板料成形有限元模拟中自适应三角形网格的研究

针对非规则几何区域的有限元网格剖分,提出了栅格法与推进法结合的新的三角形自适应剖分算法、三角形单元网格的动态自适应加密和聚合算法和基于板料模具穿透量的加密判据和基于法矢量的聚合判据,实现了空间三角形单元网格的划分、自适应加密、动态聚合和重划分.     

Numerical simulation on directional solidification of Al-Ni-Co alloy based on FEM

The ratio,of the temperature gradient at the solidifiationfront to the solidification rate of solid-liquid interface,plays a large part in columnar grain growth.The transient temperature fields of directional solidification of Al-Ni-Co alloy were studied by employing a finite element method.The temperature gradient at the solidification front and the solidification rate were analyzed for molten steels pouring at different temperatures.The results show that with different initial pouring temperatures,the individual ratio of the temperature gradient at solidification front to the solidification rate soars up in the initial stage of solidification,then varies within 2,000-6,000℃.s.cm-2,and finally goes down rapidly and even tend to be closed to each other when the solidification thickness reaches 5-6 cm.The simulation result is consistent with the practical production which can provide an available reference for process optimization of directional solidified Al-Ni-Co alloy.     

Phase field modeling the selection mechanism of primary dendritic spacing in directional solidification

Selection mechanisms of primary dendritic spacing in directional solidification are investigated by the phase field method. Results show that the lower and upper limits of primary spacing are determined by the interdendritic solutal interactions and the interdendritic undercooling respectively. The upper limit of primary spacing resulting from overgrowth of the tertiary arm could be about four times as large as the lower limit. The microstructural evolution from the onset of planar instability during directional solidification with a constant pulling velocity can be divided into three stages: an initial competition stage, a submerging stage and a lateral adjustment stage. Simulation results also demonstrate that the final primary spacing with a constant pulling velocity is very close to the lower limit due to the dendrite submerging mechanism.     

Microstructure morphologies during the transient solidification of hypomonotectic and monotectic Al-Pb alloys

The solidification cooling rate (T), growth rate (v), temperature gradient (G), interphase spacing (λ) and diameter (d) of the Pb-rich phase have been experimentally determined for a hypomonotectic Al-0.9 wt%Pb and a monotectic Al-1.2 wt%Pb alloys directionally solidified under unsteady-state heat flow conditions. It is shown for both cases that, from the cooled bottom of the casting up to a certain position along the casting length, the microstructure was characterized by well-dispersed Pb-rich droplets in the aluminum-rich matrix, followed by a region of morphological transition (with the Pb-rich phase formed by droplets and fibers) and finally by a mixture of fibers and strings of pearls for positions closer to the top of the casting. It has been also observed that such microstructural transition was anticipated for the alloy with higher solute content. It is shown that the correlation between the morphology of the Pb-rich phase and the growth rate can be synthesized as follows: Al-0.9 wt%Pb alloy, droplets for v > 1.0 mm/s and fibers for v < 0.65 mm/s; Al-1.2 wt%Pb alloy, droplets for v > 1.1 mm/s and fibers for v < 0.87 mm/s. Experimental growth laws relating the interphase spacing to both G and v are proposed.     

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.     

Onset of rod eutectic morphology in directional solidification

Abstract

Initial dynamics of morphological selection in a succinonitrile-(D)camphor organic transparent rod eutectic system is investigated experimentally using directional solidification with specimen thicknesses of 20 and 200 μm. The shape of the solid/liquid interface, the specimen thickness, the initial single-phase boundary thickness, and the grain boundaries are all observed to influence the onset of the eutectic morphology in a geometrically constrained system. Additionally, initiation of eutectic growth within a thin liquid layer at the specimen slide wall and lateral propagation of the array is observed, as suggested in a previous study by the present authors.     

