新型熔炼工艺下GH4169合金的凝固组织控制研究

为探求新型熔炼工艺(三联)下GH4169合金大型重熔锭组织调控、元素偏析改善的方法,研究了熔速对氩气保护电渣重熔GH4169合金重熔锭枝晶间距、Laves相的尺寸及分布和显微疏松的影响,定量分析了熔速对组织与成分偏析的影响规律.研究发现:随着熔速的增加,GH4169合金重熔锭边缘处的枝晶间距基本保持不变;中心处二次枝晶间距呈增大趋势.边缘和中心处的疏松尺寸随熔速增加变化平缓,R/2处先增大后减小.心部的Laves相比例较高且随着熔速增加呈上升趋势,而R/2处趋势相反;重熔锭不同部位的偏析区比例随熔速无明显变化.枝晶间距越小,越有利于减轻偏析.     

铁镍基耐蚀合金凝固组织控制研究

采用固定式电渣重熔工艺、单电极导电结晶器抽锭电渣重熔工艺和双极串联抽锭电渣重熔工艺以不同的熔化速度生产出UNS N08825合金电渣锭,分析了电渣锭的结晶组织、热加工性能以及三种冶炼工艺的电极熔化速度、冷却条件和温度场差别。结果表明,当UNS N08825合金电渣锭凝固组织的柱状晶方向与纵轴方向夹角θ不大于54°时,钢锭具有良好的热加工塑性。     

铸锭GH 3625合金微观偏析及均匀化热处理

为消除铸态GH 3625合金的显微偏析,改善其热加工性能,建立其均匀化动力学并制订均匀化处理制度,采用ImagePro Plus软件、扫描电镜(SEM)和能谱分析仪(EDS),对通过真空感应熔炼和电渣重熔双联工艺制备的GH 3625合金电渣锭的显微组织及元素偏析情况进行分析和研究.同时,对铸态GH 3625合金在不同温度下同一时间及同一温度下不同时间进行了均匀化处理.结果表明:GH 3625合金电渣锭存在明显的枝晶间微观偏析,主要偏析元素为Nb、Mo等,形成富Nb的Laves相、MC碳化物;不同元素的偏析程度为NbMoTiAlCr;Nb、Mo、Ti、Al在枝晶间大量富集,使得Laves等多种非平衡相在枝晶间析出;在均匀化过程中,随着均匀化温度的升高和时间的延长,偏析元素逐渐扩散均匀;当热处理制度为1 130℃×32 h时,元素偏析基本消除;Laves相体积分数随均匀化处理时间呈明显指数函数特征,V1 130℃=0.033 5exp(-0.163 1t).     

Ti-2.5Cu合金铸锭微区成分分析

真空自耗电弧炉熔炼方法生产的钛合金锭可能存在许多缺陷,如难熔金属夹杂、间隙元素偏析、合金元素偏析所致的组织缺陷、反常的α相形态等组织缺陷以及化学成分的偏析.其中宏观偏析是必然存在且最难解决的一个,本文对典型Ti-2.5Cu钛合金进行了微区成分分析和宏观成分分析,得出了合金元素宏观和微观偏析的规律,并探讨了引起宏观偏析的微观原因.     

大尺寸Al-Cu-Mg-Mn合金铸锭均匀化工艺研究

本工作通过金相、DSC、SEM等手段研究了均匀化工艺对大尺寸Al-Cu-Mg合金扁锭的组织演变和力学性能的影响。研究结果表明,铸态合金中枝晶偏析从芯部区域到边部区域越来越严重,晶界分布大量的块状A_2Cu相和Al_2CuMg相。采用接近低熔点共晶融化温度进行均匀化退火后,选择合适的均匀化时间使得合金中的枝晶偏析基本消除,晶内成分分布较为均匀。经500℃/36 h均匀化后,残留第二相含量为0.88%,经过轧制变形后的薄板T42态的抗拉强度达到480 MPa,屈服强度达到327 MPa,延伸率为19%.     

