AZ91D-Y半固态坯不同制备方法及对触变模锻影响研究
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摘要
基于国家节能减排的政策引导和金属矿产资源供给日益恶化的形势,镁合金以其密度轻和资源丰富越来越受到重视。加速镁合金成形技术的研究是实现可持续发展的重要措施之一。目前镁合金的成形技术,以压铸为主,兼有液态模锻和锻造成形,但这三种工艺本身,均有其不足。例如,采用锻造成形尽管能满足零件较高力学性能的要求,但很难满足其形状复杂的需求。半固态触变模锻技术是一种近净成形复杂形状零件的技术。半固态坯料组织最显著的特征是固相颗粒呈球状,成形后零件的复杂程度远高于锻件,其力学性能高于压铸件和液态模锻件。本文期望通过采用AZ91D-Y镁合金半固态触变模锻成形筒形件,分别对铸造法、近液相线模锻法和等通道角挤压法(Equal channel angular extrusion,ECAE)制备坯料在二次加热过程中的组织演变、球晶组织的生成及特征对触变模锻成形和成形件力学性能的影响展开深入的研究,探讨不同半固态制坯方法的适用范围和应用的可能性。
本文采用铸造法、近液相线模锻法和ECAE法制备了AZ91D-Y半固态坯。借助金相显微镜、扫描电子显微镜、X射线衍射仪和万能拉伸试验机分别研究了不同方法制备坯料的微观组织和力学性能。研究表明,添加稀土Y细化了α(Mg)和β(Mg17Al12),产生了杆状的Al2Y新相;在铸造制坯中,可获得粗大的等轴晶,柱状晶不明显;在近液相线模锻制坯中,可获得细小的枝晶组织,且随着模锻压力的增加,坯料的力学性能上升;在ECAE变形中,随着温度的升高,有利于获得等轴状晶粒,但不利于获得较高的屈服强度和抗拉强度,增加ECAE变形道次,有利于获得细小的等轴状再结晶组织。
分别将铸态、近液相线模锻态和ECAE态的坯料加热到半固态温度区间。采用金相显微镜研究了铸造法、近液相线模锻法和ECAE法制备半固态坯料在二次加热过程中的组织演变及特征。研究结果表明,铸造法坯料在二次加热过程中组织的演变规律是由发达的树枝晶演变为大块状组织,大块状组织逐渐分离成碎块状组织,随后固相颗粒球化并主要通过合并的方式长大;近液相线模锻法坯料组织的演变规律是由细小的树枝晶演变为块状组织,块状组织分离成碎块状组织,随后固相颗粒球化并主要通过Ostwald熟化机制长大;ECAE法坯料组织的演变规律是挤压态组织发生再结晶,形成再结晶块状组织,块状组织分离后,发生球化并主要通过Ostwald熟化机制长大。近液相线模锻法和ECAE法坯料的平均固相颗粒尺寸小于铸造法;三种制坯方法中,ECAE法制备坯料的组织演变进程最快,固相颗粒球化效果最好。
采用热模拟试验研究了铸造法、近液相线模锻法和ECAE法制备坯料的触变流动行为。研究结果表明,ECAE法制备坯料在较小的应力作用下,便可实现稳态充填,触变流动性能最好;近液相线模锻法坯料次之,铸造法坯料较差。借助万能拉伸试验机研究了触变模锻工艺参数和坯料制备方法对模锻制件力学性能的影响。研究结果表明,在半固态温度为560℃,模锻压力为200MPa的条件下,铸造法制备坯料在球化30min后触变模锻获得的力学性能最好,其屈服强度、抗拉强度和断后伸长率分别是131MPa、280MPa和9.2%;近液相线模锻法制备的坯料在球化20min后触变模锻获得的力学性能最好,其屈服强度、抗拉强度和断后伸长率分别是161MPa、302MPa和9.7%;ECAE法(一道次ECAE变形)制备的坯料在球化15min后触变模锻获得的力学性能最好,其屈服强度、抗拉强度和断后伸长率分别是164MPa、307MPa和11.8%,四道次变形坯料触变模锻后的屈服强度、抗拉强度和断后伸长率分别为220MPa、333MPa和16.1%,大大高于一道次变形;在相同成形条件下,ECAE法制备坯料触变模锻后的力学性能最好,近液相线模锻法次之,铸造法较差。
上述比较研究结果表明,三种制坯方法均具有不同的优势,因而适用于不同的镁合金半固态模锻件对形状、尺寸和性能的要求。其中从制坯成本、制件复杂程度和触变成形件力学性能考虑,以近液相线模锻法具有综合优势,有希望成为高性能镁合金半固态模锻的主要制坯方法之一。
Based on the policy guidance of energy-saving and emission reduction and the deteriorating situation of metal mineral resources supply, we attach great importance to the development of magnesium alloys because of their low density and great abundance. Accelerated research on the forming technology of magnesium alloys is the one of important measures to realize sustainable development. Currently, the forming technology of magnesium alloys is dominated by diecasting, in combination with liquid forging and forging. However, these technologies have their own drawbacks. For example, although forging can meet the requirement of forming parts with good mechanical properties, it is difficult for this technology to form parts with complex shape. Semi-solid thixoforging is the one of near-net shape technologies to form parts with complex shape. The semi-solid microstructure is characterized by spherical grains. The complexity of parts formed by semi-solid thixoforging exceeds that formed by forging. The mechanical properties of parts formed by semi-solid thixoforging exceed those formed by diecasting and liquid forging. The aim of this paper is to research the preparation of semi-solid billets by casting, near-liquidus forging and equal channel angular extrusion (ECAE), respectively. The microstructure evolution during reheating, the effect of the formation and characteristics of spherical grains on thixoforging and the mechanical properties of parts formed by thixoforging are also studied. Moreover, the application scope and possibility of semi-solid billets prepared by different methods are discussed.
