大体积Fe-Ga磁致伸缩合金的深过冷定向凝固
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摘要
磁致伸缩合金是重要的传感和微驱动材料,在声纳换能器、武器系统和机器人领域具有广泛应用。目前较为常用的以Tb-Dy-Fe为代表的超磁致伸缩材料虽然具有应变大、居里温度高等优良的性能,但同时具有脆性大、原材料成本高等一些缺点。而近年来出现的Fe-Ga系磁致伸缩合金具有高强度、良好韧性和低成本,并且在单晶材料的[100]方向获得了近400 ppm的大磁致伸缩等优异性能,从而使之具有广泛的应用前景和商业价值。
关于Fe-Ga系磁致伸缩合金的大量研究成果表明:适当的合金成分、快速凝固和取向生长是制备高性能Fe-Ga材料的先决条件。因此,寻求一种可生长大体积、可良好取向和可得到快速凝固亚稳结构的凝固控制技术就成为制备高性能Fe-Ga类磁致伸缩材料的关键问题之一。深过冷快速定向凝固无疑在这些方面具有得天独厚的优势。深过冷技术是近年来发展迅速的一种新型快速凝固技术,在深过冷条件下,一旦受到激发形核,合金熔体可以高达数米每秒的速度高速生长,通过人为控制合金晶体生长时的形核条件,可以制备出成分均匀的定向材料,被认为是极具发展潜力的新型快速定向凝固技术。因此,本文使用熔融玻璃净化结合循环过热的方法首先开展了净化剂玻璃成分及其它因素对Fe_(81)Ga_(19)合金净化效果的影响的研究;为有效应用深过冷快速定向凝固技术,又开展了深过冷凝固条件下Fe_(81)Ga_(19)合金组织演变规律及其磁力显微镜的研究工作;并在此基础上将该技术引入Fe-Ga合金的定向材料制备中。此外,还对所制备的Fe_(81)Ga_(19)合金棒材晶体生长中的择优取向、微观结构以及磁性能进行了分析;最后,对不同过冷度下激发过冷熔体获得的Fe_(81)Ga_(19)合金棒材的织构和磁致伸缩性能进行了探讨。主要得到以下几方面研究成果:
通过熔融玻璃净化结合循环过热的方法对B_2O_3、NaSiCa+B_2O_3(简称Na-Si-Ca-Al-B)和Na-Si-Ca-Al-B+Na_2B_4O_7玻璃作为净化剂对Fe_(81)Ga_(19)合金熔体过冷的效果分别作了分析。发现B_2O_3玻璃净化机制只是物理吸附,只能获得较小过冷;Na-Si-Ca-Al-B玻璃为物理化学综合净化,获得过冷度大,但其粘度过大,造成获得过冷度不稳定;Na-Si-Ca-Al-B+Na_2B_4O_7玻璃保留了物理化学综合净化机制,同时有效降低了Na-Si-Ca-Al-B玻璃的粘度。并分析了样品重量、过热度、保温时间等其它影响因素对过冷度的影响,确定了过冷实验的具体工艺:采用70%Na-Si-Ca-Al-10B+30%Na_2B_4O_7玻璃作为净化剂,加热过程中应先在400℃以下低温充分排气两分钟,在过热度为200 K左右,保温1.5 min,进行过热循环,使Fe_(81)Ga_(19)合金熔体成功获得最高300 K以上的过冷度。
通过对过冷Fe_(81)Ga_(19)合金的凝固组织演化过程及其磁畴结构的研究发现:在0~315 K宽的过冷度范围内,Fe_(81)Ga_(19)合金的凝固组织可被分为三大类:即在低过冷度下(ΔT≤50 K)的熔断枝晶、中间过冷度范围内(50 K<ΔT<200 K)的细小等轴晶以及大过冷度下(ΔT>200 K)时的再结晶组织;并对其各自的形成机制进行了探讨。值得注意的是,在过冷度为150~200 K的范围内,凝固组织中细小粒状晶粒的生长具有一定方向性,由此选定该过冷区域作为深过冷定向凝固的激发过冷度区间。另外,对过冷样品的磁力显微镜研究显示,Fe_(81)Ga_(19)合金的表面磁畴结构对过冷度的变化也非常敏感。
