相场模型凝固组织模拟进展

本文对相场模型的物理本质、数值计算方法以及在凝固微观组织模拟中的应用和进展进行了综述，并指出相场模型凝固微观组织模拟的发展方向。     

对流影响枝晶生长的相场法模拟研究进展

液态金属的对流和枝晶生长的相互作用在凝固模型中是非常重要的,因为铸造和焊接过程常伴随有自然或强迫对流。综述了耦合对流时相场的数学模型、数值计算方法以及在凝固微观组织模拟中的应用和进展,指出了该领域目前面临的问题和未来发展趋势。     

金属凝固微观组织数值模拟研究现状

通过对凝固微观组织的模拟,能很好地预测材料的性能,对实际应用具有重要意义。对微观组织模拟中的3个主要模型(确定性模型、随机性模型和相场模型)及它们的应用现状进行了阐述,并分析了它们的优缺点。随着计算机技术的发展,新的计算模型的出现将使金属凝固微观组织的数值模拟向着高精度、高效率和高速度的方向发展。     

铸件凝固组织数值模拟研究进展

综述了铸件凝固微观组织数值模拟在国内外的研究进展,阐述了该研究领域主要采用的3种模拟方法(确定性方法、随机性方法、相场方法),指出了该研究领域目前存在的问题及今后的发展方向.     

电磁搅拌金属熔体数值模拟的研究进展

随着电磁搅拌技术在连续铸造、半固态加工、冷坩埚熔炼等领域被广泛采用,电磁搅拌金属熔体的数值模拟技术也得到了迅速的发展,分别从搅拌磁场的数值模拟、搅拌磁场作用下金属熔体内宏观传输现象的数值模拟、搅拌磁场作用下凝固铸坯的微观组织模拟方面详细叙述了电磁搅拌数值模拟技术的发展现状,并预测了其未来发展趋势。详细介绍了电磁场、传热传质、微观组织等各种计算模型。     

凝固过程中对流效应的相场模拟研究进展

阐述了相场方法是凝固过程中对流效应数值模拟的有效方法,分别介绍了考虑强迫对流、剪流、自然对流的相场模型,综述了相场方法在对流领域研究中的应用情况,指出了该研究领域目前存在的问题及今后的发展方向.     

基于元胞自动机的多相合金凝固过程微观组织仿真探究

多相合金凝固过程微观组织的模拟长期以来一直引起不同领域学者的广泛关注和研究,归根结底是因为其在工程应用及理论研究等方面都具有很大的价值。21世纪,计算机及电子科学技术异军突起,并得到全面发展和进步,所以研究多相合金凝固过程微观组织模拟除了可以应用传统研究方法,也可以适时地去应用计算机数值模拟方法,而且随着技术的进步,这方面的研究已经取得了长足的进步,尤其是在凝固应力场,温度场等各种场效应的数值模拟初见成效后,微观组织模拟研究有了新的发展方向和突破口。采用元胞自动机方法对比其他研究方法,对于研究凝固的各种结构模型有以下优点:将固液界面两侧的锐变转化为界面胞元固相份数的渐变,既坚持了尖锐界面的基本假设,又避免了跟踪复杂的固液界面。而且研究时所应用的模型不仅考虑了成分过冷、曲率过冷、界面能各向异性,还考虑到了界面扰动等影响枝品生长的各种不同外界影响因素。     

定向凝固微观组织相场法模拟的研究进展

定向凝固过程中的界面形态对凝固组织有着决定性作用,相场法可以很好地展示凝固过程固液界面形态的演变。阐述了定向凝固相场方法数值模拟的基本原理及国内外研究现状,并指出了该领域目前面临的问题及未来发展趋势。     

铸件凝固过程组织计算机模拟研究动态

介绍了铸件凝固组织模拟的3种方法,并对利用各种数值方法所取得的计算机模拟结果进行了评述.重点介绍了各模型的形核和生长的数学模型,同时也分析了这些数学模型所存在的问题.展望了铸件凝固组织模拟的发展方向.     

金属激光3D打印过程数值模拟应用及研究现状

数值模拟可以高效、有针对性地对金属激光选区熔化成型过程中的温度场、熔池形状、残余应力和变形、凝固过程微观组织演变等过程建立相应的模型并对成形件的相关性能做出准确预测,为工艺优化提供科学的依据,显著降低工艺开发成本和缩短工艺开发周期,有力推动金属增材制造向工业级应用的转变。本文综述了金属激光增材制造过程中温度场、熔池动力学、成形件内部残余应力和变形、显微组织变化4个方面数值模拟的最新研究进展,概述了金属SLM过程数值模拟所取得的最新进展,分析了金属SLM数值模拟领域的研究热点和所存在的计算时间长、成本高等问题,最后提出金属SLM过程数值模拟应将3D打印过程中快速凝固、微熔池等特征与大数据、人工智能、深度学习等技术相结合,进一步提高数值模拟精度,拓宽金属激光增材制造加工窗口,为个性化产品开发提供指导。     

焊接接头组织模拟进展

介绍了焊接接头组织模拟的现状,阐述了组织模拟的主要方法:Monte Carlo方法、Cellular Automaton方法及相场法,分析了不同方法在模拟凝固及固态相变过程中的晶粒生长、组织形貌和各相分数等不同方面的特点和存在的不足.     

