Search2008 Vol. 15, No. 3
Display Method:
2008, vol. 15, no. 3, pp.
209-214.
https://doi.org/10.1016/S1005-8850(08)60040-7
Abstract:
The cavity formation and propagation process of stress wave from parallel hole cut blasting was simulated with ANSYS/LS-DYNA 3D nonlinear dynamic finite element software. The distribution of element plastic strain, node velocity, node time-acceleration history and the blasting cartridge volume ratio during the process were analyzed. It was found that the detonation of charged holes would cause the interaction of stress wave with the wall of uncharged holes. Initial rock cracking and displacement to neighboring uncharged holes become the main mechanism of cavity formation in early stage.
The cavity formation and propagation process of stress wave from parallel hole cut blasting was simulated with ANSYS/LS-DYNA 3D nonlinear dynamic finite element software. The distribution of element plastic strain, node velocity, node time-acceleration history and the blasting cartridge volume ratio during the process were analyzed. It was found that the detonation of charged holes would cause the interaction of stress wave with the wall of uncharged holes. Initial rock cracking and displacement to neighboring uncharged holes become the main mechanism of cavity formation in early stage.
2008, vol. 15, no. 3, pp.
215-219.
https://doi.org/10.1016/S1005-8850(08)60041-9
Abstract:
No. 5 coal seam in Huating Coal Mine is a deep-seated, steep-inclined extra-thick coal seam where excavation disturbance is quite frequent. The maximum and minimum principal stresses differ widely. During mining, dynamical destabilization happens frequently and induce tragedies. Based on the comparison between the acoustic emission (AE) experiment on dynamical destabilization of coal rock and the related in situ testing results, this article provides comprehensive analysis on the regular quantificational AE patterns (energy rate, total events) of coal rock destabilization in complex-variable environment. The comparison parameters include dynamic tension energy rate, deformation resistance to compression, and shear stress.
No. 5 coal seam in Huating Coal Mine is a deep-seated, steep-inclined extra-thick coal seam where excavation disturbance is quite frequent. The maximum and minimum principal stresses differ widely. During mining, dynamical destabilization happens frequently and induce tragedies. Based on the comparison between the acoustic emission (AE) experiment on dynamical destabilization of coal rock and the related in situ testing results, this article provides comprehensive analysis on the regular quantificational AE patterns (energy rate, total events) of coal rock destabilization in complex-variable environment. The comparison parameters include dynamic tension energy rate, deformation resistance to compression, and shear stress.
2008, vol. 15, no. 3, pp.
220-226.
https://doi.org/10.1016/S1005-8850(08)60042-0
Abstract:
The deoxidation, desulfurization, dephosphorization, microstructure, and mechanical properties of steels treated by barium-bearing alloys were investigated in laboratory and by industrial tests. The results show that barium takes part in the deoxidation reaction at the beginning of the experiments, generating oxide and sulfide compound inclusions, which easily float up from the molten steel, leading to the rapid reduction of total oxygen content to a very low level. The desulfurization and dephosphorization capabilities of calcium-bearing alloys increase with the addition of barium. The results of OM and SEM observations and mechanical property tests show that the structure of the steel treated by barium-bearing alloys is refined remarkably, the lamellar thickness of pearlitic structure decreases, and the pearlitic morphology shows clustering distribution. Less barium exists in steel substrate and the enrichment of barium-bearing precipitated phase mostly occurs in grain boundary and phase boundary, which can prevent the movement of grain boundary and dislocation during the heat treatment and the deformation processes. Therefore, the strength and toughness of barium-treated steels are improved by the effect of grain-boundary strengthening and nail-prick dislocation.
The deoxidation, desulfurization, dephosphorization, microstructure, and mechanical properties of steels treated by barium-bearing alloys were investigated in laboratory and by industrial tests. The results show that barium takes part in the deoxidation reaction at the beginning of the experiments, generating oxide and sulfide compound inclusions, which easily float up from the molten steel, leading to the rapid reduction of total oxygen content to a very low level. The desulfurization and dephosphorization capabilities of calcium-bearing alloys increase with the addition of barium. The results of OM and SEM observations and mechanical property tests show that the structure of the steel treated by barium-bearing alloys is refined remarkably, the lamellar thickness of pearlitic structure decreases, and the pearlitic morphology shows clustering distribution. Less barium exists in steel substrate and the enrichment of barium-bearing precipitated phase mostly occurs in grain boundary and phase boundary, which can prevent the movement of grain boundary and dislocation during the heat treatment and the deformation processes. Therefore, the strength and toughness of barium-treated steels are improved by the effect of grain-boundary strengthening and nail-prick dislocation.
2008, vol. 15, no. 3, pp.
227-235.
https://doi.org/10.1016/S1005-8850(08)60043-2
Abstract:
The effects of various factors, such as argon flow rate and slide gate opening ratio, on the alumina deposition rate were researched by the numerical simulation method. The pressure in the nozzle is significantly affected by argon flow rate and slide gate opening ratio. To keep positive pressure in the nozzle, the argon flow rate should be increased with a decrease in slide gate opening ratio. The effect of argon flow rate on the alumina deposition rate depends on the condition of opening ratio or casting speed. The effect of increasing the argon flow rate on the deposition rate is not obvious when the opening ratio is small. The Al203 deposition rate decreases significantly with an increase in argon flow rate when the argon flow rate is low, but it decreases slowly when the argon flow rate reaches a certain value. The alumina deposition rate is linear with alumina content at different slide gate opening ratios and argon flow rates. The observed thickness of the deposition layer at the bottom and outlet of a real clogged nozzle is almost equal to the result of the numerical simulation.
