Deep learning has achieved great progress in image recognition,segmentation,semantic recognition and game theory.In this study,a latest deep learning model,a conditional diffusion model was adopted as a surrogate mode...Deep learning has achieved great progress in image recognition,segmentation,semantic recognition and game theory.In this study,a latest deep learning model,a conditional diffusion model was adopted as a surrogate model to predict the heat transfer during the casting process instead of numerical simulation.The conditional diffusion model was established and trained with the geometry shapes,initial temperature fields and temperature fields at t_(i) as the condition and random noise sampled from standard normal distribution as the input.The output was the temperature field at t_(i+1).Therefore,the temperature field at t_(i+1)can be predicted as the temperature field at t_(i) is known,and the continuous temperature fields of all the time steps can be predicted based on the initial temperature field of an arbitrary 2D geometry.A training set with 3022D shapes and their simulated temperature fields at different time steps was established.The accuracy for the temperature field for a single time step reaches 97.7%,and that for continuous time steps reaches 69.1%with the main error actually existing in the sand mold.The effect of geometry shape and initial temperature field on the prediction accuracy was investigated,the former achieves better result than the latter because the former can identify casting,mold and chill by different colors in the input images.The diffusion model has proved the potential as a surrogate model for numerical simulation of the casting process.展开更多
In the production of castings,intrusive gas pore represents a kind of common defects which can lead to leakage in high gas-tightness requirement castings,such as cylinder blocks and cylinder heads for engines.It occur...In the production of castings,intrusive gas pore represents a kind of common defects which can lead to leakage in high gas-tightness requirement castings,such as cylinder blocks and cylinder heads for engines.It occurs due to the intrusion of gases generated during the resin burning of the sand core into castings during the casting process.Therefore,a gas generation and flow constitution model was established,in which the gas generation rate is a function of temperature and time,and the flow of gas is controlled by the gas release,conservation,and Darcy's law.The heat transfer and gas flow during casting process was numerically simulated.The dangerous point of cores is firstly identified by a virtual heat transfer method based on the similarity between heat transfer and gas flow in the sand core.The gas pores in castings are predicted by the gas pressure,the viscosity and state of the melt for these dangerous points.Three distinct sand core structures were designed and used for the production of iron castings,and the simulated gas pore results were validated by the obtained castings.展开更多
Magnesium matrix nanocomposite reinforced with carbon nanotubes(CNTs/AZ91D) was fabricated by mechanical stirring and high intensity ultrasonic dispersion processing.The microstructures and mechanical properties of th...Magnesium matrix nanocomposite reinforced with carbon nanotubes(CNTs/AZ91D) was fabricated by mechanical stirring and high intensity ultrasonic dispersion processing.The microstructures and mechanical properties of the nanocomposite were investigated.The results show that CNTs are well dispersed in the matrix and combined with the matrix very well.As compared with AZ91D magnesium alloy matrix,the tensile strength,yield strength and elongation of the 1.5%CNTs/AZ91D nanocomposite are improved by 22%,21%and 42%respectively in permanent mold casting.The strength and ductility of the nanocomposite are improved simultaneously.The tensile fracture analysis shows that the damage mechanism of nanocomposite is still brittle fracture.But the CNTs can prevent the local crack propagation to some extent.展开更多
This paper expatiates on domestic status of heavy steel casting production, with a special focus on hydraulicturbine castings for Three Gorges Project. In China, there is magnificent demand for heavy castings with the...This paper expatiates on domestic status of heavy steel casting production, with a special focus on hydraulicturbine castings for Three Gorges Project. In China, there is magnificent demand for heavy castings with the rapidgrowth of the national economy in recent years and the expected high growth in the coming 10 to 20 years. Someheavy and large castings such as mill housing and hydraulic turbine runner crown, blade and band for Three GorgesProject have been successfully made. However, the domestic production capability is still far from meeting the giganticrequirements. The domestic capability still lags behind the world class level, and a lot of heavy castings still dependon import. The paper also gives a particular introduction of the key technologies in the manufacturing of heavy steelcastings like metal melting, foundry technology, heat treatment technology and numerical simulation technique, etc.In addition, several case studies on the application of numerical simulation in the production of heavy steel castingsare presented.展开更多
Numerical simulation is the most powerful computational and analysis tool for a large variety of engineering and physical problems.For a complex problem relating to multi-field,multi-process and multi-scale,different ...Numerical simulation is the most powerful computational and analysis tool for a large variety of engineering and physical problems.For a complex problem relating to multi-field,multi-process and multi-scale,different computing tools have to be developed so as to solve particular fields at different scales and for different processes.Therefore,the integration of different types of software is inevitable.However,it is difficult to perform the transfer of the meshes and simulated results among software packages because of the lack of shared data formats or encrypted data formats.An image processing based method for three-dimensional model reconstruction for numerical simulation was proposed,which presents a solution to the integration problem by a series of slice or projection images obtained by the post-processing modules of the numerical simulation software.By means of mapping image pixels to meshes of either finite difference or finite element models,the geometry contour can be extracted to export the stereolithography model.The values of results,represented by color,can be deduced and assigned to the meshes.All the models with data can be directly or indirectly integrated into other software as a continued or new numerical simulation.The three-dimensional reconstruction method has been validated in numerical simulation of castings and case studies were provided in this study.展开更多
