含硅铝合金半固态坯料制备过程中微观组织演变的研究
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摘要
金属半固态成形技术以其高效率、高性能、低成本、节能环保等突出优点被誉为“21世纪最具发展前途的近净成形技术”之一,铝合金半固态零件以其质轻、比强度高、导热性好、机加工性能优异和可回收等优点广泛应用于航空航天、汽车和民用领域等行业,尤其是随着汽车产业的发展,汽车轻量化越来越受到人们的重视,半固态成形方法生产的铝合金部件将具有广阔的应用前景。因此,近年来6061、A390、ADC12等含硅铝合金的半固态成形技术研究受到材料加工领域研究人员的广泛关注。
不论是半固态流变成形还是触变成形,制得具有细小、均匀的非枝晶组织半固态坯料是半固态成形技术的关键。为此,人们开发了多种半固态坯料制备工艺,其中半固态坯料的近液相线半连续铸造制备方法以其工艺简单、生产效率高、非枝晶组织细小、利于产业化等优势引起人们的重视,尽管人们对铝合金半固态成形开展了大量工作,但到目前为止,关于近液相线半连续铸造方法制备近共晶和过共晶铝合金的半固态坯料的研究尚未见文献报道。另外,虽然用近液相线半连续铸造方法制备的半固态坯料的平均晶粒尺寸小于50μm,晶粒形貌为非枝晶组织,但是仍然包含有一定量的蔷薇晶,有待于进一步改善。为此,本文采用近液相线半连续铸造方法制备含硅铝合金半固态坯料,并进一步通过形变热处理改善微观组织,本文称之为优化Strain Induced Melt Activation(SIMA)法。
通过实验、理论和多尺度模拟系统研究了亚共晶、近共晶及过共晶含硅铝合金半固态坯料制备过程中微观组织演变的规律,获得的主要结果如下：
(1)根据均质形核理论,考虑晶粒长大因素,建立了近液相线半连续铸造中液固相变的形核模型,nnuclei=IV(1一Q(t))t式中,nnuclei—形核数目；I—单位时间单位体积内的形核率；Q(t)—熔体内未发生形核与晶粒长大部分所占的体积分数；t—凝固时间。进而得出晶粒尺寸d的预测模型该模型对6061合金晶粒尺寸的预测结果与实验吻合,表明均质形核是近液相线半连续铸造过程中液固相变的主要形核机制。
(2)利用多尺度模拟方法对近液相线半连续铸造过程中微观组织演变过程进行了模拟,模拟结果与实验吻合。模拟发现,晶粒生长过程中不断向液相排出溶质,导致晶粒液固界面前沿的溶质浓度较高，引起成分过冷,从而导致晶粒以不同形状生长。当成分过冷度较小时,晶粒以球形生长,当成分过冷度较大时,晶粒以蔷薇状生长。
(3)Si含量对Al-Si合金晶粒尺寸的影响在亚共晶区和过共晶区具有不同的规律。当Si含量在亚共晶范围时,初生相平均尺寸随着Si含量的增加而减小；Si含量接近共晶点时,组织中初生α-Al相、初生Si和共晶组织共存,且晶粒细小；Si含量在过共晶范围时,初生Si和α-A1相平均尺寸随着Si含量的增加而增大
(4)用近液相线半连续铸造方法可以获得优质的过共晶铝硅合金半固态坏料,并能得到均匀分布的近球形初生Si,其平均尺寸大约为10gm。
(5)提出了对近液相线半连续铸造组织进一步改善的处理方法—优化Strain Induced Melt Activation (SIMA)法,对近液相线半连续铸造制得的组织进行形变热处理。当塑性变形程度小于50%时,经过热处理后,随着变形量的增加晶粒尺寸急剧减小,变形量越大,球化度越好；当塑性变形程度大于50%时,经过热处理后,晶粒与小于50%变形的热处理组织相比更加细小、圆整,并且晶粒变化不明显,因此本文选择变形量大于50%。变形后组织经过低温长时间或高温短时间均可获得具有细小、圆整的半固态组织坯料。当对6061合金采用60%变形量进行等温热处理时,满足半固态组织要求的等温温度和时间最佳组合见图5.17(第103页)。
(6)6061、ADC12、A390合金采用近液相线半连续铸造方法可以获得具有细小近球形组织的优质半固态坯料。其最佳工艺参数为浇注温度高于合金液相线温度10℃以内,铸造速度在150mm/min-170mm/min范围内。
Semisolid metal processing is regarded as one of the near-net shape forming technologies with wide application in the21st century due to such advantages as high efficiency, high quality and low cost, energy-saving and environmental protection and so on. The aluminum alloy parts of semi-solid forming have a lot of excellent properties such as light weight, high strength/weight ratio, good heat conductivity, excellent machinability and recycle etc. Semisolid aluminum parts have widely been applied as structural components in the fields of aerospace, automotive, and other commercial application, etc. Especially with the development of the automobile industry, the lightweight of vehicle has drawn more and more attention. In recent years, the study of the semisolid metal processing of such silicon containing aluminum alloys as6061, A390, ADC12has aroused broad attention in the field of materials.
