铝合金低频电磁铸造过程中的热量传输
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摘要
本课题是国家重点基础研究“973”计划项目“高性能铝材与铝资源高效利用的基础研究”中的课题“大铸锭能量传输与宏微观缺陷的产生及控制”中的部分内容,主要研究：低频电磁场对铝合金半连续铸造过程中的流场、温度场及铸锭凝固时的热量传输行为的影响,以及低频电磁场对铝合金铸锭表面质量及铸锭凝固组织的影响,为工业化生产大规格铝合金铸锭工艺参数的制定提供理论和实验依据。
在本研究中,建立了描述低频电磁铸造过程中热量传输的数学模型；采用实验的方法对建立的数学模型进行了验证；用数值模拟的方法研究了低频电磁场对铸造过程的熔体流动及热量传输的影响；用实验的方法研究了低频电磁场对铸锭表面的冷隔、偏析瘤、偏析层厚度以及铸锭凝固组织的影响。
本文通过实验测量Φ200mm 6063铝合金传统热顶和低频电磁热顶铸造过程中石墨环及铸锭内部温度,分析了低频电磁场对传统热顶铸造过程中结晶器一冷及铸锭表面二冷热量传输的影响。结果发现：在传统热顶铸造的稳定阶段施加低频电磁场,增强了结晶器一冷区域及铸锭表面凝固前沿的热量传输,减少了铝熔体与结晶器一冷的有效接触高度,使结晶器内的铸锭初始凝壳点上移；降低了熔池内液穴深度；降低了铸锭表面的最大热通量和温度梯度；铸锭内部的温度场也得到了改善,降低了铸造应力。在传统热顶铸造过程的启车阶段施加低频电磁场,加强了铸锭表面及铸锭底部的冷却,使铸锭内部的温度场较为均匀；铝熔体的强制对流使铸造启车阶段液穴底部较为平坦,减缓液穴的加深速度,有利于降低铸锭的热应力。
对Φ200mm 6063铝合金传统热顶和低频电磁热顶铸造过程进行了数值模拟,研究了电磁场对熔池内的温度分布、流体流动、热量传输、逆流导热距离(UCD)及模单独冷却距离(MAL)的影响。结果发现：传统热顶铸造过程中熔池内的温度不均匀,施加低频电磁场后,熔池内的温度非常均匀,且熔池内的温度在合金的液相线附近；电磁场能加快铸锭表面附近的流动流动,导致固液界面处的流动边界层及温度边界层厚度变薄,固液界面处温度梯度增大；而在铸锭中心部位附近,传统热顶和低频电磁热顶铸造过程流体流速相差不大,流动边界层和温度边界层相差也不是很大。在传统热顶铸造过程中,铝熔体在浇口附近的流动速度比较快,从浇口进入熔池的高温铝熔体直接流向液穴底部。因此,在铸锭内部的固液界面处,传统热顶铸造过程的温度梯度比低频电磁热顶铸造过程的温度梯度高。
在Φ200mm 6063铝合金传统热顶铸造过程中,施加低频电磁场,使二冷水的逆流冷却距离(UCD)增大；在铸造速度一定的情况下,随着电流频率的升高、电流强度的增大,UCD也逐渐增大；在铸造速度较低的情况下,电磁场使UCD增大的作用较为明显；在铸造速度较高的情况下,电磁场使UCD增大的作用不明显。此外,电磁场能使结晶器一冷引起的模单独冷却距离(MAL)发生改变；在铸造速度较高时,低频电磁场使MAL增大；在铸造速度较低时,低频电磁场使MAL减小；在铸造速度一定的情况下,随着电流频率的升高、电流强度的增大,MAL也逐渐增大；在铸造速度较低的情况下,电磁场增大MAL的作用不显著；在铸造速度较高的情况下,电磁场增大MAL的作用明显。
采用实验和数值模拟的方法,研究了低频电磁场对传统同水平铸造Φ200mm Al-4.5wt%Cu铝合金凝固过程的影响。结果表明：两相区范围较宽(约100℃)的A1-4.5wt%Cu铝合金,低频电磁场促进铝熔体过热散失及均匀熔池内部温度场的作用也非常明显；在传统同水平铸造过程中,保温帽内的铝熔体流动较为缓慢,铝熔体的流动主要受惯性和热浮力的作用,造成熔池内铝熔体温度呈层状分布,保温帽内铝熔体上部温度高、下部温度低；在低频电磁同水平铸造过程中,铝熔体在电磁力的作用下,在水平方向上保温帽内铝熔体的分流更加均匀,在竖直方向上保温帽内形成较强的涡流,熔池内的铝熔体温度场更加均匀。
研究了低频电磁场对铸锭表面质量及凝固组织的影响,分析了低频电磁场对铸锭表面质量的影响机制。结果发现：在Φ500mm 7050铝合金传统热顶铸造过程中施加低频电磁场,减少了保温帽探出部位铝熔体弯月面的大小,消除了传统热顶铸造过程中的铸锭表面的冷隔,使铝熔体与结晶器的有效接触高度降低,降低了铸锭表面激冷层的厚度；在Φ200mm 6063铝合金传统热顶铸造过程中施加低频电磁场,极大的细化了铸锭表面及内部的凝固组织；在(D200mm Al-4.5wt%Cu铝合金传统同水平铸造过程中施加低频电磁场,抑制了铸锭表面偏析瘤的出现,降低了铸锭表面的偏析层厚度,提高了铸锭的表面质量。
This subject is part work of "The energy transport in large size ingot and formation and control of its macroscopic and microscopic defects", which is the subject of "The fundamental research of high property aluminium and high efficiency utilization of aluminium resources" supported by the Key Foundational Research Program of China (973). The aim is to study study the fluid flow and temperature field in the liquid pool during the DC casting of aluminum alloys, the effects of low frequency electromagnetic field on heat transport during the solidification process, the effects of low frequency electromagnetic field on ingot surface quality and solidification structure of the ingot, and provide theoretical and experimental evidence for establishing technological parameters of industrial run of large size aluminum alloys ingots.
