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Design and implementation of materials database for heat treatment process simulation

Zhang Lunfeng, Wang Zhihan, Zhao Junyu, An Kang, Xu Jun, Gu Jianfeng

Heat Treatment of Metals 2023, 48 (9): 247-252. doi:10.13251/j.issn.0254-6051.2023.09.042

Abstract （41）

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Material parameters are the crucial data support in heat treatment process simulation. However, at present, there is a lack of relevant material databases in China, and a few existing databases have problems such as low data accuracy, poor integrity, and inability to share data, they only distinguish materials based on chemical composition, which cannot meet the parameter requirements of heat treatment process simulation. Therefore, a data structure focusing on chemical composition and microstructure was designed, and an online special material database was also independently developed. The database optimizes the data storage structure according to the characteristics of material parameters required for heat treatment process simulation. Adopting B/S architecture design realizes data sharing and improves the convenience of data use. Furthermore, by using data mining technology, the database introduces four machine learning algorithms: multivariable linear regression, Bayesian linear regression, decision tree, and random forest, and establishes an innovative data extraction mechanism. The effective data extraction strategy can be determined through the application analysis of existing data, and then the actual data requires at present can be obtained, which preliminarily solves the problem of data missing currently, and strongly supports the development of heat treatment process simulation.

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Technology knowledge base framework of aluminum alloy heat treatment integrated management and control based on multi-parameter variables

Liu Qi, Wan Rutao, Chong Yonggang, Li Mutian, Qu Ming

Heat Treatment of Metals 2023, 48 (9): 253-257. doi:10.13251/j.issn.0254-6051.2023.09.043

Abstract （26）

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In response to the process characteristics of multi-parameter variables in heat treatment, aviation aluminum alloy material type and heat treatment process type were selected as variables, and a multi condition judgment rule was adopted to construct an integrated management and control knowledge base for aluminum alloy heat treatment. The temperature rise, holding, cooling, and quenching parameters during the aluminum alloy heat treatment process were digitized, and the integration of heat treatment control process knowledge base in the heat treatment information control system and directly interfaces with other information systems such as MES in the workshop were achieved. It automatically retrieves data-driven process parameters and completes distribution, promoting the direct control of the heat treatment information control system over the process of heat treatment equipment. This has theoretical and practical significance for promoting the informatization, integration, quality monitoring, and process management of special heat treatment process production.

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Laser quenching temperature field and phase transformation hardened zone of 45 steel

Ma Zhenghe, Adayi Xieeryazidan, Liu Junjie, Guli Nigaer

Heat Treatment of Metals 2023, 48 (9): 258-264. doi:10.13251/j.issn.0254-6051.2023.09.044

Abstract （29）

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Transient law of temperature field and phase transformation hardening law of 45 steel during quenching process were obtained by numerical simulation, and the influence of single factor change on phase transformation hardened zone was analyzed. The thermal coupling model of laser quenching process of the 45 steel was established based on software Comsol Multiphysics, the whole of which is then modified by JMatpro calculated phase transformation curves and CCT curves, and the change curves of some thermal physical parameters of the material with temperature. The phase transformation hardened zone was defined based on the phase transformation curve and CCT curve. The results show that the hardened layer has a Gaussian distribution, and the laser quenching hardened layer is obviously different under different process parameters. Under the same other conditions, the depth and width of phase transformation hardened layer are positively correlated with laser power, and negatively correlated with scanning speed and spot diameter. It is concluded that, by combining JMatpro with Comsol Multiphysics, a thermodynamic coupling model of laser quenching considering the change of thermal physical parameters can be established and calculated, by which the prediction of laser quenching temperature field and phase transformation hardened zone can be realized.

