基于电磁场与流场耦合的电沉积加工过程仿真
|
摘要
在电沉积过程中运用COMSOL Multiphysics建立电磁场、流场的数学模型,将有限元和有限差分相结合进行电磁场和流场的耦合模拟分析,研究磁场对流场、电流密度分布、镀层表面形貌、晶粒及SiC含量的影响规律,并进行预测与验证。结果表明:施加平行磁场时,磁感应强度在极头之间分布均匀,溶液呈现不规则的运动,镀层厚度预测值的最小误差为1.84%,镀层的晶粒尺寸随着磁感应强度的增大而细化;施加垂直磁场时,两极头间区域的磁感应强度较强,溶液呈现漩涡流动,且流速随磁场感应强度的增大而增大。XRD分析表明:在所研究磁感应强度范围内磁场对晶粒的取向没有明显的影响,镀层中SiC含量随着磁感应强度的增大而增加。
The mathematical models of the electromagnetic field and the flow field in process of electrode positions were established by COMSOL Multiphysics.The simulation analysis of coupling electromagnetic field and flow field was realized by combining finite element and finite difference.The influences of the magnetic field on the flow field,distribution of current density,morphology of coating surface,grain size and SiC content were studied.The prediction and validation were conducted.The results show that the magnetic flux density between the poles is uniform distribution and the solution appears irregular movement in the parallel magnetic field,and the predictive value of minimum error of coating thickness is 1.84%.The grain size of coating is refinement with the increase of magnetic flux density.The magnetic flux density between the poles is stronger,and the solution presents the swirl flow and the flow rate increases with the magnetic flux density increasing in the vertical magnetic field.It is obtained by XRD analysis that the magnetic field has no significant impact on the grain orientation in the studied range of magnetic flux density.The SiC content in the coating increases with the magnetic flux density increasing.
The mathematical models of the electromagnetic field and the flow field in process of electrode positions were established by COMSOL Multiphysics.The simulation analysis of coupling electromagnetic field and flow field was realized by combining finite element and finite difference.The influences of the magnetic field on the flow field,distribution of current density,morphology of coating surface,grain size and SiC content were studied.The prediction and validation were conducted.The results show that the magnetic flux density between the poles is uniform distribution and the solution appears irregular movement in the parallel magnetic field,and the predictive value of minimum error of coating thickness is 1.84%.The grain size of coating is refinement with the increase of magnetic flux density.The magnetic flux density between the poles is stronger,and the solution presents the swirl flow and the flow rate increases with the magnetic flux density increasing in the vertical magnetic field.It is obtained by XRD analysis that the magnetic field has no significant impact on the grain orientation in the studied range of magnetic flux density.The SiC content in the coating increases with the magnetic flux density increasing.
引文
[1]赵林,樊占国,杨中东,高鹏,秦高梧.磁场下电沉积制备CuCo颗粒膜的巨磁电阻效应[J].中国有色金属学报,2009,19(5):924-929.ZHAO Lin,FAN Zhan-guo,YANG Zhong-dong,GAO Peng,QIN Gao-wu.Giant magnetoresistance of CuCo granular films electrodeposited in magnetic field[J].The Chinese Journal of Nonferrous Metals,2009,19(5):924-929.
[2]方建军,李素芳,查文珂,陈宗璋.电镀法制备镍-天然石墨复合材料及外加磁场的影响[J].电镀与涂饰,2010,29(9):1-4.FANG Jian-jun,LI Su-fang,ZHA Wen-ke,CHEN Zong-zhang.Electrodeposition of nickel–graphite composite and the effect of external magnetic field[J].Electroplating&Finishing,2010,29(9):1-4.
[3]贾晶,钟云波,汪超,雷作胜,任维丽,任忠鸣.强磁场中电沉积Ni-P合金的研究[J].上海金属.2009,31(4):10-14.JIA Jing,ZHONG Yun-bo,WANG Chao,LEI Zuo-sheng,REN Wei-li,REN Zhong-ming.Study of Ni-P alloy electro-deposited with high magnetic field[J].Shanghai Metals,2009,31(4):10-14.
