连铸坯凝固过程热模拟研究
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摘要
研究连铸坯凝固过程和组织形成规律，对于冶金生产中合理制定连铸工艺，改善铸坯质量具有十分重要的意义。目前对连铸钢坯凝固过程的研究主要有数值模拟、物理模拟和工业实验三种方法。受热物性参数和计算能力的制约，数值模拟尚不能准确反映连铸坯凝固过程。物理模拟方法可以定性地揭示凝固原理，但无法定量研究金属的凝固规律。工业试验成本高，因此较少采用。本文根据连铸坯传热及凝固特点，基于枝晶生长条件相似原理，提出连铸坯枝晶生长水平式单向凝固热模拟方法并设计制造了连铸坯枝晶生长热模拟试验机。该热模拟试验机具有原位浇注、控制冷速和冷却强度及施加搅拌等功能。该方法用数百克钢再现连铸坯枝晶生长过程，为研究连铸坯凝固过程、固液界面形貌及溶质分布、柱状晶向等轴晶转变（简称CET）规律及连铸工艺对凝固组织的影响提供了实验手段。
本文以2205双相不锈钢为实验材料，从传热及凝固组织两方面验证了连铸坯枝晶生长热模拟方法与连铸坯凝固之间的相似性。热模拟试样的热流密度及其变化规律与连铸坯的传热较一致，且浇注温度和水冷端的冷却强度可以调节，从而可模拟不同的工艺条件。热模拟试样的宏观、微观组织与相同过热度浇注的连铸坯相似度很好，柱状晶向等轴晶转变位置、晶粒尺寸及两相比例与连铸坯基本一致。这些结果证明，该热模拟方法能够比较准确地再现连铸坯的凝固过程。
利用热模拟装置研究了外部强冷条件下的CET，发现对流对CET影响很大，材料凝固特性对CET也有一定的影响。在强制对流条件下，Al-Cu合金凝固初期会出现游离晶粒，而双相不锈钢则未发现游离晶。液淬实验表明，柱状晶生长期间出现的游离晶是枝晶熔断或者型壁附近形核并被液流卷入的结果。无强制对流时，CET之前未发现游离晶，等轴晶区的晶核来源是液相过冷形核和液面形核产生的“结晶雨”。
利用连铸坯枝晶生长热模拟装置研究了连铸工艺条件对双相不锈钢、T10A钢和铝铜合金凝固组织演变的影响规律。发现几种材料在连铸条件下表现出不同的凝固特点。这些材料凝固组织对浇注温度和冷却强度变化的敏感性差异很大，按照大小排序为：Al-4.5wt.%Cu（铝铜单相合金）>T10A（高碳钢）>2101、2205和2304（双相不锈钢）。据此可以推断，双相不锈钢可以在较宽松的连铸条件下生产而不显著改变凝固组织。这一方面是由于三种材料凝固过程中溶质富集程度不同，另一方面是传热能力不同。另外还发现，机械振动可以大幅增加Al-Cu合金和T10A的等轴晶率，但是对双相不锈钢影响很小。由此可以推断，强制对流可有效提高溶质分配系数k<<1的合金的等轴晶率，但是对纯金属和平衡分配系数接近1的合金影响不明显。
本文采用简化的合金凝固KGT模型，利用有限元商业软件ProCAST数值模拟了连铸坯热模拟试样的传热及凝固过程。发现Al-4.5wt.%Cu合金热模拟试样凝固组织及CET转变的预测结果与实际凝固组织相似度较高，证明KGT模型可以较准确预测二元合金连铸条件下的凝固组织。而2205双相不锈钢微观组织预测结果与实际凝固组织偏差较大，说明利用KGT模型预测多元合金尤其是钢的微观组织并不理想，实验模拟仍然是连铸钢坯凝固过程必要的研究手段。
To investigate the solidification process and structure of slab is of great importancefor choosing rational production parameters and improving the quality of continuouscasting billets. There are three methods to study the solidification process of continuouscasting, which are numerical simulation, physical simulation and industrial experiments.Restricted by the thermal-physical parameters and the computing power, numericalsimulation still cannot accurately reflect the billet’s solidification process. Physicalsimulation method can reveal qualitatively the solidification principle, but cannot evaluatethe development of solidification structure of metals quantitatively. Due to the high cost,industrial experiments are rarely used. Based on the analysis of heat transfer, solidificationfeatures of billets, and the similarity of dendrite growth conditions, a horizontal directionalsolidification thermal simulation method for dendritic growth in continuous casting wasproposed and a corresponding thermal simulation system was designed. The system canachieve in-situ pouring, cooling rate and intensity controlling and mechanical stirring. Withsuch a system, the dendrite growth process of billets can be reproduced by use of dozens orhundreds of grams of steel, offering a laboratory technique to study the slab solidificationprocess, morphology of solid-liquid interface, solute distribution, columnar to equiaxedtransition (CET) and the effect of production parameters on slab solidification structure.
