金属型球铁磨球非平衡凝固特性的研究

探索了金属型球铁磨球非平衡结晶过程，并就磨球的非平衡凝固特性进行了较深入的分析研究。过共晶球铁凝固时出现非平衡奥氏体；亚共晶球铁出现晕圈铁素体和非平衡渗碳体相；在柱状晶与等轴晶过渡区中存在着偏聚物。为改善球铁磨球的显微组织及性能，球铁成分应控制在共晶或稍过共晶处。     

Precipitation and evolution of nodular graphite during solidification process of ductile iron

The quantity and morphology of spheroidal graphite have an important effect on the properties of ductile iron,and the characteristics of spheroidal graphite are determined by the solidification process.The aim of this work is to explore the precipitation and evolution of graphite nodules in hypoeutectic,eutectic,and hypereutectic ductile irons by thermal analysis,liquid quenching and metallographic technique.Results show that hypoeutectic ductile iron has the longest solidification time and the lowest eutectic temperature;eutectic ductile iron has the shortest solidification time;hypereutectic ductile iron has the highest eutectic temperature.After solidification is completed,hypoeutectic ductile iron has the lowest nodule count,nodularity and graphite fraction;eutectic ductile iron has the highest nodule count,nodularity and the smallest nodule diameter;hypereutectic has the highest nodule diameter and graphite fraction.The nucleation and growth of graphite nodules in hypereutectic ductile iron starts before bulk eutectic crystallization stage,however,the precipitation and evolution of graphite nodules of hypoeutectic and eutectic ductile irons mainly occur in the eutectic crystallization stage.The graphite precipitated in eutectic crystallization of hypoeutectic,eutectic,and hypereutectic ductile irons,are 61%,68% and 43% of total graphite volume fraction,respectively.Simultaneously,there are plenty of austenite dendrites in hypoeutectic and hypereutectic ductile irons,which are prone to shrinkage defects.Therefore,the eutectic ductile iron has the smallest shrinkage tendency.     

Inoculation and its effect on primary solidification structure of hypoeutectic grey cast iron

Abstract

The solidification of grey cast iron is controlled by the addition of inoculants. This is done in order to provide nucleation sites and hence facilitate the formation of eutectic cells and decrease the degree of undercooling. The number of eutectic cells and the graphite morphology affect the final properties of the casting. Preceding the nucleation of graphite and the eutectic cells is the nucleation of the primary austenite. It was found that the addition of inoculants also influences the primary solidification. The largest effect on the primary dendrites is obtained by inoculation using pure iron powder. It was also shown how the columnar to equiaxed transition (CET) depends on the number of equiaxed dendrites per unit volume. In addition, the primary structure was found to influence the eutectic solidification. The relationship between the secondary dendrite arm spacing and the eutectic cell size was found to correlate well with the work of others.     

过共晶球铁凝固过程中奥氏体的生长方式与形貌特征

采用着色腐蚀技术显示出过共晶球铁中的高温凝固组织，观察分析过共晶球铁凝固过程中奥氏体的生长方式与形持征。结果表明：在非平衡凝固条件下，过共晶球铁凝固时通常会析出初生枝晶和晕圈枝晶，其形成条件主要与冷却速率和熔体的过冷有关。随铸件模数Mc增大，枝晶数量减少，二次臂间距显著增大，形态趋于不发达，由初生枝晶向晕圈枝晶过渡。当Mc≤0.3cm时，二次臂间距的实测值与理论预测值基本吻合。初生石墨球周围往往形成环状封闭奥氏体壳；共晶前期石墨球周围形成封闭或不封闭的框架奥氏体壳；共晶后期石墨球往往被周边生长着的共晶奥氏体所包覆，最终成为共晶奥氏体的一部分。     

灰铸铁凝固过程结晶潜热处理模型

基于潜热处理的温度回升法,针对灰铸铁凝固过程中具有初晶和共晶两个阶段的凝固特性,提出了适合灰铸铁的带共晶的潜热处理方法。根据Fe-C-Si三元合金相图,采用杠杆定律来计算初晶和共晶的分配系数。将该方法应用于实际灰铸铁件的凝固模拟计算,并将计算结果与不区分初晶与共晶过程的潜热处理方法的计算结果相比较。该方法的计算结果更接近实际凝固情况。     

