基于CAFE模拟钛合金丝材电弧增材制造凝固过程的组织演变
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摘要
采用CAFE(Cellular automation finite element)对Ti6Al4V合金丝材电弧增材制造的快速凝固过程进行模拟计算。通过建立不同阶段(堆积层)的三维模型,建立晶体形核与生长模型,并结合三维热传导(包含结晶潜热释放)模型,研究了不同阶段的温度场对固-液转变、初始β晶形核及生长等影响。结果表明:初始阶段初始β晶取向杂乱且晶粒尺寸细小;随着增材高度的增加,水平方向温度梯度变缓,平均固-液转变糊状区域宽度增加,初始β晶平均晶粒尺寸增加,晶体取向趋于热流传递方向(垂直于冷基板方向);其模拟结果与实际增材制造后的初始β晶组织形貌基本一致。
CAFE model was adopted to simulate the rapid solidification process of wire+arc additive manufactured Ti6Al4V alloy. Moreover, the influences of temperature field on solid-liquid transition as well as the initial I-Ti nucleation and growth in different manufacturing stages were analyzed by three-dimensional mode in different stages(deposition layer), grain nucleation and growth model and three-dimensional heat transferring(including latent heat release) model. The results show that β-Ti crystal has extremely disordered orientation and fine grain size in initial solidification stage(the first layer). Besides, with the increase of manufacturing sample height and the decrease of temperature gradient, both the average mushy zone width and average primary β-Ti grain size increase, and the crystal orientation tends to heat transfer direction(vertical cold-board direction). Final, the results of initial β-Ti crystal growth simulation basically conform to the actual additive manufacturing.
CAFE model was adopted to simulate the rapid solidification process of wire+arc additive manufactured Ti6Al4V alloy. Moreover, the influences of temperature field on solid-liquid transition as well as the initial I-Ti nucleation and growth in different manufacturing stages were analyzed by three-dimensional mode in different stages(deposition layer), grain nucleation and growth model and three-dimensional heat transferring(including latent heat release) model. The results show that β-Ti crystal has extremely disordered orientation and fine grain size in initial solidification stage(the first layer). Besides, with the increase of manufacturing sample height and the decrease of temperature gradient, both the average mushy zone width and average primary β-Ti grain size increase, and the crystal orientation tends to heat transfer direction(vertical cold-board direction). Final, the results of initial β-Ti crystal growth simulation basically conform to the actual additive manufacturing.
引文
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[11]仲红刚,曹欣,陈湘茹,张捷宇,翟启杰.Al-Cu合金水平单向凝固组织预测及实验观察[J].中国有色金属学报,2013,23(10):2792-2799.ZHONG Hong-gang,CAO Xin,CHEN Xiang-ru,ZHANG Jie-yu,ZHAI Qi-jie.Numerica and experimental investigation of solidification structure in horizontal directional solidification process of Al-Cu alloy[J].The Chinese Journal of Nonferrous Metals,2013,23(10):2792-2799.
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[13]SALUJA R S,NARAYANAN R G,DAS S.Cellular automata finite element(CAFE)model to predict the forming of friction stir welded blanks[J].Computational Materials Science,2012,58:87-100.
[14]DEZFOLI A R A,HWANG W S,AUGUSTO J,SHUKUR A K,TZENG S.Modeling of poly-crystalline silicon ingot crystallization during casting and theoretical suggestion for ingot quality improvement[J].Materials Science in Semiconductor Processing,2016,53:36-46.
[15]付作鑫,谢明,沈月,张吉明,杨有才.CAFE法凝固组织数值模拟的应用研究进展[J].材料导报,2012,26(11):154-158.FU Zuo-xin,XIE Ming,SHEN Yue,ZHANG Ji-ming,YANGYou-cai.Recent developments in numerical simulation of solidification using CA-FE method[J].Materials Review,2012,26(11):154-158.
[16]KURZ W,GIOVANOLA B,TRIVEDI R.Theory of microstructural development during rapid solidification[J].Acta Metallurgica,1986,34(5):823-830.
[17]杨雪梅.全域铸锭宏微观耦合的数值模拟研究[D].天津:河北工业大学,2015.YANG Xue-mei.The numerical simulation research of the global ignot macro micro coupling[D].Tianjin:Heibei University of Technology,2015.
[18]CHASSAING G,POUGIS A,PJILIPPON S,LIPINSKI P,FAURE L,MERIAUX J,DEMMOU K,LEFEBVRE A.Experimental and numerical study of frictional heating during rapid interactions of a Ti6Al4V tribopair[J].Wear,2015,342(15):342-343.
[2]SZOST B A,TERZI S,MARTINA F,BOISSELIER D,PRYTULIAK A.A comparative study of additive manufacturing techniques:Residual stress and microstructural analysis of CLADand WAAM printed Ti-6Al-4V components[J].Materials&Design,2016,89:559-567.
[3]李涤尘,贺健康,田小永,刘亚雄,张安峰,连芩,靳忠民,卢秉恒.增材制造:实现宏微结构一体化制造[J].机械工程学报,2013,49(6):129-135.LI Di-chen,HE Jian-kang,TIAN Xiao-yong,LIU Ya-xiong,ZHANG An-feng,LIAN Qin,JIN Zhong-min,LU Bing-heng.Additive manufacturing:Integrated fabrication of macro/microstructures[J].Chinese Journal of Mechanical Engineering,2013,49(6):129-135.
