Al-Bi过偏晶合金显微组织演变的数值模拟

基于Al-Bi过偏晶合金凝固通过难混溶区阶段产生的液-液相分解及分离的运动行为,采用两相体积平均法,对质量、动量、能量、组分及液滴密度守恒方程进行数值模拟,计算中考虑了形核、扩散长大、Stokes运动及Marangoni运动等多种复杂物理现象的耦合作用,分析了两相运动速度、第二相尺寸分布、第二相体积分数分布以及液滴密度分布对过偏晶合金凝固的显微组织演变及宏观偏析的影响。结果表明,过偏晶合金凝固过程中显微组织演化在不同阶段的主要影响因素不同:凝固初始阶段主要以形核和扩散长大为主;凝固中期和后期第二相迁移运动行为将逐渐占主导作用。凝固过程中,铸件顶角位置首先获得过冷度驱动形核,并以较快的形核速率达到最大形核密度。随着凝固过程不断地进行,第二相小液滴受到的Marangoni力约为Stokes粘滞阻力的两倍,开始由铸件顶角和边缘低温区向中心高温区聚集。凝固时间为1 s时,铸件顶角和边缘第二相小液滴的生长直径和第二相体积分数大于铸件中心位置,而凝固时间为5和7 s时,第二相小液滴直径随铸件中心距离变化的曲线斜率随凝固过程的进行而逐渐变缓,长大速率逐渐变慢。     

球墨铸铁离异共晶凝固组织生长模拟

采用所开发的微观元胞自动机模型,耦合热力学模型计算获得的凝固路径,将浓度分布、温降与晶体生长相结合,模拟了亚共晶球墨铸铁(Fe-4wt.%C合金)离异共晶组织生长过程。结果表明,奥氏体与石墨生长相互促进,奥氏体晶粒快速包裹石墨,生长形态由枝晶状转为团簇状,石墨晶粒最终孤立分布于奥氏体基体中。等温下仅依靠溶质扩散的奥氏体与石墨生长速度略低于温降和溶质扩散共同作用下数值。二者生长速度随熔体初始过冷度增大均增快;随冷却速率增加均呈线性增长,增幅大致相同。本计算参数范围内,冷却速率对石墨生长速度的影响强度大于熔体初始过冷度。所预测的石墨平均半径与文献实验值相符。研究结果可为控制球墨铸铁凝固组织形貌及性能提供依据。     

铁液洁净度对凝固热力学参数的影响

为了给高洁净钢连铸细晶技术提供相关理论依据，在高温钼丝炉中通过对电解纯铁加金属铝和硅脱氧，获得不同铁液洁净度的试样。利用差热分析法测定了试样在相同冷却速度下的过冷度。利用凝固过程热力学理论研究了铁液洁净度与过冷度、凝固热力学驱动力、形核功和临界晶核半径等的关系。结果表明：随着铁液洁净度的提高，铁液凝固时的过冷度增大，形核所需的凝固热力学驱动力变大，非均质形核功和临界晶核半径减小。     

球墨铸铁离异共晶凝固组织生长模拟

摘要：采用所开发的微观元胞自动机模型,耦合热力学模型计算获得的凝固路径,将浓度分布、温降与晶体生长相结合,模拟了亚共晶球墨铸铁(Fe-4wt%C合金)离异共晶组织生长过程。结果表明,奥氏体与石墨生长相互促进,奥氏体晶粒快速包裹石墨,生长形态由枝晶状转为团簇状,石墨晶粒最终孤立分布于奥氏体基体中。等温下仅依靠溶质扩散的奥氏体与石墨生长速度略低于温降和溶质扩散共同作用下数值。二者生长速度随熔体初始过冷度增大均增快;随冷却速率增加均呈线性增长,增幅大致相同。本计算参数范围内,冷却速率对石墨生长速度的影响强度大于熔体初始过冷度。所预测的石墨平均半径与文献实验值相符。研究结果可为控制球墨铸铁凝固组织形貌及性能提供依据。     

