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Residual Stress During Stamping-Forging of 2024 Aluminum Alloy Sheet 2024铝合金板材冲压成形过程中的残余应力
Pub Date : 2018-11-16 DOI: 10.1201/9781351045636-140000209
Xinyun Wang, L. Deng, Jinbo Li
Stamping-forging processing can significantly reduce the residual stress of sheet metal parts. First, the variation of residual stress field during stamping-forging processing and the influence of relative bending radii and forming temperature on the residual stresses of stamping-forged V-shaped parts have been studied by finite-element analysis. Then, the stamping-forging processing has been employed in the forming of 2024 aluminum alloy square cups with nonuniform thickness to investigate the effects of process parameters, such as punch radius, die entrance radius, and die corner radius, on the residual stresses of stamping-forged square cups. The optimum process parameters of stamping-forging have been obtained, which can produce square cups with low residual stresses, that is, the maximum residual stress value can be reduced from 190 MPa for deep drawn square cups to around 60 MPa for stamping-forged square cups. Therefore, it is indicated that the stamping-forging processing can significantly reduce the residual stress of sheet metal parts.
冲压锻压加工可以显著降低钣金件的残余应力。首先,通过有限元分析,研究了冲压成形过程中残余应力场的变化规律,以及相对弯曲半径和成形温度对冲压成形v形件残余应力场的影响。在此基础上,对厚度不均匀的2024铝合金方杯进行了压锻成形,研究了冲床半径、模口半径、模角半径等工艺参数对压锻方杯残余应力的影响。获得了最优的压锻工艺参数,可生产出残余应力较低的方杯,即最大残余应力值可从深拉方杯的190 MPa降至冲压锻造方杯的60 MPa左右。结果表明,锻压加工能显著降低钣金件的残余应力。
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引用次数: 0
Control Principle of Thermal Spray Process 热喷涂过程控制原理
Pub Date : 2018-11-16 DOI: 10.1201/9781351045636-120050685
M. Fukumoto
In general, an essential target in the research and development of material process lies in how to establish the controlling principle on a designated material process. In this article, the current situation in the controlling of an ordinary thermal spray process, which is a representative of a thick coating formation process using particle deposition, is reviewed. Precise observation results were introduced to the ordinary thermal spray process. In the flattening behavior of the sprayed particle onto the substrate surface, critical conditions were recognized in both the substrate temperature and the ambient pressure. A transition temperature, Tt, and a transition pressure, Pt, were defined and introduced, respectively, for these critical conditions. Three-dimensional transition curvature, by combining both the Tt and the Pt dependence, was proposed as a control principle of the thermal spray process. Furthermore, particle melting in the ordinary thermal spray process has been recognized as a negative process. To overcome this problem, a new direction in coating technology development by using non-fusion solid particles has been tried recently, which is typically called the cold spray or the aerosol deposition process. As these processes have common characteristic for all, namely, a thick coating formation by the deposition of several micron-sized particles, the present state of the art, academic/technological issues, and the prospects for the future of these coating formation processes is comprehensively summarized in this article.
一般来说,材料过程研究和开发的一个重要目标是如何建立对指定材料过程的控制原则。本文综述了以颗粒沉积技术为代表的普通热喷涂工艺的控制现状。介绍了普通热喷涂工艺的精确观测结果。在喷射颗粒在基材表面的压扁行为中,基材温度和环境压力都是临界条件。在这些临界条件下,分别定义和引入了转变温度Tt和转变压力Pt。结合对Tt和Pt的依赖,提出了三维过渡曲率作为热喷涂过程的控制原理。此外,在普通热喷涂过程中,颗粒熔化已被认为是一个负过程。为了克服这一问题,近年来人们尝试了使用非熔合固体颗粒作为涂层技术发展的新方向,这一技术通常被称为冷喷涂或气溶胶沉积工艺。由于这些工艺具有共同的特点,即通过沉积几个微米大小的颗粒形成厚涂层,因此本文对这些涂层形成工艺的现状,学术/技术问题以及未来的前景进行了全面总结。
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引用次数: 0
Hardness–Yield Strength Relationships in Al-Zn-Mg(-Cu) Alloys Al-Zn-Mg(-Cu)合金的硬度-屈服强度关系
Pub Date : 2018-11-16 DOI: 10.1201/9781351045636-140000313
M. Tiryakioğlu
Mean pressure developed during Vickers and Rockwell hardness testing of Al-Zn-MgCualloys is reviewed. Relationships between mean pressure and yield strength are introduced for these alloys by using both Vickers and Rockwell hardness data from the literature. Results have shown that the slope of the mean pressure–yield strength relationships is 0.355 for Vickers tests and 0.264 for Rockwell B tests. The y-intercepts calculated for best fits are all negative, implying that the representative strains in both tests have exceeded the yield strain. Results also have indicated that mean pressure is affected by the indenter geometry and therefore is not a universal hardness number.