Microporosity formed in the solidification process of Al alloys is detrimental to the alloy properties.A two-dimensional cellular automaton(CA)model was developed to simulate the microstructure and microporosity forma...Microporosity formed in the solidification process of Al alloys is detrimental to the alloy properties.A two-dimensional cellular automaton(CA)model was developed to simulate the microstructure and microporosity formation in Al-Cu alloys,considering variations in Cu content and solidification rate.The results indicate that the Cu content primarily influences the growth of microporosity.To validate the model,directional solidification experiments were conducted on Al-Cu alloys with varing Cu contents and withdrawal rates.The experimental results of dendrites and microporosity characteristics agree well with the predictions from the developed model,thus confirming the validity of the model.The alloy’s liquidus temperature,dendrite morphology,and hydrogen saturation solubility arising from different Cu contents have significant effects on microporosity morphology.The withdrawal rate primarily affects the nucleation of hydrogen microporosity by altering cooling rates and dendritic growth rates,resulting in different microporosity characteristics.展开更多
Particulate reinforced metal matrix composite(PR-MMC) has excellent properties such as good wear resistance,corrosion resistance and high temperature properties.Laser cladding is usually used to form PR-MMC on metal s...Particulate reinforced metal matrix composite(PR-MMC) has excellent properties such as good wear resistance,corrosion resistance and high temperature properties.Laser cladding is usually used to form PR-MMC on metal surface with various volume fractions of ceramic particles.Recent literatures showed that laser melting of powder mixture containing carbon and carbide-forming elements,was favorable for the formation of in-situ synthesized carbide particles.In this paper,rare earth oxide(RE2O3) was added into t...展开更多
The insulation effect of the air cavity surrounding the riser in a 3D printed sand mold was studied. The influence of the air cavity on heat flux was theoretically analyzed. The results demonstrated that the heat flux...The insulation effect of the air cavity surrounding the riser in a 3D printed sand mold was studied. The influence of the air cavity on heat flux was theoretically analyzed. The results demonstrated that the heat flux of the air cavity in the 3D printed sand mold was significantly less than that of resin-bonded sand. The insulation effect of the air cavity in sand molds for a cylinder casting and a stress-frame casting were simulated using software COMSOL. The results illustrated that the air cavity could be used to insulate the riser and it was more suitable for a lower melting point metal casting. An air cavity with 10-15 mm width and 5-10 mm away from the riser can significantly prolong the solidification of the riser by over 10%. Meanwhile, the sand mold for the stressframe was made by 3D printing technology and poured with aluminum alloy A356 melt. The experiment results showed that the presence of the air cavity led to a 12.5% increase of the solidification time of its riser.展开更多
In the present study, the influence of natural convection on the lamellar eutectic growth is determined by a phase-field-lattice Boltzmann study for Al-Cu eutectic alloy. The mass difference resulting from concentrati...In the present study, the influence of natural convection on the lamellar eutectic growth is determined by a phase-field-lattice Boltzmann study for Al-Cu eutectic alloy. The mass difference resulting from concentration difference led to the fluid flow, and a robust parallel and adaptive mesh refinement algorithm was employed to improve the computational efficiency without any compromising accuracy. Results show that the existence of natural convection would affect the growth undercooling and thus control the interface shape by adjusting the lamellar width. In particular, by alternating the magnitude of the solute expansion coefficient, the strength of the natural convection is changed. Corresponding microstructure patterns are discussed and compared with those under no-convection conditions.展开更多
Vacuum die casting can reduce the'air entrapment'phenomenon during casting process.Based on the temperature measurements at metal-die interface with different processing parameters,such as slow shot speed(VL),...Vacuum die casting can reduce the'air entrapment'phenomenon during casting process.Based on the temperature measurements at metal-die interface with different processing parameters,such as slow shot speed(VL),high shot speed(VH),pouring temperature(Tp)and initial die temperature(Tm),inverse method was developed to determine the interfacial heat transfer coefficient(IHTC).The results indicate that a closer contact between the casting and die could be achieved when the vacuum system is used.It is found that the vacuum could strongly increase the values of IHTC and decrease the grain size in castings.The IHTC could have a higher peak value with increasing the Tp from680to720℃or the VL from0.1to0.4m/s.In addition,the influence of the VH and Tm on IHTC could be negligible.展开更多