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Effect of aging temperature on Cu-rich precipitates in Fe-Cu-Mn-Ni alloy studied by phase-field method

Wang Kanghong, Xu Yangyang

Heat Treatment of Metals 2023, 48 (9): 265-270. doi:10.13251/j.issn.0254-6051.2023.09.045

Abstract （30）

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A phase-field model for simulating the microstructure evolution in the solid-state phase transformation of multi-component alloys was constructed by coupling the CALPHAD thermodynamic database. Taking Fe-Cu-Mn-Ni alloy as an example, the effect of aging temperature on the precipitation mechanism of Cu-rich precipitates was revealed from the kinetic point of view. The results show that the transformation of α to γ phase and the formation of B2 ring depend on the size of Cu-rich phase. In addition, the change of aging temperature results in the change of the morphology and precipitation mechanism of the Cu-rich phase. The higher the aging temperature, the shorter the precipitation time of the Cu-rich phase, the larger the volume fraction and radius of the Cu-rich phase, and the faster the reduction rate of the precipitated phase quantity.

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Design of fuzzy PID heat treatment temperature control system based on Kalman filter

Li Guangbao, Gao Dong, Lu Yong, Ping Hao, Zhou Yuanyuan

Heat Treatment of Metals 2023, 48 (8): 235-241. doi:10.13251/j.issn.0254-6051.2023.08.038

Abstract （23）

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Aiming at the problems of hysteresis, overshoot, easy interference and slow response of temperature control in the heat treatment process of aerospace complex casting parts, a fuzzy PID(proportional-integral-derivative) temperature control method based on Kalman filter was proposed. Particle swarm optimization (PSO) was used to optimize the parameters of PID controller, and Kalman filter was also used to filter the measurement noise. Finally, the fuzzy strategy was used to realize the rapid response and overshoot control of temperature control. Through the research of fuzzy PID control, fuzzy rules were analyzed and fuzzy reasoning was carried out. According to the requirements of heat treatment process temperature control and its reasoning rules, selecting the most suitable control factor, through the simulation comparison with MATLAB software, it is proved that the accuracy of the designed heat treatment temperature control system is greatly improved, the robustness of the system is better, the response speed is obviously improved, the overshoot is reduced, the adjustment time is shortened, and the interference is also strongly inhibited.

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Displacement boundary conditions in heat treatment simulation analysis of 17CrNiMo6 steel helical gear

Liang Ruijun, Wang Zhiqiang, Li Huawen

Heat Treatment of Metals 2021, 46 (12): 262-267. doi:10.13251/j.issn.0254-6051.2021.12.044

Abstract （49）

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Based on the mathematical models of heat transfer, structure field transformation and thermo-elastoplasticity in 17CrNiMo6 steel heat treatment process, a finite element model of the helical gear heat treatment was established. The heat treatment process of the 17CrNiMo6 steel helical gear was simulated, and the influence of the three displacement boundary conditions (fixed constraint, symmetric constraint and friction constraint) on the distortion of heat treatment simulation was analyzed. The results show that the surface on the 17CrNiMo6 steel helical gear is subjected to compressive stress after quenching, but the core is subjected to tensile stress, and the compressive stress at the root of the tooth is greater than that at the top of the tooth. Compared with the commonly used boundary conditions of fixed or symmetrical constraints, the simulation results of friction constraints are more in line with the actual results.

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Simulated research on influence of carburized layer thickness on quenching distortion of 18Cr2Ni4WA steel gear

Kong Lingli, He Ruijun, Li Guifa

Heat Treatment of Metals 2021, 46 (12): 268-275. doi:10.13251/j.issn.0254-6051.2021.12.045

Abstract （49）

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Influence of carburized layer on the temperature field, stress field and strain field of the 18Cr2Ni4WA steel arc-gear during gas quenching process was analyzed by means of finite element simulation software, and the action mechanism was explored further in combination with the first-principles method. The results show that the influence of depth of carburized layer on the temperature field of 18Cr2Ni4WA arc gear is small. But the stress field of surface layer in gear fluctuates is obvious when the depth of carburized layer is smaller than 0.5 mm, which increases from 86.7 MPa at the thickness 0.1 mm of the carburized layer to 278.6 MPa at 2.0 mm. The results of the strain field show that when the thickness of the carburized layer is 2.0 mm, the initial value of the equivalent strain on the surface of tooth top reaches 2%. The first-principles calculation results show that with the increase of carbon concentration, the bond strength between Fe-Fe atoms weakens. However, the newly formed Fe-C bond and Cr-C bond are obviously strengthened, and the electron density between Fe and C atoms shows obvious directionality. Therefore, the weakness of the Fe-Fe bond causes expansion coefficient of the 18Cr2Ni4WA steel to increase with the addition of carbon concentration. Then it will cause the heating-up distortion of the gear be not capable of recovering during the gas quenching and cooling process for its excessively thick carburized layer. As a result, the fluctuation of gear geometric dimension will be aggravated obviously.

