模具钢电渣重熔铸坯凝固组织形貌的分形特征

为了更为精细化地表达及控制铸坯质量,以H13模具钢电渣重熔铸坯凝固组织为研究对象,引入分形维数对其主体形貌特征进行定量描述。结果表明,基于数盒子法计算得到的分形维数可定量表征凝固组织形貌的自相似复杂程度,其值从柱状晶向中心等轴晶先减小后增大;凝固组织分形维数可作为衡量铸坯偏析程度（偏析率大小）的指标,且分形维数越大,对应区域偏析率越小,偏析越轻;通过凝固组织分形维数、偏析率和偏析点平均面积与二次枝晶间距关系的研究发现,使用二次枝晶间距表征铸坯凝固组织形貌差异并由此反映偏析程度的方法存在局限性。     

模具钢电渣重熔铸坯凝固组织形貌的分形特征

为了更为精细化地表达及控制铸坯质量,以H13模具钢电渣重熔铸坯凝固组织为研究对象,引入分形维数对其主体形貌特征进行定量描述。结果表明,基于数盒子法计算得到的分形维数可定量表征凝固组织形貌的自相似复杂程度,其值从柱状晶向中心等轴晶先减小后增大;凝固组织分形维数可作为衡量铸坯偏析程度(偏析率大小)的指标,且分形维数越大,对应区域偏析率越小,偏析越轻;通过凝固组织分形维数、偏析率和偏析点平均面积与二次枝晶间距关系的研究发现,使用二次枝晶间距表征铸坯凝固组织形貌差异并由此反映偏析程度的方法存在局限性。     

基于高通量试验原理82B连铸坯组织形貌特征

 凝固组织形貌对铸坯宏观偏析的形成有非常重要的影响,并在一定程度上决定了铸坯后续的加工使用性能。基于高通量试验原理,引入分形维数和无量纲周长对82B帘线钢连铸坯凝固组织形貌特征展开分析。结果表明,对于连铸坯两侧中间区,窄宽度长区域取样方法得到的凝固组织面积率可近似等效为固相率;同时凝固组织整体形貌的分形维数随着固相率的增加而增加,但其无量纲周长呈现相反的趋势,故两者对凝固组织渗透率大小存在相反的影响作用;计算表明,实际铸坯组织的渗透率最小值对应的固相率为0.667。提出了一种基于实际铸坯分析凝固组织形貌特征变化规律的新方法,同时能为连铸末端电磁搅拌与轻压下等偏析控制技术的最佳作用固相率提供参考。     

多元合金两相区凝固过程的数值仿真研究

基于微观枝晶计算域内的溶质质量守恒关系，推导出适用于枝晶凝固方式的二元合金微观偏析半解析数学模型，并根据简单加合原理对模型进行了多元化扩展，应用扩展后的微观偏析模型针对浇铸钢种（视为Fe—C多元合金）的两相区凝固过程进行了数值仿真计算，通过仿真获得了连铸凝固传热计算中所需要的钢种的非平衡凝固路径及实际固相线温度，研究结果表明，本文所建立的多元合金两相区凝固计算微观偏析数学模型及其仿真程序具有较好的合理性和广泛的适用性，可以方便地在连铸过程静态及动态仿真计算中加以耦合运用。     

镍基高温合金GH4151的偏析及相析出行为

摘要：利用电子探针(EPMA)、场发射扫描电镜（SEM）及差热分析（DTA）研究了GH4151合金的元素偏析行为、铸态组织特征以及析出相种类,并对合金凝固过程进行讨论。结果表明：GH4151合金凝固过程中,W元素偏聚于枝晶干,Mo、Nb、Ti元素偏聚于枝晶间,Co、Cr、Al元素几乎不发生偏析,Nb、Ti元素偏析较重。GH4151铸锭心部为粗大的等轴晶,主要析出相包括强化相γ′相、一次碳化物、η相、（γ+γ′）共晶相以及Laves相,其中枝晶间分布的η相、（γ+γ′）共晶相和Laves相为低温脆性相在凝固末期形成,扩大了合金的凝固区间,从而导致合金热裂敏感性增加。     

