电磁搅拌制备半固态大过共晶铝硅合金的研究
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摘要
本文针对目前Al-Si合金相关应用和理论研究多集中于亚共晶和共晶合金的现实，在前人的基础成果和研究方法的基础上，对大过共晶Al-Si合金电磁搅拌进行了系统分析，深入研究了搅拌功率、等温时间、冷却速度等影响半固态加工效果的因素对大过共晶铝硅合金中初生硅和共晶硅的大小、形状和分布的影响，揭示了大过共晶铝硅合金的成分、组织、性能之间的内在关系，为研制新型的大过共晶铝硅合金提供理论依据和工业应用方向。
研究结果表明：剧烈的搅拌使得初生相在长大过程中，不断发生着枝晶臂的弯曲融合、熔断和机械断裂，从而使晶体以等轴生长及合并生长的方式向球形形态发展长大。较高的搅拌强度可以有效地减小初晶硅的尺寸，并使之边角钝化和均匀化。同时，随着电磁搅拌强度的增加，初生相球化且初生硅相尺寸减小。过高的冷却速率不利于初生相球化，但高强的电磁搅拌有利于球化和均化初生晶粒。对于Al-25％Si％材料，经过复合处理试棒比同种成分的金属型试棒的室温σ_b提高20～30％；延伸率δ提高2.8～4.5％，在相同的磨损条件下半固态铸造试样磨耗比金属型试样降低21％。
本文的特色之处在于通过电磁搅拌对高含Si量的大过共晶铝硅合金进行了全面系统的研究。在国内属于开创性研究，研究成果将应用于结构材料、高耐磨材料等生产领域，对材料工业、汽车和摩托车从业的发展具有重大的经济意义和推动作用。
The current theory and application of Al-Si alloy mainly focus on the research of eutectic and hypereutectic, therefore we systematically analyzed the preparation of hypereutectic Al-Si alloy with
electromagnetic stirring based on the methods and results of predecessors.
A electromagnetic stirring apparatus is designed to produce hypereutectic Al-20%~30%Si alloy billet with tiny primary phase by semi-solid process. Around the main electromagnetic stirring technology parameters of agitation strength, stirring rate and cooling rate, series of trials are designed to find the influence of technology parameters on the size, shape and distribution of primary Si and eutectic Si, and discover the correlation between technology parameters and semi-solid microstructure providing evidences for theory and showing the direction for industry development.
The experiments results show that, during solidification, the early growth of the primary crystals of Al-Si alloy slurry continues dendritially. With further vigorous agitation, the dendrite arms gradually bend and merge. Meanwhile, the dendrite arms are melted and/or ruptured into numerous small crystals at the root of arms. As the continuous growth, the primary
crystals evolve toward more spherical. As the increasing of electromagnetic
stirring strength, primary phase is spherer and the size of primary silicon
decreases. The experiments show that too high cooling rate disadvantages the formation of spherical primary crystals, while higher electromagnetic stirring strength is necessary to spheroidize and homogenize the primary crystals. For Al-25%Si alloy, the tensile strength of semi-solid metal(SSM) sample is higher 20~30% than that of metal mold sample. Elongance 8 of
SSM sample is higher 2.8~4.5% than that of metal mold sample. At the same
condition of attrition wear and tear, SSM sample wear and tear is reduced 21% than that of metal mold sample.
The characteristic of this essay is that we systematically analyzed the preparation of hypereutectic Al-Si alloy with electromagnetic stirring. The results will be applied to fields as structure material with high abrasive wear and tear, which will boost the economics and its development.
研究结果表明：剧烈的搅拌使得初生相在长大过程中，不断发生着枝晶臂的弯曲融合、熔断和机械断裂，从而使晶体以等轴生长及合并生长的方式向球形形态发展长大。较高的搅拌强度可以有效地减小初晶硅的尺寸，并使之边角钝化和均匀化。同时，随着电磁搅拌强度的增加，初生相球化且初生硅相尺寸减小。过高的冷却速率不利于初生相球化，但高强的电磁搅拌有利于球化和均化初生晶粒。对于Al-25％Si％材料，经过复合处理试棒比同种成分的金属型试棒的室温σ_b提高20～30％；延伸率δ提高2.8～4.5％，在相同的磨损条件下半固态铸造试样磨耗比金属型试样降低21％。
本文的特色之处在于通过电磁搅拌对高含Si量的大过共晶铝硅合金进行了全面系统的研究。在国内属于开创性研究，研究成果将应用于结构材料、高耐磨材料等生产领域，对材料工业、汽车和摩托车从业的发展具有重大的经济意义和推动作用。
The current theory and application of Al-Si alloy mainly focus on the research of eutectic and hypereutectic, therefore we systematically analyzed the preparation of hypereutectic Al-Si alloy with
electromagnetic stirring based on the methods and results of predecessors.
A electromagnetic stirring apparatus is designed to produce hypereutectic Al-20%~30%Si alloy billet with tiny primary phase by semi-solid process. Around the main electromagnetic stirring technology parameters of agitation strength, stirring rate and cooling rate, series of trials are designed to find the influence of technology parameters on the size, shape and distribution of primary Si and eutectic Si, and discover the correlation between technology parameters and semi-solid microstructure providing evidences for theory and showing the direction for industry development.
