镁（铝）合金真空低压消失模铸造工艺优化及组织质量控制研究
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摘要
真空低压消失模铸造技术将低压铸造的原理应用于真空消失模铸造中,使得液态镁(铝)合金在真空和较低气压作用下反重力充填消失模铸型,它比压力铸造、砂型铸造和普通消失模铸造具有明显的优势。本研究从实际应用出发,针对镁合金真空低压消失模铸造工艺的特点,系统研究了主要充型工艺参数对铸件质量的影响规律;结合国内外镁合金改性现状,探讨了改善镁合金铸态组织和提高性能的方法。
在分析普通消失模铸造充型工艺理论的基础上,探讨了真空低压消失模铸造的工艺规范,推导了加压速度(dP充)/(dτ)与气体流量Q、凝固过程中补缩机理的数学关系式。真空低压消失模铸造过程中,当气源初始充型气压一定时,液态金属的加压速度(dP充)/(dτ)与充气流量Q呈线性正比关系,充气流量Q越大,加压速度(dP充)/(dτ)就越快,液态金属的充型速度也就越大。合金成份、浇注温度确定以后,对于晶间同一部位,单位时间内补缩液流经过晶粒的数量N主要取决于凝固结晶时的保压压力P保,保压压力P保越大,补缩液流经过晶粒的数量N越多,补缩能力就越强,组织也就越致密。
采用阶梯试样对镁合金真空低压消失模铸造中的工艺参数进行了系统研究,掌握了浇注温度、真空度、充气流量、充型与抽真空耦合方式等因素对铸件质量的影响规律,确立了镁合金真空低压消失模铸造技术的最佳充型工艺参数范围:浇注温度710～750℃、真空度0.02～0.03MPa、充气流量8～14m3/h、采用先充型再抽真空的模式以及开放式浇注系统。复杂薄壁铸件一般选择工艺参数值的上限(如:浇注温度750℃等),简单厚壁铸件可以选择工艺参数值下限。
分析了镁合金真空低压消失模铸件中典型缺陷的物理特征及形成原因。孔洞缺陷可通过适当降低浇注温度、充型速度、真空度以及改善涂料层的透气性和调控充型与抽真空的耦合模式等来消除;浇不足、冷隔缺陷可以适当调节浇注温度、充型速度等来抑制;粘砂缺陷可以通过合理增加涂料厚度、控制真空度和浇注温度、选用粒径较小的干砂造型来消除。
系统研究了机械振动、Ce-Sb复合合金化以及半固态热处理对镁合金消失模铸件组织和性能的影响,表明三种方法均能细化AZ91D镁合金消失模铸造试样的显微组织、提高其室温力学性能。(1)振动凝固条件下镁合金消失模铸造试样的组织、性能随试样厚度增加效果越好;(2)0.4%Sb+1.0%Ce为最佳合金化配比,合金化后基体中生成了粒状CeSb相和杆状相Al11Ce3相,合金化试样的抗拉强度、延伸率比未合金化处理试样分别提高了35.5%和36.7%,合金化叠加振动可以进一步细化AZ91D镁合金铸态组织、提高力学性能,比单纯合金化试样的抗拉强度、延伸率分别提高了11.2%和11%,断口中少量的韧窝和大量的撕裂棱同时出现,表明试样在拉伸过程中已有明显的塑性变形特征;(3)半固态等温热处理工艺下可以得到形状圆整的球状晶组织,抗拉强度、延伸率比铸态试样分别提高了32.4%和83.4%,最佳的工艺方案是530℃保温60min后取出水冷。
散热片、制动器缸盖等消失模铸件的试制实验结果表明,真空低压消失模铸造工艺具有较强的充型能力,可以消除重力下镁(铝)合金消失模铸件中常出现的浇不足、冷隔等缺陷,获得外观轮廓良好的铸件,该工艺对于生产复杂薄壁的镁(铝)合金铸件具有非常明显的技术优势。
The low-pressure expendable pattern casting (LP-EPC) process applies the principle of low-pressure casting to expendable pattern casting (EPC), in which the melt metal is filled under anti-gravity condition at low pressure. It obviously gains the advantages over die-casting, sand casting and conventional EPC process. In the present dissertation, the effect of main processing parameters on LP-EPC castings has been investigated systematically, which aims at the application of LP-EPC. Based on the modification of magnesium alloy, this study focuses on the methods to modify as-cast microstructure of magnesium alloy and improve its mechanical property.