The effects of various factors, such as argon flow rate and slide gate opening ratio, on the alumina deposition rate were researched by the numerical simulation method. The pressure in the nozzle is significantly affected by argon flow rate and slide gate opening ratio. To keep positive pressure in the nozzle, the argon flow rate should be increased with a decrease in slide gate opening ratio. The effect of argon flow rate on the alumina deposition rate depends on the condition of opening ratio or casting speed. The effect of increasing the argon flow rate on the deposition rate is not obvious when the opening ratio is small. The Al203 deposition rate decreases significantly with an increase in argon flow rate when the argon flow rate is low, but it decreases slowly when the argon flow rate reaches a certain value. The alumina deposition rate is linear with alumina content at different slide gate opening ratios and argon flow rates. The observed thickness of the deposition layer at the bottom and outlet of a real clogged nozzle is almost equal to the result of the numerical simulation.
2008, vol. 15, no. 3, pp.
236-240.
https://doi.org/10.1016/S1005-8850(08)60044-4
Abstract:
The mechanism of coke size segregation in the radial direction of pre-chamber in coke dry quenching (CDQ) shaft was investigated by experiment and numerical analysis. The experimental apparatus was a cold three-dimensional semicircle model for bell-type charging, which was used to study the influences of different kinds of bells and different stock line levels on the radial distribution of coke size in the radial direction of a pre-chamber. A mathematical model was used, which is capable of estimating the radial average size distribution as well as the radial deposit distribution of each particle size for multiple size coke with a few fixed parameters. The calculated results agree well with the experimental data, which proves the reliability of both experimental study and numerical analysis.
The mechanism of coke size segregation in the radial direction of pre-chamber in coke dry quenching (CDQ) shaft was investigated by experiment and numerical analysis. The experimental apparatus was a cold three-dimensional semicircle model for bell-type charging, which was used to study the influences of different kinds of bells and different stock line levels on the radial distribution of coke size in the radial direction of a pre-chamber. A mathematical model was used, which is capable of estimating the radial average size distribution as well as the radial deposit distribution of each particle size for multiple size coke with a few fixed parameters. The calculated results agree well with the experimental data, which proves the reliability of both experimental study and numerical analysis.
2008, vol. 15, no. 3, pp.
241-244.
https://doi.org/10.1016/S1005-8850(08)60045-6
Abstract:
A theoretical analysis for the boundary layer flow over a continuous moving surface in an otherwise quiescent pseudo-plastic non-Newtonian fluid medium was presented. The types of potential flows necessary for similar solutions to the boundary layer equations were determined and the solutions were numerically presented for different values of power law exponent.
A theoretical analysis for the boundary layer flow over a continuous moving surface in an otherwise quiescent pseudo-plastic non-Newtonian fluid medium was presented. The types of potential flows necessary for similar solutions to the boundary layer equations were determined and the solutions were numerically presented for different values of power law exponent.
2008, vol. 15, no. 3, pp.
245-249.
https://doi.org/10.1016/S1005-8850(08)60046-8
Abstract:
For preparing large-scale nano-grained and ultrafine-grained steel sheets by warm rolling and annealing, the effects of deforming temperature on both the flow stress and the microstructure evolution of 09MnNiD steel with lath martensitic microstructure were studied by warm-compression test and transmission electron microscopy (TEM) observation. Thereafter, the steel with the lath martensitic structure was multi-pass warm-rolled and then annealed. TEM results indicate that nano-grained and ultrafine-grained steel sheets are formed by warm rolling at 400℃ and annealing at 400-600℃. In comparison with the as-warm-rolled specimen, the tensile strength at room temperature changes a little when the rolled samples are annealed below 450℃, and the tensile strength is greatly lowered as the annealing temperature increases to above 550℃.
For preparing large-scale nano-grained and ultrafine-grained steel sheets by warm rolling and annealing, the effects of deforming temperature on both the flow stress and the microstructure evolution of 09MnNiD steel with lath martensitic microstructure were studied by warm-compression test and transmission electron microscopy (TEM) observation. Thereafter, the steel with the lath martensitic structure was multi-pass warm-rolled and then annealed. TEM results indicate that nano-grained and ultrafine-grained steel sheets are formed by warm rolling at 400℃ and annealing at 400-600℃. In comparison with the as-warm-rolled specimen, the tensile strength at room temperature changes a little when the rolled samples are annealed below 450℃, and the tensile strength is greatly lowered as the annealing temperature increases to above 550℃.
2008, vol. 15, no. 3, pp.
250-254.
https://doi.org/10.1016/S1005-8850(08)60047-X
Abstract:
Single pass compression tests were conducted on Gleeblel500 thermal simulator. The effect of different deformation parameters on the grain size of dynamically recrystallized austenite was analyzed. A mathematical model of dynamic recrystallization and a material database of JB800 steel, whose tensile strength is above 800 MPa, were set up. A subprogram was compiled using Fortran language and called by Marc finite element software. A thermal coupled elastoplastic finite element model was established to simulate the compression process. The grain size of recrystallized austenite obtained by different recrystallization models was simulated. The results show that the optimized dynamic recrystallization model of JB800 bainitic steel has a higher precision and yields good agreement with metallographic observations.
Single pass compression tests were conducted on Gleeblel500 thermal simulator. The effect of different deformation parameters on the grain size of dynamically recrystallized austenite was analyzed. A mathematical model of dynamic recrystallization and a material database of JB800 steel, whose tensile strength is above 800 MPa, were set up. A subprogram was compiled using Fortran language and called by Marc finite element software. A thermal coupled elastoplastic finite element model was established to simulate the compression process. The grain size of recrystallized austenite obtained by different recrystallization models was simulated. The results show that the optimized dynamic recrystallization model of JB800 bainitic steel has a higher precision and yields good agreement with metallographic observations.
