CuFe合金微观组织中的枝晶生长

研究了含铁20%、30%和40%的Cu-Fe包晶合金微观组织中的富Fe枝晶生长行为.结果表明,过冷液相的传热能力影响微观组织中枝晶的分布.当传热能力较强时,枝晶的分布较为均匀,枝晶的大小差别较小;反之,则枝晶分布不匀,且尺寸差别较大.对于溶质含量较低的合金,微观组织中枝晶分布的随机性与浓度起伏的不确定性有关.在溶质富集微区的过冷液相中容易产生枝晶晶核.随着溶质Fe含量的增加,单位面积上富Fe枝晶所占的比例、枝晶分枝的层次、枝晶分枝长度和密度都明显增加,而分枝的直径增加较少.溶质富集主要影响枝晶的侧向生长,而枝晶尖端的生长受溶质富集的影响较小.     

镁合金半固态浆料制备中非枝晶生长的相场法研究

采用相场法对镁合金自孕育半固态浆料制备中非枝晶生长过程进行模拟,研究了空间步长对非枝晶生长行为的影响。结果表明:镁合金多晶粒共同竞争生长时,晶粒形貌由晶体结构特征和生长空间共同决定。晶粒在具有较大生长空间的优先生长方向上,固液界面前沿溶质富集程度低,保持生长优势,形成主枝;晶粒在具有较小生长空间的优先生长方向上,固液界面前沿溶质富集严重,尖端变秃,形成非枝晶形貌。随着空间步长的增加,晶粒合并生长趋势减弱,固液界面前沿溶质富集和溶质偏析程度降低。     

温度和溶质分布对枝晶竞争生长的影响

实时观测了丁二腈-5%乙醇模型合金在定向凝固过程中枝晶的生长过程,研究了温度和溶质分布对枝晶生长形貌的影响.结果表明,两相互竞争生长的枝晶所夹击的枝晶界面上的溶质浓度由于两边枝晶生长时溶质的排泄而不断增大,溶质偏析越来越严重,最终在所夹击的枝晶上形成缩颈;多个枝晶竞争生长时,被夹在中间的枝晶,由于其他枝晶生长过程中凝固潜热的释放,夹击区域温度较高而形成一个成分过冷,使得被夹击的枝晶生长速度较小而出现缩颈.理论分析认为,提高固液界面的液体流动速度,加大温度和溶质浓度分布的不均匀,导致颈缩加剧,这与试验结果吻合.     

一种Ni-Fe-Cr基合金的凝固特征和偏析行为研究

采用定向凝固技术结合液淬法研究了一种Ni-Fe-Cr基合金平界面和枝晶生长条件下的凝固特征和溶质偏析行为。结果表明,合金的组成相为γ基体、MC型碳化物和γˊ沉淀强化相,凝固顺序为L→L+γ→L+γ+MC→γ+γˊ+MC。平界面生长条件下淬火界面两侧溶质含量测定结果表明, Ti、Nb和Mo元素富集于液相,溶质分配系数小于1。Fe元素富集于固相,溶质分配系数大于1。Al和Cr元素在液固两相中浓度差别较小,溶质分配系数接近1。此外,固/液界面前沿存在溶质边界层,边界层内溶质原子通过扩散传输,边界层外主要借助流动传输。枝晶与平界面生长的溶质偏析行为基本一致,然而,枝晶生长时糊状区残余液相中溶质浓度与平界面生长时固/液界面前沿溶质浓度存在显著差别。枝晶生长条件下糊状区溶质偏析程度显著高于稳态生长区,固相反扩散和MC型碳化物的析出显著降低枝晶偏析程度。     

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-Mn三元合金等温凝固过程枝晶生长的相场法模拟

采用相场方法模拟了Fe-1.0%C-0.1%Mn三元合金等温凝固过程二维枝晶生长,预测了溶质浓度分布以及Mn元素对枝晶形貌的影响.结果表明:Mn和C浓度分布相似,枝晶主干溶质浓度最低,而在二次枝晶臂之间形成了溶质富集浓度最高.与Fe-1.0%C合金比较,Fe-1.0%C-0.1%Mn合金由于Mn元素的添加抑制了侧向分枝的生长,使二次枝晶不发达.     

