Optimizing design of lattice materials based on finite element simulation

The optimized design of simple cross-truss and column lattice structures was carried out by the SolidWorks simulation module.The effective density of the structure was calculated according to the weight reduction requirements proposed by the project.Then,the vari-ation curve between the maximum bearing stress of the unit structure and the structural variables was obtained by simulation.Meanwhile,the mathematical equation between the maximum bearing stress and the structural variables could be obtained through MATLAB fitting.The results indicated that with the decrease in the number of cells,the compressive strength of the prepared column lattice increased(400 to 4 cells,compressive strength 29 MPa to 160 MPa).However,the yield strength increased with the number of cells.The compression strength of the simple cross-truss lattice samples indicated an increase trend with the decrease of the pillar size(an increase of the number of units),reaching 91 MPa(pillar diameter 0.52 mm,number of units 25).While the yield strength increased with the increasing of the number of units.In addition,the additive manufacturing processes of simple cubic lattice and simple cross-pillar lattice were investigated using selective laser melting.The compression performance obtained from the experiment is compared with the simulation results,which are in good agreement.The results of this paper can provide an important reference for optimizing design of lattice materials.

Kinetic Laws of Heating Initiated Reactions for Materials in Aerospace Applications

Cure and decomposition reaction kinetics of typical organic materials in aerospace applications are introduced.From the data of dynamic differential scanning calorimetry(DSC)experiments,and based on changes of the peak temperatures(T_(p))with different heating rates(β),a linear equation,T_(p)=T_(1)+△Tlnβ,has been obtained more reasonably.The above equation can be used to explain some laws of higher or lower of apparent activation energies(E_(a)),by which the apparent activation energy(E_(a))is nearly equal to RT^(2)_(1)/△T.A number of kinetic investigations of typical thermosetting resins and energetic materials in aerospace applications were chosen to validate the above equations.

Stress-assisted corrosion mechanism of 3Ni steel by using gradient boosting decision tree machining learning method

Traditional 3Ni weathering steel cannot completely meet the requirements for offshore engineering development,resulting in the design of novel 3Ni steel with the addition of microalloy elements such as Mn or Nb for strength enhancement becoming a trend.The stress-assisted corrosion behavior of a novel designed high-strength 3Ni steel was investigated in the current study using the corrosion big data method.The information on the corrosion process was recorded using the galvanic corrosion current monitoring method.The gradi-ent boosting decision tree(GBDT)machine learning method was used to mine the corrosion mechanism,and the importance of the struc-ture factor was investigated.Field exposure tests were conducted to verify the calculated results using the GBDT method.Results indic-ated that the GBDT method can be effectively used to study the influence of structural factors on the corrosion process of 3Ni steel.Dif-ferent mechanisms for the addition of Mn and Cu to the stress-assisted corrosion of 3Ni steel suggested that Mn and Cu have no obvious effect on the corrosion rate of non-stressed 3Ni steel during the early stage of corrosion.When the corrosion reached a stable state,the in-crease in Mn element content increased the corrosion rate of 3Ni steel,while Cu reduced this rate.In the presence of stress,the increase in Mn element content and Cu addition can inhibit the corrosion process.The corrosion law of outdoor-exposed 3Ni steel is consistent with the law based on corrosion big data technology,verifying the reliability of the big data evaluation method and data prediction model selection.

Structure characterization of the oxide film on FGH96 superalloy powders with various oxidation degrees

The structure of the oxide film on FGH96 alloy powders significantly influences the mechanical properties of superalloys.In this study,FGH96 alloy powders with various oxygen contents were investigated using high-resolution transmission electron microscopy and atomic probe technology to elucidate the structure evolution of the oxide film.Energy dispersive spectrometer analysis revealed the presence of two distinct components in the oxide film of the alloy powders:amorphous oxide layer covering the γ matrix and amorphous oxide particles above the carbide.The alloying elements within the oxide layer showed a laminated distribution,with Ni,Co,Cr,and Al/Ti,which was attributed to the decreasing oxygen equilibrium pressure as oxygen diffused from the surface into the γ matrix.On the other hand,Ti enrichment was observed in the oxide particles caused by the oxidation and decomposition of the carbide phase.Comparative analysis of the oxide film with oxygen contents of 140,280,and 340 ppm showed similar element distributions,while the thickness of the oxide film varies approximately at 9,14,and 30 nm,respectively.These findings provide valuable insights into the structural analysis of the oxide film on FGH96 alloy powders.