[4]龚春红,杜陈强,张玉,吴志申,张治军.外加磁场条件下镍纳米材料的形貌可控制备[J].无机化学学报,2009,25(9):1569-1574.GONG Chun-hong,DU Chen-qiang,ZHANG Yu,WU Zhi-shen,ZHANG Zhi-jun.Morphology-controlled synthesis of nickel nanostructures under magnetic fields[J].Chinese Journal of Inorganic Chemistry,2009,25(9):1569-1574.
[5]TSCHULIK K,KOZA J A,UHLEMANN M,GEBERT A,SCHULTZ L.Effects of well-defined magnetic field gradients on the electrodeposition of copper and bismuth[J].Electrochemistry Communications[J].2009,11(11):2241-2244.
[6]WANG Chao,ZHONG Yun-bo,WANG Jiang,WANG Zhi-qiang,REN Wei-li,LEI Zuo-sheng,REN Zhong-ming.Effect of magnetic field on electroplating Ni/nano-Al2O3 composite coating[J].Journal of Electroanalytical Chemistry.2009,630(1/2):42-48.
[7]王森林,洪亮亮.平行电极表面磁场对电沉积钴-镍镀层的影响[J].稀有金属,2007,31(2):211-215.WANG Sen-lin,HONG Liang-liang.Effect of magnetic field parallel to cathodic surface on electro-plating Co-Ni alloy[J].Chinese Journal of Rare Metals,2007,31(2):211-215.
[8]杨中东,高鹏,薛向欣,樊占国,刘素兰,国栋.稳恒磁场下Ni-W合金镀膜的制备与耐蚀性[J].中国有色金属学报,2006,16(10):1710-1715.YANG Zhong-dong,GAO Peng,XUE Xiang-xin,FAN Zhan-guo,LIU Su-lan,GUO Dong.Preparation and corrosion resistance properties of nickel-tungsten alloy films by electroplating in stabilized magnetic field[J].The Chinese Journal of Nonferrous Metals,2006,16(10):1710-1715.
[9]温艳玲,钟云波,任忠鸣,黄琦晟,邓康,徐匡迪.强磁场对电沉积镍铁合金膜显微组织的影响[J].中国有色金属学报,2006,16(4):715-721.WEN Yan-ling,ZHONG Yun-bo,REN Zhong-ming,HUANG Qi-sheng,DENG Kang,XU Kuang-di.Effect of high static magnetic field on microstructure of electrodeposited NiFe film[J].The Chinese Journal of Nonferrous Metals,2006,16(4):715-721.
[10]黄琦晟.磁场下铜和铬电结晶过程的初步研究[D].上海:上海大学,2006:54-56.HUANG Qi-sheng.Preliminary study of copper and chromium electrocrystallization process in the magnetic field[D].Shanghai:Shanghai University,2006:54-56.
[11]张佳明.磁场引导电沉积纳米晶铁的制备与性能研究[D].武汉:武汉理工大学,2007:32-34.Zhang Jia-ming.Preparation and properties study of nanocrystalline iron using electrodeposition under magnetic field[D].Wuhan:Wuhan University of Technology,2007:32-34.
[12]李茂,周孑民,王长宏.300kA铝电解槽电,磁,流多物理场耦合仿真[J].过程工程学报,2007,7(2):354-359.LI Mao,ZHOU Jie-min,WANG Chang-hong.Coupled simulation of multiple physical fields in a 300 kA aluminum electrolysis cell[J].The Chinese Journal of Process Engineering,2007,7(2):354-359.
[13]孙泽,路贵民,李冰,宋兴福,于建国.电磁场作用下的镁电解槽流场分析[J].华东理工大学学报:自然科学版,2010,36(2):187-191.SUN Ze,LU Gui-min,LI Bing,SONG Xing-fu,YU Jian-guo.Coupled analysis of flow field in magnesium electrolyzer under electromagnetic field[J].Journal of East China University of Science and Technology:Natural Science Edition,2010,36(2):228中国有色金属学报2013年1月187-191.
