Zr基大块非晶合金连续成型的凝固过程数值模拟
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摘要
大块非晶合金材料,因其结构特征独特,而具有许多优异的性能,有着良好的应用前景。大块非晶合金的制备是其广泛应用的一个重要方面,因此研究低成本、高效率的大块非晶合金连续制备技术具有重要的现实意义。
本文总结了非晶合金凝固过程数值模拟的研究成果及动态。对铜模铸造法制备Zr基大块非晶合金的凝固过程进行了模拟计算,通过计算结果与实测结果的对比,验证模型的准确程度。并通过计算,分析了大块非晶合金热物性参数的选值对模拟结果的影响,优化了铜模铸型的尺寸。
在对铜模铸造法制备大块非晶合金的凝固过程模拟研究基础上,结合课题组已有成果,对Zr48Cu36Ag8A18大块非晶合金连续成型的凝固过程进行模拟研究。针对自主研发的连铸设备本身特点,推导了复合铸型内的热流密度的计算公式。分析了非晶合金熔体的凝固特性以及Zr基非晶合金热物性参数随温度的变化规律。建立了二维连铸坯温度场有限元模型,确定了初始条件和边界条件,利用ANSYS大型有限元通用分析软件对Zr48Cu36Ag8Al8大块非晶合金连续成型的温度场进行了模拟计算,得到了连铸过程中铸坯的温度场及各主要节点温度随时间的变化曲线。
Zr48Cu36Ag8Al8大块非晶合金连铸过程温度场的模拟计算结果表明：在复合铸型中,水冷铜模对合金熔体起主要冷却作用,石墨铸型内合金熔体温度变化较小；在连铸工艺参数中,浇注温度、冷却水流量、拉坯速率等参数的改变均对铸坯的温度分布和最终结构产生影响。通过工艺参数的优化,使铸件达到非晶合金的形成条件,从而成功实现大块非晶合金的连铸制备。将大块非晶合金的连铸实验结果与模拟结果的对比,验证了连铸模型的准确性。
There are many excellent performances of Bulk glassy alloys (BGA) because of their unique characteristic. The preparation of BGA is an important aspect in engineering application of BGA, therefore the investigation of high efficiency and low cast continuous manufacturing techniques of glassy alloys makes a good sense nowadays.
In this paper, the current status about numerical simulation of amorphous alloys during casting solidification process is reviewed. The temperature fields of solidification of Zr-based BGA during cooper casting were also simulated. Through comparison of the calculation results and the experimental results, the accuracy of the mold, the influence of approximate treatment of thermal physical parameters of BGA and the thickness of copper were analyzed.
On the base of existing research and the results of cooper casting, the numerical simulation of continuous casting of Zr48Cu36Ag8Al8BGA is studied. According to the characteristic of our continuous casting machine, the mathematical model of multi-mold is developed. The character of amorphous alloy melt during solidification and the influence of temperature with Zr-based amorphous had been analyzed. Through application of large-scale general-purpose finite element analysis software ANSYS, under the equations of heat transfer, initial conditions and boundary conditions, two-dimensional finite element model were established and the temperature field of the continuous casting process of Zr48Cu36Ag8Al8had been calculated. BGA had been calculated. The temperature field distribution contour and temperature-time curve of the main point during solidification were acquired.
The simulation results of Zr48Cu36Ag8Al8BGA solidification process show that:in the multi-mold, the cooper mold with water made the main cooling effect and the graphite mold made little; among the casting parameters, pour temperature, cooling water flow rate and casting speed all made influence of the casting result. In order to meet the amorphous formation conditions, these parameters were discussed. At last, with the right parameters, the continuous casting experiments succeed, and the mold was proved correct.
