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I-DCGAN and TOPSIS-IFP:A simulation generation model for radiographic flaw detection images in light alloy castings and an algorithm for quality evaluation of generated images

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China Foundry 2024年第3期21卷 239-247页

作者： Ming-jun Hou Hao Dong Xiao-yuan Ji Wen-bing Zou Xiang-sheng Xia Meng Li Ya-jun Yin Bao-hui Li Qiang Chen jian-xin zhou State Key Laboratory of Materials Processing and Die&Mould Technology Huazhong University of Science and TechnologyWuhan 430074China xinjiang Technology(jiangsu)Co. Ltd.Nantong 226100JiangsuChina Southwest Technique and Engineering Research Institute Chongqing 400039China Shanghai Spaceflight Precision Machinery Institute Shanghai 201600China

The intelligent detection technology driven by X-ray images and deep learning represents the forefront of advanced techniques and development trends in flaw detection and automated evaluation of light alloy castings.However,the efficacy of deep learning models hinges upon a substantial abundance of flaw samples.The existing research on X-ray image augmentation for flaw detection suffers from shortcomings such as poor diversity of flaw samples and low reliability of quality evaluation.To this end,a novel approach was put forward,which involves the creation of the Interpolation-Deep Convolutional Generative Adversarial Network(I-DCGAN)for flaw detection image generation and a comprehensive evaluation algorithm named TOPSIS-IFP.I-DCGAN enables the generation of high-resolution,diverse simulated images with multiple appearances,achieving an improvement in sample diversity and quality while maintaining a relatively lower computational complexity.TOPSIS-IFP facilitates multi-dimensional quality evaluation,including aspects such as diversity,authenticity,image distribution difference,and image distortion degree.The results indicate that the X-ray radiographic images of magnesium and aluminum alloy castings achieve optimal performance when trained up to the 800th and 600th epochs,respectively.The TOPSIS-IFP value reaches 78.7%and 73.8%similarity to the ideal solution,respectively.Compared to single index evaluation,the TOPSIS-IFP algorithm achieves higher-quality simulated images at the optimal training epoch.This approach successfully mitigates the issue of unreliable quality associated with single index evaluation.The image generation and comprehensive quality evaluation method developed in this paper provides a novel approach for image augmentation in flaw recognition,holding significant importance for enhancing the robustness of subsequent flaw recognition networks.

关键词： light alloy casting flaw detection image generator discriminator comprehensive evaluation index

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Finite element simulation of real cavity closure in cast Ti6Al4V alloy during hot isostatic pressing

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China Foundry 2022年第1期19卷 55-62页

作者： Qian Xu Wen Li Ya-jun Yin jian-xin zhou Hai Nan State Key Laboratory of Materials Processing and Die and Mould Technology Huazhong University of Science and TechnologyWuhan 430074China AECC Beijing Institute of Aeronautical Materials Beijing 100095China

The healing behavior of shrinkage cavity inside the cast Ti6Al4V alloy during hot isostatic pressing(HIP)was investigated experimentally by interrupted hot isostatic pressing tests.The X-ray micro computed tomography was used to record the morphology changes before and after hot isostatic pressing.The two-dimensional geometry obtained by the microCT scan was used in simulation to study the evolution of the real shrinkage cavity during hot isostatic pressing.Shrinkage cavities,shrinkage porosity and small gas pores can be effectively eliminated under proper HIP conditions.The two-dimensional morphology in the simulation results agrees well with the experimental results.This study reveals that plastic deformation,creep and diffusion are the main mechanisms of cavity closure during hot isostatic pressing.In addition,the simplified elliptical pores with aspect ratios at different positions were used to replace the real pores to further study the factors affecting the position of dimples after HIP by simulation.It is found that the position of the dimples mainly depends on the aspect ratio of the elliptical pore and the distance between the pore surface and the external surface of the geometric model.

关键词： cast Ti6Al4V alloy hot isostatic pressing shrinkage cavity simulation closure behavior

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Effects of Ag,Co,and Ge additions on microstructure and mechanical properties of Be-Al alloy fabricated by investment casting

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China Foundry 2022年第5期19卷 435-442页

作者： Yao Xie Ya-jun Yin Dong-xin Wang jian-xin zhou Jun-yi Li Xiao-yuan Ji Zhao-gang Liu Xu Shen Wei Fu State Key Laboratory of Materials Processing and Die&Mould Technology Huazhong University of Science&TechnologyWuhan 430074China State Key Laboratory of Special Rare Metal Materials Northwest Rare Metal Materials Research Institute Ningxia Co.Ltd.Shi Zuishan753000NingxiaChina State Key Laboratory for Mechanical Behavior of Materials Xi'an Jiaotong UniversityXi'an 710049China