[14]刘伟,李继,赖延清,徐宇杰,刘业翔.铝电解槽电磁流场的数学建模与应用[J].中国有色金属学报.2008,18(5):909-916.LIU Wei,LI Jie,LAI Yan-qing,XU Yu-jie,LIU Ye-xiang.Development and application of electro-magneto-flow mathematic model of aluminum reduction cells[J].The Chinese Journal of Nonferrous Metals,2008,18(5):909-916.
[15]陈兴润,张志峰,徐骏,石力开.电磁搅拌法制备半固态浆料过程电磁场,流场和温度场的数值模拟[J].中国有色金属学报,2010,20(5):937-944.CHEN Xing-run,ZHANG Zhi-feng,XU Jun,SHI Li-kai.Numerical simulation of electromagnetic field,flow field and temperature field in semi-solid slurry preparation by electromagnetic stirring[J].The Chinese Journal of Nonferrous Metals,2010,20(5):937-944.
[16]高鹏,杨中东,徐小连,陈义庆,钟彬,艾芳芳,李琳.磁场约束下碳钢表面Ni-W合金电镀层的制备与性能[J].材料热处理学报,2012,33(4):136-140.GAO Peng,YANG Zhong-dong,XU Xiao-lian,CHEN Yi-qing,ZHONG Bin,AI Fang-fang,LI Lin.Preparation and properties of electrodeposited nickel-tungsten alloy on carbon steel under magnetic field[J].Transactions of Materials and Heat Treatment,2012,33(4):136-140.
[2]方建军,李素芳,查文珂,陈宗璋.电镀法制备镍-天然石墨复合材料及外加磁场的影响[J].电镀与涂饰,2010,29(9):1-4.FANG Jian-jun,LI Su-fang,ZHA Wen-ke,CHEN Zong-zhang.Electrodeposition of nickel–graphite composite and the effect of external magnetic field[J].Electroplating&Finishing,2010,29(9):1-4.
[3]贾晶,钟云波,汪超,雷作胜,任维丽,任忠鸣.强磁场中电沉积Ni-P合金的研究[J].上海金属.2009,31(4):10-14.JIA Jing,ZHONG Yun-bo,WANG Chao,LEI Zuo-sheng,REN Wei-li,REN Zhong-ming.Study of Ni-P alloy electro-deposited with high magnetic field[J].Shanghai Metals,2009,31(4):10-14.
[4]龚春红,杜陈强,张玉,吴志申,张治军.外加磁场条件下镍纳米材料的形貌可控制备[J].无机化学学报,2009,25(9):1569-1574.GONG Chun-hong,DU Chen-qiang,ZHANG Yu,WU Zhi-shen,ZHANG Zhi-jun.Morphology-controlled synthesis of nickel nanostructures under magnetic fields[J].Chinese Journal of Inorganic Chemistry,2009,25(9):1569-1574.
[5]TSCHULIK K,KOZA J A,UHLEMANN M,GEBERT A,SCHULTZ L.Effects of well-defined magnetic field gradients on the electrodeposition of copper and bismuth[J].Electrochemistry Communications[J].2009,11(11):2241-2244.
[6]WANG Chao,ZHONG Yun-bo,WANG Jiang,WANG Zhi-qiang,REN Wei-li,LEI Zuo-sheng,REN Zhong-ming.Effect of magnetic field on electroplating Ni/nano-Al2O3 composite coating[J].Journal of Electroanalytical Chemistry.2009,630(1/2):42-48.
[7]王森林,洪亮亮.平行电极表面磁场对电沉积钴-镍镀层的影响[J].稀有金属,2007,31(2):211-215.WANG Sen-lin,HONG Liang-liang.Effect of magnetic field parallel to cathodic surface on electro-plating Co-Ni alloy[J].Chinese Journal of Rare Metals,2007,31(2):211-215.