2008, vol. 15, no. 3, pp.
255-260.
https://doi.org/10.1016/S1005-8850(08)60048-1
Abstract:
Plain carbon steel Q215 honeycomb sandwich panels were manufactured by brazing in a vacuum furnace. Their characteristic parameters, including equivalent density, equivalent elastic modulus, and equivalent compressive strength along out-of-plane (z-direction) and in-plane (x-and y-directions), were derived theoretically and then determined experimentally by an 810 material test system. On the basis of the experimental data, the compressive stress-strain curves were given. The results indicate that the measurements of equivalent Young's modulus and initial compressive strength are in good agreement with calculations, and that the maximum compressive strain near to solid can be up to 0.5-0.6 along out-of-plane, 0.6-0.7 along in-plane. The strength-to-density ratio of plain carbon steel honeycomb panels is near to those of Al alloy hexagonal-honeycomb and 304L stainless steel square-honeycomb, but the compressive peak strength is greater than that of Al alloy hexagonal-honeycomb.
Plain carbon steel Q215 honeycomb sandwich panels were manufactured by brazing in a vacuum furnace. Their characteristic parameters, including equivalent density, equivalent elastic modulus, and equivalent compressive strength along out-of-plane (z-direction) and in-plane (x-and y-directions), were derived theoretically and then determined experimentally by an 810 material test system. On the basis of the experimental data, the compressive stress-strain curves were given. The results indicate that the measurements of equivalent Young's modulus and initial compressive strength are in good agreement with calculations, and that the maximum compressive strain near to solid can be up to 0.5-0.6 along out-of-plane, 0.6-0.7 along in-plane. The strength-to-density ratio of plain carbon steel honeycomb panels is near to those of Al alloy hexagonal-honeycomb and 304L stainless steel square-honeycomb, but the compressive peak strength is greater than that of Al alloy hexagonal-honeycomb.
2008, vol. 15, no. 3, pp.
261-266.
https://doi.org/10.1016/S1005-8850(08)60049-3
Abstract:
Cavitation erosion is an especially destructive and complex phenomenon. To understand its basic mechanism, the fatigue process of materials during cavitation erosion was investigated by numerical simulation technology. The loading spectrum used was generated by a spark-discharged electrode. Initiation crack life and true stress amplitude was used to explain the cavitation failure period and damage mechanism. The computational results indicated that the components of different materials exhibited various fatigue lives under the same external conditions. When the groove depth was extended, the initiation crack life decreased rapidly, while the true stress amplitude was increased simultaneously. This gave an important explanation to the accelerating material loss rate during cavitation erosion. However, when the groove depth was fixed and the length varied, the fatigue life became complex, more fluctuant than that happened in depth. The results also indicate that the fatigue effect of cavitation plays an important role in contributing to the formation and propagation of characteristic pits.
Cavitation erosion is an especially destructive and complex phenomenon. To understand its basic mechanism, the fatigue process of materials during cavitation erosion was investigated by numerical simulation technology. The loading spectrum used was generated by a spark-discharged electrode. Initiation crack life and true stress amplitude was used to explain the cavitation failure period and damage mechanism. The computational results indicated that the components of different materials exhibited various fatigue lives under the same external conditions. When the groove depth was extended, the initiation crack life decreased rapidly, while the true stress amplitude was increased simultaneously. This gave an important explanation to the accelerating material loss rate during cavitation erosion. However, when the groove depth was fixed and the length varied, the fatigue life became complex, more fluctuant than that happened in depth. The results also indicate that the fatigue effect of cavitation plays an important role in contributing to the formation and propagation of characteristic pits.
2008, vol. 15, no. 3, pp.
267-271.
https://doi.org/10.1016/S1005-8850(08)60050-X
Abstract:
The effect of Kovar alloy oxidized in simulated field atmosphere on its sealing with glass was studied in this article. After Kovar plates and pins were preoxidized in N2 with 0℃, 10℃ and 20℃ dew points at 1000℃ for different times, Fe304 and Fe203 existed in the oxidation products on Kovar surface, and the quantity of Fe203 increased with increasing dew point and oxidation time. Then they were sealed with borosilicate glass insulator at 1030℃ for 20 rain. The results indicated that the type and quantity of oxidation products would directly influence the quality of glass-to-metal seals. With the increase of oxidation products, gas bubbles in the glass insulator were more serious, the climbing height of glass along the pins was higher, and corrosion of Kovar pins caused from the molten glass was transformed from uniform to the localized.
The effect of Kovar alloy oxidized in simulated field atmosphere on its sealing with glass was studied in this article. After Kovar plates and pins were preoxidized in N2 with 0℃, 10℃ and 20℃ dew points at 1000℃ for different times, Fe304 and Fe203 existed in the oxidation products on Kovar surface, and the quantity of Fe203 increased with increasing dew point and oxidation time. Then they were sealed with borosilicate glass insulator at 1030℃ for 20 rain. The results indicated that the type and quantity of oxidation products would directly influence the quality of glass-to-metal seals. With the increase of oxidation products, gas bubbles in the glass insulator were more serious, the climbing height of glass along the pins was higher, and corrosion of Kovar pins caused from the molten glass was transformed from uniform to the localized.
2008, vol. 15, no. 3, pp.
