发动机缸体模具设计

发动机缸体作为发动机中最重要的部件之一,其尺寸较大、结构复杂、壁厚较薄且很不均匀(最薄处仅为3～5mm),同时其工艺范围狭窄,影响因素众多,是典型难以成形的复杂铸件,因此比较适合于采用消失模铸造生产.在发动机缸体的模具设计中,考虑产品的特点和后续生产的便利性,结合消失模模具本身的特点,设计出结构合理的模具,有利于提高产品的合格率和综合性能.     

Al-Si7-Mg消失模振动凝固组织半固态热处理

利用消失模铸造振动凝固技术,得到Al-Si7-Mg合金的近等轴晶组织。在此基础上研究了580℃不同时间保温半固态等温热处理(SSIT)组织中α-Al晶体的形貌与尺寸变化。结果表明:合金580℃保温1h,得到α晶粒的等积圆直径在50~150μm的分布比例达85%,α晶粒圆度均值1.41。通过凝固动力学和热力学分析,得出半固态热处理过程中,低熔点的三元共晶和二元共晶相首先熔化,并随着溶质元素扩散速度的增加,液相不断增多,α晶体形状大小不断改变;当液相率达到平衡之后,α晶粒在界面张力的作用下,不断圆整球化,合并长大。半固态热处理α枝晶演变形式明显不同于等轴晶演变过程。     

Novel technologies for the lost foam casting process

Lost foam casting (LFC) is a green precision casting process categorized as a near net forming technology. Yet, despite its popularity, it still suffers from some technological problems, such as poor filling ability of the castings, coarse and non-dense microstructure, low mechanical properties for the Al and Mg LFC processes, and defective carburization for the low carbon steel LFC process. These drawbacks restrict the development and widespread application of the LFC process. To solve these problems, the present study developed several novel LFC technologies, namely, LFC technologies under vacuum and low pressure, vibration solidification, and pressure solidification conditions; expendable shell casting technology; and preparation technology of bimetallic castings based on the LFC process. The results showed that the LFC under vacuum and low pressure evidently improved the filling ability and solved the oxidization problem of the alloys, which is suitable for producing complex and thinwall castings. The vibration and pressure solidifications increased the compactness of the castings and refined the microstructure, significantly improving the mechanical properties of the castings. The expendable shell casting technology could solve the pore, carburization, and inclusion defects of the traditional LFC method, obtaining castings with acceptable surface quality. Moreover, the Al/Mg and Al/Al bimetallic castings with acceptable metallurgical bonding were successfully fabricated using the LFC process. These proposed novel LFC technologies can solve the current technological issues and promote the technological progress of the LFC process.     

Design and analysis of tilt integral derivative controller with filter for load frequency control of multi-area interconnected power systems

In this paper, a novel Tilt Integral Derivative controller with Filter (TIDF) is proposed for Load Frequency Control (LFC) of multi-area power systems. Initially, a two-area power system is considered and the parameters of the TIDF controller are optimized using Differential Evolution (DE) algorithm employing an Integral of Time multiplied Absolute Error (ITAE) criterion. The superiority of the proposed approach is demonstrated by comparing the results with some recently published heuristic approaches such as Firefly Algorithm (FA), Genetic Algorithm (GA) and Particle Swarm Optimization (PSO) optimized PID controllers for the same interconnected power system. Investigations reveal that proposed TIDF controllers provide better dynamic response compared to PID controller in terms of minimum undershoots and settling times of frequency as well as tie-line power deviations following a disturbance. The proposed approach is also extended to two widely used three area test systems considering nonlinearities such as Generation Rate Constraint (GRC) and Governor Dead Band (GDB). To improve the performance of the system, a Thyristor Controlled Series Compensator (TCSC) is also considered and the performance of TIDF controller in presence of TCSC is investigated. It is observed that system performance improves with the inclusion of TCSC. Finally, sensitivity analysis is carried out to test the robustness of the proposed controller by varying the system parameters, operating condition and load pattern. It is observed that the proposed controllers are robust and perform satisfactorily with variations in operating condition, system parameters and load pattern.     

铸钢节点的消失模-砂型复合铸造工艺研究

铸钢节点铸件由于其结构复杂、材质要求严格,一直是铸造生产中的难点。采用消失模-砂型复合铸造工艺的原理如下:用泡沫代替部分木模造型,然后取出泡沫,再放入砂芯后浇注。并使用华铸CAE对铸件凝固过程进行数值模拟,优化浇注工艺。结果表明,泡沫造型提高了节点设计自由度和精度,并显著降低生产成本,缩短工时,同时空腔砂型浇注保证铸件材质不受影响,综合利用了两种铸造工艺的优势。经华铸CAE对浇注系统进行优化设计,降低了铸件的废品率。     