纯铁和高洁净钢的非均质形核

采用电解纯铁通过高温钼丝炉制备含有不同数量异质核心的试样,用差热分析法分别测定了纯铁和高洁净钢试样在相同冷却速度下的过冷度.结果发现,随着洁净度的提高,高洁净钢和纯铁凝固的过冷度增加,形核功降低,临界晶核半径变小,形核率增大,凝固组织中晶粒的数量增加,晶粒得到细化.在洁净度相同的情况下,高洁净钢形核凝固的过冷度比纯铁小.     

非线性界面动力学影响下颗粒增长的界面稳定性

研究了一个带有非线性温度依赖界面动力学的颗粒生长数学模型,分析颗粒界面的演化及其形态稳定性.利用渐近展开方法,获得颗粒生长的渐近解以及界面扰动的变化率.当界面动力学增加时,界面动力学过冷减小,颗粒增长速度也减小,非线性温度依赖界面动力学使得颗粒界面生长倾向于稳定.与忽略界面动力学的情形比较,非线性界面动力学显著减弱了球颗粒的生长速度.      

Al固/液界面动力学因子和动力学行为

从固/液界面的动力学方程出发,通过设计不同的计算模型,系统地研究了平面型界面和圆柱型界面的动力学行为,并计算了固/液界面的动力学因子(μ)。模拟平面型界面的运动和涨落行为,并分别提取了μ,两种模拟给出的结果非常接近,都有:μ100μ110μ111。模拟平面型界面回复现象,当界面偏离平衡位置时,会在界面张力的作用下发生回复,界面形貌在回复过程满足Gauss衰减规律。模拟圆柱型短晶核的界面运动行为,发现晶核在凝固或熔化过程中,晶核半径的变化速度逐渐加快,但存在一个函数,变化速度为匀速。研究了圆柱型长晶核的熔断行为,解释了界面涨落导致晶核熔断的内在机制,并发现熔断断口形貌近似服从Gauss分布。     

粉末冶金文摘

994001A2工具钢在雾化沉积中孔隙的评估／Jean－PierreDelplanque等／／TheInternationalJournalofPowderMetallurgy.l999,35（2）提供了一个数学模型,用于确定工具钢喷射成形的最佳工艺参数。用探索式模型预测孔隙度,综合考虑了液流时间和凝固时间对孔隙形成过程的影响。根据这些假设,将孔隙度表达为颗粒尺寸分布。喷射的平均固化百分数和凝固收缩率的函数。由液滴的尺寸分布和给定的尺寸凝固百分数来评估平均固化百分数。后者由液滴动力学和加热过程计算所决定。研究了工艺参数对孔隙度大小的影响（过热。沉积距离和熔流速度）。…     

Fe-6.5％Si高硅钢凝固过程铁素体相生长行为原位观察

采用共聚焦激光扫描显微镜(CLSM)原位观察Fe-6.5%Si高硅钢凝固过程中铁素体(δ)相生长行为,揭示了不同冷却速率对高硅钢δ相生长行为和形貌的影响。结果表明,在一定的过冷度下发生L→δ转变,δ相枝晶生长过程中会发生合并现象;随着凝固时间增加,枝晶尖端的粗化速率逐渐降低,L→δ相变开始和结束点延后;通过数据拟合得到二次枝晶臂间距(d)和冷却速度(R)关系:d=53.4R-0.23。     

各向异性表面张力对柱晶界面形态的影响

本文研究了拟稳态时各向异性表面张力作用下柱晶界面的生长行为.在运用渐近分析方法求解柱晶界面形态数学表达式的基础上,分析在不同各向异性表面张力强度影响下柱晶界面形态的变化.各向异性表面张力对柱晶界面形态有显著影响.在柱晶生长开始阶段,柱晶部分界面首先向内收缩,当收缩达到某个临界值后,界面开始向外生长.柱晶界面沿着优先生长方向更快地生长.柱晶界面形态上形成突起变形,各向异性表面张力强度越大,柱晶界面形态的突起变形越明显.      