Fe-C合金等温凝固过程的相场法模拟

基于KKS模型,采用耦合相场和溶质场的方法,对Fe-0．5mol％C合金凝固过程中的枝晶生长进行了模拟,并研究了过冷度、各向异性强度和扰动强度对枝晶生长形貌的影响。结果表明：随着过冷度的减小,枝晶主干细化,各向异性程度增大,晶粒生长速度减小,溶质扩散层厚度增加,枝晶的最高溶质浓度降低,溶质梯度减小;随着各向异性的增加,晶粒由海藻状转变为枝晶态,枝晶生长速度也随之增大;扰动强度引发了侧向分枝,侧枝间互相竞争生长,根部出现“颈缩”现象,但扰动强度的加入并不改变枝晶尖端的稳态行为。     

基于元胞自动机法的等轴枝晶生长数值模拟

基于溶质扩散和界面能的作用,考虑成分过冷、曲率过冷、界面能各向异性和界面扰动等因素,建立了单个等轴枝晶的生长模型.采用元胞自动机(cellular automata)方法模拟了枝晶生长、界面扰动和分枝的竞争演化.对液相中的溶质传输进行了计算.通过模拟发现,凝同过程中溶质容易富集在枝晶臂之间,同时,随着凝固时间的延长,界面前沿的溶质浓度梯度逐渐下降.     

Fe-C合金等温凝固过程枝晶形貌的相场法模拟

基于KKS模型,采用相场和溶质场耦合的方法,对Fe-0.5%C(摩尔分数)合金凝固过程枝晶的生长进行了数值模拟,研究了晶粒的长大过程及各向异性强度和扰动等对枝晶形貌的影响.结果表明:晶体生长初期,晶粒形貌为球状,随着时间的推移,晶粒形貌由球状经星形向枝晶形转变,最后形成复杂的树枝晶;随着各向异性的增大,晶粒形貌由球形逐渐向四边形转变,最后形成树枝形;各向异性使晶粒形貌以枝晶方式生长,扰动是引发枝晶的侧向分支的主要原因.     

噪声对NiCu合金凝固过程中枝晶生长影响的数值模拟

利用相场模型与溶质场进行耦合计算,模拟了二元Ni-Cu合金等温凝固的枝晶生长过程,研究了扰动对枝晶生长及溶质场和相场分布的影响。结果表明:当扰动大小取值适当时,热噪声的引入能引发侧向分枝,但不改变枝晶尖端的稳态行为;扰动可促进二次晶臂生长,加扰动后初生枝晶要长一些,即生长速度要快,枝晶形貌也更加复杂;随着扰动幅值的增大,枝晶尖端分叉程度增大;在枝晶生长过程中,枝晶尖端的浓度梯度最大,另外在被二次晶臂包围的界面区域,溶质浓度最高。     

The effects of the distribution aspect of precipitate on the corrosion behavior of as-cast magnesium alloys

In the present study, the corrosion behavior of AZ91D as-cast alloy was investigated form the viewpoint of the distribution aspect of precipitate (Mg₁₇Al₁₂) and the variation of Al concentration in the Mg-rich matrix. The dendrite arm spacing (DAS) of an as-cast specimen was measured as a function of degree which describes the distribution aspect of the precipitate, and the salt spray test was conducted for various grain-sized specimens for 20 days. The dendrite arm spacing increased as the grain size increased to about 150 μm, but a constant value is indicated when the grain size exceeds that range. Although the relationship between the corrosion rate and grain size is of a nonlinear type, the linear trend between the corrosion rate and the dendrite arm spacing is maintained for the overall range of dendrite arm spacing. Since the precipitate in the as-cast alloy is discontinuously distributed, this linear relationship means that the variation of Al-solute concentration in the Mg-rich matrix has a more potent effect than the protective action of the precipitate on the corrosion behavior of an as-cast alloy.     

