A CELLULAR AUTOMATON-APPROACH TO SIMULATION OF GRAIN STRUCTURE DEVELOPMENT IN ELECTROSLAG CASTING

1.IntroductionElectroslagcastingcanproducepartsofgoodquality,ofwhichthemechanicalpropertiesarecomparablewithorsuperiortothoseofforgedproducts.Ithasbeenmoreandmoreutilizedtomakestructuresofcriticalimportance,whichconventionallywoulddoubtlesslybemadebyforging.Understandingandcontrolofmicrostructures,especiallyshape,sizeandorientationofcrystallitesinelectroslagcastingarethereforemoreandmoreimportantforsafetyconcernintheirapplication.Experimentalstudiesofthegrainstructuresandtheirdependenceonvario…     

Properties of Cast Aluminium Alloys as Thermal Storage Materials

Abstract

This paper discusses the concept of using a cast aluminium alloy for thermal storage, utilising a phase change. The specific heat of both liquid and solid metal and the latent heat of melting of Al-Si, Al-Si-Mg and Al-Si-Cu alloys were measured using Differential Scanning Calorimetry (DSC) and by use of an Isothermal Copper-block Calorimeter (ICC). The thermal-cycling characteristics of these alloys, together with the change in the latent heat of Al-Si alloy were also measured during a holding period of 300 hr at elevated temperature. Taking into account the density of thermal storage, the thermal-cycling characteristics and cost, it is suggested that Al-Si alloy is probably the best choice when selecting a phase-change metal for thermal storage.     

低熔点金属相变材料的熔点和相变潜热的理论预测

为根据实际需求 “设计”金属相变材料,建立了低熔点合金的熔点和相变潜热的计算模型。通过分析二元共晶合金相变中熵及焓等状态量的变化特点推导出熔点和相变潜热预测模型,并将预测模型向多元合金进行了推广。利用预测模型计算得到15种低熔点合金的熔点和相变潜热的计算值,通过与DSC的测试结果进行比较并且对误差进行分析发现：熔点和相变潜热的计算值与测量值具有较好的一致性。并且得出一个配制金属相变材料的原则：若想得到相变潜热较高的合金,则应该选取相变潜热高的元素作为合金组元,并且提高该元素的含量。该预测模型的优点是仅依靠合金元素本身的物理参数即可较准确地预测合金的熔点和相变潜热,从而避免了大量的实验。     

镁合金电阻点焊内部喷溅产生的原因分析

在电阻点焊过程中喷溅的产生直接降低焊接接头的强度,因此是最不希望出现的焊接缺陷.文中引入基于显微接触理论的接触电阻模型,通过轴对称有限元模型分析了镁合金电阻点焊过程中的温度场分布及塑性变形过程,以揭示内部喷溅产生的原因.结果表明,由于AZ31镁合金高热导率、低熔点、低比热容和大的线膨胀系数,焊接中需要采用大电流短时间的强参数焊接,所以相对于铝合金和钢铁来说,喷溅在镁合金焊接中更容易发生.内部喷溅产生的原因主要与金属熔化导致熔核内部压强增大相关,增加的压力致使周围的塑性环产生缺口,保护液态金属冲破周围固态金属的束缚,形成喷溅.     

Numerical simulation of molten pool dynamics in high power disk laser welding

A single-phase problem is solved rather than a multiphase problem for numerical simplicity: and the solution is based on the assumption that the region of gas or plasma can be treated as a void because solid or liquid steel has a greater density level than gas or plasma. The volume-of-fluid method, which can calculate the free surface shape of the keyhole, is used in conjunction with a ray-tracing algorithm to estimate the multiple reflections. Fresnel's reflection model is simplified by the Hagen-Rubens relation for handling a laser beam interaction with materials. Factors considered in the simulations include buoyancy force, Marangoni force and recoil pressure; furthermore, pore generation is simulated by means of an adiabatic bubble model, which can also lead to the phenomenon of a keyhole collapse. Models of the shear stress on the keyhole surface and of the heat transfer to the molten pool via a plasma plume are introduced in simulations of the weld pool dynamics. Analysis of the temperature profile characteristics of the weld bead and molten pool flow in the molten pool is based on the results of the numerical simulations. The simulation results are used to estimate the weld fusion zone shape; and the results of the simulated fusion zone formation are compared with the results of the experimental fusion zone formation and found to be in good agreement. The effects of laser beam profile (Gaussian vs. measured), vapor shear stress, vapor heat source and sulfur content on the molten pool behavior and fusion zone shape are analyzed.     

