Search2014 Vol. 21, No. 6
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2014, vol. 21, no. 6, pp.
523-530.
https://doi.org/10.1007/s12613-014-0938-1
Abstract:
A three-dimensional computational fluid dynamics (CFD) model was developed to simulate a 150-t top-blown converter. The effect of different lance heights on the cavity shape was investigated using the volume of fluid (VOF) method. Numerical simulation results can reflect the actual molten bath surface waves impinged by the supersonic oxygen jets. With increasing lance height, the cavity depth decreases, and the cavity area, varying like a parabola, increases and then decreases. The cavity area maximizes at the lance height of 1.3 m. Under the three different lance heights simulated in this study, all of the largest impact velocities at the molten bath surface are between 50 m/s and 100 m/s.
A three-dimensional computational fluid dynamics (CFD) model was developed to simulate a 150-t top-blown converter. The effect of different lance heights on the cavity shape was investigated using the volume of fluid (VOF) method. Numerical simulation results can reflect the actual molten bath surface waves impinged by the supersonic oxygen jets. With increasing lance height, the cavity depth decreases, and the cavity area, varying like a parabola, increases and then decreases. The cavity area maximizes at the lance height of 1.3 m. Under the three different lance heights simulated in this study, all of the largest impact velocities at the molten bath surface are between 50 m/s and 100 m/s.
2014, vol. 21, no. 6, pp.
531-543.
https://doi.org/10.1007/s12613-014-0939-0
Abstract:
Subsurface macro-inclusions and hooks are detrimental to the surface quality of deep-drawing steel sheets. However, little is known about the relationship between macro-inclusions and hooks. Thus, in this work, two ultralow carbon (ULC) steel slabs and two low carbon (LC) aluminum-killed steel slabs were sampled to study the relationship between hooks and subsurface macro-inclusions, which were detected on the cross-sections of steel samples with an area of 56058 mm2 using an automated scanning electron microscopy/energy-dispersive X-ray spectroscopy system. Results show that subsurface inclusions larger than 200 μm were almost entrapped by hook structures, whereas the location of other inclusions smaller than 200 μm had no obvious dependence on the location of solidified hooks. Furthermore, the number density (ND) of subsurface inclusions larger than 200 μm decreased from 0.02 to 0 cm-2 in ULC steel as the mean hook depth decreased from 1.57 to 1.01 mm. Similar trends were also observed in LC steel. In addition, the detected inclusions larger than 200 μm were concentrated in the region near the slab center (3/8 width-5/8 width), where hook depths were also larger than those at any other locations. Therefore, minimizing the hook depth is an effective way to reduce inclusion-induced sliver defects in deep-drawing steels.
Subsurface macro-inclusions and hooks are detrimental to the surface quality of deep-drawing steel sheets. However, little is known about the relationship between macro-inclusions and hooks. Thus, in this work, two ultralow carbon (ULC) steel slabs and two low carbon (LC) aluminum-killed steel slabs were sampled to study the relationship between hooks and subsurface macro-inclusions, which were detected on the cross-sections of steel samples with an area of 56058 mm2 using an automated scanning electron microscopy/energy-dispersive X-ray spectroscopy system. Results show that subsurface inclusions larger than 200 μm were almost entrapped by hook structures, whereas the location of other inclusions smaller than 200 μm had no obvious dependence on the location of solidified hooks. Furthermore, the number density (ND) of subsurface inclusions larger than 200 μm decreased from 0.02 to 0 cm-2 in ULC steel as the mean hook depth decreased from 1.57 to 1.01 mm. Similar trends were also observed in LC steel. In addition, the detected inclusions larger than 200 μm were concentrated in the region near the slab center (3/8 width-5/8 width), where hook depths were also larger than those at any other locations. Therefore, minimizing the hook depth is an effective way to reduce inclusion-induced sliver defects in deep-drawing steels.
2014, vol. 21, no. 6, pp.
