摘要
微精密铸造工艺可以低成本、大批量的高效制备三维复杂微金属构件,是近几年来问世的最具竞争力的微构件微细加工工艺之一。本文研发了新型金属型微铸造工艺,并对涉及到的微米尺度空间内液态金属的充型流动规律和停止流动机理以及凝固成形规律,微铸件的显微组织与力学性能等一系列基础科学理论问题进行了深入系统研究,并揭示了微米尺度下流动、凝固、显微组织和力学性能等方面的显著微尺度效应及微观机理。
液态金属在微米尺度空间内充型流动时,金属液粘度急剧降低,气体反压力和毛细管力作用显著,宏观流动的传统Navier-Stokes方程不再适用,在考虑上述诸附加修正项后,建立了适合于液态金属微米尺度流动的新型Navier-Stokes微分方程,以及相关的物理和数学模型,对微米尺度空间内液态金属流动、传热和凝固过程进行了计算机数值模拟。
微管道内液态金属的充型流动,呈现出宏观尺度流动时所没有的三个显著微尺度效应——附面层相对厚度的增大,“凸进效应”的形成和负压力梯度区的产生:管径进入微尺度后,管径越细,靠近壁面的附面层厚度与管径的比值越大,沿径向流体流动的速度梯度越大,流股前沿与宏观流动时相比更加向前凸出,形成“凸进效应”,且“凸进效应”随时间增加和压力减小而愈加显著。此外,在流动前沿区域和上游区域之间的中部区域会产生负压力区,且管径越细越明显。
微管道内液态金属的停止流动机理呈现出非常明显的微尺度效应:停止流动机理由宏观尺度时的端部堵塞机理,转变为微尺度时端部堵塞与后续流体的半固态堵塞两者复合的停止流动机理,该转变对应的临界尺寸为500μm。
微齿轮铸件的流动、传热和凝固数值模拟结果表明,金属液保持入射惯性首先填充后面的齿轮轴,撞击后方型腔型壁后,产生二次压头,然后再向齿轮的齿盘部位反充,形成回流现象。型腔内气体被高速运动的金属液搅拌、切割,形成若干微气泡,被带入主流区,从排气道排除。
借助新型的金属型微铸造工艺,实际铸造成形了不同厚度的片状微铸件和具有三维复杂形状的微齿轮铸件,片状微铸件最薄可达200μm,充型长度可达60mm。微齿轮铸件的所有尺寸已进入微米尺度:齿轮盘外径580μm,齿盘厚350μm,齿轮轴直径300μm,长400μm,最小充型壁厚可达50μm。证明了金属型微铸造工艺制备三维复杂微米尺度铸件的可行性。
微铸件的显微组织表现出强烈的微尺度效应。首先,与宏观尺度试样相比,随铸件尺寸的减小,微铸件的组织显著细化。再者,微铸件中初生相β-Zn的含量增加,共晶组织逐渐减少,微铸件的共晶组织形态为棒状形态,完全不同于宏观尺度铸件的层片状形态。固溶强化、细晶强化以及棒状共晶引起的界面强化是微铸件的主要强化因素。
微铸件的力学性能表现也出了强烈的微尺度效应。片状微铸件的抗拉强度和延伸率均比常规厚度2mm时提高近1倍。断口韧窝处存在大量纳米尺度的颗粒,阻碍了相邻晶粒间滑移系的开动和微裂纹的扩展。微齿轮铸件的硬度比宏观尺度铸件提高了约1.7倍,微齿轮铸件的室温蠕变速率敏感指数m值明显小于宏观尺度铸件,说明微铸件具有更高的抗蠕变性能,使用寿命更长。
Micro-precision casting is one of the most competitive processing technology for micro-parts in recent years. And it can prepare three-dimension complicated micro-metal parts with low-cost and mass. In this paper, a new micro-permanent mold casting processing technology is developed. And the involved basic science and theory, such as the filling flow law of fluid, the cessation mechanism and solidification forming in micro-scale, microstructure and mechanical properties of micro-castings, were studied deeply and systematically. Meanwhile, the micro-scale effects and microscopic mechanism about flow, solidification, microstructure and mechanical properties were revealed.
When flow in micro-scale space, the viscosity of liquid metal decreases sharply and the gas anti-pressure and capillary force have significant effects on liquid metal flow . In this case, traditional macroscopic N-S equation cannot be applied. So amelioration N-S equation and related physical and mathematical model was established.
Three obvious micro-scale effects which cannot occur under macroscopic state were observed when liquid metal fill in micro-pipe: increasion of boundry layer relative thickness, form of“convex effects”and generation of the gradient zone of negative pressure. The ratio between the boundry layer thickness and the pipe diameter increases with the decrease of the pipe diameter. In micro-scale, the stream-front is more prominent in comparision with that of macroscopic flow with increase of speed gradient. Then“convex effects”is formed, which increase significantly as the time increase and the pressure decreases. In addition, the gradient zone of negative pressure between the zone of flow front and upper zone is found. And the gradient zone becomes more and more obvious with the decrease of pipe diameter. The obvious micro-scale effects of the cessation of liquid metal flow in micro-pipe were observed. The cessation mechanism changed from the macroscopic front blocking mechanism to the composite cessation mechanism mixed with the front blocking mechanism and the semi-solid blocking mechanism. And the critical size of transition is 500μm.
The results of numerical simulation of micro-flow, micro-heat transfer and micro-solidification of micro-gear castings illustrated that the second pressure head is formed by filling firstly melt metal into opposite gear axis to impact the back wall of mould cavity. Then the back flow is formed by reversible filling melt metal into each tooth of micro-gear. The gases in the mould cavity are stirred and cut by high speed motion of melt metal, and get out from discharge ports by the overflow of melt metal.
The the plate microparts with different thickness and three-dimension microgears were prepared by micro-permanent mold casting. The minimum thickness of plate microparts is 200μm, and the length is 60mm. All the size of microgears reached the micron scale: the diameter of gear disk is 580μm, the thickness of gear disk is 350μm, the diameter of gear axis is 300μm, the length is 400μm and the minimum wall thickness is 50μm. This feasibility that three-dimensional complicate castings in micron-scale are produced by micro-permanent mold casting processing were proved.
The microstructure of micro-parts exhibit obvious micro-scale effects. Firstly, compared with samples in macroscopic, the grain size is refined significantly as the size of micro-castings decrease. Secondly, the primary phaseβ-Zn decreases gradually, while eutectic structure increases. The morphology of eutectic structure of micro-castings is rod-like and different from lamellar on regular castings. Fine grain strengthening, solid solution strengthening and interface strengthening caused by rod eutectic were the main intensified factors.
Mechanical properties of micro-castings also exhibit obvious micro-scale effects. Tensile strength and elongation of flake-like micro-castings are improved one time than that of castings of normal thickness of 2mm. Plentiful nano-scale particles in the dimples were found and hinder the beginning of slip systems in the intercrystalline and the extension of micro cracks. The hardness of micro-castings is higher than that of regular castings, by 1.7 times in the maximum. The sensitivity index m of strain rate of room temperature creep is apparently lower than that of macro-castings. This illustrates that micro-castings have higher creep resistance and longer service life.
引文
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