薄板试样定向凝固枝晶竞争生长

深入理解高温合金定向凝固杂晶演化具有重要的科学和工程意义,其中枝晶竞争生长是揭示晶界演化与淘汰的关键环节。定向凝固双晶竞争生长的实验研究证实了传统尖端过冷度理论的局限性,定量相场模拟的研究获得了大量统计规律,促进了人们对定向凝固双晶竞争生长的理解。本研究在薄板状试样的定向凝固过程中,同时获得了大量的不同取向竞争生长的枝晶,通过拼接金相显微组织同时获得多个晶界的取向演化规律。结果表明,枝晶列竞争生长主要通过晶界两侧不同取向一次枝晶臂及二次枝晶臂的交互作用实现。在汇聚生长过程中,择优枝晶一次臂阻挡非择优枝晶,并且择优枝晶自身无法形成三次臂,导致晶界方向沿择优枝晶生长方向。发散生长过程中,处于温度梯度方向一侧时,两列枝晶的竞争生长方式以非择优枝晶新生三次臂为主,晶界以沿择优枝晶方向生长为主;当两列枝晶处于温度梯度不同侧时,两列枝晶均有三次臂新生的概率,其晶界在两列枝晶取向之间。实验统计结果给出了晶界随两列竞争生长枝晶的取向的变化规律,与定量相场模拟结果吻合。商业软件ProCAST的CAFE计算晶粒定向竞争生长晶界演化统计结果与实验结果存在较大偏差,其主要原因是CAFE仅给出晶粒尺度的轮廓信息,未考虑溶质扩散及二次臂的竞争。本研究获得的薄板状试样枝晶竞争生长的统计规律,对认识高温合金定向凝固过程中晶界取向的演化具有重要的意义,对柱状晶叶片的制备具有指导意义。     

基于计算机模拟的焊缝金属组织凝固过程中枝晶生长分析

模拟焊缝凝固过程的枝晶生长,得到焊接熔池中心柱状晶和等轴晶溶质浓度分布、生长形态。熔池凝固结晶过程中,晶界偏析很大,枝晶竞争生长且相互作用。采用元胞自动机方法模拟枝晶生长可行,但仍需考虑多方面因素,并且在熔池内复杂多角度枝晶状态方面做更细致和深入的研究。     

Ni-Cr二元合金焊接熔池中柱状枝晶生长模拟

通过构建元胞自动机与有限差分耦合的CA-FD(cellular automaton-finite difference)模型,实现Ni-Cr二元合金焊接熔池柱状枝晶生长过程的模拟,研究熔池边缘柱状晶的生长过程以及该过程中的溶质浓度分布形态.模拟结果再现了焊接熔池中二次、三次枝晶的生长,枝晶间的竞争生长以及晶界偏析等微观现象.基于模拟结果深入分析了焊接熔池中枝晶生长的特点,同时对溶质浓度场进行了定量分析.对模拟结果的分析表明,焊接熔池中枝晶间竞争生长激烈,枝晶形态复杂,枝晶偏析和晶界偏析显著.     

单相合金凝固过程微观组织的三维数值模拟

基于晶粒形核和生长物理过程及热质基本传输过程，建立了单相合金凝固过程微观组织和微观偏析形成及枝晶形貌演化的三维数学模型，模型中考虑了成分过冷．曲率过冷和各向异性等重要因素．数值模拟结果表明，所建数学模型能够合理反映质点形核、晶粒生长和柱状→等轴晶转变物理过程，温度场．溶质场和微观组织形貌的模拟计算结果合理自由枝晶生长过程的模拟结果表明，各向异性强度对枝晶生长和最终组织形貌具有重要影响：强各向异性趋于得到分支发达的树型结构，内部组织为取向平行排列规则的二次枝晶臂簇；而弱各向异性趋于得到表面凹凸不平的近似正八面体结构．模拟结果还证实枝晶内部存在小的孤立熔池，这有助于揭示微观组织中出现点偏析和微观缩松的根本原因．     