A ladle-tundish-mould transportation model considering the entire multiple pouring(MP) process is proposed. Numerical simulation is carried out to study the carbon distribution and variation in both the tundish and th...A ladle-tundish-mould transportation model considering the entire multiple pouring(MP) process is proposed. Numerical simulation is carried out to study the carbon distribution and variation in both the tundish and the mould for making a 292 t steel ingot. Firstly, the fluid flow as well as the heat and mass transfer of the molten steel in the tundish is simulated based on the multiphase transient turbulence model. Then, the carbon mixing in the mould is calculated by using the species concentration at the tundish outlet as the inlet condition during the teeming process. The results show a high concentration of carbon at the bottom and a low concentration of carbon at the top of the mould after a MP process with carbon content high in the first ladle and low in the last ladle. Such carbon concentration distribution would help reduce the negative segregation at the bottom and the positive segregation at the top of the solidified ingot.展开更多
A new seam-tracking method based on dynamic trajectory planning for a mobile welding robot is proposed in order to improve the response lag of the mobile robot and the high frequency oscillation in seam-tracking.By us...A new seam-tracking method based on dynamic trajectory planning for a mobile welding robot is proposed in order to improve the response lag of the mobile robot and the high frequency oscillation in seam-tracking.By using a front-placed laser-based vision sensor to dynamically extract the location of the weld seam in front of torch,the trend and direction of the weld line is roughly obtained.The robot system autonomously and dynamically performs trajectory planning based on the isometric approximation model.Arc sensor technology is applied to detect the offset during welding process in real time.The dynamic compensation of the weld path is done in combination with the control of the mobile robot and the executive body installed on it.Simulated and experimental results demonstrate that the method effectively increases the stability of welding speed and smoothness of the weld track,and hence the weld formation in curves and corners is improved.展开更多
3D printing technology has been used for sand molding and core printing, but they simply substitute the traditional molding and core making method without changing the shape or size of the sand mold(core) and their de...3D printing technology has been used for sand molding and core printing, but they simply substitute the traditional molding and core making method without changing the shape or size of the sand mold(core) and their dense structure. In this study, a new type of hollow mold based on 3D printing is presented. The new type of mold is a rib reinforced thickness-varying shell mold. This mold design can realize the controlled cooling of castings, i.e., different cooling rates at different areas, and improve the temperature uniformity of a casting after its solidifi cation. Therefore, the performance of castings can be improved and their residual stress and deformation can be reduced. This kind of new mold was applied to a stress frame of A356 aluminum alloy. The 3D printed rib reinforced thickness-varying shell mold was compared with the traditional dense mold, and the castings obtained by these two kinds of molds were also compared. The experimental results showed that the rib reinforced shell mold increased the cooling rate of the casting by 30%, tensile strength by 17%, yield strength by 11%, elongation by 67%, and decreased its deformation by 43%, while sand consumption was greatly reduced by 90%.展开更多
Bulk metallic glasses are prepared in Pd4o.sNi4o.sSixP19-x （x = 0-14 at.%） alloys by a combination of flux treatment and water quenching technique. It is found that the thermal stability of the Pd4o.sNi4o.sSixP19=x ...Bulk metallic glasses are prepared in Pd4o.sNi4o.sSixP19-x （x = 0-14 at.%） alloys by a combination of flux treatment and water quenching technique. It is found that the thermal stability of the Pd4o.sNi4o.sSixP19=x glassy alloys depends on the addition of Si content. Among the Pd4o.sNi4o.sSixP19=x glassy alloys studied, the Pd4o.sNi4o.sSisPls bulk metallic glass exhibits the largest supercooled liquid region （△T = 119 K） and the highest activation energy of crystallization （283.3k J/tool）, showing enhanced glass formation ability and extraordinary glassy thermal stability.展开更多
Graphene,an emerging fabric of carbon atoms,has manifested its versatility in all kinds of fields encompassing electronics,optoelectronics,thermoelectrics,taking advantage of its excellent mechanical strength,exceptio...Graphene,an emerging fabric of carbon atoms,has manifested its versatility in all kinds of fields encompassing electronics,optoelectronics,thermoelectrics,taking advantage of its excellent mechanical strength,exceptional electronic and thermal conductivities,high surface specific area,and so forth.The prosperity of graphene never seen before has led the attention to silicene,siloxene,germanene,stanene,and plumbene due to their promising applications in the quantum spin Hall effect,topological insulator,batteries,capacitors,catalysis,and topological superconductivity.Herein,we review the existing production methods,numerous applications of two-dimensional group-IVA materials,and critically discuss the challenges of these materials,providing potential implications to the exploration of uncharted material systems.展开更多
The cooling control of the melt during the casting process is of great significance. A comprehensive closed-loop cooling control of castings by adopting a skeletal sand mold design was proposed. The skeletal sand mold...The cooling control of the melt during the casting process is of great significance. A comprehensive closed-loop cooling control of castings by adopting a skeletal sand mold design was proposed. The skeletal sand mold consisting of an adaptive shell, functional cavities and a support was designed and created based on the finite difference meshes of a casting. It was applied to a round wall test casting. Two kinds of skeletal sand molds, one with lattice support and the other with enforcing ribs for this casting were designed and printed out by the 3 D printing(3 DP) method. Aluminum alloy A356 was cast by using these two sand molds. The first mold was cooled by natural convection, the other one by water spray cooling. Two sound castings were obtained. The sand mold temperature, cooling curves, microstructures, mechanical properties, residual stress and deformation were measured, compared and discussed. Water spray cooling hastened the cooling rate by 62%, increased the content of Mg and Cu in the α-Al matrix, improved the mechanical properties, and altered the surface residual stress state.展开更多