544-555.
https://doi.org/10.1007/s12613-014-0940-7
Abstract:
Thermomechanical experiments were carried out to reproduce the hot stamping process and to investigate the effects of process parameters on the microstructure and mechanical properties of stamped parts. The process parameters, such as austenitizing temperature, soaking time, initial deformation temperature and cooling rate, are studied. The resulting microstructures of specimens were observed and analyzed. To evaluate the mechanical properties of specimens, tensile and hardness tests were also performed at room temperature. The optimum parameters to achieve the highest tensile strength and the desired microstructure were acquired by comparing and analyzing the results. It is indicated that hot deformation changes the transformation characteristics of 22MnB5 steel. Austenite deformation promotes the austenite-to-ferrite transformation and elevates the critical cooling rate to induce a fully martensitic transformation.
Thermomechanical experiments were carried out to reproduce the hot stamping process and to investigate the effects of process parameters on the microstructure and mechanical properties of stamped parts. The process parameters, such as austenitizing temperature, soaking time, initial deformation temperature and cooling rate, are studied. The resulting microstructures of specimens were observed and analyzed. To evaluate the mechanical properties of specimens, tensile and hardness tests were also performed at room temperature. The optimum parameters to achieve the highest tensile strength and the desired microstructure were acquired by comparing and analyzing the results. It is indicated that hot deformation changes the transformation characteristics of 22MnB5 steel. Austenite deformation promotes the austenite-to-ferrite transformation and elevates the critical cooling rate to induce a fully martensitic transformation.
2014, vol. 21, no. 6, pp.
556-562.
https://doi.org/10.1007/s12613-014-0941-6
Abstract:
A fitted function method to describe the strain fields during forging was discussed to optimize the homogeneous distribution of strain in the axial forging zones during successive stretching. The results are verified by experiment and numerical simulation, and the deviations between experiment and simulation are less than 24%. Therefore, the fitted function method can be applied to optimize the stretching process for large forgings. The optimal value of feed determined by the analytic method ensures that the degree of inhomogeneity in strain in the axial ingot zone is less than 6%. This work provides a mathematic model to optimize technological parameters in stretch forging of large ingots.
A fitted function method to describe the strain fields during forging was discussed to optimize the homogeneous distribution of strain in the axial forging zones during successive stretching. The results are verified by experiment and numerical simulation, and the deviations between experiment and simulation are less than 24%. Therefore, the fitted function method can be applied to optimize the stretching process for large forgings. The optimal value of feed determined by the analytic method ensures that the degree of inhomogeneity in strain in the axial ingot zone is less than 6%. This work provides a mathematic model to optimize technological parameters in stretch forging of large ingots.
2014, vol. 21, no. 6, pp.
563-568.
https://doi.org/10.1007/s12613-014-0942-5
Abstract:
The existence of residual austenite in weld metal plays an important role in determining the properties and dimensional accuracy of welded rotors. An effective corrosive agent and the metallographic etching process were developed to clearly reveal the characteristics of residual austenite in the weld metal of a 9Cr1MoNbV welded rotor. Moreover, the details of the distribution, shape, length, length-to-width ratio, and the content of residual austenite were systematically characterized using the Image-Pro Plus image analysis software. The results revealed that the area fraction of residual austenite was approximately 6.3% in the observed weld seam; the average area, length, and length-to-width ratio of dispersed residual austenite were quantitatively evaluated to be (5.5 ± 0.1) μm2, (5.0 ± 0.1) μm, and (2.2 ± 0.1), respectively. The newly developed corrosive agent and etching method offer an appropriate approach to characterize residual austenite in the weld metal of welded rotors in detail.
The existence of residual austenite in weld metal plays an important role in determining the properties and dimensional accuracy of welded rotors. An effective corrosive agent and the metallographic etching process were developed to clearly reveal the characteristics of residual austenite in the weld metal of a 9Cr1MoNbV welded rotor. Moreover, the details of the distribution, shape, length, length-to-width ratio, and the content of residual austenite were systematically characterized using the Image-Pro Plus image analysis software. The results revealed that the area fraction of residual austenite was approximately 6.3% in the observed weld seam; the average area, length, and length-to-width ratio of dispersed residual austenite were quantitatively evaluated to be (5.5 ± 0.1) μm2, (5.0 ± 0.1) μm, and (2.2 ± 0.1), respectively. The newly developed corrosive agent and etching method offer an appropriate approach to characterize residual austenite in the weld metal of welded rotors in detail.
2014, vol. 21, no. 6, pp.
