快速凝固铝硅合金的制备、组织特征及断裂行为

快速凝固Al-Si合金是一种高性能结构材料,目前主要通过快速凝固/粉末冶金(RS/PM)和喷射沉积(SF)两种方法进行制备;此类合金具有超细化显微组织、成分均匀分布、非平衡亚稳相和过饱和固溶体及高密度位错等组织特征;其断裂方式主要呈脆性断裂。本文主要对上述内容进行综合评述     

Study on Improving Solidification Structure of Rare Earth Al-Si Alloys with Electropulse Acting on Liquid Alloy

Electropulse modification (EPM) process, a new physical field method for improving the solidification structure of metals was introduced.Different from other research, EPM is only acting pulse current on melt under liquid state.The solidification structure of Al-Si alloys, A1-Cu alloys,cast iron and steel can be modified obviously with this method: the solidification structure of ZL101 alloy presented the Na and Sr modification and the mechanical properties were enhanced; a large number of primary silicon appeared in the microstructure of ZL109 alloy; the equiaxed grain zone was expanded and the grains were fined in Al-5.0wt% Cu alloy; the graphitization took place in solidification process of molten cast iron; the grain sizes of solidification structure of T8 steel were reduced significantly and the shape of steel pearlites also changed; the equiaxed grain zone increased to 88% from original untreated 19%, the equiaxed grains were fined and the intercrystalline crack was avoided in concasting billet by continuously treating liquid electrical sheet steel in tundish.Effects of rare earths on casting Al-Si alloys were also summarized.The method of modifying the solidification structure of rare earth Al-Si alloys with EPM in producing the alloys was proposed.     

自然沉降法去除铝硅合金中铁相的机制探讨

对碳电热还原法生产的共晶铝硅合金加锰自然沉降法除铁进行了研究。通过差热热重及对自然沉降后获得的合金富铁相成分进行分析,结果表明:共晶铝硅合金加锰后,锰会与合金中的富铁相结合,增大富铁相的密度,提高富铁相的初晶温度;当合金中Mn/Fe达到1以上时,富铁相的初晶温度提高100℃以上;当富铁相中锰含量大于10%时,多呈块状,利于沉降到合金熔体底部,当锰含量低于6%时,富铁相多为针状留在合金中。通过加锰自然沉降可将合金中60%以上的富铁相去除。     

Mn元素对过流冷却过共晶Al-22Si-2Fe-xMn合金显微组织及耐磨性的影响

采用常规铸造和分段式倾斜板过流冷却铸造工艺制备Al-22Si-2Fe-xMn合金，研究表明:过流冷却制备工艺能够改善初生Si形貌及尺寸，但对针状富Fe相作用有限.利用扫描电镜、X射线衍射及透射电镜等手段分析过流冷却条件下Mn元素添加对富Fe相晶体结构的影响，通过摩擦磨损实验研究不同Mn/Fe质量比的过共晶Al-Si合金的硬度及耐磨损性能.结果表明:随着过流冷却铸造过共晶Al-Si合金中Mn/Fe质量比增加，合金中四方结构的长针状富Fe相逐渐减少直至基本消失，当Mn/Fe质量比为0.7时，富Fe相主要为六方结构的块状或鱼骨状α-Al₁₅（Fe，Mn）₃Si₂相，此时，合金耐磨性较未添加Mn元素时有所提升，磨损机制以磨料磨损方式为主.      

稀土在Al-Si活塞合金中的作用及其机理

Al-Si合金常作为一种高质量活塞合金广泛应用于内燃机生产中,在Al-Si活塞合金中添加稀土元素可以明显改善合金的机械力学性能和铸造加工性能。本文概述了稀土在Al-Si活塞合金中的作用。通过对大量试验研究结果的分析,着重论述了稀土对Al-Si活塞合金的细化变质、脱氧、除气和除Fe的作用及其机理,对进一步开展稀土在铝硅合金中的细化变质等应用研究具有广泛的理论和现实意义。     

含铝50%的硅铝合金生产技术

通过对冶炼硅铝合金的理论分析，结合国外生产的工艺技术，提出了解决我国冶炼硅铝合金的技术难题。指出矿热炉冶炼含铝50％的硅铝合金是可行的。     

Density,Viscosity, and Diffusion Coefficients in Hypoeutectic Al-Si Liquid Alloys: An Assessment of Available Data

This article is a review of empirical and calculated data on density, viscosity, and diffusion coefficients in hypereutectic Al-Si liquid alloys. Many regressions of the data were effected in order to consolidate the data as functions, which can be used to calculate each property as a function of temperature and concentration of Si. The chemical diffusion coefficient in the alloys was derived based on the Sutherland model, which relates the diffusion coefficient to viscosity.     