The consistency of thermal simulation system and continuous casting were verified bycomparing heat transfer and solidification structure using2205duplex stainless steel (DSS).It is shown that the heat flux of thermal simulation samples agreed well with continuouscasting slab. In addition, the pouring temperature and cooling intensity could be regulatedto simulate different production conditions. The macro and micro structure of thermalsimulation sample, such as the CET positions, grain sizes and proportions of two phases,etc. were similar to that of slab. These results demonstrate that the thermal simulationmethod can reproduce the billet solidification process properly.
The CET behaviors under external strong cold conditions were studied on the thermalsimulation system. It’s found that the CET was strongly affected by the liquid convection,and was also affected by the materials’ coherent solidification characteristics. With forcedconvection, free dendritic grains were observed during the columnar dendritic growth inAl-Cu alloy simples while not in DSS. The solid-liquid interface and dendriticmetallography of quenched samples indicated that these free dendritic grains werefragments of remelted dendrites or the nucleus which formed on chill mold wall and embroiled into bulk liquid by convection. Without forced convection, none free dendriticgrain was distinguished in quenched samples. The equiaxed grains nucleated inundercooled bulk liquid and free surface, and then the grains nucleated on free surfacesedimentated into bulk liquid with convection, which was called as “grain rain”.
The effect of continuous casting production parameters on solidification structure ofDSS, T10A steel and Al-Cu alloy were investigated using the thermal simulation system.These materials showed different solidification characteristics in continuous castingconditions. The sensitivity of these materials’ solidification structure on pouringtemperature and cooling intensity were of great difference, which sorted as follows:Al-4.5wt%Cu (single-phase alloys)> the T10A (high carbon steel)>>2101,2205and2304(DSS). So, it can be inferred that the solidification structure of DSS will not change assignificantly as other two materials under wide continuous casting conditions. Thisphenomenon is due to the difference of solute concentration of these materials duringsolidification and the different heat conductivities are another important factor. It alsofound that mechanical vibration can substantially increase equiaxed grain rate of Al-Cualloys and T10A steel, while has little effect on the DSS. It can be inferred that the forcedconvection can effectively improve the equiaxed grain proportion of alloy with little solutedistribution coefficient (k <<1), but has little effect on pure metals and alloy with k closeto unity.
In this paper, based on the simplified alloy solidification Kurz-Giovanola-Trivedi(KGT) model, the billet thermal simulation specimens heat transfer and solidificationprocess were numerically simulated on the finite element commercial software ProCAST.The numerical simulate solidification structure and CET of Al-4.5wt.%Cu alloy weresimilar to the actual structure of thermal simulation sample, which approve the KGT modelcan accurately predict the binary alloy’s solidification process under continuous castingconditions. However, the prediction of solidification of2205DSS was not consistent to thethermal simulation samples. These results demonstrated that numerical simulation thesolidification of multicomponent alloy was not accurate enough now, and the experimentalsimulation is still a necessary means for study of solidification during continuous casting.
本文以2205双相不锈钢为实验材料，从传热及凝固组织两方面验证了连铸坯枝晶生长热模拟方法与连铸坯凝固之间的相似性。热模拟试样的热流密度及其变化规律与连铸坯的传热较一致，且浇注温度和水冷端的冷却强度可以调节，从而可模拟不同的工艺条件。热模拟试样的宏观、微观组织与相同过热度浇注的连铸坯相似度很好，柱状晶向等轴晶转变位置、晶粒尺寸及两相比例与连铸坯基本一致。这些结果证明，该热模拟方法能够比较准确地再现连铸坯的凝固过程。
利用热模拟装置研究了外部强冷条件下的CET，发现对流对CET影响很大，材料凝固特性对CET也有一定的影响。在强制对流条件下，Al-Cu合金凝固初期会出现游离晶粒，而双相不锈钢则未发现游离晶。液淬实验表明，柱状晶生长期间出现的游离晶是枝晶熔断或者型壁附近形核并被液流卷入的结果。无强制对流时，CET之前未发现游离晶，等轴晶区的晶核来源是液相过冷形核和液面形核产生的“结晶雨”。
利用连铸坯枝晶生长热模拟装置研究了连铸工艺条件对双相不锈钢、T10A钢和铝铜合金凝固组织演变的影响规律。发现几种材料在连铸条件下表现出不同的凝固特点。这些材料凝固组织对浇注温度和冷却强度变化的敏感性差异很大，按照大小排序为：Al-4.5wt.%Cu（铝铜单相合金）>T10A（高碳钢）>2101、2205和2304（双相不锈钢）。据此可以推断，双相不锈钢可以在较宽松的连铸条件下生产而不显著改变凝固组织。这一方面是由于三种材料凝固过程中溶质富集程度不同，另一方面是传热能力不同。另外还发现，机械振动可以大幅增加Al-Cu合金和T10A的等轴晶率，但是对双相不锈钢影响很小。由此可以推断，强制对流可有效提高溶质分配系数k<<1的合金的等轴晶率，但是对纯金属和平衡分配系数接近1的合金影响不明显。
本文采用简化的合金凝固KGT模型，利用有限元商业软件ProCAST数值模拟了连铸坯热模拟试样的传热及凝固过程。发现Al-4.5wt.%Cu合金热模拟试样凝固组织及CET转变的预测结果与实际凝固组织相似度较高，证明KGT模型可以较准确预测二元合金连铸条件下的凝固组织。而2205双相不锈钢微观组织预测结果与实际凝固组织偏差较大，说明利用KGT模型预测多元合金尤其是钢的微观组织并不理想，实验模拟仍然是连铸钢坯凝固过程必要的研究手段。
