Fabrication of W–Ni–Fe alloys with gradient structures

A sintering couple of green compacts with compositions of 88W–5Mo–4.9–2.1Fe and 93W–4.9Ni–2.1Fe respectively, were processed by liquid phase sintering. The microstructure and content of binding phase at different regions along the direction perpendicular to the original interface were investigated by scanning electron microscopy (SEM). The distribution of Mo content in composite was determined by energy dispersive analysis (EDS) and the micro hardness in different regions were measured by Vickers micro hardness tester. Results show that the grain size, volume fraction of binding phase and micro hardness vary gradually due to the graded distribution of molybdenum, which also introduces a solid/liquid interfacial tension gradient and the unbalanced liquid phase pressure serving as the driving force for liquid phase migration during liquid phase sintering.     

2-Dimensional FEM modeling of macrosegregation in the directional solidification with mesh adaptation

In order to improve the prediction accuracy of macrosegregation channel, an algorithm for dynamic remeshing is proposed. The basic idea is to generate fine elements near the liquidus isotherm. The norm of the gradient of solid fraction is used for piloting the remeshing in the mushy zone; whereas, the objective mesh size in the liquid is considered as a function of the distance to the liquidus isotherm. The efficiency of mesh adaptation is demonstrated by prediction of macrosegregation channel in a case of unidirectional solidification.     

糊状区变形及浓度再分布的模拟实验

用丁二腈－丙酮合金实验研究试样变形开始时间、初始厚度及变形量对枝晶变形及溶质再分布的影响。结果表明，枝晶变形满足幂次大于1的能量函数关系；枝晶变形能力主要与变形时糊状区固相分数有关；从糊状区挤出的液相相对浓度与固相分数、变形比率成线性关系。实验结果对建立糊状区变形与宏观偏析数学模型及优化连铸液芯压下工艺有意义。     

高温高压烧结金刚石-铜复合材料的研究

采用高温高压烧结工艺制备了金刚石体积分数为80%的金刚石-铜复合材料。研究了金刚石颗粒大小、烧结温度、烧结时间等因素对复合材料成分、界面状态和热导率的影响。结果表明:金刚石颗粒直径为80μm时,在高温高压条件下可获得热导率高达639 W.m-1.K-1的金刚石-铜复合材料。当金刚石体积分数一定时,存在一临界粒径,随金刚石颗粒直径增大复合材料热导率先增大后减小。恰当的烧结温度和时间有助于获得黏结良好的界面和高热导率。     

高温高压法制备金刚石/铜复合材料的研究

采用高温高压法制备金刚石/铜复合材料。研究金刚石体积分数、烧结压力、保温时间、烧结温度、金刚石表面金属化对金刚石/铜复合材料热导率及热膨胀系数的影响。实验表明:金刚石体积分数70%,烧结压力2 GPa,烧结时间300 s,烧结温度1200℃时,金刚石/铜复合材料热导率达426 W/（m·K）。      

Experimental and simulation studies on grain growth in TiC and WC-based cermets during liquid phase sintering

The grain growth behaviors of TiC and WC particles in TiC-Ni, TiC-Mo₂C-Ni, WC-Co and WC-VC-Co alloys during liquid phase sintering were investigated for different Ni or Co contents and compared with the results of Monte Carlo simulations. In the experimental study, TiC-Ni and WC-Co alloys had a maximum grain size at a certain liquid volume fraction, while the grain size in TiC-Mo₂C-Ni and WC-VC-Co alloys increased monotonically with an increasing liquid volume fraction. These results mean that the grain growth of these alloys cannot be explained by the conventional mechanisms for Ostwald ripening, namely diffusion or reaction controlled processes. Monte Carlo simulations with different energy relationships between solidliquid interfaces predicted the effect of the liquid volume fraction on grain size similar to the experimental results. The contiguous boundaries between solid (carbide) particles appear to influence the grain growth behavior in TiC- and WC-based alloys during liquid phase sintering.     