Phase-field simulation of dendritic growth for binary alloys with complicate solution models

1 INTRODUCTION The formation of complex microstructures during solidification of metals and alloys have fas- cinated researchers in materials science and related areas for so many years , especially the formation of dendritic structures . In many commercial al- loys , microstructural features that determine the mechanical integrity of a cast ingot ,such as solute segregation, grain size and porosity , all depend critically on the morphologies and velocities of in- dividual or arrays of gr…     

90W-7Ni-3Fe激光选区熔化热行为及试验分析

激光选区熔化是一种成形难加工金属的方法,文中以90W-7Ni-3Fe为研究对象,分别考虑材料在粉末和实体状态下的物性参数,建立温度场有限元模型,模拟成形过程中的温度场,研究了不同工艺参数下的熔池尺寸、温度梯度、冷却速率变化等. 温度场分析表明,熔道中心温度超过了钨的熔点,粉末充分熔化,而熔道搭接处温度仅超过镍铁熔点,钨颗粒并未熔化,因此在相邻道之间区域是以液相烧结方式形成. 同时,设计了相应参数的工艺试验,发现增大能量输入,可以使液相填充更加充分,成形件致密度提高.     

Flexible manufacturing of metallic products by selective laser melting of powder

In order to produce metallic parts directly from powder material using CAD data, the selective laser melting (SLM) process has been developed. From a series of material tests, nickel-based alloy, Fe alloy and pure titanium powders are found to be feasible for fabrication of metallic models by SLM. Finite element simulation shows stress distribution within the solid single layer formed on the powder bed during forming and some methods for avoiding defects in the products are suggested. The die for metal forming from the nickel-based alloy and the pure titanium models of bone and dental crown are demonstrated. The density of the model made by SLM is higher than 90% of the solid model. The mechanical properties of the formed model can be improved to those of the solid by post-processing.     

电火花钛合金加工的数值模拟(英文)

建立电火花钛合金加工的三维有限元轴对称热物理模型。为了更好地预测温度场分布和材料去除效率,采用模型分析了基于电流和脉宽变化的等离子体半径、熔化和气化潜热、能量分配系数和高斯分布的热流密度等影响因素,模拟了单脉冲电火花放电加工钛合金的温度场,并研究了沿放电凹坑的半径方向上温度场分布的放电参数。通过实验数据的对比,验证该模型在材料去除效率方面具有很好的预测效果。     

二元合金激光快速熔凝过程的非Fourier模型

基于非Fourier定律，建立了脉冲激光加热条件下单相二元合金表面快速重熔和凝固过程的非平衡传热传质模型，并根据碰撞理论和Aziz的连续生长模型处理固／液界面，以解释快速熔凝过程界面动力学的非平衡效应，快速熔凝问题是涉及热质传输的移动界面问题，通过二阶精度的Von Neumann隐式差分格式和界面跟踪方法进行过程模型的数值求解。应用该模型，分析了Al-Cu二元合金的激光表面熔凝过程，结果表明，激光的高能量密度和非平衡界面动力学所引起的熔化过程和凝固过冷对于快速熔凝过程的影响很大，在快速熔凝过程中，界面速度的变化很大，且因基底材料和热流大小而不同，通过计算获得了界面温度，速度、溶质浓度及非平衡分配系数随界面位置的变化，结果显示，在凝固过程中界面速度和界面溶质浓度都存在着很大的波动。     