Influence of Phosphorus on the Nucleation of Eutectic Silicon in Al-Si Alloys

The role of phosphorus (P) in the heterogeneous nucleation of eutectic silicon (Si) and the evolution of eutectic grains in hypoeutectic aluminum-silicon alloys were investigated. Systematic additions of P in the range of 0.5 to 20 ppm to Al-7 wt pct Si alloys of different purities have shown that the morphology of the eutectic Si changes from a fine plate- to a coarse flake-like structure. The growth of eutectic grains was investigated by interrupting the eutectic reaction by quenching experiments. Moreover, the macroscopic growth mode of the eutectic grains was characterized by electron backscatter diffraction. An increase in P concentration from 2 to 3 ppm resulted in a transition of the macroscopic growth mode of the Al-Si eutectic in high purity alloys from growth with a planar front with a strong dependence of the thermal gradient, to nucleation in the vicinity of the primary Al dendrites and subsequent growth of distinct eutectic grains. It is suggested that AlP particles are the key impurities acting as potential nucleation sites for eutectic Si. This is further substantiated as with increasing P concentration nucleation and growth of the Al-Si occurred at higher temperatures close the equilibrium Al-Si eutectic solidification temperature at 850 K (577 °C). In addition, the recalescence undercooling ΔT _R,eu was reduced from 4.5 K (0.5 ppm P) to 1.5 K (20 ppm P) in high purity alloys. This was accompanied by a drastic increase of the nucleation rate of the eutectic grains.     

Investigation of warm compaction and sintering behaviour of aluminium alloys

Abstract

The effects of warm compaction on the green density and sintering behaviour of aluminium alloys were investigated. Particular attention is paid to prealloyed powders, i.e. eutectic and hypereutectic Al-Si alloys, regarding their potential applications in the automotive industry. The effects of chemical composition, alloying method, compacting temperature and the amount of powder lubricant were studied. The compaction behaviour was examined by an instrumented die enabling simultaneous measurement of density, die wall friction coefficient, the triaxial stresses acting on the powder during the course of compaction and ejection pressure. The sintering behaviour was studied via dilatometeric analysis as well as normal batch sintering. The results show that warm compaction could be a promising way to increase the green density of aluminium alloys, especially prealloyed powders, and to decreased imensional instability during sintering. Moreover, it reduces the sliding friction coefficient and the ejection force during the powder shaping process. This paper presents the significant advantages and drawbacks of using the warm compaction process for commercial PM aluminium alloys.     

Al—3B中间合金的加工量对亚共晶Al—Si合金晶粒细化的影响

研究了Al-3B中间合金不同的加入量对亚共晶Al-Si合金晶粒尺寸的影响。该中间合金对所研究全部范围内的Al-Si合金都具有一定的细化效果,但在不同的含硅量下其细化能力并不相同,同时证实对未经细化处理的亚共晶Al-Si合金而言,在含硅量约3%（质量分数,下同）时合金具有最小的晶粒尺寸。随着Al-3B中间合金加入量的提高,出现最小晶粒尺寸的合成成分向高硅方向移动,当加入量达到1%时,在含硅量为6%的Al-Si合金中出现最小的晶粒尺寸。     

Investigating the dependence of the properties of sintered boron-containing steels on conditions of synthesis and the content of employed foundry alloys

Results from investigating the effect of technological conditions for the synthesis of powdered boron-containing foundry alloys on their chemical and phase compositions and the content of foundry alloys in the charge on the structure and properties of sintered steels fabricated using them are presented. It is shown that using denser briquettes obtained at a pressure of ??700 MPa allows us to reduce substantially boron evaporation through the gas phase during the synthesis of foundry alloys, relative to briquettes compacted at lower pressures. Using an elevated foundry alloy synthesis temperature (1200°C) leads to higher density of the post-sintered material, and thus to enhanced strength characteristics. Increasing the boron content in the initial charge increases the hardness and lowers the strength of sintered steels, while the curve of the strength??s dependence on the boron content after thermal treatment peaks at ??0.8% B.     

