厚板坯连铸过程宏观偏析数值模拟与测定

采用商业软件Calcosoft模拟了实际250 mm厚板坯连铸冷却条件下铸坯内部温度场、流场和溶质场的分布.为了对模拟结果进行验证,对实际铸坯进行了刨屑化学成分检验.结果表明,模拟的宏观偏析结果与铸坯实际偏析度检测的情况极为相似.凝固初期自然对流可能引起较大的内部紊流,将凝固前沿溶质带到中心液相,但是由于此时中心液相体积较大起到了稀释作用;而在凝固末期,糊状区显著阻碍了液相的流动,自然对流非常微弱,不能将枝晶间的浓化液相带到中心,因此大大减小了溶质元素向中心的聚集程度,削弱了中心宏观偏析.     

方坯连铸中心偏析的数值模拟

基于连续模型对连铸方坯的中心偏析进行了数值模拟,分析了枝晶间液相流动对铸坯中心偏析的影响.采用SIMPLER算法开发程序,耦合求解模型中动量、能量和溶质守恒方程.对方坯的三维模拟结果表明,液相密度差异引起的自然对流使枝晶间富含溶质的液相不断向铸坯中心聚集.中心区域平均溶质浓度在液相穴深处迅速升高,并在凝固末端达到最大值.严重的正偏析集中在中心线周围.改善中心偏析关键在于控制液相穴末端的枝晶间液相的流动状况.     

板坯凝固末端轻压下流动与溶质分布的研究

在有限元分析坯壳变形的基础上,采用连续模型研究了轻压下过程中板坯凝固末端两相区的流动与溶质分布.在铸坯凝固末端轻压下直接作用区域,两相区受到压缩,枝晶间富含溶质的液相被挤出,相对于铸坯向液芯方向流动.轻压下之后,铸坯中心区域由糊状区内被压缩的固相及残留的液相构成,中心区域偏析指数下降.凝固末端被挤出的液相重新参与溶质分配过程,铸坯部分区域的溶质浓度有所升高.     

关于连铸传热数学模型中等效导热系数的讨论

讨论了连铸传热数学模型中等效导热系数对模拟结果的影响,结论表明,采用等效导热系数法可以较为准确的预测铸坯表面温度及凝固终点,但等效导热系数越大,凝固前期的铸坯坯壳厚度越薄;等效导热系数的取值对铸坯两相区将产生较大影响,等效导热系数越大,某一厚度处钢液越早进入两相区,相应地,两相区厚度越大、两相区内温度梯度越小,局部凝固时间越大;采用计算获得的二次枝晶间距与实测值强制拟合的方法可以获得对流等效因子[（m）]的合理取值;对于铸机,在液相穴中强制对流区取[m＝7、]强制对流与自然对流的过渡区取[m＝5、]自然对流区取[m＝3、]静滞区取[m＝1]计算,可以获得较为准确的模拟结果。     

电磁搅拌对HRB335铸坯质量影响的试验研究

采用对比试验研究的方法分析不同电磁搅拌强度下对低碳钢大方坯铸坯内部质量的影响,试验中采用搅拌电流分别为200、250、300、350 A.研究结果表明:增大低碳钢HRB335钢连铸结晶器电磁搅拌电流强度可以显著改善铸坯内部质量,铸坯中心区域等轴晶率由21.22%增至26.51%;搅拌电流对HRB335钢铸坯中心偏析、中心疏松等没有明显影响,铸坯横断面碳成分分布均比较均匀.使用结晶器电磁搅拌后,凝固前沿的液相对流会加剧,对以柱状晶生长的凝固前沿进行冲刷和清洗,凝固前沿的液相流动使母液与两相区的液体互相混合,使溶质浓度趋向均匀.     

方坯连铸过程中钢液流动、凝固及溶质分布的耦合数值模拟

采用Fe-C二元合金的连续介质模型，对方坯连铸过程进行紊流动，凝固及溶质传输的三维耦合数值模拟，计算表明，注流在结晶器上部形成的回,大部分返回主入流股，其余部分随凝固坯壳向下流动，凝固坯壳在截面上由于注流冲刷造成不均匀分布，与实际情况相符，随凝固进行，液相中的溶质不断富集，最终在铸坯中心区域形成宏观偏析。     

基于“射钉法”的凝固坯壳厚度测定的应用研究

在双相钢生产过程中,对钢材内部质量有着严格要求,特别是溶质元素的中心偏析现象对钢材使用性能有严重影响。连铸工序实施凝固末端轻压下可以改善铸坯中心偏析,但实施效果与压下位置紧密相关。以双相钢590DP连铸过程为研究对象,通过射钉试验确定不同工况条件下凝固末端的准确位置,并构建铸坯凝固过程的预测模型。对断面尺寸为230 mm×1 200 mm的铸坯,在拉速1.0 m/min和1.2 m/min条件下的凝固过程进行了模型预测,并有针对性地实施了凝固末端轻压下,试验结果表明:铸坯内部质量得到明显改善,铸坯中心偏析由原先的B1.0提升到C0.5,铸坯中心偏析的曼内斯曼标准符合率由改进前的72%提高到改进后95.3%。     