电子束冷床(EB)炉熔炼TC4合金组织与性能研究

在前期大量试验基础上,应用电子束冷床(EB)炉一次制备工业化TC4合金扁锭,通过多点取样进行合金扁锭的成分分析,表明所制备的合金铸锭满足国家标准对TC4合金成分均匀性的要求,证明国内已经完全掌握TC4合金EB炉熔炼过程中的元素挥发和控制技术,可以一次熔炼制备TC4合金。应用该铸锭,进行不同变形方式、变形量的加工试验,并对加工的样品进行典型热处理,结果表明在加工的初期和中期,不同变形方式和变形量对本实验EB炉制备的TC4合金扁锭组织影响显著,但不同组织状态下合金力学性能差别不大。随着变形的继续深入,组织差异性逐渐减小,但性能差异性增大。这种不同于常规用电弧炉制备TC4钛合金的规律,可能与EB炉熔炼方法所特有的性质有关,需要进一步研究。     

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。     

一种高性能低偏析耐蚀合金的研究

研究了硫对Hastelloy C-4合金凝固偏析和耐蚀性的影响。结果表明，严格控制硫含量，能减小固液两相区的间隔和温度范围以及合金的偏析程度，明显改善合金耐蚀性能。     

使用细长规格结晶器 推进电渣锭锭型细长化

通过粗、细结晶器规格／电渣锭锭型规格的对比，阐述细长锭型在产品质量、成本方面的优点，证明电渣锭锭型细长化更具合理性、适用性。     

18Cr2Ni4WA电渣钢与电炉钢的组织与性能

通过低倍组织检验、化学成分分析、金相检验及力学性能测试的方法,对比分析了18Cr2Ni4WA电渣钢与电炉钢组织与性能的差异。结果表明:与18Cr2Ni4WA电炉钢相比,18Cr2Ni4WA电渣钢的硫、磷含量较低,显微组织较为均匀致密,带状组织偏析少,纵、横向力学性能差异小。该试验结果可为鉴别电渣钢和电炉钢提供参考。     

电渣重熔连续定向凝固FGH96合金非金属夹杂物研究

本文通过真空感应熔炼+惰性气氛保护电渣重熔连续定向凝固制备FGH96合金,对FGH96合金中的非金属夹杂物进行对比研究。结果表明,活泼元素Al、Ti、Zr、Ce、B等有轻微的烧损,主要元素含量都在合金要求的范围之内,氧含量略有降低,达到了真空熔炼的水平,氮含量有较大幅度的降低,主要存在两种类型的夹杂物,呈球形的夹杂物是Al、Ti、Mg的复合氧化物和TiN。图像统计分析结果表明,和传统电渣重熔相比,电渣重熔连续定向凝固工艺重熔后FGH96合金中的非金属夹杂物面积百分比、100个视场中的夹杂物个数降低了50%以上,夹杂物的最大尺寸由16μm降低到5.5μm,这主要是与熔池的形状、深度和结晶方式有较大关系,传统电渣重熔过程中金属熔池的形状是V字形,深度约占铸锭直径的50%左右,而电渣重熔连续定向凝固过程中形成的熔池呈扁平状,深度占直径10-20%。     

螺旋磁场对Sn-Sb合金成分偏析的影响

为了深入研究螺旋磁场解决重力偏析的效果及作用机理,本文选用低熔点Sn-Sb合金,分析不同励磁电流下螺旋磁场对铸锭宏观成分偏析的影响,并与常规条件下及相同工艺参数旋转磁场条件下的凝固组织进行比较.结果表明,螺旋磁场的电磁力分布特点有利于在铸锭内部形成更大区域的均匀搅拌,相比于旋转磁场可以更好地改善铸锭成分的宏观偏析;随着励磁电流的增大,两种磁场改善偏析、细化凝固组织的效果更好;当螺旋磁场励磁电流为100 A时,基本消除铸锭上、下部位由于重力作用导致的成分偏差,β相(SnSb)变得细小且均匀分布在基体内.在金属熔体凝固的过程中施加螺旋磁场可消除重力偏析,效果优于旋转磁场.     