本文总结了非晶合金凝固过程数值模拟的研究成果及动态。对铜模铸造法制备Zr基大块非晶合金的凝固过程进行了模拟计算,通过计算结果与实测结果的对比,验证模型的准确程度。并通过计算,分析了大块非晶合金热物性参数的选值对模拟结果的影响,优化了铜模铸型的尺寸。
在对铜模铸造法制备大块非晶合金的凝固过程模拟研究基础上,结合课题组已有成果,对Zr48Cu36Ag8A18大块非晶合金连续成型的凝固过程进行模拟研究。针对自主研发的连铸设备本身特点,推导了复合铸型内的热流密度的计算公式。分析了非晶合金熔体的凝固特性以及Zr基非晶合金热物性参数随温度的变化规律。建立了二维连铸坯温度场有限元模型,确定了初始条件和边界条件,利用ANSYS大型有限元通用分析软件对Zr48Cu36Ag8Al8大块非晶合金连续成型的温度场进行了模拟计算,得到了连铸过程中铸坯的温度场及各主要节点温度随时间的变化曲线。
Zr48Cu36Ag8Al8大块非晶合金连铸过程温度场的模拟计算结果表明：在复合铸型中,水冷铜模对合金熔体起主要冷却作用,石墨铸型内合金熔体温度变化较小；在连铸工艺参数中,浇注温度、冷却水流量、拉坯速率等参数的改变均对铸坯的温度分布和最终结构产生影响。通过工艺参数的优化,使铸件达到非晶合金的形成条件,从而成功实现大块非晶合金的连铸制备。将大块非晶合金的连铸实验结果与模拟结果的对比,验证了连铸模型的准确性。
There are many excellent performances of Bulk glassy alloys (BGA) because of their unique characteristic. The preparation of BGA is an important aspect in engineering application of BGA, therefore the investigation of high efficiency and low cast continuous manufacturing techniques of glassy alloys makes a good sense nowadays.
In this paper, the current status about numerical simulation of amorphous alloys during casting solidification process is reviewed. The temperature fields of solidification of Zr-based BGA during cooper casting were also simulated. Through comparison of the calculation results and the experimental results, the accuracy of the mold, the influence of approximate treatment of thermal physical parameters of BGA and the thickness of copper were analyzed.
On the base of existing research and the results of cooper casting, the numerical simulation of continuous casting of Zr48Cu36Ag8Al8BGA is studied. According to the characteristic of our continuous casting machine, the mathematical model of multi-mold is developed. The character of amorphous alloy melt during solidification and the influence of temperature with Zr-based amorphous had been analyzed. Through application of large-scale general-purpose finite element analysis software ANSYS, under the equations of heat transfer, initial conditions and boundary conditions, two-dimensional finite element model were established and the temperature field of the continuous casting process of Zr48Cu36Ag8Al8had been calculated. BGA had been calculated. The temperature field distribution contour and temperature-time curve of the main point during solidification were acquired.
The simulation results of Zr48Cu36Ag8Al8BGA solidification process show that:in the multi-mold, the cooper mold with water made the main cooling effect and the graphite mold made little; among the casting parameters, pour temperature, cooling water flow rate and casting speed all made influence of the casting result. In order to meet the amorphous formation conditions, these parameters were discussed. At last, with the right parameters, the continuous casting experiments succeed, and the mold was proved correct.
引文
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[25]柳百成,荆涛等.铸造过程的模拟仿真与质量控制[M].北京：机械工程出版社,2001.
[26]荆涛.凝固过程数值模拟[M].电子工业出版社,2002.
[27]TAKESHITA K, SHINGU P H. An Analysis of the Ribbon Formation Process by the Single Roller Rapid Solidification Technique [J]. Trans Jap Inst Met,1983,24:529-536.
[28]巴发海,沈宁福.平面流铸快速凝固过程的数值研究进展[J].材料科学与工程,2001,19(4)：97-103.
[29]惠希东,杨院生,陈晓明,等.单辊法制备非晶合金中的传热与熔体流动数值模拟[J].金属学报1999,35(11)：1206-1210.
[30]张伟堂,白敏丽,杨洪武.单辊法制备非晶合金中冷器速率的数值计算[J].金属功能材料,2002,9(1)：12-18.
[31]INOUE A, OHTERE K, KITA K, et al. New amorphous Mg-Ce-Ni alloys with high strength and good ductility [J]. Japan J Appl Phys,1988,27:2248-2251.