[8]杨中东,高鹏,薛向欣,樊占国,刘素兰,国栋.稳恒磁场下Ni-W合金镀膜的制备与耐蚀性[J].中国有色金属学报,2006,16(10):1710-1715.YANG Zhong-dong,GAO Peng,XUE Xiang-xin,FAN Zhan-guo,LIU Su-lan,GUO Dong.Preparation and corrosion resistance properties of nickel-tungsten alloy films by electroplating in stabilized magnetic field[J].The Chinese Journal of Nonferrous Metals,2006,16(10):1710-1715.
[9]温艳玲,钟云波,任忠鸣,黄琦晟,邓康,徐匡迪.强磁场对电沉积镍铁合金膜显微组织的影响[J].中国有色金属学报,2006,16(4):715-721.WEN Yan-ling,ZHONG Yun-bo,REN Zhong-ming,HUANG Qi-sheng,DENG Kang,XU Kuang-di.Effect of high static magnetic field on microstructure of electrodeposited NiFe film[J].The Chinese Journal of Nonferrous Metals,2006,16(4):715-721.
[10]黄琦晟.磁场下铜和铬电结晶过程的初步研究[D].上海:上海大学,2006:54-56.HUANG Qi-sheng.Preliminary study of copper and chromium electrocrystallization process in the magnetic field[D].Shanghai:Shanghai University,2006:54-56.
[11]张佳明.磁场引导电沉积纳米晶铁的制备与性能研究[D].武汉:武汉理工大学,2007:32-34.Zhang Jia-ming.Preparation and properties study of nanocrystalline iron using electrodeposition under magnetic field[D].Wuhan:Wuhan University of Technology,2007:32-34.
[12]李茂,周孑民,王长宏.300kA铝电解槽电,磁,流多物理场耦合仿真[J].过程工程学报,2007,7(2):354-359.LI Mao,ZHOU Jie-min,WANG Chang-hong.Coupled simulation of multiple physical fields in a 300 kA aluminum electrolysis cell[J].The Chinese Journal of Process Engineering,2007,7(2):354-359.
[13]孙泽,路贵民,李冰,宋兴福,于建国.电磁场作用下的镁电解槽流场分析[J].华东理工大学学报:自然科学版,2010,36(2):187-191.SUN Ze,LU Gui-min,LI Bing,SONG Xing-fu,YU Jian-guo.Coupled analysis of flow field in magnesium electrolyzer under electromagnetic field[J].Journal of East China University of Science and Technology:Natural Science Edition,2010,36(2):228中国有色金属学报2013年1月187-191.
[14]刘伟,李继,赖延清,徐宇杰,刘业翔.铝电解槽电磁流场的数学建模与应用[J].中国有色金属学报.2008,18(5):909-916.LIU Wei,LI Jie,LAI Yan-qing,XU Yu-jie,LIU Ye-xiang.Development and application of electro-magneto-flow mathematic model of aluminum reduction cells[J].The Chinese Journal of Nonferrous Metals,2008,18(5):909-916.
[15]陈兴润,张志峰,徐骏,石力开.电磁搅拌法制备半固态浆料过程电磁场,流场和温度场的数值模拟[J].中国有色金属学报,2010,20(5):937-944.CHEN Xing-run,ZHANG Zhi-feng,XU Jun,SHI Li-kai.Numerical simulation of electromagnetic field,flow field and temperature field in semi-solid slurry preparation by electromagnetic stirring[J].The Chinese Journal of Nonferrous Metals,2010,20(5):937-944.
[16]高鹏,杨中东,徐小连,陈义庆,钟彬,艾芳芳,李琳.磁场约束下碳钢表面Ni-W合金电镀层的制备与性能[J].材料热处理学报,2012,33(4):136-140.GAO Peng,YANG Zhong-dong,XU Xiao-lian,CHEN Yi-qing,ZHONG Bin,AI Fang-fang,LI Lin.Preparation and properties of electrodeposited nickel-tungsten alloy on carbon steel under magnetic field[J].Transactions of Materials and Heat Treatment,2012,33(4):136-140.