铜及铜合金管坯水平电磁连续铸造技术研究
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摘要
近年来随着工业及国民经济的迅速发展,对铜及铜合金管材的需求数量日益增多,并对其质量和生产效率也提出了越来越高的要求。管坯连续铸造技术被认为是管材生产更深层次的近终形制备技术,具有生产效率高以及金属利用率高等众多优势。但目前采用水平连续铸造技术所生产的管坯存在凝固组织粗大且周向分布不均匀、表面质量差等缺陷。因此,如何生产出优质的铜及铜合金管坯,使其能够满足后续加工要求,是提高生产效率、获得高质量管材的技术关键。电磁场在材料加工领域的大量研究及应用为制备高质量的铜及铜合金管坯提供了契机。
本文以制备高质量铜及铜合金管坯为目的,研究了紫铜和BFe10-1-1白铜管坯水平电磁连续铸造技术,论文主要包括以下内容:
采用ANSYS软件计算了Φ90×25 mm紫铜管坯水平电磁连续铸造过程中,结晶器压板和法兰材料对电磁发生器作用效果和磁感应强度分布的影响。并将ANSYS和FLUENT软件相结合,计算了在紫铜管坯水平连续铸造过程中,电磁场对紫铜管坯凝固过程,包括速度场、温度场、液相率分布的影响;以及电流强度和铸造速度对电磁场作用下紫铜管坯凝固过程的影响。结果表明,结晶器压板和法兰材料对电磁发生器作用效果有着强烈的影响。当压板和法兰均为强导磁材料时,电磁场的作用效果几乎被屏蔽;当压板和法兰均为弱导磁材料时,对电磁发生器的作用效果几乎没有影响,并且法兰对电磁发生器作用效果的影响要强于压板。电磁场显著的改变了管坯内金属液的流动方式,使其在管坯横截面产生旋转运动,当电流频率为50 Hz,电流强度为50 A,铸造温度为1150℃,铸造速度为250 mm/min时,最大切向速度可达到0.233 m/s;并且金属液在管坯纵截面形成环流。电磁场强烈的均匀了管坯内部金属液的温度场,使温度梯度由748 K/m降低到196 K/m,使液穴深度由48.8 mm降至29.0 mm,并显著的扩大了固液两相共存区。随着电流强度的增加,管坯横截面金属液的切向速度显著提高,液穴内温度场和液相率分布变均匀。温度梯度和液相率梯度极大的降低,固液两相共存区明显增大,液穴深度显著变浅。随着铸造速度的增加,管坯横截面金属液的切向速度略有增加,温度梯度和液相率梯度降低较小。固液两相共存区略有扩大,液穴深度略微变浅。
采用Sn-3.5%Pb做为模拟合金,研究了在管坯外结晶器施加旋转磁场时,电磁场对管坯内金属液运动行为以及凝固过程的影响,结果表明,电磁场均匀了管坯内金属液的温度场,降低了温度梯度;电磁场也降低了管坯内金属熔体的液穴深度,均匀了液穴的形状,与数值模拟结果一致。
将紫铜管坯水平电磁连续铸造技术应用到工业生产中,突破了结晶器结构,磁场发生器设计、安装等难题。进行了Φ90×25 mm紫铜管坯水平电磁连续铸造在线实验,系统研究了磁感应强度、磁场施加模式对紫铜管坯凝固组织及性能的影响,并探索了铸造速度、铸造温度、冷却水强度对电磁场作用效果的影响,结果表明,随着磁感应强度的增加,管坯的凝固组织不断细化,但当电流强度高于50 A时,由感应电流产生的Joule热过大,凝固组织开始变粗;间歇磁场与连续磁场对管坯凝固细化效果相同。提高铸造速度有利于电磁场对管坯凝固组织的细化作用;降低铸造温度,增大冷却强度不利于电磁场对凝固组织的细化作用。当电流频率为50Hz,电流强度为50A,铸造温度为1150℃,铸造速度为250 mm/min,冷却水量为1 m~3/h时,管坯的凝固组织细化效果相对较好,等轴晶比例达到98%以上,消除了水平连续铸造紫铜管坯凝固组织的各向异性,平均抗拉强度提高了15.9%,平均延伸率提高了63.8%。紫铜管坯的密度由8.9123 g/cm~3提高到8.9372 g/cm~3,并延长了石墨模具的使用寿命。同时降低了制备冷凝管时的平均伤点数。
对BFe10-1-1白铜管坯水平连续铸造中常见的铸造缺陷进行了研究,在此基础上对电磁连续铸造工艺参数进行优化,从而开发出了Φ83×21 mm BFe10-1-1白铜管坯水平电磁连续铸造新工艺。并系统研究了电磁场作用下管坯宏观、微观凝固组织的演变规律;电磁场对管坯表面质量、溶质元素分布、富Ni相的偏聚状态及生长形貌、力学性能的影响,结果表明,电磁场使BFe10-1-1白铜管坯宏观凝固组织显著细化,微观凝固组织呈现一定的变化规律。并有效抑制了Ni、Fe、Mn元素的偏析,改变了富Ni相的分布。当电流频率为50 Hz,电流强度为120 A,铸造温度为1230℃,铸造速度为350 mm/min,冷却水量为1.8 m~3/h时,管坯的凝固组织最佳,平均晶粒尺寸达到0.56 mm,消除了管坯凝固组织的各向异性,管坯的抗拉强度提高了20.3%,延伸率提高了65.7%,为最佳工艺参数。
In recent years, with the development of industry and national economy, the needs of high quality copper and copper alloy tubes and the requirements for the high production efficiency increase quickly. Continuous casting of hollow billets is considered as a profound near-net forming technology with the advantage of high production efficiency and high utilization ratio. But there are many problems for the hollow billets such as poor surface quality, too many casting defects, and coarse grains in solidification structure and poor uniformity of structure in the circumferential direction. How to produce high quality copper and copper alloy hollow billets to satisfy the requirements of succeeding treatment is the key to acquire the high quality tubes. The successful application of electromagnetic field in materials processing provides a chance for producing high quality copper and copper alloy hollow billets.
