基于CAFE模拟双辊连铸纯铝凝固微观组织

鉴于双辊薄带连铸等轴晶区半固态铸轧组织对产品性能的重要性,基于热传输、流动传输、溶质传输等基本传输过程以及晶粒生长物理过程,建立了双辊连续铸轧纯铝凝固过程的宏观温度场、浓度场、微观组织及枝晶形貌演化的三维数学模型.采用CA-FE法对双辊连续铸轧纯铝在水冷钢辊连续铸轧中的凝固过程进行了模拟,采用光学显微镜研究了铸轧工艺参数对凝固组织的影响.数值模拟结果表明,所建立的数学模型能够合理描述晶粒沿任意角度生长的过程,温度场、溶质场和微观组织形貌的模拟计算结果合理.模拟结果与实验结果基本吻合,检验了模型的正确性.     

基于CA-FE的双辊连铸纯铝凝固组织模拟

鉴于双辊薄带连铸等轴晶区半固态铸轧组织对产品性能的重要性,应用Procast软件中的CA-FE方法对工业纯铝在水冷钢辊连续铸轧中的凝固过程进行了模拟,建立了宏观温度场、浓度场和微观生长过程耦合的凝固组织模拟模型。以CA(Cellular Automaton)模型为基础,建立了晶粒生长过程的局部演变规则,在晶粒尺度上模拟了其凝固过程。应用建立的微观组织模型,研究了工艺参数对凝固组织的影响。模拟结果与实验结果基本吻合,检验了模型的正确性与适用条件。     

基于一种改进CA模型模拟双辊连续铸轧纯铝微观组织

基于枝晶生长的基本传输过程和元胞自动机(Cellular Automaton,简称CA)-有限元(Finite Element,简称FE)模型基本原理,建立了适应双辊连续铸轧纯铝薄带工艺特点的凝固过程形核和晶体生长的数学模型.模型耦合了宏观温度场和微观组织模拟计算,考虑了溶质扩散、曲率过冷和各向异性等重要因素的影响,定义了界面单元捕获规则,能够模拟凝固过程中枝晶生长的形态.应用本模型对双辊连续铸轧纯铝薄带凝固过程中等轴晶生长、等轴晶多晶粒生长及柱状晶生长、柱状晶向等轴晶演化进行模拟并与实验结果进行对比,模拟结果与实验结果吻合较好,验证了模型的正确性.     

铸轧镁合金薄带组织演变实验研究与模拟

以镁合金薄带双辊铸轧新技术为背景,开展了铸轧成形过程中组织性能的模拟研究。镁合金薄带双辊铸轧是以液态镁合金为原料,用两个反向转动的水冷铸辊为结晶器,直接制备1.5~3.0 mm镁合金薄带的短流程新工艺。对双辊铸轧轻合金薄带的凝固组织演化过程进行数值模拟,用以优化和指导制备技术,具有重要的理论意义和应用前景。项目研究组通过对双辊铸轧过程动态凝固成形的有限元数值模拟研究、镁合金薄带铸轧实验研究以及后续加工过程中的组织演变规律研究,得到了主要工艺参数对铸轧工艺稳定性及组织性能的影响规律。     

快速凝固7000系超高强铝合金的研究现状

在对传统7000系高强铝合金分析的基础上,着重阐述了快速凝固超高强铝合金的发展过程、存在问题和研究现状.快速凝固技术可有效细化组织、提高合金元素的极限固溶度、抑制宏观和微观偏析,并提高超高强铝合金的综合性能,最后提出了快凝超高强铝合金的应用和发展前景.     

