空心管坯电磁离心过程的数值模拟

用有限元法模拟了铸造合金的流动和热量传输过程中瞬态速度场和温度场的分布,研究了电磁场强度和离心机转速对电磁铸造空心管坯的影响.结果表明,电磁搅拌引起的熔体相对运动是凝固过程中晶粒细化的主要原因.最优的电磁搅拌条件:转速1200 r/min,磁场强度为0.08 T,磁场持续加载25 s.在一定的转速和磁场强度条件下电磁离心铸造的温度场和凝固时的温度梯度对凝固组织有重要的的影响.合金液的外层,温度梯度达到最大值,铸件的温度下降得快,容易形成细小的等轴晶.     

工艺参数对MIG焊铝铜合金焊缝组织的影响

研究了电磁搅拌工艺参数对2219铝铜合金脉冲MIG焊焊缝形状和组织的影响．结果表明,随着磁感应强度增加,焊缝枝晶数量减少,等轴晶数量增加,焊缝由指状熔深变为成形良好的椭圆形熔深．当磁感应强度和频率匹配合适时,焊缝成形良好,焊缝组织几乎为细小的等轴晶．但随着磁感应强度继续增加,焊缝成形变差,焊缝等轴晶数量减少,枝晶数量增多．电磁搅拌频率对焊缝成形影响不大,频率较低和较高时都会降低焊缝组织的细化效果．     

表面脉冲电磁场处理下7A04铝合金凝固组织演变

采用一种新型熔体表面脉冲电磁技术对7A04超硬铝合金凝固组织进行细化处理。通过分析脉冲电磁场对组织形貌、晶体择优取向及凝固温度过程的影响,探讨脉冲电磁场下凝固组织演变机理。结果表明,随着脉冲电磁场强度增加,凝固组织发生球化细化→枝晶化再粗化的转变;在磁场强度为241mT时,晶粒尺寸可降低40%左右。由于晶体磁各向异性产生的磁能差导致凝固初期尺寸为225nm~100μm的晶粒发生转动,晶粒择优生长;此外,在脉冲电磁场孕育处理条件下,熔体凝固初期温度升高导致固相分数降低,有利于晶核运动,也可获得良好的组织细化效果。     

电磁铸造对Al–Si12.6%共晶合金微观组织的影响

目的 了解外加耦合场作用下Al–Si合金的微观组织演变情况。方法 利用外磁场加强凝固过程中熔体的流动,从而获得合金中各相的形态、分布和取向等,利用扫描电子显微分析技术(SEM)和电子背散射衍射分析技术(EBSD)研究电磁场对Al–Si12.6%共晶合金微观组织的影响规律。结果 在磁场作用下,铸件的组织均匀性增加,初生铝和共晶硅的尺寸均减小,并且随着磁场强度的增大,共晶硅的含量和尺寸呈减小趋势,其形态趋于等轴状,共晶硅附近各铝枝晶之间的外延生长关系消失,相互独立形核和长大。结论研究成果可以为电磁铸造对Al–Si系共晶合金微观组织研究提供一定的参考。     

低频电磁场对奥氏体不锈钢铸坯组织的影响

在工业实验中研究了低频电磁场对水平连铸奥氏体不锈钢组织的影响,结果表明:在低频电磁场作用下,合适的电磁搅拌参数使奥氏体不锈钢宏观组织在一定程度上得到了明显改善,铸坯的柱状晶和等轴晶得到了显著的细化,消除了穿晶现象,等轴晶区扩大,中心缩孔、中心疏松级别明显降低;多次实验发现:对于奥氏体不锈钢,所需的搅拌强度应高于一般钢种,即使搅拌器的中心磁感应强度达900GS平均值(幅值达到1413GS),采用3～4Hz的频率,搅拌后对钢液的组织影响较小;在同样的磁场强度下,不锈钢液由于粘度大,因而其转速比碳钢液的转速约低20%～30%。     

