振动凝固对消失模铸造球铁组织特征的影响

试验研究了振动凝固对消失模铸造球铁合金石墨形态、基体组织及硬度的影响,浇注不同厚度的试样,对比了厚度5mm、10mm、20mm、40mm试样在静止凝固与振动凝固条件下组织特征的变化。结果表明：振动凝固可以增加石墨球个数,随振动频率的提高,石墨球个数增加明显;振动凝固可以显著减少粗大石墨的比例,提高石墨分布的均匀性,随振动频率的提高,粗大石墨的比例呈减小趋势;振动凝固可以降低薄壁铸铁件中的碳化物含量,随振动频率提高,碳化物比例下降,硬度降低。     

Modelling of compacted graphite cast iron solidification-Discussion of microstructure parameters

A melt maintained for hours in a press pour unit allowed the following changes over time from spheroidal graphite to compacted graphite iron by casting thermal cups at regular time intervals.This provided extensive experimental information for checking the possibility of simulating solidification of compacted graphite irons by means of a microstructure modelling approach.During solidification,compacted graphite develops very much as lamellar graphite but with much less branching.On this basis,a simulation of the thermal analysis records was developed which considers solidification proceeding in a pseudo binary Fe-C system.The simulated curves were compared with the experimental ones obtained from three representative alloys that cover the whole microstructure change during the holding of the melt.The most relevant result is that the parameter describing branching capability of graphite is the most important for reproducing the minimum eutectic temperature and the recalescence which are so characteristic of the solidification of compacted graphite cast irons.     

Understanding compacted graphite iron solidification through interrupted solidification experiments

While the manufacture of compacted graphite (CG) iron castings has seen significant expansion over the recent years, the growth of CG during iron solidification is still not fully understood. In this work, effort was expanded to experimentally reveal the evolution of graphite shape during early solidification and its relationship to the solid fraction. To this purpose, interrupted solidification experiments were carried out on hypereutectic irons with three magnesium levels. The graphite shape factors were measured and analysed as a function of chemical composition and solid fraction. Scanning electron microscopy was carried out to establish the fraction of solid at which the transition from spheroidal graphite (SG) to CG occurs. It was confirmed that solidification started with the development of SG for all CG irons. The SG-to-CG transition was considered to occur when the SG developed a tail (tadpole graphite). The findings were integrated in previous knowledge to attempt an understanding of the solidification of CG iron.     

On the mechanism of the formation of widmanstätten graphite in flake graphite cast irons

The mechanism whereby Widmanstätten graphite develops during the solidification of flake graphite cast irons has been found to involve the preferential segregation and a complex interaction of specific elements at the surface of the graphite flake during solidification and the development of the plate like appendages in the solid austenite adjacent to the graphite flake. The literature has suggested that lead, calcium and hydrogen may be causal to the formation of Widmanstätten graphite, but has the interaction of these elements has not been effectively documented. While the formation of this degraded graphite is often attributed to the presence of a sufficient amount of lead alone, it has been observed that Widmanstätten graphite develops only in conjunction with a combination of factors operative at the graphite-austenite interface. Commercial flake graphite cast irons may exhibit Widmanstätten graphite as a function of lead and calcium content in the iron, moisture content in the molding media, solidification cooling rate and the rate of cooling immediately after solidification, etc. Lead contamination of cast irons was also observed to increase the chilling tendency of the iron. The detrimental effects of lead can be counteracted by the presence of rare earths in the iron, where rare earth elements react with lead to form stable, high melting point compounds.     

