Effects of the deep rolling process on the surface roughness and properties of an Al-3vol%SiC nanoparticle nanocomposite fabricated by mechanical milling and hot extrusion

Deep rolling is one of the most widely used surface mechanical treatments among several methods used to generate compressive residual stress. This process is usually used for axisymmetric components and can lead to improvements of the surface quality, dimensional accuracy, and mechanical properties. In this study, we deduced the appropriate deep rolling parameters for Al-3vol%SiC nanocomposite samples using roughness and microhardness measurements. The nanocomposite samples were fabricated using a combination of mechanical milling, cold pressing, and hot extrusion techniques. Density measurements indicated acceptable densification of the samples, with no porosity. The results of tensile tests showed that the samples are sufficiently strong for the deep rolling process and also indicated near 50% improvement of tensile strength after incorporating SiC nanoparticle reinforcements. The effects of some important rolling parameters, including the penetration depth, rotation speed, feed rate, and the number of passes, on the surface quality and microhardness were also investigated. The results demonstrated that decreasing the feed rate and increasing the number of passes can lead to greater surface hardness and lower surface roughness.     

超声表面滚压加工参数对40Cr表面粗糙度的影响

研究了超声表面滚压加工各种加工参数对供货态40Cr轴表面粗糙度的影响。采用表面粗糙度分析仪对初始及加工表面进行测定,并使用显微硬度计测量该技术对40Cr表层沿深度方向的硬化作用。试验结果表明：超声表面滚压加工技术能显著降低车削的加工痕迹,改善金属材料的表面质量;各工艺参数对试样表面粗糙度均有一定影响,并产生不同程度的表层硬化作用;并且给出了各工艺参数的合理范围,试样的表面粗糙度值可降低至0.2μm以下。     

粉末的物理性能对热喷涂涂层的影响

在SUS316L不锈钢基体上,采用HVOF和DGS两种不同的工艺方法,分别喷涂WC-12Co和FeAl涂层,观察WC-12Co和FeAl粉末的颗粒形貌、粒度组成以及DTA,研究它们对热喷涂涂层质量的影响.通过表面粗糙度、显微硬度、形貌相以及X射线衍射谱等分析表明,球化程度高,颗粒大小均匀的粉末可使涂层的组织均匀,致密性好,结合强度高.采用HVOF方法喷涂WC-12Co涂层的质量最好,而采用DGS工艺喷涂FeAl涂层的工艺参数还有待于进一步优化.     

Processing and characterization of the microstructure and mechanical properties of Al6061–TiB2 composite

In the present research, aluminum metal matrix composites were processed by the stir casting technique. The effects of TiB2 rein-forcement particles, severe plastic deformation through accumulative roll bonding (ARB), and aging treatment on the microstructural charac-teristics and mechanical properties were also evaluated. Uniaxial tensile tests and microhardness measurements were conducted, and the micro-structural characteristics were investigated. Notably, the important problems associated with cast samples, including nonuniformity of the rein-forcement particles and high porosity content, were solved through the ARB process. At the initial stage, particle-free zones, as well as particle clusters, were observed on the microstructure of the composite. However, after the ARB process, fracturing phenomena occurred in brittle ceramic particles, followed by breaking down of the fragments into fine particles as the number of rolling cycles increased. Subsequently, com-posites with a uniform distribution of particles were produced. Moreover, the tensile strength and microhardness of the ARB-processed com-posites increased with the increase in the reinforcement mass fraction. However, their ductility exhibited a different trend. With post-deforma-tion aging treatment (T6), the mechanical properties of composites were improved because of the formation of fine Mg2Si precipitates.     

增材-微锻造加工工艺应力场数值模拟研究

激光熔丝增材制造过程中,材料快热快冷的特点使熔覆层产生不利于表面强度的残余应力,而增材-微锻加工工艺可提高增材制件的加工质量,改善增材制件微观组织及力学性能缺陷.以TC4为研究对象,通过超声微锻造工具头与熔池保持一定的相对距离做进给运动,对材料表面进行高频次冲击与滚压,使熔覆层表面得到改善和强化.对增材-微锻加工工艺进行顺序热结构耦合数值模拟研究,分析加工过程中熔覆层应力场变化情况.研究表明:对尚未冷却的增材熔覆层表面进行超声微锻造,熔覆层由于热源加载产生的残余拉应力转化为较为有益的残余压应力,降低了熔覆层表层缺陷发生的概率.不同的超声振幅、进给速度以及锻造温度参数对残余压应力及法向变形量有较大影响.     