Relation between SDAS and eutectic cell size in grey iron

Abstract

The solidification of cast components is a complex and important process as this is the moment when the final properties are established. For hypoeutectic grey iron, solidification starts with nucleation and growth of the primary austenite followed by the eutectic reaction forming eutectic cells. In this work, the microstructure and significance of the different constituents formed during solidification has been examined. It was found that the size of the eutectic cells is a function of secondary dendrite arm spacing (SDAS). The SDAS, on the other hand, was found to depend on the solidification time and hence the growth rate of the dendrites. The effect of chemical composition on SDAS and eutectic cell size was found to depend on cooling rate. It is suggested that the relationship between the eutectic cells and dendrite arm spacing is based on segregation effects and the nucleating capacity of the melt.     

高碳当量灰铸铁用稳定化孕育剂的研究

采用微分热分析法、着色腐蚀技术及自动图象分析仪对比研究了１＃ＲＥ，６８Ｍｎ－Ｆｅ，６３Ｃｒ－Ｆｅ，３０Ｔｉ－Ｆｅ，纯Ｓｂ等稳定化孕育剂对高碳当量灰铸铁的过冷度，初生奥氏体枝晶粒量，共晶团数，石墨组织等的影响，研究了高碳当量灰铸铁的凝固组织及稳定化孕育剂的孕育机理，试验结果表明，稳定化孕育剂均能增大高碳当量灰铸铁的过冷度，增加初生奥氏体枝晶数量，共晶团数量，且随加入量的增加而增大，孕育作用的强弱按稳     

灰铁凝固过程中缩孔缩松的预测

通过热分析实验及对灰铁试件的浇注实验,分析了碳当量及孕育对灰铁凝固过程的影响.在动态膨胀叠加法的基础上,综合考虑了初始温度、碳当量、孕育、初晶和共晶体积的收缩与膨胀,建立了灰铁缩孔预测模型.开发了灰铁凝固过程数值模拟分析系统,并对实际的灰铁浇注件进行验证分析,预测结果与实验结果吻合较好.     

Effect of cooling rate on solidification parameters and microstructure of Al-7Si-0.3Mg-0.15Fe alloy

The effects of cooling rate on the solidification parameters and microstructure of Al-7Si-0.3Mg-0.15Fe alloy during solidification process were studied. To obtain different cooling rates, the step casting with five different thicknesses was used and the cooling rates and solidification parameters were determined by computer-aided thermal analysis method. The results show that at higher cooling rates, the primary α(Al) dendrite nucleation temperature, eutectic reaction temperature and solidus temperature shift to lower temperatures. Besides, with increasing cooling rate from 0.19 °C/s up to 6.25 °C/s, the secondary dendritic arm spacing decreases from 68 μm to 20 μm, and the primary dendritic volume fraction declines by approximately 5%. In addition, it reduces the length of Fe-bearing phase from 28 μm to 18 μm with a better uniform distribution. It is also found that high cooling rates make for modifying eutectic silicon into fibrous branched morphology, and decreasing block or lamella shape eutectic silicon.     

半固态灰铸铁的制备与显微组织

建立了一种不需搅拌和其它附加处理的半固态灰铸铁制备技术 ,用浇注前合理调整熔体温度或调温 适当快冷的铸造方法 ,并配以合适的凝固冷却速度 ,成功地制备了球状初生奥氏体圆整、尺寸细小、分布均匀的半固态亚共晶灰铸铁 ,得到了最佳工艺条件 ,并用铸铁金相计算机辅助检测系统 ,对初生奥氏体的形状系数和等效直径进行了测量与统计分析 ,定量描述了半固态组织的特性     

热处理对不同冷速Al合金共晶相形貌及含量的影响

选取成分为Al-5.17Cu-2.63Si(合金A)、Al-4.29Cu-1.09Mg(合金B)和Al-2.09Si-1.66Mg(合金C)三元铝合金,分别进行不同冷速下的凝固实验。对比研究不同凝固速率下得到的共晶相形貌与含量在接近各合金体系三元共晶温度下热处理前后的变化行为。结果表明:同一合金冷速越慢,得到的原始组织二次枝晶间距越大,合金A的石墨型、砂型、保温型冷却组织的二次枝晶间距分别为24.17、63.32和99.88μm,合金B的二次枝晶间距分别为24.35、82.78和139.42μm。均匀化热处理的热扩散过程可以明显地溶解非平衡共晶相,由于原始组织的尺度不同,共晶相所处的溶解阶段与溶解程度不同。合金A的石墨型、砂型、保温型组织热处理后与热处理前的共晶相含量比值分别为0.44、0.49和0.68,合金B的共晶相含量比值分别为0.084、0.30和0.38。     

