The mold filling and solidification process of a marine propeller hub were simulated using ProCAST. Three casting processes–gravity casting, centrifugal casting and low pressure casting–were compared in order to get the best process. The heat transfer coefficient of the casting/mold interface was determined using a reverse method. The simulated results of velocity, temperature and shrinkage porosity distribution were discussed in detail for the three casting processes. A smooth filling was found in all three casting processes, especially the low pressure casting exhibiting a better filling performance than the other two, but the solidification processes were different. The casting did not experience the sequential solidification, and the feeding paths were blocked, leading to shrinkage porosity defects in the riser and the bottom of the casting in gravity casting and in the upper zone of the casting in low pressure casting. While, the sequential solidification was well controlled in the solidification process of centrifugal casting, and majority of the shrinkage porosity defects can only be observed in the riser. It could be concluded that the centrifugal casting process is the most suitable casting process for the production of propeller hub body. The casting experiments verified the simulation results, and a defect-free propeller hub was obtained by centrifugal casting with a rotational speed of 150 r·min-1.
Wang TongminLi JiaWu LiJie JinchuanCao ZhiqiangKang Huijun
A modified horizontal continuous casting process under the electromagnetic field was proposed for preparing AA3003/ AA4045 clad composite hollow billets. To investigate the effect of electromagnetic field on this process, a comprehensive three-dimensional model was developed. Two cases with and without electromagnetic field were compared using the simulations. When rotating electromagnetic stirring is applied, the flow pattern of fluid melt is greatly modified; the mushy zone becomes much wider, the temperature profile becomes more uniform, and the solid fraction decreases for both the external and internal alloy melt layers. These modifications are beneficial for the formation of a bimetal interface and fine and uniform grain structure of the clad composite hollow billet. Experiments conducted using the same electrical and casting parameters as the simulations verify that under the electromagnetic field the microstructure of the clad composite hollow billet becomes fine and the diffusion of the elements at the interface is promoted.
The three dimensional(3D) microstructures of Al-Bi alloys with different grain refiners(Al-5Ti-B, Al-3B and Al-3Ti) have been studied using synchrotron X-ray microtomography. The relationships between the microstructures and the corresponding wear behavior are verified through the friction and wear tests. The worn surfaces of the samples with grain refiners tested under 15 and 60 N loads are analyzed using Scanning Electron Microscopy(SEM). The results indicate that the addition of grain refiners is beneficial to the size and distribution of the Bi-rich particles in Al-Bi alloys. Compared with Al-5Ti-B and Al-3B grain refiners, the Bi-rich particles are more uniformly distributed and spherical with finer size with the addition of Al-3Ti grain refiner. The refinement renders the Al-20wt%Bi alloy refined by Al-3Ti the superior wear resistance with respect to those refined by Al-5Ti-B and Al-3B grain refiners, corresponding to the microstructures with fine and uniformly distributed Bi-rich particles in the Al matrix.
WANG TongMinCAO FeiCHEN ZongNingKANG HuiJunZHU JingFU YaNanXIAO TiQiaoLI TingJu
A three-dimensional finite-element model has been established to investigate the thermal behavior of the medium-thick slab copper casting mold with different cooling water slot designs. The mold wall temperatures measured using thermocouples buried in different positions of the mold with the original designed cooling system were analyzed to determine the corresponding heat flux profile. This profile was then used for simulation to predict the temperature distribution and the thermal stress distribution of the molds. The predicted temperatures during operation matched the plant measurements. The results showed that the maximum temperature, about 635 K in the wide hot surface, was found about 60 mm below the meniscus and 226 mm from the center of the mold. For the mold with the type I modified design, there was an insignificant decrease in temperature of about 5 K, and for the mold with the type II modified design, the maximum temperature was decreased by about 15 K and the temperature of the hot surface was distributed more uniformly along the length of the mold. The corresponding maximum thermal stress at the hot surface of the mold was reduced from 408 MPa to 386 MPa with the type II modified design. The results indicated that the modified design II is beneficial to the increase of mold life and the quality of casting slabs.
Xue-lin YinLi WuJun-jia ZhangHui-jun KangZong-ning ChenJin-song ChenZhi-qiang CaoTing-ju LiTong-min Wang
The coarsening process of second-phase droplet in solidifying Al-20 wt% Bi immiscible alloy is in situ studied using synchrotron radiation imaging technology.The collision-induced coarsening and Ostwald coarsening phenomena are directly observed and analyzed.It is found that through observation,collision-induced coarsening phenomenon occurs between droplets with little difference in radius,while Ostwald coarsening phenomenon occurs among droplets with much difference in radius.Moreover,the coarsening rate of Ostwald coarsening is much higher than that of collision-induced coarsening.
Hui-Jun KangPeng ZhouFei CaoJing ZhuYa-Nan FuWan-Xia HuangTi-Qiao XiaoTong-Min Wang
Three-dimensional morphology and formation process of icosahedral quasicrystal phase have been investigated in a melt-spun AI-18Mn alloy （in wt%）. Three distinct layers corresponding to varying temperature gradient have been observed on the cross section of the ribbons. 3D morphologies of cellular and dendritic icosahedral phase have been obtained through electro-etching. A model has been proposed to describe the formation process of the icosahedral phase and a-A1 during the rapid solidification. The icosahedral phases are primarily precipitated from the melt into fine cellular and dendritic particles, and subsequently engulfed by the a-A1 which propagates in a planar morphology.