Influence of the structure of the AlSi20 foundry alloy on the microstructure and viscosity of the Al-6% Si model silumin in solid and liquid states

The influence of the structure of starting charge alloys Al-20 wt % Si on their structure after single remelting and crystallization with an identical cooling rate of 20 K/s is investigated. It is established that the structural transformation from the starting charge alloys stably retains, being translated in the “solid-liquid-solid” system. The viscosimetry investigation of the melts obtained from the coarse-crystalline and the fine-crystalline charge alloys in the heating mode to 1350°C and the subsequent cooling confirmed the conclusion that these melts are translators of structural information. It is established that the branching temperature (hysteresis) of viscosity polytherms (t _h) in the heating and cooling modes for the melt made from the coarse-crystalline charge alloy is 1100°C, while that for the fine-crystalline charge alloy is 1000°C. It is noted that, in the second case, the viscosity in the cooling mode below t _h is elevated, while the polythermal branch ascends more steeply. These results indicate the favorability of using special methods of processing the charge metals with the goal of laying positive structural information into them. The use of this approach is most reasonable when obtaining aluminum-based foundry alloys.     

Influence of Mg on Grain Refinement of Near Eutectic Al-Si Alloys

Although the grain-refinement practice is well established for wrought Al alloys, in the case of foundry alloys such as near eutectic Al-Si alloys, the underlying mechanisms and the use of grain refiners need better understanding. Conventional grain refiners such as Al-5Ti-1B are not effective in grain refining the Al-Si alloys due to the poisoning effect of Si. In this work, we report the results of a newly developed grain refiner, which can effectively grain refine as well as modify eutectic and primary Si in near eutectic Al-Si alloys. Among the material choices, the grain refining response with Al-1Ti-3B master alloy is found to be superior compared to the conventional Al-5Ti-1B master alloy. It was also found that magnesium additions of 0.2 wt pct along with the Al-1Ti-3B master alloy further enhance the near eutectic Al-Si alloy’s grain refining efficiency, thus leading to improved bulk mechanical properties. We have found that magnesium essentially scavenges the oxygen present on the surface of nucleant particles, improves wettability, and reduces the agglomeration tendency of boride particles, thereby enhancing grain refining efficiency. It allows the nucleant particles to act as potent and active nucleation sites even at levels as low as 0.2 pct in the Al-1Ti-3B master alloy.     

Effects of microstructure on the erosion of Al-Si alloys ny solid particles

The effects of microstructure on the erosion of Al-Si alloys by 40 μm Al₂O₃ particles were investigated. The impact angle dependence of the erosion rate of Al and the Al-Si alloys exhibited the ductile signature, whereas that for pure Si showed the brittle signature. The eroded surface of pure Al was characterized by craters, lips, overlaps and folds, and platelets; that for pure Si exhibited complex radial and lateral cracking at the impact site. At shallow impact angles these features were elongated in the direction of the tangential component of the velocity in both materials. The measured erosion rates of the Al-Si alloys were found to be in accord with an inverse rule of mixtures based on pure Al and pure Si; better agreement was, however, obtained if pure Al and the eutectic were taken as the two constituents for the hypoeutectic alloys, and pure Si and the eutectic for the hypereutectic alloys. The microstructure size had two effects: (a) scaling with respect to the impact damage zone size and (b) an influence on the physical and mechanical properties which govern material removal. The present results are considered in terms of current models for the erosion of ductile and brittle materials.     