[32]INOUE A, ZHANG T, MASURMOTO T. Al-La-Ni amorphous alloys with a wide supercooled liquid region [J]. Mater Trans JIM,1989,30:965-972.
[33]INOUE A, ZHANG T, MASURMOTO T. Zr-Al-Ni amorphous alloys with high glass transition temperature and significant supercooled liquid region [J]. Mater Trans JIM,1990,31: 177-183.
[34]INOUE A, ZHANG T, NISHIYAMA N. Preparation of 16mm diameter rod of amorphous Zr65Al7.5Ni10Cu17.5 alloy [J]. Mater Trans JIM,1993,34(12):1234-1237.
[35]INOUE A, GOOK J S. Fe-based ferromagnetic glassy alloys with wide supercooled liquid region [J]. Mater, Trans JIM,1995,36:1180-1183.
[36]INOUE A, ZHANG T, ITOI T, et al. New Fe-Co-Ni-Zr-B amorphous alloys with wide supercooled liquid region and good soft magnetic properties [J]. Mater Trans JIM,1997, 38:359-362.
[37]INOUE A, NISHIYAMA N, MATSUDA T. Preparation of bulk glassy Pd40Ni10Cu30P20 alloy of 40mm in diameter by water quenching [J]. Mater Trans JIM,1996,37:181-184.
[38]ZHANG T, INOUE A. Thermal and mechanical properties of Ti-Ni-Cu-Sn amorphous alloys with a wide supercooled liquid region before crystallization [J]. Mater Trans JIM,1998, 39:1001-1006.
[39]ZHANG T, INOUE A. Preparation of Ti-Cu-Ni-Si-B amorphous alloys with a large supercooled liquid region [J]. Mater Trans JIM,1999,40:301-306.
[40]AKARSUKA R, ZHANG T, KOSHIBA M, et al. Preparation of new Ni-based amorphous alloys with a large supercooled liquid region [J]. Mater Trans JIM,1999,40:258-261.
[41]惠希东,陈国良.块体非晶合金[M].化学工业出版社,2006.1-5.
[42]田学雷,沈君,孙剑飞.大块非晶合金的热物性及冷却过程的数值模拟[J].特种铸造及有色合金,2003,1：29.
[43]郝秋红.Zr基块体非晶合金铸造凝固过程的数值模拟[D].燕山大学硕士毕业论文,2010.
[44]LEE J G, LEE H, OH Y S, et al. Continuous fabrication of bulk amorphous alloy sheets by twin-roll strip casting [J]. Intermetallics,2006,14(8-9):987-993.
[45]LEE J G, PARK S S, LEE S B, et al. Sheet fabrication of bulk amorphous alloys by twinroll strip casting [J]. Scripta Materialia,2005,53(6):693-697.
[46]DUGGAN G, BROWNE D J. Modelling and simulation of twin-roll casting of bulk metallic glasses [J]. Trans Ind Ins Met,2009,62(5):417-421.
[47]SCHROERS M J, ZHOU Z, JOHNSON W L. High temperature viscosity and specific volume of bulk metallic glasses and their correlation with glassforming ability [J]. Acta Materialia,2004,52:3689.
[48]ZHANG Q S, ZHANG W, INOUE A. Preparation of Cu36Zr48Ag8Al8 bulk metallic glass with a diameter of 25mm by copper mold casting [J]. Japan Institute Metals,2007,48(3): 629-631.
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[53]ALBERTUS D, SETYAWAN, HIDEMI KATO, et al. Glass formation dependence on casting-atmosphere pressure in Zr65Al7.5Ni10Cu17.6Pdx(x=0-17.5) alloy system:A resultant effect of quasicrystalline phase transformation and cooling mechanism during mold-casting process [J]. J. Appl. Phys,2008.
[2]PEREPEZKO J H, SMITH J S. Glass-formation and crystallization of highly undercooled Te-Cu alloys [J]. Non-Cryst Solids,1981,44:65-83.