The purpose of the dissertation is to produce high quality copper and copper alloy hollow billets. The technology of horizontal electromagnetic continuous casting of copper and BFe10-1-1 copper alloy hollow billets is studied. The main contents are as follows:
ANSYS software is used to compute the influence of the materials of press plate and flange on the active effect of the electromagnetic generator and the distribution of magnetic flux density during horizontal electromagnetic continuous casting ofΦ90×25 mm copper hollow billets. The softwares ANSYS and FLUENT are coupled to simulate the effect of electromagnetic field on the solidification process of copper hollow billets, including velocity field, temperature field and liquid fraction, and the effect of current intensity and casting speed on the solidification process of copper hollow billets with electromagnetic field. The results show that the materials of press plate and flange have great influence on the active effect of the electromagnetic generator. When the materials of press plate and flange are strong permeablility magnetic materials, the active effect of the electromagnetic generator is almost weakened completely. When the materials of press plate and flange are weak permeablility magnetic materials, the active effect of the electromagnetic generator is not nearly weakened. The flange has much greater influence than the press plate on the active effect of the electromagnetic generator. The electromagnetic field obviously changes the flow pattern of the melt in hollow billet. The melt circumrotates in cross section and swirls in longitudinal section of the hollow billet. When the current frequency is 50 Hz, the current intensity is 50 A, the casting temperature is 1150℃, the casting speed is 250 mm/min, the maximum tangential velocity is 0.233 m/s. The electromagnetic field fiercely promotes the temperature field uniform and the temperature gradient is greatly reduced from 748 K/m to 196 K/m. The sump depth decreases from 0.194 m to 0.148 m and the mushy zone enlarges remarkably. When current intensity increases, the tangential velocity increases obviously, the temperature filed and liquid fraction in the sump become even, the temperature and liquid fraction gradient decrease greatly, the mushy zone enlarges obviously and the sump depth becomes significantly shallow. When the casting speed increases, the tangential velocity increases slightly, the temperature and liquid fraction gradient decrease slightly, the mushy zone enlarges slightly and the sump depth becomes slightly shallow.
The Sn-3.5%Pb simulation alloy is used to study the effect of rotating magnetic field outside the graphite mold on the movement behavior and the solidification process of the melt in hollow billet. The result shows that the electromagnetic field reduces the temperature gradient and makes the temperature field uniform. The electromagnetic field reduces the sump depth and makes the shape of sump uniform in the hollow billet. The experimental results are consistent with the simulation results.