The effects of Ag,Co,and Ge additions on microstructure and mechanical properties of Be-35Al(wt.%)alloys fabricated by investment casting were studied.The results reveal that the trace metals 1.5wt.%Ag,0.7wt.%Co,and 0.8wt.%Ge additions do not change the nucleation temperature of Be phase.However,the nucleation temperature of the Al phase decreases from 642℃ to 630℃ by DSC due to the Ge addition.The strength of the alloys sharply increases due to the dissolution of the Ag and Ge solutes into the Al phase and the Co into the Be phase characterized by SEM and EDS.Obviously,the strength of Be-Al-Ag-Co-Ge alloy is improved by the solution strengthening.Furthermore,a few Ag_(3) Al particles contribute to the strength of the Al phase.Be-Fe-Al ternary intermetallic compounds which can effectively reduce the negative effect of an impurity element Fe on the mechanical properties of Be-Al alloys are also found by XRD and EDS.

关键词： Be-Al alloys solution strengthening investment casting mechanical properties

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Gas evolution characteristics of three kinds of no-bake resin-bonded sands for foundry in production

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China Foundry 2022年第2期19卷 140-148页

作者： Xue-wen Qian Peng Wan Ya-jun Yin Yu-yang Qi Xiao-yuan Ji Xu Shen Yuan-cai Li jian-xin zhou State Key Laboratory of Materials Processing and Die&Mould Technology Huazhong University of Science and TechnologyWuhan 430074China

No-bake resin-bonded sand is commonly used in casting production.However,its air pollution is relatively serious,especially in the molding and pouring process.For this reason,it is necessary to study the gas evolution characteristics of no-bake resin-bonded sand from room temperature to high temperatures,and not only the amount of gaseous products,but also the composition of the gaseous products.No-bake furan resin-bonded sand(#1),phenolic urethane no-bake resin-bonded sand(#2),and alkaline phenolic no-bake resin-bonded sand(#3)are the three most common no-bake resin-bonded sands in casting.The gas evolution volume and rate of these three no-bake resin-bonded sands were studied.Thermogravimetry-mass spectrometer(TG-MS),headspace-gas chromatography/mass spectrometer(HS-GC/MS),and pyrolysis-gas chromatography/mass spectrometer(PY-GC/MS)were used to measure the composition of the gaseous products emitted from binders at room temperature and high temperatures.The differences between formaldehyde,heterocyclic aromatic compounds(HAC),monocyclic aromatic hydrocarbons(MAH),and polycyclic aromatic hydrocarbons(PAHs)gaseous products from the three types of no-bake resin-bonded sands during the molding and casting process were compared.From the perspective of environmental protection,alkaline phenolic no-bake resin-bonded sand and no-bake furan resin-bonded sand are better than phenolic urethane no-bake resin-bonded sand.

关键词： no-bake resin-bonded sand gas evolution volume gas evolution rate composition of gaseous products

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Temperature field simulations during selective laser melting process based on fully threaded tree

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China Foundry 2017年第5期14卷 405-411页

作者： Wei Duan Ya-jun Yin jian-xin zhou State Key Laboratory of Materials Processing and Die&Mould Technology Huazhong University of Science and TechnologyWuhan 430074China

Selective laser melting(SLM) is a promising technique for additive manufacturing. During SLM of metallic powder, the temperature field and thermal history are important to understand physical phenomena involved. The purpose of this study is to simulate the temperature field during the SLM process of a hollow cylinder shape part based on a fully threaded tree(FTT) technique, and to analyze the temperature variation with time in different regions of the part. A revised model for temperature field simulation in the SLM process was employed, which includes the transition of powder-to-dense sub-model and a moving volumetric Gaussian distribution heat source sub-model. The FTT technique is then adopted as an adaptive mesh strategy in the simulation. The simulation result shows that during the SLM process of cylinder part, the temperature of inner powder bed is obviously higher than external one. The temperature at the internal of the molten pool is also higher than external, which may lead to differences in microstructures and other properties between the two regions.

关键词：充分线程的树选择激光融化温度分发数字模拟 TP391.99 一

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Phase field study on crystal orientation effects in eutectoid phase transformation

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China Foundry 2017年第5期14卷 435-442页

作者： Dong-qiao Zhang Ya-jun Yin jian-xin zhou Zhi-xin Tu State Key Laboratory of Materials Processing and Die&Mould Technology Huazhong University of Science and TechnologyWuhan 430074China

In this present work, a multi-phase field model was used to simulate the eutectoid transformation process, and on the basis of the nucleation model that was previously proposed by our research team, anisotropic and orientation relationship models were introduced to study the growth mechanism of the pearlite lamellae with anisotropy. It was found that the growth direction of the pearlite lamellae is related to its orientation and spacing. In the process of lamellar growth, deflection growth of pearlite will appear along with the adjustment of lamellar spacing, and the deflection angle is equal to the orientation difference between the austenite and the pearlite. Comparison between experimental and numerical results indicates a good consistency in pearlite morphology.

