Ultrasonic Forming of Amorphous Alloys With Local Gradient Toughening
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Solution Overview
Problem
Existing methods for toughening amorphous alloys fail to achieve local nanocrystallization and mechanical property gradients in complex-shaped parts, requiring additional processing steps and long production cycles, while also compromising the material's high strength and corrosion resistance.
Innovation Solution
A method and device utilizing ultrasonic vibration applied through inserts connected to an ultrasonic amplitude transformer, combined with resistance heating, to induce nanocrystallization in specific regions of amorphous alloy parts during thermoplastic forming, allowing for simultaneous forming and toughening without additional processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If additional processing steps are added to achieve local nanocrystallization, then the mechanical property gradient is improved, but the production cycle time increases
Solution Approach 1:
The patent combines the nanocrystallization treatment and thermoplastic forming processes into a single integrated operation. The ultrasonic vibration inserts are incorporated into the mold cavity, allowing nanocrystallization to occur simultaneously with the forming process rather than as a separate subsequent step, thereby achieving the mechanical property gradient without extending the production cycle time.
Solution Approach 2:
The ultrasonic vibration inserts are pre-positioned in the mold cavity before the forming process begins, and the treatment is applied during the forming operation itself. This preliminary integration of the toughening mechanism into the forming process eliminates the need for additional post-processing steps to achieve local nanocrystallization and the associated mechanical property gradient.
2Strength
If complex-shaped parts are toughened using existing methods, then the toughness is improved, but the dimensional accuracy and forming precision deteriorate
Solution Approach 1:
The patent uses inserts positioned at specific locations in the mold cavity to apply ultrasonic vibration only to regions where toughness improvement is needed, rather than treating the entire complex-shaped part. This localized approach allows the bulk of the part to maintain its precise dimensional accuracy while specific regions gain enhanced toughness through controlled nanocrystallization.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach simplifies production processes, shortens forming time, improves dimensional accuracy, and enhances the material's toughness and strength by creating a mechanical property gradient within the amorphous alloy composite, effectively addressing the limitations of prior methods.
Implementation Method 1
applying ultrasonic vibration to the local region to be toughened with an insert connected to an ultrasonic vibration amplitude transformer
Implementation Method 2
one or more resistance heating rods, the one or more resistance heating rods are used for heating raw material blank to be processed to a forming temperature
Implementation Method 3
nanocrystallines can be induced locally in the amorphous matrix by some means to form a nanocrystalline toughened amorphous matrix composite
Data Source
Figure 1~2
AI summary
The present invention belongs to the field of amorphous alloy thermoplastic forming, and discloses a plastic forming and gradient toughening method and a device based on ultrasonic vibration. The method includes: (a) dividing one or more portions to be toughened on an amorphous alloy part to be formed, the portion being used for generating a nanocrystalline toughening phase; (b) designing a toughening device for forming, wherein the toughening device comprises one or more inserts connected to an ultrasonic vibration amplitude transformer and one or more heating rods, the insert is disposed corresponding to the portion to be toughened and used for applying ultrasonic vibration to the portion to be toughened, and the heating rod is used for heating raw material blank to be processed to a forming temperature, and (c) placing the raw material blank in the device, heating it by the heating rod, and performing mold closing of the device to form a required amorphous alloy part, ultrasonic vibration being started in the mold closing process and stopped when mold opening is performed. Meanwhile, the invention further discloses the utilized device. With the method of the present invention, toughening and thermoplastic forming can be performed at the same time, so that integration of forming and toughening is achieved, which simplifies production processes, shortens the processing time and improves the dimensional accuracy.