The key to semisolid metal processing is fabricating the semi-solid metals with fine, uniform and spheroidal microstructure for thixoforming or rheoforming. Several fabrication techniques have been applied for a wide variety of alloys. Thereinto the method of near-liquidus semi-continuous casting has attracted extensive study for its advantages such as simple process, high efficiency, fine non-dendritic structure and conducive industrialization, etc.In despite of lots of work for semisolid forming of aluminum alloy, but so far, it can hardly be found literatures about the processing of semisolid billet of the near-eutectic and hypereutectic aluminum alloys by means of near-liquidus. In addition, the average grain size obtained by this method is about50μm and the grain morphology is non-dendritic microstructure. But there still exist a certain amount of rosette grains to be further improved in the alloys. In this paper, the semi-solid billet of silicon containing aluminum alloy was fabricated by near-liquidus semi-continuous casting, and then deformed and heat treated for further improvement of the microstructure, which is called optimization Strain Induced Melt Activation (SIMA) method here.
Evolution of the semisolid microstructures of6061. A390and ADC12were studied by means of experiments, theoretical analysis and multiscale simulation. The main results achieved are as follows:
(1) A nucleation model for the liquid-solid phase transformation was established concerning the semi-continuous casting process according the theory of homogeneous nucleation taking into account the grain growth, as follows nnuclei＝IV(1-Q(t))t
where nnuclei is the nucleation number. I is defined as the nucleation rate equal to the number of the nucleation in the unit time and the unit volume. Q (t) is equal to the fraction of the untransformed volume.t is solidification time.Thus obtaining the model for predicting the grain size The predicting results of the grain size for6061alloy are consistent with the experimental results. It indicates that homogeneous nucleation is the primary nucleation mechanism for liquid-solid phase transformation of alloys in near-liquidus semi-continuous casting process.
(2) The microstructural evolution of the alloys was simulated by multiscale simulation method during the near-liquidus semi-continuous casting process. The simulated morphology and size of the grains are consistent with the experimental results. The simulated results show that the concentration of the melt near the liquid/solid boundary becomes higher because of the solute discharged in the course of solidification, which leads to constitutional supercooling. The degree of the constitutional supercooling results in the different styles of grain growth in the solidification. The grains grow with near-spheroide when the constitutional supercooling is small. The grains grow with rosette character when the composition supercooling is large.
(3) The effects of silicon content on the grain size of Al-Si alloy show different law in hypoeutectic and hypereutectic range.
In the hypoeutectic range, the average size of primary α-Al phase increases with the decrease of Si content. Near the eutectic point, it coexist the primary α-Al phase, the primary Si and the eutectic micro structure, and the obtained grains are fine. In hypereutectic range, the average size of primary Si and that of α-Al phase increase with Si content.
(4) Near-liquidus semi-continuous casting can be used to obtain semisolid billets of hypereutectic Al-Si alloy with fine, uniform, globular and non-dendritic microstructures. which is suitable for semisolid metal processing. The primary Si is near-spheroide and uniformly distributed. The average size of primary Si is about10μm.
(5) The optimal Strain Induced Melt Activation (SIMA) method is proposed in this paper to further improve the microstructure of semi-solid alloys fabricated by near-liquidus semi-continuous casting. When the reduction of the deformation is less than50%, the grain size of the heat treated samples decreases sharply with increasing the degree of the deformation. The larger the degree of the deformation is, the better the roundness of the grain is. When the reduction of the deformation is more than50%, the grain size is smaller, the roundness is better after heat treatment and the grain does not significantly change with increasing the degree of deformation. Therefore, the better reduction is larger than50%. The semisolid billet with fine and near-spheroide microstructure can be obtained at elevated temperature in shorter isothermal holding time or at low temperature in longer isothermal holding time. The appropriate matching of isothermal holding temperature and corresponding isothermal holding time is shown in figure5.17(See p.103).
