磁场对铝硅合金凝固组织和变质处理的影响
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摘要
铸造Al-Si合金应用广泛，对Al-Si合金进行变质处理是提高Al-Si合金性能的重要措施。然而亚共晶型和共晶型Al-Si合金的Na变质处理存在有效时间短、重熔失效和过变质的问题，过共晶型Al-Si合金的P变质(细化)处理中则容易出现初晶Si偏聚的问题。
本文研究了强磁场对Al-Si合金凝固组织和变质处理的影响，较系统地考察了稳恒强磁场(以下简称强磁场)影响亚共晶和共晶Al-Si合金Na盐变质处理的现象和机制；进行了强磁场对过共晶Al-Si合金凝固组织和P盐变质细化处理的影响的实验研究，并探讨了磁场方向对实验结果的影响：研究了强制流动对过共晶Al-Si合金P盐变质细化处理的影响，得到以下主要结论：
1)在亚共晶Al—6w_t％Si合金的凝固过程中，单独施加强磁场使凝固组织中的共晶Si粗大。进行Na盐变质处理后冷却至固态，在不施加强磁场的条件下，重熔并在740℃保温20分钟，则凝固组织重新变为未变质组织，即发生了变质失效的现象；在施加强磁场的条件下，重熔并在740℃保温20分钟，没有发生重熔失效的现象。即施加强磁场可以解决Na变质的重熔失效问题。
2)对亚共晶Al—6w_t％Si合金进行Na盐变质处理后，分别在不施加与施加强磁场的条件下，在液相区740℃、固液两相区590℃和固相区470℃3个温度，使合金快速冷却，观察到了共晶Si的不同形貌。B=0T时，在740℃快速冷却的试样的凝固组织中，共晶Si呈短小的层片状。在590℃快速冷却的试样的凝固组织中，共晶Si呈较长的层片状。在470℃快速冷却的试样的凝固组织中，共晶Si呈形态尖锐的纤维状；B=10T时，在740℃快速冷却的试样的凝固组织中共晶Si细小并呈弥散分布。在590℃快速冷却的试样的凝固组织中，共晶Si呈复杂的丛簇状。在470℃快速冷却的试样的凝固组织中，共晶Si呈形态圆钝分布均匀的颗粒状。即施加强磁场可以使变质效果更好。对上述试样进行X线衍射表明，B=10T时，在470℃快速冷却的试样中出现Si(200)晶面的峰值。而B=0T时，没有Si(200)晶面的峰值，表明强磁场促使Si以孪晶形式生长。X线衍射还表明，B=10T时，在740℃、590℃和470℃快速冷却的试样中均出现Al(200)晶面垂直于磁场方向取向的现象。
3)强磁场使共晶Al-12.6w_t％Si合金凝固组织中的共晶组织发达，共晶Si增多，且间距变小。对合金进行Na盐变质处理后保温，如果在保温过程中施加强磁场，则得到的试样的变质效果明显优于不施加强磁场的试样。延长保温时间至40分钟，未施加强磁场的试样出现严重的变质衰退现象，施加强磁场的试样变质衰退现象相对比较轻。即强磁场具有延长变质有效时间的作用。电子探针的检测结果表明，不施加强磁场的条件下，Na的分布不均匀，并且在共晶硅上发生Na的聚集现象。施加强磁场的条件下，Na的分布均匀，避免了出现过变质现象。
4)在过共晶Al-18w_t％Si合金的凝固过程中，施加强磁场使初晶Si由粗大的板片状变为块状，且由集中在试样周边变为均匀分布在试样的整个横截面上。但是强磁场也使得过共晶Al-18w_t％Si合金的凝固组织中的共晶Si变粗大。进行P盐变质处理后，不施加强磁场的条件下，块状初晶Si仍然偏聚在试样周边，试样中心处为共晶组织；而施加强磁场的条件下，块状初晶Si均匀分布在试样的整个横截面上，而且共晶Si也得到细化。
5)将磁场方向由平行于圆柱试样的轴向改变为垂直于圆柱试样的轴向，可以使过共晶Al-18w_t％Si合金的凝固组织和P盐变质处理后的凝固组织更细化。
6)对过共晶Al-18w_t％Si合金进行P盐变质处理后施加旋转交变磁场，初晶Si呈粗大的板片状且偏聚于试样边缘。如果只在P盐变质处理后的保温过程中施加旋转交变磁场，而在冷却过程中停止施加旋转交变磁场，则初晶Si呈块状，得到明显细化。即P盐变质处理后的凝固过程中，强制流动对凝固组织不利，而抑制流动对凝固组织有利。
本论文工作为提高Al-Si合金变质处理的效果提供了新的手段，为形成一种单纯利用静磁场的全新的绿色环保的过共晶Al-Si合金变质细化处理新方法提供了理论基础。
Al-Si alloys are used widedly, while modification of them is the most important methodto improve their mechanical properties. However, there are some problems in the Na-Saltmodification of hypoeutectic Al-Si alloy and eutectic Al-Si alloy, such as the short effectivetime, the loss of efficacy after re-melt and over modification. For P-Salt modifiedhypereutectic Al-Si alloy, the primary Si tends to concentrate at the edge of the sample.