[4]ABE T,SASAHARA H.Dissimilar metal deposition with a stainless steel and nickel-based alloy using wire and arc-based additive manufacturing[J].Precision Engineering,2016,45:387-395.
[5]RAPPAZ M.Modeling of microstructure formation in solidification processes[J].International Materials Reviews,1989,34(1):93-124.
[6]GANDIN Ch-A,RAPPAZ M.A 3D cellular automaton algorithm for the prediction of dendritic grain growth[J].Acta Materialia,1997,45(5):2187-2195.
[7]GANDIN C A,DESBIOLLES J L,RAPPAZ M.Athree-dimensional cellular automation-finite element model for the prediction of solidification grain structures[J].Metallurgical and Materials Transactions A,1999,30(12):3153-3165.
[8]张璞,侯华,赵宇宏,靳玉春,赵宇辉,睦怀明.基于CAFE模型的镍基合金定向凝固过程显微组织模拟[J].中国有色金属学报,2016,26(4):782-789.ZHANG Pu,HOU Hua,ZHAO Yu-hong,Jin Yu-chun,ZHAOYu-hui,MU Huai-ming.Microstructure simulation during directional solidification of nickel-based alloy based on CAFEmodel[J].The Chinese Journal of Nonferrous Metals,2016,26(4):782-789.
[9]张颖娟,寇宏超,李鹏飞,钟宏,胡锐,李金山,周廉.真空自耗电弧熔炼TC4铸锭的凝固组织和缩松缩孔的模拟[J].特种铸造及有色合金,2012,32(5):31-34.ZHANG Ying-juan,KOU Hong-chao,LI Peng-fei,ZHONGHong,HU Yue,LI Jin-shan,ZHOU Lian.Simulation on solidification structure and shrinkage porosity(hole)in TC4 ingot during vacuum arc remelting process[J].Special Casting&Nonferrous Alloys,2012,32(5):31-34.
[10]庞瑞朋,王福明,张国庆,李长荣.基于3D-CAFE法对430铁素体不锈钢凝固热参数的研究[J].金属学报,2013,49(10):1234-1242.PANG Rui-peng,WANG Fu-ming,ZHANG Guo-qing,LIChang-rong.Study of solidification thermal parameters of 430ferrite stainless steel based on 3D-CAFE method[J].Acta Metallurgica Sinica,2013,49(10):1234-1242.
[11]仲红刚,曹欣,陈湘茹,张捷宇,翟启杰.Al-Cu合金水平单向凝固组织预测及实验观察[J].中国有色金属学报,2013,23(10):2792-2799.ZHONG Hong-gang,CAO Xin,CHEN Xiang-ru,ZHANG Jie-yu,ZHAI Qi-jie.Numerica and experimental investigation of solidification structure in horizontal directional solidification process of Al-Cu alloy[J].The Chinese Journal of Nonferrous Metals,2013,23(10):2792-2799.
[12]卜晓兵,李落星,张立强,朱必武,王水平.Al-Cu合金凝固微观组织的三维模拟及优化[J].中国有色金属学报,2011,21(9):2195-2201.BU Xiao-bin,LI Luo-xin,ZHANG Li-qiang,ZHU Bi-wu,WANG Shu-ping.Three-dimensional numerical simulation and optimization of solidification structure of Al-Cu alloy[J].The Chinese Journal of Nonferrous Metals,2011,21(9):2195-2201.
[13]SALUJA R S,NARAYANAN R G,DAS S.Cellular automata finite element(CAFE)model to predict the forming of friction stir welded blanks[J].Computational Materials Science,2012,58:87-100.
[14]DEZFOLI A R A,HWANG W S,AUGUSTO J,SHUKUR A K,TZENG S.Modeling of poly-crystalline silicon ingot crystallization during casting and theoretical suggestion for ingot quality improvement[J].Materials Science in Semiconductor Processing,2016,53:36-46.
[15]付作鑫,谢明,沈月,张吉明,杨有才.CAFE法凝固组织数值模拟的应用研究进展[J].材料导报,2012,26(11):154-158.FU Zuo-xin,XIE Ming,SHEN Yue,ZHANG Ji-ming,YANGYou-cai.Recent developments in numerical simulation of solidification using CA-FE method[J].Materials Review,2012,26(11):154-158.
[16]KURZ W,GIOVANOLA B,TRIVEDI R.Theory of microstructural development during rapid solidification[J].Acta Metallurgica,1986,34(5):823-830.
[17]杨雪梅.全域铸锭宏微观耦合的数值模拟研究[D].天津:河北工业大学,2015.YANG Xue-mei.The numerical simulation research of the global ignot macro micro coupling[D].Tianjin:Heibei University of Technology,2015.
[18]CHASSAING G,POUGIS A,PJILIPPON S,LIPINSKI P,FAURE L,MERIAUX J,DEMMOU K,LEFEBVRE A.Experimental and numerical study of frictional heating during rapid interactions of a Ti6Al4V tribopair[J].Wear,2015,342(15):342-343.