(6) It is demonstrated that near-liquidus semi-continuous casting is a simple, feasible and effective method to prepare the6061、ADC12and A390semi-solid billets. The optimum process parameters for fine and near-spheroide microstructure are less than10℃above the liquidus temperature for the pouring temperature, and the range of150mm/min-170mm/min for the casting velocity.
不论是半固态流变成形还是触变成形,制得具有细小、均匀的非枝晶组织半固态坯料是半固态成形技术的关键。为此,人们开发了多种半固态坯料制备工艺,其中半固态坯料的近液相线半连续铸造制备方法以其工艺简单、生产效率高、非枝晶组织细小、利于产业化等优势引起人们的重视,尽管人们对铝合金半固态成形开展了大量工作,但到目前为止,关于近液相线半连续铸造方法制备近共晶和过共晶铝合金的半固态坯料的研究尚未见文献报道。另外,虽然用近液相线半连续铸造方法制备的半固态坯料的平均晶粒尺寸小于50μm,晶粒形貌为非枝晶组织,但是仍然包含有一定量的蔷薇晶,有待于进一步改善。为此,本文采用近液相线半连续铸造方法制备含硅铝合金半固态坯料,并进一步通过形变热处理改善微观组织,本文称之为优化Strain Induced Melt Activation(SIMA)法。
通过实验、理论和多尺度模拟系统研究了亚共晶、近共晶及过共晶含硅铝合金半固态坯料制备过程中微观组织演变的规律,获得的主要结果如下：
(1)根据均质形核理论,考虑晶粒长大因素,建立了近液相线半连续铸造中液固相变的形核模型,nnuclei=IV(1一Q(t))t式中,nnuclei—形核数目；I—单位时间单位体积内的形核率；Q(t)—熔体内未发生形核与晶粒长大部分所占的体积分数；t—凝固时间。进而得出晶粒尺寸d的预测模型该模型对6061合金晶粒尺寸的预测结果与实验吻合,表明均质形核是近液相线半连续铸造过程中液固相变的主要形核机制。
(2)利用多尺度模拟方法对近液相线半连续铸造过程中微观组织演变过程进行了模拟,模拟结果与实验吻合。模拟发现,晶粒生长过程中不断向液相排出溶质,导致晶粒液固界面前沿的溶质浓度较高，引起成分过冷,从而导致晶粒以不同形状生长。当成分过冷度较小时,晶粒以球形生长,当成分过冷度较大时,晶粒以蔷薇状生长。
(3)Si含量对Al-Si合金晶粒尺寸的影响在亚共晶区和过共晶区具有不同的规律。当Si含量在亚共晶范围时,初生相平均尺寸随着Si含量的增加而减小；Si含量接近共晶点时,组织中初生α-Al相、初生Si和共晶组织共存,且晶粒细小；Si含量在过共晶范围时,初生Si和α-A1相平均尺寸随着Si含量的增加而增大
(4)用近液相线半连续铸造方法可以获得优质的过共晶铝硅合金半固态坏料,并能得到均匀分布的近球形初生Si,其平均尺寸大约为10gm。
(5)提出了对近液相线半连续铸造组织进一步改善的处理方法—优化Strain Induced Melt Activation (SIMA)法,对近液相线半连续铸造制得的组织进行形变热处理。当塑性变形程度小于50%时,经过热处理后,随着变形量的增加晶粒尺寸急剧减小,变形量越大,球化度越好；当塑性变形程度大于50%时,经过热处理后,晶粒与小于50%变形的热处理组织相比更加细小、圆整,并且晶粒变化不明显,因此本文选择变形量大于50%。变形后组织经过低温长时间或高温短时间均可获得具有细小、圆整的半固态组织坯料。当对6061合金采用60%变形量进行等温热处理时,满足半固态组织要求的等温温度和时间最佳组合见图5.17(第103页)。
(6)6061、ADC12、A390合金采用近液相线半连续铸造方法可以获得具有细小近球形组织的优质半固态坯料。其最佳工艺参数为浇注温度高于合金液相线温度10℃以内,铸造速度在150mm/min-170mm/min范围内。
Semisolid metal processing is regarded as one of the near-net shape forming technologies with wide application in the21st century due to such advantages as high efficiency, high quality and low cost, energy-saving and environmental protection and so on. The aluminum alloy parts of semi-solid forming have a lot of excellent properties such as light weight, high strength/weight ratio, good heat conductivity, excellent machinability and recycle etc. Semisolid aluminum parts have widely been applied as structural components in the fields of aerospace, automotive, and other commercial application, etc. Especially with the development of the automobile industry, the lightweight of vehicle has drawn more and more attention. In recent years, the study of the semisolid metal processing of such silicon containing aluminum alloys as6061, A390, ADC12has aroused broad attention in the field of materials.