Microstructual evolution and stability of second generation single crystal nickel-based superalloy DD5

The microstructual evolution and stability of a second generation single crystal (SC) nickel-based superalloy DD5 with minor grain boundary (GB) strengthening elements (C, B and Hf) were studied as a function of as-cast, heat treatment and thermal exposure. The microstructure and composition of the alloy were investigated by optical microscopy, scanning electron microanalysis (SEM), electron probe microanalysis (EPMA), energy dispersive spectrometry (EDS) and extraction analysis. In the as-cast condition,the microstructure observations and composition analysis showed that γ phase was the primary solidification phase and there were three microsegregations in the metal matrix. The morphology of these microsegregations depended on element segregations. After heat treatment, the dendrite cores contained fine and cuboidal-shaped γ′ particles with an average edge length of about 0.5 μm, whileinterdendritic regions contained irregularly-shaped γ′ particles and MC/M23C6 carbides. The mass fraction of γ′ phases was 61.685%.After exposure at 980 °C for 1000 h, no TCP phase was observed in both dendritic and interdendritic regions, indicating a good microstructual stability of the DD5 alloy at 980 °C.

Orientation dependence of transverse tensile properties of nickel-based third generation single crystal superalloy DD9 from 760 to 1100 ℃

At temperatures ranging from 760 to 1100 °C, the tensile properties of a nickel-based third generation single crystal superalloy DD9 with [100],[120] and [110] orientations were studied. The microstructures and fracture surfaces were observed by OM, SEM and TEM. Results show that the tensile strength of [100] specimen is higher than that of [120] and [110] specimens at 760 and 850 °C;while at the temperatures higher than 980 °C, the tensile strength of all specimens has little difference. The fracture mechanisms of [100],[120] and [110] specimens are the same at 760 and 980 °C. At 1100 °C, the fracture surfaces of [100] and [120] specimens are characterized by dimple features;while [110] specimen shows mixed quasi-cleavage and dimple featured fracture surfaces. At 760 °C, obvious superlattice stacking faults (SSFs) are observed only in [100] specimen;while at 1100 °C, the dislocation configurations of all specimens are similar. The difference in the number of potential active slip systems in [100],[120] and [110] specimens during the tensile deformation process is the main reason for the transverse tensile anisotropy.

Deformation behavior and mechanisms of Ti-1023 alloy

The deformation behavior and mechanisms of Ti-1023 alloy were studied in the temperature range of 650-900 ℃ and strain rate range of 0.001-10 s-1 by compression and tensile tests. The results show that in a limited strain rate range of 0.001-0.1 s-1, the kinetic rate equation is obeyed and a linear fit is obtained at all the temperatures. The apparent activation energy is 322 kJ/mol in the α-β region and 160 kJ/mol in the β region, respectively. Power dissipation maps of this alloy developed by using Gleeble test data show three domains in the tested range. Superplasticity, marked by abnormal elongation at 700 ℃, occurs in the temperature range of 650-750 ℃ and at strain rates below about 0.03 s-1. Large grain superplasticity takes place in the temperature range of 750-850 ℃ and strain rates range of 0.001-0.03 s-1. Dynamic recrystallization occurs in the temperature range of 850-900 ℃ and at strain rates below about 1 s-1. The instability maps of this alloy were also developed.

Microstructure and mechanical properties of forged Al-7.1Zn-1.1Mg-1.6Cu-0.14Zr alloy after two-step ageing treatment at 120 and 170℃

The tensile properties, electrical conductivity, and microstructure of the forged A1-7.1Zn-1.1Mg-1.6Cu-0.14Zr alloy were investigated after a two-step ageing treatment at 120 and 170℃. The results indicate that the strength of the alloy reaches the peak value at 170~C for 1 h during the second step ageing and then decreases sharply. However, the electrical conductivity value increases continuously with the second ageing time increasing. The fracture mechanism of the alloy is intergranular fracture for 1 h and then changes to dimple transgranular fracture later, and the toughness of the alloy is improved significantly. The phases of rl＇ and 1＂1 are major precipitates in the alloy under the two-step ageing condition. Discontinuous grain boundary precipitates and precipitate-flee zones along the grain boundary are clearly observed.

