镁合金板带铸轧凝固前沿控制及缺陷成形机理研究
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摘要
双辊铸轧是一种将铸造与轧制两道工序合二为一、直接从液态金属制备板坯的近终形生产工艺。双辊铸轧技术应用于镁合金板带生产时，可大幅缩短工艺流程、提高成材率，并显著降低板材加工成本，在镁合金板带加工领域具有重要意义。镁合金板带铸轧过程中，铸轧区熔体凝固前沿的位置与形状对板坯的凝固、变形行为产生重要影响，并进一步影响板坯缺陷形成及表面质量。资料显示，目前镁合金铸轧过程中凝固、变形行为及缺陷成形机理等基础研究鲜有报道。本文根据镁合金铸轧技术研究现状，结合已有的研究基础，在镁合金板带铸轧凝固前沿控制、液流分配技术及缺陷成形机理三个方面开展了研究。
本文第一部分采用工艺试验与数理计算相结合的方法，在忽略铸轧区熔体沿板宽方向上温度场分布差异的理想条件下，分析了镁合金铸轧工艺参数对铸轧区凝固前沿位置、板坯表面缺陷影响作用。研究结果表明，铸轧速度显著影响镁合金铸轧板坯凝固层焊合点位置，并进一步影响板坯表面质量。将铸轧速度控制在合理范围后，凝固层焊合点位置位于优化区域，可消除板坯表面缺陷，铸带表面质量良好。结合凝固层焊合点位置与铸轧主要工艺参数之间的关系，建立了凝固层焊合点位置控制模型。将控制模型应用于工艺试验时，可改善并消除镁合金铸轧板坯表面缺陷（冷凝、缩边、横向裂纹、孔洞、飞边及流淌等），提高镁合金铸轧板坯表面质量。
本文第二部分研究了液流分配结构对铸轧区熔体温度场分布的影响规律，阐述了镁合金铸轧板坯热带缺陷的形成机制与控制措施。
采用SOLA-VOF有限差分法，对普通液流分配结构下镁合金铸轧区熔体温度场分布规律进行仿真，分析液流分配结构对铸轧区熔体温度场分布影响规律。仿真结果表明，采用普通液流分配结构时，铸轧区镁合金熔体在板宽方向上区域温度分布极不均匀，温度差值达到15℃；针对模拟工况开展工艺试验时，制备铸轧板坯均出现不同程度的热带缺陷，而供液嘴内部镁合金熔体温度区域温度之间差值达到25℃。因此，普通液流分配结构不满足镁合金铸轧工艺要求。
针对镁合金铸轧板坯热带缺陷特征、形成机理及控制措施进行研究。结果表明，铸轧过程中板坯局部温度在离开轧辊后仍高于合金非平衡凝固固相线温度时，将在铸带局部产生热带缺陷。忽略液流分配的影响时，铸轧区内全凝固点位置决定了全凝固基准线的位置；而液流分配直接影响铸轧过程中熔体温度分布均匀性，决定带坯在宽度方向上全凝固线位置与形状，最终决定镁合金铸轧板坯热带缺陷出现的几率与严重程度。采用优化液流分配技术，可大幅改善铸轧板坯熔体温度分布均匀性，从而有效控制热带缺陷。
针对对普通液流分配结构分流效果，采用数值模拟方法进行结构优化，并开展工艺试验进行验证。结果表明：采用优化的分流结构开展镁合金铸轧工艺试验，板坯热带缺陷基本消除；实测供液嘴内部熔体温度结果表明，区域之间温度差值控制在10℃以内。优化分流结构大幅度改善铸轧区镁合金熔体温度均匀性，铸轧板坯热带缺陷得到有效控制。
本文第三部分对镁合金铸轧板坯表面点状偏析、中心线偏析缺陷的特征及形成机制进行研究，提出了镁合金铸轧板坯偏析缺陷的控制措施。
采用金相检测、扫描电镜等分析了镁合金铸轧板坯表面点状偏析、中心线偏析缺陷特征，结果表明：镁合金铸轧板坯表面点状偏析、中心线偏析由富含溶质Al、Zn元素的金属间化合物组成，偏析内由细小等轴晶组成，与基体组织特征差异明显，部分表面点状偏析缺陷与基体之间存在明显分界线。
采用快速停机的方式，获得铸轧区急停试样，分析了点状偏析的形成过程。实际工艺中，可通过缩短结晶区长度、控制前箱液位高度以及将铸轧合金溶质控制在下限等措施改善镁合金铸轧板坯表面点状偏析缺陷。镁合金铸轧工艺中凝固与变形行为对中心线偏析缺陷产生重要影响。铸轧过程中带坯的轧制变形将挤压液穴中心区域富集溶质液态金属，使其朝铸轧反方向移动；供液嘴不断供给的过热金属液持续冲刷凝固前沿，导致凝固界面重熔并产生强迫对流，促进溶质扩散；合理控制凝固前沿位置，可通过上述两种作用达到抑制、消除中心线偏析缺陷目的。
Twin-roll casting (TRC) is a near-net-shape process which combines rapidsolidification with hot rolling by one-step method to produce thin strips directly frommolten metal. It is believed that strip casting-annealing is a promising route toproduce magnesium alloy strip with low cost and high productivity. Position andconfiguration of solidification front in set-back play an important role on thesolidification and deformation behaviors during twin-roll casting processing ofmagnesium alloys strip. Furthermore, this effects influence the defect-formation ofstrips. On the basis of brief review of the history and the evaluation of previousresearch works, the controlling of solidification front, melt distribution anddefect-formation mechanism of magnesium alloys strip processed by twin-rollcasting was investigated experimentally and theoretically.