Visual image sensor is developed to detect the weld pool images in pulsed MIG welding. An exposure controller, which is composed of the modules of the voltage transforming, the exposure parameters presetting, the comp...Visual image sensor is developed to detect the weld pool images in pulsed MIG welding. An exposure controller, which is composed of the modules of the voltage transforming, the exposure parameters presetting, the complex programmable logic device （CPLD） based logic controlling, exposure signal processing, the arc state detecting, the mechanical iris driving and so on, is designed at first. Then, a visual image sensor consists of an ordinary CCD camera, optical system and exposure controller is established. The exposure synchronic control logic is described with very-high-speed integrated circuit hardware description language （VHDL） and programmed with CPLD , to detect weld pool images at the stage of base current in pulsed MIG welding. Finally, both bead on plate welding and V groove filled welding are carried out, clear and consistent weld pool images are acquired.展开更多
In this study, the effect of the processing route using a friction stir processing(FSP) method on the microstructure and mechanical behavior of a Mg-9Li-1Zn alloy was systematically investigated. In the FSP method, th...In this study, the effect of the processing route using a friction stir processing(FSP) method on the microstructure and mechanical behavior of a Mg-9Li-1Zn alloy was systematically investigated. In the FSP method, the odd-numbered(1st and 3rd) process directions and even-numbered(2nd and 4th) passes were alternated to distribute the strain throughout the whole processed zone uniformly. Consequently, the processed zone had a much more uniform microstructure and hardness distribution than the processed zone obtained using the conventional FSP method. Using this method, the grain size of a Mg-9Li-1Zn sheet alloy was refined from ~31 μm to ~0.21 μm with uniformly distributedα and β phases. The processed alloy exhibited a high strength-ductility synergy with an ultimate tensile strength(UTS) of 220.1 MPa and total elongation of 70.0% at a strain rate of 10^(-3)s^(-1), overwhelmingly higher than those of the base metal, 155.6 MPa in UTS and 36.0%in elongation. The in-situ SEM-DIC analysis and TEM observation demonstrated that such an outstanding ductility with moderate strength is caused by grain boundary sliding, the dominant deformation mechanism of the ultra-fine-grained sample after FSP. The processing route with reverse processing direction was proven to be efficient in producing the ultrafine grain size microstructure and improving the mechanical properties of superlight Mg-9Li-1Zn alloy.展开更多
In Additive Manufacturing field, the current researches of data processing mainly focus on a slicing process of large STL files or complicated CAD models. To improve the efficiency and reduce the slicing time, a paral...In Additive Manufacturing field, the current researches of data processing mainly focus on a slicing process of large STL files or complicated CAD models. To improve the efficiency and reduce the slicing time, a parallel algorithm has great advantages. However, traditional algorithms can＇t make full use of multi-core CPU hardware resources. In the paper, a fast parallel algorithm is presented to speed up data processing. A pipeline mode is adopted to design the parallel algorithm. And the complexity of the pipeline algorithm is analyzed theoretically. To evaluate the performance of the new algorithm, effects of threads number and layers number are investigated by a serial of experiments. The experimental results show that the threads number and layers number are two remarkable factors to the speedup ratio. The tendency of speedup versus threads number reveals a positive relationship which greatly agrees with the Amdahl＇s law, and the tendency of speedup versus layers number also keeps a positive relationship agreeing with Gustafson＇s law. The new algorithm uses topological information to compute contours with a parallel method of speedup. Another parallel algorithm based on data parallel is used in experiments to show that pipeline parallel mode is more efficient. A case study at last shows a suspending performance of the new parallel algorithm. Compared with the serial slicing algorithm, the new pipeline parallel algorithm can make full use of the multi-core CPU hardware, accelerate the slicing process, and compared with the data parallel slicing algorithm, the new slicing algorithm in this paper adopts a pipeline parallel model, and a much higher speedup ratio and efficiency is achieved.展开更多
3D stereoscopic visualization technology is coming into more and more common use in the field of entertainment,and this technology is also beginning to cut a striking figure in casting industry and scientific research...3D stereoscopic visualization technology is coming into more and more common use in the field of entertainment,and this technology is also beginning to cut a striking figure in casting industry and scientific research.The history,fundamental principle,and devices of 3D stereoscopic visualization technology are reviewed in this paper.The authors’research achievements on the 3D stereoscopic visualization technology in the modeling and simulation of the casting process are presented.This technology can be used for the observation of complex 3D solid models of castings and the simulated results of solidification processes such as temperature,fluid flow,displacement,stress strain and microstructure,as well as the predicted defects such as shrinkage/porosity,cracks,and deformation.It can also be used for other areas relating to 3D models,such as assembling of dies,cores,etc.Several cases are given to compare the illustration of simulated results by traditional images and red-blue 3D stereoscopic images.The spatial shape is observed better by the new method.The prospect of3D stereoscopic visualization in the casting aspect is discussed as well.The need for aided-viewing devices is still the most prominent problem of 3D stereoscopic visualization technology.However,3D stereoscopic visualization represents the tendency of visualization technology in the future;and as the problem is solved in the years ahead,great breakthroughs will certainly be made for its application in casting design and modeling and simulation of the casting processes.展开更多