569-576.
https://doi.org/10.1007/s12613-014-0943-4
Abstract:
In this study, annealed pure copper was extruded using equal channel angular extrusion (ECAE) for a maximum of eight passes. The fatigue resistance of extruded specimens was evaluated for different passes and applied stresses using fatigue tests, fractography, and metallography. The mechanical properties of the extruded material were obtained at a tensile test velocity of 0.5 mm/min. It was found that the maximum increase in strength occurred after the 2nd pass. The total increase in ultimate strength after eight passes was 94%. The results of fatigue tests indicated that a significant improvement in fatigue life occurred after the 2nd pass. In subsequent passes, the fatigue life continued to improve but at a considerably lower rate. The improved fatigue life was dependent on the number of passes and applied stresses. For low stresses (or high-cycle fatigue), a maximum increase in fatigue resistance of approximately 500% was observed for the extruded material after eight passes, whereas a maximum fatigue resistance of 5000% was obtained for high-applied stresses (or low-cycle fatigue). Optical microscopic examinations revealed grain refinements in the range of 32 to 4 μm. A maximum increase in impact energy absorption of 100% was achieved after eight passes. Consistent results were obtained from fractography and metallography examinations of the extruded material during fatigue tests.
In this study, annealed pure copper was extruded using equal channel angular extrusion (ECAE) for a maximum of eight passes. The fatigue resistance of extruded specimens was evaluated for different passes and applied stresses using fatigue tests, fractography, and metallography. The mechanical properties of the extruded material were obtained at a tensile test velocity of 0.5 mm/min. It was found that the maximum increase in strength occurred after the 2nd pass. The total increase in ultimate strength after eight passes was 94%. The results of fatigue tests indicated that a significant improvement in fatigue life occurred after the 2nd pass. In subsequent passes, the fatigue life continued to improve but at a considerably lower rate. The improved fatigue life was dependent on the number of passes and applied stresses. For low stresses (or high-cycle fatigue), a maximum increase in fatigue resistance of approximately 500% was observed for the extruded material after eight passes, whereas a maximum fatigue resistance of 5000% was obtained for high-applied stresses (or low-cycle fatigue). Optical microscopic examinations revealed grain refinements in the range of 32 to 4 μm. A maximum increase in impact energy absorption of 100% was achieved after eight passes. Consistent results were obtained from fractography and metallography examinations of the extruded material during fatigue tests.
2014, vol. 21, no. 6, pp.
577-582.
https://doi.org/10.1007/s12613-014-0944-3
Abstract:
In this study, 7A52 aluminum alloy sheets of 4 mm in thickness were welded by tungsten inert gas welding using microalloying welding wires containing traces of Zr and Er. The influence of rare earth elements Zr and Er on the microstructure and mechanical properties of the welded joints was analyzed by optical microscopy, energy dispersive X-ray spectroscopy, transmission electron microscopy, hardness testing, and tensile mechanical properties testing. Systematic analyses indicate that the addition of trace amounts of Er and Zr leads to the formation of fine Al3Er, Al3Zr, and Al3(Zr,Er) phases that favor significant grain refinement in the weld zone. Besides, the tensile strength and hardness of the welded joints were obviously improved with the addition of Er and Zr, as evidenced by the increase in tensile strength and elongation by 40 MPa and 1.4%, respectively, and by the welding coefficient of 73%.
In this study, 7A52 aluminum alloy sheets of 4 mm in thickness were welded by tungsten inert gas welding using microalloying welding wires containing traces of Zr and Er. The influence of rare earth elements Zr and Er on the microstructure and mechanical properties of the welded joints was analyzed by optical microscopy, energy dispersive X-ray spectroscopy, transmission electron microscopy, hardness testing, and tensile mechanical properties testing. Systematic analyses indicate that the addition of trace amounts of Er and Zr leads to the formation of fine Al3Er, Al3Zr, and Al3(Zr,Er) phases that favor significant grain refinement in the weld zone. Besides, the tensile strength and hardness of the welded joints were obviously improved with the addition of Er and Zr, as evidenced by the increase in tensile strength and elongation by 40 MPa and 1.4%, respectively, and by the welding coefficient of 73%.
2014, vol. 21, no. 6, pp.