In the first part, the effect of parameters on the position of the solidificationfront and surface defects of strip was analyzed regardless of the difference of moltenmetal temperature distribution in set-back. Experimental results show the roll speedhas a prominent effect on the solidification front position and surface-defectsforming. Optimum zone of kiss-point of solidification layer was achieved from thetheoretically derivation and experimental results. A kiss-point model which considersthe strip thickness, set-back length and roll speed was established to optimizeprocess and enhance surface quality of magnesium alloys strip. Results showed thatthe model of kiss-point of solidification layer effectively optimized the twin-rollcasting processing and enhanced the surface quality of magnesium alloys strip.
In the second part, the effect of configuration of feed tip nozzle on cavitytemperature field and location/shape of the solidification front was investigated by themethod which combined numerical simulation with experiments; furthermore, hot lineforming mechanism and correlated controlling methods was exploited.
Temperature field in magnesium twin roll casting under regular configuration was simulated utilizing the SOLA-VOF finite difference method, simulation resultsshowed magnesium melts in the set-back presented extraordinary non-uniformtemperature distribution in the width direction. Experiments results indicated thatunder regular configuration, with temperature difference up to25℃，hot line defectsof various degree was observed on the strip. Therefore, the regular configuration offeed tip nozzle was unable to achieve the qualified strip.
During twin-roll casting processing of magnesium alloys, if local temperatureswere higher than the non-equilibrium solidification solid line temperature after thedeparture of the strip from the rollers, and hot line defects were thus generated. Meltdistribution had a prominent influence on the temperature distribution uniformity, thusdetermined the location/shape of the fully solidified line, which resulted in the oddsand severance degree of hot line defects in twin-roll casting process of magnesiumalloy.
The optimized configuration of feed tip nozzle was achieved by numericalsimulation which was validated by the experiments. Experimental results indicatedthat under the optimized configuration, the melts temperature difference in the tipfront zones can be decreased to less than10℃. The simulation results were validatedwith experimental results, and the hotline-free magnesium strips have achieved bytwin-roll casting though the optimized configuration of feed tip nozzle.
The third part of this thesis was focused on the forming mechanism of surfacebleeds and centerline segregations were studied.
Results showed that surface bleeds were compromised by solute richintermetalics. The experimental investigations were mainly conducted on so-calledstop-samples, which are produced by abruptly interrupting casting. By analyzing theheat, mass and momentum transfer and the deformation characters in the set-back ofmagnesium alloys strips, the character, forming mechanism and measurement ofsurface bleeds were discussed. In practical processing, surface segregation can bealleviated by shortening the length of solidification zone, controlling the melts height and lower the solute percentage to the lower limits.
Centerline segregation of magnesium alloys strip was compromised by soluterich intermetalics. Solidification and deformation behavior of the twin-roll castinghave a major influence over the centerline segregation. Deformation in the twin-rollcasting squeezed the solute rich melts in the central of strips, and melts moved againstthe roll direction, which changes the shape of the solidification interface. Bycontrolling the solidification front in a proper location, the overheated melts suppliedby feed tip could washouts the solidification front, which can cause the re-melt of thesolidification front and the forced convection. It was beneficial to the solute diffusion,and the center line segregation could be decreased or eliminated. When otherconditions determined, by controlling the cast velocity according to the modelsinduction, the solidification front could be controlled to the proper domain, andcenterline segregation could be decreased or eliminated.