Effects of centerline macrosegregation on necking of P-added extra low carbon steel sheet

Effects of centerline macrosegregation on necking was examined by the stretching experiment for cold rolled P-added extra low carbon steel sheets. The centerline macrosegregated zone containing high concentration of Mn and P was elongated in the rolling process. The elongated macrosegregated zone induced instability in the strain state when the sheet was stretched, thus resulted in the waved sheet surface. The formability of cold rolled steel sheet was deteriorated due to the wave formed by the macrosegregation. The waved surface was thought to be caused by the higher hardness in the macrosegregated zone compared to the segregation free zone. The experiments on the stretching of sheet including macrosegregation showed that the macrosegregation was the important source of instability in that of the cold rolled steel sheets. A 3D FEM analysis was carried out for the quantitative evaluation of waved surface. It was confirmed that the main source of the waved surface was the macrosegregation. Stretching in the transverse direction under the plane strain condition made the cold rolled steel sheet more inhomogeneous than stretching in any other strain condition. The thickness difference in the stretched sheet was linearly increased when the ratio of hardness in the macrosegregated zone to that of the segregation free zone was increased. The macrosegregation formed in the internal crack close to the surface was more harmful to the formability in the cold rolled steel sheet than the centerline macrosegregation.     

基于正交试验的液态模锻Al-Sn-Cu轴套中Sn的宏观偏析

采用正交试验法分析了液态模锻Al-Sn-Cu轴套中Sn的宏观偏析规律。结果表明:液态模锻Al-Sn-Cu轴套不可避免的产生Sn的宏观偏析,铸件中同时存在着正偏析和逆偏析,正偏析出现在浇铸中心的近端,逆偏析主要存在于浇铸中心的远端;铸件凝固后期,低熔点液相被强制挤压至热节位置,形成粗晶区和细晶区相间的双峰组织,细晶区Sn的质量分数明显较高。液态模锻工艺参数对铸件宏观偏析产生较大影响,对Sn偏析影响由大到小依次是浇注温度、模具温度、保压时间及比压;本次实验条件下,当浇注温度为700℃,模具温度为240℃,比压为80 MPa,保压时间为5 s时,轴套铸件中Sn元素分布较均匀,Sn元素的宏观偏析得到减轻。     

钨合金-钼叠层飞片的热压烧结连接

通过以Ｗ、Ｍｏ连接板材间均匀铺填Ｗ－Ｍｏ粉末中间层,并加入４Ｎｉ－３Ｃｕ烧结剂,在在实现Ｗ－Ｍｏ合金的热压烧结致密化的同时,完成了难熔金属Ｗ－Ｍｏ的低温连接（１５７３Ｋ）,并制备出平行精度高、平大幅度好、致密度高的钨合金－钼叠层飞片材料。其间详细探讨了Ｗ－Ｍｏ合金的烧结致密化机理和叠层飞片的界面连接机理。试验结果表明,由于低熔点Ｃｕ的添加,部分活性烧结剂Ｎｉ以液态形式存在,使元素Ｗ、Ｍｏ更易向Ｎｉ     

Numerical Simulation of Macrosegregation in Water-Cooled Heavy Flat Ingot During Solidification

Based on a volume-averaged two-phase approach, a coupled concentration, temperature, and velocity fields model has been established to predict the formation of macrosegregation during solidification. Because of the significant influence of velocity field on solute transfer and distribution during solidification process, the density of liquid steel was set as a function of temperature and concentration to accurately calculate the velocity field. Therefore, the influence of gravity, temperature gradient, concentration gradient, and volume shrinkage on velocity field distribution was comprehensively considered. The calculation result showed good agreement with previous reports. Thereafter, the current model was applied to simulate the solidification of 12Cr2Mo1R (ASTM standard 2.25Cr1Mo) heavy ingot, and the influence of surface cooling intensity on the final carbon macrosegregation was investigated. The results showed that with the increase of cooling intensity, the solidification time, flow velocity, and mushy zone width decrease, and as a result, macrosegregation is alleviated. When the heat-transfer coefficient is less than 1000 W m^?2 K^?1, macrosegregation dramatically decreases with the rise of cooling intensity. In contrast, when heat-transfer coefficient is greater than 1000 W m^?2 K^?1, the effect of reducing the central carbon segregation by increasing cooling is weakened.     