过共晶球墨铸铁中石墨球周围奥氏体壳的形成机制

有用着色腐蚀技术，可清晰地显示出过共晶球墨铸铁中的高温凝固组织，观察分析了石墨球周围奥氏体壳（奥氏体壳是奥氏体枝晶的一部分）的形成机制。结果表明，初生枝晶和晕圈枝晶交替生长，促成石墨球周围奥氏体壳的形成；奥氏体以石墨生长面（0001）为衬底形核、生长，在初生石墨球周围形成环状封闭奥氏体壳；共晶前期石墨球在枝晶臂间或框架中形核、生长、尔后为枝晶高次臂所包围，形成封闭或不封闭的框架奥氏体壳。共晶后期石墨球不形成奥氏体壳。     

金属型球铁磨球非平衡凝固特性与成分控制

通过分析不同成分球铁磨球零件性能和金相组织,对金属型磨球的非平衡凝固特性进行了较深入的研究.试验结果发现,过共晶球铁凝固时出现非平衡奥氏体;亚共晶球铁出现非平衡渗碳体相和晕圈铁素体;在柱状晶与等轴晶过渡区中存在着夹杂和偏聚物.为改善球铁磨球的显微组织及性能,球铁成分应控制在共晶或稍过共晶范围.     

Volume change during the solidification of grey cast iron: its relation with the microstructural variation,comparison between experimental and theoretical analysis

The expansion/contraction during the solidification of grey cast iron was studied using Linear Variable Differential Transformer (LVDT). The experiments were conducted with and without melt treatment. Two types of inoculant used for melt treatment: ASSC (Si, Ca, Sr & Al) and MBZCAS (Si, Ca, Zr, Ba, Mn & Al). Microstructural investigations carried out to quantify the eutectic cells, undercooled graphite, primary austenite and secondary dendritic arm spacing (SDAS). It was found that the casting shows hardly any shrinkage during early solidification but in the eutectic region, the casting expands until the end of solidification. The measured and the calculated volume changes are close to one another, but the former shows more expansion. The addition of MBZCAS promotes more flake graphite, and ASSC does not increase eutectic cells much. In addition to that, it lowers the primary austenite fraction, promotes more eutectic growth, decreases undercooled graphite and SDAS. As a result, the volume expansion changes in the eutectic region.     

非平衡凝固条件下Zn-5Al合金的组织形成

对Zn-5Al合金采用液淬凝固和定量金相统计试验,考察了合金在非平衡冷却凝固过程中组织的形成和转变。研究表明:合金在非平衡凝固下析出初生富铝相α,它随着冷却速度的提高是逐渐减少的;初生相逐渐从胞状向树枝状转变。Zn-5Al合金在非平衡凝固条件下因析出初生相而获得亚共晶组织,冷速较大时共晶组织皆无明显的共晶核心,并且共晶层片组织逐渐变细,有的甚至无法看到,只有在共晶团搭界处才可看出明显的层片,共晶团内部的共晶层片基本呈无序状态。通过对本试验结果探讨,定性得到了锌铝合金共晶共生区相图,为以后研究Zn-5Al合金在非平衡凝固条件下凝固结晶提供了一些参考。     

Effect of casting technology on microstructure and phases of high carbon high speed steel

The as-cast microstructures of high carbon high speed steels (HC-HSS) made by sand casting,centrifugal casting and electromagnetic centrifugal casting, respectively, were studied by using of optical microscopy (OM) and D/max2200pc X-ray diffraction. The results show that the microstructure of as-cast HCHSS is dominated by alloy carbides (W2C, VC, Cr7C3), martensite and austenite. The centrifugal casting and electromagnetic centrifugal casting apparently improve the solidification structure of HC-HSS. With the increase of magnetic intensity (B), the volume fraction of austenite in the HC-HSS solidification structure increases significantly while the eutectic ledeburite decreases. Moreover, the secondary carbides precipitated from the austenite are finer with more homogeneous distribution in the electromagnetic centrifugal castings. It has also been found that the lath of eutectic carbide in ledeburite becomes finer and carbide phase spacing in eutectic ledeburite increases along with the higher magnetic field strength.     