In this study, a mathematic model was built to simulate DC and low frequency electromagnetic casting processes, and the mathematic model was verified by experimental results. The effects of low frequency electromagnetic field on the fluid flow and heat transport were studied by numerical simulation during the DC casting of aluminum alloys process, and the effects of low frequency electromagnetic field on the ingot surface quality (cold fold, exudation on the surface and the thickness of segregation layer) and solidification structure of the ingot were studied by the experiments.
The temperature of the graphite ring and ingot during the hot-top and low frequency electromagnetic hot-top casting ofΦ200mm 6063 aluminum alloy was measured, and the effects of low frequency electromagnetic field on heat transport of ingot surface in the primary cooling of mold and secondary cooling of water regions during the hot-top and low frequency electromagnetic hot-top casting processes are analyzed. The results showed that when the low frequency electromagnetic field was applied during the steady state of conventional hot-top casting process, the heat transport near the primary cooling zone of mold and solidification front of ingot surface was intensified, the height of effective contact zone between the melt and the primary cooling zone of mold was reduced, and the initial solidification point on the wall of the mold moved up; the depth of sump decreased; the largest heat flux and the temperature gradient in casting direction on the ingot surface decreased; the temperature field in the ingot was modified, so the stress in the ingot was reduced. When the low frequency electromagnetic field was applied during the start-up phase of conventional hot-top casting process, the heat transport between the ingot, the mold and the starting block was intensified greatly, the temperature field in the ingot became more uniform; the sump during the start-up phase of low frequency electromagnetic casting was very flat, which is caused by the forced convection, the speed of sump becoming deeper was reduced, and the thermal stress in the ingot decreased.