The technology of horizontal electromagnetic continuous casting of copper hollow billets is applied to the industrial production. The difficult problems such as the structure of the crystallizer and the design and installation of electromagnetic generator are solved. The experiments of horizontal electromagnetic continuous casting ofΦ90×25 mm copper hollow billets doing in industrial production line study the effects of magnetic flux density and the imposed pattern of electromagnetic field on the solidification structure and mechanical properties of copper hollow billets and investigate the influence of casting speed, cooling intensity and casting temperature on the active effect of the electromagnetic field systematically. The results show that with the increase of magnetic flux density, the solidification structure is refined correspondingly. But when the current intensity is more than 50 A, the solidification structure turns to get coarse because of the Joule heat. The intermittent electromagnetic field has the same effect as the consecutive electromagnetic field on refining the solidification structure. Increasing the casting speed is helpful for electromagnetic field to refine the solidification structure. Reducing the casting temperature and enhancing cooling intensity are harmful for electromagnetic field to refine the solidification structure. When the current frequency is 50 Hz, the current intensity is 50 A, the casting temperature is 1150℃, the casting speed is 250 mm/min, the cooling intensity is 1 m~3/h, the refined solidification structure of copper hollow billet is better than any others. The inhomogeneous columnar grains change into homogeneous equiaxed grains and the ratio of equiaxed grains is more 98 %. The tensile strength is increased by 15.9 % and the elongation is improved by 63.8 % compared to those without electromagnetic field. The density of copper hollow billet increases from 8.9123 g/cm~3 to 8.9372 g/cm~3, the service life of the graphite inner-mold is increased and the injury points of the copper tubes are deduced because of electromagnetic field.
The regular casting defects occuring during horizontal continuous casting of BFe10-1-1 copper alloy hollow billets are studied. The parameters of horizontal electromagnetic continuous casting ofΦ83×21 mm BFe10-1-1 copper alloy hollow billets are optimized to explore new technics. The effect of electromagnetic field on the evolutions of macrostructures and microstructures, the surface quality, solute distribution, the accumulated state and growth morphology of Ni-rich phase, mechanical properties of BFe10-1-1 copper alloy hollow billet is studied systematically. The results show that the macrostructures are greatly refined and the microstructures transform in certain rule by electromagnetic field. The segregations of Ni, Fe and Mn are restrained and the distribution of Ni-rich phase is changed with electromagnetic field. When the current frequency is 50 Hz, the current intensity is 120 A, the casting temperature is 1230℃, the casting speed is 350 mm/min and the cooling intensity is 1.8 m~3/h, the inhomogeneous columnar grains change to homogeneous equiaxed grains which are better than any others and the average grain size reaches to 0.56 mm. The tensile strength is increased by 20.3 % and the elongation is improved by 65.7 % compared to those without electromagnetic field.
