铝-7石墨复合材料的半固态加工

采用电磁机械复合搅拌法制备了铝-7石墨的半固态浆料,研究了常规铸造条件下浆料的固相率对铸锭中石墨颗 粒分布的影响,得到了合理的铝-7石墨复合材料半固态加工工艺条件。     

Pb-Sn合金凝固通道偏析的实验与数值模拟研究

通过实验和数值模拟研究了Pb-19%Sn合金侧向凝固过程中的通道偏析.结果表明:铸锭侧向冷却时,糊状区中的富集溶质(Sn)由于密度小而向上运动.固相分数愈大,枝晶间流动强度愈小.偏析通道中的富集溶质相对于周围凝固时间长;通道由糊状区向最后凝固区域生长.侧向凝固的铸锭在顶部形成正偏析,在底部形成负偏析,在表面形成"沟槽"偏析,在铸锭内部形成A形偏析.基于本文数学模型的数值模拟结果与实验模拟结果一致,可反映侧向凝固与通道偏析的形成规律.     

Al—20%Sn轴瓦合金凝固偏析的研究

提出了消除Al-20%Sn崭瓦合金宏观偏析的局部偏析思想,通过采用Al-20%Sn半固态浆料进行常规铸造,实现了Sn的局部偏析,确定了Sn的偏析与半固态浆料固相率之间的关系,并且得到了消除Sn宏观偏析的技术条件,研究结果表明,随着Al-20%Sn半固态浆料固相率增大,Sn的宏观偏析程度逐渐减小,并且当半固态浆料固相率大于30%时,局部偏析消除了宏观偏析。     

电磁搅拌对水冷热顶铸造A356合金质量的影响

通过常规铸造A356合金锭与电磁搅拌＋水冷热顶铸造A356合金棒的质量差异的对比,分析电磁搅拌＋水冷热顶铸造对铝合金棒组织性能的影响,结果表明采用电磁搅拌＋水冷热顶铸造方法生产出的A356铝合金棒的质量在各个方面均优于常规铸造A356合金锭的。     

近液相线半连续铸造A356铝合金显微组织

采用近液相线半连续铸造法制备铸造A356铝合金，获得金属半固态加工要求的细小，等轴的“非枝晶”组织，研究了铸造温度、保温时间及冷却速度对该组织的影响规律。结果表明，在液相线附近，降低铸造温度，有利于减小晶粒尺寸；晶粒平均等积圆直径最小可达42．6μm，初始固相体积分数最多可达98．4％，同一温度下，晶粒尺寸随保温时间的延长而粗化；冷却速度快，晶粒尺寸细小；同一铸锭，其中心部位的组织比边缘部位的组织粗大，且分布均匀、等轴特征明显。     

铝合金扁锭热顶电磁铸造技术

根据热顶-电磁铸造的基本思想,设计了一套适合于制取铝合金扁锭的热顶-电磁成型系统,用小线圈法测量了系统内的磁场强度,计算了电磁压力分布,并与普通电磁铸造成型系统的结果进行对比分析;依据热顶电磁铸造的成型条件,确定了相关的控制参数;通过大量的拉坯实验,探讨了热顶对防止电磁铸造坯易产生表面夹杂缺陷的作用.结果表明:采用热顶-电磁铸造法不仅可有效去除电磁铸造中因电磁搅拌产生的氧化夹杂,而且使得电磁铸造过程简便而易于控制.     

NUMERICAL SIMULATION OF MACRO-SEGREGATION IN STEEL INGOT DURING SOLIDIFICATION

A mathematical model coupling the momentum, energy and species conservation equations was proposed to calculate the macro-segregation of Fe-C alloy ingot during solidification. The corresponding simulation software which concurrently solves the macroscopic mass, momentum, energy and species conservation equations has been developed by applying the SIMPLE algorithm. The thermo-solutal convection in a NH4 Cl-H2O ingot is verified and the result shows good agreement with that reported. Then macro-segregation in a steel ingot is simulated by using the developed program. The steel ingot is in a rectangular mold with a riser. The fluid flow is mainly induced by the temperature field and the solid fraction. The macro-segregation pattern is mainly affected by the thermo-induced convection in the mushy zone. The negative segregation forms along the walls of the casting. The positive segregation forms at the top center of the casting into the riser. The species concentration reaches the peak in the center of the ingot where solidification ends lastly.     