This dissertation has studied the effects of high magnetic fields on the solidificationstructure and modification of Al-Si alloys. The phenomena and mechanism of the impacts ofstable high magnetic field(high magnetic field hereafter)on the Na-modified hypoeutectic Al-Sialloy and eutectic Al-Si alloy are studied. Experimental studies on the impacts of high magneticfiled on the structure of the hypereutectic Al-Si alloy and on P-Salt modification are implemented.Moreover, impacts of compulsory floating on P-Salt modification of hypereutectic Al-Si alloy arealso studied. The following conclusions can be drawn from the studies.
1) For Al-6w_t％Si hypoeutectic alloy, eutectic Si in solidification structure became thicker underthe condition with high magnetic field. If the Na-Salt modified sample was re-melted and keptat 740℃for 20 minutes under the condition without high magnetic field, its solidificationstructure returned to its origin, i.e. the loss of efficacy after re-melt, while under the conditionwith high magnetic field the effect of modification was remained. It can be said that highmagnetic field could solve the problem of the loss of efficacy after re-melt.
2) After Na-Salt modification of Al-6w_t％Si, quickly cooling the samples from 740℃(liquidphase), 590℃(solid-liquid phase) and 470℃(solid phase) under the conditions with andwithout magnetic filed respectively, then the different configurations of eutectic Si couldbe observed. When B=0T, the eutectic Si in solidified structure of the sample quicklycooled from 740℃is short-layer-like. The eutectic Si in solidified structure of the samplequickly cooled from 590℃is long-layer-like. The eutectic Si in solidified structure of thesample quickly cooled from 470℃is sharped-acicular-like. When B=10T, the eutectic Siin solidified structure of the sample quickly cooled from 740℃was thin and distributedevenly. The eutectic Si in solidified structure of the sample quickly cooled from 590℃iscluster-like. The eutectic Si in the solidified structure of the sample quickly cooled from 470℃was ball-particle-like and distributed evenly. It could be said that magnetic filedcould improve the quality of the modification. After diffracting the sample with X-Ray, itwas found that when B=10T, the peak of Si(200) crystal lattice face appared in the samplequickly cooled from 470℃. While B=0T, the peak of Si(200) crystal lattice face did notappear. It means that high magnetic field impelled the growth of the Si in the style of thetwins. The results of the X-Ray diffraction also shows that the Al(200) crystal lattice facetends to arrange in the direction perpendicular to the magnetic strength.
3) High magnetic filed enforced the eutectic Si in solidification structure of the Al-12.6w_t％Si eutectic alloy, with high magnetic filed the eutectic Si increased and the spacebetween eutectic Si became smaller. If the sample modified by Na-Salt was kept warmunder the condition with high magnetic filed, the modification is obviously better than thatwithout high magnetic field. When the sample was kept warm for 40 minutes, the effectsof modification without high magnetic filed declined seriously, while the decline of themodification with high magnetic field was less. It means that high magnetic field couldpostpone the effective time of the modification. The observed results from the electron-probe shown that without high magnetic filed Na got together and concentrated on theeutectic Si, while with high magnetic filed Na distributed evenly and the overmodification was avoid.
4) During the solidification of hypereutectic Al-18w_t％Si alloy under the condition with highmagnetic filed, it is found that the shape of primary Si changed to plat-like from sheet-like,and concentrated at the edge of the sample and distribute at the whole cross section of thesample evenly. However, this time the eutectic Si was appreciably thicker than thatwithout high magnetic filed. If the sample was modified by P-Salt under the conditionwithout high magnetic field, the plate-like primary Si still concentrated at the edge of thesample, and the center is concentrated with the eutectic Si. While with the magnetic fieldthe plate-like primary Si distributed evenly at the whole cross section of the sample andthe eutectic Si became fine.
5) Changing the direction of magnetic filed from the direction paralleled to the axis of thesample to the vertical direction, it found that the solidified structure of the hypereutecticAl-18w_t％Si alloy and the P-Salt modified sample tended to be finer.
6) Posing rotary magnetic filed on the P-Salt modified hypereutectic Al-18w_t％Si alloy, theprimary Si would be thick and block-like and concentrated at the edge of the sample. If therotary magnetic filed was posed only during the warming after P-Salt modification, thenprimary Si would be fine and plate-like. It means that compulsory floating is not good to the solidified structure during the solidification after the P-Salt modification, and restrainfloating is good to solidified structure.