[3]INOUE A, KITA K, ZHANG T, et al. An amorphous La55Al25Ni20 alloy prepared by water quenching [J]. Mater rans,1989,30(9):722-725.
[4]NISHIYAMA N, INOUE A. Preparation of bulk glassy Pd40Ni10Cu30P20 alloy of 40 mm in diameter by water quenching [J]. Mater. Trans.,1996,37(2):181-184.
[5]LI Q F, WENG H R, SUO Z Y, et al. Microstructure and mechanical properties of bulk Mg-Zn-Ca amorphous alloys and amorphous matrix composites. Mater. Sci. Eng. A,2008,487: 301-308.
[6]INOUE A, ZHANG T, MASURMOTO T. Al-La-Ni amorphous alloys with a wide supercooled liquid region [J]. Mater Trans JIM,1989,30:965-972.
[7]IQBAL M, AKHTER J I, ZHANG H F, et al. Synthesis and mechanical properties of Zr-based bulk amorphous alloys [J]. Non-Cryst. Solids,2008,354:3291-3298.
[8]KIM Y C, PARK J K, LEE J K, et al. Amorphous and icosahedral phases in Ti-Zr-Cu-Ni-Be alloys [J].Mat. Sci. Eng,2004,375-377:749-753.
[9]LI Q. Critical cooling rate for the glass formation of ferromagnetic Fe40Ni49P14B6 alloy [J]. Mater. Lett,2007,61:3323-3328.
[10]INOUE A, KATUYA A. Multicomponent Co-based amorphous alloys with wide supercooled liquid region[J]. Mater. Trans,1996(37):1332-1336
[11]OLESZAK D, KOLESNIKOV D, KULIK T. Ni59Zr20Ti16Si5 bulk amorphous alloy obtained by mechanical alloying and powder consolidation [J]. Mat. Sci. Eng,2007,449-451: 1127-1130.
[12]LI C, SAIDA J, KIMINAMI M, et al. Dynamic crystallization process in a supercooled liquid region of Cu40Ti30Ni15Zr10Sn5 amorphous alloy [J]. Non-Cryst. Solids,2000,261(1-3): 108-114.
[13]PEKER A JOHNSON W L. A Highly Processable Metallic Glass:Zn41Ti14Cu12.5Ni10Be22.5[J]. Appl Phys Lett,1993,63(17):2342-2344.
[14]彭伟.La基大块非晶合金的变形行为研究[D].中国科学院力学研究,2007.
[15]INOUE A, SHEN B L, KOSHIBA H, et al. Acta Materialia,2004,52:1631-1637.
[16]FLORE K M, DAUSHKARDT R H. Scripta Materialia.1999,41:937-943.
[17]何圣静,高莉如.非晶态材料及其应用[M].北京：机械工业出版社,1987.
[18]RAMACHANDRA P, CANTOR B, CAHN R W. Viscous behaviour of undercooled metallic Melts [J]. J. Non-Crystal. Solid,1977,24:109-120.
[19]TANNER L E, RAY R. Metallic glass formation and properties in Zr and Ti alloyed with Be-I the binary Zr-Be and Ti-Be systems [J]. Acta. Metall,1979,27:1727-1747.
[20]HNG H H, LI Y, NG S C, et al. Critical cooling rates.for glass formation in Zr66Al9Cu16Ni9 [J]. Int. J. Rapid Solidifi.1996,1:91-102.
[21]JOHNSON, WILLIAM L. Continuous casting of bulk solidifying amorphous alloys [P]. US 2006/0260782. October 28,2004.
[22]刘平日.大块非晶合金连续铸扎技术[P].中国发明专利,CN1486800.2004,4,7.
[23]李金富,阎志杰,何顺荣.大块非晶合金分步冷却连续铸造方法[P].中国发明专利,CN1389317,2003,1,8.
[24]ZHANG TAO, ZHANG XINGGUO, ZHANG WEI, et al. Study on continuous casting of bulk metallic glass. Materials Letters,2011,65(14):2257-2260.