The semi-solid billets are prepared by casting, near-liquidus forging and ECAE, respectively. By means of metallographic microscope, scanning electronic microscope, X-ray diffraction and universal material testing machine, microstructure and mechanical properties of semi-solid billets prepared by three different methods are analyzed. The results show that the addition of Y to AZ91D alloy refines primaryα(Mg) matrix andβ(Mg17Al12) phase. The addition of Y forms rod-shaped Al2Y phase. In the as-cast billet, coarse equiaxed grains are obtained and columnar crystals are not obvious. In the near-liquidus forged billet, fine dendritic microstructures are produced and with increasing applied pressure the mechanical properties of billets are improved. In the ECAE-formed billet, increasing temperature is helpful for obtaining equiaxed grains but unfavorable for improving yield strength and ultimate tensile strength. Moreover, increasing the number of pass promotes the formation of fine equiaxed grains.
Semi-solid billets prepared by casting, near-liquidus forging and ECAE are reheated in the semi-solid temperature range. Microstructure evolution and characteristics of semi-solid billets prepared by casting, near-liquidus forging and ECAE during reheating are also studied. The results show that in the as-cast billet, coarse dendritic structures evolve into large blocked structures, then into cloddy pulverescent structures, finally irregular grains are spheroidized and coarsening mainly by coalescence. In the near-liquidus forged billet, fine dendritic structures evolve into blocked structure, then into cloddy pulverescent structure, finally irregular grains are spheroidized and coarsening mainly by Ostwald ripening mechanism.In the ECAE formed billet, deformed structures transform into recrystallised structures in the early stage. Then recrystallised structures are penetrated by liquid and disintegrated into seperated grains. These seperated grains are spheroidized and coarsening mainly by Ostwald ripening mechanism. Compared with that of as-cast billet, the mean grain sizes of near-liquidus forged and ECAE formed billets are much smaller. Amoung these three methods, the microstructure evolution for ECAE formed billet is the fastest and the degree of spherpidization is also best.
Thixotropic behaviors of billets prepared by casting, near-liquidus forging and ECAE are studied in the semi-solid state by thermal simulation experiments. The results show that under low stress the steady state filling is achieved for the ECAE formed billet and the thixotropic fluidity of the ECAE formed billet is best, that of near-liquidus formed billet the second and that of as-cast billet the third. The effect of processing parameters and methods of preparing billets on the mechanical properties of thixoforged billets are studies by universal material testing machine. The results show that when the preheating temperature of billet is 560℃and applied pressure is 200MPa, the best mechanical properties of thixoforged parts prepared by casting can be obtain after 30min isothermal holding; the yield strength, ultimate tensile strength and elongation to fracture are 131MPa、280MPa and 9.2%, respectively. The best mechanical properties of thixoforged parts prepared by near-liquidus forging can be obtain after 20min isothermal holding; the yield strength, ultimate tensile strength and elongation to fracture are 161MPa、302MPa and 9.7%, respectively. The best mechanical properties of thixoforged parts prepared by ECAE can be obtain after 15min isothermal holding; the yield strength, ultimate tensile strength and elongation to fracture are 164MPa、307MPa and 11.8%, respectively. As for the four-pass ECAE formed billet, the yield strength, ultimate tensile strength and elongation to fracture are 220MPa、333MPa and 16.1%, respectively under the same conditions with the one-pass ECAE formed billet. The mechanical properties of thixoforged parts prepared by ECAE are first, those prepared by near-liquidus forging are second and those prepared by casting are third.