The studies provided a new methodology to improve the modification effect of Al-Sialloy. It provided a theoretical base for the new method that modifies the hypereutectic Al-Sialloy with a brand new and green method base on high magnetic filed.
本文研究了强磁场对Al-Si合金凝固组织和变质处理的影响，较系统地考察了稳恒强磁场(以下简称强磁场)影响亚共晶和共晶Al-Si合金Na盐变质处理的现象和机制；进行了强磁场对过共晶Al-Si合金凝固组织和P盐变质细化处理的影响的实验研究，并探讨了磁场方向对实验结果的影响：研究了强制流动对过共晶Al-Si合金P盐变质细化处理的影响，得到以下主要结论：
1)在亚共晶Al—6w_t％Si合金的凝固过程中，单独施加强磁场使凝固组织中的共晶Si粗大。进行Na盐变质处理后冷却至固态，在不施加强磁场的条件下，重熔并在740℃保温20分钟，则凝固组织重新变为未变质组织，即发生了变质失效的现象；在施加强磁场的条件下，重熔并在740℃保温20分钟，没有发生重熔失效的现象。即施加强磁场可以解决Na变质的重熔失效问题。
2)对亚共晶Al—6w_t％Si合金进行Na盐变质处理后，分别在不施加与施加强磁场的条件下，在液相区740℃、固液两相区590℃和固相区470℃3个温度，使合金快速冷却，观察到了共晶Si的不同形貌。B=0T时，在740℃快速冷却的试样的凝固组织中，共晶Si呈短小的层片状。在590℃快速冷却的试样的凝固组织中，共晶Si呈较长的层片状。在470℃快速冷却的试样的凝固组织中，共晶Si呈形态尖锐的纤维状；B=10T时，在740℃快速冷却的试样的凝固组织中共晶Si细小并呈弥散分布。在590℃快速冷却的试样的凝固组织中，共晶Si呈复杂的丛簇状。在470℃快速冷却的试样的凝固组织中，共晶Si呈形态圆钝分布均匀的颗粒状。即施加强磁场可以使变质效果更好。对上述试样进行X线衍射表明，B=10T时，在470℃快速冷却的试样中出现Si(200)晶面的峰值。而B=0T时，没有Si(200)晶面的峰值，表明强磁场促使Si以孪晶形式生长。X线衍射还表明，B=10T时，在740℃、590℃和470℃快速冷却的试样中均出现Al(200)晶面垂直于磁场方向取向的现象。
3)强磁场使共晶Al-12.6w_t％Si合金凝固组织中的共晶组织发达，共晶Si增多，且间距变小。对合金进行Na盐变质处理后保温，如果在保温过程中施加强磁场，则得到的试样的变质效果明显优于不施加强磁场的试样。延长保温时间至40分钟，未施加强磁场的试样出现严重的变质衰退现象，施加强磁场的试样变质衰退现象相对比较轻。即强磁场具有延长变质有效时间的作用。电子探针的检测结果表明，不施加强磁场的条件下，Na的分布不均匀，并且在共晶硅上发生Na的聚集现象。施加强磁场的条件下，Na的分布均匀，避免了出现过变质现象。
4)在过共晶Al-18w_t％Si合金的凝固过程中，施加强磁场使初晶Si由粗大的板片状变为块状，且由集中在试样周边变为均匀分布在试样的整个横截面上。但是强磁场也使得过共晶Al-18w_t％Si合金的凝固组织中的共晶Si变粗大。进行P盐变质处理后，不施加强磁场的条件下，块状初晶Si仍然偏聚在试样周边，试样中心处为共晶组织；而施加强磁场的条件下，块状初晶Si均匀分布在试样的整个横截面上，而且共晶Si也得到细化。
5)将磁场方向由平行于圆柱试样的轴向改变为垂直于圆柱试样的轴向，可以使过共晶Al-18w_t％Si合金的凝固组织和P盐变质处理后的凝固组织更细化。
6)对过共晶Al-18w_t％Si合金进行P盐变质处理后施加旋转交变磁场，初晶Si呈粗大的板片状且偏聚于试样边缘。如果只在P盐变质处理后的保温过程中施加旋转交变磁场，而在冷却过程中停止施加旋转交变磁场，则初晶Si呈块状，得到明显细化。即P盐变质处理后的凝固过程中，强制流动对凝固组织不利，而抑制流动对凝固组织有利。
本论文工作为提高Al-Si合金变质处理的效果提供了新的手段，为形成一种单纯利用静磁场的全新的绿色环保的过共晶Al-Si合金变质细化处理新方法提供了理论基础。
Al-Si alloys are used widedly, while modification of them is the most important methodto improve their mechanical properties. However, there are some problems in the Na-Saltmodification of hypoeutectic Al-Si alloy and eutectic Al-Si alloy, such as the short effectivetime, the loss of efficacy after re-melt and over modification. For P-Salt modifiedhypereutectic Al-Si alloy, the primary Si tends to concentrate at the edge of the sample.