[25]柳百成,荆涛等.铸造过程的模拟仿真与质量控制[M].北京：机械工程出版社,2001.
[26]荆涛.凝固过程数值模拟[M].电子工业出版社,2002.
[27]TAKESHITA K, SHINGU P H. An Analysis of the Ribbon Formation Process by the Single Roller Rapid Solidification Technique [J]. Trans Jap Inst Met,1983,24:529-536.
[28]巴发海,沈宁福.平面流铸快速凝固过程的数值研究进展[J].材料科学与工程,2001,19(4)：97-103.
[29]惠希东,杨院生,陈晓明,等.单辊法制备非晶合金中的传热与熔体流动数值模拟[J].金属学报1999,35(11)：1206-1210.
[30]张伟堂,白敏丽,杨洪武.单辊法制备非晶合金中冷器速率的数值计算[J].金属功能材料,2002,9(1)：12-18.
[31]INOUE A, OHTERE K, KITA K, et al. New amorphous Mg-Ce-Ni alloys with high strength and good ductility [J]. Japan J Appl Phys,1988,27:2248-2251.
[32]INOUE A, ZHANG T, MASURMOTO T. Al-La-Ni amorphous alloys with a wide supercooled liquid region [J]. Mater Trans JIM,1989,30:965-972.
[33]INOUE A, ZHANG T, MASURMOTO T. Zr-Al-Ni amorphous alloys with high glass transition temperature and significant supercooled liquid region [J]. Mater Trans JIM,1990,31: 177-183.
[34]INOUE A, ZHANG T, NISHIYAMA N. Preparation of 16mm diameter rod of amorphous Zr65Al7.5Ni10Cu17.5 alloy [J]. Mater Trans JIM,1993,34(12):1234-1237.
[35]INOUE A, GOOK J S. Fe-based ferromagnetic glassy alloys with wide supercooled liquid region [J]. Mater, Trans JIM,1995,36:1180-1183.
[36]INOUE A, ZHANG T, ITOI T, et al. New Fe-Co-Ni-Zr-B amorphous alloys with wide supercooled liquid region and good soft magnetic properties [J]. Mater Trans JIM,1997, 38:359-362.
[37]INOUE A, NISHIYAMA N, MATSUDA T. Preparation of bulk glassy Pd40Ni10Cu30P20 alloy of 40mm in diameter by water quenching [J]. Mater Trans JIM,1996,37:181-184.
[38]ZHANG T, INOUE A. Thermal and mechanical properties of Ti-Ni-Cu-Sn amorphous alloys with a wide supercooled liquid region before crystallization [J]. Mater Trans JIM,1998, 39:1001-1006.
[39]ZHANG T, INOUE A. Preparation of Ti-Cu-Ni-Si-B amorphous alloys with a large supercooled liquid region [J]. Mater Trans JIM,1999,40:301-306.
[40]AKARSUKA R, ZHANG T, KOSHIBA M, et al. Preparation of new Ni-based amorphous alloys with a large supercooled liquid region [J]. Mater Trans JIM,1999,40:258-261.
[41]惠希东,陈国良.块体非晶合金[M].化学工业出版社,2006.1-5.
[42]田学雷,沈君,孙剑飞.大块非晶合金的热物性及冷却过程的数值模拟[J].特种铸造及有色合金,2003,1：29.
[43]郝秋红.Zr基块体非晶合金铸造凝固过程的数值模拟[D].燕山大学硕士毕业论文,2010.
[44]LEE J G, LEE H, OH Y S, et al. Continuous fabrication of bulk amorphous alloy sheets by twin-roll strip casting [J]. Intermetallics,2006,14(8-9):987-993.
[45]LEE J G, PARK S S, LEE S B, et al. Sheet fabrication of bulk amorphous alloys by twinroll strip casting [J]. Scripta Materialia,2005,53(6):693-697.
[46]DUGGAN G, BROWNE D J. Modelling and simulation of twin-roll casting of bulk metallic glasses [J]. Trans Ind Ins Met,2009,62(5):417-421.
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