CNC平面浮雕工艺参数对木制部件表面粗糙度的影响

计算机数字控制机床(CNC)平面浮雕雕刻是批量加工实木家具及实木工艺品的普遍方式,在实际生产加工中,大多凭借工人的经验,没有精确的数据设定参数,加工过程会增加损耗.通过正交试验L25(56)分析树种、刀尖直径、雕刻深度、X轴进给速度、路径间距、纤维方向与X轴夹角对雕刻质量的影响,利用3D激光轮廓扫描仪检测加工的木制部件表面粗糙度.结果表明:路径间距对浮雕产品的表面粗糙度和加工效率影响较大,其次是纤维方向与X轴夹角、刀尖直径,进给速度和雕刻深度对加工表面粗糙度影响较小.     

感应重熔对高速轧机轴承热喷涂层微观组织性能的影响

为了改善高速轧机轴承热喷涂层的微观组织性能,采用感应重熔技术对GCr15轴承钢表面预制备的高能火焰喷涂Ni60A涂层进行感应重熔处理,并利用金相显微镜、扫描电镜、X射线衍射仪、显微硬度计对感应重熔前后涂层的孔隙率、微观组织、显微硬度等进行对比研究,探讨感应重熔对涂层以及界面微观组织、显微硬度的影响.结果表明,高能火焰喷...     

预应力淬硬磨削复合加工表面粗糙度试验

以预应力淬硬磨削条件下试件表面粗糙度变化规律为研究对象,通过对45钢试件进行预应力淬硬磨削试验并进行表面粗糙度测量,分析了预应力淬硬磨削工艺参数(预应力、磨削深度、进给速度等)对试件表面粗糙度的影响机制.结果表明,粗糙度在试件表面分布并不均匀,其数值基本上都是从切入区到切出区逐渐增大的;适当增加预拉应力数值可以降低工件表面粗糙度,有效抑制试件表面微观裂纹的扩展,降低磨削温度,改善试件表面质量;预应力淬硬磨削中磨削深度和进给速度对表面粗糙度的影响与普通磨削一致,即随着磨削深度和进给速度增加表面粗糙度数值逐渐增大.     

Morphology observation for surface orange peel and fracture in tension sample of aluminum alloy sheet and characterization of nano hardness

The tension property of aluminum-alloy sheet with different microstructures is measured,and the surface and tension fracture morphology of tension sample with and without orange peel are observed by using scanning electron microscope(SEM).Surface roughness and nano hardness of tension sample are measured.The results show that the average elongation of the samples with orange peel is lower than that without orange peel;especially the r value of perpendicular to the rolling direction is much lower than that without orange peel.The tension surface of the orange peel samples is very rough;various parameters of surface roughness are higher.Under the observation of SEM,a wider sliding band with a micro crack on the surface of orange peel sample can be found.The various parameters of surface roughness without orange peel sample are near to zero,the sliding band is narrow and without micro cracks.The dimple width in tensile fracture of orange peel sample is larger than that without orange peel sample,but shear lip is narrower.The nano hardness testing results show that samples with orange peel behave high elastic modulus,high hardness,and high maximum load,but low plastic deformation depth.These mentioned features can completely describe surface and fracture morphology of tension samples with orange peel.     

氧化锆陶瓷微尺度磨削表面质量试验研究

为提高氧化锆陶瓷零件微细加工过程中的加工表面质量,改善氧化锆陶瓷零件的使用寿命,采用0.9 mm磨头直径、500#磨粒的微磨棒对氧化锆陶瓷进行微尺度磨削三因素五水平正交试验.首先通过极差和方差分析,研究了磨削参数影响氧化锆陶瓷表面质量主次因素;其次优化出获得较低表面粗糙度值的工艺参数组合;最后通过单因素试验研究氧化锆陶瓷磨削表面粗糙度随磨削参数的变化规律.结果表明,磨削参数对表面粗糙度影响顺序依次为:磨削深度、进给速度、主轴转速;当主轴转速v_s=40 000 r/min,进给速度v_w=20μm/s,磨削深度a_p=3μm时,表面粗糙度最小;表面粗糙度随主轴转速增大呈先下降后上升的趋势,随进给速度和磨削深度的增大而增大.     