Al-Cu合金凝固枝晶生长的数值模拟

基于元胞自动机方法构建了枝晶生长数值模型,并将其应用于Al-Cu二元合金凝固过程的模拟。在该模型中,枝晶尖端生长速度模型基于溶质守恒建立。模拟过程中重点考虑不同冷却速率及形核条件对柱状树枝晶形态与溶质偏析的影响。计算结果表明,凝固过程中溶质易于富集在枝晶臂之间的封闭或半封闭区域。同时,随着冷却速率加大,晶界偏析变得更为显著。形核密度在一定程度上影响着枝晶形态,特别是影响着二次和三次枝晶的生长。     

镍基合金TIG焊接熔池及热影响区组织模拟

基于枝晶生长动力学和晶粒长大理论,采用元胞自动机法(CA)建立了焊接熔池及热影响区的微观组织演变模型.通过有限元模型计算了TIG焊接过程的温度场分布,并利用插值算法将热循环曲线应用于CA模型,计算了镍基合金TIG焊接熔池凝固过程枝晶生长及热影响区的晶粒长大.结果表明,焊缝边缘的晶核主要以柱状晶的形式向焊缝中心生长,其最终形貌取决于半熔化母材晶粒上的联生结晶及不同取向枝晶间的竞争生长,焊缝中心为等轴晶组织.焊接热影响区的晶粒长大使得熔池凝固形成的柱状晶组织粗大.模拟结果与试验结果吻合较好.     

镍基合金TIG焊接熔池及热影响区组织模拟

基于枝晶生长动力学和晶粒长大理论，采用元胞自动机法(CA)建立了焊接熔池及热影响区的微观组织演变模型. 通过有限元模型计算了TIG焊接过程的温度场分布，并利用插值算法将热循环曲线应用于CA模型，计算了镍基合金TIG焊接熔池凝固过程枝晶生长及热影响区的晶粒长大. 结果表明，焊缝边缘的晶核主要以柱状晶的形式向焊缝中心生长，其最终形貌取决于半熔化母材晶粒上的联生结晶及不同取向枝晶间的竞争生长，焊缝中心为等轴晶组织. 焊接热影响区的晶粒长大使得熔池凝固形成的柱状晶组织粗大. 模拟结果与试验结果吻合较好.     

ULCB钢焊接熔池凝固过程数值模拟

采用元胞自动机法建立ULCB钢焊接熔池凝固过程的宏微观耦合模型,模拟非均匀温度场下焊接熔池凝固过程的组织形貌演变和溶质场分布,分析不同形核参数和合金成分对焊接熔池枝晶形貌的影响。结果表明,熔池边缘形成柱状晶,熔池中心形成等轴晶,柱状晶和等轴晶相互抑制长大;枝晶生长过程中始终存在着枝晶偏析现象;形核密度和合金成分影响枝晶的形核和生长,随着形核密度和合金成分的增加,焊缝中等轴晶区域增加,晶粒细化。     

二次枝晶取向对镍基高温合金晶粒竞争生长行为的影响

采用精密铸造法制备板状双晶和三晶试样,研究晶粒的二次枝晶取向对晶粒竞争生长的影响。结果表明,对于一次枝晶取向相同的双晶,随二次晶界角增大,晶界位置始终位于板状试样的中间,2个晶粒之间几乎不存在竞争生长。对于一次枝晶取向不同的三晶,汇聚晶粒和发散晶粒的竞争生长情况不同。在汇聚生长的情况下,择优取向枝晶与非择优取向枝晶互相阻挡,导致晶界向择优取向晶粒倾斜,这与经典的WaltonChalmers模型不一样。并且二次取向不影响汇聚晶粒的竞争生长。在发散生长的情况下,择优取向枝晶与非择优取向枝晶都能分枝出新的枝晶,使晶界向非择优取向晶粒倾斜,这与Walton-Chalmers模型一样。此外,二次取向不影响发散晶粒的竞争生长。     

焊接熔池凝固过程组织演变模拟

以枝晶生长动力学和晶粒生长能量最小原理为基础,建立了宏观传热与微观传质、形核、生长相耦合的焊接熔池CAMC晶粒生长二维数学模型.模型以CA方法模拟晶粒生长主干,MC在内部辅助晶粒生长以体现枝晶分枝机制,同时考虑非均匀形核对熔池结晶的影响因素,模拟了焊接熔池组织形成过程.结果表明,CAMC模型能够定量地描述熔池晶粒数目、尺寸和形貌演变,可以较准确地反映焊接熔池微观组织结构和熔池凝固过程中晶粒择优生长、柱状晶向等轴晶转换等物理机制.     

