developed using multi-field and multi-scale coupling analysis method.Subsequently,a series of parameters loading path schemes for force and current were designed by varying the initial value,peak value and value level,and their effects on basin-like depression and mixed grain structure were simulated and uncovered.It is concluded that the changes of heating speed and pressurization speed result in the different flow velocities between the inner and outer layers of billet,thus exerting the basin-like depression.Simulation results also indicate that these defects can be optimized through the parameter coordination between force and current.Finally,the validity and reliability of the finite element model were verified by physical experiments in electric upsetting process.