The comparative studies mentioned above demonstrate that casting, near-liquidus forging and ECAE have their own advantages and these methods can satisfy the different requirements for shape, size and mechanical properties of thixoforged magnesium alloy parts. Considering the cost of preparing billet, the complexity of parts and mechanical properties, near-liquidus forging has competitive advantage and is likely to become one of main methods to producing billets with high performance.
本文采用铸造法、近液相线模锻法和ECAE法制备了AZ91D-Y半固态坯。借助金相显微镜、扫描电子显微镜、X射线衍射仪和万能拉伸试验机分别研究了不同方法制备坯料的微观组织和力学性能。研究表明,添加稀土Y细化了α(Mg)和β(Mg17Al12),产生了杆状的Al2Y新相;在铸造制坯中,可获得粗大的等轴晶,柱状晶不明显;在近液相线模锻制坯中,可获得细小的枝晶组织,且随着模锻压力的增加,坯料的力学性能上升;在ECAE变形中,随着温度的升高,有利于获得等轴状晶粒,但不利于获得较高的屈服强度和抗拉强度,增加ECAE变形道次,有利于获得细小的等轴状再结晶组织。
分别将铸态、近液相线模锻态和ECAE态的坯料加热到半固态温度区间。采用金相显微镜研究了铸造法、近液相线模锻法和ECAE法制备半固态坯料在二次加热过程中的组织演变及特征。研究结果表明,铸造法坯料在二次加热过程中组织的演变规律是由发达的树枝晶演变为大块状组织,大块状组织逐渐分离成碎块状组织,随后固相颗粒球化并主要通过合并的方式长大;近液相线模锻法坯料组织的演变规律是由细小的树枝晶演变为块状组织,块状组织分离成碎块状组织,随后固相颗粒球化并主要通过Ostwald熟化机制长大;ECAE法坯料组织的演变规律是挤压态组织发生再结晶,形成再结晶块状组织,块状组织分离后,发生球化并主要通过Ostwald熟化机制长大。近液相线模锻法和ECAE法坯料的平均固相颗粒尺寸小于铸造法;三种制坯方法中,ECAE法制备坯料的组织演变进程最快,固相颗粒球化效果最好。
采用热模拟试验研究了铸造法、近液相线模锻法和ECAE法制备坯料的触变流动行为。研究结果表明,ECAE法制备坯料在较小的应力作用下,便可实现稳态充填,触变流动性能最好;近液相线模锻法坯料次之,铸造法坯料较差。借助万能拉伸试验机研究了触变模锻工艺参数和坯料制备方法对模锻制件力学性能的影响。研究结果表明,在半固态温度为560℃,模锻压力为200MPa的条件下,铸造法制备坯料在球化30min后触变模锻获得的力学性能最好,其屈服强度、抗拉强度和断后伸长率分别是131MPa、280MPa和9.2%;近液相线模锻法制备的坯料在球化20min后触变模锻获得的力学性能最好,其屈服强度、抗拉强度和断后伸长率分别是161MPa、302MPa和9.7%;ECAE法(一道次ECAE变形)制备的坯料在球化15min后触变模锻获得的力学性能最好,其屈服强度、抗拉强度和断后伸长率分别是164MPa、307MPa和11.8%,四道次变形坯料触变模锻后的屈服强度、抗拉强度和断后伸长率分别为220MPa、333MPa和16.1%,大大高于一道次变形;在相同成形条件下,ECAE法制备坯料触变模锻后的力学性能最好,近液相线模锻法次之,铸造法较差。
上述比较研究结果表明,三种制坯方法均具有不同的优势,因而适用于不同的镁合金半固态模锻件对形状、尺寸和性能的要求。其中从制坯成本、制件复杂程度和触变成形件力学性能考虑,以近液相线模锻法具有综合优势,有希望成为高性能镁合金半固态模锻的主要制坯方法之一。
Based on the policy guidance of energy-saving and emission reduction and the deteriorating situation of metal mineral resources supply, we attach great importance to the development of magnesium alloys because of their low density and great abundance. Accelerated research on the forming technology of magnesium alloys is the one of important measures to realize sustainable development. Currently, the forming technology of magnesium alloys is dominated by diecasting, in combination with liquid forging and forging. However, these technologies have their own drawbacks. For example, although forging can meet the requirement of forming parts with good mechanical properties, it is difficult for this technology to form parts with complex shape. Semi-solid thixoforging is the one of near-net shape technologies to form parts with complex shape. The semi-solid microstructure is characterized by spherical grains. The complexity of parts formed by semi-solid thixoforging exceeds that formed by forging. The mechanical properties of parts formed by semi-solid thixoforging exceed those formed by diecasting and liquid forging. The aim of this paper is to research the preparation of semi-solid billets by casting, near-liquidus forging and equal channel angular extrusion (ECAE), respectively. The microstructure evolution during reheating, the effect of the formation and characteristics of spherical grains on thixoforging and the mechanical properties of parts formed by thixoforging are also studied. Moreover, the application scope and possibility of semi-solid billets prepared by different methods are discussed.