基于以上两方面研究,利用过冷度的遗传性,在200 K过冷度下通过点激发和面激发过冷熔体方式,成功实现了Fe_(81)Ga_(19)合金的深过冷快速定向凝固。通过对200 K过冷度下点激发制备Fe_(81)Ga_(19)合金定向凝固棒材的取向分析发现,样品柱状晶部分具有很强的[100]织构,该棒材的[100]择优取向与试样轴向的夹角为10°左右,这个结果优于以往文献中报道的最优结果;通过XRD、DSC、TEM等手段对该棒材样品的微观结构研究发现,深过冷快速定向凝固的Fe_(81)Ga_(19)合金内部不是均匀的完全无序的A2结构,而是在微观上弥散着许多由Ga的原子团簇构成的发生晶格畸变的DO3结构以及一些纳米尺度的具有[111]取向的嵌入畴的结构;通过对该样品磁性能研究发现,在该样品的轴向方向上获得了超过800 ppm的大磁致伸缩性能,这几乎是以往报道中块体Fe-Ga材料中获得最大磁致伸缩性能的两倍,我们认为激发过冷熔体制备的Fe_(81)Ga_(19)多晶棒材沿轴向方向高度的[100]织构以及快速凝固过程中出现的Ga的原子团簇构成晶格畸变DO3结构以及不均匀的微观结构是磁致伸缩性能大大提高的主要因素。
最后,还对激发过冷度对定向凝固Fe_(81)Ga_(19)合金棒材凝固组织、织构以及其对性能的影响进行了研究,发现在可以获得定向组织的激发过冷度区间内,随着激发过冷度的提高,获得棒材的[100]取向程度逐渐提高,其饱和磁致伸缩性能也有所提高,从150 K激发过冷度的750 ppm提高到210 K时的885 ppm。另外,由于样品的[100]择优取向与棒材轴向存在一定夹角,造成其磁致伸缩性能随着磁场的增加出现先增加后减小的现象。
Magnetostrictive materials are widely used in various sensor and micro-actuator applications as sonar transducers, weapon systems and robot devices. At present, the widely used RFe2 intermetallic compounds (where R refers to rare-earth elements) such as Tb-Dy-Fe alloys show large magnetostrictive strains and high Curie temperatures. However, Terfenal alloys are brittle, require large fields for saturation, and are expensive due to the high costs of Tb and Dy. Very recently, it was found that the magnetostriction of bcc Fe is greatly enhanced by the addition of Ga. A large magnetostriction of 400 ppm can be achieved in a single crystal [100] oriented Fe_(81)Ga_(19) alloy which depends on the quenching conditions. In addition to their high magnetostriction, Fe-Ga alloys show high mechanical strength, good ductility, and low associated cost which render it a good candidate for commercial application.