双辊连铸不锈钢的微观和宏观偏析

介绍了对双辊工艺生产的ＡＩＳＩ３０４不锈钢薄带所作的偏析研究的结果。根据带钢的显微结构、可能出现的合金成分波动以及工艺择偏析作了研究。枝晶间的微观偏析与初始凝固方式相对应，由于钢水的过冷度和成分存在波动，其初始凝固表现出一种交替的相形成方式（奥氏体与铁素体的交替凝固）。所观察到的Ｋ０〈１的合金化组元的宏观偏析方式（正偏析和负偏析的更迭区）可以根据工艺参数，用枝晶间熔体的转移加以解释。     

高碳中锰耐磨钢凝固过程溶质微观偏析模型

通过定向凝固、电子探针(EPMA)、Factsage等多种实验与理论计算相结合的手段对中锰耐磨钢凝固过程溶质元素微观偏析行为进行了系统研究.研究表明在定向凝固试验中当拉速为50μm·s^-1时,中锰钢的二次枝晶间距平均值为59.77μm;中锰钢凝固过程组织转变为L→L+γ→γ属于奥氏体凝固模式,无包晶反应的发生,也无铁素体相及其他相的出现;中锰钢定向凝固过程中Mn、Cr在枝晶间的含量明显高于枝晶内,表明Mn、Cr元素发生了明显的正偏析行为;通过对各特征参数求解,构建了中锰钢溶质元素微观偏析模型,发现中锰钢定向凝固过程中Mn元素偏析指数与Brody–Flemings模型符合较好,而Cr元素偏析指数与Clyne–Kurz模型分布较为一致.     

UNS N10276合金电渣重熔凝固组织及成分偏析研究

研究了UNS N10276合金大规格电渣重熔锭铸态组织、合金元素偏析行为以及合金中析出相的析出规律,并结合热力学计算系统分析了电渣重熔凝固组织及偏析的形成原因。研究结果表明,UNS N10276合金电渣锭具有典型枝晶组织,电渣锭头部的二次枝晶间距明显大于尾部。合金在凝固过程中,Mo、Mn、Si、C等元素富集于枝晶间,属于正偏析元素;Fe、W、Cr等元素富集于枝晶干,属于负偏析元素。Mo是偏析最严重的元素且在电渣锭头部偏析量最大。UNS N10276合金电渣锭中的主要析出相为枝晶间和沿晶界分布的大尺寸μ相和M6C碳化物相。Mo元素是析出相主要形成元素,且在电渣锭头部析出数量多,析出相尺寸大。因此,为改善UNS N10276合金冶金质量及其热加工性能,在成分设计和实际生产中应尽量减少Mo元素偏析,并尽可能地减少其析出相的形成。     

枝晶凝固过程中的微观偏析半解析数学模型

基于典型微观凝固单元体内的溶质质量守恒,结合前人的研究工作,建立了一个适合于枝晶凝固方式的二元合金微观偏析半解析模型.本模型同时考虑了反向扩散和粗化对微观偏析的影响,并对枝晶臂间距的粗化直接进行计算,因此更为精确.若只考虑反向扩散的影响,本模型可以简化为BF模型形式;而如果只考虑粗化的影响,本模型可简化为Mortensen模型.本模型完整地统一了以BF模型为代表的反向扩散类模型和以Mortensen模型为代表的粗化模型.利用本模型同样可以对多元合金的微观偏析进行很好预测.以Fe-C-X（Si,Mn,P,S）合金体系为例对本模型的求解过程进行了详细的阐述.本模型可以很好地预测Al-4.9%Cu二元合金的共晶分数以及Fe-C-X（Si,Mn,P,S）多元合金体系的零强度温度和零塑性温度,并与实测值吻合良好.      