文摘Deep learning has achieved great progress in image recognition,segmentation,semantic recognition and game theory.In this study,a latest deep learning model,a conditional diffusion model was adopted as a surrogate model to predict the heat transfer during the casting process instead of numerical simulation.The conditional diffusion model was established and trained with the geometry shapes,initial temperature fields and temperature fields at t_(i) as the condition and random noise sampled from standard normal distribution as the input.The output was the temperature field at t_(i+1).Therefore,the temperature field at t_(i+1)can be predicted as the temperature field at t_(i) is known,and the continuous temperature fields of all the time steps can be predicted based on the initial temperature field of an arbitrary 2D geometry.A training set with 3022D shapes and their simulated temperature fields at different time steps was established.The accuracy for the temperature field for a single time step reaches 97.7%,and that for continuous time steps reaches 69.1%with the main error actually existing in the sand mold.The effect of geometry shape and initial temperature field on the prediction accuracy was investigated,the former achieves better result than the latter because the former can identify casting,mold and chill by different colors in the input images.The diffusion model has proved the potential as a surrogate model for numerical simulation of the casting process.
基金funded by the Beijing Nature Sciences Fund Haidian Originality Cooperation Project (Grant No. L212002)。
文摘In the production of castings,intrusive gas pore represents a kind of common defects which can lead to leakage in high gas-tightness requirement castings,such as cylinder blocks and cylinder heads for engines.It occurs due to the intrusion of gases generated during the resin burning of the sand core into castings during the casting process.Therefore,a gas generation and flow constitution model was established,in which the gas generation rate is a function of temperature and time,and the flow of gas is controlled by the gas release,conservation,and Darcy's law.The heat transfer and gas flow during casting process was numerically simulated.The dangerous point of cores is firstly identified by a virtual heat transfer method based on the similarity between heat transfer and gas flow in the sand core.The gas pores in castings are predicted by the gas pressure,the viscosity and state of the melt for these dangerous points.Three distinct sand core structures were designed and used for the production of iron castings,and the simulated gas pore results were validated by the obtained castings.
文摘Magnesium matrix nanocomposite reinforced with carbon nanotubes(CNTs/AZ91D) was fabricated by mechanical stirring and high intensity ultrasonic dispersion processing.The microstructures and mechanical properties of the nanocomposite were investigated.The results show that CNTs are well dispersed in the matrix and combined with the matrix very well.As compared with AZ91D magnesium alloy matrix,the tensile strength,yield strength and elongation of the 1.5%CNTs/AZ91D nanocomposite are improved by 22%,21%and 42%respectively in permanent mold casting.The strength and ductility of the nanocomposite are improved simultaneously.The tensile fracture analysis shows that the damage mechanism of nanocomposite is still brittle fracture.But the CNTs can prevent the local crack propagation to some extent.
文摘This paper expatiates on domestic status of heavy steel casting production, with a special focus on hydraulicturbine castings for Three Gorges Project. In China, there is magnificent demand for heavy castings with the rapidgrowth of the national economy in recent years and the expected high growth in the coming 10 to 20 years. Someheavy and large castings such as mill housing and hydraulic turbine runner crown, blade and band for Three GorgesProject have been successfully made. However, the domestic production capability is still far from meeting the giganticrequirements. The domestic capability still lags behind the world class level, and a lot of heavy castings still dependon import. The paper also gives a particular introduction of the key technologies in the manufacturing of heavy steelcastings like metal melting, foundry technology, heat treatment technology and numerical simulation technique, etc.In addition, several case studies on the application of numerical simulation in the production of heavy steel castingsare presented.
基金funded by National Key R&D Program of China(No.2021YFB3401200)the National Natural Science Foundation of China(No.51875308)the Beijing Nature Sciences Fund-Haidian Originality Cooperation Project(L212002).
文摘Numerical simulation is the most powerful computational and analysis tool for a large variety of engineering and physical problems.For a complex problem relating to multi-field,multi-process and multi-scale,different computing tools have to be developed so as to solve particular fields at different scales and for different processes.Therefore,the integration of different types of software is inevitable.However,it is difficult to perform the transfer of the meshes and simulated results among software packages because of the lack of shared data formats or encrypted data formats.An image processing based method for three-dimensional model reconstruction for numerical simulation was proposed,which presents a solution to the integration problem by a series of slice or projection images obtained by the post-processing modules of the numerical simulation software.By means of mapping image pixels to meshes of either finite difference or finite element models,the geometry contour can be extracted to export the stereolithography model.The values of results,represented by color,can be deduced and assigned to the meshes.All the models with data can be directly or indirectly integrated into other software as a continued or new numerical simulation.The three-dimensional reconstruction method has been validated in numerical simulation of castings and case studies were provided in this study.