Heat Flow during Rapid Solidification of Undercooled Metal Droplets

The solidification of undercooled spherical droplets with a discrete melting temperature is analyzed using both a Newtonian and a non-Newtonian (Enthalpy) model. Relationships are established between atomization parameters, the growth kinetics, the interface velocity and undercooling, and other important solidification variables. A new mathematical formulation and solution methodology is developed for simulating the solidification process in an undercooled droplet from a single nucleation event occurring at its surface. The computational mesh used in the enthalpy model is defined on a superimposed bispherical coordinate system. Numerical solutions for the solidification of pure aluminum droplets based on the enthalpy model are developed, and their results are compared to the trends predicted from the Newtonian model. The implications of single vs multiple nucleation events are also discussed. In general, the results indicate that when substantial undercoolings are achieved in a droplet prior to nucleation, the thermal history consists of two distinct solidification regimes. In the first, the interface velocities are high, the droplet absorbs most of the latent heat released, and the external cooling usually plays a minor role. The second regime is one of slower growth, and strongly depends on the heat extraction at the droplet surface. The extent of “rapid solidification”, as determined from the fraction of material solidified at temperatures below a certain critical undercooling, is a function of the nucleation temperature, the particle size, a kinetic parameter, and the heat translow as 10~4. Formerly a Research Associate at the University of Illinois,     

Morphologies of silicon crystals solidified on a chill plate

Electromagnetically levitated liquid droplets of pure Si or a Si-Ge alloy were cooled to different temperatures and then dropped onto a chill plate of Cu. Droplet oscillations mark the solid/liquid interface during solidification and permit the different crystal morphologies of silicon to be observed on the quenched surface by scanning electron microscopy (SEM). A spherical morphology found on the quenched surface represents the initial stage of crystal growth. Further growth leads to octahedral crystals bounded by {111} faces near equilibrium and to other polyhedra or even faceted dendrites further from equilibrium. The spherical growth can be observed only when the initial melt undercooling is moderately high. The critical size at which spherical crystals start to develop dendritic growth is much bigger than that calculated from the Mullins and Sekerka model, and is bigger than the Coriell and Parker model when kinetic undercooling is taken into account.     

Morphologies of silicon crystals solidified on a chill plate

Electromagnetically levitated liquid droplets of pure Si or a Si-Ge alloy were cooled to different temperatures and then dropped onto a chill plate of Cu. Droplet oscillations mark the solid/liquid interface during solidification and permit the different crystal morphologies of silicon to be observed on the quenched surface by scanning electron microscopy (SEM). A spherical morphology found on the quenched surface represents the initial stage of crystal growth. Further growth leads to octahedral crystals bounded by {111} faces near equilibrium and to other polyhedra or even faceted dendrites further from equilibrium. The spherical growth can be observed only when the initial melt undercooling is moderately high. The critical size at which spherical crystals start to develop dendritic growth is much higger than that calculated from the Mullins and Sekerka model, and is bigger than the Coriell and Parker model when kinetic undercooling is taken into account.     

Modelling of crystal growth during the ribbon formation in planar flow casting

The crystalline solidification during rapid substrate quenching in planar-flow casting was simulated by using a numerical model based on a rapid solidification algorithm and the infinite viscosity approximation. The calculation shows that the existence of a real melt puddle shape suppresses undercooling and recalescence on the melt surface as well as on the solidifying ribbon. The melt puddle length is mainly determined by the heat-transfer coefficient. With increasing heat transfer across the melt – substrate interface the melt puddle length decreases. If the formation rate of critical nuclei on the substrate surface is low compared to the present cooling rate a large undercooling may occur. The performed calculations reveal that an undercooling of up to 600 K does neither affect the temperature distribution on the surface of the melt nor the melt puddle length, perceptibly. Therefore, investigations on microstructural features of rapidly quenched metals might give detailed information on the amount of undercooling present at the beginning of solidification.     