Researches on Fe-Ga magnetostrictive alloys show that proper composition range, metastable phase formation and [100] preferred orientation are crucial for the improving of magnetostrictive property. Therefore, a controllable solidification technique is urgently wanted to prepare bulk Fe-Ga magnetostrictive alloys which could achieve high texture and the metastable phase formed in rapid solidification. Our recent work indicates that Fe-Ga alloys produced by the technique of rapid directional solidification from the undercooled melts (UDS) meet all these expectations. UDS is a newly-developed rapid solidification technique. When the melt is triggering nucleated in a specific undercooling range, the dendrites grow rapidly into the undercooled melts with a preferred orientation at a speed of several m/s. So, directional solidified alloys with a homogenous composition can be obtained through the control of nucleation condition of crystal growth which renders UDS a potentially directional solidification technique. In this paper, the effect of denucleating glass composition on the undercooling of Fe-Ga alloy melts was investigated using the method of glass fluxing combined with superheating cycles. Microstructure evolution and MFM domain structures of undercooled Fe_(81)Ga_(19) alloys were also studied with respect to different undercoolings. Then, based on the results of these experiments, UDS technique was applied in the preparation of directional solidified Fe-Ga alloys. The texture, microstructure and the magnetic properties of directional solidified Fe-Ga alloys were also investigated systematically. In addition, the effect of triggering undercooling on the texture and the magnetostriction property of Fe_(81)Ga_(19) alloys prepared by UDS technique were discussed. The main conclusions are as follows:
Firstly, adopting glass fluxing combined with superheating cycling method, the undercooling and its stability of Fe_(81)Ga_(19) alloy melts were investigated using different kinds of denucleating glass: B_2O_3, NaSiCa+B_2O_3(simplified as Na-Si-Ca-Al-B) and Na-Si-Ca-Al-B+Na_2B_4O_7. The results showed that different glass has different denucleating mechanism. The purification of B_2O_3 glass is only a physical process, by which the stable bulk undercooling cannot be obtained during superheating-cooling cycles. While taking Na-Si-Ca-Al-B glass as purifying agent, its denucleating mechanism is a comprehensively physicochemical process. But the stability of undercooling is still undesirable because of the separation between melt and glass during cooling process in superheating cycling. A stable bulk undercooling of above 300 K can be obtained by physicochemical denucleating process in the case of 70% Na-Si-Ca-Al-10B+30%Na_2B_4O_7 molten glass owing to its suitable viscosity. Combined with the analyses of the effect of sample weight, superheating temperature and holding time on undercooling of Fe_(81)Ga_(19) alloy, a stable experimental process was established which has been proved feasible.
Secondly, high undercoolings up to 305 K have been successfully achieved in the bulk Fe_(81)Ga_(19) magnetostrictive alloy melts by means of glass fluxing combined with superheating cycling method. When the undercooling is less than 50 K, the structures consist of coarse and broken dendrites with some cells present. The remelting of primary dendrites plays an important role in the crystal growth and the refinement. When the undercooling is in the rage of 100-200 K, the grain size decreases smoothly with increasing undercooling. Within the range of 230-260 K, abnormal large grains coexist with fine equiaxed grains. When the undercooling reaches 305 K, only large grains with an average size of 200μm exist. The competition between the strain energy stored in the rapid solidified crystals with the critical strain energy for recrystallization which results in different degrees of recrystallization explains the experiment results reasonable. In addition, the magnetic domain structure of undercooled Fe_(81)Ga_(19) alloys has been found to be very sensitive to the variation of undercooling during the solidification process. With increasing the degree of undercooling, the evolution of domain patterns, magnetic contrast and the degree of the orientation were investigated which is relative to the magnetostriction. It should be noted that the grains tended to possess a preferred orientation within the undercooling range 150-200 K.
Thirdly, bulk textured Fe_(81)Ga_(19) alloy rods were successfully prepared using the technique of UDS by point and face triggering. The columnar grains of Fe_(81)Ga_(19) rod directional solidified by point triggering have strong [100] texture. This preferred orientation of the [100] axis was approximately 10°from the rod direction. The microstructure of the rod was also studied by XRD, DSC and TEM. Results showed that the Fe_(81)Ga_(19) alloy present in our sample is not a homogeneous bcc solution, but rather a nanodispersion of small Ga clusters within the A2 matrix which is corresponding to the modified DO3 structure. All these unique structural features have been attributed to the enhancement of magnetostrition of F81Ga19 alloy. The saturation magnetostriction is above 800 ppm, which is about 2 times as large as the maximum of the earlier report on Fe-Ga bulk samples. It has been ascribed to the high concentration of Ga-Ga atom pairs created by rapid solidification and their preferential orientation in (100) textured rod.