基金financially supported by the National Natural Science Foundation of China(Grant No.51875211)the Beijing Natural Science Foundation(Grant No.L223001)。
文摘Microporosity formed in the solidification process of Al alloys is detrimental to the alloy properties.A two-dimensional cellular automaton(CA)model was developed to simulate the microstructure and microporosity formation in Al-Cu alloys,considering variations in Cu content and solidification rate.The results indicate that the Cu content primarily influences the growth of microporosity.To validate the model,directional solidification experiments were conducted on Al-Cu alloys with varing Cu contents and withdrawal rates.The experimental results of dendrites and microporosity characteristics agree well with the predictions from the developed model,thus confirming the validity of the model.The alloy’s liquidus temperature,dendrite morphology,and hydrogen saturation solubility arising from different Cu contents have significant effects on microporosity morphology.The withdrawal rate primarily affects the nucleation of hydrogen microporosity by altering cooling rates and dendritic growth rates,resulting in different microporosity characteristics.
文摘Particulate reinforced metal matrix composite(PR-MMC) has excellent properties such as good wear resistance,corrosion resistance and high temperature properties.Laser cladding is usually used to form PR-MMC on metal surface with various volume fractions of ceramic particles.Recent literatures showed that laser melting of powder mixture containing carbon and carbide-forming elements,was favorable for the formation of in-situ synthesized carbide particles.In this paper,rare earth oxide(RE2O3) was added into t...
基金funded by the National Science and Technology Major Project of the Ministry of Science and Technology of China under Project No.2016YFB1100703
文摘The insulation effect of the air cavity surrounding the riser in a 3D printed sand mold was studied. The influence of the air cavity on heat flux was theoretically analyzed. The results demonstrated that the heat flux of the air cavity in the 3D printed sand mold was significantly less than that of resin-bonded sand. The insulation effect of the air cavity in sand molds for a cylinder casting and a stress-frame casting were simulated using software COMSOL. The results illustrated that the air cavity could be used to insulate the riser and it was more suitable for a lower melting point metal casting. An air cavity with 10-15 mm width and 5-10 mm away from the riser can significantly prolong the solidification of the riser by over 10%. Meanwhile, the sand mold for the stressframe was made by 3D printing technology and poured with aluminum alloy A356 melt. The experiment results showed that the presence of the air cavity led to a 12.5% increase of the solidification time of its riser.
基金supported by the National Natural Science Foundation of China[grant number U1537202]the TsinghuaGeneral Motor International collaboration project[grant number 20153000354]+1 种基金the UK Royal Society through the Newton International Fellowship Schemethe National Laboratory for Information Science and Technology in Tsinghua University for access to supercomputing facilities
文摘In the present study, the influence of natural convection on the lamellar eutectic growth is determined by a phase-field-lattice Boltzmann study for Al-Cu eutectic alloy. The mass difference resulting from concentration difference led to the fluid flow, and a robust parallel and adaptive mesh refinement algorithm was employed to improve the computational efficiency without any compromising accuracy. Results show that the existence of natural convection would affect the growth undercooling and thus control the interface shape by adjusting the lamellar width. In particular, by alternating the magnitude of the solute expansion coefficient, the strength of the natural convection is changed. Corresponding microstructure patterns are discussed and compared with those under no-convection conditions.
基金Project (2016YFB0301001) supported by the National Key Research and Development Program of ChinaProject (2015M580093) supported by the General Financial Grant from the China Postdoctoral Science Foundation of China
文摘Vacuum die casting can reduce the'air entrapment'phenomenon during casting process.Based on the temperature measurements at metal-die interface with different processing parameters,such as slow shot speed(VL),high shot speed(VH),pouring temperature(Tp)and initial die temperature(Tm),inverse method was developed to determine the interfacial heat transfer coefficient(IHTC).The results indicate that a closer contact between the casting and die could be achieved when the vacuum system is used.It is found that the vacuum could strongly increase the values of IHTC and decrease the grain size in castings.The IHTC could have a higher peak value with increasing the Tp from680to720℃or the VL from0.1to0.4m/s.In addition,the influence of the VH and Tm on IHTC could be negligible.