液体轧制Al─Si合金薄带的强韧化

液体轧制是将快速凝固技术引入连续铸轧中形成的一种新的加工方法研究结果表明，液体轧制Ａｌ－Ｓｉ合金薄带的强度较未变质铸态的提高３９％，塑性指标亦明显提高．这是由于液体轧制过程中液体处于快速流动状态和一定压力双重作用下快速结晶凝固成形，从而改变了Ａｌ－Ｓｉ合金薄带的显微组织，尤其是Ｓｉ相的形态、尺寸及其分布状态，使薄带获得了明显的强韧化效果．     

液体轧制Al—Si合金薄带的强韧化

液体轧制是将快速凝固技术引入连续铸轧中形成的一种新的加工方法，研究结果表明，液体轧制Ａｌ－Ｓｉ合金薄带的强度较未变质铸态的提高３９％，塑性指标亦明显提高，这是由于液体轧制过程中液体处于速流动状态和一定压力双重作用下快速结晶凝固成开，从而改变了Ａｌ－Ｓｉ合金薄带的显微组织，尤其是Ｓｉ相的形态，尺寸其分布状态，使薄带获得了明显的强韧化效果。     

镍基单晶高温合金定向凝固的数值模拟

概述了目前国内外镍基单晶高温合金定向凝固数值模拟的研究进展,定向凝固过程的数值模拟由宏观向微观转变,详细介绍了微观组织数值模拟的几种主要方法:决定论方法、随机论方法和相场方法,评述了这几种方法的特点以及局限性,指出宏观和微观现象的完整耦合可以对镍基单晶高温合金凝固过程做出更加准确的模拟预测。     

镍基单晶高温合金定向凝固的数值模拟

概述了目前国内外镍基单晶高温合金定向凝固数值模拟的研究进展,定向凝固过程的数值模拟由宏观向微观转变,详细介绍了微观组织数值模拟的几种主要方法：决定论方法、随机论方法和相场方法,评述了这几种方法的特点以及局限性,指出宏观和微观现象的完整耦合可以对镍基单晶高温合金凝固过程做出更加准确的模拟预测。     

铝合金连续铸轧数值模拟现状及研究展望

介绍了目前关于铝合金连续铸轧过程数值模拟方法的种类以及面临的突出问题,结合当前国内外研究的现状,展望了铝合金连续铸轧数值模拟的发展趋势。     

Numerical Simulation of Microporosity Evolution of Aluminum Alloy Castings

A mathematical model to calculate the size and distribution of microporosities was studied and coupled with a stochastic microstructure evolution model. The model incorporates various solidification phenomena such as grain structure evolution, solidification shrinkage, interdendritic fluid flow and formation and growth of pores during solidification processes. The nucleation and growth of grains were modeled with a cellular automaton method that utilizes the results from a macro scale modeling of the solidification process. Experiments were made to validate the proposed models. The calculated results of aluminum alloy castings agreed with the experimental measurements.     

Experimental Study and Numerical Simulation of Directionally Solidified Turbine Blade Casting

The directional solidification process of turbine blade sample castings was investigated in the work. Variable withdrawal rates were used in one withdrawal process and compared with the other using uniform rate. A mathematical model for heat radiation transfer and microstructure simulation of directional solidification process was developed based on CA-FD method. The temperature distribution and microstructure w.ere simulated and compared with the experimental results. The stray grains were predicted and compared with the experimental results. The uneven temperature distribution of platform was the main reason of the formation of stray grains.     

Study on Numerical Simulation of Mold Filling and Solidification Processes under Pressure Conditions

The mold filling and solidification simulation for the high pressure die casting (HPDC) and low pressure die casting (LPDC) processes were studied.A mathematical model considering the turbulent flow and heat transfer phenomenon during the HPDC process has been established and paralled computation technique was used for the mold filling simulation of the process.The laminar flow characteristics of the LPDC process were studied and a simplified model for the mold filling process of wheel castings has been developed.For the solidification simulation under pressure conditions,the cyclic characteristics and the complicated boundary conditions were considered and techniques to improve the computational efficiency are discussed.A new criterion for predicting shrinkage porosity of Al alloy under low pressure condition has been developed in the solidification simulation process.     

Pb-Sn合金侧向凝固过程A偏析的数值模拟

基于二元系凝固过程热溶质的传输行为,建立了描述A偏析形成及演化的数学模型,给出了固相分数与温度场及浓度场的耦合关系.先用已有的实验结果验证了模型的正确性,然后模拟计算了Pb-Sn合金侧向凝固过程A偏析的形成及演化过程,并研究了浮力数对A偏析形成位置及偏析程度的影响.结果表明,在糊状区中双扩散对流引起的密度变化,导致局部流动,形成偏析通道;为了维持偏析通道中局部液体的流动,枝晶间的液体通过糊状区从液相区得到补充.在相同的凝固条件下,浮力数越小,A偏析的形成时间愈迟,偏析的程度也越小.     

