Numerical simulation of boundary heat flow effects on directional solidification microstructure of a binary alloy

The boundary heat flow has important significance for the microstructures of directional solidified binary alloy.Interface evolution of the directional solidified microstructure with different boundary heat flow was discussed.In this study, only one interface was allowed to have heat flow, and Neumann boundary conditions were imposed at the other three interfaces.From the calculated results, it was found that different boundary heat flows will result in different microstructures.When the boundary heat flow equals to 20 W·cm-2, the growth of longitudinal side branches is accelerated and the growth of transverse side branches is restrained, and meanwhile, there is dendritic remelting in the calculation domain.When the boundary heat flow equals to 40 W·cm-2, the growths of the transverse and longitudinal side branches compete with each other, and when the boundary heat flow equals to 100-200 W·cm-2, the growth of transverse side branches dominates absolutely.The temperature field of dendritic growth was analyzed and the relation between boundary heat flow and temperature field was also investigated.     

纤维增强二元铝合金凝固偏析的数值模拟

根据合金凝固过程中的守恒定律和传输原理 ,建立了纤维增强二元铝合金的凝固模型。利用所建立的模型 ,对Al2 O3 /Al Cu合金复合材料凝固时溶质传输和分布进行了数值模拟 ,研究了复合材料凝固时溶质偏析对纤维 /基体界面的影响。模拟结果与实验结果吻合较好。     

快速凝固-粉末冶金工艺制备高强阻尼铝合金的阻尼性能(英文)

采用快速凝固-粉末冶金(RS-PM)工艺制备两种不同类型的高强阻尼铝合金(LZ7),一种是直接挤压成型材,另一种是先挤压至棒材再轧制成板材。利用阻尼机械热分析仪(DMTA)在25~300°C下对其进行阻尼性能测试,利用光学显微镜(OM)、扫描电镜(SEM)、透射电镜(TEM)观察材料的微观组织。结果表明,随着温度的升高材料的阻尼性能提高,在300°C时板材的内耗值高达11.5×10-2,型材的内耗值达到6.0×10-2和7.5×10-2。轧制板材的内部析出相的颗粒形貌较挤压型材的析出相更规则,分布更均匀;板材中颗粒相与基体结合较疏松。基体与颗粒相结合情况的不同可以解释板材在高温阶段(120°C)阻尼性能优于型材阻尼性能的原因。     

Undercooling and rapid solidification of Nb-Si eutectic alloys studied by long drop tube

Niobium-silicide alloys have great potential for high temperature turbine applications. The two-phase Nb/Nb5Si3 in situ composites exhibit a good balance in mechanical properties. Using the 52 m drop tube, the effect of undercooling and rapid solidification on the solidification process and micro-structural characterization of Nb-Si eutectic alloy was studied, The microstructures of the Nb-Si composites were investigated by optics microscope （OM）, X-ray diffraction （XRD） and scanning electron microscope （SEM） equipped with X-ray energy dispersive spectrometry （EDS）. Up to 480 K, deep undercooling of the Nb-Si eutectic samples was successfully obtained, which corresponds to 25% of the liquidus temperature. Contrasting to the conventional microstructure usually found in the Nb-Si eutectic alloy, the microstructure of the undercooled sample is divided into the fine and coarse regions. The most commonly observed microstructure is Nb＋Nb5Si3, and the Nb3Si phase is not be found. The change of coarseness of microstructure is due to different cooling rates during and after recalescence. The large undercooling is sufficient to completely bypass the high temperature phase field.     

激光快速成形过程中粉末与熔池交互作用的数值模拟

建立了描述激光快速成形过程中气/粉两相流送粉、粉末与熔池交互作用及激光熔覆成形温度场的联合模型.采用有限单元生死技术模拟了熔池形成和自由界面形状演化及熔覆层的沉积过程:根据界面温度与粉末粒子动量损失状况模拟了熔池对粒子的捕捉以及工件对粉末的反射,并采用Lagrangian粒子追踪模型实现了对粉末颗粒的跟踪.在此基础上,模拟了激光快速成形过程中316L不锈钢粉末、激光与熔池的交互作用过程.计算结果与实验结果吻合.     