93W和97W钨合金破坏机制研究

对粉末冶金法制备的两种不同钨含量的钨合金材料进行SHPB试验和原位拉伸试验,研究了钨合金中钨含量与其显微组织、断裂方式及力学性能之间的关系。结果表明,在拉伸情况下随着钨含量的增加,钨合金的破坏方式由W-W间开裂转变为钨颗粒开裂,材料由韧性变为脆性。利用Ostwald烧结理论,对两种材料的微观结构进行预测,结果与实验符合较好。利用细观力学模型对所观察的实验结果进行了定量解释。烧结理论和细观力学相结合,可建立材料烧结条件、体积分数及力学性能之间的关系,为材料的设计、制备和力学性能的预测提供理论依据     

Application of CALPHAD approach in simulation of liquid phase migration of cellular cemented carbide

This paper presents the experimental investigation of the liquid phase migration and its numerical simulation by applying the CALPHAD approach. The liquid phase migration during sintering is studied through the diffusion couple technique along with electron probe micro-analysis (EPMA) measurements. Based on the CALPHAD approach, the relation between the volume fraction of liquid phase and the mass fraction of Co is calculated for the WC–Co cemented carbide system. The information on the volume fraction of liquid phase could serve as the input in a numerical model. The simulation of liquid Co migration in WC–Co cemented carbide is performed and compared with the previous and present experimental results. These simulations could be used in choosing the suitable initial composition for raw materials of liquid phase sintered cemented carbide.     

The effect of contiguity on growth kinetics in liquid-phase sintering

Experimental and mathematical consideration of microstructural coarsening during liquid-phase sintering has resulted in kinetic laws which define grain size to the third power as being proportional to the isothermal sintering time. Despite thoseprior efforts, the situations typical to liquid-phase sintering are poorly treated by the current models because the models assume a structure consisting of widely separated spherical grains (zero contiguity). No experiment had been completed to quantify the effect of contiguity on the growth kinetics. In order to do this, the contiguity and growth rates of tungsten grains in a liquid matrix at 1,750K were measured in sintered heavy alloys of 78,83, 88,93 and 98 wt.% Wbalanced with 70Ni-30Fe. The observed grain growth rates were compared with the theoretical predictions of the LSW theory and volume fraction modified theories. By modifying the volume fraction effect with a contiguity term, a model was produced that closely followed the experimental results.     

过偏晶合金Ni-40%Pb深过冷凝固组织

采用熔融玻璃净化与循环过热相结合的方法研究过冷Ni-40%Pb(质量分数)过偏晶合金的组织演化规律. 结果发现 过偏晶合金在快速凝固阶段本质上是以枝晶方式生长; 当ΔT《50K时, 合金组织为粗大枝晶+枝晶间Pb相+团块状Pb相; 当100《ΔT《198K时, 合金组织宏观偏析严重; 当ΔT＝292K时, 合金组织呈粒状晶, 第二相均匀弥散分布. 分析表明凝固组织宏观偏析与快速凝固阶段固液相变速率和体系残余液相分数有关; 粒状晶粒化机制属于枝晶碎断再结晶机制.     

Microstructural control of and mechanical properties of mechanically alloyed tungsten heavy alloys

93W-5.6Ni-l.4Fe tungsten heavy alloys with controlled microstructures were fabricated by mechanically alloying of elemental powders of tungsten, nickel and iron by two different process routes. One was the full mechanical alloying of blended powders with a composition of 93W-5.6Ni-l.4Fe, and the other was the partial mechanical alloying of blended powders with a composition of 30W-56Ni-14Fe followed by blending with tungsten powders to form a final composition of 93W-5.6Ni-l.4Fe. The raw powders were consolidated by die compaction followed by solid state sintering at 1300°C for 1 hour in a hydrogen atmosphere. The solid state sintered tungsten heavy alloys were subsequently liquid phase sintered at 1445∼1485°C for 4-90 min. The two-step sintered tungsten heavy alloy using mechanically alloyed 93W-5.6Ni-l.4Fe powders showed tungsten particles of about 6-15 μm much finer than those of 40 um in a conventional liquid phase sintered tungsten heavy alloy. An inhomogeneous distribution of the solid solution matrix phase was obtained in the two-step sintered tungsten heavy alloy using partially mechanically alloyed powders. The two-step sintered tungsten heavy alloy using mechanically alloyed 93W-5.6Ni-l.4Fe powders showed larger elongation of 16% than that of 1% in the solid state sintered tungsten heavy alloy due to the increase in matrix volume fraction and decrease in W/W contiguity. Dynamic torsional tests of the two-step sintered tungsten heavy alloys showed reduced shear strain at maximum shear stress than did the sintered tungsten heavy alloys using the conventional liquid phase sintering.     

