挤压坯预成形模压成形过程中镁合金组织与性能的演变
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摘要
一次封闭模压挤压预成形型材,是高材料利用率、短流程、高效率生产高品质镁合金锻件的新方法。尽管在镁合金挤压变形规律、组织性能检测及工艺理论基础上目前投入了大量人力物力,形成了巨量的文献报道,但迄今仍然鲜有对镁合金挤压变形材在封闭模压过程中的组织和性能演变的实验观察和理论研究报道。
本文拟通过对典型镁合金的挤压变形组织在封闭热模压过程中的演化及其对机械性能的影响进行深入系统的实验研究和理论分析,探明镁合金挤压变形型材在封闭模压过程中的组织和性能演变规律,为奠定挤压预成形模压成形技术的理论和实验基础提供了一定实验依据。
为此,以挤压态AZ81镁合金为主要研究对象,用半连续铸坯挤压制备了具有锻件二维几何特征的预成形坯型材,截取与锻件等体积的模压坯料,然后对截断型材用封闭模压方法一次模压成形获得最终成形锻件。采用Gleeble1500热力模拟机对挤压态AZ81镁合金的热压缩变形行为进行分析研究,为确定模压成形工艺参数的制定提供一定的理论依据,然后对进行模压成形试验,采用金相、SEM、EBSD、常温拉伸和硬度检测等检测手段,深入分析了镁合金在挤压预成形坯模压成形过程中的材料内部组织及力学性能的演变规律,对挤压预成形坯模压近(或净)终成形工艺的经济性及可行性进行了探讨。
主要研究内容及结论如下:
(1)研究了挤压工艺对镁合金组织与力学性能的影响,并通过SEM分析了挤压工艺对镁合金断裂机制的影响。研究表明在热挤压过程中发生了动态再结晶,合金的晶粒在热挤压过程中产生了明显细化。挤压比相同时,随挤压温度的升高,基体的再结晶程度增加,合金的晶粒在370℃,挤压速度6~20mm/s时,晶粒最细,力学性能最好,温度继续升高,合金的再结晶晶粒尺寸逐渐增大;挤压温度相同时,挤压比越大,基体的再结晶就越完全,晶粒分布越均匀,合金的晶粒尺寸也随之减小,抗拉强度、屈服强度及伸长率得到大幅改善。与铸态合金相比,通过挤压方法提高了合金的屈服强度的同时还提高了镁合金的塑性,为后续的模压成形提供了高品质的预成形模压坯料;
(2)研究了挤压态AZ81镁合金高温压缩变形行为。合金在高温压缩过程中表现为典型的动态再结晶特征。温度较低或应变速率较高时,流变曲线所达到的峰值应力较大,而在相同应变速率下,峰值应变随温度升高而明显减小;流变应力、应变速率和变形温度之间的关系可用双曲正弦函数表示,其中平均激活能Q=182.17KJ/mol,应力指数α=0.0043Mpa-1,应力指数n=4.4865,其高温塑性流变行为的本构方程为:峰值应变与变形条件(Z参数)之间满足关系式
(3)对挤压态AZ81镁合金进行热加工性能进行分析,根据功率耗散图及失稳图制定模压成形工艺,并对模压成形后试样的显微组织及力学性能进行了研究,结果表明:经400℃模压变形后,合金的晶粒在三向压力及挤压态下等轴晶粒沿模压方向被拉长或被破碎成无数个细小单元个体,试样断面易形成强烈的纤维组织,力学性能较挤压态时有较大幅度的提高,挤压态AZ81镁合金的抗拉强度σ_b=331MPa;屈服强度σ_s=236.7MPa;延伸率δ=16.6%;模压成形后σ_b=350.2Mpa,σ_s=244.8MPa;δ=16.1%;经T6热处理后合金,AZ81镁合金的抗拉强度改善不明显,而屈服强度有了明显的改善,但延伸率显著下,其力学性能为σ_b=358.5Mpa,σ_s=270.7MPa;δ=9.8%;
(4)模压成形过程中,合金显著细化,挤压态时晶粒平均尺寸为3.5μm;当变形量较小时,晶粒有长大趋势,随变形量增至30%时,晶粒细化至2~3μm,晶粒细化不明显,当变形量增加到50%~60%,由于外加机械强应力作用,晶粒细化至1~2.5μm,挤压板主要以基面织构(basal texture){0001}<1010>为主,且与挤压方向平行,随变形量的增加,合金内部晶粒在剪切内应力作用下,沿晶界发生一定角度的转动,并随变形量的增加,初始基面织构及晶粒取向的变化越明显,但织构强度较挤压态时变弱,基面的择优取向(Preferential orientation)偏离了ED方向,向FD方向集中,随变形量的增加,由于非基面滑移开动,织构方向偏离挤压方向,而向模压方向偏转,且晶粒取向差分布逐渐转向大角方向,在模压过程中易于形成与模压方向垂直的织构;挤压预成形坯模压复合成形过程中,晶粒细化是提高合金力学性能的重要手段,而合金的织构对材料的力学性能起着重要的作用。
(5)分析了挤压预成形模压复合成形工艺的经济性及技术可行性,通过该工艺不仅能获得具有模具内腔形状及尺寸的净终成形的锻件产品,而且所获得的锻件晶粒显著细化,组织致密均匀,综合力学性能好,且是一种高效率、低能耗、高品质、高工艺收得率的一种塑性成形工艺,具有一定的工业发展前景。
The one-shot closed-die pressing for extruded preform is a new process to produce magnesium forging products with high material utilization, short process, high efficiency as well as high quality. The current research are focused on the law of Mg deformation, tests of microstructure and properties and the theory of process, and the extensive literature is consequently presented. However, it is rare to see reports about the experimental observations and theoretical research on the evolution of the microstructure and performance for magnesium extruded preforing profile in the process of closed-die pressing.