关键词：模拟阶段地薄片状的生长珠泽铁形态学生长方向 TP391.99 一

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Chinese expert consensus on sedation and analgesia for neurocritical care patients

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中华医学杂志(英文版) 2024年第11期137卷 2024 Apr 19页

作者： Zhang Linlin Liu Shuai Wang Shuya zhou jian-xin the National Center for Healthcare Quality Management in Neurological Diseases Chinese Society of Critical Care Medicine Working group of the Expert Consensus on Sedation and Analgesia for Neurocritical Care Patients Department of Critical Care Medicine Beijing Tiantan Hospital Capital Medical University Beijing China Department of Critical Care Medicine Beijing Shijitan Hospital Capital Medical University Beijing China

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Digital management technology and its application to investment casting enterprises

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China Foundry 2016年第5期13卷 301-309页

作者： Xiao-yuan Ji Hu Ye jian-xin zhou Wei-lin Deng State Key Laboratory of Materials Processing and Die & Mould Technology Huazhong University of Science & Technology

With the advent of Industry 4.0, more and more investment casting enterprises are implementing production manufacturing systems, especially in the last two years. This paper summarizes three new common requirements of the digital management aspect in precision casting enterprises, and puts forward three corresponding techniques. They are: the production process tracking card technology based on the main-sub card mode; the workshop site production process processing technology based on the barcode; and the equipment data integration technology. Then, this paper discusses in detail the principle, application and effect of these technologies; to provide the reference for enterprises to move towards digital casting and intelligent casting.

关键词： investment casting digital management task driven main-sub card workshop site processing data integration

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Optimal design of feeding system in steel casting by constrained optimization algorithms based on InteCAST

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China Foundry 2016年第6期13卷 375-382页

作者： Chang-chun Dong Xu Shen jian-xin zhou Tong Wang Ya-jun Yin State Key Laboratory of Materials Processing and Die & Mould Technology Huazhong University of Science and Technology

The traditional foundry industry has developed rapidly in recently years due to advancements in computer technology. Modifying and designing the feeding system has become more convenient with the help of the casting software, Inte CAST. A common method of designing a feeding system is to first design the initial systems, run simulations with casting software, analyze the feedback, and then redesign. In this work, genetic, fruit fly, and interior point optimizer(IPOPT) algorithms were introduced to guide the optimal riser design for the feeding system. The results calculated by the three optimal algorithms indicate that the riser volume has a weak relationship with the modulus constraint; while it has a close relationship with the volume constraint. Based on the convergence rate, the fruit fly algorithm was obviously faster than the genetic algorithm. The optimized riser was also applied during casting, and was simulated using Inte CAST. The numerical simulation results reveal that with the same riser volume, the riser optimized by the genetic and fruit fly algorithms has a similar improvement on casting shrinkage. The IPOPT algorithm has the advantage of causing the smallest shrinkage porosities, compared to those of the genetic and fruit fly algorithms, which were almost the same.

关键词： casting process design optimal solution Inte CAST

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Optimization of steel casting feeding system based on BP neural network and genetic algorithm

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China Foundry 2016年第3期13卷 182-190页

作者： Xue-dan Gong Dun-ming Liao Tao Chen jian-xin zhou Ya-jun Yin State Key Laboratory of Materials Processing and Die & Mould Technology Huazhong University of Science and Technology School of Mechanical Engineering Hubei University of Technology

The trial-and-error method is widely used for the current optimization of the steel casting feeding system, which is highly random, subjective and thus ineff icient. In the present work, both the theoretical and the experimental research on the modeling and optimization methods of the process are studied. An approximate alternative model is established based on the Back Propagation(BP) neural network and experimental design. The process parameters of the feeding system are taken as the input, the volumes of shrinkage cavities and porosities calculated by simulation are simultaneously taken as the output. Thus, a mathematical model is established by the BP neural network to combine the input variables with the output response. Then, this model is optimized by the nonlinear optimization function of the genetic algorithm. Finally, a feeding system optimization of a steel traveling wheel is conducted. No shrinkage cavities and porosities are induced through the optimization. Compared to the initial design scheme, the process yield is increased by 4.1% and the volume of the riser is decreased by 5.48×10~6 mm3.

关键词： steel casting numerical simulation process parameters optimization BP neural network

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