272-275.
https://doi.org/10.1016/S1005-8850(08)60051-1
Abstract:
Bulk skutterudite (FeNi)xCo4-xSbl2 with x varying from 0.05 to 1.0 were prepared by mechanical alloying and spark plasma sintering (MA-SPS). The phases of the samples were analyzed by X-ray diffraction, and their thermoelectrical properties were tested by electrical constant instrument and laser thermal constant instrument. The experimental results show that bulk (FeNi)xCo4-xSb12 have the characteristic of typical semiconductor electricity. The addition of FeNi improves the electrical properties to a large extent; the samples of bulk (FeNi)xCo4-xSbl2 (x = 0.05-1.0) are n-type semiconducting materials; the increase of FeNi content can decrease the absolute value of Seebeck coefficient and therefore decrease the ZT value; FeNi with a higher content when x > 0.5 leads to an evident increase in thermal conductivity and also a decrease in ZT value. In general, for ZT value, the optimal added content of FeNi is 0.25-0.5 and the maximum ZT value is 0.2467 when x = 0.5 at 500℃.
Bulk skutterudite (FeNi)xCo4-xSbl2 with x varying from 0.05 to 1.0 were prepared by mechanical alloying and spark plasma sintering (MA-SPS). The phases of the samples were analyzed by X-ray diffraction, and their thermoelectrical properties were tested by electrical constant instrument and laser thermal constant instrument. The experimental results show that bulk (FeNi)xCo4-xSb12 have the characteristic of typical semiconductor electricity. The addition of FeNi improves the electrical properties to a large extent; the samples of bulk (FeNi)xCo4-xSbl2 (x = 0.05-1.0) are n-type semiconducting materials; the increase of FeNi content can decrease the absolute value of Seebeck coefficient and therefore decrease the ZT value; FeNi with a higher content when x > 0.5 leads to an evident increase in thermal conductivity and also a decrease in ZT value. In general, for ZT value, the optimal added content of FeNi is 0.25-0.5 and the maximum ZT value is 0.2467 when x = 0.5 at 500℃.
2008, vol. 15, no. 3, pp.
276-279.
https://doi.org/10.1016/S1005-8850(08)60052-3
Abstract:
An ultra-high strength aluminum alloy was produced by casting and then extruded to rods. The effect of heat treatment on the microstructure and mechanical properties of the alloy was investigated. After single ageing (120℃, 24 h), the tensile strength was 812.4 MPa and the elongation was 6.2%. After retrogression reaging (RRA), the tensile strength was 751.2 MPa and the elongation was 6.4%. The strengthening mechanism is considered as fine grain strengthening, substructure strengthening and dispersion strengthening by Al3(Sc, Zr).
An ultra-high strength aluminum alloy was produced by casting and then extruded to rods. The effect of heat treatment on the microstructure and mechanical properties of the alloy was investigated. After single ageing (120℃, 24 h), the tensile strength was 812.4 MPa and the elongation was 6.2%. After retrogression reaging (RRA), the tensile strength was 751.2 MPa and the elongation was 6.4%. The strengthening mechanism is considered as fine grain strengthening, substructure strengthening and dispersion strengthening by Al3(Sc, Zr).
2008, vol. 15, no. 3, pp.
280-284.
https://doi.org/10.1016/S1005-8850(08)60053-5
Abstract:
The alloy 5052 was welded by friction stir welding (FSW) and tungsten inert gas (TIG) welding. The effect of welding processes (FSW and TIG) on the fatigue properties of 5052 aluminum-welded joints was analyzed based on fatigue testing, and the S-N curve of the joints were established. The results show that the fatigue properties of FSW welded joints are better than those of TIG welded joints. The fatigue strength is determined as 65 MPa under 106 cycling of fatigue life. The microstructure of joints is fine grains and narrow HAZ zone in FSW welds, which inhibit the growth of cracks and produce high fatigue life compared with that of TIG welds. Fracture morphologies also show that the fatigue fracture results from weld defects.
The alloy 5052 was welded by friction stir welding (FSW) and tungsten inert gas (TIG) welding. The effect of welding processes (FSW and TIG) on the fatigue properties of 5052 aluminum-welded joints was analyzed based on fatigue testing, and the S-N curve of the joints were established. The results show that the fatigue properties of FSW welded joints are better than those of TIG welded joints. The fatigue strength is determined as 65 MPa under 106 cycling of fatigue life. The microstructure of joints is fine grains and narrow HAZ zone in FSW welds, which inhibit the growth of cracks and produce high fatigue life compared with that of TIG welds. Fracture morphologies also show that the fatigue fracture results from weld defects.
2008, vol. 15, no. 3, pp.
285-289.
https://doi.org/10.1016/S1005-8850(08)60054-7
Abstract:
To simulate irradiation damage, argon ion was implanted in the Zircaloy-4 with the fluence ranging from 1×1016 to 1×1017 cm-2, using accelerating implanter at an extraction voltage of 190 kV and liquid nitrogen temperature. Then the influence of argon ion implantation on the aqueous corrosion behavior of Zircaloy-4 was studied. The valence states of elements in the surface layer of the samples were analyzed using X-ray photoelectron spectroscopy (XPS). Transmission electron microscopy (TEM) was used to examine the microstructure of the argon-implanted samples. The potentiodynamic polarization technique was employed to evaluate the aqueous corrosion resistance of implanted Zircaloy-4 in 1 mol/L HzSO4 solution. It is found that there appear bubbles on the surface of the samples when the argon fluence is 1×1016 cm-2. The microstructure of argon-implanted samples changes from amorphous to partial amorphous, then to polycrystalline, and again to amorphous. The corrosion resistance of implanted samples linearly declines with the increase of fluence approximately, which is attributed to the linear increase of the irradiation damage.