电磁搅拌对功能材料凝固组织和心部缺陷的影响

分别采用电磁搅拌和传统模铸工艺制备金基合金,研究了电磁场对金基合金显微组织和心部缺陷的影响,结果表明：采用电磁搅拌技术制备的金基合金其凝固组织的枝晶化程度明显降低,与此同时,消除了在传统模铸条件下金基合金铸锭心部所普遍出现的中心缩孔和缩松等缺陷,并对电磁搅拌作用下,金基合金凝固组织的细化和铸锭心部缺陷的消除机理进行了探讨。     

高强度Cu-Ni-(Al)-Si合金的组织和性能

通过光学显微镜、维氏硬度计、双臂电桥、扫描电子显微镜、透射电子显微镜等测试手段对Cu-5.2Ni-1.2Si和Cu-5.2Ni-1.5Al-1.2Si合金的组织结构和性能进行了表征与测试。结果表明:2种合金的铸态组织均为发达的树枝晶组织,包括白亮的枝晶区、非平衡凝固相粒子及中间过渡区。其中枝晶为富Cu区,凝固相为富Ni和Si区,Al元素则比较均匀地分布在铸态组织中。峰值时效后,Cu-5.2Ni-1.5Al-1.2Si合金具有比Cu-5.2Ni-1.2Si合金更高的硬度。Al元素不但促进了Ni2Si的沉淀析出,还形成了Ni3Al沉淀相,从而大大提高合金强度。2种合金的时效早期均出现了有序化,峰时效时主要为沉淀析出强化,合金具有较好的抗过时效能力。     

Control of equiaxed grains in a complicated Cu-Ni based alloy prepared by centrifugal casting

A complicated Cu-Ni based alloy was developed to fabricate wear-resisting bush for high temperature application.The concern focuses on the control of equiaxed grains in the developed alloy ingot prepared by centrifugal casting.The results show that the equiaxed grains are determined by the pouring temperature of the melt,the cooling rate and the rotation speed of the mold.With the decrease in pouring temperature,the fraction of the equiaxed grains in the transverse section of the ingot increases and the average length of columnar grain decreases.When the pouring temperature is confined below 1,250℃,complete equiaxed grains can be obtained.Based on the optimal centrifugal casting processing,the tensile strength of the developed alloy ingot with complete equiaxed grains reaches to 810 MPa and 435 MPa at room temperature and 500℃,respectively,which is 14% and 110% higher than that of common commercial QAl10-4-4 alloy.The wear rate of the developed alloy is 7.0 × 10-8 and 3.8 × 10-7 mm3?N-1?mm-1 at room temperature and 500℃,respectively,which is 5 times and 39 times lower than that of QAl10-4-4 alloy.     

原位TiC颗粒含量对近液相线铸造7075铝合金二次加热组织的影响

采用原位反应近液相线铸造法制备具有不同原位TiC颗粒含量的TiC_p/7075铝基复合材料,在7075铝合金固-液两相区间(477～635 ℃)的580和600 ℃进行二次加热并保温20 min,水淬固定其半固态组织,应用Image Pro Plus软件测量平均晶粒尺寸及形状因子,研究原位TiC颗粒含量对该合金二次加热组织的影响.结果表明:当原位TiC颗粒质量分数为0～4.4%时,随着原位TiC颗粒质量分数增加,合金铸态组织直接转变为等轴晶组织,且在二次加热过程中,原位TiC颗粒对晶粒的长大行为具有明显的抑制作用;在相同的二次加热条件下,4.4%TiC_p/7075铝基复合材料的平均晶粒尺寸比7075基体合金的减少30～40 μm,更加适合于半固态触变成形.     