铝合金真空低压消失模壳型铸造工艺参数研究

研究了铝合金真空低压消失模壳型铸造工艺参数与铸件充型能力、内部质量的关系。结果表明,铸件的充型能力与浇注温度、充气流量、真空度、充气压力成正比;相比真空度和充气压力,充气流量与浇注温度对铸件充型能力的影响更为显著。工艺参数对薄壁铸件充型能力的影响要大于厚壁铸件;铸件孔隙率随浇注温度的提高先降低后升高,随着充气流量、充气压力、真空度的增大而降低,而密度则随各工艺参数的增大而增大。真空低压消失模壳型优化的工艺参数:浇注温度为720~750℃,充气流量为12~19m3/h,真空度为-0.03~-0.04MPa,充气压力为0.03~0.04MPa。     

铝(镁)合金消失模铸造近净成形技术研究进展

阐述了铝(镁)合金消失模铸造技术的研究现状,着重介绍了铝(镁)合金消失模铸造在金属液充型、振动凝固、压力凝固以及消失模壳型铸造等技术方面的最新研究进展。研究表明,铝(镁)合金在消失模铸造过程中,需重点解决针孔、缩松等缺陷,提高液态合金的充型能力和铸件的力学性能;通过采用振动凝固和压力凝固的手段,可以提高金属液充型能力、细化组织、提高组织致密性,明显提高铸件力学性能。真空低压消失模壳型铸造技术,可以解决普通消失模铸造易于出现的孔洞和夹杂等缺陷以及浇不足和浇注温度高等问题,是一种生产复杂薄壁高质量铝、镁合金精密铸件的新方法。     

Cost-efficient thermophotovoltaic cells based on germanium substrates

This paper describes the realisation of cost-efficient thermophotovoltaic (TPV) cells based on germanium substrates. Because the majority of the photons incident on the TPV cell in a typical TPV system will have a long wavelength it is important to apply optical confinement in the TPV cell. In this paper this has been done by using a highly reflective rear contact. Electrical contact at the rear has been created with a laser (laser fired contact, LFC) such that the metal is locally heated and contact is formed.The optimal TPV cell is based on a low doped p-type germanium substrate having a 500 nm thick n-type emitter , where front and rear are both passivated with hydrogen rich PECVD amorphous silicon. An AM1.5G record efficiency has been measured for a germanium TPV cell with an LFC rear contact. The application of optical confinement leads to a clear improvement of the spectral response in the wavelength region which is dominant in TPV systems and results in a potential 20% increase of current density compared to the use of a classical germanium photovoltaic cell.     

Performance enhancement of a hydro-hydro power system using RFB and TCPS

The design of load frequency control (LFC) for the hydro-hydro power system suffers from poor dynamic performance owing to large time constants associated with hydro power generations. The dynamic performance of the hydro-hydro power system can be improved using a thyristor control phase shifter (TCPS) and energy storage battery system. This paper presents a comprehensive study on LFC of an interconnected hydro-hydro power system having TCPS in series with the tie-line and redox flow battery (RBF) at the terminal of one area through few and available state technique, i.e. the output feedback technique. The LFC are designed with the help of few and available states and the performance is judged for typical demand change in the power system area and the results are matched with the LFC obtained via a technique that require all system states, i.e. full state feedback in order to justify the effectiveness of the designed LFC in terms of achieved feedback gains, eigenvalues and the dynamic system responses.

Abbreviations: AC: Alternating Current; BESS: Battery Energy Storage System; FACTS: Flexible Alternating Current Transmission System; LFC: Load Frequency Control; RFB: Redox Flow Battery; SSSC: Static Synchronous Series Compensator; SMES: Superconducting Magnetic Energy Storage; TCPS: Thyristor Control Phase Shifter; UPFC: Unified Power Flow Control     

Disconnection control of wind power generators for the purpose of reducing frequency fluctuation

This paper proposes a new approach for disconnection control of wind power generators to reduce the frequency fluctuation caused by wind power. The approach is based on the correlation between frequency and total output of wind power generators and the turbulence degrees of individual wind power generators. At a control center, frequency and all the outputs of wind power generators are monitored, and the correlation and the turbulence degrees are computed on‐line. If the large variation of frequency is detected, then whether the variation comes from the wind power generators or loads is checked by using the correlation. When the wind power generators cause the frequency variation, the wind power generator with maximum turbulence degree is searched and disconnected from the power systems. This search and disconnection process is repeated until the correlation reaches the level where the frequency variation observed is not caused by the wind power generators. The effectiveness of the proposed approach was confirmed with the simulation studies of a two‐area interconnected power system including many wind power generators. The results show that the correlation and the turbulence degree are useful for the reduction of frequency fluctuation so as not to disconnect too many wind power generators. © 2010 Wiley Periodicals, Inc. Electr Eng Jpn, 171(1): 10–18, 2010; Published online in Wiley InterScience ( www.interscience.wiley.com ). DOI 10.1002/eej.20911