A three-dimensional cellular automaton model of dendrite growth with stochastic orientation during the solidification in the molten pool of binary alloy

A three-dimensional (3D) cellular automaton model is developed for the prediction of dendrite growth with stochastic orientation during solidification process in the molten pool of binary alloy. An angle-information transfer method is proposed for improving cellular automaton technique to simulate the growth of the dendrites whose preferred growth direction owns stochastic misorientation with respect to the direction of the coordinate system. Dendrite morphologies and solute distributions of single dendrite growth and multi-dendrite growth are able to be obtained by the simulation using present model. The model is also employed to study the difference between two-dimensional simulation and 3D simulation on solute segregation and dendritic growth. Using the established model, 3D multi-columnar dendrites with stochastic crystallographic orientations can be obtained efficiently, and the competitive growth and impinging of dendrites can be reproduced in practice. The simulation results agree well with the experimental results.     

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.     

Phase field modeling of multiple dendrite growth of AI-Si binary alloy under isothermal solidification

Phase field method offers the prospect of being able to perform realistic numerical experiments on dendrite growth in metallic systems. In this study, the growth process of multiple dendrites in AI-2-mole-%-Si binary alloy under isothermal solidification was simulated using phase field model. The simulation results showed the impingement of arbitrarily oriented crystals and the competitive growth among the grains during solidification. With the increase of growing time, the grains begin to coalesce and impinge the adjacent grains. When the dendrites start to impinge, the dendrite growth is obviously inhibited.     

Analysis of Competitive Growth Mechanism of Stray Grains of Single Crystal Superalloys during Directional Solidification Process

在高梯度定向凝固装置中采用枝晶方向与热流偏离的籽晶制备AM3晶体,分析晶体生长过程中杂晶的形核原理和不同晶粒的竞争淘汰机制。结果表明,枝晶方向与热流偏离造成的过冷可促使杂晶的形成。枝晶生长方向与热流偏离较大的晶粒在一定条件下可淘汰枝晶方向与热流接近的晶粒;晶粒的竞争与淘汰过程受晶粒间枝晶的相对位向、晶粒生长方向与热流方向的夹角大小、晶粒的晶体取向等因素有关。     

Phase-field numerical simulation of three-dimensional competitive growth of dendrites in a binary alloy

The normal vector of migration direction in the solid-liquid interface of dendrites was used to describe the phase-field governing equation. By using the three angles formed by the normal vector for the migration direction of the dendritic growth interface and the coordinate axes of the simulation region, the authors expressed the interfacial anisotropy equation, and built a phase-field model for the competitive growth of multiple grains. Taking a Al-2%mole-Cu binary alloy as an example, the competitive growth of multiple grains during isothermal solidification was simulated by applying parallel computing techniques. In addition, the phase field simulation results were verified by the experimental method. The simulation results show that the competitive growth of equiaxed dendrite is divided into two types: the first occurs during the process of competitive growth, the tips of primary dendrite on different grains taking part in the competition stop growing in their optimal growth direction; the second also occurs during competitive growth, the tips of primary dendrite which participate in the competition on different grains never stop growing in their optimal growth direction. The dendritic morphologies of the first competition growth type are divided into two types. Primary dendrites of grains taking part in the competition stop growing in their optimal growth direction and the competition plane enlarges when neither one wins the competition. However, when one wins the competition, the primary dendrites of grains with superiority go through the blocking grains and continue to grow in their optimal growth direction. The primary dendrites of inferior grains stop growing in their optimal growth direction and then instead grow in those areas without obstacles. The dendritic morphology of the second competition-growth type is shown to be the deformation of primary dendrites, which are mainly represented as the deflection and bending observed from different views. Compared with the metallographic picture, the simulation results can show the morphology of the competitive growth in all directions, so this simulation method can better characterize the competitive growth process.     