0Cr17Mn14Mo2N空心管坯的电磁离心铸造

研究了稳衡电磁场的强度和作用时间对离心铸造０Ｃｒ１７Ｍｎ１４Ｍｏ２Ｎ空心管坯的组织和性能的影响。结果表明，适当的电磁搅拌可以细化组织，提高铸造坯的室温塑性。理论分析表明电磁搅拌引起熔体速度场和压力场的变化是铸坯组织与性能发生改变的主要原因。     

电磁搅拌作用下CoCrMo合金熔模铸件凝固细晶研究

目的 研究电磁搅拌对CoCrMo合金熔模铸件晶粒尺寸的影响,解决熔模铸造CoCrMo合金铸件晶粒粗大的问题。方法 将CoCrMo合金熔化后,在其凝固过程中分别施加不同工艺参数的电磁搅拌,并对其凝固后的组织进行表征分析。同时,采用有限元法对电磁搅拌在金属熔体中的电磁场和流场进行数值模拟。结果 在不同的电磁搅拌参数下,CoCrMo合金铸件凝固组织出现了不同程度的细晶效果,浇道处的细晶效果优于铸件试棒处的。铸件试棒处的晶粒尺寸最小能控制在1 mm以下,等轴晶率最高能提升至31%。数值模拟结果表明,在电磁搅拌过程中,铸件试棒的磁场、电流和洛伦兹力都呈周期性变化,铸件试棒内部的流速随搅拌时间的延长而增大,最后趋于稳定。结论 电磁搅拌对CoCrMo合金的凝固组织产生了明显的细化效果,促进了柱状晶向等轴晶转变。电磁搅拌的时间越长,铸件凝固组织的细化效果越好,铸件厚大部位的细晶效果越显著。结合实验结果和数值模拟结果发现,在电磁搅拌过程中,熔体流动引发枝晶断裂是晶粒细化的主要原因,而电磁场促进异质形核为次要原因。     

添加剂对离心自蔓延高温合成陶瓷层组织结构与性能的影响

为了改善钢管内衬陶瓷层的韧性,在铝热剂中分别添加ZrO2,Al2O3,SiO2进行改性,采用离心自蔓延高温合成工艺制备了钢管内衬陶瓷层,研究了添加剂对陶瓷层形貌、结构和性能的影响.结果表明:加入ZrO2或Al2O3可以改变陶瓷层的组织结构,使Al2O3由树枝状晶变为等轴晶;加入SiO2可在Al2O3枝晶间隙形成网状Ca...     

喷射成形H13钢的微观组织及形成特点

采用常规铸造和喷射成形工艺分别制备了H13钢,应用OM、SEM、XRD等方法研究了铸态、喷射沉积态及过喷粉的组织。采用LMS-30粒度仪对过喷粉进行了粒度分析。结果表明:铸态H13钢为粗大的枝晶组织,合金元素与碳化物偏析严重,而喷射成形H13钢为细小的等轴晶组织,几乎没有碳化物,含有较多的残余奥氏体。过喷粉是枝晶组织,随粉末尺寸的减小,一次枝晶变小,二次枝晶臂已不明显,是欠发达枝晶组织。雾化压力的增加对小颗粒过喷粉的尺寸和数量影响甚微,但会明显减小大颗粒过喷粉末的尺寸,并增加其数量。喷射成形等轴晶的形成机制在气液比偏小时以未破碎枝晶的均质化与碎断枝晶的连接长大为主,而在气液比偏高时以大量破碎枝晶作为异质形核核心为主。     

线性电磁搅拌对K417高温合金母合金锭质量的影响

为了提高高温合金母合金锭的质量,本文提出了在高温合金真空熔铸过程中,施加线性电磁搅拌的真空电磁铸造新技术。使用电子探针和光学显微镜,研究了在真空熔铸的凝固过程,施加工频线性电磁搅拌对K417高温合金母合金锭质量的影响。实验结果表明:在K417高温合金真空熔铸的凝固过程中施加140A的工频线性电磁搅拌,能够细化高温合金母合金锭的等轴晶组织、增加高温合金母合金锭的断面等轴晶比例、大幅减轻枝晶偏析的程度并能将高温合金母合金锭的中心缩松缩孔比率从54%降低到35%,从而使高温合金母合金锭的质量得到明显改善。     