The semi-solid billets are prepared by casting, near-liquidus forging and ECAE, respectively. By means of metallographic microscope, scanning electronic microscope, X-ray diffraction and universal material testing machine, microstructure and mechanical properties of semi-solid billets prepared by three different methods are analyzed. The results show that the addition of Y to AZ91D alloy refines primaryα(Mg) matrix andβ(Mg17Al12) phase. The addition of Y forms rod-shaped Al2Y phase. In the as-cast billet, coarse equiaxed grains are obtained and columnar crystals are not obvious. In the near-liquidus forged billet, fine dendritic microstructures are produced and with increasing applied pressure the mechanical properties of billets are improved. In the ECAE-formed billet, increasing temperature is helpful for obtaining equiaxed grains but unfavorable for improving yield strength and ultimate tensile strength. Moreover, increasing the number of pass promotes the formation of fine equiaxed grains.
Semi-solid billets prepared by casting, near-liquidus forging and ECAE are reheated in the semi-solid temperature range. Microstructure evolution and characteristics of semi-solid billets prepared by casting, near-liquidus forging and ECAE during reheating are also studied. The results show that in the as-cast billet, coarse dendritic structures evolve into large blocked structures, then into cloddy pulverescent structures, finally irregular grains are spheroidized and coarsening mainly by coalescence. In the near-liquidus forged billet, fine dendritic structures evolve into blocked structure, then into cloddy pulverescent structure, finally irregular grains are spheroidized and coarsening mainly by Ostwald ripening mechanism.In the ECAE formed billet, deformed structures transform into recrystallised structures in the early stage. Then recrystallised structures are penetrated by liquid and disintegrated into seperated grains. These seperated grains are spheroidized and coarsening mainly by Ostwald ripening mechanism. Compared with that of as-cast billet, the mean grain sizes of near-liquidus forged and ECAE formed billets are much smaller. Amoung these three methods, the microstructure evolution for ECAE formed billet is the fastest and the degree of spherpidization is also best.
Thixotropic behaviors of billets prepared by casting, near-liquidus forging and ECAE are studied in the semi-solid state by thermal simulation experiments. The results show that under low stress the steady state filling is achieved for the ECAE formed billet and the thixotropic fluidity of the ECAE formed billet is best, that of near-liquidus formed billet the second and that of as-cast billet the third. The effect of processing parameters and methods of preparing billets on the mechanical properties of thixoforged billets are studies by universal material testing machine. The results show that when the preheating temperature of billet is 560℃and applied pressure is 200MPa, the best mechanical properties of thixoforged parts prepared by casting can be obtain after 30min isothermal holding; the yield strength, ultimate tensile strength and elongation to fracture are 131MPa、280MPa and 9.2%, respectively. The best mechanical properties of thixoforged parts prepared by near-liquidus forging can be obtain after 20min isothermal holding; the yield strength, ultimate tensile strength and elongation to fracture are 161MPa、302MPa and 9.7%, respectively. The best mechanical properties of thixoforged parts prepared by ECAE can be obtain after 15min isothermal holding; the yield strength, ultimate tensile strength and elongation to fracture are 164MPa、307MPa and 11.8%, respectively. As for the four-pass ECAE formed billet, the yield strength, ultimate tensile strength and elongation to fracture are 220MPa、333MPa and 16.1%, respectively under the same conditions with the one-pass ECAE formed billet. The mechanical properties of thixoforged parts prepared by ECAE are first, those prepared by near-liquidus forging are second and those prepared by casting are third.
The comparative studies mentioned above demonstrate that casting, near-liquidus forging and ECAE have their own advantages and these methods can satisfy the different requirements for shape, size and mechanical properties of thixoforged magnesium alloy parts. Considering the cost of preparing billet, the complexity of parts and mechanical properties, near-liquidus forging has competitive advantage and is likely to become one of main methods to producing billets with high performance.
引文
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