Papers by Author: Jian Min Zeng

Abstract: A new method for removal of impurities in pure molten aluminum has been presented in this paper. The basic principle of this method is that the molten fluxes are forced to inject into the molten aluminum under counter-gravity, creating strong vortex to mix fully with the molten aluminum. In this way, the impurities in the aluminum will transfer into the flux because of the absorption of the flux to the inclusions. As the result, the molten aluminum is purified. The experiments were carried out for pure aluminum combined with the flux (40wt.% NaCl，30wt.% KCl，10wt.% NaF and 20wt.%Na3AlF6). The results show that after 3 purifying cycles (6 minutes), the inclusion contents decreased from 2. 1% to 0.35%, a removal rate of 83.3%; and hydrogen concentration decreased from 0.37ml/100gAl to 0.12ml/100gA, with hydrogen removal rate being 68%.

Abstract: Hot-dip aluminizing panels of Q235 steels were produced in laboratory. Then the hot-dip aluminizing samples were executed diffusion at elevated temperatures protecting with flowing argon gas. Metallographic microscope, scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS) were employed for compositional analyses and graphical analyses of coating. The diffusion process was researched and the phase’s microstructure after diffusion was analyzed and discussed. The hot-dip aluminizing diffusion mathematical model was established with the finite element method. The results show that after diffusion in hot-dip aluminizing, the aluminum of the coating disappeared. The thickness of diffusion layer increased and the dentate frame disappeared. There are some iron-rich phases such as Fe2Al5, FeAl and Fe3Al in the diffusion layer. The phase Fe2Al5 decreases and the phase FeAl increases. The mathematical model corresponds with the actual situation. The diffusion coefficients of Al atoms diffusing in intermetallic compounds were calculated at 950°C, which were 0.29×10-12 m2/s for Fe2Al5, 0.7×10-12 m2/s for FeAl, and 0.27×10-12 m2/s for Fe3Al, respectively.

Abstract: The structure and properties of A357 aluminum alloy with different second dendrite arm spacing (SDAS) in different situations of overheating were investigated. The results indicate that serious overheating characteristic structure takes on compound melting ball, crystal separating phase and overheating triangle section; The overheating level of A357 alloy raises with solution temperature increasing; The mechanical properties decrease with the overheating level increasing; The overheating temperature of casting increases as the SDAS decreases, the regression equations of the correlation between SDAS and overheating temperature is as follows: T = 575.46-0.213SDAS; Optimum solution temperature could be selected for A357 alloy with different SDAS depending on supercritical solution region proposed in this paper.

Abstract: The scanning electron microscope (SEM) and energy dispersive spectrometer (EDS) were used to characterize samples prepared from the surface scum of melt, the middle flake residues on the furnace wall and the “bottom bulk” after the A357 alloy pouring. The morphology and impurities composition of these features were investigated. Some of particles and regions in samples during the analyses were also studied in detail. The results of analyses show that the surface scum of melt include Al2O3, MgO or MgAl2O4; the impurities of the middle flake residues is comprised of Al2O3, MgO or MgAl2O4, as well as SiO2 particle, Al9Fe2Si2 compound and dimple like C-rich areas; the bottom bulk contains C-rich impurities such as Al4C3 or some of unknown phase or elemental carbon.

Abstract: Aluminum alloy A357 can be heat treated in order to obtain optimum mechanical properties. Moreover, SDAS (Second dendrite arm spacing) is an important structure feature in cast aluminum alloys. The effects of SDAS on the homogenization of Al-Si-Mg alloy are investigated through measurement of SDAS and hardness analysis. The results show that the homogenization time increases as the value of SDAS increases and the homogenization temperature decreases in the homogenization process. The homogenization kinetics equation is: . In addition, the hardness after homogenization treatment at 540°C for 6 hours is advanced with the reduction of SDAS.

Abstract: Al-10Sn matrix composites reinforced by TiB2 particles were fabricated by Mixed Salt Reaction in situ synthesis process. The oil lubricated sliding wear tests of composites and matrix alloy were conducted on a small thrust ring versus disc wear testing machine at room temperature under different applied loads and the wear surfaces were observed using SEM. The results indicate that the coefficient of friction, friction temperature, and wear weight loss increase with the increase of applied loads, but compared with matrix alloy, the composites exhibit better anti-friction property and higher wear resistance. The analysis of wear surface suggests that light ploughing is predominant for composites and matrix alloy at low loads, and ploughing is still predominant for composites at high loads, but adhesion and delamination are predominant for matrix alloy at high loads

Abstract: This present work investigate the hydrogen content in Al-12Si alloy at different holding temperatures of 993K, 1023K, and 1053K and under different ambient relative humidity 30%RH, 50%RH, 80%RH. The relationship of the hydrogen content with atmosphere relative humidity and the reaction time was investigated. A HYSCAN II analyzer was used to evaluate the hydrogen content in aluminum melts. The experimental results show that the hydrogen content increased with the holding temperature and the relative humidity. At the temperature 1053K, the hydrogen content has an inverse change. The hydrogen content is more depend on the liquid structure than physical mass transfer and chemical reaction because of the sudden change in liquid microstructure. A group of kinetic regression equations of the hydrogen absorption in Al-12Si melts was obtained.

Abstract: Microporosity in cast aluminum alloys formed during solidification of castings can be due to the evolution of dissolved hydrogen gas from the liquid metal, the inability of liquid metal to feed through interdendritic channels, or a combination of both. The secondary dendrite arm spacing (SDAS) of the casting may affect either the evolution of hydrogen gas or the ability of feeding. In this investigation, a method based on the Nearest-Neighbor-Distance (NND for short) cluster analysis of image analysis data was used for distinguishing the gas and shrinkage pores in A357 alloy, in order to study the effects of SDAS on the microporosity formation. It shows that the shrinkage pores are prone to form in the specimens with small SDAS. The discrete, isolated gas microporosity is prone to form in the specimens with large SDAS.

Abstract: Hydrogen is the only gas that is appreciably soluble in aluminum and its alloy. Its solubility is small but its effects on the mechanical properties and finishing characteristics of aluminum alloys are significant. In this paper, a patented degassing process, which is based on the vacuum metallurgy principle, is proposed. The diffusion equation was used for explaining hydrogen transfer in the liquid aluminum under the function of a porous sucking head. RPT experiment was carried out to evaluate effectiveness of the process. The experiment indicates that the hydrogen content can be dramatically reduced to 0.05ml/100gAl owing to the use of this new process.

Abstract: In this investigation, experiments were carried out to study the relationship of solidification parameters and the secondary dendrite arm spacing (SDAS) in A357 alloy casting with various thicknesses under the same solidification condition. The results show that the cooling rate decreases as the thickness of specimens increases, the local solidification time increased, and SDAS increased. The relationships between the SDAS and cooling rate and local solidification time under the condition of furan resin self-hardening sand casting were obtained: SDAS = 20.8 tf 0.3, SDAS = 69.34 v -0.3. The mechanical properties have some linear relations with SDAS of A357 alloy after aging heat treatment. The correlations can be expressed: UTS=410.4-0.8SDAS and El%=7.9-0.05SDAS.