Precipitation and evolution of nodular graphite during solidification process of ductile iron

The quantity and morphology of spheroidal graphite have an important effect on the properties of ductile iron,and the characteristics of spheroidal graphite are determined by the solidification process.The aim of this work is to explore the precipitation and evolution of graphite nodules in hypoeutectic,eutectic,and hypereutectic ductile irons by thermal analysis,liquid quenching and metallographic technique.Results show that hypoeutectic ductile iron has the longest solidification time and the lowest eutectic temperature;eutectic ductile iron has the shortest solidification time;hypereutectic ductile iron has the highest eutectic temperature.After solidification is completed,hypoeutectic ductile iron has the lowest nodule count,nodularity and graphite fraction;eutectic ductile iron has the highest nodule count,nodularity and the smallest nodule diameter;hypereutectic has the highest nodule diameter and graphite fraction.The nucleation and growth of graphite nodules in hypereutectic ductile iron starts before bulk eutectic crystallization stage,however,the precipitation and evolution of graphite nodules of hypoeutectic and eutectic ductile irons mainly occur in the eutectic crystallization stage.The graphite precipitated in eutectic crystallization of hypoeutectic,eutectic,and hypereutectic ductile irons,are 61%,68% and 43% of total graphite volume fraction,respectively.Simultaneously,there are plenty of austenite dendrites in hypoeutectic and hypereutectic ductile irons,which are prone to shrinkage defects.Therefore,the eutectic ductile iron has the smallest shrinkage tendency.     

Influence of inoculation on solidification in cast iron

Abstract

Inoculation of cast iron has been mainly studied for the nucleus materials and the development of new inoculants. The effect is widely recognised; nevertheless, the mechanism was not fully understood. Inoculation leads to a decrease in chill depth, depressed the formation of D type graphite to form A type graphite and increase in the eutectic cell number. The transition from A type to the D type graphite is also accelerated by Ti addition; therefore we used Ti added samples for the study of D type graphite formation. The increase in the eutectic cell number produces a decrease in the cell size, namely the radius; nevertheless, the solidification time of the castings does not change by inoculation. Therefore, the solidification rate of the cell, namely the linear solidification rate, should decrease with inoculation and the decrease produces a depression in the chill and D type graphite due to the smaller undercooling. Therefore, we have to consider the three-dimensional solidification rate for discussing the cooling curve.     

Eutectic solidification mode of spheroidal graphite cast iron and graphitization

The shrinkage and chilling tendency of spheroidal graphite (abbreviated SG) cast iron is much greater than that of the flake graphite cast iron in spite of its higher amount of C and Si contents. Why? The main reason should be the difference in their graphitization during the eutectic solidification. In this paper, we discuss the difference in the solidification mechanism of both cast irons for solving these problems using unidirectional solidification and the cooling curves of the spheroidal graphite cast iron. The eutectic solidification rate of the SG cast iron is controlled by the diffusion of carbon through the austenite shell, and the final thickness is 1.4 times the radius of the SG, therefore, the reduction of the SG size, namely, the increase in the number, is the main solution of these problems.     

灰口铸铁中石墨分布的优化

控制石墨的形态和分布是优化灰口铸铁性能的关键;石墨的形态取决于凝固过程中经过共晶温度区间时的冷却条件;通过选择合适的化学成分和金属液处理方法可以控制共晶凝固过程,获得分散的、均匀分布的A型石墨,从而得到性能优良的灰铁铸件。     

Study of shrinkage porosity in spheroidal graphite cast iron

This study aims at identifying the relationship between the shrinkage cavities and the solidification structure in spheroidal graphite cast iron. Cast samples specially designed to contain shrinkage cavities were used. The solidification macrostructure was revealed using the Direct Austempering After Solidification method, while the solidification microstructure was revealed by using colour etching. At the midsection of the pieces, the shrinkage cavities and the solidification structure were observed jointly. The study showed that the classification of shrinkage porosity found in literature does not correspond to the ductile iron solidification model recognized by most of the scientific community. Early solidification models, and therefore shrinkage formation mechanisms, were proposed in instances when there was not a thorough knowledge of the morphology of the solid phases during solidification. Nowadays, defects formation mechanisms can be described with higher accuracy. Therefore, an updated classification of shrinkage porosity for spheroidal graphite iron is proposed.     