Morphological stability of Sm123 superconductor during peritectic solidification from Sm211+L mixture

The interface stability of the Sm 123 superconductor was analyzed in accordance with the constitutional undercooling criterion. As the single-crystal growth of the 123 phase is largely dependent on the growth-interface stability, a quantitative analysis was very much required. From this analysis, it was clarified that the constitutional undercooling must exist in the liquid when the 123 growth interface comes close to a 211 particle during the peritectic solidification. It was also predicted that the larger 211 particle radius, smaller volume fraction of the 211 particles, larger growth rate, or smaller imposed temperature gradient would cause easy occurrence of the constitutional undercooling ahead of the 123 growth interface. Taking into account the nucleation at the L/211 interface just ahead of the 123 growth front due to the constitutional undercooling, the transition of 123 growth from a planar-interface morphology to an equiaxed blocky morphology was investigated quantitatively and qualitatively.     

Solidification of highly undercooled Fe-P alloys

Rapid solidification behavior of highly undercooled iron-phosphorus alloys was investigated by using a high-speed optical temperature measurement system. The experimental results on solidification rate as a function of bulk undercooling agree well with a model which includes a treatment of nonequilibrium effects during the solidification process. The model is based on an earlier analysis by Boettinger, Coriell, and Trivedi_[81] (BCT) and employs temperature-dependent values of equilibrium liquidus slope, equilibrium solute distribution coefficient, and solute interdiffusion coefficient. Values of the kinetic parameters,a ₀ andV ₀ , in the analysis which best fit the experimental results are 5 x 10_-10 m and 600 m/s, respectively. Comparison of experimental results and theory suggests that a transition from local equilibrium to nonequilibrium solidification takes place with increasing undercooling and that interface kinetic effects become predominant at higher undercooling (or growth velocity).     

Spangle formation in galvanized sheet steel coatings

Very large grains, termed “spangles,” are produced on galvanized sheet steel coatings when lead is added to the zinc bath. The spangles have been attributed to melt undercooling prior to solidification. The present results indicate this is not the case, undercooling being less than 1 °C. The spangle diameter is shown to be dependent on the alloy addition to the bath, large spangles being obtained with Bi and Sb as well as Pb. The spangle size is related to the surface tension of the alloying addition, the size decreasing as the melt vapor surface tension of the alloying element increases. It is proposed that spangles form dendritically from a nucleus in the melt. Alloy additions with low interfacial energies and very limited solid solubility are highly concentrated ahead of the dendrite tip. This decreases the tip radius and increases the dendrite velocity, producing large grains. The basal plane orientation of the samples varies between 17 and 80 deg with respect to the steel sheet surface, which is inconsistent with basal plane dendritic growth in Zn along (1010) directions. It is proposed that solute additions to the melt and growth in a thin liquid layer can modify the dendrite growth direction, accounting for the spangle orientation. On leave from Obafemi Awolowo University, lie Ife, Oyo State, Nigeria     

Direct observation of the crystal-growth transition in undercooled silicon

Using an electromagnetic levitation facility with a laser heating unit, silicon droplets were highly undercooled in the containerless state. The crystal morphologies on the surface of the undercooled droplets during the solidification process and after solidification were recorded live by using a high-speed camera and were observed by scanning electron microscopy. The growth behavior of silicon was found to vary not only with the nucleation undercooling, but also with the time after nucleation. In the earlier stage of solidification, the silicon grew in lateral, intermediary, and continuous modes at low, medium, and high undercoolings, respectively. In the later stage of solidification, the growth of highly undercooled silicon can transform to the lateral mode from the nonlateral one. The transition time of the sample with 320 K of undercooling was about 535 ms after recalescence, which was much later than the time where recalescence was completed.     