本文以制备高质量铜及铜合金管坯为目的,研究了紫铜和BFe10-1-1白铜管坯水平电磁连续铸造技术,论文主要包括以下内容:
采用ANSYS软件计算了Φ90×25 mm紫铜管坯水平电磁连续铸造过程中,结晶器压板和法兰材料对电磁发生器作用效果和磁感应强度分布的影响。并将ANSYS和FLUENT软件相结合,计算了在紫铜管坯水平连续铸造过程中,电磁场对紫铜管坯凝固过程,包括速度场、温度场、液相率分布的影响;以及电流强度和铸造速度对电磁场作用下紫铜管坯凝固过程的影响。结果表明,结晶器压板和法兰材料对电磁发生器作用效果有着强烈的影响。当压板和法兰均为强导磁材料时,电磁场的作用效果几乎被屏蔽;当压板和法兰均为弱导磁材料时,对电磁发生器的作用效果几乎没有影响,并且法兰对电磁发生器作用效果的影响要强于压板。电磁场显著的改变了管坯内金属液的流动方式,使其在管坯横截面产生旋转运动,当电流频率为50 Hz,电流强度为50 A,铸造温度为1150℃,铸造速度为250 mm/min时,最大切向速度可达到0.233 m/s;并且金属液在管坯纵截面形成环流。电磁场强烈的均匀了管坯内部金属液的温度场,使温度梯度由748 K/m降低到196 K/m,使液穴深度由48.8 mm降至29.0 mm,并显著的扩大了固液两相共存区。随着电流强度的增加,管坯横截面金属液的切向速度显著提高,液穴内温度场和液相率分布变均匀。温度梯度和液相率梯度极大的降低,固液两相共存区明显增大,液穴深度显著变浅。随着铸造速度的增加,管坯横截面金属液的切向速度略有增加,温度梯度和液相率梯度降低较小。固液两相共存区略有扩大,液穴深度略微变浅。
采用Sn-3.5%Pb做为模拟合金,研究了在管坯外结晶器施加旋转磁场时,电磁场对管坯内金属液运动行为以及凝固过程的影响,结果表明,电磁场均匀了管坯内金属液的温度场,降低了温度梯度;电磁场也降低了管坯内金属熔体的液穴深度,均匀了液穴的形状,与数值模拟结果一致。
将紫铜管坯水平电磁连续铸造技术应用到工业生产中,突破了结晶器结构,磁场发生器设计、安装等难题。进行了Φ90×25 mm紫铜管坯水平电磁连续铸造在线实验,系统研究了磁感应强度、磁场施加模式对紫铜管坯凝固组织及性能的影响,并探索了铸造速度、铸造温度、冷却水强度对电磁场作用效果的影响,结果表明,随着磁感应强度的增加,管坯的凝固组织不断细化,但当电流强度高于50 A时,由感应电流产生的Joule热过大,凝固组织开始变粗;间歇磁场与连续磁场对管坯凝固细化效果相同。提高铸造速度有利于电磁场对管坯凝固组织的细化作用;降低铸造温度,增大冷却强度不利于电磁场对凝固组织的细化作用。当电流频率为50Hz,电流强度为50A,铸造温度为1150℃,铸造速度为250 mm/min,冷却水量为1 m~3/h时,管坯的凝固组织细化效果相对较好,等轴晶比例达到98%以上,消除了水平连续铸造紫铜管坯凝固组织的各向异性,平均抗拉强度提高了15.9%,平均延伸率提高了63.8%。紫铜管坯的密度由8.9123 g/cm~3提高到8.9372 g/cm~3,并延长了石墨模具的使用寿命。同时降低了制备冷凝管时的平均伤点数。
对BFe10-1-1白铜管坯水平连续铸造中常见的铸造缺陷进行了研究,在此基础上对电磁连续铸造工艺参数进行优化,从而开发出了Φ83×21 mm BFe10-1-1白铜管坯水平电磁连续铸造新工艺。并系统研究了电磁场作用下管坯宏观、微观凝固组织的演变规律;电磁场对管坯表面质量、溶质元素分布、富Ni相的偏聚状态及生长形貌、力学性能的影响,结果表明,电磁场使BFe10-1-1白铜管坯宏观凝固组织显著细化,微观凝固组织呈现一定的变化规律。并有效抑制了Ni、Fe、Mn元素的偏析,改变了富Ni相的分布。当电流频率为50 Hz,电流强度为120 A,铸造温度为1230℃,铸造速度为350 mm/min,冷却水量为1.8 m~3/h时,管坯的凝固组织最佳,平均晶粒尺寸达到0.56 mm,消除了管坯凝固组织的各向异性,管坯的抗拉强度提高了20.3%,延伸率提高了65.7%,为最佳工艺参数。
In recent years, with the development of industry and national economy, the needs of high quality copper and copper alloy tubes and the requirements for the high production efficiency increase quickly. Continuous casting of hollow billets is considered as a profound near-net forming technology with the advantage of high production efficiency and high utilization ratio. But there are many problems for the hollow billets such as poor surface quality, too many casting defects, and coarse grains in solidification structure and poor uniformity of structure in the circumferential direction. How to produce high quality copper and copper alloy hollow billets to satisfy the requirements of succeeding treatment is the key to acquire the high quality tubes. The successful application of electromagnetic field in materials processing provides a chance for producing high quality copper and copper alloy hollow billets.