The microstructure evolution for typical Mg extruded profiles in hot closed-die pressing and the effects on mechanical properties in this paper were experimentally investigated and theoretically analyzed. And the evolution of microstructure and performance on extrude Mg profile during pressing were eventually discovered, which laid a theoretical and experimental foundation on the technology of closed-die pressing process for extruded preform.
Therefore, a preform extrusion profile with the 2D geometrical feature of the specimens was first produced in use of AZ81, Then, the profile was sectioned, and net-shapely pressed into the specimens with the required geometry. The Gleeble1500 thermo-simulation machine was adopted to conduct analytical investigation on the hot deformation behavior of the as-extruded AZ81 in preparation for process parameters of pressing forming. Instruments such as metaloscope, SEM,EBSD, tensile testing machine as well as hardness test equipments were used during the whole experiment to deeply analyze the evolution of microstructure and mechanical properties of the profile during pressing forming. The economy and feasibility of near-net-shape pressing for extruded preform were also discussed.
The major contests and conclusions are as follows:
(1) The influence of extrusion preforming process on mechanical performance together with on fracture mechanism for Mg alloys through SEM were studied, and preventive measures for avoiding material defects in extrusion preforming were also presented to guarantee the profiles with uniform and fine microstructure. Study shows that dynamic recrystallization (DRX) and grain refinement are occurred during hot pressing. With same extrusion ratio, DRX increases as temperatures elevates. The finest grain size and excellent mechanical properties can be obtained with temperature at 370℃and extrusion rate 6~20mm/s, while the size of recrystalized grain becomes larger as temperature continues to increase. Under the same temperature, the larger the extrusion ratio is, the more the DRX happens, and the more uniform the grains are. Meanwhile, the grain size is coherently decreased, and tensile strength, yield strength as well as elongation are improved. The extrusion preforming process not only increases the yield strength of Mg alloys but also improves the plasticity in comparison with as-cast alloys, in order that following press forming experiment can be done with the high quality profiles.
