Coupled heat and fluid flow model and experimental verification of aluminium plate die casting

Abstract

The present work aims to forecast mould filling, void shape, location and size as well as columnar to equiaxed transition (CET) in commercial pure aluminium casting. A model coupling the momentum equations of the fluid flow and heat transfer equations is presented, in which metallostatic pressure, air gap and oxide layer are considered. Different casting parameters were investigated such as casting configuration by varying the plate thickness from 5 to 20 mm, melt superheat from 40 to 120°C, mould preheat up to 200°C and different pouring heads ranging from 0·3 to 0·6 m. Regarding the microstructure and void formation, the approach based on the Niyama criterion, was considered. The experimental verification of the model was achieved by gravity die casting in the form of a rectangular cavity. Voids inside aluminium plate were investigated by X-ray imaging. Microstructure and CET was investigated microscopically. The supposed model proves its validity for mould filling and in detecting the void features and CET.     

Effect of sulphides on corrosion of Cu–Ni–Fe–Mn alloy in sea water

Abstract

The corrosion behaviour of Cu–30Ni–2Fe–2Mn commercial alloy (similar to C71640) in quiescent, hermetically closed sulphide polluted and unpolluted natural sea water at 25°C was investigated. The corrosion resistance was examined using free corrosion and electrochemical tests and the surface film was characterised by chemical analysis and X-ray photoelectron spectroscopy. The different susceptibilities to corrosion were closely linked to the initial sulphide concentration; the accelerated attack occurring with an initial sulphide concentration of 4 ppm correlated with the amount of dissolved oxygen in solution and with the chemical composition of the corrosion layer.     

Is there any contradiction between the stress and energy failure criteria in micromechanical tests? Part III. Experimental observation of crack propagation in the microbond test

A direct observation of crack propagation in the microbond test was carried out for five different fiber/polymer matrix systems. This technique appeared to be a very effective tool for interface characterization. Experimental plots of the force required for further crack propagation as a function of debond length were analyzed using both energy-based and stress-based models of debonding. The fracture mechanics analysis was used to construct families of crack resistance or R-curves which showed the variation of energy release rate, G, with the debond length, and included the effect of interfacial friction in debonded regions. For the first time, analogs of the R-curves were created within the scope of the stress-based model to present the local shear stress near the crack tip, τ, as a function of crack length. In both models, the behavior of the interfacial parameter (G or τ) strongly depends on the assumed value of the interfacial frictional stress (τ_f). However, for each matrix/fiber system there exists such a τ_f value for which the investigated parameter is nearly constant over the whole region of stable crack propagation (70–90% of the embedded length). Moreover, these best-fit τ_f values for each specimen appeared to be practically the same for both energy-based and stress-based approaches. Thus, both interfacial toughness, G _ic, and local interfacial shear strength, τ_d, adequately characterize the strength of a fiber/matrix interface. Extrapolation of R-curves and their analogs to zero crack length allows measurement of the interfacial parameters with good accuracy.     

Abnormal transient phenomena in the continuous casting process: Part 1

Abstract

This paper is the first of a series of two describing online monitoring of the continuous casting machine and the abnormal transient phenomena observed. The present paper, Part 1, pays attention to assessment of the friction between the billet and mould based upon the cam rod force and the electric current intensity of the mould oscillation motor. Information relating to casting parameters before 58 breakouts has been obtained with a monitoring computing program. Almost 40% of the breakouts could have been forecast through assessment of the billet-mould friction force before the breakouts. Transient phenomena in the withdrawal machine have been detected. The jerking of the strand is related to high billet-mould friction; however, other parameters such as the billet cutoff unit and roller bed design also have some effects on this transient phenomenon. Some mechanisms influencing the jerking of the strand are proposed.     

A generalized stress singularity approach for material failure prediction and its application to adhesive joint strength analysis

The concept of stress is very useful to describe the effect of external loads on structures. However, as a basis for the prediction of failure the concept of stress becomes meaningless when the structure encompasses singularities as a result of discrete stiffness steps or geometric anomalies such as cracks. In this article it is argued that the concept of failure stress is incorrect and should be replaced by a generalized concept based on stress intensity factors and singularity orders. It appears that material failure stress is the critical stress intensity factor for a zero-order singularity stress field. By plotting the critical stress intensity factor as a function of singularity order, the strength of a material can be characterized in a general fashion that integrates tensile strength, fracture toughness and critical singularities in adhesive joints. It is also shown that plasticity does not eliminate the stress singularity in an adhesive joint but changes the order of the singularity due to the induced change in interface corner angle between the dissimilar materials in the joint.     

Residual stress and thermal cycling of planar solid oxide fuel cells

Abstract

The published literature relating to damage to planar solid oxide fuel cells caused by thermally induced stresses and thermal cycling is reviewed. This covers reported studies of thermal cycling performance and stresses induced by temperature gradients and differences in thermal expansion coefficients in typical planar SOFC configurations, namely electrolyte supported; anode supported and inert substrate supported cells. Generally good agreement is found between electrolyte residual stresses measured by X-ray diffraction or cell curvature and stresses calculated from simple thermo-elastic analysis. Finite element modelling of temperature distributions in cells and stacks in steady state operation are well advanced and capable of being extended to compute stress distributions. Failure criteria are then discussed for laminated cell structures based on critical energy release rate fracture mechanics models developed originally for coatings. However, in most cases the data required to apply the models quantitatively (such as elastic moduli of actual laminated material and fracture energies of materials and interfaces) are not available. Where data are available there are inconsistencies that require resolution. Seals are critical components in many planar solid oxide fuel cell configurations, but again there are discrepancies in experimental mechanical properties and the role of internal stresses in their fracture. In addition, there is as yet no firm evidence that thermal cycling damage involves any true materials fatigue process.     

Investigation of a black oxide layer on the surface of pressure-diecasting dies

Detailed experiments have been carried out to study the effectiveness of two methods of generating a black oxide layer on a pressure-diecasting die in order to prevent soldering of molten aluminium. Three types of steel surface were examined: bare, black oxidised with oil and black oxidised using an acidic anti-solder grease.

As a result of experiments involving the pressure- diecasting of aluminium alloys, it was determined that the black oxidised surface obtained with the acidic anti-solder grease increased the yield of an insert by three times compared to a similar insert oxidised with oil, and by six times when compared with a bare steel insert.

This effect was confirmed in laboratory tests. The strength of the interface between aluminium alloy and a steel surface oxidised with an acidic anti-solder grease was six times lower than that of the interface between the aluminium alloy and bare steel. The oxide layer obtained with an acidic anti-solder grease is, therefore, seen to provide effective protection from soldering. This fact was also confirmed by a special laboratory test designed to determine the tendency of various aluminium alloys to solder to a die surface.

The treated surfaces of the die cavity were examined by X-ray Photoelectron Spectroscopy and Auger Electron Spectroscopy. It was found that the blue-black oxide layer was twice as deep when oxidised using an acidic anti-solder grease than when oxidised in oil.