一种镍基单晶高温合金的显微偏析行为

研究了一种新型镍基单晶高温合金DD98铸态组织的显微偏析行为.实验结果表明,当合金以枝晶凝固时,组织中存在显微偏析.其中元素Mo、Cr、Ti、Ta、Al在枝晶间富集,Ti、Mo、Ta、Cr的偏析较为严重,Al的偏析程度相对小一些,Ni、Co、W为枝晶干偏析元素,其中W的偏析最为严重;共晶中富集Al、Ta、Ti、Ni,贫Co、W、Cr、Mo.凝固速率对枝晶偏析有显著的影响.随着抽拉速率的增加,元素Al、Mo、Co、Ti的偏析程度增加,而Ta的偏析程度降低,其它元素的偏析程度变化不大.     

<Emphasis Type="Italic">In-Situ</Emphasis> Analysis of Coarsening during Directional Solidification Experiments in High-Solute Aluminum Alloys

Coarsening within the mushy zone during continuous directional solidification experiments was studied on an Al-30 wt pct Cu alloy. High brilliance synchrotron X-radiation microscopy allowed images to be taken in-situ during solidification. Transient conditions were present during directional solidification. Under these conditions, solute-rich settling liquid flow affects the dendritic array and thus coarsening. Coarsening was studied by following the secondary dendrite arm spacing (SDAS) of a developing dendrite at different local solidification times according to the mush depth and instant interface velocity. Solute enrichment and liquid flow cause deceleration and acceleration of the solidification front, which in turn influences both the mush depth and local growth and coarsening due to variations in solutal gradients and thus local undercooling. In addition, spacing between neighboring dendrites (i.e., primary dendrite arm spacing), which determines permeability within the mushy zone, affects the development of high-order branches. This article is based on a presentation given at the International Symposium on Liquid Metal Processing and Casting (LMPC 2007), which occurred in September 2007 in Nancy, France.     

Macrotransport-solidification kinetics modeling of equiaxed dendritic growth: Part I. Model development and discussion

An analytical model that describes solidification of equiaxed dendrites has been developed for use in solidification kinetics-macrotransport modeling. It relaxes some of the assumptions made in previous models, such as the Dustin-Kurz, Rappaz-Thevoz, and Kanetkar-Stefanescu models. It is assumed that nuclei grow as unperturbed spheres until the radius of the sphere becomes larger than the minimum radius of instability. Then, growth of the dendrites is related to morphological instability and is calculated as a function of melt undercooling around the dendrite tips, which is controlled by the bulk temperature and the intrinsic volume average concentration of the liquid phase. When the general morphology of equiaxed dendrites is considered, the evolution of the fraction of solid is related to the interdendritic branching and dynamic coarsening (through the evolution of the specific interfacial areas) and to the topology and movement of the dendrite envelope (through the tip growth velocity and dendrite shape factor). The particular case of this model is the model for globulitic dendrite. The intrinsic volume average liquid concentration and bulk temperature are obtained from an overall solute and thermal balance around a growing equiaxed dendritic grain within a spherical closed system. Overall solute balance in the integral form is obtained by a complete analytical solution of the diffusion field in both liquid and solid phases. The bulk temperature is obtained from the solution of the macrotrasport-solidification kinetics problem.     

Simulation of Microsegregation in Multicomponent Alloys During Solidification

A phase‐field model is applied to the simulation of microsegregation and microstructure formation during the solidification of multicomponent alloys. The results of the one‐dimensional numerical simulations show good agreement with those from the Clyne–Kurz equation. Phase‐field simulations of non‐isothermal dendrite growth are examined. Two‐dimensional computation results exhibit different dendrites in multicomponent alloys for different solute concentrations. Changes in carbon concentration appear to affect dendrite morphology. This is due to a larger concentration and a lower equilibrium partition coefficient for carbon. On the other hand, changes in phosphorus concentration affect the dendrites and interface velocity in multicomponent alloys during solidification when phosphorus content is increased from 10^?3 mol% P. With additional manganese, the solidification kinetics slow down; dendrite morphology, however, is not affected. The potential of the phase‐field model for applications pertaining to solidification has been demonstrated through the simulations herein.     