583-588.
https://doi.org/10.1007/s12613-014-0945-2
Abstract:
Co68.15Fe4.35Si12.25B15.25 (at%) amorphous microwires with a smooth surface and a circular cross-section were fabricated by the glass-coated melt spinning method. Their mechanical properties were evaluated through tensile tests of the glass-coated amorphous microwires, and their fracture reliability was estimated using two- and three-parameter Weibull analysis. X-ray diffraction and transmission electron microscopy results showed that these glass-coated Co-based microwires were mostly amorphous. The coated Co-based microwires exhibit a tensile strength of 1145 to 2457 MPa, with a mean value of 1727 MPa and a variance of 445 MPa. Weibull statistical analysis showed that the tensile two-parameter Weibull modulus of the amorphous microwires is 4.16 and the three-parameter Weibull modulus is 1.61 with a threshold value as high as 942 MPa. These results indicate that the fabricated microwires exhibit good tensile properties and fracture reliability, and thus appear to be good candidates for electronics reliability engineering applications.
Co68.15Fe4.35Si12.25B15.25 (at%) amorphous microwires with a smooth surface and a circular cross-section were fabricated by the glass-coated melt spinning method. Their mechanical properties were evaluated through tensile tests of the glass-coated amorphous microwires, and their fracture reliability was estimated using two- and three-parameter Weibull analysis. X-ray diffraction and transmission electron microscopy results showed that these glass-coated Co-based microwires were mostly amorphous. The coated Co-based microwires exhibit a tensile strength of 1145 to 2457 MPa, with a mean value of 1727 MPa and a variance of 445 MPa. Weibull statistical analysis showed that the tensile two-parameter Weibull modulus of the amorphous microwires is 4.16 and the three-parameter Weibull modulus is 1.61 with a threshold value as high as 942 MPa. These results indicate that the fabricated microwires exhibit good tensile properties and fracture reliability, and thus appear to be good candidates for electronics reliability engineering applications.
2014, vol. 21, no. 6, pp.
589-594.
https://doi.org/10.1007/s12613-014-0946-1
Abstract:
In this study, we have investigated how the dielectric loss tangent and permittivity of AlN ceramics are affected by factors such as powder mixing methods, milling time, sintering temperature, and the addition of a second conductive phase. All ceramic samples were prepared by spark plasma sintering (SPS) under a pressure of 30 MPa. AlN composite ceramics sintered with 30wt%–40wt% SiC at 1600℃ for 5 min exhibited the best dielectric loss tangent, which is greater than 0.3. In addition to AlN and β-SiC, the samples also contained 2H-SiC and Fe5Si3, as detected by X-ray difraction (XRD). The relative densities of the sintered ceramics were higher than 93%. Experimental results indicate that nano-SiC has a strong capability of absorbing electromagnetic waves. The dielectric constant and dielectric loss of AlN-SiC ceramics with the same content of SiC decreased as the frequency of electromagnetic waves increased from 1 kHz to 1 MHz.
In this study, we have investigated how the dielectric loss tangent and permittivity of AlN ceramics are affected by factors such as powder mixing methods, milling time, sintering temperature, and the addition of a second conductive phase. All ceramic samples were prepared by spark plasma sintering (SPS) under a pressure of 30 MPa. AlN composite ceramics sintered with 30wt%–40wt% SiC at 1600℃ for 5 min exhibited the best dielectric loss tangent, which is greater than 0.3. In addition to AlN and β-SiC, the samples also contained 2H-SiC and Fe5Si3, as detected by X-ray difraction (XRD). The relative densities of the sintered ceramics were higher than 93%. Experimental results indicate that nano-SiC has a strong capability of absorbing electromagnetic waves. The dielectric constant and dielectric loss of AlN-SiC ceramics with the same content of SiC decreased as the frequency of electromagnetic waves increased from 1 kHz to 1 MHz.
2014, vol. 21, no. 6, pp.
595-603.
https://doi.org/10.1007/s12613-014-0947-0
Abstract:
Sr2+ modified polycrystalline PZT-PMN ceramics were synthesized by a semi-wet route. Impedance spectroscopy studies indicate the bulk and grain boundary effects of PZT-PMN material along with the negative temperature coefficient of resistance. The bulk conductivity exhibits an Arrhenius-type thermally activated hopping process which is supported by the AC conductivity behavior as a function of frequency and temperature. It is observed that the remnant polarization increases with an increase in the Sr2+ content in PZT-PMN.