This dissertation has studied the effects of high magnetic fields on the solidificationstructure and modification of Al-Si alloys. The phenomena and mechanism of the impacts ofstable high magnetic field(high magnetic field hereafter)on the Na-modified hypoeutectic Al-Sialloy and eutectic Al-Si alloy are studied. Experimental studies on the impacts of high magneticfiled on the structure of the hypereutectic Al-Si alloy and on P-Salt modification are implemented.Moreover, impacts of compulsory floating on P-Salt modification of hypereutectic Al-Si alloy arealso studied. The following conclusions can be drawn from the studies.
1) For Al-6w_t％Si hypoeutectic alloy, eutectic Si in solidification structure became thicker underthe condition with high magnetic field. If the Na-Salt modified sample was re-melted and keptat 740℃for 20 minutes under the condition without high magnetic field, its solidificationstructure returned to its origin, i.e. the loss of efficacy after re-melt, while under the conditionwith high magnetic field the effect of modification was remained. It can be said that highmagnetic field could solve the problem of the loss of efficacy after re-melt.
2) After Na-Salt modification of Al-6w_t％Si, quickly cooling the samples from 740℃(liquidphase), 590℃(solid-liquid phase) and 470℃(solid phase) under the conditions with andwithout magnetic filed respectively, then the different configurations of eutectic Si couldbe observed. When B=0T, the eutectic Si in solidified structure of the sample quicklycooled from 740℃is short-layer-like. The eutectic Si in solidified structure of the samplequickly cooled from 590℃is long-layer-like. The eutectic Si in solidified structure of thesample quickly cooled from 470℃is sharped-acicular-like. When B=10T, the eutectic Siin solidified structure of the sample quickly cooled from 740℃was thin and distributedevenly. The eutectic Si in solidified structure of the sample quickly cooled from 590℃iscluster-like. The eutectic Si in the solidified structure of the sample quickly cooled from 470℃was ball-particle-like and distributed evenly. It could be said that magnetic filedcould improve the quality of the modification. After diffracting the sample with X-Ray, itwas found that when B=10T, the peak of Si(200) crystal lattice face appared in the samplequickly cooled from 470℃. While B=0T, the peak of Si(200) crystal lattice face did notappear. It means that high magnetic field impelled the growth of the Si in the style of thetwins. The results of the X-Ray diffraction also shows that the Al(200) crystal lattice facetends to arrange in the direction perpendicular to the magnetic strength.
3) High magnetic filed enforced the eutectic Si in solidification structure of the Al-12.6w_t％Si eutectic alloy, with high magnetic filed the eutectic Si increased and the spacebetween eutectic Si became smaller. If the sample modified by Na-Salt was kept warmunder the condition with high magnetic filed, the modification is obviously better than thatwithout high magnetic field. When the sample was kept warm for 40 minutes, the effectsof modification without high magnetic filed declined seriously, while the decline of themodification with high magnetic field was less. It means that high magnetic field couldpostpone the effective time of the modification. The observed results from the electron-probe shown that without high magnetic filed Na got together and concentrated on theeutectic Si, while with high magnetic filed Na distributed evenly and the overmodification was avoid.
4) During the solidification of hypereutectic Al-18w_t％Si alloy under the condition with highmagnetic filed, it is found that the shape of primary Si changed to plat-like from sheet-like,and concentrated at the edge of the sample and distribute at the whole cross section of thesample evenly. However, this time the eutectic Si was appreciably thicker than thatwithout high magnetic filed. If the sample was modified by P-Salt under the conditionwithout high magnetic field, the plate-like primary Si still concentrated at the edge of thesample, and the center is concentrated with the eutectic Si. While with the magnetic fieldthe plate-like primary Si distributed evenly at the whole cross section of the sample andthe eutectic Si became fine.
5) Changing the direction of magnetic filed from the direction paralleled to the axis of thesample to the vertical direction, it found that the solidified structure of the hypereutecticAl-18w_t％Si alloy and the P-Salt modified sample tended to be finer.
6) Posing rotary magnetic filed on the P-Salt modified hypereutectic Al-18w_t％Si alloy, theprimary Si would be thick and block-like and concentrated at the edge of the sample. If therotary magnetic filed was posed only during the warming after P-Salt modification, thenprimary Si would be fine and plate-like. It means that compulsory floating is not good to the solidified structure during the solidification after the P-Salt modification, and restrainfloating is good to solidified structure.
The studies provided a new methodology to improve the modification effect of Al-Sialloy. It provided a theoretical base for the new method that modifies the hypereutectic Al-Sialloy with a brand new and green method base on high magnetic filed.
引文
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