Based on analysis of theory in conventional EPC process, the technical parameters of LP-EPC were discussed. And the relations linking lifting pressure velocity (dP充)/(dτ) with gas flux Q , as well as the mechanics of solidification feeding in LP-EPC process were established. It was pointed that linear relation was existed between lifting pressure velocity (dP充)/(dτ) and gas fluxQ when the initial pressure of air supply was a certain value. The more gas fluxQ flowed in the crucible, the faster filling velocity. The grain number N of feeding melt metal flowing per unit of time at identical inter-granular location is mainly depended on holding pressure P_保when the alloy composition and pouring temperature have been selected. As the holding pressure increases, the grain number of feeding melt metal flowing would increase, the feeding capacity would become intensive and the microstructure would become more compact also.
In this study, researches are focused on the effect of process parameters on the LP-EPC casting quality of AZ91D by using ladder samples. Those samples were tested for different combinations of the LP-EPC process parameters. Specifically, pouring temperature, vacuum level, filling velocity and coupling action of above factors were manipulated to observe their effect on the porosity and density distribution of casting. The optimal process parameters for the castings are pouring temperature 710～750℃, vacuum level 0.02-0.03MPa, gas flux 8～14m3/h. The unpressurized gating system and coupled modes of filling several seconds before suction also be selected. Complicated thin-walled castings require an upper limit magnitude(e.g. pouring temperature 750℃),and simple thick-walled casting should use lower limited magnitude。
The physical feature and genesis of typical casting defects of LP-EPC process for magnesium castings were investigated. The result indicated that hole defects could be avoided through reducing pouring temperature, filling velocity and vacuum level, improving the permeability of coating as well as adjusting coupled modes of filling mold and vacuum level. Misrun and cold laps can be restricted by proper adjustments on pouring temperature and filling velocity, etc. While burning-on defect can be eliminated by increasing coating thickness,decreasing pouring temperature and vacuum,selecting smaller size sand to mold.
Mechanical vibration, Ce-Sb alloying and semi-solid isothermal heat-treatment were used to improve the structure and performance of AZ91D magnesium alloy via EPC process. The result indicated that above three methods could refine its microstructure and improve tensile strength at room temperature:
(1) The performance of AZ91D alloy via EPC process was improved when the casting was produced under mechanical vibration, and the microstructure evolved refiner and mechanical property became higher as the thickness of sample increase.
(2) The optimal alloying composition was AZ91D with the addition of 0.4% Sb and1.0% Ce. Some new granulated CeSb and rod-shaped Al11Ce3 phases had been formed, which are present at the grain boundary and intracrystalline. Compared to AZ91D, the ultimate tensile strength and elongation of AZ91D-1.0%Ce-0.4%Sb alloy are enhanced by 35.5% and 36.7%, respectively. Ce-Sb alloying compound with mechanical vibration could further refine its microstructure and improve tensile strength. Its ultimate tensile strength and elongation were improved by11.2%,11%. The morphology of tensile fracture has more features of quasi-cleavage. It indicates that has had the bigger plastic deformation before failure.
(3) When AZ91D magnesium is heat-treated at semi-solid temperature, the reticularβ-Mg17 Al12 phase almost solutionizes in matrix and primary grain gradually evolves into spheroidal shape. Its ultimate tensile strength and elongation were improved by32.4%,83.4%. The optimal process parameters of semi-solid isothermal heat-treatment are 560℃×60min, cooling in water.