20CrMnTi连铸瞬态与平均冷速条件下凝固原位观察

 宽淬透性带和大尺寸TiN析出物严重危害20CrMnTi齿轮钢的产品质量,其控制的关键基础是掌握连铸过程中凝固组织演变行为机理。传统高温激光共聚焦扫描显微镜(HT-CSLM)原位观察研究通常将糊状区冷却速率设定为固定值,这不能有效反映连铸凝固过程中冷却速率的变化。为此,以国内某钢厂20CrMnTi 160 mm×160 mm小方坯为研究对象,首先通过二维切片凝固传热计算,确定内弧表面下方20、40、60 mm位置处糊状区的热历程、瞬态与平均冷却速率,进而设计HT-CSLM试验升温与降温方案。然后,开展这些位置处糊状区瞬态与平均冷却速率条件下HT-CSLM试验,研究揭示不同冷却条件下20CrMnTi的凝固过程、δ晶粒生长动力学和包晶相变机制。最后,通过电子探针分析(EPMA),考察冷却条件对凝固组织尺寸的影响规律。结果表明,由于凝固潜热的补偿,内弧皮下20、40、60 mm位置处初始凝固阶段冷却速率较小,凝固中后期逐渐增大,且越深入方坯内部越显著。这些位置处的平均冷却速率分别为102.81、44.63和34.93 ℃/min。δ晶粒率先从钢液中析出,其平均生长速率随着冷却速率的提升而增大。在瞬态冷却速率条件下,随着凝固的进行,瞬时生长速率呈增大的趋势,但是在平均冷却速率条件下瞬时生长速率则略微降低。这是因为在瞬态冷却速率条件下,糊状区冷却速率由慢至快,不断补偿了凝固潜热,同时初始形核数量少,生长空间大,溶质过冷度的影响相对较弱。当熔体温度降低至包晶相变临界温度时,δ晶粒快速转变为γ晶粒,即发生块状转变,导致固相率迅速增加,且伴随有部分γ晶粒快速聚合。整体上讲,包晶相变临界温度随着冷却速率的增大而降低,但是也受溶质初始含量的影响。此后,剩余液相向γ相转变,直至完全凝固。晶粒半径随着冷却速率的提升而减小,且在平均冷却速率条件下比瞬态冷却速率条件更小,这取决于初始凝固阶段的形核数量。     

Influence of rare earth metals on the nucleation and solidification behavior of iron and 1045 steel

Two series of experiments have been conducted to determine the influence of rare earth additions on the nucleation and crystallization behavior of pure iron and 1045 steel. In the first series, additions of rare earth suicide or cerium dioxide powder to two-Kg 1045 steel ingots indicated that rare earth suicide can refine the as-cast structure of such ingots. However, if the holding time after rare earth silicide addition is over two minutes, the grain refinement decreases. With cerium dioxide additions, a relatively large columnar zone was obtained. In the second series, the effects of cerium metal or cerium dioxide powder additions on the degree of undercooling obtainable in pure iron and 1045 steel were examined by the lévitation melting method. Surface tension measurements of the levitated droplets were carried out at the same time to investigate the possible effects of surface tension variations on the nucleation and crystallization behavior of the metals. The experimental data show that rare earth inclusions can greatly reduce the degree of undercooling of iron and steel, and that a small amount of dissolved cerium can further reduce the degree of undercooling of levitated droplets. The structure and reaction products obtained with Fe-Ce levitated droplets were examined with both optical and scanning electron microscopy as well as X-ray diffraction analysis. The experimental results clearly indicated that cerium solute redistribution during solidification is the dominant factor in refining the as-cast structure. A nucleation and solidification model for the Fe-Ce levitated droplets has been developed, which can successfully explain the experimental results. on research leave from Beijing University of Iron and Steel Technology