Through the guidance of the research results, twin roll casting of magnesiumalloys could be stabilized and optimized, and the defects-free magnesium alloys stripshad been achieved by twin-roll casting.
本文第一部分采用工艺试验与数理计算相结合的方法，在忽略铸轧区熔体沿板宽方向上温度场分布差异的理想条件下，分析了镁合金铸轧工艺参数对铸轧区凝固前沿位置、板坯表面缺陷影响作用。研究结果表明，铸轧速度显著影响镁合金铸轧板坯凝固层焊合点位置，并进一步影响板坯表面质量。将铸轧速度控制在合理范围后，凝固层焊合点位置位于优化区域，可消除板坯表面缺陷，铸带表面质量良好。结合凝固层焊合点位置与铸轧主要工艺参数之间的关系，建立了凝固层焊合点位置控制模型。将控制模型应用于工艺试验时，可改善并消除镁合金铸轧板坯表面缺陷（冷凝、缩边、横向裂纹、孔洞、飞边及流淌等），提高镁合金铸轧板坯表面质量。
本文第二部分研究了液流分配结构对铸轧区熔体温度场分布的影响规律，阐述了镁合金铸轧板坯热带缺陷的形成机制与控制措施。
采用SOLA-VOF有限差分法，对普通液流分配结构下镁合金铸轧区熔体温度场分布规律进行仿真，分析液流分配结构对铸轧区熔体温度场分布影响规律。仿真结果表明，采用普通液流分配结构时，铸轧区镁合金熔体在板宽方向上区域温度分布极不均匀，温度差值达到15℃；针对模拟工况开展工艺试验时，制备铸轧板坯均出现不同程度的热带缺陷，而供液嘴内部镁合金熔体温度区域温度之间差值达到25℃。因此，普通液流分配结构不满足镁合金铸轧工艺要求。
针对镁合金铸轧板坯热带缺陷特征、形成机理及控制措施进行研究。结果表明，铸轧过程中板坯局部温度在离开轧辊后仍高于合金非平衡凝固固相线温度时，将在铸带局部产生热带缺陷。忽略液流分配的影响时，铸轧区内全凝固点位置决定了全凝固基准线的位置；而液流分配直接影响铸轧过程中熔体温度分布均匀性，决定带坯在宽度方向上全凝固线位置与形状，最终决定镁合金铸轧板坯热带缺陷出现的几率与严重程度。采用优化液流分配技术，可大幅改善铸轧板坯熔体温度分布均匀性，从而有效控制热带缺陷。
针对对普通液流分配结构分流效果，采用数值模拟方法进行结构优化，并开展工艺试验进行验证。结果表明：采用优化的分流结构开展镁合金铸轧工艺试验，板坯热带缺陷基本消除；实测供液嘴内部熔体温度结果表明，区域之间温度差值控制在10℃以内。优化分流结构大幅度改善铸轧区镁合金熔体温度均匀性，铸轧板坯热带缺陷得到有效控制。
本文第三部分对镁合金铸轧板坯表面点状偏析、中心线偏析缺陷的特征及形成机制进行研究，提出了镁合金铸轧板坯偏析缺陷的控制措施。
采用金相检测、扫描电镜等分析了镁合金铸轧板坯表面点状偏析、中心线偏析缺陷特征，结果表明：镁合金铸轧板坯表面点状偏析、中心线偏析由富含溶质Al、Zn元素的金属间化合物组成，偏析内由细小等轴晶组成，与基体组织特征差异明显，部分表面点状偏析缺陷与基体之间存在明显分界线。
采用快速停机的方式，获得铸轧区急停试样，分析了点状偏析的形成过程。实际工艺中，可通过缩短结晶区长度、控制前箱液位高度以及将铸轧合金溶质控制在下限等措施改善镁合金铸轧板坯表面点状偏析缺陷。镁合金铸轧工艺中凝固与变形行为对中心线偏析缺陷产生重要影响。铸轧过程中带坯的轧制变形将挤压液穴中心区域富集溶质液态金属，使其朝铸轧反方向移动；供液嘴不断供给的过热金属液持续冲刷凝固前沿，导致凝固界面重熔并产生强迫对流，促进溶质扩散；合理控制凝固前沿位置，可通过上述两种作用达到抑制、消除中心线偏析缺陷目的。
Twin-roll casting (TRC) is a near-net-shape process which combines rapidsolidification with hot rolling by one-step method to produce thin strips directly frommolten metal. It is believed that strip casting-annealing is a promising route toproduce magnesium alloy strip with low cost and high productivity. Position andconfiguration of solidification front in set-back play an important role on thesolidification and deformation behaviors during twin-roll casting processing ofmagnesium alloys strip. Furthermore, this effects influence the defect-formation ofstrips. On the basis of brief review of the history and the evaluation of previousresearch works, the controlling of solidification front, melt distribution anddefect-formation mechanism of magnesium alloys strip processed by twin-rollcasting was investigated experimentally and theoretically.