To investigate the solidification process and structure of slab is of great importancefor choosing rational production parameters and improving the quality of continuouscasting billets. There are three methods to study the solidification process of continuouscasting, which are numerical simulation, physical simulation and industrial experiments.Restricted by the thermal-physical parameters and the computing power, numericalsimulation still cannot accurately reflect the billet’s solidification process. Physicalsimulation method can reveal qualitatively the solidification principle, but cannot evaluatethe development of solidification structure of metals quantitatively. Due to the high cost,industrial experiments are rarely used. Based on the analysis of heat transfer, solidificationfeatures of billets, and the similarity of dendrite growth conditions, a horizontal directionalsolidification thermal simulation method for dendritic growth in continuous casting wasproposed and a corresponding thermal simulation system was designed. The system canachieve in-situ pouring, cooling rate and intensity controlling and mechanical stirring. Withsuch a system, the dendrite growth process of billets can be reproduced by use of dozens orhundreds of grams of steel, offering a laboratory technique to study the slab solidificationprocess, morphology of solid-liquid interface, solute distribution, columnar to equiaxedtransition (CET) and the effect of production parameters on slab solidification structure.
The consistency of thermal simulation system and continuous casting were verified bycomparing heat transfer and solidification structure using2205duplex stainless steel (DSS).It is shown that the heat flux of thermal simulation samples agreed well with continuouscasting slab. In addition, the pouring temperature and cooling intensity could be regulatedto simulate different production conditions. The macro and micro structure of thermalsimulation sample, such as the CET positions, grain sizes and proportions of two phases,etc. were similar to that of slab. These results demonstrate that the thermal simulationmethod can reproduce the billet solidification process properly.
The CET behaviors under external strong cold conditions were studied on the thermalsimulation system. It’s found that the CET was strongly affected by the liquid convection,and was also affected by the materials’ coherent solidification characteristics. With forcedconvection, free dendritic grains were observed during the columnar dendritic growth inAl-Cu alloy simples while not in DSS. The solid-liquid interface and dendriticmetallography of quenched samples indicated that these free dendritic grains werefragments of remelted dendrites or the nucleus which formed on chill mold wall and embroiled into bulk liquid by convection. Without forced convection, none free dendriticgrain was distinguished in quenched samples. The equiaxed grains nucleated inundercooled bulk liquid and free surface, and then the grains nucleated on free surfacesedimentated into bulk liquid with convection, which was called as “grain rain”.
The effect of continuous casting production parameters on solidification structure ofDSS, T10A steel and Al-Cu alloy were investigated using the thermal simulation system.These materials showed different solidification characteristics in continuous castingconditions. The sensitivity of these materials’ solidification structure on pouringtemperature and cooling intensity were of great difference, which sorted as follows:Al-4.5wt%Cu (single-phase alloys)> the T10A (high carbon steel)>>2101,2205and2304(DSS). So, it can be inferred that the solidification structure of DSS will not change assignificantly as other two materials under wide continuous casting conditions. Thisphenomenon is due to the difference of solute concentration of these materials duringsolidification and the different heat conductivities are another important factor. It alsofound that mechanical vibration can substantially increase equiaxed grain rate of Al-Cualloys and T10A steel, while has little effect on the DSS. It can be inferred that the forcedconvection can effectively improve the equiaxed grain proportion of alloy with little solutedistribution coefficient (k <<1), but has little effect on pure metals and alloy with k closeto unity.
In this paper, based on the simplified alloy solidification Kurz-Giovanola-Trivedi(KGT) model, the billet thermal simulation specimens heat transfer and solidificationprocess were numerically simulated on the finite element commercial software ProCAST.The numerical simulate solidification structure and CET of Al-4.5wt.%Cu alloy weresimilar to the actual structure of thermal simulation sample, which approve the KGT modelcan accurately predict the binary alloy’s solidification process under continuous castingconditions. However, the prediction of solidification of2205DSS was not consistent to thethermal simulation samples. These results demonstrated that numerical simulation thesolidification of multicomponent alloy was not accurate enough now, and the experimentalsimulation is still a necessary means for study of solidification during continuous casting.
引文
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