The purpose of the dissertation is to produce high quality copper and copper alloy hollow billets. The technology of horizontal electromagnetic continuous casting of copper and BFe10-1-1 copper alloy hollow billets is studied. The main contents are as follows:
ANSYS software is used to compute the influence of the materials of press plate and flange on the active effect of the electromagnetic generator and the distribution of magnetic flux density during horizontal electromagnetic continuous casting ofΦ90×25 mm copper hollow billets. The softwares ANSYS and FLUENT are coupled to simulate the effect of electromagnetic field on the solidification process of copper hollow billets, including velocity field, temperature field and liquid fraction, and the effect of current intensity and casting speed on the solidification process of copper hollow billets with electromagnetic field. The results show that the materials of press plate and flange have great influence on the active effect of the electromagnetic generator. When the materials of press plate and flange are strong permeablility magnetic materials, the active effect of the electromagnetic generator is almost weakened completely. When the materials of press plate and flange are weak permeablility magnetic materials, the active effect of the electromagnetic generator is not nearly weakened. The flange has much greater influence than the press plate on the active effect of the electromagnetic generator. The electromagnetic field obviously changes the flow pattern of the melt in hollow billet. The melt circumrotates in cross section and swirls in longitudinal section of the hollow billet. When the current frequency is 50 Hz, the current intensity is 50 A, the casting temperature is 1150℃, the casting speed is 250 mm/min, the maximum tangential velocity is 0.233 m/s. The electromagnetic field fiercely promotes the temperature field uniform and the temperature gradient is greatly reduced from 748 K/m to 196 K/m. The sump depth decreases from 0.194 m to 0.148 m and the mushy zone enlarges remarkably. When current intensity increases, the tangential velocity increases obviously, the temperature filed and liquid fraction in the sump become even, the temperature and liquid fraction gradient decrease greatly, the mushy zone enlarges obviously and the sump depth becomes significantly shallow. When the casting speed increases, the tangential velocity increases slightly, the temperature and liquid fraction gradient decrease slightly, the mushy zone enlarges slightly and the sump depth becomes slightly shallow.
The Sn-3.5%Pb simulation alloy is used to study the effect of rotating magnetic field outside the graphite mold on the movement behavior and the solidification process of the melt in hollow billet. The result shows that the electromagnetic field reduces the temperature gradient and makes the temperature field uniform. The electromagnetic field reduces the sump depth and makes the shape of sump uniform in the hollow billet. The experimental results are consistent with the simulation results.
The technology of horizontal electromagnetic continuous casting of copper hollow billets is applied to the industrial production. The difficult problems such as the structure of the crystallizer and the design and installation of electromagnetic generator are solved. The experiments of horizontal electromagnetic continuous casting ofΦ90×25 mm copper hollow billets doing in industrial production line study the effects of magnetic flux density and the imposed pattern of electromagnetic field on the solidification structure and mechanical properties of copper hollow billets and investigate the influence of casting speed, cooling intensity and casting temperature on the active effect of the electromagnetic field systematically. The results show that with the increase of magnetic flux density, the solidification structure is refined correspondingly. But when the current intensity is more than 50 A, the solidification structure turns to get coarse because of the Joule heat. The intermittent electromagnetic field has the same effect as the consecutive electromagnetic field on refining the solidification structure. Increasing the casting speed is helpful for electromagnetic field to refine the solidification structure. Reducing the casting temperature and enhancing cooling intensity are harmful for electromagnetic field to refine the solidification structure. When the current frequency is 50 Hz, the current intensity is 50 A, the casting temperature is 1150℃, the casting speed is 250 mm/min, the cooling intensity is 1 m~3/h, the refined solidification structure of copper hollow billet is better than any others. The inhomogeneous columnar grains change into homogeneous equiaxed grains and the ratio of equiaxed grains is more 98 %. The tensile strength is increased by 15.9 % and the elongation is improved by 63.8 % compared to those without electromagnetic field. The density of copper hollow billet increases from 8.9123 g/cm~3 to 8.9372 g/cm~3, the service life of the graphite inner-mold is increased and the injury points of the copper tubes are deduced because of electromagnetic field.
The regular casting defects occuring during horizontal continuous casting of BFe10-1-1 copper alloy hollow billets are studied. The parameters of horizontal electromagnetic continuous casting ofΦ83×21 mm BFe10-1-1 copper alloy hollow billets are optimized to explore new technics. The effect of electromagnetic field on the evolutions of macrostructures and microstructures, the surface quality, solute distribution, the accumulated state and growth morphology of Ni-rich phase, mechanical properties of BFe10-1-1 copper alloy hollow billet is studied systematically. The results show that the macrostructures are greatly refined and the microstructures transform in certain rule by electromagnetic field. The segregations of Ni, Fe and Mn are restrained and the distribution of Ni-rich phase is changed with electromagnetic field. When the current frequency is 50 Hz, the current intensity is 120 A, the casting temperature is 1230℃, the casting speed is 350 mm/min and the cooling intensity is 1.8 m~3/h, the inhomogeneous columnar grains change to homogeneous equiaxed grains which are better than any others and the average grain size reaches to 0.56 mm. The tensile strength is increased by 20.3 % and the elongation is improved by 65.7 % compared to those without electromagnetic field.
引文
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