综述了al - zn - mgcualloy在维氏和洛氏硬度试验中产生的平均压力。通过使用文献中的维氏和洛氏硬度数据,介绍了这些合金的平均压力和屈服强度之间的关系。结果表明,维氏试验的平均压力-屈服强度关系斜率为0.355,罗克韦尔B试验的斜率为0.264。为最佳拟合计算的y截距均为负,这意味着两个试验中的代表性应变均超过屈服应变。结果还表明,平均压力受压头几何形状的影响,因此不是一个通用的硬度数。
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引用次数: 0
Recrystallization and Grain Growth 再结晶和晶粒长大
Pub Date : 2018-11-16 DOI: 10.1201/9781351045636-140000432
W. Mao
Recrystallization occurs in all heating processes of aluminum alloys subjected to hot or cold deformation. The chemical, physical and mechanical property of aluminum alloys is dependent on recrystallization and grain growth. This article provides an overview of the mechanism and characteristics of deformation microstructure and defect structures in aluminum alloys.
再结晶发生在铝合金受热变形或冷变形的所有加热过程中。铝合金的化学、物理和机械性能取决于再结晶和晶粒长大。本文综述了铝合金变形组织和缺陷组织形成的机理和特点。
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引用次数: 1320
Iron: Removal from Aluminum 铁:从铝中去除
Pub Date : 2018-11-16 DOI: 10.1201/9781351045636-140000434
Lifeng Zhang, Jianwei Gao, L. Damoah, D. Robertson
In this paper, the Fe-rich phases in and their detrimental effect on aluminum alloys are summarized. The existence of brittle platelet β-Fe-rich phases lowers the mechanical properties of aluminum alloys. The methods to neutralize the detrimental effect of iron are discussed. The use of high cooling rate, solution heat treatment, and addition of elements such as Mn, Cr, Be, Co, Mo, Ni, V, W, Cu, Sr, or the rare earth elements Y, Nd, La, and Ce are reported to modify the platelet Fe-rich phases in aluminum alloys. The mechanism of the modification is briefly described. Technologies to remove iron from aluminum are reviewed extensively. The precipitation and removal of Fe-rich phases (sludge) are discussed. The dense phases can be removed by methods such as gravitational separation, electromagnetic (EM) separation, and centrifuge. Other methods include electrolysis, electro-slag refining, fractional solidification, and fluxing refining. The expensive three-layer cell electrolysis process is the most successful technique to remove iron from aluminum so far.