Electrodeposition of functionally graded Ni-W/Er_2O_3 rare earth nanoparticle composite film

Multi-layered functionally graded(FG) structure Ni-W/Er_2O_3 nanocomposite films were prepared by continuously changing the deposition parameters, in which the Er_2O_3 and W contents varied with thickness. The microstructure and chemical composition of the electrodeposited Ni-W/Er_2O_3 films were determined by scanning electron microscopy(SEM) and energy-dispersive X-ray spectroscopy(EDS). The anti-corrosion and wear properties of the electrodeposition films were investigated by electrochemical measurement and ball-on-disk friction test. The microhardness distribution of the cross section of nanocomposites was measured by nanoindentation. The results showed that with decreasing agitation rate or increasing average current density, the contents of Er_2O_3 nanoparticles and tungsten were distributed in a gradient along the thickness, and the contents on the surface were larger. By comparison, FG Ni-W/Er_2O_3 films had better anti-corrosion and wear properties than the uniform Ni-W/Er_2O_3 films. Atomic force microscopy(AFM) and profilometry measurements indicated that Er_2O_3 nanoparticles had an effect on the surface roughness.     

弹性流体动力润滑状态下滚动轴承摩擦的分析

基于非牛顿弹性流体动力润滑(弹流润滑)点接触问题的数值求解方法,对深沟球轴承滚动体与滚道椭圆接触的稳态与瞬态润滑问题进行了分析.依据油膜压力与油膜厚度的数值计算结果,讨论了接触表面粗糙度、表面几何形态(粗糙表面峰谷高度)、滑滚比、接触力以及滚动速度等参数的改变对润滑深沟球轴承摩擦系数的影响.结果表明:表面粗糙度的改变对摩擦系数的影响较小;粗糙度一定时,表面几何形态的差别对摩擦系数影响较小;摩擦系数随着滑滚比的提高而增大;接触力与滚动速度的提高导致摩擦系数增大.     

钛合金螺旋铣孔参数对表面粗糙度影响研究

螺旋铣削作为一种新工艺在钛合金制孔方面得到广泛应用,表面粗糙度是评价钛合金孔加工质量的重要指标。基于Matlab建立钛合金螺旋铣孔表面粗糙度预测模型,开展钛合金螺旋铣孔实验,研究发现:在0.15~0.25 mm/rev范围内,随着螺距的增大,钛合金孔表面粗糙度呈现先减小后增大的变化趋势;在0.03~0.05 mm/tooth范围内,随着切向每齿进给的增大,表面粗糙度呈现先逐渐增大后减小的趋势;类似的,在2 500~3 500 r/min范围内,随主轴转速的提高,表面粗糙度变化曲线呈现先升高再降低的规律,但之后又有平缓上升的趋势。研究结果可为钛合金螺旋铣孔参数优化及表面粗糙的控制研究提供重要实验依据。     

Preparation of high-strength Al-Mg-Si-Cu-Fe alloy via heat treatment and rolling

An Al-Mg-Si-Cu-Fe alloy was solid-solution treated at 560°C for 3 h and then cooled by water quenching or furnace cooling. The alloy samples which underwent cooling by these two methods were rolled at different temperatures. The microstructure and mechanical properties of the rolled alloys were investigated by optical microscopy, scanning electron microscopy, transmission electron microscopy, X-ray diffraction analysis, and tensile testing. For the water-quenched alloys, the peak tensile strength and elongation occurred at a rolling temperature of 180°C. For the furnace-cooled alloys, the tensile strength decreased initially, until the rolling temperature of 420°C, and then increased; the elongation increased consistently with increasing rolling temperature. The effects of grain boundary hardening and dislocation hardening on the mechanical properties of these rolled alloys decreased with increases in rolling temperature. The mechanical properties of the 180°C rolling water-quenched alloy were also improved by the presence of β″ phase. Above 420°C, the effect of solid-solution hardening on the mechanical properties of the rolled alloys increased with increases in rolling temperature.     

时效状态对Cu-Cr-Zr系合金性能的影响

采用不同时效状态和随后形变热处理工艺制备了Cu-Cr-Zr系合金,采用微观组织观察、硬度和导电率测试等手段研究了不同时效状态对双级时效Cu-Cr-Zr系合金性能的影响.结果表明：欠时效+冷轧+时效工艺和峰时效+冷轧+时效工艺制备的Cu-Cr-Zr-Mg-Si和Cu-Cr-Zr-Ni-Si合金均可获得力学性能和电学性能的优良组合.其中：欠时效+冷轧+时效工艺所制备的合金综合性能更优,但加工热处理过程中性能变化剧烈,材料生产过程中性能均匀性不易控制;峰时效+冷轧+时效工艺制备的合金综合性能极其稳定,易于在生产中控制.不同工艺下的合金性能差异是由析出相与位错的交互作用机制不同造成的.     