Lastly, the effect of triggering undercooling on the texture and magnetostriction of directional solidified Fe_(81)Ga_(19) alloy rods was discussed. Results showed that the [100] preferred orientation and the magnetostriction property were enhanced with the increasing of triggering undercooling in the rage of undercooling which could achieve directional growth crystals. The magnetostriction increases from 750 ppm for the triggering undercooling of 150 K to 885 ppm for the triggering undercooling of 210 K. In addition, the magnetostriction was found to decrease after it was saturated with the increasing applied field. It may be attributed to the fact that the [100] direction of textured grains tilted about 10°from the rod axis.
关于Fe-Ga系磁致伸缩合金的大量研究成果表明:适当的合金成分、快速凝固和取向生长是制备高性能Fe-Ga材料的先决条件。因此,寻求一种可生长大体积、可良好取向和可得到快速凝固亚稳结构的凝固控制技术就成为制备高性能Fe-Ga类磁致伸缩材料的关键问题之一。深过冷快速定向凝固无疑在这些方面具有得天独厚的优势。深过冷技术是近年来发展迅速的一种新型快速凝固技术,在深过冷条件下,一旦受到激发形核,合金熔体可以高达数米每秒的速度高速生长,通过人为控制合金晶体生长时的形核条件,可以制备出成分均匀的定向材料,被认为是极具发展潜力的新型快速定向凝固技术。因此,本文使用熔融玻璃净化结合循环过热的方法首先开展了净化剂玻璃成分及其它因素对Fe_(81)Ga_(19)合金净化效果的影响的研究;为有效应用深过冷快速定向凝固技术,又开展了深过冷凝固条件下Fe_(81)Ga_(19)合金组织演变规律及其磁力显微镜的研究工作;并在此基础上将该技术引入Fe-Ga合金的定向材料制备中。此外,还对所制备的Fe_(81)Ga_(19)合金棒材晶体生长中的择优取向、微观结构以及磁性能进行了分析;最后,对不同过冷度下激发过冷熔体获得的Fe_(81)Ga_(19)合金棒材的织构和磁致伸缩性能进行了探讨。主要得到以下几方面研究成果:
通过熔融玻璃净化结合循环过热的方法对B_2O_3、NaSiCa+B_2O_3(简称Na-Si-Ca-Al-B)和Na-Si-Ca-Al-B+Na_2B_4O_7玻璃作为净化剂对Fe_(81)Ga_(19)合金熔体过冷的效果分别作了分析。发现B_2O_3玻璃净化机制只是物理吸附,只能获得较小过冷;Na-Si-Ca-Al-B玻璃为物理化学综合净化,获得过冷度大,但其粘度过大,造成获得过冷度不稳定;Na-Si-Ca-Al-B+Na_2B_4O_7玻璃保留了物理化学综合净化机制,同时有效降低了Na-Si-Ca-Al-B玻璃的粘度。并分析了样品重量、过热度、保温时间等其它影响因素对过冷度的影响,确定了过冷实验的具体工艺:采用70%Na-Si-Ca-Al-10B+30%Na_2B_4O_7玻璃作为净化剂,加热过程中应先在400℃以下低温充分排气两分钟,在过热度为200 K左右,保温1.5 min,进行过热循环,使Fe_(81)Ga_(19)合金熔体成功获得最高300 K以上的过冷度。
通过对过冷Fe_(81)Ga_(19)合金的凝固组织演化过程及其磁畴结构的研究发现:在0~315 K宽的过冷度范围内,Fe_(81)Ga_(19)合金的凝固组织可被分为三大类:即在低过冷度下(ΔT≤50 K)的熔断枝晶、中间过冷度范围内(50 K<ΔT<200 K)的细小等轴晶以及大过冷度下(ΔT>200 K)时的再结晶组织;并对其各自的形成机制进行了探讨。值得注意的是,在过冷度为150~200 K的范围内,凝固组织中细小粒状晶粒的生长具有一定方向性,由此选定该过冷区域作为深过冷定向凝固的激发过冷度区间。另外,对过冷样品的磁力显微镜研究显示,Fe_(81)Ga_(19)合金的表面磁畴结构对过冷度的变化也非常敏感。
基于以上两方面研究,利用过冷度的遗传性,在200 K过冷度下通过点激发和面激发过冷熔体方式,成功实现了Fe_(81)Ga_(19)合金的深过冷快速定向凝固。通过对200 K过冷度下点激发制备Fe_(81)Ga_(19)合金定向凝固棒材的取向分析发现,样品柱状晶部分具有很强的[100]织构,该棒材的[100]择优取向与试样轴向的夹角为10°左右,这个结果优于以往文献中报道的最优结果;通过XRD、DSC、TEM等手段对该棒材样品的微观结构研究发现,深过冷快速定向凝固的Fe_(81)Ga_(19)合金内部不是均匀的完全无序的A2结构,而是在微观上弥散着许多由Ga的原子团簇构成的发生晶格畸变的DO3结构以及一些纳米尺度的具有[111]取向的嵌入畴的结构;通过对该样品磁性能研究发现,在该样品的轴向方向上获得了超过800 ppm的大磁致伸缩性能,这几乎是以往报道中块体Fe-Ga材料中获得最大磁致伸缩性能的两倍,我们认为激发过冷熔体制备的Fe_(81)Ga_(19)多晶棒材沿轴向方向高度的[100]织构以及快速凝固过程中出现的Ga的原子团簇构成晶格畸变DO3结构以及不均匀的微观结构是磁致伸缩性能大大提高的主要因素。
最后,还对激发过冷度对定向凝固Fe_(81)Ga_(19)合金棒材凝固组织、织构以及其对性能的影响进行了研究,发现在可以获得定向组织的激发过冷度区间内,随着激发过冷度的提高,获得棒材的[100]取向程度逐渐提高,其饱和磁致伸缩性能也有所提高,从150 K激发过冷度的750 ppm提高到210 K时的885 ppm。另外,由于样品的[100]择优取向与棒材轴向存在一定夹角,造成其磁致伸缩性能随着磁场的增加出现先增加后减小的现象。
Magnetostrictive materials are widely used in various sensor and micro-actuator applications as sonar transducers, weapon systems and robot devices. At present, the widely used RFe2 intermetallic compounds (where R refers to rare-earth elements) such as Tb-Dy-Fe alloys show large magnetostrictive strains and high Curie temperatures. However, Terfenal alloys are brittle, require large fields for saturation, and are expensive due to the high costs of Tb and Dy. Very recently, it was found that the magnetostriction of bcc Fe is greatly enhanced by the addition of Ga. A large magnetostriction of 400 ppm can be achieved in a single crystal [100] oriented Fe_(81)Ga_(19) alloy which depends on the quenching conditions. In addition to their high magnetostriction, Fe-Ga alloys show high mechanical strength, good ductility, and low associated cost which render it a good candidate for commercial application.