The trail manufacture of plate-fin cooler and compressor cylinder head indicated that LP-EPC possess has great mold filling ability which could largely reduce or overcome the defects like misrun and cold laps encountered in conventional EPC process. The complex thin-walled Mg (Al) alloy castings can be produced perfectly by LP-EPC, so the process is very suitable for casting Mg (Al) alloy parts with complex geometries and high dimensional tolerances.
在分析普通消失模铸造充型工艺理论的基础上,探讨了真空低压消失模铸造的工艺规范,推导了加压速度(dP充)/(dτ)与气体流量Q、凝固过程中补缩机理的数学关系式。真空低压消失模铸造过程中,当气源初始充型气压一定时,液态金属的加压速度(dP充)/(dτ)与充气流量Q呈线性正比关系,充气流量Q越大,加压速度(dP充)/(dτ)就越快,液态金属的充型速度也就越大。合金成份、浇注温度确定以后,对于晶间同一部位,单位时间内补缩液流经过晶粒的数量N主要取决于凝固结晶时的保压压力P保,保压压力P保越大,补缩液流经过晶粒的数量N越多,补缩能力就越强,组织也就越致密。
采用阶梯试样对镁合金真空低压消失模铸造中的工艺参数进行了系统研究,掌握了浇注温度、真空度、充气流量、充型与抽真空耦合方式等因素对铸件质量的影响规律,确立了镁合金真空低压消失模铸造技术的最佳充型工艺参数范围:浇注温度710～750℃、真空度0.02～0.03MPa、充气流量8～14m3/h、采用先充型再抽真空的模式以及开放式浇注系统。复杂薄壁铸件一般选择工艺参数值的上限(如:浇注温度750℃等),简单厚壁铸件可以选择工艺参数值下限。
分析了镁合金真空低压消失模铸件中典型缺陷的物理特征及形成原因。孔洞缺陷可通过适当降低浇注温度、充型速度、真空度以及改善涂料层的透气性和调控充型与抽真空的耦合模式等来消除;浇不足、冷隔缺陷可以适当调节浇注温度、充型速度等来抑制;粘砂缺陷可以通过合理增加涂料厚度、控制真空度和浇注温度、选用粒径较小的干砂造型来消除。
系统研究了机械振动、Ce-Sb复合合金化以及半固态热处理对镁合金消失模铸件组织和性能的影响,表明三种方法均能细化AZ91D镁合金消失模铸造试样的显微组织、提高其室温力学性能。(1)振动凝固条件下镁合金消失模铸造试样的组织、性能随试样厚度增加效果越好;(2)0.4%Sb+1.0%Ce为最佳合金化配比,合金化后基体中生成了粒状CeSb相和杆状相Al11Ce3相,合金化试样的抗拉强度、延伸率比未合金化处理试样分别提高了35.5%和36.7%,合金化叠加振动可以进一步细化AZ91D镁合金铸态组织、提高力学性能,比单纯合金化试样的抗拉强度、延伸率分别提高了11.2%和11%,断口中少量的韧窝和大量的撕裂棱同时出现,表明试样在拉伸过程中已有明显的塑性变形特征;(3)半固态等温热处理工艺下可以得到形状圆整的球状晶组织,抗拉强度、延伸率比铸态试样分别提高了32.4%和83.4%,最佳的工艺方案是530℃保温60min后取出水冷。
散热片、制动器缸盖等消失模铸件的试制实验结果表明,真空低压消失模铸造工艺具有较强的充型能力,可以消除重力下镁(铝)合金消失模铸件中常出现的浇不足、冷隔等缺陷,获得外观轮廓良好的铸件,该工艺对于生产复杂薄壁的镁(铝)合金铸件具有非常明显的技术优势。
The low-pressure expendable pattern casting (LP-EPC) process applies the principle of low-pressure casting to expendable pattern casting (EPC), in which the melt metal is filled under anti-gravity condition at low pressure. It obviously gains the advantages over die-casting, sand casting and conventional EPC process. In the present dissertation, the effect of main processing parameters on LP-EPC castings has been investigated systematically, which aims at the application of LP-EPC. Based on the modification of magnesium alloy, this study focuses on the methods to modify as-cast microstructure of magnesium alloy and improve its mechanical property.