包晶合金定向凝固中的共生生长

对包晶合金定向生长特性进行分析，并与共晶系经典共生生长模型（Jackson-Hunt模型）所描述的共生生长特性进行对比，提出包晶稳态过热共生生长模型，同时以Fe-Ni合金系为对象，对其亚包晶和过包晶成分在不同温度梯度G和生长速度1，下进行定向凝固实验及组织分析。研究结果表明：在定向凝固条件下，包晶系两相严格的共生生长只有在进入稳态且温度高于包晶相变温度时才可能进行；包晶合金两相的共生生长尤其在G／v值高的平／胞界面形态，确实发生在Tp温度以上，与提出的模型所预测的一致。     

相场法凝固数值模拟的研究进展

相场方法能有效地避免跟踪固-液相界面,已成为对各种材料建模和计算界面、相边界移动的有效方法,是目前国内外的研究热点.本文论述了相场法模拟凝固微观组织的原理和国内外的研究现状,指出了进一步的研究方向.     

New approach to quantifying solidification path in modelling of macrosegregation in multicomponent Al alloys

Abstract

The continuum model Alsim, which computes the macroscopic transport of mass, enthalpy, momentum, and solute in aluminium castings, is being coupled with a new module based on the microsegregation model Alstruc in order to update the solidification path in macrosegregation computations for industrial multicomponent aluminium alloys. The coupling deals with two main challenges; the first being the need for accessing thermodynamical phase diagram data within reasonable limits of computational time and storage. This is solved in Alstruc by approximating the phase diagram data by simple, analytical expressions. The second challenge is that many advanced microsegregation models are restricted to 'closed' volume elements of constant total alloy composition. This is solved by calling the Alstruc module at each nodal point and time step in Alsim and thereby allowing for an 'open system'. The usefulness of the new module is preliminary assessed.     

A solidification model for prediction of castability in the precipitation-strengthened nickel-based superalloys

The Scheil equation was used to model the solidification path, microsegregation of alloying elements in the interdendritic regions, solidification temperature ranges, and to predict the formation of secondary structures and the castability behavior of as-cast superalloys. 4 experimental alloys with pre-specified γ-Ti,Nb,Al,Mo composition containing different Nb, Ti and Al contents were designed using vacuum induction melting furnace. The produced as-cast superalloys were characterized using optical and scanning electron microscopy equipped with energy dispersive X-ray spectrometer and TG–DSC analysis. The experiments showed logic conformity to the modeling results. The model and experiment confirmed the highest segregation behavior for Ti and Nb. All the experimental superalloys indicated the remarkable tendency to form secondary eutectic structures at the last stages of solidification. Superalloy with chemical composition of γ-3.5%Mo,1.8%Al,4%Ti,2.9%Nb showed the shorter solidification temperature range and the best castability.     

单相合金定向凝固的特征尺度和过冷度研究

采用透明合金丁二腈（SCN）-1．48％水杨酸苯酯（Salol）（质量分数）进行恒速定向凝固实验,考察了一次间距、尖端半径和尖端温度随凝固生长速度变化的规律．通过考察平界面失稳孕育时间和失稳时界面速度的关系,获得了平界面失稳的临界速度．实验发现,随着生长速度的增大,一次间距先减小到一个极小值然后又增大到一个极大值,随后逐渐下降,呈现S形的变化趋势,并且在从极小值增大到极大值区间发生了胞／枝转变．将实验结果与经典的BHL模型以及自洽数值模型进行了比较,发现BHL模型所预言的尖端温度与实验结果存在较大偏差,而所有实验结果与自洽模型吻合较好．     

Modelling of dendritic solidification in undercooled dilute Ni–Zr melts

The kinetics of dendritic solidification in undercooled Ni–Zr samples is analyzed using new experimental results and theoretical studies based on a sharp-interface model and phase-field simulations. The predictions of a sharp-interface model and of a diffuse-interface model describing the phase transition considering both thermal and solutal diffusion are compared with the new experimental results by evaluating the dendritic tip velocity in electromagnetically levitated Ni–Zr samples.     