(2) The hot deformation behavior of the as-extruded AZ81 were also investigated, and microstructure during hot compressive deformation is mainly characterized by DRX. The peak stress of flow curve is higher either at lower temperature or faster strain rate. While at the same rate, the peak strain obviously decreases as temperature increases. The relationship amongst flow stress, strain rate and temperature can be described as , where the average activation energy Q=182.17KJ/mol, the stress exponentα= 0.0043Mpa-1, the strain exponent n=4.4865, And the constitutive equation for high-temperature plastic flow behavior is in which the peak strain and deformation condition(Z) suit to
(3) Analysis on the hot deformation mecahnism and processing Map of as-extruded AZ81 magnesium alloy, according to power dissipation map and instablility map developed molding forming process. The microstructure and mechanical properties of specimens after pressing forming were researched. The results show that after pressed at 400℃, the equiaxed grains are elongated along pressing direction or fragmented into numerous small unit particles under three-dimensional compressive stress and extrusion force. A strong texture structure is formed in the fracture area, and mechanical properties are increased a certain degree but not too much compared with that of as-extruded AZ81. The tensile strengthσ_b, the yield strengthσ_s, the elongationδof as-extruded AZ81 are 331MPa, 236.7MPa and 16.6% respectively, while that of after-pressed AZ81 are 350.2MPa, 244.8MPa, and 16.1% respectively. After T6 heat-treated alloy, AZ81 magnesium alloy to improve the tensile strenght is not obvious, while the yield strength has been significicantly improved, but the extension rate was significantly, its mechanical properties ofσ_b = 358.5Mpa,σ_s = 270.7MPa;δ= 9.8%.
(4) Remarkable grain refinement occurs during pressing process, while the average grain size in as-extruded is 3.5μm. With small deformation ratio, the grain tends to grow, whereas the grain is refined to 1~2.5μm when deformation ratio increases to 50%~60% together with outer force is applied. The profiles of extruded preforming is dominantly on basal texture {0001}<10 1 0>, and the basal plane is parallel to extrusion direction(ED). As deformation continues, the inner shear stress gives rise to grain rotation along boundaries with certain angles and initial basal texture and grain orientation vary remarkably, though the texture intensity is weaker than that of as-extruded. The basal preferential orientation deviates from extrusion direction (ED) and aligns with the FD. With deformation ratio increased and non-basal slip activated, the texture orientation turns away from extrusion direction(ED) and deflects along pressing direction. And the grain misorientation gradually turns into the direction of the larger angle. Consequently, it is prone to create a texture perpendicular to pressing direction. The grain refinement and texture for extruded preform and pressing compound process make great contributions to the mechanical properties.
(5) The economy and feasibility of the pressing for extruded preform were finally analyzed. Through this technique, the near-net shape products with remarkable refined and uniform grains and excellent comprehensive mechanical properties can be obtained. It is a plastic process that combines with high efficiency, low energy consumption, high quality as well as high yield ratio, which can be put into industry in the future.
本文拟通过对典型镁合金的挤压变形组织在封闭热模压过程中的演化及其对机械性能的影响进行深入系统的实验研究和理论分析,探明镁合金挤压变形型材在封闭模压过程中的组织和性能演变规律,为奠定挤压预成形模压成形技术的理论和实验基础提供了一定实验依据。
