镍基双晶高温合金定向凝固过程中的竞争生长

研究了镍基双晶高温合金定向凝固过程中的竞争生长.实验结果表明：当原始籽晶一次枝晶方向均平行于热流方向且二次枝晶取向不同时,定向凝固过程中双晶共存,但双晶的界面存在波动,抽拉速率对其影响不大.当原始籽晶一次枝晶([001])异面并保持其中一组二次枝晶取向([010]相同时,双晶竞争生长过程是一个三维竞争生长过程.晶粒竞争...     

镍基合金焊接熔池凝固组织模拟

对原有元胞自动机中网格的捕获规则进行修正,完善了"对角线模拟角度"法则,并用其成功地模拟了镍基合金熔池凝固过程枝晶生长以及晶界偏析情况.结果表明,在焊接熔池凝固过程中,不同取向的晶粒之间存在着激烈的竞争生长.结晶取向与温度梯度最大的方向相一致的晶粒生长速度快,将其它取向的晶粒淘汰,在竞争中能够持续生长.同时,在枝晶与枝晶、枝晶臂与枝晶臂之间的残余液相中,存在溶质堆积现象,在凝固过程结束后,形成了严重的晶界偏析.     

镍基高温合金定向凝固过程中的汇聚型双晶竞争生长

采用籽晶法控制晶体取向,研究了不同抽拉速率下镍基高温合金汇聚型双晶的竞争生长.结果表明,低抽拉速率下,非择优枝晶能够穿插进入择优枝晶间的液相通道,抑制择优枝晶的生长,使晶界向择优晶粒方向偏移.高抽拉速率下,非择优枝晶几乎全部被晶界择优枝晶阻挡,晶界与择优枝晶干平行.非择优枝晶进入择优枝晶间的液相通道使择优枝晶萎缩消失是非择优晶粒淘汰择优晶粒的主要因素,并以此提出了抽拉速率对竞争生长的影响机制.     

晶体相场法模拟纳米晶体的单向拉伸变形

通过籽晶法控制晶体取向,研究了双晶镍基高温合金AM3胞状枝晶界面定向凝固过程中的双晶竞争生长.结果表明,两籽晶<001>取向的相对位置对晶粒竞争生长有很大的影响.双晶<001>取向在不同平面时,晶粒竞争生长的主要方式是通过物理阻挡,在晶界处处于阻挡优势的晶粒在竞争生长中胜出.对双晶的<001>取向在同一平面时,两籽晶以大角度背离发散生长时,在双晶的发散区容易生成杂晶.     

定向凝固过程中镍基高温合金双晶竞争生长分析

通过调整双籽晶<001>的取向进而控制晶体取向,使之处于不同的平面位置,并让晶粒在低速抽拉下生长,研究了双晶镍基高温合金AM3胞状枝晶界面在定向凝固过程中双晶粒的相对位置及其影响,并进行定向凝固过程中镍基高温合金双晶竞争生长分析。结果表明:当两籽晶<001>取向的偏差角度几乎一样时,两晶粒竞争生长主要是通过胞状枝晶干的物理阻挡;当两籽晶<001>取向处于同一平面内时,伴随着凝固过程,在晶界处非常容易形成与原双籽晶<001>取向都不相同的晶粒。     

镍基高温合金胞状枝晶界面定向凝固过程中的双晶竞争生长

通过籽晶法控制晶体取向,研究了双晶镍基高温合金AM3胞状枝晶界面定向凝固过程中的双晶竞争生长。结果表明,两籽晶<001>取向的相对位置对晶粒竞争生长有很大的影响。双晶<001>取向在不同平面时,晶粒竞争生长的主要方式是通过物理阻挡,在晶界处处于阻挡优势的晶粒在竞争生长中胜出。对双晶的<001>取向在同一平面时,两籽晶以大角度背离发散生长时,在双晶的发散区容易生成杂晶。     

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。     

三维相场法模拟定向凝固过程枝晶交叉生长研究

以Al-Cu二元合金为例,基于三维相场模型,模拟了定向凝固过程中初始晶粒以锯齿形排列,枝晶交叉生长时的竞争生长行为,研究了晶粒取向对枝晶交叉生长的影响规律。设定两层晶粒交叉生长时晶粒取向角的绝对值相等。结果表明,在一定的计算区域内,交叉生长时晶粒生长方向与温度梯度方向之间夹角的绝对值越大,两组枝晶通过液相通道穿插过对方枝晶之后,其生长越早被抑制,枝晶生长速度越小;当晶粒生长方向与温度梯度方向之间夹角的绝对值达到30°时,两组枝晶互相穿插过对方枝晶后,其中一组枝晶产生新的分枝。这种三维竞争生长很好地解释了相关实验研究,组织中枝晶断断续续生长的现象。     