Numerical Simulation of Stress and Deformation for a Duplex Stainless Steel Impeller during Casting and Heat Treatment Processes

A large-scale, thin wall duplex stainless steel impeller with complex geometry was deformed severely and unpredictably during casting and heat treatment processes resulted in dimensional failure for the final part. In this paper, the distortion of the impeller during casting and heat treatment was calculated. A commercial software, Experto-ViewCast, was used to simulate the transient heat transfer, solidification and mechanical behaviors during the casting and the heat treatment process. The coupled set of governing differential equations for mass, energy and mechanical balance were solved by finite control volume and finite element method. A thermoelastic-visco-plastic rheological model was used to compute the constrained shrinkage of the casting. At each time increment, a coupling of the heat transfer and mechanics was performed. Comparison of the experimental measurements with the model predictions showed good agreement. From the calculated displacements of key points of the blade, the proper inverse displacements were determined to provide an optimum casting pattern and to achieve a uniform and reasonable machining allowance for both faces of the blade.     

镁合金铸造成形过程宏观/微观模拟

通过研究镁合金压铸过程中界面热,采用热传导反算法确定压铸过程的界面换热系数,研究镁合金压铸过程中工艺参数及凝固过程对铸件界面换热系数的影响规律,建立镁合金压铸过程界面换热边界条件的处理模型,以实现镁合金压铸过程中凝固过程的准确预测。通过实验研究镁合金压铸过程中凝固组织,建立了镁合金压铸过程中形核模型。采用CA方法,建立了镁合金枝晶生长模型,以实现镁合金凝固组织的预测。采用相场方法研究了镁合金枝晶生长形貌。     

等轴晶移动条件下金属凝固温度场、流场及溶质分布数值模拟

本文利用作者提出的固相移动条件下金属凝固传热、传质及动量传输数学模型对砂型铸造 Al-4.5%Cu 合金铸锭凝固过程进行了数值模拟研究与试验验证。模拟冷却曲线及宏观偏析与试验结果基本相符。     

Application of a Solidification Mathematical Model and a Genetic Algorithm in the Optimization of Strand Thermal Profile Along the Continuous Casting of Steel

This work presents an optimization method based on a genetic algorithm applied to continuous casting process. A simple genetic algorithm was developed, which works linked to a mathematical model permitting the determination of optimum values for the water flow rates in the secondary cooling zones. First, experimental data (industrial) were compared with simulated results obtained by the solidification mathematical model, to determine the metal/cooling heat transfer coefficients along the machine by the inverse heat conduction problem method. The industrial data concerning surface strand temperature were obtained by using infrared pyrometers along a continuous caster machine during casting of both SAE 1007 and 1025 steels. In a second step, these results were used by a numerical code based on a genetic algorithm for determining optimum settings of water flow rates in the different sprays zones, which are conducive to the best quality of the solidified strand. The simulations were carried out by analyzing the solidification process during continuous casting to attain metallurgical restrictions concerning the reheating of strand surface temperature and metallurgical length.     

Numerical Modeling of Grain Structure in Continuous Casting of Steel

A numerical model is developed for the simulation of solidification grain structure formation (equiaxed to columnar and columnar to equiaxed transitions) during the continuous casting process of steel billets. The cellular automata microstructure model is combined with the macroscopic heat transfer model. The cellular automata method is based on the Nastac's definition of neighborhood, Gaussian nucleation rule, and KGT growth model. The heat transfer model is solved by the meshless technique by using local collocation with radial basis functions. The microscopic model parameters have been adjusted with respect to the experimental data for steel 51CrMoV4. Simulations have been carried out for nominal casting conditions, reduced casting temperature, and reduced casting speed. Proper response of the multiscale model with respect to the observed grain structures has been proved.