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Effect of process parameters on interface heat transfer efficiency of aluminum alloy during forced air cooling

Xu Rong, Li Luoxing

Heat Treatment of Metals 2021, 46 (12): 276-281. doi:10.13251/j.issn.0254-6051.2021.12.046

Abstract （47）

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The heat transfer process of high-speed gas impact on the hot metal surface was studied through a series of air-cooled quenching experiments. The inverse heat transfer method was used to calculate the interfacial heat flux(q) and the interfacial heat transfer coefficient(h). The effects of initial quenching temperature of specimen, surface roughness and air flow density on specimen surface on heat transfer process were studied. The results show that the initial quenching temperature of specimen has a significant effect on the heat transfer at the air-cooled quenching interface. When it increases from 470 ℃ to 520 ℃, the maximum value of both q and h is increased by about 50%, and the average cooling rate of quenching surface temperature, when decreases to 200 ℃, is increased by about 43%. With the increase of the air flow density on specimen surface, the interfacial heat exchange shows a tendency of first increasing and then decreasing, that is, when the interfacial heat transfer efficiency is highest, there is a critical air flow density on specimen surface corresponding to it, and the closer the injection angle is to 90°, the smaller the critical value is. As the surface roughness of the specimen increases, the interfacial heat transfer decreases continuously, which may be attributed to the more obvious the rougher surface pinning effect on the fluid in the boundary layer, the more unfavorable it is to improve the interfacial heat transfer efficiency. Moreover, in the range between 250-380 ℃, there is generally a depressed region in the curve of h with surface temperature, which may be related to the precipitation of secondary phase during quenching and cooling of aluminum alloy.

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Numerical simulation of heat treatment for 3Cr2NiMo steel module bulk after forging

Wang Linchun, Wu Yongqiang, Wang Kaikun, Li Heng

Heat Treatment of Metals 2021, 46 (3): 184-190. doi:10.13251/j.issn.0254-6051.2021.03.037

Abstract （66）

PDF （636KB）（32）

Taking the forging module of 3Cr2NiMo die steel as the research object, the thermal physical parameters of which were calculated by JMatPro software. And the heat treatment after forging was studied by means of numerical simulation using Deform-3D software, the test verification was made at last. The results show that, the cooling rate of the outer surface of the module is higher than that of the core during quenching. The martensite transformation from the core to the surface does not simultaneously occur and the microstructure distribution from the surface to the core after quenching is martensite, bainite and ferrite in turn. The equivalent stress distribution along thickness direction is more uniform, but there is stress concentration at the edge position. The distribution of hardness values is positively correlated with the martensite distribution, and the average hardness value of the surface is 34.86 HRC. Meanwhile, the average thickness of martensite layer is 45 mm and the average hardness of surface is 36.23 HRC by the test verification. The error results between simulation and test are less than 10%, which has good accuracy.

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Heating process analysis and system design of continuous annealing furnace for cold-rolled stainless steel

Li Zhiming, Li Chunming, Qin Fenghua, Hu Yinping

Heat Treatment of Metals 2021, 46 (3): 191-195. doi:10.13251/j.issn.0254-6051.2021.03.038

Abstract （63）

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Based on the continuous annealing process and system analyses for cold-rolled stainless steel, the heating system of continuous annealing furnace was designed, and the furnace length configuration and the combustion power configuration were respectively calculated by the surface energy balance equation and the energy conservation equation. By comparison and analysis of the actual calculation example and the actual operation, it verifies that the design method is effective and has the ability to complete the design process from the product outline and process analysis basis to the unit heating system integration, arrangement and overall arrangement of equipment. Thus, it provides a theoretical basis for the secondary model of the heating system of the cold-rolled stainless steel continuous annealing furnace.