Casting/mould interfacial heat transfer during solidification in graphite,steel and graphite lined steel moulds

Heat flow between the casting and the mould during solidification of three commercially pure metals, in graphite, steel and graphite lined steel moulds, was assessed using an inverse modelling technique. The analysis yielded the interfacial heat flux (q), heat transfer coefficient (h) and the surface temperatures of the casting and the mould during solidification of the casting. The peak heat flux was incorporated as a dimensionless number and modeled as a function of the thermal diffusivities of the casting and the mould materials. Heat flux transients were normalised with respect to the peak heat flux and modeled as a function of time. The heat flux model proposed was used to estimate the heat flux transients during solidification in graphite lined copper composite moulds.     

球墨铸铁缩松形成机理研究的现状

为全面、准确认识球墨铸铁缩松形成机理,从球墨铸铁的凝固特性、凝固过程以及生产工艺等方面综合评述了球墨铸铁缩松形成机理的研究现状.对球墨铸铁的缩松形成机理中存在的一些问题或矛盾之处进行剖析和总结,且对下一步研究工作的方向进行展望.     

Numerical simulation of microstructure evolution on near eutectic spheroidal graphite cast iron

A multiphase cellular automaton model was developed to simulate microstructure evolution of near eutectic spheroidal graphite cast iron (SGI) during its solidification process, and both dendritic austenite and spheroidal graphite growth models were adopted. To deduce the mesh anisotropy of cellular automaton method, the composition averaging and geometrical parameter were introduced to simulate the spheroidal graphite growth. Solute balance method and decentered square algorithms were employed to simulate austenite dendrites growth with different crystallographic orientations. The simulated results indicate that the graphite nodule grows in a spherical morphology when the surrounding environment of a single graphite nodule is same. However, for two adjacent graphite nodules, the environment is different. The higher the carbon concentration, the faster the growth of graphite. By comparison with experimental results, it is found that the microstructure evolution of near eutectic spheroidal graphite cast iron during solidification process can be reproduced quantitatively by numerical simulation with this model.     

定向凝固Fe—C共晶合金的组织参数与拉伸特性

研究了凝固速度对Fe—C共晶合金的固/液界面形貌、组织及拉伸性能的影响,提出石墨片混乱度参数,并给出了混乱度、拉伸性能随凝固速度的变化曲线     

Kinetics of graphite expansion during eutectic solidification of cast iron

The paper introduces a new linear displacement analysis (LDA)/thermal analysis (TA) experimental device for measuring linear displacement during the solidification of cast iron. The experimental device comprises a sand mould encased in a steel shell that prevents mould wall movements. Thus, only the linear displacement caused by the shrinkage or expansion of the metal is recorded by the transducers. Two quartz rods introduced directly at different heights into the liquid metal and connected to two transducers record the linear displacement during the liquid–solid transformation and subsequent cooling. Two thermocouples positioned at the same height with the quartz rods allow for the concomitant TA and LDA and thus for the direct correlation between expansion/contraction and the temperature change during solidification events such as graphite formation. The LDA device was used to study the differences in the solidification mechanisms of irons with different graphite morphologies (lamellar, compacted/vermicular and spheroidal) at carbon equivalent in the range of 3·7–4·4%. The analysis included the LDA and TA curves and full metallographic characterisation of the cast irons. In general, graphite expansion increased as the graphite shape changed from lamellar, to compacted and then to spheroidal. The most important process variables are the magnesium and carbon contents. Higher Mg residual and C in the iron produced more graphite expansion. Compacted graphite (CG) iron was particularly sensitive to the Mg residual. Indeed, the high Mg CG irons exhibited similar graphite expansion to that of spheroidal graphite (SG) iron, while the low Mg CG iron expansion was closer to that of the lamellar graphite (LG) iron. Graphite expansion increased for all data with the time interval over which graphite expansion occurred. It also increased with both carbon and carbon equivalent. The time for graphite expansion increased noticeably with the carbon content of the iron. It did not depend on the graphite shape. By combining TA and LDA, it was possible to plot the evolution of graphite expansion as a function of the fraction solid and thus to understand the kinetics of graphite expansion. The amount of expansion available at the end of solidification was quantified. Such data, when correlated with process variables, will be useful in decreasing microshrinkage and in producing riserless compacted and SG irons.     