Three-dimensional simulation of isotropic coarsening in liquid phase sintering I: A model

A three-dimensional, Potts model of liquid phase sintering in a system with full solid wetting was introduced in order to investigate the coarsening kinetics and microstructures associated with this process. Kinetic Monte Carlo simulation was used to probe the coarsening dynamics and obtain the properties of solid particles, including the volume of critical nuclei and the distribution of particle sizes as a function of time. It was found that the average particle volume increased linearly with time and that the particle size distributions were consistent with those obtained experimentally, as in the W–Ni–Fe and Sn–Pb systems. In obtaining these results careful consideration was given to the role of the initial microstructural features in the subsequent evolution of the system.     

基于三相模型的Al-4%Cu合金三维半连铸圆锭的宏观偏析数值模拟

本文采用基于 Eulerian-Eulerian方法的等轴晶、柱状晶以及熔体三相完全混合的凝固模型计算了三维半连铸Al-4%Cu铝合金圆锭的宏观偏析。基于热溶质对流的基础上,模型考虑了等轴晶的移动,以及柱状晶对浮游等轴晶的捕获,等轴晶和柱状晶的相互竞争生长行为。模拟结果表明铸锭底部出现了明显的锥形负偏析区(CET转变区域),铸锭中心正偏析带,毗邻中心的负偏析区,以及铸锭1/2半径处正偏析带,总的偏析形态呈现W型,与铸锭实际情况基本一致。此外,铸造速度相较于浇注温度对铸锭宏观偏析具有更大的影响。     

铸造WC/Ni基合金复合材料二体磨料磨损性能的研究

用真空热压液相烧结技术制备铸造WC／Ni基合金复合材料。研究了铸造WC的颗粒尺寸及体积分数对复合材料的二体磨料磨损性能的影响，并将它与高铬铸铁(Cr28)相比较。结果表明：随着铸造碳化钨颗粒尺寸和体积分数的增大，复合材料的耐磨性提高，且远高于高铬铸铁。     

TGZM效应下Co-87.9wt%Sb合金糊状区的组织演化及成分变化

以TGZM效应为理论基础,将Co-87.9wt%Sb合金置于定向凝固设备中加热熔化,在一定温度梯度下分别保温20min,2h,4h后淬火,对其糊状区的凝固组织和成分分布进行了研究。结果表明：在一定温度梯度下,介乎于完全液相区和未熔固相区之间存在着固液相共存的糊状区,Co-87.9wt%Sb合金的糊状区沿温度梯度方向分为(CoSb3+L),(CoSb2+L)以及(CoSb+L)三层;在TGZM效应作用下,随着保温时间的增加,糊状区内液相体积分数逐渐减少,糊状区与完全液相区界面向低温区移动;经保温处理后,由EDS获得的糊状区成分分布,糊状区内的溶质浓度明显偏离合金初始浓度,完全液相区溶质浓度高于初始值;通过理论分析与计算解释了上述现象。经过4h保温处理后,糊状区(CoSb3+L)部分中的CoSb3含量大幅增加,在该部分高温端甚至可达98.8%,表明借助TGZM效应经过长时间保温制备CoSb3热电材料的方法是可行的。     

On structure property correlation in high strength tungsten heavy alloys

Detailed structure-property correlation has been carried out in high strength tungsten heavy alloys. Alloys of compositions 90W-6Ni-2Fe-2Co, 89W-6Ni-2Fe-3Co, 89.5W-6Ni-2Fe-2Co-0.5Mo, 89.75W-6Ni-2Fe-2Co-0.25Mo, 90W-6Ni-1.5Fe-2.5Co and 90W-6Ni-1Fe-3Co have been prepared by liquid phase sintering followed by large deformation during thermo mechanical processing and studied for microstructure and mechanical properties. Despite differences in composition, higher volume fraction of matrix and lower W-W contiguity in the microstructure result in superior tensile strength and impact toughness. Increasing W content in the matrix enhances mechanical properties by imparting solid solution strengthening, increasing the matrix volume fraction and reducing W-W contiguity. The alloy 90W-6Ni-1Fe-3Co shows superior balance of properties with ultimate tensile strength of 1600 MPa and average impact toughness of 121 J/cm².