The key to semisolid metal processing is fabricating the semi-solid metals with fine, uniform and spheroidal microstructure for thixoforming or rheoforming. Several fabrication techniques have been applied for a wide variety of alloys. Thereinto the method of near-liquidus semi-continuous casting has attracted extensive study for its advantages such as simple process, high efficiency, fine non-dendritic structure and conducive industrialization, etc.In despite of lots of work for semisolid forming of aluminum alloy, but so far, it can hardly be found literatures about the processing of semisolid billet of the near-eutectic and hypereutectic aluminum alloys by means of near-liquidus. In addition, the average grain size obtained by this method is about50μm and the grain morphology is non-dendritic microstructure. But there still exist a certain amount of rosette grains to be further improved in the alloys. In this paper, the semi-solid billet of silicon containing aluminum alloy was fabricated by near-liquidus semi-continuous casting, and then deformed and heat treated for further improvement of the microstructure, which is called optimization Strain Induced Melt Activation (SIMA) method here.
Evolution of the semisolid microstructures of6061. A390and ADC12were studied by means of experiments, theoretical analysis and multiscale simulation. The main results achieved are as follows:
(1) A nucleation model for the liquid-solid phase transformation was established concerning the semi-continuous casting process according the theory of homogeneous nucleation taking into account the grain growth, as follows nnuclei＝IV(1-Q(t))t
where nnuclei is the nucleation number. I is defined as the nucleation rate equal to the number of the nucleation in the unit time and the unit volume. Q (t) is equal to the fraction of the untransformed volume.t is solidification time.Thus obtaining the model for predicting the grain size The predicting results of the grain size for6061alloy are consistent with the experimental results. It indicates that homogeneous nucleation is the primary nucleation mechanism for liquid-solid phase transformation of alloys in near-liquidus semi-continuous casting process.
(2) The microstructural evolution of the alloys was simulated by multiscale simulation method during the near-liquidus semi-continuous casting process. The simulated morphology and size of the grains are consistent with the experimental results. The simulated results show that the concentration of the melt near the liquid/solid boundary becomes higher because of the solute discharged in the course of solidification, which leads to constitutional supercooling. The degree of the constitutional supercooling results in the different styles of grain growth in the solidification. The grains grow with near-spheroide when the constitutional supercooling is small. The grains grow with rosette character when the composition supercooling is large.
(3) The effects of silicon content on the grain size of Al-Si alloy show different law in hypoeutectic and hypereutectic range.
In the hypoeutectic range, the average size of primary α-Al phase increases with the decrease of Si content. Near the eutectic point, it coexist the primary α-Al phase, the primary Si and the eutectic micro structure, and the obtained grains are fine. In hypereutectic range, the average size of primary Si and that of α-Al phase increase with Si content.
(4) Near-liquidus semi-continuous casting can be used to obtain semisolid billets of hypereutectic Al-Si alloy with fine, uniform, globular and non-dendritic microstructures. which is suitable for semisolid metal processing. The primary Si is near-spheroide and uniformly distributed. The average size of primary Si is about10μm.
(5) The optimal Strain Induced Melt Activation (SIMA) method is proposed in this paper to further improve the microstructure of semi-solid alloys fabricated by near-liquidus semi-continuous casting. When the reduction of the deformation is less than50%, the grain size of the heat treated samples decreases sharply with increasing the degree of the deformation. The larger the degree of the deformation is, the better the roundness of the grain is. When the reduction of the deformation is more than50%, the grain size is smaller, the roundness is better after heat treatment and the grain does not significantly change with increasing the degree of deformation. Therefore, the better reduction is larger than50%. The semisolid billet with fine and near-spheroide microstructure can be obtained at elevated temperature in shorter isothermal holding time or at low temperature in longer isothermal holding time. The appropriate matching of isothermal holding temperature and corresponding isothermal holding time is shown in figure5.17(See p.103).
(6) It is demonstrated that near-liquidus semi-continuous casting is a simple, feasible and effective method to prepare the6061、ADC12and A390semi-solid billets. The optimum process parameters for fine and near-spheroide microstructure are less than10℃above the liquidus temperature for the pouring temperature, and the range of150mm/min-170mm/min for the casting velocity.
引文
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