基于一种改进CA模型模拟双辊连续铸轧纯铝微观组织

基于枝晶生长的基本传输过程和元胞自动机(Cellular Automaton,简称CA)-有限元(Finite Element,简称FE)模型基本原理,建立了适应双辊连续铸轧纯铝薄带工艺特点的凝固过程形核和晶体生长的数学模型.模型耦合了宏观温度场和微观组织模拟计算,考虑了溶质扩散、曲率过冷和各向异性等重要因素的影响,定义了界面单元捕获规则,能够模拟凝固过程中枝晶生长的形态.应用本模型对双辊连续铸轧纯铝薄带凝固过程中等轴晶生长、等轴晶多晶粒生长及柱状晶生长、柱状晶向等轴晶演化进行模拟并与实验结果进行对比,模拟结果与实验结果吻合较好,验证了模型的正确性.     

Atomistic to continuum modeling of solidification microstructures

We summarize recent advances in modeling of solidification microstructures using computational methods that bridge atomistic to continuum scales. We first discuss progress in atomistic modeling of equilibrium and non-equilibrium solid–liquid interface properties influencing microstructure formation, as well as interface coalescence phenomena influencing the late stages of solidification. The latter is relevant in the context of hot tearing reviewed in the article by M. Rappaz in this issue. We then discuss progress to model microstructures on a continuum scale using phase-field methods. We focus on selected examples in which modeling of 3D cellular and dendritic microstructures has been directly linked to experimental observations. Finally, we discuss a recently introduced coarse-grained dendritic needle network approach to simulate the formation of well-developed dendritic microstructures. This approach reliably bridges the well-separated scales traditionally simulated by phase-field and grain structure models, hence opening new avenues for quantitative modeling of complex intra- and inter-grain dynamical interactions on a grain scale.     

Phase-field simulation of directional solidification of a binary alloy under different boundary heat flux conditions

Complicated morphologies of directional solidification structures attract a lot of theoretical studies and commercial uses. As known, the boundary heat flux has an important significance to the microstructures of directional solidification. In this article, the interface evolution of directional solidification with different boundary heat fluxes is discussed. In this study, only one interface has heat flow, and Neumann boundary conditions are imposed at the other three interfaces. From the calculated results, it is found that different heat fluxes cause different microstructures in the directional solidification. When the heat flux equal to 18 W/cm², the growth of lengthways side branches is accelerated and the growth of transverse side branches is restrained. At the same time, there is dendritic remelting in the calculating domain. When the heat flux equal to 36 W/cm², the growth of the transverse side branches and the growth of the lengthways side branches compete with each other. When the heat flux equal to 90 or 180 W/cm², the growth of transverse side branches absolutely dominates. The temperature field of dendritic growth is also analyzed and the relation between heat flux and temperature field is found.     

Solidification microstructure development

In the present article, evolution of microstructure during solidification, as a function of various parameters, is discussed. Macrosegregation is described as being due to insufficient diffusivity of solute in the solid. Pattern formation is discussed in the light of instabilities at the solidification growth front. An overview of the scaling relations for various microstructures is given. Metastable extensions to equilibrium phase diagrams and corrections to equilibrium quantities are described.     

Modeling of gas porosity and microstructure formation during dendritic and eutectic solidification of ternary Al-Si-Mg alloys

A two-dimensional(2-D)multi-component and multi-phase cellular automaton(CA)model coupled with the Calphad method and finite difference method(FDM)is proposed to simulate the gas pore for-mation and microstructures in solidification process of hypoeutectic Al-Si-Mg alloys.In this model,the pore growth,and dendritic and eutectic solidification are simulated using a CA technique.To achieve the equilibrium among multiple phases during ternary Al-based alloy solidification,the phase transition thermodynamics and kinetics are evaluated by adopting the Calphad method.The diffusion equations of hydrogen and two solutes are solved by FDM.The developed CA-FDM coupled model can be used for sim-ulating the evolution of gas microporosity and microstructures,involving dendrites and irregular binary and ternary eutectics,of ternary hypoeutectic Al-Si-Mg alloys.It has the capability of reproducing the interactions between the hydrogen microporosity formation and the growth of dendrites and eutectics,the competitive growth among the growing gas pores of different sizes,together with the time-evolving concentration fields of hydrogen and solutes.The simulated morphology of gas pore and microstructure has a good agreement with the experimental observation.The influences of the initial hydrogen concen-tration and cooling rate on the microporosity formation are investigated.It is found that the main portion of porosity formation occurs in the eutectic solidification stage through analyzing the profiles of porosity percentage and solid fraction varying with solidification time.The varying features of simulated porosity percentage,the maximum and average pores radii indicate that increasing initial hydrogen concentration promotes the formation of higher final porosity percentage and larger pores,while the size of gas pores will significantly reduce with increasing cooling rate,leading to a lower final porosity percentage.     