Al-7Si-0.36Mg合金定向凝固一次枝晶臂间距实验和模拟

通过Al-7Si-0.36Mg合金定向凝固实验和元胞自动机模型,开展定向凝固枝晶形貌演化和一次枝晶臂间距选择过程的实验和模拟。结果表明:在给定的凝固条件下,一次枝晶臂间距范围是一个连续的变化区间。在恒定温度梯度和不同凝固速度条件下,测得Al-7Si-0.36Mg合金一次枝晶臂间距上限值(λmax)、下限值(λmin)和平均值(λave)以及生长速率之间的关系,且上限值和下限值的比值接近3。模拟结果与实验结果的吻合程度明显优于Hunt-Lu等解析模型的预测结果,表明CA模型在枝晶定向凝固过程枝晶形貌演化模拟和枝晶臂间距预测等方面的准确性。结合模拟研究和文献调研分析影响定向凝固一次枝晶臂选择的因素,包括抽拉速度v、温度梯度G、界面能大小、溶质扩散系数DL、枝晶生长取向与热流方向的偏离角度θ等。     

定向凝固发散双晶的竞争生长研究

采用SCN-1.7%Eth(质量分数)透明模型合金,应用自制的晶粒择优取向角度可控的透明模型合金双籽晶试样盒,对定向凝固中双晶竞争生长的微观组织演化进行了实时观察,研究了二维条件下,抽拉速率和晶粒取向对发散晶粒竞争淘汰的影响.结果表明,对于发散双晶,随抽拉速率的提高,择优取向晶粒淘汰非择优取向晶粒的速度变慢,其主要原因在于,抽拉速率增大会减小一次枝晶间距并降低择优取向晶粒一次臂新增频率;当择优取向晶粒优先生长方向与热流方向不完全一致时,在特定抽拉速率下,择优取向晶粒由于受到型壁的制约,最终亦可能被淘汰.     

Mechanism of competitive growth during directional solidification of a nickel-base superalloy in a three-dimensional reference frame

The microstructure evolution of bicrystal samples during directional solidification was studied, both by simulation and experiment, to explore the mechanism of competitive growth. A new orientation relationship of bicrystal samples, the non-uniplanar case, is proposed, which expands the orientation relationship of bicrystal samples from two dimensions to three dimensions. The results show that, in the non-uniplanar case, the favorably oriented grain overgrows the unfavorably oriented grain by developing new dendrites in the lateral gap where the primary dendrites of the unfavorably oriented grain diverge from the mold wall. During this process, the grain boundary is found to move in two directions, one perpendicular to the grain boundary and the other parallel to the grain boundary. To characterize the state of dendrite growth, a three-dimensional reference frame is constructed. In this reference frame, the mechanism of competitive growth can be categorized as a converging case, a non-uniplanar case and a diverging case. Furthermore, the simulation results are in good agreement with the experimental findings.     

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.     

Mechanism of competitive grain growth in directional solidification of a nickel-base superalloy

The structure evolution of bicrystal (BC) samples during directional solidification (DS) was explored in an attempt to understand the mechanism of competitive grain growth. It was found that in the case of diverging dendrites the favorably oriented grain overgrows the misaligned grain. However, in the case of converging dendrites the result differs from the prediction of the generally accepted model for competitive grain growth. First, the unfavorably oriented dendrites are able to overgrow the favorably oriented dendrites. Second, the misaligned grain overgrows the favorably oriented grain by blocking the dendrites of the favorably oriented grain at the grain boundary. Based on the experimental results, the process by which a favored 〈0 0 1〉 texture is developed during DS process of a nickel-base superalloy is illustrated.     

一种镍基单晶叶片叶身-缘板转接区铸造缺陷的形成机理

某种铸态镍基单晶叶片腐蚀后,观察到叶身-缘板转接区存在一种形状规则的条带状杂晶缺陷,且具有方向性,其长度方向平行(或垂直)于叶身和缘板的枝晶生长方向。采用光镜法(OM)、电子探针(EPMA)和电子背散射衍射技术(EBSD),分别研究了缺陷的组织、成分、取向,采用ProCAST模拟研究了缘板区域的温度场和过冷度分布。研究结果表明,叶身-缘板转接区杂晶缺陷由多个柱状晶粒构成;柱状晶粒的组织和成分与缘板基体一致,与基体的取向差形成小角度和大角度晶界;叶身-缘板转接区的过冷度比缘板边缘小,为缘板上的最后凝固区域。在此基础上,提出叶身-缘板转接区杂晶缺陷的形成机理,为消除该缺陷提供了理论基础。     