铜合金低压铸造中浇不足缺陷的数值模拟

浇不足是铜合金低压铸造中常见的缺陷之一,采用数值模拟不仅可以预测铸件最终的浇不足形态,还可以进一步分析浇不足的产生与演化过程,而预测浇不足的关键是处理好合金糊状区对金属液流动的影响。针对铜合金修正了糊状区的变粘度-多孔介质-临界固相率模型,基于变物性参数计算并对比分析了其与变粘度-临界固相率模型模拟结果的差异性。实际生产表明,修正后的变粘度-多孔介质-临界固相率模型可以准确预测出铸件的浇不足缺陷,数值计算模型更可靠。     

Zr_(47)Cu_(44)Al_9大块非晶合金的制备及其力学性能

利用电弧炉制备一系列(Zr_(51.6)Cu_(48.4))_(100-x)Al_x(x=6.0～10.0, 摩尔分数,%)大块非晶合金,利用示差扫描量热仪、X射线衍射仪和金相显微镜研究Al的含量对其非晶形成能力的影响.结果表明:当铝的含量为9.0%时,合金具有最优的非晶形成能力.适量铝的加入不仅能够抑制初生相CuZr的析出,而且还能有效地抑制其长大.临界冷却速率的经验公式计算结果显示该合金的临界冷却速率为10 K/s,室温压缩力学性能显示其断裂强度为1.9 GPa,且有0.5%的塑性变形,式为韧性剪切断裂.     

Microstructural evolution of high strength 7B04 ingot during homogenization treatment

The evolution of the microstructure and phases of the direct chill semicontinuous casting ingot of 7B04 super-high strength aluminum alloy during homogenization treatment was studied with metallographic analysis, scanning electron microscopy（SEM）, energy spectroscopy and differential scanning calorimetry（DSC）. The results show that a considerable amount of non-equilibrium eutectics containing AI, Zn, Cu and Mg exist in the direct chill semicontinuous casting ingot of 7B04 super-high strength aluminum alloy, and their melting point is 478℃. During homogenization treatment at 470℃, these eutectics dissolve into the matrix partly, coarsen and also transform into Al2CuMg phase whose equilibrium melting point is 490℃ in the alloy. Moreover, the homogenization treatment at 470℃ for 72 h results in the disappearance of the non-equilibrium eutectics though Al2CuMg phase can not dissolve completely.     

变形处理Al—P中间合金对Al—Si合金变质作用的影响

将Al-2.5%P中间合金锭挤压成丝材能显著改善中间合金中AIP颗粒的分布形态,增加AIP的表面自由能。比较了Al-2.5%P中间合金锭和丝材对Al-Si合金的变质时间,发现采用Al-2.5%P中间合金丝能缩短变质时间,约15min即能使Al-Si合金获得良好的变质效果,更符合实际生产的要求。     

铝合金半固态浆料中球形颗粒的演变

用AlSi7Mg0.6半固态浆料进行实验,研究球形颗粒的演变机理.在略高于液相线温度下水淬的样品中结晶相主要为枝晶,而采用旋转圆筒的方式来搅拌熔体使其冷却到半固态温度范围内时样品的结晶相完全球化.在铸造前进行较长时间的内冷却和搅拌,可以得到较高的固相分数.不同大小的枝晶碎片的存在表明,在搅拌过程中,初始的固相分数形成后不再受冷却的影响.     