To simulate irradiation damage, argon ion was implanted in the Zircaloy-4 with the fluence ranging from 1×1016 to 1×1017 cm-2, using accelerating implanter at an extraction voltage of 190 kV and liquid nitrogen temperature. Then the influence of argon ion implantation on the aqueous corrosion behavior of Zircaloy-4 was studied. The valence states of elements in the surface layer of the samples were analyzed using X-ray photoelectron spectroscopy (XPS). Transmission electron microscopy (TEM) was used to examine the microstructure of the argon-implanted samples. The potentiodynamic polarization technique was employed to evaluate the aqueous corrosion resistance of implanted Zircaloy-4 in 1 mol/L HzSO4 solution. It is found that there appear bubbles on the surface of the samples when the argon fluence is 1×1016 cm-2. The microstructure of argon-implanted samples changes from amorphous to partial amorphous, then to polycrystalline, and again to amorphous. The corrosion resistance of implanted samples linearly declines with the increase of fluence approximately, which is attributed to the linear increase of the irradiation damage.
2008, vol. 15, no. 3, pp.
290-296.
https://doi.org/10.1016/S1005-8850(08)60055-9
Abstract:
Bioactive glass is well known for its ability of bone regeneration, and sol-gel bioactive glass has many advantages compared with melt-derived bioactive glass. 3-D scaffold prepared by the sol-gel method is a promising substrate material for bone tissue engineering and large-scale bone repair. Porous sol-gel glass in the CaO-SiO2-P205 system with macropores larger than 100 μm was prepared by the addition of stearic acid as a pore former. The diameter of the pore created by the pore former varied from 100 to 300 μm. The formation of a hydroxyapatite layer on the glass was analyzed by studying the surface of the porous glass by scanning electron microscopy, energy dispersive spectroscopy, X-ray diffraction, and Raman spectra after they had been immersed in simulated body fluid (SBF) for some time, and the porous glass shows good bioactivity.
Bioactive glass is well known for its ability of bone regeneration, and sol-gel bioactive glass has many advantages compared with melt-derived bioactive glass. 3-D scaffold prepared by the sol-gel method is a promising substrate material for bone tissue engineering and large-scale bone repair. Porous sol-gel glass in the CaO-SiO2-P205 system with macropores larger than 100 μm was prepared by the addition of stearic acid as a pore former. The diameter of the pore created by the pore former varied from 100 to 300 μm. The formation of a hydroxyapatite layer on the glass was analyzed by studying the surface of the porous glass by scanning electron microscopy, energy dispersive spectroscopy, X-ray diffraction, and Raman spectra after they had been immersed in simulated body fluid (SBF) for some time, and the porous glass shows good bioactivity.
2008, vol. 15, no. 3, pp.
297-301.
https://doi.org/10.1016/S1005-8850(08)60056-0
Abstract:
The influence of four kinds of binders consisting of paraffin wax (PW), random-polypropylene (RPP), high-density polyethylene (HDPE), and stearic acid (SA) on the theological behavior of injection-molded SiC feedstocks was investigated over a temperature range of 150℃ to 180℃ and a shear rate range of 4 s-1 to 1259 s-1. The results showed that all the feedstocks exhibited pseudoplastic flow behavior. The wax-based binder of multipolymer components (PW-RPP-HDPE) exhibited better comprehensive rheological properties compared with the binder of monopolymer components (PW-RPP or PW-HDPE). The addition of 5wt% SA to the binder could reduce the viscosity of the feedstock but enhance the rheological stability by improving the wettability between the binder and the SiC powder. The binder of 65wt% PW + 15wt% HDPE + 15wt% RPP + 5wt% SA was found to be a better binder for microsized SiC injection molding.
The influence of four kinds of binders consisting of paraffin wax (PW), random-polypropylene (RPP), high-density polyethylene (HDPE), and stearic acid (SA) on the theological behavior of injection-molded SiC feedstocks was investigated over a temperature range of 150℃ to 180℃ and a shear rate range of 4 s-1 to 1259 s-1. The results showed that all the feedstocks exhibited pseudoplastic flow behavior. The wax-based binder of multipolymer components (PW-RPP-HDPE) exhibited better comprehensive rheological properties compared with the binder of monopolymer components (PW-RPP or PW-HDPE). The addition of 5wt% SA to the binder could reduce the viscosity of the feedstock but enhance the rheological stability by improving the wettability between the binder and the SiC powder. The binder of 65wt% PW + 15wt% HDPE + 15wt% RPP + 5wt% SA was found to be a better binder for microsized SiC injection molding.
2008, vol. 15, no. 3, pp.
302-306.
https://doi.org/10.1016/S1005-8850(08)60057-2
Abstract:
High toughness and reliable three-dimensional needled C/SiC composites were fabricated by chemical vapor infiltration (CVI). An approach to analyze the tensile behaviors at room temperature and the damage accumulation of the composites by means of acoustic emission was researched. Also the fracture morphology was examined by S-4700 SEM after tensile tests to prove the damage mechanism. The results indicate that the cumulative energy of acoustic emission (AE) signals can be used to monitor and evaluate the damage evolution in ceramic-matrix composites. The initiation of room-temperature tensile damage in C/SiC composites occurred with the growth of micro-cracks in the matrix at the stress level about 40% of the ultimate fracture stress. The level 70% of the fracture stress could be defined as the critical damage strength.
High toughness and reliable three-dimensional needled C/SiC composites were fabricated by chemical vapor infiltration (CVI). An approach to analyze the tensile behaviors at room temperature and the damage accumulation of the composites by means of acoustic emission was researched. Also the fracture morphology was examined by S-4700 SEM after tensile tests to prove the damage mechanism. The results indicate that the cumulative energy of acoustic emission (AE) signals can be used to monitor and evaluate the damage evolution in ceramic-matrix composites. The initiation of room-temperature tensile damage in C/SiC composites occurred with the growth of micro-cracks in the matrix at the stress level about 40% of the ultimate fracture stress. The level 70% of the fracture stress could be defined as the critical damage strength.