单晶高温合金铸件结构对定向凝固过程中温度场的影响

为了提高单晶涡轮叶片的气冷效果,其冷却通道内部结构越来越复杂,导致制备过程中凝固缺陷出现频率增高,凝固缺陷的形成与定向凝固过程中温度场演变密切相关。采用ProCAST数值模拟的方法研究了铸件结构对定向凝固过程中温度场的影响。结果表明,单晶高温合金铸件尺寸突变和渐变都会导致液固界面位置和温度梯度的变化;相比渐变截面结构,突变截面结构容易形成较大的凝固界面曲率,且边角处形成较大的过冷,更容易导致凝固缺陷的形成。     

基于一种改进CA模型的微观组织模拟

基于热传输、溶质传输等基本传输过程及晶粒生长物理过程,建立了单相合金凝固过程微观组织及枝晶形貌演化的三维数学模型,并提出了新的生长模型和单元捕获规则,新规则在三维立方有限差分单元的基础上保证了晶粒在各个随机的优先生长方向生长时的枝晶连续性,并较好的在三维立方网格中体现出了晶粒形貌.此外,模型中考虑了成分过冷、曲率过冷和晶粒随机各向异性生长等重要因素.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.多晶核定向生长模拟结果表明,多晶核定向竞争生长达到稳定状态时,枝晶间的一次枝晶臂间距与初始形核数目无关.所建立的模型和晶粒捕获规则适用于进一步定向凝固微观组织演化的研究.     

焊缝金属凝固组织元胞自动机模拟

应用元胞自动机方法进行了焊缝金属凝固组织的模拟.所建立的焊缝凝固组织二维元胞自动机模型考虑了晶粒的概率性成核、曲率过冷、温度过冷、成分过冷、潜热的释放、溶质浓度的再分布以及焊接熔池晶粒的联生长大等影响因素.模型在统一网格下分别采用差分法计算温度和溶质的扩散,应用元胞自动机方法模拟晶粒形核及生长.模拟结果能够定性地再现焊缝金属晶粒择优取向与竞争长大机制.结果表明,元胞自动机方法较好地反映了焊缝金属凝固的特点,是焊缝凝固组织模拟的新途径.     

高温合金单晶叶片定向凝固过程的宏微观数值模拟

基于有限元和Panda热动力学数据库建立了单晶叶片真空熔模铸造定向凝固过程的数理模型,对不同工艺下单晶叶片试样凝固过程中的温度场、糊状区演变及枝晶二次臂间距进行了仿真,研究了缺陷形成机理和规律。计算结果与实验吻合良好。计算结果显示,拉速大时二次臂细小,但杂晶产生的趋势加大;拉速小时杂晶不易形成,但二次臂增粗。对实际空心薄壁复杂单晶叶片定向凝固过程的模拟研究表明,二次臂间距在叶身部分分布比较均一, 3.5 mm/min抽拉时有可能在缘板处产生杂晶。采用变拉速工艺,不仅可避免杂晶缺陷,还能保证工件大部分枝晶细小,提高生产效率和成品率     

TC17钛合金自表面纳米化机制及组织演化

采用二元合金晶体相场模型,耦合原子密度场和浓度场,在扩散时间尺度上模拟过冷熔体的形核,生长及粗化过程.研究表明:增加冷却速率,模拟区域内晶核富集,快速长大;一定范围内,随着冷却速率增大,晶粒尺寸减小,组织细化;晶粒长大过程中,晶界主要依靠位错的迁移或攀移进行运动.二元合金模拟还可以应用到枝晶凝固、外延生长,调幅分解中,前景广阔.     

Progress on modeling and simulation of directional solidification of superalloy turbine blade casting

Directional solidified turbine blades of Ni-based superalloy are widely used as key parts of the gas turbine engines.The mechanical properties of the blade are greatly influenced by the final microstructure and the grain orientation determined directly by the grain selector geometry of the casting.In this paper,mathematical models were proposed for three dimensional simulation of the grain growth and microstructure evolution in directional solidification of turbine blade casting.Ray-tracing method was applied to calculate the temperature variation of the blade.Based on the thermo model of heat transfer,the competitive grain growth within the starter block and the spiral of the grain selector,the grain growth in the blade and the microstructure evolution were simulated via a modified Cellular Automaton method.Validation experiments were carried out,and the measured results were compared quantitatively with the predicted results.The simulated cooling curves and microstructures corresponded well with the experimental results.The proposed models could be used to predict the grain morphology and the competitive grain evolution during directional solidification.