Numerical simulation was made to study the hot-top and low frequency electromagnetic hot-top casting of 6063 aluminum alloy ingot with a diameter of 200mm. The effects of low frequency electromagnetic field on the temperature profile, fluid flow, heat transport, upstream conduction distance (UCD), and mold along length (MAL) were studied. The results showed that the temperature profile of the melt pool was nonuniform during the conventional hot-top casting process, when the low frequency electromagnetic field was applied, the temperature profile of the melt pool became uniform, and the temperature was near the liquidus temperature of 6063 aluminum alloy; near the ingot surface, the low frequency electromagnetic field can intensify the fluid flow, made the flow and thermal boundary layer on the liquid/solid interface thinner, and cause the temperature gradient on liquid/solid interface larger; near the ingot center, the effect of low frequency electromagnetic field on the velocity of melt flow is not obvious, the difference of the flow and thermal boundary layer on the liquid/solid interface during the conventional and low frequency electromagnetic hot-top casting process is not obvious. During the conventional hot-top casting process, the velocity of the melt flow at the inlet is fast, the melt from the inlet with higher temperature flows to the bottom of sump directly, so the temperature gradient on the liquid/solid interface near the ingot center in the conventional hot-top casting process is a little higher than that in the low frequency electromagnetic hot-top casting process.
During the conventional hot-top casting of 6063 aluminum alloy with a diameter of 200mm process, when the low frequency electromagnetic field is applied, the upstream conduction distance caused by the secondary cooling water increases; when the casting speed is constant, UCD increases with the increase of current frequency and intensity; The effect of low frequency electromagnetic field enlarging the UCD is obvious when the casting speed is slow; the effect of low frequency electromagnetic field enlarging the UCD is not obvious when the casting speed is high. Additionally, when the low frequency electromagnetic field is applied during the conventional hot-top casting process the mold along length (MAL) can be changed; the MAL increases when the casting speed is high, and the MAL decreases when the casting speed is slow; when the casting speed is constant, MAL increases with the increase of current frequency and intensity; the effect of low frequency electromagnetic field enlarging the MAL is not obvious when the casting speed is slow, but the effect of low frequency electromagnetic field enlarging the UCD is obvious when the casting speed is high.
The experiment and numerical simulation were made to study the effects of low frequency electromagnetic field on the process of conventional level pour casting of Al-4.5wt%Cu aluminum alloy with a diameter of 200mm. The results show that for Al-4.5wt%Cu aluminum alloy with a broad two-phase region(about 100 degrees centigrade), the effects of low frequency electromagnetic field promoting the evacuation of superheat and making the temperature profile in the liquid pool more homogeneous are also obvious. During the conventional level pour casting process, the fluid flow in the liquid pool is slow, which is mastered by inertia and thermal buoyancy of the liquid, and the temperature profile of the melt in the liquid pool is layered, the temperature of the melt is high in the top of refractory, and the temperature of the melt is low in the base of refractory. During the low frequency electromagnetic level pour casting process, the melt in the liquid pool is driven by the electromagnetic force, the fluid flow is intensified, the distributary of melt in the refractory on the horizontal plane is more reasonable, there is a strong eddy flow in the refractory on the vertical plane, and the temperature profile of melt in the liquid pool is very homogeneous.
The effects of low frequency electromagnetic field on the ingot surface quality and solidification structure were studied by experiments and the reasons of the effects were analyzed. The results show that when low frequency electromagnetic field is applied during the conventional hot-top casting of 7050 aluminum alloy with a diameter of 500mm, the size of meniscus under the overhang is reduced, the cold fold near the ingot surface is eliminated, the length of effective contact zone between the melt and the primary cooling of mold is reduced, and the thickness of shell zone near the ingot surface is reduced; when low frequency electromagnetic field is applied during the conventional hot-top casting of 6063 aluminum alloy with a diameter of 200mm. the macrostructure and microstructure of the ingot border and center are refined greatly; when low frequency electromagnetic field is applied during the conventional level pour casting of Al-4.5wt%Cu aluminum alloy with a diameter of 200mm, the number of exudations on the ingot surface is decreased, the thickness of segregation layer on the ingot surface is reduced, and the surface quality of ingot is improved.