2008, vol. 15, no. 3, pp.
307-313.
https://doi.org/10.1016/S1005-8850(08)60058-4
Abstract:
In order to study the production of porous silica compacts by the combustion of rice husk ash (RHA) for tundish lining, the experimental design technique was used to evaluate the effect of firing temperature, soaking time and compaction pressure on controlling both the porosity degree and compressive strength of rice husk ash compacts. The results revealed that while the porosity degree of the compacts decreased with the increase in the entire studied parameters, the compressive strength exhibited another trend especially at a lower soaking time. At a lower soaking time, the increase in firing temperature led to a slight decrease in compressive strength and then increasing thereafter. The porous silica compacts having 30% porosity and 〉 2.5 MPa compressive strength suitable for tundish lining could be obtained from the combustion of rice husk ash compacts.
In order to study the production of porous silica compacts by the combustion of rice husk ash (RHA) for tundish lining, the experimental design technique was used to evaluate the effect of firing temperature, soaking time and compaction pressure on controlling both the porosity degree and compressive strength of rice husk ash compacts. The results revealed that while the porosity degree of the compacts decreased with the increase in the entire studied parameters, the compressive strength exhibited another trend especially at a lower soaking time. At a lower soaking time, the increase in firing temperature led to a slight decrease in compressive strength and then increasing thereafter. The porous silica compacts having 30% porosity and 〉 2.5 MPa compressive strength suitable for tundish lining could be obtained from the combustion of rice husk ash compacts.
2008, vol. 15, no. 3, pp.
314-319.
https://doi.org/10.1016/S1005-8850(08)60059-6
Abstract:
Lead-free piezoelectric (K0.5Na0.5)1-xLixNbO3 (x = 0at%-20at%) ceramics were synthesized by spark plasma sintering (SPS) at low temperature and the effects of LiNbO3 addition on its crystal structure and properties were also studied. When the Li content was less than 6at%, a single proveskite phase with the similar structure of (K0.5Na0.5)NbO3 was formed; and a secondary phase with K3Li2Nb5O15 structure was observed in the 6at% < x < 20at% compositional range. Furthermore, LiNbO3 existed as the third phase when the Li content was higher than 8at%. The grain sizes increased from 200-500 nm to 5-8 μm when the K3Li2Nb5O15 and LiNbO3 like phases were formed. With increasing Li content, the relative density of the ceramics first decreased from 97% to 93% and then kept constant. The piezoelectric coefficient d33, dielectric constant, and planner electromechanical coupling factor exhibited a decreasing tendency with increasing Li content because of the decrease in density and the formation of the secondary phase such as K3Li2Nb5O15 and LiNbO3. The formation of dense microstructure with a single phase is necessary in improving the properties of the (K0.5Na0.5)1-xLixNbO3 ceramics.
Lead-free piezoelectric (K0.5Na0.5)1-xLixNbO3 (x = 0at%-20at%) ceramics were synthesized by spark plasma sintering (SPS) at low temperature and the effects of LiNbO3 addition on its crystal structure and properties were also studied. When the Li content was less than 6at%, a single proveskite phase with the similar structure of (K0.5Na0.5)NbO3 was formed; and a secondary phase with K3Li2Nb5O15 structure was observed in the 6at% < x < 20at% compositional range. Furthermore, LiNbO3 existed as the third phase when the Li content was higher than 8at%. The grain sizes increased from 200-500 nm to 5-8 μm when the K3Li2Nb5O15 and LiNbO3 like phases were formed. With increasing Li content, the relative density of the ceramics first decreased from 97% to 93% and then kept constant. The piezoelectric coefficient d33, dielectric constant, and planner electromechanical coupling factor exhibited a decreasing tendency with increasing Li content because of the decrease in density and the formation of the secondary phase such as K3Li2Nb5O15 and LiNbO3. The formation of dense microstructure with a single phase is necessary in improving the properties of the (K0.5Na0.5)1-xLixNbO3 ceramics.
2008, vol. 15, no. 3, pp.
320-323.
https://doi.org/10.1016/S1005-8850(08)60060-2
Abstract:
To investigate the effect of clay concentration on the structures and properties of bisphenol-A epoxy/nanoclay composites, three composites with organoclay concentrations of 2.5wt%, 5wt%, and 7.5wt% of the epoxy resin were prepared by in-situ polymerization under mechanical stirring followed by ultrasonic treatment. The clay aggregates on micro-scale indicate the absence of fully exfoliated nanocomposites. The layer space decreases with the increase of clay concentration, which suggests that the exfoliation would be constrained if more clay is added as the ultrasonic force is exerted. The thermal decomposition temperature remains almost unchanged with the increase of clay concentration. The glass transition temperature of the composites decreases slightly with the increase of clay concentration, whereas the storage modulus increases with the increase of clay concentration.
To investigate the effect of clay concentration on the structures and properties of bisphenol-A epoxy/nanoclay composites, three composites with organoclay concentrations of 2.5wt%, 5wt%, and 7.5wt% of the epoxy resin were prepared by in-situ polymerization under mechanical stirring followed by ultrasonic treatment. The clay aggregates on micro-scale indicate the absence of fully exfoliated nanocomposites. The layer space decreases with the increase of clay concentration, which suggests that the exfoliation would be constrained if more clay is added as the ultrasonic force is exerted. The thermal decomposition temperature remains almost unchanged with the increase of clay concentration. The glass transition temperature of the composites decreases slightly with the increase of clay concentration, whereas the storage modulus increases with the increase of clay concentration.
2008, vol. 15, no. 3, pp.