Corrosion resistance enhancement of marine alloys by rapid solidification

Copper-nickel alloys used in marine applications, are known for their anti-fouling properties. However, they are generally of low strength and are moderately susceptible to corrosion when used in a marine environment. Attempts at adding iron to Copper-nickel alloys by conventional ingot metallurgy, to improve their mechanical and corrosion resistant properties, have met with limited success. In this work, rapid solidification technology was employed to produce rapidly solidified (RS) Cu-10Ni and Cu-10Ni-8Fe. It was found that both the RS Cu-10Ni and Cu-10Ni-8Fe exhibited superior mechanical and corrosion resistant properties, compared with their sand-cast counterparts. Furthermore, the addition of iron to Cu-10Ni alloy, produced by RS, increased the corrosion resistance of the alloy, whereas the addition of iron to Cu-10Ni alloy produced by conventional means, had an adverse effect.     

熔速对氩气保护GH4169G合金电渣锭组织及夹杂物的影响

研究了熔速对氩气保护GH4169G电渣锭宏微观组织及非金属夹杂物的影响。结果表明:适当增加熔速有利于缩短铸锭的局部凝固时间,减小二次枝晶间距,从而细化枝晶组织,但对Nb、Ti等易偏析元素沿径向的宏观分布影响不大。熔速对GH4169G铸锭中的夹杂物类型影响较小,主要为氧化物、氟化物和氮化物三类。夹杂物在铸锭表面最多,向内部迅速减少并趋于稳态。铸锭内部夹杂物多以氧化物为核心,氮化物为次外层,碳化物为最外层的双层或三层结构。采用MeltFlow-ESR模拟方法,分析了熔速对重熔过程中夹杂物运动轨迹的影响,发现提高熔速有利于夹杂物向铸锭表面运动,降低铸锭表面夹杂物富集区的厚度和铸锭内部夹杂物的数量。此外,提高熔速有利于缩短夹杂物析出长大的时间,降低夹杂物尺寸。     

Processing of Fe-Al-C-Ce alloys through air induction melting with flux cover (AIMFC) and electroslag remelting (ESR)

The effect of process parameters on recovery of reactive element, cerium, during air induction melting with flux cover (AIMFC) and electroslag remelting (ESR) of Fe-10.5 wt% Al-0.8 wt% C-(0.1 and 0.3) wt% Ce alloys and also the effect of melting techniques on hot workability, structure and tensile properties (at room temperature and at 873 K) of Fe-10.5 wt% Al-0.8 wt% C-0.3 wt% Ce alloy have been investigated. Good recovery of cerium was obtained by AIMFC. While conventional fluxes were found to be unsatisfactory, modified flux containing CeO₂ gave better recovery of cerium during ESR. The best recovery of cerium was achieved by using calcium as a deoxident during ESR. The combination of AIMFC and ESR yields a sound ingot of Fe-Al-C-Ce quaternary alloys free from gas and shrinkage porosity with very low oxygen, nitrogen and sulphur contents. Processing of AIMFC ingots through ESR has resulted in improved hot-workability. The ESR processed and hot-rolled alloy exhibited superior tensile elongation as compared to hot-rolled AIMFC alloy. This may be attributed to the comparatively sound, homogeneous and clean ingot, with a refined microstructure and fine uniform distribution of precipitates observed in hot-rolled ESR ingots.     