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Inpainting of metallographic image based on improved PatchMatch algorithm

Li Songtao, Li Weigang, Shi Jingrui, Gan Ping

Heat Treatment of Metals 2021, 46 (3): 196-205. doi:10.13251/j.issn.0254-6051.2021.03.039

Abstract （56）

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Combining the DCT pyramid compression algorithm and the multi-patch optimal matching mechanism to improve the traditional PatchMatch image repair algorithm, using different algorithms to repair and compare the metallographic images with pollution characteristics. The results show that the improved PatchMatch algorithm greatly improves the repair speed and repair quality. The repaired images are more effective than other image repair algorithms, the internal texture details of the metallographic images are restored more accurately and delicately, and metallurgical images repair can solve the problems that conventional metallurgical image segmentation can not eliminate the big noise.

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Numerical simulation and experimental verification of Jominy test for SA508-3 steel

Xu Dacheng, Bo Hengyong, Zheng Shanjü, Li Mengnie

Heat Treatment of Metals 2020, 45 (12): 231-237. doi:10.13251/j.issn.0254-6051.2020.12.045

Abstract （62）

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Influence of continuous cooling on microstructure evolution of SA508-3 steel was studied by numerical simulation and Jominy test. The models for predicting the temperature field and the microstructure field in the SA508-3 steel during the Jominy test were established by using the FLIM and UMATHT subroutine of finite element ABAQUS software, and used to simulate the end quenching process. And finally, the simulation was verified by microstructure observation at different positions on the basis of Jominy test. The results show that no pearlite is produced in the specimens after the end quenching test. With the increase of distance from the quenching end, the microstructure in the specimen changes from martensite (M) to bainite (B) and retained austenite, and the semi-martensitic region appears at 9 mm from the quenching end. The test results are in good agreement with the predicted results.

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Self-adaptive temperature control of vacuum furnace based on single neuron PID

Fan Zhanwen, Shan Qiongfei, Yin Chengkun, Yang Guangwen, Wang He, Cong Peiwu

Heat Treatment of Metals 2020, 45 (12): 237-241. doi:10.13251/j.issn.0254-6051.2020.12.046

Abstract （57）

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According to the characteristics of vacuum heat treatment system, the single neuron PID control algorithm was applied to the temperature control of vacuum heat treatment system. Combined with the nonlinear approximation ability of neural network and the characteristics of self-learning and self-adaptive, the single neural network was combined with PID control to realize the control of vacuum furnace temperature, so as to improve the quality of vacuum furnace temperature control. The simulation results show that the single neuron network PID control system can self-tuning the control parameters, it is more robust to temperature control, has stronger anti-interference ability and robustness. After building the experimental platform of vacuum furnace temperature control system, it is found that the temperature rise process of vacuum furnace system with single neuron PID control shows good stability, but the response speed of temperature control and the accuracy of heat preservation slightly decrease. In order to further improve the quality of temperature control, the single neuron PID control method needs to be further improved in response speed and control accuracy.

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Intelligent information production scheduling technology of heat treatment process

Zhou Yulong, Zhang Zhen, Zhou Yongsong, Chen Jie, Yin Heping, Li Jie, Zhang Jiulin, Lin Xin

Heat Treatment of Metals 2020, 45 (12): 242-247. doi:10.13251/j.issn.0254-6051.2020.12.047

Abstract （59）

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Heat treatment is an important part in the manufacturing industry. In view of the multi variety and variable batch production mode of heat treatment enterprises, it is an urgent problem for heat treatment enterprises to reasonably coordinate workshop production resources, ensure product quality, improve production efficiency, reduce production energy consumption, and improve enterprise intelligent management level. Based on the actual production process of heat treatment, a set of intelligent control system platform of heat treatment was constructed by using the technology of internet of things information collection, heterogeneous information data fusion, production process information management and control, combined with production scheduling genetic algorithm. Through the system platform, the real-time production scheduling of heat treatment process is realized, the production efficiency is improved, and the control ability of quality consistency of heat treatment products is improved.

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