In the first part, the effect of parameters on the position of the solidificationfront and surface defects of strip was analyzed regardless of the difference of moltenmetal temperature distribution in set-back. Experimental results show the roll speedhas a prominent effect on the solidification front position and surface-defectsforming. Optimum zone of kiss-point of solidification layer was achieved from thetheoretically derivation and experimental results. A kiss-point model which considersthe strip thickness, set-back length and roll speed was established to optimizeprocess and enhance surface quality of magnesium alloys strip. Results showed thatthe model of kiss-point of solidification layer effectively optimized the twin-rollcasting processing and enhanced the surface quality of magnesium alloys strip.
In the second part, the effect of configuration of feed tip nozzle on cavitytemperature field and location/shape of the solidification front was investigated by themethod which combined numerical simulation with experiments; furthermore, hot lineforming mechanism and correlated controlling methods was exploited.
Temperature field in magnesium twin roll casting under regular configuration was simulated utilizing the SOLA-VOF finite difference method, simulation resultsshowed magnesium melts in the set-back presented extraordinary non-uniformtemperature distribution in the width direction. Experiments results indicated thatunder regular configuration, with temperature difference up to25℃，hot line defectsof various degree was observed on the strip. Therefore, the regular configuration offeed tip nozzle was unable to achieve the qualified strip.
During twin-roll casting processing of magnesium alloys, if local temperatureswere higher than the non-equilibrium solidification solid line temperature after thedeparture of the strip from the rollers, and hot line defects were thus generated. Meltdistribution had a prominent influence on the temperature distribution uniformity, thusdetermined the location/shape of the fully solidified line, which resulted in the oddsand severance degree of hot line defects in twin-roll casting process of magnesiumalloy.
The optimized configuration of feed tip nozzle was achieved by numericalsimulation which was validated by the experiments. Experimental results indicatedthat under the optimized configuration, the melts temperature difference in the tipfront zones can be decreased to less than10℃. The simulation results were validatedwith experimental results, and the hotline-free magnesium strips have achieved bytwin-roll casting though the optimized configuration of feed tip nozzle.
The third part of this thesis was focused on the forming mechanism of surfacebleeds and centerline segregations were studied.
Results showed that surface bleeds were compromised by solute richintermetalics. The experimental investigations were mainly conducted on so-calledstop-samples, which are produced by abruptly interrupting casting. By analyzing theheat, mass and momentum transfer and the deformation characters in the set-back ofmagnesium alloys strips, the character, forming mechanism and measurement ofsurface bleeds were discussed. In practical processing, surface segregation can bealleviated by shortening the length of solidification zone, controlling the melts height and lower the solute percentage to the lower limits.
Centerline segregation of magnesium alloys strip was compromised by soluterich intermetalics. Solidification and deformation behavior of the twin-roll castinghave a major influence over the centerline segregation. Deformation in the twin-rollcasting squeezed the solute rich melts in the central of strips, and melts moved againstthe roll direction, which changes the shape of the solidification interface. Bycontrolling the solidification front in a proper location, the overheated melts suppliedby feed tip could washouts the solidification front, which can cause the re-melt of thesolidification front and the forced convection. It was beneficial to the solute diffusion,and the center line segregation could be decreased or eliminated. When otherconditions determined, by controlling the cast velocity according to the modelsinduction, the solidification front could be controlled to the proper domain, andcenterline segregation could be decreased or eliminated.
Through the guidance of the research results, twin roll casting of magnesiumalloys could be stabilized and optimized, and the defects-free magnesium alloys stripshad been achieved by twin-roll casting.
引文
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