为此,以挤压态AZ81镁合金为主要研究对象,用半连续铸坯挤压制备了具有锻件二维几何特征的预成形坯型材,截取与锻件等体积的模压坯料,然后对截断型材用封闭模压方法一次模压成形获得最终成形锻件。采用Gleeble1500热力模拟机对挤压态AZ81镁合金的热压缩变形行为进行分析研究,为确定模压成形工艺参数的制定提供一定的理论依据,然后对进行模压成形试验,采用金相、SEM、EBSD、常温拉伸和硬度检测等检测手段,深入分析了镁合金在挤压预成形坯模压成形过程中的材料内部组织及力学性能的演变规律,对挤压预成形坯模压近(或净)终成形工艺的经济性及可行性进行了探讨。
主要研究内容及结论如下:
(1)研究了挤压工艺对镁合金组织与力学性能的影响,并通过SEM分析了挤压工艺对镁合金断裂机制的影响。研究表明在热挤压过程中发生了动态再结晶,合金的晶粒在热挤压过程中产生了明显细化。挤压比相同时,随挤压温度的升高,基体的再结晶程度增加,合金的晶粒在370℃,挤压速度6~20mm/s时,晶粒最细,力学性能最好,温度继续升高,合金的再结晶晶粒尺寸逐渐增大;挤压温度相同时,挤压比越大,基体的再结晶就越完全,晶粒分布越均匀,合金的晶粒尺寸也随之减小,抗拉强度、屈服强度及伸长率得到大幅改善。与铸态合金相比,通过挤压方法提高了合金的屈服强度的同时还提高了镁合金的塑性,为后续的模压成形提供了高品质的预成形模压坯料;
(2)研究了挤压态AZ81镁合金高温压缩变形行为。合金在高温压缩过程中表现为典型的动态再结晶特征。温度较低或应变速率较高时,流变曲线所达到的峰值应力较大,而在相同应变速率下,峰值应变随温度升高而明显减小;流变应力、应变速率和变形温度之间的关系可用双曲正弦函数表示,其中平均激活能Q=182.17KJ/mol,应力指数α=0.0043Mpa-1,应力指数n=4.4865,其高温塑性流变行为的本构方程为:峰值应变与变形条件(Z参数)之间满足关系式
(3)对挤压态AZ81镁合金进行热加工性能进行分析,根据功率耗散图及失稳图制定模压成形工艺,并对模压成形后试样的显微组织及力学性能进行了研究,结果表明:经400℃模压变形后,合金的晶粒在三向压力及挤压态下等轴晶粒沿模压方向被拉长或被破碎成无数个细小单元个体,试样断面易形成强烈的纤维组织,力学性能较挤压态时有较大幅度的提高,挤压态AZ81镁合金的抗拉强度σ_b=331MPa;屈服强度σ_s=236.7MPa;延伸率δ=16.6%;模压成形后σ_b=350.2Mpa,σ_s=244.8MPa;δ=16.1%;经T6热处理后合金,AZ81镁合金的抗拉强度改善不明显,而屈服强度有了明显的改善,但延伸率显著下,其力学性能为σ_b=358.5Mpa,σ_s=270.7MPa;δ=9.8%;
(4)模压成形过程中,合金显著细化,挤压态时晶粒平均尺寸为3.5μm;当变形量较小时,晶粒有长大趋势,随变形量增至30%时,晶粒细化至2~3μm,晶粒细化不明显,当变形量增加到50%~60%,由于外加机械强应力作用,晶粒细化至1~2.5μm,挤压板主要以基面织构(basal texture){0001}<1010>为主,且与挤压方向平行,随变形量的增加,合金内部晶粒在剪切内应力作用下,沿晶界发生一定角度的转动,并随变形量的增加,初始基面织构及晶粒取向的变化越明显,但织构强度较挤压态时变弱,基面的择优取向(Preferential orientation)偏离了ED方向,向FD方向集中,随变形量的增加,由于非基面滑移开动,织构方向偏离挤压方向,而向模压方向偏转,且晶粒取向差分布逐渐转向大角方向,在模压过程中易于形成与模压方向垂直的织构;挤压预成形坯模压复合成形过程中,晶粒细化是提高合金力学性能的重要手段,而合金的织构对材料的力学性能起着重要的作用。
(5)分析了挤压预成形模压复合成形工艺的经济性及技术可行性,通过该工艺不仅能获得具有模具内腔形状及尺寸的净终成形的锻件产品,而且所获得的锻件晶粒显著细化,组织致密均匀,综合力学性能好,且是一种高效率、低能耗、高品质、高工艺收得率的一种塑性成形工艺,具有一定的工业发展前景。
The one-shot closed-die pressing for extruded preform is a new process to produce magnesium forging products with high material utilization, short process, high efficiency as well as high quality. The current research are focused on the law of Mg deformation, tests of microstructure and properties and the theory of process, and the extensive literature is consequently presented. However, it is rare to see reports about the experimental observations and theoretical research on the evolution of the microstructure and performance for magnesium extruded preforing profile in the process of closed-die pressing.
The microstructure evolution for typical Mg extruded profiles in hot closed-die pressing and the effects on mechanical properties in this paper were experimentally investigated and theoretically analyzed. And the evolution of microstructure and performance on extrude Mg profile during pressing were eventually discovered, which laid a theoretical and experimental foundation on the technology of closed-die pressing process for extruded preform.
Therefore, a preform extrusion profile with the 2D geometrical feature of the specimens was first produced in use of AZ81, Then, the profile was sectioned, and net-shapely pressed into the specimens with the required geometry. The Gleeble1500 thermo-simulation machine was adopted to conduct analytical investigation on the hot deformation behavior of the as-extruded AZ81 in preparation for process parameters of pressing forming. Instruments such as metaloscope, SEM,EBSD, tensile testing machine as well as hardness test equipments were used during the whole experiment to deeply analyze the evolution of microstructure and mechanical properties of the profile during pressing forming. The economy and feasibility of near-net-shape pressing for extruded preform were also discussed.