薄板坯连铸凝固过程中宏观偏析的数值模拟

建立了连铸凝固宏观传输过程的温度场、溶质场、紊流流场模型,并对其进行了耦合求解.模拟分析了薄板坯凝固过程和宏观偏析的形成过程.计算表明,浸入式水口射流冲击到结晶器窄壁后形成上下两股回流,液相的紊流流动对传热、传质等都有显著的影响.随凝固的进行,液相中的溶质不断富集,最终在铸坯的中心区域形成宏观偏析.采用Schneider等的溶质传输模型,计算了固相溶质逆扩散对糊状区及固相溶质分布的影响.     

基于改善连铸板坯中心偏析的传热仿真软件

针对连铸坯中心偏析的形成机制,本文设计开发了基于改善连铸板坯中心偏析的凝固传热仿真优化软件。软件模型细化了连铸过程中的边界条件,充分考虑了各个方向上(尤其是铸坯宽度方向)和不同铸坯表面位置的冷却边界条件差异,可准确地预测连铸过程中铸坯的凝固行为和液芯三维形状,以及分析预测铸坯的偏析区域。针对模拟分析结果,软件可以对实际铸机的冷却系统进行优化,改善连铸坯的中心偏析问题。针对AH36的实际生产工艺参数,软件对连铸板坯的液芯形状和中心偏析产生区域进行了预测。预测结果与实际生产中的铸坯中心偏析位置完全吻合。     

兴澄厚板连铸机二冷控制研究及应用

基于以跟踪单元建立起的在线凝固模型的以坯龄建立起的二冷模型,根据生产现场工艺条件,有利于制定出合理的二冷制度,控制合理的铸坯表面温度、凝固末端的液相穴的形状及深度,为进行凝固末端轻压下创造条件,最终改善铸坯表面质量及内部质量。该系统优化之后杜绝了表面纵裂及横裂,中心疏松及偏析明显改善,消除了内部裂纹。     

生长速率对NiAl-7.8Mo亚共晶合金定向凝固组织及界面形态的影响

采用高温度梯度定向凝固装置制备了NiAl-7.8Mo亚共晶合金,系统研究了生长速率对合金凝固时界面形态、枝晶生长及初生相析出的影响.随生长速率的增大,固液界面依次呈现平、胞枝、枝的形貌转变,初生β相的一次枝晶间距λ1在胞晶生长阶段逐渐增大,而在枝晶生长阶段λ1又逐渐减小;二次枝晶间距λ2随生长速率的增加一直减小.初生β相的析出量随生长速率的增加而增加.分析结果表明:生长速率增加导致熔体过冷度增加,使得NiAl初生相形核率增加,最终导致初生β相的析出量随生长速率的增加而增加.     

基于改进元胞自动机方法的强制对流作用下三维枝晶生长的数值模拟

建立了一种改进的元胞自动机模型来模拟熔体对流条件下的二元合金三维枝晶的生长。模型中考虑了界面能各向异性和溶质扩散对固/液界面推移的影响,在同一套网格中耦合求解质量传输和液相流动方程,从而可以模拟溶质扩散和熔体对流之间的相互作用。使用该模型模拟了一定过冷度条件下,强制对流对Al-7%Si(质量分数,下同)合金三维枝晶生长形貌的影响。模拟结果表明,熔体强制对流导致迎流侧尖端溶质富集层减薄,枝晶生长出现了迎流生长现象。将模拟得到的溶质过饱和度与Oseen-Ivantsov解析解进行对比,当流速较大时两者吻合较好。同时模拟了三维和二维强制对流作用下枝晶生长形貌的演化,由于三维条件下对流使得熔体能够绕过垂直于对流方向的一次枝晶臂主干将溶质带到背流侧,而二维条件下只能绕过垂直方向一次臂的尖端,因此三维MCA模型能更准确地反映强制对流对枝晶生长的影响。     

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     

凝固过程中自然对流作用下组织演化模拟

以Fe-C二元合金铸锭为例，模拟了其冷却过程中自然对流对凝固组织形成的影响。首先采用有限差分方法计算宏观温度场、速度场和溶质场。然后将计算得到的温度场和溶质场作为已知值耦合元胞自动机方法(CA)对铸锭的组织演化进行模拟。通过模拟发现，在冷却过程中自然对流改变了铸锭内的温度场、速度场和溶质场的分布，进而影响到凝固组织的形貌。     

强迫对流影响合金凝固过程枝晶生长的数值模拟

利用耦合溶质场与流场的相场模型,对Al-2.5Cu合金等温凝固时枝晶生长过程进行了模拟.研究了强迫对流、扰动强度及各向异性强度对枝晶生长形貌的影响.结果表明,在流场作用下,枝晶呈非对称性生长,上游的生长速度大于下游;对流影响溶质场的分布,将溶质从上游冲刷到下游,使得上游液相中的浓度低于下游;扰动强度越大,诱发的侧向分枝越多,二次枝晶越发达;各向异性强度越大,枝晶尖端的生长速度越快,曲率半径越小.     