Effect of combined application of electromagnetic fields on horizontal direct chill casting of 7050 aluminium alloy

Abstract

Influence of combined electromagnetic field application on horizontal direct chill casting of 7050 aluminium alloy is investigated. Temperature measurement and structure observation are carried out to analyse the casting process under different electromagnetic fields. Combined electromagnetic field can reduce the harmful gravitational thermal effect in the horizontal direct chill casting process and improve the ingot properties. With application of combined electromagnetic field, temperature distribution in the melt is more uniform, sump of the ingot becomes flat and symmetric, surface quality of ingot improves markedly, grain morphology changes from feathery grains to equiaxed grains and grain size decreases. Distribution of copper and zinc in the transverse section of the ingot becomes more uniform.     

Nichtmagnetisierbarer warmbeständiger nichtrostender Stahl für Wälzlager

Nonmagnetic heating‐resistant stainless steel for roller bearings A low cost austenitic chromium manganese steel with about 1 mass% of carbon and nitrogen was molten under normal pressure which reveals an amazing combination of properties. Starting from a yield strength of about 600 MPa it is cold work hardened to 60 HRC. This high hardness is brought about for the first time without a martensitic microstructure which is usual for roller bearings. In addition this steel is stainless, non‐magnetic and heating resistant up to about 500 °C, i.e. a material to serve under complex loading. Manufacturing by ingot metallurgy, ESR, hot working, solution annealing and machining was carried out on an industrial scale. The investigation of the structure was carried out on several scales, beginning with the electronic structure, the TEM structure, the light optical microscopy up to macro‐etchings. In this manner an extensive understanding of the outstanding combination of properties of the steel named CARNIT was derived.     

等轴晶移动对宏观偏析影响的数值模拟

建立了自由等轴晶移动对宏观偏析影响的数学模型,对铸锭凝固过程中的对流和溶质分布进行了数值模拟.在模型中按照临界固相分数将糊状区分为紧密树枝晶和自由等轴晶两个不同的区域.对带冒口铸钢锭的宏观偏析进行了数值模拟,并同实验结果进行了比较.与假设糊状区内固相静止的模型相比,考虑等轴晶移动的模型得到的溶质分布结果与实验结果更接近.在凝固过程中,等轴晶随液体流动并在铸锭的底部中心聚集,在凝固后的铸锭中形成锥形的负偏析.还发现,在铸锭的中心靠上的区域形成正偏析,在铸锭的外部区域形成负偏析.     

Equi-axed growth and related segregations in cast metallic alloys

Full-scale trials of DC ingots and laboratory scale directional solidification experiments have been performed to study the effect of grain structure on macro-segregation in industrial cast products. An Al alloy sheet ingot was cast with constant casting conditions (speed, superheat, cooling rate) except for the grain refiner: the first half of the ingot was non-inoculated, while the second half was inoculated. The results indicate that the extent and intensity of the centreline segregation is modified via the grain-refinement treatment: the finer the grains are, the more intense is the macro-segregation.Numerical simulations of directional solidification of binary Al–Cu alloys have been carried out with the help of a 2D finite volume software which takes account of the movement of the liquid with respect to the solid in the mushy zone. It is possible to account for the segregation pattern of the directionally solidified ingots that exhibit columnar or coarse equi-axed grain structures. Contrarily, the intense segregation of the fine-grained ingots is not yet understood.     

Segregation Behaviour and Microstructure of Alloy 718VADER Ingot

The segregation behaviour and miclostructure of an alloy 718 VADER ingot in comparison with a VAR ingot were studied. The results show that one serious problem of the alloy 718 VADER ingot is dealing with radial chemistry gradients (especially macro-segregation in Nb). The main factor of Nb gradient forming is the flow of Nb rich fluid through passages among the cellular structures driven by centrifugal force from the rotating mold, Detailed structure and micro-segregation studies on ingots impress us that the VADER process does not show the advantage on the improvement of micro-segregation especially in Nb. The cellular structure produced by the VADER process is no more effective in reducjng Nb micro-segregation during homogenization treatment than the dendritic structure by the VAR process. Experimental results lead us to believe that the VADER process is unsuitable to manufacture alloy 718.