Effect of sample diameter on primary dendrite spacing of directionally solidified Al-4%Cu alloy

The relationship between primary dendrite arm spacing and sample diameter was studied during directional solidification for Al-4%Cu (mass fraction) alloy. It is shown that primary dendrite spacing is decreased with the decrease of the sample diameter at given growth rate. By regressing the relationship between primary dendrite arm spacing and the growth rate, the primary dendrite arm spacing complies with 461.76v-0.53, 417.92v-0.28 and 415.83v-0.25 for the sample diameter of 1.8, 3.5 and 7.2 mm, respectively. The primary dendrite spacing, growth rate and thermal gradient for different sample diameters comply with 28.77v-0.35G-0.70, 23.17v-0.35G-0.70 and 23.84v-0.35G-0.70, respectively. They are all consistent with the theoretical model , and b1/a1=2. By analyzing the experimental results with classical models, it is shown that KURZ-FISHER model fits for the primary dendrite spacing in smaller sample diameters with weaker thermosolute convection. Whereas TRIVEDI model is suitable for describing primary dendrite arm spacing with a larger diameter (d＞2 mm) where convection should be considered.     

Numerical simulation of dendrite growth in Ni-based superalloy casting during directional solidification process

An understanding of dendrite growth is required in order to improve the properties of castings. For this reason, cellular automaton?finite difference (CA?FD) method was used to investigate the dendrite growth during directional solidification (DS) process. The solute diffusion model combined with macro temperature field model was established for predicting the dendrite growth behavior. Model validation was performed by the DS experiment, and the cooling curves and grain structures obtained by the experiment presented a reasonable agreement with the simulation results. The competitive growth of dendrites was also simulated by the proposed model, and the competitive behavior of dendrites with different misalignment angles was also discussed in detail. Subsequently, 3D dendrites growth was also investigated by experiment and simulation, and both were in good accordance. The influence on dendrites growth of initial nucleus was investigated by three simulation cases, and the results showed that the initial nuclei just had an effect on the initial growth stage of columnar dendrites, but had little influence on the final dendritic morphology and the primary dendrite arm spacing.     

连续冷却和搅拌条件下树枝晶向粒状晶转变时间的估算

介绍了连续冷却和搅拌条件下树枝晶向粒状晶转变的填充间隙(FAS)和颈缩熔断(NMAR)两种机制, 并通过理论推导得到了可以用来计算其转变时间的数学公式. 两种机制下的转变时间计算结果与实验结果吻合较好.     

A high thermal gradient directional solidification method for growing superalloy single crystals

The experiments here were conducted at withdrawal rates of 3 mm/min and 1 mm/min using a CMSX-6 and a CMSX-4 superalloy, respectively. The process was assessed in terms of the thermal gradient (G_L), structural refinement, microsegregation and porosity distribution, and compared to those using a Bridgman process. The G_L of the process was 200–236 K/cm, which was 10–12 times higher than that in the Bridgman process. A more refined microstructure was produced having average primary and secondary dendrite arm spacing values as low as 243 μm and 72 μm, as well as 272 μm and 76 μm in the CMSX-6 and the CMSX-4 castings, respectively. The diameter of γ′ phase in the dendrite core of CMSX-6 and CMSX-4 castings was reduced from 0.8 μm to 0.3 μm and from 1.2 μm to 0.6 μm, respectively. The average areas of (γ′ + γ) eutectic pools became smaller and more homogeneously distributed. The mean pore sizes in the castings were reduced by 57% and 43% for the CMSX-6 and CMSX-4 superalloys, respectively, and the area fractions of the pores in the CMSX-6 and CMSX-4 samples were 16% and 12% of those produced in the Bridgman samples. The segregation coefficients of the major alloying elements were closer to unity than those in the Bridgman process, which indicates that the composition distribution is more uniform.     