The experiments results show that, during solidification, the early growth of the primary crystals of Al-Si alloy slurry continues dendritially. With further vigorous agitation, the dendrite arms gradually bend and merge. Meanwhile, the dendrite arms are melted and/or ruptured into numerous small crystals at the root of arms. As the continuous growth, the primary
crystals evolve toward more spherical. As the increasing of electromagnetic
stirring strength, primary phase is spherer and the size of primary silicon
decreases. The experiments show that too high cooling rate disadvantages the formation of spherical primary crystals, while higher electromagnetic stirring strength is necessary to spheroidize and homogenize the primary crystals. For Al-25%Si alloy, the tensile strength of semi-solid metal(SSM) sample is higher 20~30% than that of metal mold sample. Elongance 8 of
SSM sample is higher 2.8~4.5% than that of metal mold sample. At the same
condition of attrition wear and tear, SSM sample wear and tear is reduced 21% than that of metal mold sample.
The characteristic of this essay is that we systematically analyzed the preparation of hypereutectic Al-Si alloy with electromagnetic stirring. The results will be applied to fields as structure material with high abrasive wear and tear, which will boost the economics and its development.
引文
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[2] Alexander A．Kazakov著．郝风昌，管仁国译．适于半固态加工的合金成分．国外金属加工，2001(1)：1～5
[3] Moschim R., Manufacture of Automotive Components by Semiliguid Forming Processing of Semi-solid Alloys and Compsites, 2nd International Couference on the Semi-solid Processing of Alloys and Composites. M.I.T.Cambridge Massachusetts USA. June, 10～12, 1992, Warrendales, Pennsylvais, 10～12, 1992, USA. The Minerals,Metals and Materials Society(TMS). 1993, 149～158
[4] Lu Shuzu. et al.Metallurgical Transactions. 1987, 18A: 1721～1733
[5] Shibata R, Kanuechi T, Soda T, New semi-liquid metal casting process, the 4th Int Conf on SSP of Alloys and Compositions, England, 1996,296～300
[6] 洪慎章．半固态模锻的应用及发展．模具技术，1999，1：60～65
[7] R.Moshini Manufacture of Automotive Components by Semi-solid Forming Process. The Second ICCSSPAC Transcation,June 10-12, 1992, 149～158
[8] 谢水生，黄声宏．半固态金属加工技术及其应用．北京：冶金工业出版社，1999
[9] 郭钧，谢水生，半固态铝合金的制备工艺研究，稀有金属，1998，22(6)，424～428
[10] 蒋鹏．半固态成形工艺在汽车工业中的应用，汽车工业与材料，1998，3：1～3
[11] 刘国钧等．几种车用铝合金的半固态成形工艺研究．特种铸造及有色合金，2001(1)：7～9
[12] 毛卫民，赵爱民，电磁搅拌对半固态AlSi7 Mg合金初生α-Al的影响规律．金属学报，1999，35(9)，971～974
[13] 毛卫民等．Alsi_7 Mg合金半固态连铸坯料和组织形成研究．金属学报，2000(5)：539～544
[14] 邢书明，胡汉起．半固态亚共晶铝硅合金非枝晶固相的形成与演变，中国有色金属学报，1999，9(1)，270-274
[15] Merton C. Flemings. Behaverior of Metal Alloys in the Semisolid State,Metallurgical Transaction, A. 1993, 22 (5): 957-960
[16] Detering K.et al. Semisolid processing of thixotropic aluminium alloys. Aluminium, 1996, (7～8): 514
[17] 罗守靖，田文彤等．半固态加工技术及应用．中国有色金属学报，2000，12(6)：765～773．
[18] 李亚敏等．半固态连铸技术研究现状与展望．热加工工艺，2000，4：46～48
[19] 徐佩山等．国外半固态合金及复合材料成形技术发展概述．江苏冶金，1995，4：59～61
[20] 吴炳尧．半固态金属铸造工艺的研究现状及发展前景．铸造，1999(3)：45～51
[21] 蒋鹏，贺小毛，张秀峰．半固态金属成形技术的研究概况．塑性工程学报，1998，5(3)：1
[22] Kirkwood D H. The numerical modeling of heating, melting and slurry flow for semi-solid processing of alloys Proc of the 5th Int Conf on SSP of Alloys and Compositions, Colordo, 1998,33-40.
[23] Lu Shuzu. et al.Journal of Crystal Growth., 1985, 73: 316～328
[24] Flemings M C. The 3rd Int. Conf. on Semi-solid Processing of Alloy and Composites, 1994.6
[25] 刘丹，崔建忠．金属半固态加工．轻合金加工技术，1999，27(2)：8～12
[26] 罗守靖，杜之明．半固态金属加工(SSP)分类及新发展．热加工工艺，1999(5)：46～49
[27] Molenaar J M, Katgaerman L, Kool W H. J. Mater. Sci. 1986, Vol.21: 389
[28] Lehuy H,Masouave J,Blain J. Rheological behavior and microstructure of stir-casting Zn-Al alloy. J Master Sci,1985,20:105
[29] 张景新．金属半固态加工中的组织及其演变．北京有色金属研究总院硕士学位论文，2000
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