基金financially supported by the National Basic Research Program of China(No.2011CB012900)the National Science and Technology Major Project of the Ministry of Science and Technology of China(No.2012ZX04012011)
文摘A ladle-tundish-mould transportation model considering the entire multiple pouring(MP) process is proposed. Numerical simulation is carried out to study the carbon distribution and variation in both the tundish and the mould for making a 292 t steel ingot. Firstly, the fluid flow as well as the heat and mass transfer of the molten steel in the tundish is simulated based on the multiphase transient turbulence model. Then, the carbon mixing in the mould is calculated by using the species concentration at the tundish outlet as the inlet condition during the teeming process. The results show a high concentration of carbon at the bottom and a low concentration of carbon at the top of the mould after a MP process with carbon content high in the first ladle and low in the last ladle. Such carbon concentration distribution would help reduce the negative segregation at the bottom and the positive segregation at the top of the solidified ingot.
基金supported by the National Natural Science Foundation of China(51605251)Tsinghua University Initiative Scientific Research Program(2014Z05093).
文摘A new seam-tracking method based on dynamic trajectory planning for a mobile welding robot is proposed in order to improve the response lag of the mobile robot and the high frequency oscillation in seam-tracking.By using a front-placed laser-based vision sensor to dynamically extract the location of the weld seam in front of torch,the trend and direction of the weld line is roughly obtained.The robot system autonomously and dynamically performs trajectory planning based on the isometric approximation model.Arc sensor technology is applied to detect the offset during welding process in real time.The dynamic compensation of the weld path is done in combination with the control of the mobile robot and the executive body installed on it.Simulated and experimental results demonstrate that the method effectively increases the stability of welding speed and smoothness of the weld track,and hence the weld formation in curves and corners is improved.
基金funded by the National Science and Technology Major Project of the Ministry of Science and Technology of China under Project No.2016YFB1100703
文摘3D printing technology has been used for sand molding and core printing, but they simply substitute the traditional molding and core making method without changing the shape or size of the sand mold(core) and their dense structure. In this study, a new type of hollow mold based on 3D printing is presented. The new type of mold is a rib reinforced thickness-varying shell mold. This mold design can realize the controlled cooling of castings, i.e., different cooling rates at different areas, and improve the temperature uniformity of a casting after its solidifi cation. Therefore, the performance of castings can be improved and their residual stress and deformation can be reduced. This kind of new mold was applied to a stress frame of A356 aluminum alloy. The 3D printed rib reinforced thickness-varying shell mold was compared with the traditional dense mold, and the castings obtained by these two kinds of molds were also compared. The experimental results showed that the rib reinforced shell mold increased the cooling rate of the casting by 30%, tensile strength by 17%, yield strength by 11%, elongation by 67%, and decreased its deformation by 43%, while sand consumption was greatly reduced by 90%.
基金Supported by the National Natural Science Foundation of China under Grant Nos 50671050 and 50431030, and the National Center for Nanoscience and Technology of China.
文摘Bulk metallic glasses are prepared in Pd4o.sNi4o.sSixP19-x （x = 0-14 at.%） alloys by a combination of flux treatment and water quenching technique. It is found that the thermal stability of the Pd4o.sNi4o.sSixP19=x glassy alloys depends on the addition of Si content. Among the Pd4o.sNi4o.sSixP19=x glassy alloys studied, the Pd4o.sNi4o.sSisPls bulk metallic glass exhibits the largest supercooled liquid region （△T = 119 K） and the highest activation energy of crystallization （283.3k J/tool）, showing enhanced glass formation ability and extraordinary glassy thermal stability.
基金This study was supported by the National Key R&D Program of China(2017YFB1104300 and 2016YFA0200200)Natural Science Foundation of China(NSFC)(No.21671020,51433005 and 51673026)+1 种基金NSFC-MAECI(51861135202),Beijing Natural Science Foundation(2172049)Analysis&Testing Center,Beijing Institute of Technology.
文摘Graphene,an emerging fabric of carbon atoms,has manifested its versatility in all kinds of fields encompassing electronics,optoelectronics,thermoelectrics,taking advantage of its excellent mechanical strength,exceptional electronic and thermal conductivities,high surface specific area,and so forth.The prosperity of graphene never seen before has led the attention to silicene,siloxene,germanene,stanene,and plumbene due to their promising applications in the quantum spin Hall effect,topological insulator,batteries,capacitors,catalysis,and topological superconductivity.Herein,we review the existing production methods,numerous applications of two-dimensional group-IVA materials,and critically discuss the challenges of these materials,providing potential implications to the exploration of uncharted material systems.
基金funded by the National Natural Science Foundation of China (No. 51875308)。
文摘The cooling control of the melt during the casting process is of great significance. A comprehensive closed-loop cooling control of castings by adopting a skeletal sand mold design was proposed. The skeletal sand mold consisting of an adaptive shell, functional cavities and a support was designed and created based on the finite difference meshes of a casting. It was applied to a round wall test casting. Two kinds of skeletal sand molds, one with lattice support and the other with enforcing ribs for this casting were designed and printed out by the 3 D printing(3 DP) method. Aluminum alloy A356 was cast by using these two sand molds. The first mold was cooled by natural convection, the other one by water spray cooling. Two sound castings were obtained. The sand mold temperature, cooling curves, microstructures, mechanical properties, residual stress and deformation were measured, compared and discussed. Water spray cooling hastened the cooling rate by 62%, increased the content of Mg and Cu in the α-Al matrix, improved the mechanical properties, and altered the surface residual stress state.
