镁合金压铸件缺陷分析
摘要
镁合金具有质量轻、比强度和比刚度高、阻尼减震吸噪能力强、散热性好、铸造工艺性能良好、易于切削加工及回收等一系列优点,是21世纪新型绿色金属结构材料,以铸件的形式在汽摩、手持工具、3C、手持电器等领域获得越来越广泛的应用,已部分取代了钢铁、铝合金、工程塑料等传统结构材料,用于减轻产品的重量,提高产品的设计集成度、降低车辆的油耗和排放、抑制车辆震动和噪音、提高了成品的外观质量,取得了不菲的经济效益和社会效益。但我国的镁合金压铸生产相比于工业发达国家才刚刚起步、工艺技术不成熟、缺乏生产经验积累,还很落后。
为了加快我国镁合金压铸技术的熟化、为压铸生产工艺设计和品质管理提供指导,本论文叙述压铸件质量标准及检验方法,并根据铸件分类标准将镁合金压铸件缺陷进行分类。根据镁合金压铸成形原理,分析了常见压铸缺陷的特征、形成机理及产生原因,并分析了压铸合金种类、压铸工艺对压铸件产品质量的影响,提出相应的解决措施。
本文以重庆镁业股份有限公司压铸生产中出现的各种工艺缺陷分析为实例,借助外观特征、内部金相、扫描电镜等检测手段以及MAGMA数值模拟仿真软件等分析方法,通过试验观察、虚拟现实模拟、理论研究结合的方式,全面阐述了压铸工艺缺陷特征和形成机制,提出通过原材料品质控制、严格合金熔炼、改进浇注系统、镁合金压铸机性能调控、优化压铸工艺参数等切实可行的工艺对策,最后在实际生产中进行验证。
研究结果表明,在压铸成形理论指导和现代计算机技术的指导下,可以实现产品生产工艺地合理开发,缩短产品生产调试周期,降低生产成本和风险,提高产品质量,最终达到提高镁合金压铸企业及其产品的市场竞争能力。
Mg alloys are the lightest commercial structure allpys. They possess a property spectrum desirable for structure components, such as, high specific strength, outstanding damping capability, excellent heat transferring capability, excellent casting performance under pressure, easy to machining and recycling, and so on. They were claimed as the novel green metal of the 21th century, and has been massively used as castings on road vehicles, manual tools, 3C, handset wirings and so on, and began to replace the traditional materials, such as steel, Al alloys, engineering plastic and so on. they are used to lighten the components, to improve the integration of the products, to reduce oil consumption and exhaust gas emission, to diminish the vibration and noise of vehicles, to improve the exterior quality of the products, and substantial economic and social benefits have been achieved. However, as compared with the developed countries, Chinese Mg alloys die casting industry is just at its beginning stage. The processing techniques are not mature, no enough production experience accumulated.
To boost the development of Mg die casting techniques of China, and to offer directions for Mg die casting process design and quality control, the present paper devoted to describe the quality standards and quality inspection, to classify processing imperfections in Mg die casting. After an in-depth description of characteristics and forming mechanism and conditions of various die casting defects, the measurements of quality control and defects elimination were suggested.
To demonstrate the methodology and exemplifies the defect characteristics and identification, the processing defects appeared in die casting practice of Chongqing Mg Science and Technology Stock Company Limited were used. Aided by different investigation techniques such as morphology characterization, non-destructive analysis, chemistry and microstructure investigation, fracture analysis, and virtue processing by MAGMA, the characteristics, formation mechanism and control of different die casting defects commonly appeared in practice were described in details. With the proposed measurements, such as raw material quality control, stringent melting and pouring, improvement in processing and mould design, optimized processing conditions, the defects can be eliminated.