Fourier Thermal Analysis of the Eutectic Formed in Pb-Sn Alloys

The effect of the presence of two different primary phases on the microstructural characteristics and solidification kinetics of Pb-Sn eutectic was analyzed using Fourier thermal analysis method (FTA) and microstructural characterization. Three Pb-Sn alloys, a hypoeutectic, an eutectic, and a hypereutectic alloy, were melted in an electric furnace under an argon atmosphere and poured into sand molds. Cooling curves were obtained and numerically processed using FTA. Microstructural observations of the probes indicate a lamellar morphology for the eutectic microconstituent of the hypereutectic alloy; the eutectic alloy shows the presence of both lamellar and anomalous eutectic and the hypoeutectic alloy shows only the presence of anomalous eutectic. FTA results indicate that in the case of the probes showing the presence of anomalous eutectic, there is a primary eutectic formed during recalescence at high undercooling and a secondary eutectic yielded at low undercooling at the eutectic plateau temperature. This result shows that the cause behind the observed differences in the eutectic morphologies of the experimental alloys lies on the nucleating ability of the primary phase available as a potential substrate for nucleation of the eutectic microconstituent.     

Effect of liquid-liquid structure transition on solidification of Sn-Bi alloys

The effect of the liquid-liquid structure transition（L-LST） on the solidification behaviors and morphologies of Sn-Bi alloys was studied further. The results show that the undercooling of the primary and eutectic phase increases and the microstructure becomes finer after solidifying from the melt experiencing the L-LST. In the meantime, in hypoeutectic alloy, when solidifying from the melt experiencing the L-LST, the morphology of primary phase changes from the fir-tree crystal into the equiaxed crystal, and less primary phase and more eutectic structure are observed. Moreover, in eutectic alloy, the spacing of eutectic phase decreases markedly. These investigations would be beneficial to further exploration of the correlation between the melt structure and the micro mechanism of solidification.     

Eutectic solidification mode of spheroidal graphite cast iron and graphitization

The shrinkage and chilling tendency of spheroidal graphite (abbreviated SG) cast iron is much greater than that of the flake graphite cast iron in spite of its higher amount of C and Si contents. Why? The main reason should be the difference in their graphitization during the eutectic solidification. In this paper, we discuss the difference in the solidification mechanism of both cast irons for solving these problems using unidirectional solidification and the cooling curves of the spheroidal graphite cast iron. The eutectic solidification rate of the SG cast iron is controlled by the diffusion of carbon through the austenite shell, and the final thickness is 1.4 times the radius of the SG, therefore, the reduction of the SG size, namely, the increase in the number, is the main solution of these problems.     

Evolution mechanism of crystallographic orientation in grain continuator bars of a Ni-based single-crystal superalloy prepared by Bridgman technology during directional solidification

Single-crystal rods with different diameters and deviation angles with respect to the solidification direction were produced by Bridgman rapid solidification method at withdrawal rates of 3 and 6 mm·min^-1 and used as grain continuators.The crystallographic orientation of the rods,which cross-sections were perpendicular to the solidification direction at different solidification heights,was measured by electron backscattered diffraction,while the corresponding microstructures were observed by optical microscopy.The mushy zone morphology and the distribution of the temperature gradient were simulated by the finite element analysis software ProCAST.The experimental results indicate that the crystallographic orientation of the single-crystal rods corresponds to the statistical average value of all the dendrite orientations in cross-section.The crystallographic orientation of the primary and secondary dendrites of each single-crystal rod at different cross-sections fluctuates irregularly within a small range(less than 4°).The crystallographic orientation of the dendrite in each single-crystal rod is not exactly consistent with each other and is affected by their branching mode of dendrites in the solidification space.In addition,the simulation results show that the mushy zone shapes and the temperature gradient of single-crystal rods change with the increase of solidification height during the solidification process.Finally,the evolution mechanism of the crystallographic orientations and the corresponding influence factors were analyzed and discussed.