In-situ observation of solid-liquid interface transition during directional solidification of Al-Zn alloy via X-ray imaging

The morphological instability of solid/liquid(S/L) interface during solidification will result in different patterns of microstructure. In this study, two dimension(2 D) and three dimension(3 D) in-situ observation of solid/liquid interfacial morphology transition in Al-Zn alloy during directional solidification were performed via X-ray imaging. Under a condition of increasing temperature gradient(G), the interface transition from dendritic pattern to cellular pattern, and then to planar growth with perturbation was captured. The effect of solidification parameter(the ratio of temperature gradient and growth velocity(v), G/v) on morphological instabilities was investigated and the experimental results were compared to classical "constitutional supercooling" theory. The results indicate that 2 D and 3 D evolution process of S/L interface morphology under the same thermal condition are different. It seems that the S/L interface in 2 D observation is easier to achieve planar growth than that in 3 D, implying higher S/L interface stability in 2 D thin plate samples. This can be explained as the restricted liquid flow under 2 D solidification which is beneficial to S/L interface stability. The in-situ observation in present study can provide coherent dataset for microstructural formation investigation and related model validation during solidification.     

Al-Cu 合金高梯度定向凝固过程中的形态转变

本文利用 ZMLMC 定向凝固装置,研究了 Al-Cu 合金系在不同温度梯度下定向凝固时凝固界面和组织形态的变化。发现存在着两种树枝状生长和胞状生长之间的转变,即在低速范围内胞状向树枝状转变,在高速范围内树枝状向胞状转变;当温度梯度足够高时,可以在整个生长速率范围内不出现树枝状生长,获得高度细化的胞状组织;合金的结晶温度间隔越宽,完全消除树枝状生长所需的温度梯度越高。     

Microstructure evolution in equiaxed dendritic growth

Microstructure evolution in equiaxed dendritic solidification is investigated through the study of free dendritic growth in a supercooled melt. A detailed measurement of microstructural features (such as side-branch spacings, envelope shape, projection area, and contour length) of freely growing succinonitrile dendrites is performed using images from the microgravity experiment of Glicksman and co-workers. The measurements show that the microstructure evolution of an equiaxed dendrite is divided into two regimes: an initial linear regime and a subsequent non-linear coarsening regime. It is found that unique scaling relations exist between the measured geometry parameters and the primary tip radius or speed for both regimes. The underlying mechanisms involved in dendritic structure evolution are discussed. In addition, using the phase-field method, we perform numerical experiments to investigate the effects of melt convection on equiaxed dendritic growth. The dendrite tip operating state (i.e. the tip velocity and radius) is quantitatively evaluated as a function of the flow velocity and dendrite orientations and compared with Microscopic Solvability Theory. Other structural features (such as the side-branches) of an equiaxed dendrite in the presence of flow are also examined in order to show how convection influences microstructure evolution in equiaxed dendritic growth.     

Microstructure evolution in equiaxed dendritic growth

Microstructure evolution in equiaxed dendritic solidification is investigated through the study of free dendritic growth in a supercooled melt. A detailed measurement of microstructural features (such as side-branch spacings, envelope shape, projection area, and contour length) of freely growing succinonitrile dendrites is performed using images from the microgravity experiment of Glicksman and co-workers. The measurements show that the microstructure evolution of an equiaxed dendrite is divided into two regimes: an initial linear regime and a subsequent non-linear coarsening regime. It is found that unique scaling relations exist between the measured geometry parameters and the primary tip radius or speed for both regimes. The underlying mechanisms involved in dendritic structure evolution are discussed. In addition, using the phase-field method, we perform numerical experiments to investigate the effects of melt convection on equiaxed dendritic growth. The dendrite tip operating state (i.e. the tip velocity and radius) is quantitatively evaluated as a function of the flow velocity and dendrite orientations and compared with Microscopic Solvability Theory. Other structural features (such as the side-branches) of an equiaxed dendrite in the presence of flow are also examined in order to show how convection influences microstructure evolution in equiaxed dendritic growth.