Modelling mixed columnar-equiaxed solidification with melt convection and grain sedimentation – Part I: Model description

Part I of this two-part investigation presents a volume-averaging multiphase solidification model that accounts for mixed columnar-equiaxed solidification, non-dendritic and dendritic crystal growth, nucleation of equiaxed grains, columnar primary dendrite tip tracking, melt flow, sedimentation of equiaxed crystals, and their influence on macrostructure and macrosegregation. Five distinct thermodynamic phases (phase regions) are defined: solid dendrites in equiaxed grains, the interdendritic melt between equiaxed dendrites, solid dendrites in columnar trunks, the interdendritic melt between trunk dendrites, and the extradendritic melt. These five phase regions are quantified by their volume fractions and characterized by their solute concentrations. The five phase regions are grouped into three hydrodynamic phases: equiaxed grains consisting of solid dendrites and interdendritic melt, columnar trunks consisting of solid dendrites and interdendritic melt, and extradendritic melt. The extradendritic melt is separated from the interdendritic melt with a grain envelope, whose profile connects the primary, secondary or tertiary dendrite tips to form a ‘natural’ enclosure of the equiaxed grains or columnar trunks. The envelope is further simplified as a volume-equivalent sphere for equiaxed grains, or as volume-equivalent cylinder for columnar trunks by use of morphological shape factors. Expansion of the envelopes during solidification is determined by dendrite growth kinetics, using the Kurz–Giovanola–Trivedi model for growth of columnar primary dendrite tips and the Lipton–Glicksman–Kurz model for growth of columnar secondary dendrite tips (radial growth of the columnar trunk) and equiaxed primary dendrite tips. The solidification of the interdendritic melt is driven by the supersaturation of the interdendritic melt and governed by the diffusion in the interdendritic melt region. Illustrative process simulations and model verifications are presented in Part II.     

深过冷Ni-Cu-Si合金熔体中的快速枝晶生长

为了揭示多元合金中的枝晶生长规律,采用电磁悬浮技术实现了Ni-10%Cu-10%Si三元合金的深过冷与快速凝固,实验中合金熔体获得的最大过冷度为236K。对合金快速凝固过程中初生相-αNi的枝晶生长速度测定结果表明,其与过冷度之间存在幂函数关系:V=1.6×10-13ΔT5.7。当ΔT较小时,随着ΔT的增加V增加缓慢,当ΔT较大时,随着ΔT的增加V迅速增加。对比分析表明,溶质Si对-αNi枝晶的生长影响显著,而溶质Cu则几乎没有影响。随着过冷度的增加,未发现-αNi相的微观形态从枝晶向等轴晶转变,但-αNi晶粒尺寸均随着过冷度的增加而急剧细化。     

Formation and Evolution of Non-dendritic Microstructures of Semi-solid Alloys Prepared by Shearing/Cooling Roll Process

The shearing/cooling roll （SCR） process was adopted to prepare semi-solid A2017 alloy. The formation and evolution of non-dendritic microstructures in semi-solid A2017 alloy were studied. It is shown that the microstructures of semi-solid billets transform from coarse dendrites into fine equiaxed grains as the pouring temperature of molten alloy decreases o.r roll-shoe cavity height is reduced. From the inlet to the exit of roll-shoe cavity, microstructure of semi-solid slurry near the shoe surface is in the order of coarse dendrites, degenerated dendrites or equiaxed grains, but fine equiaxed grains are near the roll surface. Microstructural evolution of semi-solid slurry prepared by SCR process is that the molten alloy nucleates and grows into dendrite firstly on the roll and shoe＇s surface. Under the shearing and stirring given by the rotating roll, the dendrites crush off and disperse into the melt. Under the shearing and stirring on semi-solid slurry with high volume fraction of solid, the dendrite arms fracture and form equiaxed grain microstructures.     