Effects of Sulphur,Titanium and Zirconium on the Shape of Solid-Liquid Interface in Fe-C binary alloys

The effects of sulphur, titanium and zirconium on the shape of the eutectic solidification interface in Fe-C binary alloys were investigated by the quenching into ice water during unidirectional solidification.

The oscillatory schematic model for graphite branching is proposed by considering the shape of the solidification interface and the protuberance length of the graphite flakes. The specimens contain 0.012, 0.108, 0.37 mass % S, 0.177 mass % Ti, and 0.078 mass % Zr, respectively. They are 80 g in weight, 18 mm in diameter, and 55 mm in length. The temperature gradient at the solid-liquid interface is about 2.5 K/mm.     

Correlative thermal methodology for castability simulation of ductile iron in ADI production

The present paper investigates the simulation analysis of simultaneous mold filling and solidification of ductile iron casting in a permanent mold by virtue of its thermal characteristics. Thermal analysis was performed to determine the solidification behavior and nature of alloy of the melt during its solidification. It revealed the variation in the nature of alloy due to the variations in eutectic freezing and carbon equivalent of the melt. The obtained thermal parameters from the thermal analysis were further used for the casting simulation of the melt. The simulation results show a progressive solidification behavior of the casting. There is a significant decrease in the overall heat transfer coefficient with time during the solidification process. The simulation results were further verified experimentally. The experimental results show porosity defects at the top section of the casting. Two distinct zones (center and outer) were observed on the produced samples based on the average graphite nodule counts and average graphite nodule size.     

快淬Mg-10Ni-2Mm储氢合金的组织演化

研究一种镁基Mg-10Ni-2Mm（摩尔分数,%）储氢合金在不同凝固速率下的组织演化。结果表明：增加凝固速率可以大幅度细化合金条带的晶粒;采用的石墨冷却轮表面速度为3.1,10.5和20.9m/s时,可以分别获得微晶、纳米晶和非晶组织;当冷却轮盘表面速度为3.1m/s时,快淬试样完全结晶化,组织中除了少量富Mm晶粒外,形成了粗大的Mg和Mg2Ni微晶;加快冷却轮盘表面速度到10.5m/s时,大量的纳米颗粒形成,组织由大量的Mg和Mg2Ni纳米晶组成;进一步加快速度到20.9m/s时,形成了包括非晶和纳米晶的混合组织。理想的组织是非晶基体上析出大量纳米晶,这样的组织有望获得最大的储氢容量和优异的吸放氢动力学。     

球墨铸铁的凝固形貌--球墨铸铁基础理论的最新发展(四)

介绍了球墨铸铁的微观和宏观凝固特征,薄壁和厚壁球铁的凝固形貌特点,以及球铁铸件壁厚与凝固时间的关系,同时分析了石墨球数和共晶晶粒数对球墨铸铁凝固品质的影响。     

铸铁水平连铸中圆坯凝固过程的数值模拟

将铸铁水平连铸中圆坯凝固过程的整个传热系统作为模拟对象,采用自由热收缩模型计算铸坯与结晶器的界面传热系数,从非稳态传热的角度并按照柱坐标系中二维传热的方式进行铸坯凝固过程的数值模拟,在数值计算中,采用静、动坐标系相结合的方法,使铸坯传热的控制方程得以简化且便于耦合处理结晶器与铸坯的温度场计算,由此确立的模拟方法可用于模拟不同尺寸的圆坯在各种工艺条件下的凝固过程。     

大断面球铁碎块状石墨形成原因浅析及若干防止措施

本文从球墨铸铁石墨－－奥氏体共晶团形成及长大过程中的应力出发,分析了大断面球铁热节处非球形石墨－－碎块状石墨的形成原因及若干影响因素,提出了防止措施。