324-329.
https://doi.org/10.1016/S1005-8850(08)60061-4
Abstract:
Three-dimensional finite element models were developed to analyze 304 stainless steel rod and wire hot continuous rolling process with the help of MSC.Marc software. The entire 30-pass deformation process and the actual parameters of production line were taken into account. Static and dynamic procedures were used to study the continuous rolling process with the aid of the thermo-mechanical coupled FEM of elastic-plasticity. The properties of billets, such as deformation, temperature field and rolling force, were mainly discussed. The simulation results of temperature agree well with the measured values. Comparisons of the analysis results obtained using static implicit method and dynamic implicit method were presented. It is shown that static implicit procedure is more accurate than dynamic implicit procedure and is able to simulate the rolling process with a lower speed, such as a roughing mill. Whereas, dynamic analysis shows a higher efficiency than static analysis and is fit for simulating the rolling process with a higher speed, such as a finishing mill.
Three-dimensional finite element models were developed to analyze 304 stainless steel rod and wire hot continuous rolling process with the help of MSC.Marc software. The entire 30-pass deformation process and the actual parameters of production line were taken into account. Static and dynamic procedures were used to study the continuous rolling process with the aid of the thermo-mechanical coupled FEM of elastic-plasticity. The properties of billets, such as deformation, temperature field and rolling force, were mainly discussed. The simulation results of temperature agree well with the measured values. Comparisons of the analysis results obtained using static implicit method and dynamic implicit method were presented. It is shown that static implicit procedure is more accurate than dynamic implicit procedure and is able to simulate the rolling process with a lower speed, such as a roughing mill. Whereas, dynamic analysis shows a higher efficiency than static analysis and is fit for simulating the rolling process with a higher speed, such as a finishing mill.
2008, vol. 15, no. 3, pp.
330-334.
https://doi.org/10.1016/S1005-8850(08)60062-6
Abstract:
A modified temperature-phase transformation field coupled nonlinear mathematical model was made and used in computer simulation on the controlled cooling of 82B high-speed rods. The surface temperature history and volume fraction of pearlite as well as the phase transformation history were simulated by using the finite element software Marc/Mentat. The simulated results were compared with the actual measurement and the agreement is good which can validate the presented computational models.
A modified temperature-phase transformation field coupled nonlinear mathematical model was made and used in computer simulation on the controlled cooling of 82B high-speed rods. The surface temperature history and volume fraction of pearlite as well as the phase transformation history were simulated by using the finite element software Marc/Mentat. The simulated results were compared with the actual measurement and the agreement is good which can validate the presented computational models.
2008, vol. 15, no. 3, pp.
335-338.
https://doi.org/10.1016/S1005-8850(08)60063-8
Abstract:
The effects of oil film on the rolled surface, including surface roughness and topography, were investigated during cold rolling of aluminum strips. Various mineral oils with viscosities from 0.10 to 1.6 Pa.s were used to obtain different oil film thicknesses. Results from experiment and calculation show that the thicker oil film protects the initial roughening surface so that it leads to an increase in roughness of the rolled surface, in particular when the surface roughness has the character of direction. The rolled surface roughness was determined by λ, which is the ratio of oil film thickness to the combined surface roughness. When λ > 3, the rolled surface roughness increases rapidly with the increase in oil viscosity, whereas the surface roughening has already occurred when λ < 3, but the increase of the rolled surface roughness with increasing viscosity is not distinct.
The effects of oil film on the rolled surface, including surface roughness and topography, were investigated during cold rolling of aluminum strips. Various mineral oils with viscosities from 0.10 to 1.6 Pa.s were used to obtain different oil film thicknesses. Results from experiment and calculation show that the thicker oil film protects the initial roughening surface so that it leads to an increase in roughness of the rolled surface, in particular when the surface roughness has the character of direction. The rolled surface roughness was determined by λ, which is the ratio of oil film thickness to the combined surface roughness. When λ > 3, the rolled surface roughness increases rapidly with the increase in oil viscosity, whereas the surface roughening has already occurred when λ < 3, but the increase of the rolled surface roughness with increasing viscosity is not distinct.
2008, vol. 15, no. 3, pp.
339-343.
https://doi.org/10.1016/S1005-8850(08)60064-X
Abstract:
On the basis of the analysis of solidification interval and temperature distribution of components manufactured by the squeeze casting method, formulas for calculating the solidification interval and compaction pressure were deduced according to the principal request that the compaction pressure should be equal to or greater than the plastic deformation resistance of the forming component when solidification ended. The solidification interval was proven to be associated with many factors, such as weight of the component, specific heat of the alloy, latent heat, pouring temperature, component temperature at the end of solidification and heat-transfer coefficients. The compaction pressure was related to the strain rate, deformation temperature, and dimension of the de- forming component. The solidification interval and compaction pressure calculated by the formulas deduced in this article were adopted in the production of 45 steel bidirectional chapiter valves, and components with excellent oerformance were manufactured.
On the basis of the analysis of solidification interval and temperature distribution of components manufactured by the squeeze casting method, formulas for calculating the solidification interval and compaction pressure were deduced according to the principal request that the compaction pressure should be equal to or greater than the plastic deformation resistance of the forming component when solidification ended. The solidification interval was proven to be associated with many factors, such as weight of the component, specific heat of the alloy, latent heat, pouring temperature, component temperature at the end of solidification and heat-transfer coefficients. The compaction pressure was related to the strain rate, deformation temperature, and dimension of the de- forming component. The solidification interval and compaction pressure calculated by the formulas deduced in this article were adopted in the production of 45 steel bidirectional chapiter valves, and components with excellent oerformance were manufactured.
2008, vol. 15, no. 3, pp.