Sr2+ modified polycrystalline PZT-PMN ceramics were synthesized by a semi-wet route. Impedance spectroscopy studies indicate the bulk and grain boundary effects of PZT-PMN material along with the negative temperature coefficient of resistance. The bulk conductivity exhibits an Arrhenius-type thermally activated hopping process which is supported by the AC conductivity behavior as a function of frequency and temperature. It is observed that the remnant polarization increases with an increase in the Sr2+ content in PZT-PMN.
2014, vol. 21, no. 6, pp.
604-608.
https://doi.org/10.1007/s12613-014-0948-z
Abstract:
A series of cadmium-calcium hydroxyapatite solid solutions was prepared by an aqueous precipitation method. By various means, the characterizations confirmed the formation of continuous solid solutions over all ranges of Cd/(Cd+Ca) atomic ratio. In the results, both lattice parameters a and c display slight deviations from Vegard’s rule when the Cd/(Cd+Ca) atomic ratio is greater than 0.6. The particles change from smaller acicular to larger hexagonal columnar crystals as the Cd/(Cd+Ca) atomic ratio increases from 0–0.60 to 0.60–1.00. The area of the phosphate peak for symmetric P-O stretching decreases with the increase in Cd/(Cd+Ca) atomic ratio, and the peak disappears when the Cd/(Cd+Ca) atomic ratio is greater than 0.6; the two phosphate peaks of P-O stretching gradually merge together for the Cd/(Cd+Ca) atomic ratio near 0.60. These variations can be explained by a slight tendency of larger Cd ions to occupy M(2) sites and smaller Ca ions to prefer M(1) sites in the structure.
A series of cadmium-calcium hydroxyapatite solid solutions was prepared by an aqueous precipitation method. By various means, the characterizations confirmed the formation of continuous solid solutions over all ranges of Cd/(Cd+Ca) atomic ratio. In the results, both lattice parameters a and c display slight deviations from Vegard’s rule when the Cd/(Cd+Ca) atomic ratio is greater than 0.6. The particles change from smaller acicular to larger hexagonal columnar crystals as the Cd/(Cd+Ca) atomic ratio increases from 0–0.60 to 0.60–1.00. The area of the phosphate peak for symmetric P-O stretching decreases with the increase in Cd/(Cd+Ca) atomic ratio, and the peak disappears when the Cd/(Cd+Ca) atomic ratio is greater than 0.6; the two phosphate peaks of P-O stretching gradually merge together for the Cd/(Cd+Ca) atomic ratio near 0.60. These variations can be explained by a slight tendency of larger Cd ions to occupy M(2) sites and smaller Ca ions to prefer M(1) sites in the structure.
2014, vol. 21, no. 6, pp.
609-619.
https://doi.org/10.1007/s12613-014-0949-y
Abstract:
The production of geopolymer binders from low-purity clays was investigated. Three low-purity clays were calcined at 750℃ for 4 h. The calcined clays were chemically activated by the alkaline solutions of NaOH and Na2SiO3. The compressive strength was measured as a function of curing time at room temperature and 85℃. The results were compared with those of a pure kaolin sample. An amorphous aluminosilicate polymer was formed in all binders at both processing temperatures. The results show that, the mechanical properties depend on the type and amount of active aluminum silicates in the starting clay material, the impurities, and the processing temperature.
The production of geopolymer binders from low-purity clays was investigated. Three low-purity clays were calcined at 750℃ for 4 h. The calcined clays were chemically activated by the alkaline solutions of NaOH and Na2SiO3. The compressive strength was measured as a function of curing time at room temperature and 85℃. The results were compared with those of a pure kaolin sample. An amorphous aluminosilicate polymer was formed in all binders at both processing temperatures. The results show that, the mechanical properties depend on the type and amount of active aluminum silicates in the starting clay material, the impurities, and the processing temperature.
2014, vol. 21, no. 6, pp.