Effects of Ru on the microstructure and phase stability of a single crystal superalloy

Two experimental single crystal superalloys, the Ru-free alloy and the Ru-containing alloy with [001 ] orientation, were cast in a directionally solidified furnace, while other alloying element contents were kept unchanged. The effects of Ru on the microstructure and phase stability of the single crystal superalloy were investigated, y＇ directional coarsening and rafting were observed in the Ru-free alloy and Ru-containing alloy after long-term aging at 1070~C for 800 h. Needle-shaped o topologically close packed （TCP） phases precipitated and grew along the fixed direction in both the alloys. The precipitating rate and volume fraction of TCP phases decreased significantly by adding Ru. The compositions ofy and y＇ phases measured using an energy-dispersive X-ray spectroscope （EDS） in transmission electron microscopy （TEM） analysis showed that the addition of Ru lessened the partition ratio of TCP forming elements, Re, W and Mo, and decreased the satu- ration degrees of these elements in y phase, which can enable the Ru-containing alloy to be more resistant to the formation of TCP phases. It is indicated that the addition of Ru to the Ni-based single crystal superalloy with high content of the refractory alloying element can enhance phase stability.

Development and application of titanium alloy casting technology in China

The development and research of titanium cast alloy and its casting technology, especially its application in aeronautical industry in China are presented. The technology of molding, melting and casting of titanium alloy, casting quality control are introduced. The existing problems and development trend in titanium alloy casting technology are also discussed.

Effect of pressurizing speed on filling behavior of gradual expansion structure in low pressure casting of ZL205A alloy

The mold filling behavior of gradual expansion structure in low pressure casting was studied by two phase flow model using the Volume of Fluid method, and was verified by water simulation with a Plexiglas mold. To get smooth mold filling process and provide a guide for the pressurizing speed design in the producing practice, the mathematical model with the pressurizing speed, expansion angle and height of the gradual expansion structure was established. For validation experiments, ZL205 A alloy castings were produced under two different pressurizing speeds. Weibull probability plots were used to assess the fracture mechanisms under different pressurizing speeds. Mechanical properties of ZL205 A alloy were applied to assess the entrainment of oxide film. The results show that the filling process of a gradual expansion structure in a low pressure casting can be divided into the spreading stage and filling stage by gate velocity. The gate velocity continues to increase in the gradual expansion structure, and increases with the increase of pressurizing speed or expansion angle. Under the effect of the falling fluid raised by the jet flow along the sidewall, the fluid velocity decreases in the jet zone from ingate to free surface. As such, oxide film entrainment does not occur when the gate velocity is greater than the critical velocity, andthe gate velocity no longer reflects the real state of the free surface. The scatter of the mechanical properties is strongly affected by the entrainment of oxide films.

Effects of chromium on the corrosion and electrochemical behaviors of ultra high strength steels

The effects of chromium on the corrosion and the electrochemical behaviors of ultra high strength steels were studied by the salt spray test and electrochemical methods. The results show that ultra high strength steels remain martensite structures and have anodic dissolution characteristic with an increase of chromium content. There is no typical passive region on the polarization curves of an ultra high strength stainless steel, AerMet 100 steel, and 300M steel. However, chromium improves the corrosion resistance of the stainless steel remarkably. It has the slowest corrosion rate in the salt spray test, one order of magnitude less than that of AerMet 100 and 300M steels. With the increase of chromium content, the polarization resistance becomes larger, the corrosion potential shifts towards the positive direction with a value of 545 mV, and the corrosion current density decreases in electrochemical measures in 3.5wt% NaCl solutions. Because of the higher content of chromium, the ultra high strength stainless steel has a better corrosion resistance than AerMet 100 and 300M steels.

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 surface recrystallization on the creep rupture property of a single-crystal superalloy

The effect of surface recrystallization by heating after shot-peening on the creep rapture property and fracture behavior of a single-crystal superalloy was investigated. The results show that the creep rupture property of the single-crystal superalloy was greatly influenced by surface recrystallization. A recrystallized surface layer with a depth of 101 ~m resulted in a decrease in creep rupture life by nearly 50%, and an almost linear reduction of creep rupture life was observed with the increase of recrystallization depth. A lower strength of the recrystal- lized layer, inhomogeneous deformation between the recrystallized layer and the matrix, and stress concentration caused by notch effect resuited in the decrease in creep rupture life of the single-crystal superalloy.

Effect of directional solidification process on microstructure and stress rupture property of a hot corrosion resistant single crystal superalloy

The influences of different directional solidification processes, i.e., the high rate solidification(HRS) and liquid metal cooling(LMC), on microstructure and stress rupture property of DD488 alloy were investigated. The DD488 alloy was directional solidified by both HRS and LMC processes. The microstructure and stress rupture properties at 980 ℃/250 MPa were investigated by using optical microscopy(OM), scanning electron microscopy(SEM), electron microprobe analyzer(EPMA), transmission electron microscopy(TEM) and stress rupture testing. The results indicated that the LMC process refined the primary dendrite arm and decreased the microporosity volume fraction and solidification segregations of Cr and Co in as-cast DD488 alloy. After standard heat treatment of 1,260 ℃/4 h, AC(air cooling) + 1,080 ℃/4 h, AC + 870 ℃/24 h, AC, the γ′ morphology in LMC alloy was more cuboidal than that in HRS alloy, and the γ′ volume fraction of LMC alloy was higher than that of HRS alloy. The stress rupture life at 980 ℃/250 MPa of HRS alloy was 76.8 h, and it increased to 110.0 h in LMC al oy. The LMC process increased the stress rupture life due to the higher γ′ volume fraction, more perfect rafting structure and finer interfacial dislocation networks.