超声半固态流变挤压成形Al-20Si-2Cu-0.4Mg-1Ni合金的组织特征(英文)

通过超声振动半固态流变挤压铸造工艺制造汽车空调压缩机铝硅合金斜盘零件,研究合金的组织特征。发现在Al20Si2Cu0.4Mg1Ni合金的组织中,除了通常具有的初晶Si和α(Al)+β-Si共晶相之外,还有非平衡α(Al)颗粒或枝晶。挤压铸造过程中的较快的冷却速度而非压力是非平衡α(Al)相形成的主要原因。在半固态浆料的制备过程中,超声振动的声压作用能促进非平衡α(Al)相在共晶温度以上生成,并生长为非枝晶颗粒。超声处理的过共晶AlSi合金中的非平衡α(Al)相由共晶温度以上生成的圆形α(Al)晶粒和少量共晶温度以下生成的细小α(Al)枝晶构成。由于超声振动的作用使α(Al)基体中的Si的固溶度增加,并使初晶Si的形成温度降低,组织中初晶Si颗粒的体积分数显著降低。流变挤压斜盘中的初晶Si颗粒的平均直径和体积率分别为24.3μm和11.1%。     

Overheating temperature of 7B04 high strength aluminum alloy

The microstructure and overheating characteristics of the direct chill semicontinuous casting ingot of 7B04 high strength aluminum alloy, and those after industrial homogenization treatment and multi-stage homogenization treatments, were studied by differential scanning calorimetry(DSC), optical microscopy(OM) and scanning electron microscopy with energy dispersive X-ray spectroscopy(SEM-EDX). The results show that the microstructure of direct chill semicontinuous casting ingot of the 7B04 alloy contains a large number of constituents in the form of dendritic networks that consist of nonequilibrium eutectic and Fe-containing phases. The nonequilibrium eutectic contains Al, Zn, Mg and Cu, and the Fe-containing phases include two kinds of phases, one containing Al, Fe, Mn and Cu, and the other having Al, Fe, Mn, Cr, Si and Cu. The melting point of the nonequilibrium eutectic is 478 ℃ for the casting ingot of the 7B04 alloy which is usually considered as its overheating temperature. During industrial homogenization treatment processing at 470 ℃, the nonequilibrium eutectic dissolves into the matrix of this alloy partly, and the remainder transforms into Al2CuMg phase that cannot be dissolved into the matrix at that temperature completely. The melting point of the Al2CuMg phase which can dissolve into the matrix completely by slow heating is about 490 ℃. The overheating temperature of this high strength aluminum alloy can rise to 500-520 ℃. By means of special multi-stage homogenization, the temperature of the homogenization treatment of the ingot of the 7B04 high strength aluminum alloy can reach 500 ℃ without overheating.     

Structures and macrosegregation of a 2024 aluminum alloy fabricated by direct chill casting with double cooling field

Central region coarse grains and centerline segregation are common defects in aluminum ingots fabricated by direct chill(DC)casting.A double cooling field was introduced into the DC casting process to reduce these defects,whereby the external cooling was supplied by the mold and water jets,and intercooling was achieved by inserting a rod of the same alloy into the molten pool along the central axis of the ingot.Rather than forming a good metallurgical interface during solid-liquid compound casting,in the present work,the purpose of inserting the rod is to enforce internal cooling and consequently decrease the sump depth.Moreover,the insertion provides more nucleation sites with the unmoltenα-Al particles.The structure and the macrosegregation of 2024 Al alloy ingots prepared by DC casting with and without the inserts were investigated.Results show that when the inserting position is 50 mm above the upper edge of the graphite ring,significant grain refinement in the central region of the ingot and a reduced centerline segregation are achieved.     

利用Marangoni对流制备均质偏晶合金

利用温度场下第二相液滴的Ｍａｒａｎｇｏｎｉ运动，设计了一种在地球重力场下制备均质偏晶合金的“控制铸造”新技术。在这种技术中，偏晶合金凝固界面前沿的第二相液滴将在重力场下作Ｓｔｏｋｅｓ运动和在温度梯度场下作与重力方向相反的Ｍａｒａｎｇｏｂｎｉ运动。