Researches on Fe-Ga magnetostrictive alloys show that proper composition range, metastable phase formation and [100] preferred orientation are crucial for the improving of magnetostrictive property. Therefore, a controllable solidification technique is urgently wanted to prepare bulk Fe-Ga magnetostrictive alloys which could achieve high texture and the metastable phase formed in rapid solidification. Our recent work indicates that Fe-Ga alloys produced by the technique of rapid directional solidification from the undercooled melts (UDS) meet all these expectations. UDS is a newly-developed rapid solidification technique. When the melt is triggering nucleated in a specific undercooling range, the dendrites grow rapidly into the undercooled melts with a preferred orientation at a speed of several m/s. So, directional solidified alloys with a homogenous composition can be obtained through the control of nucleation condition of crystal growth which renders UDS a potentially directional solidification technique. In this paper, the effect of denucleating glass composition on the undercooling of Fe-Ga alloy melts was investigated using the method of glass fluxing combined with superheating cycles. Microstructure evolution and MFM domain structures of undercooled Fe_(81)Ga_(19) alloys were also studied with respect to different undercoolings. Then, based on the results of these experiments, UDS technique was applied in the preparation of directional solidified Fe-Ga alloys. The texture, microstructure and the magnetic properties of directional solidified Fe-Ga alloys were also investigated systematically. In addition, the effect of triggering undercooling on the texture and the magnetostriction property of Fe_(81)Ga_(19) alloys prepared by UDS technique were discussed. The main conclusions are as follows:
Firstly, adopting glass fluxing combined with superheating cycling method, the undercooling and its stability of Fe_(81)Ga_(19) alloy melts were investigated using different kinds of denucleating glass: B_2O_3, NaSiCa+B_2O_3(simplified as Na-Si-Ca-Al-B) and Na-Si-Ca-Al-B+Na_2B_4O_7. The results showed that different glass has different denucleating mechanism. The purification of B_2O_3 glass is only a physical process, by which the stable bulk undercooling cannot be obtained during superheating-cooling cycles. While taking Na-Si-Ca-Al-B glass as purifying agent, its denucleating mechanism is a comprehensively physicochemical process. But the stability of undercooling is still undesirable because of the separation between melt and glass during cooling process in superheating cycling. A stable bulk undercooling of above 300 K can be obtained by physicochemical denucleating process in the case of 70% Na-Si-Ca-Al-10B+30%Na_2B_4O_7 molten glass owing to its suitable viscosity. Combined with the analyses of the effect of sample weight, superheating temperature and holding time on undercooling of Fe_(81)Ga_(19) alloy, a stable experimental process was established which has been proved feasible.