The present work concluded that, with the guide of modern casting theory and computation technologies, more rational processing design can be achieved and
为了加快我国镁合金压铸技术的熟化、为压铸生产工艺设计和品质管理提供指导,本论文叙述压铸件质量标准及检验方法,并根据铸件分类标准将镁合金压铸件缺陷进行分类。根据镁合金压铸成形原理,分析了常见压铸缺陷的特征、形成机理及产生原因,并分析了压铸合金种类、压铸工艺对压铸件产品质量的影响,提出相应的解决措施。
本文以重庆镁业股份有限公司压铸生产中出现的各种工艺缺陷分析为实例,借助外观特征、内部金相、扫描电镜等检测手段以及MAGMA数值模拟仿真软件等分析方法,通过试验观察、虚拟现实模拟、理论研究结合的方式,全面阐述了压铸工艺缺陷特征和形成机制,提出通过原材料品质控制、严格合金熔炼、改进浇注系统、镁合金压铸机性能调控、优化压铸工艺参数等切实可行的工艺对策,最后在实际生产中进行验证。
研究结果表明,在压铸成形理论指导和现代计算机技术的指导下,可以实现产品生产工艺地合理开发,缩短产品生产调试周期,降低生产成本和风险,提高产品质量,最终达到提高镁合金压铸企业及其产品的市场竞争能力。
Mg alloys are the lightest commercial structure allpys. They possess a property spectrum desirable for structure components, such as, high specific strength, outstanding damping capability, excellent heat transferring capability, excellent casting performance under pressure, easy to machining and recycling, and so on. They were claimed as the novel green metal of the 21th century, and has been massively used as castings on road vehicles, manual tools, 3C, handset wirings and so on, and began to replace the traditional materials, such as steel, Al alloys, engineering plastic and so on. they are used to lighten the components, to improve the integration of the products, to reduce oil consumption and exhaust gas emission, to diminish the vibration and noise of vehicles, to improve the exterior quality of the products, and substantial economic and social benefits have been achieved. However, as compared with the developed countries, Chinese Mg alloys die casting industry is just at its beginning stage. The processing techniques are not mature, no enough production experience accumulated.
To boost the development of Mg die casting techniques of China, and to offer directions for Mg die casting process design and quality control, the present paper devoted to describe the quality standards and quality inspection, to classify processing imperfections in Mg die casting. After an in-depth description of characteristics and forming mechanism and conditions of various die casting defects, the measurements of quality control and defects elimination were suggested.
To demonstrate the methodology and exemplifies the defect characteristics and identification, the processing defects appeared in die casting practice of Chongqing Mg Science and Technology Stock Company Limited were used. Aided by different investigation techniques such as morphology characterization, non-destructive analysis, chemistry and microstructure investigation, fracture analysis, and virtue processing by MAGMA, the characteristics, formation mechanism and control of different die casting defects commonly appeared in practice were described in details. With the proposed measurements, such as raw material quality control, stringent melting and pouring, improvement in processing and mould design, optimized processing conditions, the defects can be eliminated.
The present work concluded that, with the guide of modern casting theory and computation technologies, more rational processing design can be achieved and
引文
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[3]刘海峰,高强度.抗高温蠕变压铸镁合金材质的研究〔D〕. 长春:吉林大学, 2003
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[5]刘海峰, 侯骏, 刘耀辉等. 压铸镁合金高温蠕变研究进展及现状〔J〕.铸造, 2002 , 51 (6) : 330
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[6]井藤忠男等. 轻金属, 1992 (12) : 815～ 821
[7]赖华清,徐翔,范宏训.充氧压铸及其应用. 金属成形工艺: Vol.22 №.2 2004:12～14
[8]安藤宽. 无孔性ダイヵスト法によるホィールの开发[J].アルトヒア,1987(2) :19～23.
[9]由浅明, 松井伸司等. 轻金属, 1994 (1) : 9～ 5
[10] P. M. Bralower. D ie Casting Engineer, 1992 (7～ 8) : 42～ 43
[11] J. E. King, T. E. W ilk s. M agnesium, 1995 (4) : 1～8
[12] 吴春苗编著.压铸实用技术.广州:广东科技出版社,2003.5:215.