Effects of RRA Treatments on Microstructures and Properties of a New High-strength Aluminum-Lithium Alloy-2A97

A new high strength 2A97 Al-Cu-Li-X alloy was subjected to triple-aging of retrogression and re-aging treatments （RRA）. Transmission electron microscopy （TEM）, differential scanning calorimetry （DSC）, and tensile tests were used to investigate the effects of RRA treatment on the microstructures and properties. DSC test reveals the reversion temperature range of the strengthening δ＇ （Al3Li） phase. The results show that the microstructure consists of δ＇ （Al3Li） phase, T1 （Al2CuLi） phase and θ″/θ′（Al2Cu） phase for 2A97 alloy treated by a triple-aging of a retrogression and re-aging treatment in the following order： （1） at 165℃×30 min, （2） at 220 ℃ or 240℃ × 15 min, （3） at 165℃×24 h. The plastic deformation, incorporated into the treatment after secondary high temperature aging, promotes the T1 precipitation during final re-aging. The tensile properties of the alloy treated by the retrogression and re-aging treatment reach the peak level of alloy single-aged at 165℃ in T6 temper.

Effects of Y and Ce on Microstructures and Properties of Nb-Si System Composites

The effects of yttrium and cerium on microstructures and properties of Nb-Si system composites were investigated by scanning electron microscopy( SEM), energy dispersive spectrum(EDS), X-ray diffraction(XRD) and high temperature oxidation experiments.It is found that the coarse primary silicide phase became finer and more homogeneous with Y and Ce addition.The results of high temperature oxidation experiments show that the oxidation rates of NbSi system composites with an appropriate amount of Y and Ce decrease compared with those of alloys without Y or Ce addition, and oxidation products mainly distribute along the phase boundaries between the Nb solid solution and silicide.

Research Progress of Refractory High Entropy Alloys:A Review

Owing to superior comprehensive performance than conventional superalloys at high temperature,refractory high entropy alloy(RHEA)is becoming a promising candidate for the next generation high-temperature material.Herein,contemporary aspects of corresponding development of RHEAs are reviewed to discuss various factors affecting the organization structure and service performance.It mainly covers alloying system and strengthening mechanism,the preparation method,plastic deformation and the related mechanism,as well as microstructure control by heat treatment.Firstly,the alloy systems and strengthening mechanism are introduced.This is followed by different preparation methods and the comparison of strengths and shortcomings based on different RHEAs.Then,hot deformation behavior and plastic deformation under different loadings are analyzed.Based on this,the influence of heat treatment on microstructures prior to and after the deformation is further summarized.Finally,some important research areas to be carried out in future are pointed out.This review will give a deep understanding of the effects of different factors on the service performance and provide scientific guide in designing RHEAs with improved performance.

Research on investment casting of TiAl alloy agitator treated by HIP and HT

Using TiAl alloy to substitute superalloy is a hot topic in aeroengine industry because of its low density, high elevated temperature strength, and anti-oxidization ability. In this research, Ti-47.5AL-2Cr-2Nb-0.2B alloy was used as the test material. By applying a combination process of ceramic shell mold and core making, vacuum arc melting and centrifugal pouring, and heat isostatic pressing （HIP） and heat treatment （HT） etc., the TiAl vortex agitator casting for aeroengine was successfully made. This paper introduced key techniques in making the TiAl vortex agitator with investment casting process, provided some experimental results including mechanical properties and machinability, and explained some concerns that could affect applications of TiAl castings.

Experimental Study and Numerical Simulation of Directionally Solidified Turbine Blade Casting

The directional solidification process of turbine blade sample castings was investigated in the work. Variable withdrawal rates were used in one withdrawal process and compared with the other using uniform rate. A mathematical model for heat radiation transfer and microstructure simulation of directional solidification process was developed based on CA-FD method. The temperature distribution and microstructure w.ere simulated and compared with the experimental results. The stray grains were predicted and compared with the experimental results. The uneven temperature distribution of platform was the main reason of the formation of stray grains.