在本研究中,建立了描述低频电磁铸造过程中热量传输的数学模型；采用实验的方法对建立的数学模型进行了验证；用数值模拟的方法研究了低频电磁场对铸造过程的熔体流动及热量传输的影响；用实验的方法研究了低频电磁场对铸锭表面的冷隔、偏析瘤、偏析层厚度以及铸锭凝固组织的影响。
本文通过实验测量Φ200mm 6063铝合金传统热顶和低频电磁热顶铸造过程中石墨环及铸锭内部温度,分析了低频电磁场对传统热顶铸造过程中结晶器一冷及铸锭表面二冷热量传输的影响。结果发现：在传统热顶铸造的稳定阶段施加低频电磁场,增强了结晶器一冷区域及铸锭表面凝固前沿的热量传输,减少了铝熔体与结晶器一冷的有效接触高度,使结晶器内的铸锭初始凝壳点上移；降低了熔池内液穴深度；降低了铸锭表面的最大热通量和温度梯度；铸锭内部的温度场也得到了改善,降低了铸造应力。在传统热顶铸造过程的启车阶段施加低频电磁场,加强了铸锭表面及铸锭底部的冷却,使铸锭内部的温度场较为均匀；铝熔体的强制对流使铸造启车阶段液穴底部较为平坦,减缓液穴的加深速度,有利于降低铸锭的热应力。
对Φ200mm 6063铝合金传统热顶和低频电磁热顶铸造过程进行了数值模拟,研究了电磁场对熔池内的温度分布、流体流动、热量传输、逆流导热距离(UCD)及模单独冷却距离(MAL)的影响。结果发现：传统热顶铸造过程中熔池内的温度不均匀,施加低频电磁场后,熔池内的温度非常均匀,且熔池内的温度在合金的液相线附近；电磁场能加快铸锭表面附近的流动流动,导致固液界面处的流动边界层及温度边界层厚度变薄,固液界面处温度梯度增大；而在铸锭中心部位附近,传统热顶和低频电磁热顶铸造过程流体流速相差不大,流动边界层和温度边界层相差也不是很大。在传统热顶铸造过程中,铝熔体在浇口附近的流动速度比较快,从浇口进入熔池的高温铝熔体直接流向液穴底部。因此,在铸锭内部的固液界面处,传统热顶铸造过程的温度梯度比低频电磁热顶铸造过程的温度梯度高。
在Φ200mm 6063铝合金传统热顶铸造过程中,施加低频电磁场,使二冷水的逆流冷却距离(UCD)增大；在铸造速度一定的情况下,随着电流频率的升高、电流强度的增大,UCD也逐渐增大；在铸造速度较低的情况下,电磁场使UCD增大的作用较为明显；在铸造速度较高的情况下,电磁场使UCD增大的作用不明显。此外,电磁场能使结晶器一冷引起的模单独冷却距离(MAL)发生改变；在铸造速度较高时,低频电磁场使MAL增大；在铸造速度较低时,低频电磁场使MAL减小；在铸造速度一定的情况下,随着电流频率的升高、电流强度的增大,MAL也逐渐增大；在铸造速度较低的情况下,电磁场增大MAL的作用不显著；在铸造速度较高的情况下,电磁场增大MAL的作用明显。
采用实验和数值模拟的方法,研究了低频电磁场对传统同水平铸造Φ200mm Al-4.5wt%Cu铝合金凝固过程的影响。结果表明：两相区范围较宽(约100℃)的A1-4.5wt%Cu铝合金,低频电磁场促进铝熔体过热散失及均匀熔池内部温度场的作用也非常明显；在传统同水平铸造过程中,保温帽内的铝熔体流动较为缓慢,铝熔体的流动主要受惯性和热浮力的作用,造成熔池内铝熔体温度呈层状分布,保温帽内铝熔体上部温度高、下部温度低；在低频电磁同水平铸造过程中,铝熔体在电磁力的作用下,在水平方向上保温帽内铝熔体的分流更加均匀,在竖直方向上保温帽内形成较强的涡流,熔池内的铝熔体温度场更加均匀。
研究了低频电磁场对铸锭表面质量及凝固组织的影响,分析了低频电磁场对铸锭表面质量的影响机制。结果发现：在Φ500mm 7050铝合金传统热顶铸造过程中施加低频电磁场,减少了保温帽探出部位铝熔体弯月面的大小,消除了传统热顶铸造过程中的铸锭表面的冷隔,使铝熔体与结晶器的有效接触高度降低,降低了铸锭表面激冷层的厚度；在Φ200mm 6063铝合金传统热顶铸造过程中施加低频电磁场,极大的细化了铸锭表面及内部的凝固组织；在(D200mm Al-4.5wt%Cu铝合金传统同水平铸造过程中施加低频电磁场,抑制了铸锭表面偏析瘤的出现,降低了铸锭表面的偏析层厚度,提高了铸锭的表面质量。
This subject is part work of "The energy transport in large size ingot and formation and control of its macroscopic and microscopic defects", which is the subject of "The fundamental research of high property aluminium and high efficiency utilization of aluminium resources" supported by the Key Foundational Research Program of China (973). The aim is to study study the fluid flow and temperature field in the liquid pool during the DC casting of aluminum alloys, the effects of low frequency electromagnetic field on heat transport during the solidification process, the effects of low frequency electromagnetic field on ingot surface quality and solidification structure of the ingot, and provide theoretical and experimental evidence for establishing technological parameters of industrial run of large size aluminum alloys ingots.