The major contests and conclusions are as follows:
(1) The influence of extrusion preforming process on mechanical performance together with on fracture mechanism for Mg alloys through SEM were studied, and preventive measures for avoiding material defects in extrusion preforming were also presented to guarantee the profiles with uniform and fine microstructure. Study shows that dynamic recrystallization (DRX) and grain refinement are occurred during hot pressing. With same extrusion ratio, DRX increases as temperatures elevates. The finest grain size and excellent mechanical properties can be obtained with temperature at 370℃and extrusion rate 6~20mm/s, while the size of recrystalized grain becomes larger as temperature continues to increase. Under the same temperature, the larger the extrusion ratio is, the more the DRX happens, and the more uniform the grains are. Meanwhile, the grain size is coherently decreased, and tensile strength, yield strength as well as elongation are improved. The extrusion preforming process not only increases the yield strength of Mg alloys but also improves the plasticity in comparison with as-cast alloys, in order that following press forming experiment can be done with the high quality profiles.
(2) The hot deformation behavior of the as-extruded AZ81 were also investigated, and microstructure during hot compressive deformation is mainly characterized by DRX. The peak stress of flow curve is higher either at lower temperature or faster strain rate. While at the same rate, the peak strain obviously decreases as temperature increases. The relationship amongst flow stress, strain rate and temperature can be described as , where the average activation energy Q=182.17KJ/mol, the stress exponentα= 0.0043Mpa-1, the strain exponent n=4.4865, And the constitutive equation for high-temperature plastic flow behavior is in which the peak strain and deformation condition(Z) suit to
(3) Analysis on the hot deformation mecahnism and processing Map of as-extruded AZ81 magnesium alloy, according to power dissipation map and instablility map developed molding forming process. The microstructure and mechanical properties of specimens after pressing forming were researched. The results show that after pressed at 400℃, the equiaxed grains are elongated along pressing direction or fragmented into numerous small unit particles under three-dimensional compressive stress and extrusion force. A strong texture structure is formed in the fracture area, and mechanical properties are increased a certain degree but not too much compared with that of as-extruded AZ81. The tensile strengthσ_b, the yield strengthσ_s, the elongationδof as-extruded AZ81 are 331MPa, 236.7MPa and 16.6% respectively, while that of after-pressed AZ81 are 350.2MPa, 244.8MPa, and 16.1% respectively. After T6 heat-treated alloy, AZ81 magnesium alloy to improve the tensile strenght is not obvious, while the yield strength has been significicantly improved, but the extension rate was significantly, its mechanical properties ofσ_b = 358.5Mpa,σ_s = 270.7MPa;δ= 9.8%.
(4) Remarkable grain refinement occurs during pressing process, while the average grain size in as-extruded is 3.5μm. With small deformation ratio, the grain tends to grow, whereas the grain is refined to 1~2.5μm when deformation ratio increases to 50%~60% together with outer force is applied. The profiles of extruded preforming is dominantly on basal texture {0001}<10 1 0>, and the basal plane is parallel to extrusion direction(ED). As deformation continues, the inner shear stress gives rise to grain rotation along boundaries with certain angles and initial basal texture and grain orientation vary remarkably, though the texture intensity is weaker than that of as-extruded. The basal preferential orientation deviates from extrusion direction (ED) and aligns with the FD. With deformation ratio increased and non-basal slip activated, the texture orientation turns away from extrusion direction(ED) and deflects along pressing direction. And the grain misorientation gradually turns into the direction of the larger angle. Consequently, it is prone to create a texture perpendicular to pressing direction. The grain refinement and texture for extruded preform and pressing compound process make great contributions to the mechanical properties.
(5) The economy and feasibility of the pressing for extruded preform were finally analyzed. Through this technique, the near-net shape products with remarkable refined and uniform grains and excellent comprehensive mechanical properties can be obtained. It is a plastic process that combines with high efficiency, low energy consumption, high quality as well as high yield ratio, which can be put into industry in the future.
引文
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