激光熔凝的数值模拟及其在激光定向凝固中的应用

建立了一套激光熔凝的数学模型和计算方法 ,给出了两种条件下熔池深度与扫描速度的关系曲线。计算结果与实验值吻合良好 ,验证了模型的有效性。根据计算分析了激光工艺参数与激光定向凝固组织的关系。据此通过工艺参数的匹配 ,在熔池顶部得到了与扫描方向完全一致的凝固组织     

Effects of Ti-addition on the characteristics of wear resistant Al-Si-Fe base alloys processed via rapid solidification

Rapidly solidified Al-Si-Fe base alloys were prepared by gas atomization, hot pressing and extrusion. To optimize wear resistance and mechanical properties, Al-20 wt.%Si-5 wt.%Fe base alloys containing 1–3 wt.%Ti were newly designed and characterized in detail. The additions of Ti (especially, ~2 wt.%Ti) effectively increased the wear resistance and mechanical properties such as tensile strength and hardness; however, the addition of 3 wt.%Ti was not desirable because of the precipitation of the primary Ti₇Al₅Si₁₂ phase in the as-quenched state. Based on TEM analyses, the improved properties in the Al-Si-Fe alloys containing Ti were found to be due to the formation of the (Al, Si)₃Ti phase finely dispersed in the matrix. ASCM16CE is the gas atomized and consolidated composite including 3 wt.% of SiC particles (reference alloy).     

重轨钢连铸大方坯凝固末端压下过程的数值模拟

针对重轨钢连铸坯在不同压下量条件下的热/力学行为,利用有限元仿真技术建立三维热力学耦合模型,对方坯在连铸过程和压下过程中的内部缩孔变形行为、铸坯应变分布现象、铸坯的变形行为以及拉矫机所需要的压坯力展开深入研究。结果表明,增大压下量可以将更多的变形量传递至铸坯中心、更好地闭合中心缩孔,但同时所需要的拉矫机压坯能力也更大。应综合考虑生产需求和生产能力,选择最合适的压下工艺,这为方坯的压下工艺制定提供理论和数据支撑。     

元素Y对Mg-Cu系合金的组织结构和显微硬度的影响

采用铜板空冷和铜辊甩带的方法,研究元素Y对Mg-Cu合金的组织结构和室温硬度的影响。研究表明:元素Y形成的化合物最终富集于枝晶网胞间。随着元素Y的添加,Mg-Cu二元合金试样的晶粒显著细化,显微硬度大幅提高。另外,在快速冷却条件下,Mg90Cu5Y5试样的微观结构为微晶和非晶的夹杂,形成非晶的能力大大增强。     

元素Y对Mg—Cu系合金的组织结构和显微硬度的影响

采用铜板空冷和铜辊甩带的方法，研究元素Y对Mg-Cu合金的组织结构和室温硬度的影响。研究表明：元素Y形成的化合物最终富集于枝晶网胞间。随着元素Y的添加，Mg-Cu二元合金试样的晶粒显著细化，显微硬度大幅提高。另外，在快速冷却条件下，Mg90 Cu5Y5试样的微观结构为微晶和非晶的夹杂，形成非晶的能力大大增强。     

重轨钢大方坯连铸过程中凝固传热和坯壳生长的数值模拟

采用有限元方法,对某钢厂的大方坯连铸机的凝固传热情况以及坯壳凝固生长进行了数值模拟,并通过现场数据对模型进行了验证.以此为依据,对该钢厂新建的重轨钢大方坯在不同的拉速和过热度条件下的凝固过程温度场分布情况、坯壳生长规律和凝固分率进行了预测性的模拟研究,从而为新建的重轨钢大方坯连铸机的结晶器和二冷区冷却制度的制定提供理论依据.     

铝铸锭凝固边界热交换规律及温度场模拟

研究铝铸锭凝固边界热交换的变化规律及数学模型,并对不同浇注温度下凝固过程的温度场进行模拟。利用实时数据采集系统获得凝固过程中铸锭和金属模温度变化历史数据,采用非线性反算法和一维传热差分法对试验数据处理,建立界面换热模型并将其应用于凝固温度场模拟中。结果表明：在铸锭表面凝固前后凝固界面热流密度可分段用指数函数来描述其变化规律,而所建立的热交换系数与边界温度的对应关系可更好地反映实际的传热情况。模拟结果与实验测温结果相符,验证了该铸件/铸型边界热交换规律的可靠性。     

Effect of alloy grain size and silicon content on the oxidation of austenitic Fe-Cr-Ni-Mn-Si alloys in pure O2

Austenitic Fe-18Cr-20Ni-1.5Mn alloys containing 0, 0.6, and 1.5 wt.% Si were produced both by conventional and rapid solidification processing. The isothermal and cyclic oxidation resistance of the alloys were studied at 900°C in pure O₂ to elucidate the role of alloy microstructure and Si content on oxidation properties. The conventionally-processed, large-grained alloy that contained no silicon formed Fe-rich nodules during oxidation. The nodule formation was effectively eliminated by either reducing the alloy grain size by rapid solidification or by adding Si to the alloy. The lowest weight gains were achieved when a continuous silica layer formed between the alloy and the external chromia scale. The formation of the continuous silica layer required a ombination of fine alloy grain size and high Si content. The presence of S in the alloy was found to be detrimental to oxide scale adherence when the silica layer was continuous.     