In this study, a mathematic model was built to simulate DC and low frequency electromagnetic casting processes, and the mathematic model was verified by experimental results. The effects of low frequency electromagnetic field on the fluid flow and heat transport were studied by numerical simulation during the DC casting of aluminum alloys process, and the effects of low frequency electromagnetic field on the ingot surface quality (cold fold, exudation on the surface and the thickness of segregation layer) and solidification structure of the ingot were studied by the experiments.
The temperature of the graphite ring and ingot during the hot-top and low frequency electromagnetic hot-top casting ofΦ200mm 6063 aluminum alloy was measured, and the effects of low frequency electromagnetic field on heat transport of ingot surface in the primary cooling of mold and secondary cooling of water regions during the hot-top and low frequency electromagnetic hot-top casting processes are analyzed. The results showed that when the low frequency electromagnetic field was applied during the steady state of conventional hot-top casting process, the heat transport near the primary cooling zone of mold and solidification front of ingot surface was intensified, the height of effective contact zone between the melt and the primary cooling zone of mold was reduced, and the initial solidification point on the wall of the mold moved up; the depth of sump decreased; the largest heat flux and the temperature gradient in casting direction on the ingot surface decreased; the temperature field in the ingot was modified, so the stress in the ingot was reduced. When the low frequency electromagnetic field was applied during the start-up phase of conventional hot-top casting process, the heat transport between the ingot, the mold and the starting block was intensified greatly, the temperature field in the ingot became more uniform; the sump during the start-up phase of low frequency electromagnetic casting was very flat, which is caused by the forced convection, the speed of sump becoming deeper was reduced, and the thermal stress in the ingot decreased.