620-626.
https://doi.org/10.1007/s12613-014-0950-5
Abstract:
Geopolymers are three-dimensional aluminosilicates formed in a short time at low temperature by geopolymerization. In this paper, alkali-activated foam geopolymers were fabricated from circulating fluidized bed fly ash (CFA), and the effect of SiO2/Na2O mole ratio (0.91–1.68) on their properties was studied. Geopolymerization products were characterized by mechanical testing, scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDX), and X-ray diffraction (XRD). The results show that SiO2/Na2O mole ratio plays an important role in the mechanical and morphological characteristics of geopolymers. Foam samples prepared in 28 d with a SiO2/Na2O mole ratio of 1.42 exhibit the greatest compressive strength of 2.52 MPa. Morphological analysis reveals that these foam geopolymers appear the relatively optimized pore structure and distribution, which are beneficial to the structure stability. Moreover, a combination of the Si/Al atomic ratio ranging between 1.47 and 1.94 with the Na/Al atomic ratio of about 1 produces the samples with high strength.
Geopolymers are three-dimensional aluminosilicates formed in a short time at low temperature by geopolymerization. In this paper, alkali-activated foam geopolymers were fabricated from circulating fluidized bed fly ash (CFA), and the effect of SiO2/Na2O mole ratio (0.91–1.68) on their properties was studied. Geopolymerization products were characterized by mechanical testing, scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDX), and X-ray diffraction (XRD). The results show that SiO2/Na2O mole ratio plays an important role in the mechanical and morphological characteristics of geopolymers. Foam samples prepared in 28 d with a SiO2/Na2O mole ratio of 1.42 exhibit the greatest compressive strength of 2.52 MPa. Morphological analysis reveals that these foam geopolymers appear the relatively optimized pore structure and distribution, which are beneficial to the structure stability. Moreover, a combination of the Si/Al atomic ratio ranging between 1.47 and 1.94 with the Na/Al atomic ratio of about 1 produces the samples with high strength.
2014, vol. 21, no. 6, pp.
627-635.
https://doi.org/10.1007/s12613-014-0951-4
Abstract:
A Laval-type supersonic gas atomizer was designed for low-pressure gas atomization of molten metals. The principal design objectives were to produce small-particle uniform powders at lower operating pressures by improving the gas inlet and outlet structures and optimizing structural parameters. A computational fluid flow model was developed to study the flow field characteristics of the designed atomizer. Simulation results show that the maximum gas velocity in the atomization zone can reach 440 m·s−1; this value is independent of the atomization gas pressure P0 when P0 > 0.7 MPa. When P0 = 1.1 MPa, the aspiration pressure at the tip of the delivery tube reaches a minimum, indicating that the atomizer can attain the best atomization efficiency at a relatively low atomization pressure. In addition, atomization experiments with pure tin at P0 = 1.0 MPa and with 7055Al alloy at P0 = 0.8 and 0.4 MPa were conducted to evaluate the atomization capability of the designed atomizer. Nearly spherical powders were obtained with the mass median diameters of 28.6, 43.4, and 63.5 μm, respectively. Compared with commonly used atomizers, the designed Laval-type atomizer has a better low-pressure gas atomization capability.
A Laval-type supersonic gas atomizer was designed for low-pressure gas atomization of molten metals. The principal design objectives were to produce small-particle uniform powders at lower operating pressures by improving the gas inlet and outlet structures and optimizing structural parameters. A computational fluid flow model was developed to study the flow field characteristics of the designed atomizer. Simulation results show that the maximum gas velocity in the atomization zone can reach 440 m·s−1; this value is independent of the atomization gas pressure P0 when P0 > 0.7 MPa. When P0 = 1.1 MPa, the aspiration pressure at the tip of the delivery tube reaches a minimum, indicating that the atomizer can attain the best atomization efficiency at a relatively low atomization pressure. In addition, atomization experiments with pure tin at P0 = 1.0 MPa and with 7055Al alloy at P0 = 0.8 and 0.4 MPa were conducted to evaluate the atomization capability of the designed atomizer. Nearly spherical powders were obtained with the mass median diameters of 28.6, 43.4, and 63.5 μm, respectively. Compared with commonly used atomizers, the designed Laval-type atomizer has a better low-pressure gas atomization capability.
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