快速凝固铝硅合金的性能、应用及发展方向

利用快速凝固技术制备Al-Si合金可显著改善合金组织,大幅度提高合金性能,使合金具有良好耐磨、耐热性,高强,质轻及低热膨胀系数等特点,在汽车、电子和宇航工业中具有广泛应用潜力。本文主要对上述问题进行综述,并提出在快速凝固Al-Si合金研究中存在问题和发展方向。     

合金化Cr优化含Fe过共晶Al-Si合金显微组织及其机制

采用传统铸造工艺和喷射成形技术制备了无Cr和含Cr的含Fe过共晶Al-Si合金,并利用SEM(EDS)、XRD及DSC对其显微组织、相组成及相变过程进行了研究。结果表明:2%Cr的加入不光使铸态粗大针片状的δ-Al4FeSi2相变为"骨骼状"α-Al(Fe,Cr)Si相,而且使沉积态Al-25Si-5Fe-3Cu合金中短棒状的富铁相(～10μm左右)被尺寸小于3～5μm的颗粒状α-Al(Fe,Cr)Si相所替代,从而细化的组织更有利于合金性能的提高。等温处理实验结果显示沉积态含Cr合金具有较好的组织热稳定性,其主要归因于颗粒状α-Al(Fe,Cr)Si相自身的高温稳定性,而沉积态Al-25Si-5Fe-3Cu合金热稳定差主要由于β-Al5FeSi相的长大和A7Cu2Fe相的形成。另外,结合显微组织和喷射成形工艺特点对沉积态组织形成机制分析发现α-Al(Fe,Cr)Si相有可能通过直接从液相析出和经δ-Al(Fe,Cr)Si相转变而来。     

基于霍尔-埃鲁特电解法制备铝合金技术研究进展

现代霍尔-埃鲁特(H-H)法铝电解槽规模大、工艺成熟, 利用该法电解制备铝基合金具有明显技术和经济优势. 目前国内外研究主要是在现有氟化物熔盐体系中添加多种合金元素氧化物, 合理调节电解质成分和工艺参数, 借助共电沉积和欠电位机制, 成功制备出多种铝基合金, 工业化试验亦有初步成果. 本文综合分析了上述进展及发展前景, 并指出在实现合金组成精准调控、合金产品成分均匀化、电解槽高电流效率运行等方面存在的问题, 旨在为相关研究提供参考.      

Al—10Ce中间合金对ZL102共晶Al—Si合金的变质研究

分析研究了Al—10Ce中间合金对ZL102共晶铝硅合金的变质处理效果。结果表明,Al—10Ce中间合金用量、熔体中的杂质以及冷却速度对变质效果的影响很大,Al-10Ce中间合金用量为0．9％左右时达到最佳变质效果,提高Al—Si的纯度可以获得变质组织,冷却速度超过70℃／min时才具有明显的变质效果。     

Effects of microstructure on the erosion

The effects of microstructure on the erosion of Al-Si alloys by 40 μm Al₂O₃ particles were investigated. The impact angle dependence of the erosion rate of Al and the Al-Si alloys exhibited the ductile signature, whereas that for pure Si showed the brittle signature. The eroded surface of pure Al was characterized by craters, lips, overlaps and folds, and platelets; that for pure Si exhibited complex radial and lateral cracking at the impact site. At shallow impact angles these features were elongated in the direction of the tangential component of the velocity in both materials. The measured erosion rates of the Al-Si alloys were found to be in accord with an inverse rule of mixtures based on pure Al and pure Si; better agreement was, however, obtained if pure Al and the eutectic were taken as the two constituents for the hypoeutectic alloys, and pure Si and the eutectic for the hypereutectic alloys. The microstructure size had two effects: (a) scaling with respect to the impact damage zone size and (b) an influence on the physical and mechanical properties which govern material removal. The present results are considered in terms of current models for the erosion of ductile and brittle materials. Formerly with the Department of Materials Engineering, Formerly with the Department of Materials Engineering,     

Wetting behaviour in the Al-Si/SiC system: interface reactions and solubility effects

The sessile drop technique was used to study the wetting behaviour of Al-Si alloys on SiC sintered ceramic substrates under vacuum in the 700–1100°C temperature interval. Al-Si alloys with Si concentrations up to 50% were tested. An expected non-wetting/wetting transition was observed at 900–1000°C due to the presence of an alumina film surrounding the molten alloy. At higher temperatures wetting was observed and the Si concentration of the alloy has a marked effect on the measured contact angles, θ. At 1100°C θ decreases from 55° to 25° when instead of pure al and A112.3%Si or an A116.6%Si alloy is used. The suppression of the formation of a continuous Al₄C₃ layer at the interface and a process of dissolution and reconstruction of the SiC surface, due to the increased Si concentration of the Al-Si alloys, are the key factors to explain the observed behaviour.