Secondly, high undercoolings up to 305 K have been successfully achieved in the bulk Fe_(81)Ga_(19) magnetostrictive alloy melts by means of glass fluxing combined with superheating cycling method. When the undercooling is less than 50 K, the structures consist of coarse and broken dendrites with some cells present. The remelting of primary dendrites plays an important role in the crystal growth and the refinement. When the undercooling is in the rage of 100-200 K, the grain size decreases smoothly with increasing undercooling. Within the range of 230-260 K, abnormal large grains coexist with fine equiaxed grains. When the undercooling reaches 305 K, only large grains with an average size of 200μm exist. The competition between the strain energy stored in the rapid solidified crystals with the critical strain energy for recrystallization which results in different degrees of recrystallization explains the experiment results reasonable. In addition, the magnetic domain structure of undercooled Fe_(81)Ga_(19) alloys has been found to be very sensitive to the variation of undercooling during the solidification process. With increasing the degree of undercooling, the evolution of domain patterns, magnetic contrast and the degree of the orientation were investigated which is relative to the magnetostriction. It should be noted that the grains tended to possess a preferred orientation within the undercooling range 150-200 K.
Thirdly, bulk textured Fe_(81)Ga_(19) alloy rods were successfully prepared using the technique of UDS by point and face triggering. The columnar grains of Fe_(81)Ga_(19) rod directional solidified by point triggering have strong [100] texture. This preferred orientation of the [100] axis was approximately 10°from the rod direction. The microstructure of the rod was also studied by XRD, DSC and TEM. Results showed that the Fe_(81)Ga_(19) alloy present in our sample is not a homogeneous bcc solution, but rather a nanodispersion of small Ga clusters within the A2 matrix which is corresponding to the modified DO3 structure. All these unique structural features have been attributed to the enhancement of magnetostrition of F81Ga19 alloy. The saturation magnetostriction is above 800 ppm, which is about 2 times as large as the maximum of the earlier report on Fe-Ga bulk samples. It has been ascribed to the high concentration of Ga-Ga atom pairs created by rapid solidification and their preferential orientation in (100) textured rod.
Lastly, the effect of triggering undercooling on the texture and magnetostriction of directional solidified Fe_(81)Ga_(19) alloy rods was discussed. Results showed that the [100] preferred orientation and the magnetostriction property were enhanced with the increasing of triggering undercooling in the rage of undercooling which could achieve directional growth crystals. The magnetostriction increases from 750 ppm for the triggering undercooling of 150 K to 885 ppm for the triggering undercooling of 210 K. In addition, the magnetostriction was found to decrease after it was saturated with the increasing applied field. It may be attributed to the fact that the [100] direction of textured grains tilted about 10°from the rod axis.
引文
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