本文综述了铝合金中富铁相及其对铝合金的危害。脆性血小板β-富铁相的存在降低了铝合金的力学性能。讨论了消除铁的有害影响的方法。据报道,采用高冷却速率、固溶热处理和添加Mn、Cr、Be、Co、Mo、Ni、V、W、Cu、Sr等元素或稀土元素Y、Nd、La和Ce等元素可以改性铝合金中的富铁血小板相。简要介绍了改性的机理。对铝中除铁技术进行了综述。讨论了富铁相(污泥)的沉淀与去除。密相可以通过重力分离、电磁分离和离心机等方法去除。其他方法包括电解、电渣精炼、分级凝固和熔剂精炼。昂贵的三层电解槽电解工艺是迄今为止从铝中去除铁的最成功的技术。
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引用次数: 0
Surface Chemistry of Adhesion to Aluminum 铝的表面粘附化学
Pub Date : 2018-11-16 DOI: 10.1201/9781351045636-140000441
M. Hyland
Understanding the microstructure and chemistry of the aluminum surface is the key to designing coating and structural bonding systems that endure. The focus of this article is the examination of concepts common to all polymer/aluminum bonding applications and to discuss some common surface treatments alter the surface chemistry and microstructure and how these treatments affect adhesion. Topics covered in this review include: discussion of the untreated aluminum surface, adhesion to aluminum surfaces, prevention of hydration of the bonded interface, and pretreatments,
了解铝表面的微观结构和化学性质是设计耐用涂层和结构粘合系统的关键。本文的重点是检查所有聚合物/铝粘合应用中常见的概念,并讨论一些常见的表面处理会改变表面化学和微观结构,以及这些处理如何影响粘合。本综述涵盖的主题包括:讨论未经处理的铝表面,与铝表面的粘附,防止结合界面的水化和预处理。
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引用次数: 2
Metallography of Aluminum Alloys: Atlas of Microstructures 铝合金金相学:显微组织图谱
Pub Date : 2018-11-16 DOI: 10.1201/9781351045636-140000203
S. Murty, Sushant K. Manwatkar, P. Narayanan
Microstructure plays an important role in obtaining the desired properties in metallic materials in general and aluminum alloys in particular. Mechanical properties of aluminum alloys can be significantly altered by changing the microstructure. No other alloy system can boast of as many temper conditions as aluminum alloys. With the progress in the understanding of microstructure–mechanical property relationships in these materials, “tailor made” alloys to meet specific demands are being industrially developed. The broad spectrum of aluminum alloys in wide range of temper conditions offer materials with widely varying mechanical properties for structural designers. In order to select aluminum alloys with the desired properties for the intended application, it is essential to understand the role of microstructure under actual service conditions. It is in this context “Metallography of aluminum alloys” becomes very important. This chapter provides an insight in to the microstructural evolution of aluminum alloys from the as-cast condition to the final product. Typical examples of microstructural evolution in different aluminum alloys under various thermomechanical conditions are presented here. An atlas of microstructures of commercial and experimental wrought and cast aluminum alloys is presented in an appendix to this book. This appendix includes optical photomicrographs of both cast and wrought alloys and scanning electron micrographs of polished surfaces as well as fracture surfaces of various aluminum alloys as well as transmission electron micrographs as separate annexure. Readers are encouraged to go through the optical microstructures and fractographs along with this chapter for better understanding of the evolution of microstructure as a function of alloying additions, thermomechanical processing conditions, and fracture behavior under tension.
在金属材料,特别是铝合金中,微观组织对获得理想的性能起着重要的作用。通过改变铝合金的微观组织,可以显著改变铝合金的力学性能。没有其他合金系统可以自夸像铝合金一样多的回火条件。随着对这些材料的微观结构-力学性能关系的理解的进步,满足特定需求的“定制”合金正在工业化开发。广泛的铝合金在各种回火条件下为结构设计师提供了具有广泛不同机械性能的材料。为了选择具有预期应用所需性能的铝合金,有必要了解微观组织在实际使用条件下的作用。正是在这种背景下,“铝合金金相学”变得十分重要。本章提供了铝合金从铸态到最终产品的微观组织演变的见解。本文给出了不同热力学条件下不同铝合金微观组织演变的典型实例。商业和实验锻造和铸造铝合金的显微结构的地图集是在本书的附录中提出的。本附录包括铸造和锻造合金的光学显微照片,抛光表面的扫描电子显微照片以及各种铝合金的断口表面,以及作为单独附件的透射电子显微照片。我们鼓励读者阅读本章的光学显微结构和断口图,以便更好地理解微观结构的演变,作为合金添加量、热机械加工条件和拉伸下断裂行为的函数。
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引用次数: 0
Quenching of Aluminum Alloys 铝合金的淬火
Pub Date : 2018-11-16 DOI: 10.1201/9781351045636-140000336
W. Mattos, B. Rivolta, G. Totten, L. Meekisho, L. Canale
This article aims to describe the media, procedures, and techniques applied to quenching for heat treatment of aluminum alloys besides problems related to this specific process. This article presents important topics such as quench sensitivity, cooling curves analysis, showing experimental apparatus details, influence of probe format and comparison between probe types used in quenching, and problems related to surface oxidation due quenching. Polymer quenchants types are analyzed besides quenching parameters. There is a discussion related to surface rewetting and its importance for quenching successful. Different quenching process are presented like “uphill” process comparing as cryo quenching, ultrasonic agitation, and ionic liquids besides topics related to corrosion types and residual stress after quenching.