基金This work was supported by the National High Technology Research and Development Program("863"Program) of China ( ContractNo 2007AA04Z258)
文摘Visual image sensor is developed to detect the weld pool images in pulsed MIG welding. An exposure controller, which is composed of the modules of the voltage transforming, the exposure parameters presetting, the complex programmable logic device （CPLD） based logic controlling, exposure signal processing, the arc state detecting, the mechanical iris driving and so on, is designed at first. Then, a visual image sensor consists of an ordinary CCD camera, optical system and exposure controller is established. The exposure synchronic control logic is described with very-high-speed integrated circuit hardware description language （VHDL） and programmed with CPLD , to detect weld pool images at the stage of base current in pulsed MIG welding. Finally, both bead on plate welding and V groove filled welding are carried out, clear and consistent weld pool images are acquired.
基金partially supported by the JST-Mirai Program Grant Number JPMJMI19E5a Grant-in-Aid for Science Research from the Japan Society for the Promotion of Science。
文摘In this study, the effect of the processing route using a friction stir processing(FSP) method on the microstructure and mechanical behavior of a Mg-9Li-1Zn alloy was systematically investigated. In the FSP method, the odd-numbered(1st and 3rd) process directions and even-numbered(2nd and 4th) passes were alternated to distribute the strain throughout the whole processed zone uniformly. Consequently, the processed zone had a much more uniform microstructure and hardness distribution than the processed zone obtained using the conventional FSP method. Using this method, the grain size of a Mg-9Li-1Zn sheet alloy was refined from ~31 μm to ~0.21 μm with uniformly distributedα and β phases. The processed alloy exhibited a high strength-ductility synergy with an ultimate tensile strength(UTS) of 220.1 MPa and total elongation of 70.0% at a strain rate of 10^(-3)s^(-1), overwhelmingly higher than those of the base metal, 155.6 MPa in UTS and 36.0%in elongation. The in-situ SEM-DIC analysis and TEM observation demonstrated that such an outstanding ductility with moderate strength is caused by grain boundary sliding, the dominant deformation mechanism of the ultra-fine-grained sample after FSP. The processing route with reverse processing direction was proven to be efficient in producing the ultrafine grain size microstructure and improving the mechanical properties of superlight Mg-9Li-1Zn alloy.
文摘In Additive Manufacturing field, the current researches of data processing mainly focus on a slicing process of large STL files or complicated CAD models. To improve the efficiency and reduce the slicing time, a parallel algorithm has great advantages. However, traditional algorithms can＇t make full use of multi-core CPU hardware resources. In the paper, a fast parallel algorithm is presented to speed up data processing. A pipeline mode is adopted to design the parallel algorithm. And the complexity of the pipeline algorithm is analyzed theoretically. To evaluate the performance of the new algorithm, effects of threads number and layers number are investigated by a serial of experiments. The experimental results show that the threads number and layers number are two remarkable factors to the speedup ratio. The tendency of speedup versus threads number reveals a positive relationship which greatly agrees with the Amdahl＇s law, and the tendency of speedup versus layers number also keeps a positive relationship agreeing with Gustafson＇s law. The new algorithm uses topological information to compute contours with a parallel method of speedup. Another parallel algorithm based on data parallel is used in experiments to show that pipeline parallel mode is more efficient. A case study at last shows a suspending performance of the new parallel algorithm. Compared with the serial slicing algorithm, the new pipeline parallel algorithm can make full use of the multi-core CPU hardware, accelerate the slicing process, and compared with the data parallel slicing algorithm, the new slicing algorithm in this paper adopts a pipeline parallel model, and a much higher speedup ratio and efficiency is achieved.
文摘3D stereoscopic visualization technology is coming into more and more common use in the field of entertainment,and this technology is also beginning to cut a striking figure in casting industry and scientific research.The history,fundamental principle,and devices of 3D stereoscopic visualization technology are reviewed in this paper.The authors’research achievements on the 3D stereoscopic visualization technology in the modeling and simulation of the casting process are presented.This technology can be used for the observation of complex 3D solid models of castings and the simulated results of solidification processes such as temperature,fluid flow,displacement,stress strain and microstructure,as well as the predicted defects such as shrinkage/porosity,cracks,and deformation.It can also be used for other areas relating to 3D models,such as assembling of dies,cores,etc.Several cases are given to compare the illustration of simulated results by traditional images and red-blue 3D stereoscopic images.The spatial shape is observed better by the new method.The prospect of3D stereoscopic visualization in the casting aspect is discussed as well.The need for aided-viewing devices is still the most prominent problem of 3D stereoscopic visualization technology.However,3D stereoscopic visualization represents the tendency of visualization technology in the future;and as the problem is solved in the years ahead,great breakthroughs will certainly be made for its application in casting design and modeling and simulation of the casting processes.