344-351.
https://doi.org/10.1016/S1005-8850(08)60065-1
Abstract:
In a round-oval-round pass rolling sequence, the cross-section profile of an outgoing workpiece was predicted first after getting the maximum spread. The concept "critical point on the contact boundary" was proposed and the coordinates of the critical point were solved. The equivalent contact section area was represented and the mean roll radius was determined. The validity of this model was examined by alloy bar rolling experiment and rigid-plastic FEM simulation. Compared with the existing models, the mean roll radius obtained by this model is similar to experiment data.
In a round-oval-round pass rolling sequence, the cross-section profile of an outgoing workpiece was predicted first after getting the maximum spread. The concept "critical point on the contact boundary" was proposed and the coordinates of the critical point were solved. The equivalent contact section area was represented and the mean roll radius was determined. The validity of this model was examined by alloy bar rolling experiment and rigid-plastic FEM simulation. Compared with the existing models, the mean roll radius obtained by this model is similar to experiment data.
Work roll thermal contour prediction model of nonoriented electrical steel sheets in hot strip mills
2008, vol. 15, no. 3, pp.
352-356.
https://doi.org/10.1016/S1005-8850(08)60066-3
Abstract:
The demands for profile and flatness of nonoriented electrical steels are becoming more and more severe. The temperature field and thermal contour of work rolls are the key factors that affect the profile and flatness control in the finishing trains of the hot rolling. A theoretic mathematical model was built by a two-dimensional finite difference to calculate the temperature field and thermal contour at any time within the entire rolling campaign in the hot rolling process. To improve the calculating speed and precision, some special solutions were introduced, including the development of this model, the simplification of boundary conditions, the computation of heat transfer coefficient, and the narrower mesh along the edge of the strip. The effects of rolling pace and work roll shifting on the temperature field and thermal contour of work rolls in the hot rolling process were demonstrated. The calculated results of the prediction model are in good agreement with the measured ones and can be applied to guiding profile and flatness control of nonoriented electrical steel sheets in hot strip mills.
The demands for profile and flatness of nonoriented electrical steels are becoming more and more severe. The temperature field and thermal contour of work rolls are the key factors that affect the profile and flatness control in the finishing trains of the hot rolling. A theoretic mathematical model was built by a two-dimensional finite difference to calculate the temperature field and thermal contour at any time within the entire rolling campaign in the hot rolling process. To improve the calculating speed and precision, some special solutions were introduced, including the development of this model, the simplification of boundary conditions, the computation of heat transfer coefficient, and the narrower mesh along the edge of the strip. The effects of rolling pace and work roll shifting on the temperature field and thermal contour of work rolls in the hot rolling process were demonstrated. The calculated results of the prediction model are in good agreement with the measured ones and can be applied to guiding profile and flatness control of nonoriented electrical steel sheets in hot strip mills.
2008, vol. 15, no. 3, pp.
357-361.
https://doi.org/10.1016/S1005-8850(08)60067-5
Abstract:
SmartCrown was a new system developed by VAI for improving the strip profile and flatness control first applied in 1700 mm tandem cold rolling mills at Wuhan Iron & Steel (Group) Corporation (WISCO). After tracing and testing, the application of the conventional crown backup roll matching the SmartCrown work roll of the production mill led to heavy and nonuniform wear, and the edge spalling of the backup roll often occurred. A 3-dimension finite element model of roll stacks was established, which was used to analyze the above-mentioned problems, and it was found that the main reason was the highly nonuniform contact pressure distribution between the work roll and the backup roll. A new FSR (flexible shape backup roll) was developed and applied in 1700 mm tandem cold rolling mills. A lot of good actual effects of FSR, such as evident improvement in profile and flatness of strips, non-occurring edge spalling, wear uniform, and remarkable decrease in roll consumption were validated by long-term industrial applications.
SmartCrown was a new system developed by VAI for improving the strip profile and flatness control first applied in 1700 mm tandem cold rolling mills at Wuhan Iron & Steel (Group) Corporation (WISCO). After tracing and testing, the application of the conventional crown backup roll matching the SmartCrown work roll of the production mill led to heavy and nonuniform wear, and the edge spalling of the backup roll often occurred. A 3-dimension finite element model of roll stacks was established, which was used to analyze the above-mentioned problems, and it was found that the main reason was the highly nonuniform contact pressure distribution between the work roll and the backup roll. A new FSR (flexible shape backup roll) was developed and applied in 1700 mm tandem cold rolling mills. A lot of good actual effects of FSR, such as evident improvement in profile and flatness of strips, non-occurring edge spalling, wear uniform, and remarkable decrease in roll consumption were validated by long-term industrial applications.
2008, vol. 15, no. 3, pp.
362-365.
https://doi.org/10.1016/S1005-8850(08)60068-7
Abstract:
The coiling temperature control of a typical steel strip mill was investigated. Due to the high speed of a strip and complex circumstance, it is very hard to set up a cooling model with high accuracy. A simplified dynamic model was proposed, based on which a cooling control scheme with combined feedforward, feedback and adaptive algorithms was developed. Meanwhile, the genetic algorithms were used for the optimization of model parameters. Simulations with a model validated using actual plant data were conducted, and the results have confirmed the effectiveness of the proposed control methods. At last, a simulation system for coiling temperature control was developed. It can be used for new product trials and newcomer training.
The coiling temperature control of a typical steel strip mill was investigated. Due to the high speed of a strip and complex circumstance, it is very hard to set up a cooling model with high accuracy. A simplified dynamic model was proposed, based on which a cooling control scheme with combined feedforward, feedback and adaptive algorithms was developed. Meanwhile, the genetic algorithms were used for the optimization of model parameters. Simulations with a model validated using actual plant data were conducted, and the results have confirmed the effectiveness of the proposed control methods. At last, a simulation system for coiling temperature control was developed. It can be used for new product trials and newcomer training.
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