IN718高温合金水平定向凝固和真空电弧重熔过程中“黑斑”形成的多组元数值模拟

建立了多组元两相模型来描述IN718高温合金凝固过程中的宏观/微观传输和“黑斑”形成,并应用动态网格算法模拟真空电弧重熔（VAR）过程中的填充过程。首先,使用热力学计算方法求解液相成分随固相分数的变化,并获得多组元合金的枝晶间液相密度。之后模拟了水平定向凝固工艺下形成的“黑斑”,并与实验结果进行对比,研究其形成机理和影响因素。最后,利用所开发的模型来研究工艺参数对工业规模VAR铸锭中“黑斑”的影响。结果表明,元素组成对凝固过程中液相的密度变化有显著影响,“黑斑”的形成伴随着高热溶质对流强度。“黑斑”的生长方向由液相密度差和凝固界面相对重力方向的角度决定。在VAR过程中,熔池形状受电极熔化速率和冷却速率影响。     

Thermodynamic and Microstructural Modeling of Nb-Si Based Alloys

Nb-Si alloys have gained much attention over the last decade as the next generation alloys for high-temperature aero-engine applications due to their low density and improved mechanical properties. However, the microstructures of these alloys are quite complex and vary significantly with the addition of elements such as Ti and Hf. Hence, an improved understanding of the phase stability and the microstructural evolution of these alloys is essential for alloy design for advanced high-temperature applications. In the present paper, we describe the microstructural evolution modeling results of the dendritic and eutectic solidification of the binary Nb-16 at.% Si alloy, obtained using a Phase-Field simulations performed with MICRESS. The effect of parameters; such as heat extraction rate, the ratio of the diffusivity of the solute in liquid to solid, and the interfacial energy of liquid and solid interface, on the microstructural evolution during dendritic solidification is discussed in detail.     

Untersuchungen des Korrosionsverhaltens ausgewählter Wärmeaustauscherwerkstoffe in Natriumacetat‐Trihydrat‐Schmelze für den Anwendungsfall Latentwärmespeichersysteme

Investigations of the corrosion behaviour of special heat exchanging materials in sodium acetate trihydrate melt for the application latent heat storage The development activities in the area of latent heat storage have more and more increased in the last years. The reason is the search for new energy storage systems of higher energy efficiency and the reinforced utilisation of renewable and alternative energies which are often only irregularly available. The special advantage of latent heat storage is the high energy storage density which could be reached at the melting point of selected storage materials and the resulting reduction of required space respectively the nearly constant temperature. An important topic relating to the development of these storage systems was the investigation of the long time stability, especially the corrosion stability. At the same time the heat exchange material has the function to transfer the heat and coldness from a heat transfer medium, e. g. water which has drawn the energy from an external source to the storage material. Among the storage materials the sodium acetate trihydrate (melting point: 58°C) has interesting advantages. In that reason the investigation of the corrosion behaviour and the choose of suitable materials for heat exchangers was an important goal. In the present report important results of the investigation of selected metals at 80°C in sodium acetate trihydrate are described. The corrosion influencing impurities chloride, sulphate and carbonate which could be contained in the much more inexpensive salt hydrate of technical quality were added to the analytically pure sodium acetate trihydrate. Furthermore the addition of graphite (for increasing the heat conductivity) and the contact with air were investigated. Some promising metals of high corrosion resistance are the result of the investigations.     

Preparation and characterizations of heat storage material combining porous metal with molten salt

1　INTRODUCTIONGenerallyspeaking ,theheatstoragetechnologyisdividedintotwotypes ,i.e .sensibleheatthermalstorageandlatentheatthermalstorage[13] .Sensibleheatthermalstoragetechnologyistousetheheatab sorptioncapacityoftheceramicmaterialstostoretheheatenergyintotheceramicbeads ,andtousetheheattransformedandstoredundertheconditionofhighorlowtemperature[4 ] .Inthepastfewdecades ,thesensibleheatthermalstoragematerialswerewide lyappliedowingtotheirgoodchemicalandmechani calstability ,excellentsaf…     