Fe-C合金凝固过程流动、传热、传质的耦合数值模拟

通过耦合求解凝固过程质量、动量、能量和溶质守恒方程，对Fe-C二元合金凝固过程中的流动、传热、传质现象进行了数值模拟，基于控制容积的有限差分法（CV-FDM）建立了微分方程的隐式离散格式，采用SIMPLE方法求解，代数方程的求解采用交替方向隐式（ADI）和三对角矩阵算法（TDMA）相结合的方法，对一上下边界绝热，左右边界对流换热的二维矩形区域的模拟计算表明，凝固初期排出的溶质主要被凝固前沿的液相流动带入液相区，在固液两相区中，由于枝晶骨架造成的流动阻力很大，在不考虑凝固收缩的条件下，两相区中的液相流动速度一般较纯液相区的流小2-3个数量级。     

Quantitatively comparing phase-field modeling with direct real time observation by synchrotron X-ray radiography of the initial transient during directional solidification of an Al-Cu alloy

The initial transient during directional solidification of an Al-4 wt.% Cu alloy was simulated by a quantitative phase-field model solved with the adaptive finite element method. The simulated solidification process was compared with the related analytical theory and in situ and real time observations by means of X-ray radiography at the European Synchrotron Radiation Facility. The simulated velocity of the planar interface and solute profile ahead of the solidification front in the liquid are close to the predictions of the Warren-Langer model of the initial planar solidification transient, but in fair quantitative agreement with experimental results only at early stages of planar solidification. After the accelerated flat interface lost its stability a transition to cellular solidification was initiated. The initial cell spacing predicted by the phase-field simulation agreed well with the experimental observations in the region where the cell growth direction was perpendicular to the fluid flow, whereas a discrepancy was obvious in the corners where the fluid flow was parallel to growth. An analytical relation describing the wavelength of the initial solid-liquid interface corrugations under diffusion-limited transport is screened out by comparing the phase-field simulation data with expressions based upon the Mullins-Sekerka linear stability analysis theory or derived for primary spacing. The gravity-driven natural convection in the experiment resulted in misfits between the phase-field predictions and the experimental observations in the late stage of planar solidification, onset and development of morphological instability.     

Solid Solubility in Laser Cladding

Laser cladding techniques have recently enjoyed attention in preparing in-situ novel surface clad alloys with extended solid solution. Mass transport involved in this process is rather intriguing since it plays the major role in producing new materials without being restricted by equilibrium phase diagram. Although earlier work has identified convection as the dominant factor for homogeneous liquid metal composition, very little is understood about the solute redistribution at the solid-liquid interface under such non-equilibrium conditions. In this paper, a mathematical model is presented for determining the composition of extended solid solution formed due to rapid cooling in laser cladding. This model considers a diffusion mechanism for mass transport in a one-dimensional semi-infinite molten pool of the cladding material from which heat is removed by conduction through a one-dimensional semi-infinite solid substrate. The rate of solidification was obtained by modeling the cooling process as a composite medium heat transfer problem, and the discontinuity of the concentration field was simulated using a nonequilibrium partition coefficient. A non-similar exact solution for the mass transport equation was obtained using a set of similarity variables derived using Lie group theory.     

Effect of phase change and solute diffusion on spreading on a dissolving substrate

Dissolutive wetting is investigated numerically using a diffuse-interface model that incorporates fluid flow, solute diffusion and phase change. A range of materials parameters are investigated: (1) permitting recovery of the hydrodynamic limit by suppressing the dissolution of the substrate and (2) evaluating the role of diffusion. The time history of droplet size, droplet concentration and angles between the interfaces are given. For cases in which convection dominates, the dynamics of spreading agrees with a known hydrodynamic model for spreading of inert fluids. A phase change increases wetting speed, due to a condensation that takes place near the triple junction. There is also a strong dependence of the wetting kinetics on the solute diffusivities. Details of composition changes during spreading are also discussed, such as the composition path of the bulk liquid probed at different locations in the drop.     

A new mechanism for freckle initiation based on microstructural level simulation

Freckle formation was directly simulated in three dimensions with a microstructure level model for unidirectional solidified Pb–Sn alloys. The microscale solidification model resolves the complex interaction of solute partition, interdendritic thermosolutal convection, dendrite formation and remelting. These simulations show that it is competition between all off these phenomena at the microstructural level that determines both the initiation and survival of solute channels and, hence, the propensity for freckle formation. The solute enriched interdendritic flow remelts both primary and secondary arms, and can deflect the primaries. This enables solutal channels to become self-sustaining, forming freckles. The microstructural model was then applied to predict the critical Rayleigh number, with excellent agreement with a large range of experimental data, demonstrating its potential for applications to new alloy systems and solidification processes.