Effect of sample diameter on primary and secondary dendrite arm spacings during directional solidification of Pb-26wt.%Bi hypo-peritectic alloy

The microstructure scales of dendrites,such as primary and secondary dendrite arm spacings,control the segregation profiles and the formation of secondary phases within interdendritic regions,which determine the properties of solidified structures.Investigations on primary and secondary dendrite arm spacings of primary α-phase during directionally solidified Pb-26wt%Bi hypo-peritectic alloy were carried out in this research,and systematic studies were conducted using cylindrical samples with different diameters(Φ = 1.8 and 7.0 mm) in order to analyze the effects of sample diameter on the primary and secondary dendrite arm spacings.In this work,the dependence of dendrite arm spacings on growth velocity was established.In addition,the experimental data concerning the primary and secondary dendrite arm spacings were compared with the main predictive dendritic models from the literatures.A comparison between experimental results for dendrite arm spacings of the 1.8-mm-diameter sample and 7.0-mm-diameter sample was also conducted.     

Multi-scale coupling simulation in directional solidification of superalloy based on cellular automaton-finite difference method

Casting microstructure evolution is difficult to describe quantitatively by only a separate simulation of dendrite scale or grain scale, and the numerical simulation of these two scales is difficult to render compatible. A three-dimensional cellular automaton model couplling both dendritic scale and grain scale is developed to simulate the microstructure evolution of the nickel-based single crystal superalloy DD406. Besides, a macro–mesoscopic/microscopic coupling solution algorithm is proposed to improve computational efficiency. The simulation results of dendrite growth and grain growth of the alloy are obtained and compared with the results given in previous reports. The results show that the primary dendritic arm spacing and secondary dendritic arm spacing of the dendritic growth are consistent with the theoretical and experimental results. The mesoscopic grain simulation can be used to obtain results similar to those of microscopic dendrites simulation. It is indicated that the developed model is feasible and effective.     

过共晶球墨铸铁中石墨球周围奥氏体壳的形成机制

有用着色腐蚀技术，可清晰地显示出过共晶球墨铸铁中的高温凝固组织，观察分析了石墨球周围奥氏体壳（奥氏体壳是奥氏体枝晶的一部分）的形成机制。结果表明，初生枝晶和晕圈枝晶交替生长，促成石墨球周围奥氏体壳的形成；奥氏体以石墨生长面（0001）为衬底形核、生长，在初生石墨球周围形成环状封闭奥氏体壳；共晶前期石墨球在枝晶臂间或框架中形核、生长、尔后为枝晶高次臂所包围，形成封闭或不封闭的框架奥氏体壳。共晶后期石墨球不形成奥氏体壳。     

抽拉速率对螺旋选晶器选晶行为和晶体取向演变的影响

采用宏观-微观耦合的元胞自动机（CAFE）方法,研究了不同抽拉速率对螺旋选晶器的选晶行为和晶体取向演变的影响,并通过实验对仿真结果进行了验证。结果表明：在相同的抽拉速率下,随着与激冷面距离的增大,枝晶数目逐渐减少,一次枝晶臂间距逐渐增大。随着抽拉速度由2 mm/min增加到8 mm/min,一次枝晶臂间距逐渐减小,枝晶茎数增加,枝晶间距逐渐减小,枝晶组织逐渐细化。在模拟过程中,在螺旋选择器启动块的3种抽拉速率下,固态组织的数量、面积和颜色都是相似的;在螺旋部分,在5 mm/min提取速率下晶体的微结构数量比其他2个提取速率下的少,并且面积更大,颜色更浅。从选晶器的晶粒组织演变和金相组织分析结果可以得出,中等抽拉速率（5 mm/min）下选晶器的选晶效率优于其他2种抽拉速率。