Experimental and numerical study on plasma nitriding of AISI P20 mold steel

In this study, plasma nitriding was used to fabricate a hard protective layer on AISI P20 steel, at three process temperatures (450°C, 500°C, and 550°C) and over a range of time periods (2.5, 5, 7.5, and 10 h), and at a fixed gas N₂:H₂ ratio of 75vol%:25vol%. The morphology of samples was studied using optical microscopy and scanning electron microscopy, and the formed phase of each sample was determined by X-ray diffraction. The elemental depth profile was measured by energy dispersive X-ray spectroscopy, wavelength dispersive spectroscopy, and glow dispersive spectroscopy. The hardness profile of the samples was identified, and the microhardness profile from the surface to the sample center was recorded. The results show that ε-nitride is the dominant species after carrying out plasma nitriding in all strategies and that the plasma nitriding process improves the hardness up to more than three times. It is found that as the time and temperature of the process increase, the hardness and hardness depth of the diffusion zone considerably increase. Furthermore, artificial neural networks were used to predict the effects of operational parameters on the mechanical properties of plastic mold steel. The plasma temperature, running time of imposition, and target distance to the sample surface were all used as network inputs; Vickers hardness measurements were given as the output of the model. The model accurately reproduced the experimental outcomes under different operational conditions; therefore, it can be used in the effective simulation of the plasma nitriding process in AISI P20 steel.     

岩石节理面粗糙度的分形效应与试件尺寸影响分析

 岩石节理面的粗糙度是影响岩体形变、位移和强度的主要因素,准确量测岩石节理表面的粗糙度对评价岩石力学特性非常重要.根据分形理论,岩石节理表面具有分形特征,可用分形维数描述节理表面的起伏度,但是岩石节理表面粗糙度一般不具有严格的自相似分形性质,因此,表面分形参数(分形维数D和截距A)的量测结果受到尺度的影响.本文运用三维表面激光形貌仪扫描10个不同尺度的试件(尺寸为100mm×100mm—1000mm×1000mm),结果表明,D和A随试件尺寸增大而减小,两参数都有尺度效应,但存在一个极限尺寸.综合考虑岩石表面尺寸、试件长度以及测量尺度对岩石节理表面粗糙度的影响,提出可靠的分形测量途径.     

Cu-(B4C)p metal matrix composites processed by accumulative roll-bonding

In this study, Cu/B4C metal matrix composites were prepared by accumulative roll-bonding (ARB). The microstructure of the processed samples was characterized by TEM, SEM and optical microscopy. The microhardness, uniaxial tensile and four-point probe tests were carried out to evaluate the mechanical properties and electrical resistivity of the ARBed monolithic and composite samples. The results showed that the reinforcement distribution was improved by increasing ARB cycles, which was quantitatively confirmed by some models. Based on TEM observations, the formation of an ultrafine grained structure in the composite matrix was also approved. It was shown that with increasing ARB cycles, the microhardness and tensile strength of the monolithic Cu samples were enhanced up to the 3rd cycle and then saturated, but the microhardness and tensile strength of the composites showed an increasing trend to the last cycle. Apart from a substantial improvement in the mechanical properties of the Cu/B4C composites, a minor decrement in electrical conductivity was detected after six ARB cycles.     

干平整中工作辊与带钢表面粗糙度对摩擦系数影响的研究

针对干平整轧制过程中工作辊与带钢表面粗糙度对摩擦系数的影响仅能定性分析、不能满足生产需要的问题,经过大量的现场试验与理论研究,充分结合平整机组的设备与工艺特点,基于粗糙度的基本理论,根据干平整轧制过程中摩擦特点构造了反映工作辊及带钢表面粗糙度与摩擦系数之间一一对应关系的数学模型,提出了相应的模型计算策略,并将其应用到宝钢冷轧薄板厂1 220平整机组的生产实践,定量分析了工作辊及带钢表面粗糙度对摩擦系数的影响,有效地提高了轧制压力的预报精度与产品质量,取得了良好的使用效果,具有进一步推广应用价值。     

车削氟金云母陶瓷脆性破碎机理及表面粗糙度模型

基于脆性断裂力学和刀具-工件干涉原理,研究氟金云母陶瓷脆性破碎机理及表面成形机制,预测了脆性材料车削中的裂纹扩展角度与深度;建立氟金云母陶瓷车削表面粗糙度理论模型,用以评价精密车削陶瓷表面质量并提高加工效率.脆性材料车削表面粗糙度由几何干涉粗糙度和脆性崩碎粗糙度构成.刀具几何形状和进给量主要影响几何干涉粗糙度,工件力学性能、切削速度、切削深度和切削力主要影响脆性崩碎粗糙度.验证实验结果表明,氟金云母陶瓷车削表面粗糙度随切削速度的增大而减小,随进给量或切削深度的增大而增大.本模型的理论预测值与实验结果趋势一致,与传统的几何模型相比更接近实验值.