本文旨在介绍铝合金热处理中淬火的介质、程序和技术,以及与这一特定工艺有关的问题。本文介绍了诸如淬火灵敏度、冷却曲线分析、显示实验装置细节、探针形式的影响和在淬火中使用的探针类型的比较以及由于淬火引起的表面氧化的相关问题等重要主题。分析了聚合物猝灭剂的种类及猝灭参数。讨论了表面再润湿及其对淬火成功的重要性。除了讨论了淬火后的腐蚀类型和残余应力外,还介绍了不同的淬火工艺,如冷淬火、超声搅拌、离子液体等“上坡”淬火工艺的比较。
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引用次数: 0
Designing for Aluminum 铝的设计
Pub Date : 2018-11-16 DOI: 10.1201/9781351045636-140000403
H. Kuhn
In the design of aluminum forgings, the designer must specify the material and process and geometric details so that the component will meet performance requirements. Forging produces parts of high integrity because the process sequences refines and homogenizes metallurgical structure, elimination of material defects assuring maximum material strength. This article specifically addresses the following forging design considerations: material aspects, geometrical aspects, cost aspects, forging methods, process mechanics, and forged part design.
在铝制锻件的设计中,设计者必须指定材料和工艺以及几何细节,以使部件满足性能要求。锻造生产出高完整性的零件,因为工艺序列细化和均匀化了冶金组织,消除了材料缺陷,确保了材料的最大强度。本文具体论述了以下锻件设计考虑因素:材料方面、几何方面、成本方面、锻造方法、工艺力学和锻件设计。
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引用次数: 0
High-Pressure Die-Cast AlSi9Cu3(Fe) Alloys: Models for Casting Defects and Mechanical Properties 高压压铸AlSi9Cu3(Fe)合金:铸造缺陷和力学性能模型
Pub Date : 2018-11-16 DOI: 10.1201/9781351045636-140000278
G. Timelli
The effect of casting defects on the tensile properties of high-pressure die-cast AlSi9Cu3(Fe) alloys is reported. A series of U-shaped structural components has been die-cast using a combination of injection parameters and pouring temperatures in order to produce different types and amount of casting defects throughout the casting. The results reveal how the die-castings contain defects, primarily pores and oxides, and their presence and distribution are highly sensitive to the process conditions. The tensile properties are affected by the amount and distribution of defects and can be determined by the defect area fraction. The influence of casting defects on the tensile properties are investigated through a theoretical verification based both on constitutive and stochastic models. The analytical approach, based on the Ghosh constitutive model of tension instability, correctly indicates the trends of the experimental results, while the Weibull statistics evidences how the scale parameter and the Weibull modulus are strongly affected by the casting conditions.
报道了铸造缺陷对高压压铸AlSi9Cu3(Fe)合金拉伸性能的影响。为了在整个铸件过程中产生不同类型和数量的铸造缺陷,使用注射参数和浇注温度的组合来压铸一系列u形结构部件。结果表明,压铸件中含有缺陷,主要是气孔和氧化物,它们的存在和分布对工艺条件高度敏感。拉伸性能受缺陷数量和分布的影响,可由缺陷面积分数决定。通过基于本构模型和随机模型的理论验证,研究了铸件缺陷对拉伸性能的影响。基于Ghosh拉伸失稳本构模型的分析方法正确地反映了试验结果的趋势,而Weibull统计量则证明了尺度参数和Weibull模量受浇筑条件的强烈影响。
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引用次数: 0
期刊
Encyclopedia of Aluminum and Its Alloys
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