Phase-field study of competitive dendritic growth of converging grains during directional solidification

The microstructure evolution of grains with different orientations during directional solidification is investigated by the phase-field method. For converging dendrites, in addition to the usually accepted overgrowth pattern wherein the favorably oriented dendrites block the unfavorably oriented ones, the opposite pattern of overgrowth observed in some recent experiments is also found in our simulations. The factors which may induce this unusual overgrowth are analyzed. It is found that in addition to the difference in tip undercooling, the solute interaction of converging dendrites, which has been ignored in the classical theoretical model, also has a significant effect on the nature of the overgrowth at low pulling velocities. Solute interaction can retard the growth of dendrites at the grain boundary (GB) and induce a lag of these dendrites relative to their immediate neighbors, which gives the unfavorably oriented dendrite the possibility to overgrow the favorably oriented one. However, this unusual overgrowth only occurs when the spacing between the favorably oriented GB dendrite and its immediate favorably oriented neighbor decreases to a certain level through lateral motion. These findings can broaden our understanding of the overgrowth mechanism of converging dendrites.     

Formation of twinned dendrites during unidirectional solidification of Al-32%Zn alloy

The present study focused on the formation and crystallographic orientation of twinned dendrites coexisting with equiaxed grains in unidirectional solidification of Al-32%Zn (mass fraction) alloy. The morphology was investigated by optical metallograph and electron back-scattered diffraction technique. Results showed that the macrostructure of the alloy exhibited a typical feathery and fan-like structure while the microstructures were elongated lamellas, which were separated by coherent and incoherent twin boundaries. Both the primary trunk and all lateral arms of twinned dendrites grew along 〈110〉 directions, unlike regular 〈100〉 α(Al) dendrites. The facet growth of crystals at solid/liquid interface was responsible for the origin of twinned dendrites during the weak local convection, and high thermal gradient and medium solidification velocity had significant contribution to the formation of twinned dendrites. The formation mechanism of twinned dendrites which consisted of three multiplication ways of new twin boundaries formation and one way of dendrite evolution in twin plane was shown schematically.     

铸造镁合金的枝晶生长模拟

根据hcp晶体学结构和优先生长方向,建立了铸造镁合金晶体生长的物理模型,提出了一种新的随机性模拟方法--虚拟生长中心计算模型.模型考虑了枝晶生长动力学、各向异性和二次枝晶臂粗化,采用枝晶形状函数揭示了一次枝晶和二次枝晶的生长演化过程.引入坐标变换技术可更快速准确计算任意晶向枝晶的生长捕获.耦合了微观溶质场计算,得到了更准确的枝晶生长形貌和溶质分布情况.对Mg-Al合金定向凝固和等轴晶生长的模拟验证了本模型的正确性.     

Phase field modeling of dendrite growth

Single dendrite and multi-dendrite growth for A1-2 mol pct Si alloy during isothermal solidification are simulated by phase field method. In the case of single equiaxed dendrite growth, the secondary and the necking phenomenon can be observed. For multi-dendrite growth, there exists the competitive growth among the dendrites dur-ing solidification. As solidification proceeds, growing and coarsening of the primary arms occurs, together with the branching and coarsening of the secondary arms.When the diffusion fields of dendrite tips come into contact with those of the branches growing from the neighboring dendrites, the dendrites stop growing and being to ripen and thicken.     

铝合金中孪生枝晶的研究进展

羽状晶是铸造组织中与柱状晶、等轴晶并列的第三类组织,在凝固理论研究和工业应用中有重要价值。近年来研究表明孪生枝晶是羽状晶最基本的微观组织特征。综述了孪生枝晶尖端形貌、增殖机制、与常规枝晶的竞争生长规律以及羽状晶力学性能等方面的研究进展,讨论了不同因素对孪生枝晶形成和生长的影响,总结了研究中尚未解决的问题。