Numerical Simulations of Equiaxed Dendrite Growth Using Phase Field Method

Phase field method offers the prospect of being able to perform realistic numerical experiments on dendrite growth in a metallic system.In this paper, the equiaxed dendrite evolution during the solidification of a pure material was numerically simulated using the phase field model.The equiaxed dendrite growth in a two-dimensional square domain of undercooled melt(nickel) with four-fold anisotropy was simulated.The phase field model equations was solved using the explicit finite difference method on a uniform mesh.The formation of various equiaxed dendrite patterns was shown by a series of simulations,and the effect of anisotropy on equiaxed dendrite morphology was investigated.     

Containerless solidification of germanium by electromagnetic levitation and in a drop-tube

Containerless solidification of germanium has been realized by electromagnetic levitation and drop-tube processing, respectively. The effect of undercooling in the range of 40–426 K on the as-solidified structures of levitation melted Ge drops (∼8.4 mm diameter) was investigated. For undercoolings less than 300 K, the lamellar twins were grown, whereas a microstructural transition to equiaxed grains was observed at undercoolings ≥300 K. Further increasing the undercooling to 400 K, a significant reduction in grain size was achieved. In addition to a similar microstructural development among the particles solidified during free fall in a 8.5 m drop-tube, high-undercooling-induced single crystals were found for some droplets less than 200 μm in diameter. The results on the transition from twins to fine equiaxed grains are accounted for by theories of solidification kinetics and a dendrite break-up model. This revised version was published online in November 2006 with corrections to the Cover Date.     

2024-T4铝合金光纤激光填丝焊缝成形与组织性能的相关性

2024-T4铝合金光纤激光填丝焊缝横截面分为钉头形和近X形2种典型形貌,对比分析了该2种形貌的焊缝成形与组织形态、显微硬度和接头拉伸性能的相关性。结果表明:近X形横截面的焊缝在焊接过程中更加平稳,焊接飞溅更少。焊缝区的组织特征为垂直于熔合线相对生长的柱状晶组织和焊缝中心的等轴晶组织。钉头形焊缝中心晶粒的二次枝晶较发达,逐渐形成等轴树枝晶,而近X形焊缝中心晶粒相对细小,呈现为等轴胞状晶。与钉头形横截面的接头相比,近X形横截面的接头焊缝区析出的强化相θ(Al2Cu)相对较多,平均显微硬度值略高,热影响区的软化现象逐渐减弱,接头强度和塑性略低。     

Structure refinement of pure Mg under pulsed magnetic field

Abstract

A pulsed magnetic field (PMF) was introduced into the solidification of pure Mg. Fine uniform equiaxed grains are acquired in the whole ingot from the PMF treatment, in contrast with the coarse columnar grains observed in conventional casting, and the average grain size is refined to 260 μm with a 200 V PMF treatment. Pulsed magnetic field increases melt convection during solidification, and the violent agitation causes warmer liquid to fracture the tip of columnar dendrites or to break off dendrite branches to promote the formation of an equiaxed structure, with the broken pieces transported into the bulk liquid acting as nuclei. In addition, the uniform temperature field resulting from the stirring increases the likelihood of nuclei survival. The Joule heat effect also participates in the structure refinement. The pure Mg produced with a 200 V PMF treatment exhibits improved mechanical properties, such as the ultimate compressive strength (227 MPa) and fracture strain (33·2%).     

Simulation of equiaxed growth ahead of an advancing columnar front in directionally solidified Ni-based superalloys

Growth of equiaxed grains ahead of an advancing columnar front leads to the formation of as-cast defects, such as stray grains in single crystals or tree rings in vacuum arc remelting (VAR) ingots. In this study a combined cellular automata-finite difference model was applied to simulate dendrite growth and the formation of equiaxed grains in directionally solidified nickel-based superalloys. Realistic dendritic structures and complex solute concentration profiles at the growth front were simulated. It was observed that the solute interaction between primary dendrites occurs well below their tips, while strong solute interaction occurs between the diffusion fields of secondary and tertiary arms. The influence of thermal gradient and growth velocity on CET was investigated and the results were combined on a CET map, showing that a decrease in thermal gradient and an increase in growth rate favour a CET.