[13]Busk Robert S.Magnesium Products Design. USA:The International Magnesium Association,1987.
[14]Wnandy Daude D.Autonotive the magnesium challenge[J].Magnesium2000,(1):18～22
[15]Magnesium pressuredie cast components[J].Aluninum,2000,(4):276～280.
[16]申泽骥,李宝东.镁合金铸造技术进展[J].铸造,2001,(9):522～526.
[17]吉泽升、辛明德等.压铸镁合金的研究现状及应用前景.产业论坛 2003 年第 7 期:19～22
[18] 刘正 张奎 曾小勤著 镁基轻质合金理论基础及其应用 北京:机械工业出版社,2002.9:72-74.
[19] 申泽骥等:镁合金铸造技术进展,《铸造》,2001.09:522～526
[20] The trend towards magnesium [J].Aluminum,2000,76(1/2):98～104
[21] 曾小勤等. 镁合金熔炼阻燃方法及进展.轻合金加工技术,1999(9):5～8.
[22] 张津 章宗和等编著 镁合金及应用 北京:化学工业出版社,2004.7
[23] 中国机械工程学会铸造分会编 《铸造手册.第 5 卷,铸造工艺》 北京:机械工业出版社,2003.1
[24] 傅明喜 吴晶 司乃潮编著 铸件质量控制及检验 北京:化学工业出版社,2004.7:31--37
[25] 宋忠明 葛晨光编著 铸件尺寸公差标准应用指南 北京:中国标准出版社,2001.1
[26] 赵浩峰 主编 现代压力铸造技术 北京:中国标准出版社,2002.11
[27] 陈国桢 肖柯则 姜不居编 铸件缺陷和对策手册 北京:机械工业出版社,1996
[28] 余永斌 压力铸造中欠铸产生的原因及预防铸造, 《热加工》 2000年第10期 : 14
[29] 铝合金材料压铸加工中典型缺陷分析及解决措施 《青岛科技大学学报》2004 年第 25 卷3 期:249—252.
[30] 中国机械工程学会铸造分会编 《铸造手册.第 6 卷,特种铸造》 北京:机械工业出版社,2003.2
[31] 许忠胜 王仲珏 王元桂 薄壳灰铸铁件冷隔、裂纹的特性及生产对策 《安徽机电学院学报》1997 年第 12 卷第 2 期:36—38.
[32] 许忠胜 王仲珏 薄壳灰铸铁冷隔裂纹的特性及对策《机械研究与应用》1997 年第 4 期:32—34.
[33] 秦永健 冷隔缺陷预测判据 《上海金属》 1997 年第 19 卷第 5 期:23—27.
[34] 潘宪曾主编 《压铸模设计手册》 北京:机械工业出版社,1998.10
[35] Upton B,Allsop D F,Kennedy D,et al. 压力铸造[M]. 北京:机械工业出版社,1988.150—152.
[36] 王罡,袁烺,熊守美,柳百成 压室慢压射过程流场模拟 《铸造》Nov 2004 Vol 53 No11:909-912
[37] 陈平昌 朱六妹 李赞主编 材料成形原理 北京:机械工业出版社,2001.8
[38] 许四祥,吴树森,万里,罗吉荣 镁合金中的氢及其除气方法 中国铸造装备与技术 2005.5:9—12.
[39] 陈叙 铝压铸件气孔缺陷的研究 《铝加工》1995,Vol 18 No5:1—4.
[40] 许四祥,吴树森,万里,罗吉荣.镁合金中的氢及其除气方法 《中国铸造装备与技术》2005年 5 月:9～12
[41] 贾宝仟,柳百成.铸件缩松缩孔判据G/T1/2的理论基础及应用[J].铸造,1996 ,4:13-15.
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