The Evolution of As-cast Microstructure of Ternary Mg-Al-Zn Alloys: An Experimental and Modeling Study

A numerical formulation of solidification model which can predict the microsegregation and microstructural features for multicomponent alloys is presented. The model incorporates the kinetic features during solidification such as solute back diffusion, dendrite tip undercooling, and secondary arm coarsening. The model is dynamically linked to thermodynamic library for accurate input of thermodynamic data. The modeling results are tested against the directional solidification experiments for Mg-Al-Zn alloys. The experiments were conducted in the cooling rate range of 0.13 to 2.33 K/s and microstructural features such as secondary arm spacing, primary dendrite arm spacing, second phase fraction, and microsegregation were compared with the modeling results. Based on the model and the experimental data, a solidification map was built in order to provide guidelines for as-cast microstructural features of Mg-Al-Zn alloys in a wide range of solidification conditions.     

Variations of Microsegregation and Second Phase Fraction of Binary Mg-Al Alloys with Solidification Parameters

A systematic experimental investigation on microsegregation and second phase fraction of Mg-Al binary alloys (3, 6, and 9 wt pct Al) has been carried out over a wide range of cooling rates (0.05 to 700 K/s) by employing various casting techniques. In order to explain the experimental results, a solidification model that takes into account dendrite tip undercooling, eutectic undercooling, solute back diffusion, and secondary dendrite arm coarsening was also developed in dynamic linkage with an accurate thermodynamic database. From the experimental data and solidification model, it was found that the second phase fraction in the solidified microstructure is not determined only by cooling rate but varied independently with thermal gradient and solidification velocity. Lastly, the second phase fraction maps for Mg-Al alloys were calculated from the solidification model.     

深过冷技术制备均质过偏晶合金及其形成机制的研究

采用熔融玻璃净化和循环过热相结合的方法使Ni 40 % (质量分数 )Pb合金获得 2 92K大过冷度 ,成功制备出大体积均质过偏晶合金。根据BCT模型和组织演化结果分析表明 :过冷粒状晶是在内应力的作用下 ,枝晶发生全面碎断 ,随后在枝晶段表面和应变能的驱动下使晶界移动发生再结晶的结果 ,即枝晶碎断 再结晶机制 ;试样基体上弥散分布的细密铅颗粒是由于快速凝固阶段溶质截留效应而形成的 ,少量较大尺寸铅颗粒的形成主要与慢速凝固阶段分布于枝晶骨架间残余富铅液相的聚合有关。     

Undercooling-Induced macrosegregation in directional solidification

The accepted primary mechanism for causing macrosegregation in directional solidification (DS) is thermal and solutal convection in the liquid. This article demonstrates the effects of under-cooling and nucleation on macrosegregation and shows that undercooling, in some cases, can be the cause of end-to-end macrosegregation. Alloy ingots of Pb-Sn were directionally solidified upward and downward, with and without undercooling. A thermal gradient of about 5.1 K/cm and a cooling rate of 7.7 K/h were used. Crucibles of borosilicate glass, stainless steel with Cu bottoms, and fused silica were used. High undercoolings were achieved in the glass crucibles, and very low undercoolings were achieved in the steel/Cu crucible. During under-cooling, large, coarse Pb dendrites were found to be present. Large amounts of macrosegregation developed in the undercooled eutectic and hypoeutectic alloys. This segre-gation was found to be due to the nucleation and growth of primary Pb-rich dendrites, continued coarsening of Pb dendrites during undercooling of the interdendritic liquid, Sn enrichment of the liquid, and dendritic fragmentation and settling during and after recalescence. Eutectic ingots that solidified with no undercooling had no macrosegregation, because both Pb and Sn phases were effectively nucleated at the start of solidification, thus initiating the growth of solid of eutectic composition. It is thus shown that undercooling and single-phase nucleation can cause significant macrosegregation by increasing the amount of solute rejected into the liquid and by the movement of unattached dendrites and dendrite fragments, and that macrosegregation in excess of what would be expected due to diffusion transport is not necessarily caused by convection in the liquid.