Based on analysis of theory in conventional EPC process, the technical parameters of LP-EPC were discussed. And the relations linking lifting pressure velocity (dP充)/(dτ) with gas flux Q , as well as the mechanics of solidification feeding in LP-EPC process were established. It was pointed that linear relation was existed between lifting pressure velocity (dP充)/(dτ) and gas fluxQ when the initial pressure of air supply was a certain value. The more gas fluxQ flowed in the crucible, the faster filling velocity. The grain number N of feeding melt metal flowing per unit of time at identical inter-granular location is mainly depended on holding pressure P_保when the alloy composition and pouring temperature have been selected. As the holding pressure increases, the grain number of feeding melt metal flowing would increase, the feeding capacity would become intensive and the microstructure would become more compact also.
In this study, researches are focused on the effect of process parameters on the LP-EPC casting quality of AZ91D by using ladder samples. Those samples were tested for different combinations of the LP-EPC process parameters. Specifically, pouring temperature, vacuum level, filling velocity and coupling action of above factors were manipulated to observe their effect on the porosity and density distribution of casting. The optimal process parameters for the castings are pouring temperature 710～750℃, vacuum level 0.02-0.03MPa, gas flux 8～14m3/h. The unpressurized gating system and coupled modes of filling several seconds before suction also be selected. Complicated thin-walled castings require an upper limit magnitude(e.g. pouring temperature 750℃),and simple thick-walled casting should use lower limited magnitude。
The physical feature and genesis of typical casting defects of LP-EPC process for magnesium castings were investigated. The result indicated that hole defects could be avoided through reducing pouring temperature, filling velocity and vacuum level, improving the permeability of coating as well as adjusting coupled modes of filling mold and vacuum level. Misrun and cold laps can be restricted by proper adjustments on pouring temperature and filling velocity, etc. While burning-on defect can be eliminated by increasing coating thickness,decreasing pouring temperature and vacuum,selecting smaller size sand to mold.
Mechanical vibration, Ce-Sb alloying and semi-solid isothermal heat-treatment were used to improve the structure and performance of AZ91D magnesium alloy via EPC process. The result indicated that above three methods could refine its microstructure and improve tensile strength at room temperature:
(1) The performance of AZ91D alloy via EPC process was improved when the casting was produced under mechanical vibration, and the microstructure evolved refiner and mechanical property became higher as the thickness of sample increase.
(2) The optimal alloying composition was AZ91D with the addition of 0.4% Sb and1.0% Ce. Some new granulated CeSb and rod-shaped Al11Ce3 phases had been formed, which are present at the grain boundary and intracrystalline. Compared to AZ91D, the ultimate tensile strength and elongation of AZ91D-1.0%Ce-0.4%Sb alloy are enhanced by 35.5% and 36.7%, respectively. Ce-Sb alloying compound with mechanical vibration could further refine its microstructure and improve tensile strength. Its ultimate tensile strength and elongation were improved by11.2%,11%. The morphology of tensile fracture has more features of quasi-cleavage. It indicates that has had the bigger plastic deformation before failure.
(3) When AZ91D magnesium is heat-treated at semi-solid temperature, the reticularβ-Mg17 Al12 phase almost solutionizes in matrix and primary grain gradually evolves into spheroidal shape. Its ultimate tensile strength and elongation were improved by32.4%,83.4%. The optimal process parameters of semi-solid isothermal heat-treatment are 560℃×60min, cooling in water.
The trail manufacture of plate-fin cooler and compressor cylinder head indicated that LP-EPC possess has great mold filling ability which could largely reduce or overcome the defects like misrun and cold laps encountered in conventional EPC process. The complex thin-walled Mg (Al) alloy castings can be produced perfectly by LP-EPC, so the process is very suitable for casting Mg (Al) alloy parts with complex geometries and high dimensional tolerances.
引文
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