铸铁表面激光熔凝行为及温度场数值模拟

为明确铸铁表面激光熔凝过程的热响应规律,考虑随温度变化的材料热物性参数和相变潜热影响,建立铸铁表面激光动态熔凝的三维数值模型并进行了验证,预测值与试验值吻合良好,采用该模型分析了热响应温度场规律及不同工艺参数的映射关系.结果表明,铸铁表面激光熔凝较钢材可获得更大的熔透深度,熔池内、外形成较大温度梯度且分别以深、宽方向分...     

快速凝固对微量Y添加Mg-4Al-2Zn合金显微组织,压缩性能及腐蚀行为的研究

本文通过常规铸造与快速凝固法成功制得两类Mg-4Al-2Zn-xY(AZ42,x: 0.5, 1.0 wt.%)镁合金,并系统研究了快速凝固对微量Y添加后AZ42合金组织和性能的影响。研究结果表明,快速凝固工艺较传统铸造相比可显著细化AZ42合金的微观组织并提高合金的力学性能和耐腐蚀特性。AZ42合金加入Y元素后组织主要由α-Mg基体、β-Mg₁₇Al₁₂相和Al₂Y相构成。此外,微量Y添加可显著细化AZ42合金的组织并改善网状β相分布,从而提高合金的力学与耐腐蚀性能;其中,当Y添加量为0.5%时可获得最佳综合性能。     

Si元素含量对激光快速成形制备Nb-Si二元合金显微组织演变的影响

以铌粉和硅粉为原料,采用双通道同轴送粉制备了四种不同Si元素含量的Nb-Si二元合金,通过扫描电镜（SEM）、能谱仪（EDS）及X射线衍射仪（XRD）等分析了合金的显微组织演变及维氏硬度.结果表明,硅含量由7%增加至25%,合金的显微组织由Nb_SS+Nb₃Si转变为初生Nb_SS+（Nb_SS/Nb₃Si）共晶,硅含量为18%时,呈Nb_SS/Nb₃Si全共晶组织,硅含量提高至25%,合金中出现初生β-Nb₅Si₃相,并仍存在Nb_SS/Nb₃Si共晶组织.铌和硅粉末在激光作用下原位反应并快速凝固,显著细化了Nb-Si合金的显微组织.随硅含量增加,硅化物含量逐渐增加,合金显微硬度由746 HV增至1 342 HV.     

快速凝固Al-Si-Cu合金钎料的组织和熔点研究

通过单辊旋铸法制备快速凝固Al-Si-Cu合金薄带钎料,并对其相组成和熔化特性进行了研究.结果表明,快速凝固试样主要由α(Al)、Si、θ(Al2Cu)三相组成,AlSi4.5Cu20Ni3RE合金试样中还存在少量AlNi相,并且试样中α(Al)均出现晶格畸变.与相同成分普通凝固试样相比,快速凝固试样的熔化温度降低,熔化区间变窄,熔化区间最大的减小幅度可达12.9%.     

电磁离心凝固过程中宏观偏析的数值模拟

基于连续模型建立了非惯性坐标系下电磁离心凝固过程流动、传热、传质耦合数学模型．依此模型对Al-5％Cu合金进行了模拟计算．结果表明，电磁离心凝固过程中，电磁力使熔体的平均径向运动速度下降．熔体流动状态的改变使凝固合金外层的逆偏析减轻，凝固过程中两相区的负偏析也减轻．与普通离心铸造相比，电磁离心凝固可减轻铸件宏观偏析．模拟结果与实测铸件成分分布基本吻合，表明本数学模型较好地描述了电磁离心凝固过程．     

矩形连铸坯凝固传热的变间距有限差分模拟

针对用传统有限差分法模拟计算矩形连铸坯凝固传热时在整个计算区域上离散网格大小需均匀一致且要用直角来代替铸坯圆角这一缺点,提出了变间距有限差分法.变间距有限差分能够在计算区域上灵活地配置大小不同的离散网格,也能够准确地离散铸坯的角部形状,而且直观、简单,计算工作量小,与有限单元法的计算结果几乎相同.模拟计算结果与实测值吻合.