选择性激光烧结金属粉末瞬态温度场模拟

局部输入的集中移动热源造成了选择性激光烧结过程中温度场分布不均衡且不稳定,因此研究其温度场对掌握烧结过程中温度动态分布规律具有重要意义。在考虑了热传导、热辐射和热对流,材料的非线性热物性参数和相变潜热的作用下,建立了水雾化Fe多道烧结的三维有限元模型,采用ANSYS参数化设计语言(APDL)实现移动的高斯热源的加载。模拟结果表明:激光烧结过程中,在光斑中心前端存在着较大的温度梯度;光斑中心的温度高于金属粉末的熔点,烧结过程存在液相;粉床内部温度场在深度方向呈漏斗状阶梯分布,随烧结深度的增加,粉床内部的温度和温度梯度迅速衰减;同一烧结道各点的最高温度相对稳定,但随着烧结道的增加,各点最高温度都有小幅度增加的趋势,这是温度累加的结果。     

Melting behavior of nanosized lead particles embedded in an aluminum matrix

Molecular dynamics (MD) simulations, employing semi-empirical glue-type (similar to embedded atom method) many-body potentials, have been used to model the melting behavior of nanosized Pb particles embedded in an Al matrix. All the Pb particles studied melt well above the bulk melting temperature, with the melting point elevation displaying a damped periodic trend with increasing Pb particle size. By inspecting snapshots derived from the simulations, it is also possible to conclude that melting occurs via nucleation at {1 0 0} interfaces. A phenomenological model, based on the consideration of interfacial energy, volume expansion and lattice mismatch, has been developed to describe this interesting melting behavior. Our model leads to the conclusion that the periodic variation of melting point with size is due to an oscillatory strain energy contribution arising from the large size mismatch of Pb and Al atoms.     

采用温度回升法对任意结晶区间的铸件凝固结晶潜热的数值计算

铸件凝固结晶潜热的释放行为与凝固传热、溶质传输及铸造合金种类与成分等诸多因素有关，合金凝固过程中其温度、固相体积分数与液相成分(T-fs—CL)三者之间一般存在着非线性强耦合关系．采用合金凝固传输统一模型及温度回升(补偿)法提出的处理任意结晶温度区间(包括零结晶区间)凝固潜热释放问题的数值迭代计算方法，对不同合金成分与不同固相反扩散效应的二维Al—Cu合金铸件定向凝固传输过程进行了数值计算，表明该方法对于从纯金属到共晶成分的不同成分合金及从Scheil模型到Lever-Rule模型之间的任意凝固模式均是有效的．将该方法推广应用于叶片铸件三维凝固传输过程的T-fs—CL耦合数值模拟仍显示出高的计算效率．通过对计算结果进行的三维图像数据处理，展示了铸件几何形状对凝固传输行为的重要影响．     

自然对流条件下Si-Fe在铁液中熔化过程的数值模拟

建立了描述自然对流条件下Ｓｉ－Ｆｅ在铁液中熔化过程的数学模型,固相、液相和糊状区中的动量,热量和溶质传输用统一方程描述,用控制容积差分法耦合求解质量、动量、能量和溶质守恒方程,计算结果与实验结果基本一致,计算结果还显示。Ｓｉ－Ｆｅ浸入铁 至完全熔化分为两个时期即铁壳斯和熔化期     

一种新型潜热处理模型显微偏析数值模拟的应用

在显微偏析数值模拟中,宏/微观模型通过潜热处理相互耦合.潜热模型直接决定着模拟结果的准确性.将近期先进的潜热处理模型引入显微偏析数值模拟,对Al-4.5Cu合金铸锭显微偏析的形成进行了数值模拟.在模型中考虑了树枝晶粗化、固相溶质逆扩散、枝晶尖端过冷、随温度变化的溶质扩散系数等动力学因素,微观数值方法中采用变网格技术跟踪移动界面,通过迭代求解溶质扩散方程和溶质守恒方程计算显微偏析参数.在简化耦合算法的情况下,模拟结果与试验结果符合.