Numerical simulation was made to study the hot-top and low frequency electromagnetic hot-top casting of 6063 aluminum alloy ingot with a diameter of 200mm. The effects of low frequency electromagnetic field on the temperature profile, fluid flow, heat transport, upstream conduction distance (UCD), and mold along length (MAL) were studied. The results showed that the temperature profile of the melt pool was nonuniform during the conventional hot-top casting process, when the low frequency electromagnetic field was applied, the temperature profile of the melt pool became uniform, and the temperature was near the liquidus temperature of 6063 aluminum alloy; near the ingot surface, the low frequency electromagnetic field can intensify the fluid flow, made the flow and thermal boundary layer on the liquid/solid interface thinner, and cause the temperature gradient on liquid/solid interface larger; near the ingot center, the effect of low frequency electromagnetic field on the velocity of melt flow is not obvious, the difference of the flow and thermal boundary layer on the liquid/solid interface during the conventional and low frequency electromagnetic hot-top casting process is not obvious. During the conventional hot-top casting process, the velocity of the melt flow at the inlet is fast, the melt from the inlet with higher temperature flows to the bottom of sump directly, so the temperature gradient on the liquid/solid interface near the ingot center in the conventional hot-top casting process is a little higher than that in the low frequency electromagnetic hot-top casting process.
During the conventional hot-top casting of 6063 aluminum alloy with a diameter of 200mm process, when the low frequency electromagnetic field is applied, the upstream conduction distance caused by the secondary cooling water increases; when the casting speed is constant, UCD increases with the increase of current frequency and intensity; The effect of low frequency electromagnetic field enlarging the UCD is obvious when the casting speed is slow; the effect of low frequency electromagnetic field enlarging the UCD is not obvious when the casting speed is high. Additionally, when the low frequency electromagnetic field is applied during the conventional hot-top casting process the mold along length (MAL) can be changed; the MAL increases when the casting speed is high, and the MAL decreases when the casting speed is slow; when the casting speed is constant, MAL increases with the increase of current frequency and intensity; the effect of low frequency electromagnetic field enlarging the MAL is not obvious when the casting speed is slow, but the effect of low frequency electromagnetic field enlarging the UCD is obvious when the casting speed is high.
The experiment and numerical simulation were made to study the effects of low frequency electromagnetic field on the process of conventional level pour casting of Al-4.5wt%Cu aluminum alloy with a diameter of 200mm. The results show that for Al-4.5wt%Cu aluminum alloy with a broad two-phase region(about 100 degrees centigrade), the effects of low frequency electromagnetic field promoting the evacuation of superheat and making the temperature profile in the liquid pool more homogeneous are also obvious. During the conventional level pour casting process, the fluid flow in the liquid pool is slow, which is mastered by inertia and thermal buoyancy of the liquid, and the temperature profile of the melt in the liquid pool is layered, the temperature of the melt is high in the top of refractory, and the temperature of the melt is low in the base of refractory. During the low frequency electromagnetic level pour casting process, the melt in the liquid pool is driven by the electromagnetic force, the fluid flow is intensified, the distributary of melt in the refractory on the horizontal plane is more reasonable, there is a strong eddy flow in the refractory on the vertical plane, and the temperature profile of melt in the liquid pool is very homogeneous.
The effects of low frequency electromagnetic field on the ingot surface quality and solidification structure were studied by experiments and the reasons of the effects were analyzed. The results show that when low frequency electromagnetic field is applied during the conventional hot-top casting of 7050 aluminum alloy with a diameter of 500mm, the size of meniscus under the overhang is reduced, the cold fold near the ingot surface is eliminated, the length of effective contact zone between the melt and the primary cooling of mold is reduced, and the thickness of shell zone near the ingot surface is reduced; when low frequency electromagnetic field is applied during the conventional hot-top casting of 6063 aluminum alloy with a diameter of 200mm. the macrostructure and microstructure of the ingot border and center are refined greatly; when low frequency electromagnetic field is applied during the conventional level pour casting of Al-4.5wt%Cu aluminum alloy with a diameter of 200mm, the number of exudations on the ingot surface is decreased, the thickness of segregation layer on the ingot surface is reduced, and the surface quality of ingot is improved.
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