Continuous and directional solidification technology of titanium alloys with cold crucible

The experiments of continuous and directional solidification of titanium alloys with cold crucible were carried out in a multifunctional electromagnetic cold crucible apparatus. Parameters and factors influencing the surface crack and macrostructure of titanium alloy ingots were studied. The mechanism of the parameters and factors influencing the surface crack and macrostructure of the ingots were interpreted. The results show that the surface cracks of the prepared ingots decrease with the increase of the input power from 50 to 60 kW or with the increase of the coil turns from 3 to 5 circles. The surface cracks increase with the increase of withdrawal velocity from 3 to 5 mm/min or the height of the primer from 2 to 3 cm, then decrease with the increase of withdrawal velocity from 5 to 8.7 rnm/min or the height of the primer from 3 to 4 cm. Coil turns is the most important one in all parameters effect on the surface crack, the input power is more important, then the withdrawal velocity is important and the height of the primer is the least important. Withdrawal velocity is the most important factor affecting the macrostructure, and effects of other factors on maerostructure is slight. With the decrease of velocity from 8.7 to 0.5 mm/min, the quantity of grains reduces, the grain orientation degree becomes small, and the solidification fronts change from concave to plane to convex. The ingot can be directional solidified at velocity of 1 mm/min. The ingot with free surface crack and directional macrostructure is prepared under definite conditions.     

Structure and oil retaining capacity of gasar copper fabricated by radial solidification with a combined crystallizer

Porous copper with elongated pores was fabricated by a radial solidification method. The process was carried out in a combined crystallizer under high pressure of a mixture of hydrogen and argon. Pore size, pore length, pore density and porosity of the porous copper were characterized. Furthermore, the oil retaining capacity including oil content and oil efficiency was also evaluated. It is found that porous copper solidified with water-circulated chiller through a thick graphite jacket possesses a gradient structure with increasing pore size, and thus pore density decreases. Also pore length and pore aspect ratio decrease from lateral inwardly, while its porosity is almost uniform. The results show that the porous copper with radial pores has a good oil retaining capacity.     

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.     

Al-Cu合金水平单向凝固组织预测及实验观察

使用有限元耦合元胞自动机模型预测水平单向凝固实验中 Al-4.5%Cu(质量分数)合金试样的温度场和微观凝固组织。晶体形核和枝晶生长动力学模型分别采用Rappaz连续形核模型和Kurz-Giovanola-Trivedi(KGT)模型简化形式,基于纯扩散条件,采用 KGT 模型简化公式计算生长参数。结果显示：数值模拟可以较准确地预测柱状晶向等轴晶转变(CET)位置和等轴晶晶粒尺寸,但因模拟未考虑晶核的运动,激冷等轴晶区的模拟有较大偏差。模拟和实验结果都证明过热度显著影响Al-Cu合金的凝固组织,过热度低于20℃条件下可以获得全等轴晶组织,否则会出现柱状晶;过热度50℃以上的试样CET位置几乎不发生变化。     

Study of solidification behavior and splat morphology of vacuum plasma sprayed Ti alloy by computational modeling and experimental results

The microstructure of Ti-6Al-4V alloy manufactured by vacuum plasma spraying consists of individual lamellae, inter-lamellae boundaries, and porosity. Mechanical properties of the as-sprayed structure depend mainly upon the solidification behavior and resultant microstructure and morphology of the individual splats and cohesion between splats. Using a three-dimensional numerical model, the cooling rate and solidification behavior of a single Ti-6Al-4V droplet (50 μm) impacting on a titanium substrate under vacuum plasma spray conditions were investigated. Results were verified with experimental observations in single splats and as-sprayed microstructures obtained by vacuum plasma sprayed form of Ti-6Al-4V alloy. The average cooling rate of a single splat obtained from the numerical simulation was on the order of 10⁸ °C/s and the solidification front velocity was approximately 63 cm/s which is in the range of the rapid solidification. The thickness of the splat was calculated to be around 3 μm and the deposition efficiency was approximately 70%. These results illustrated good agreements with those obtained from experiments.