7075铝合金螺旋电磁搅拌技术及应用研究
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摘要
7075铝合金具有超高强度,广泛应用于航天、航空及军工行业。但由于该合金元素含量高,凝固组织粗大不均匀,合金元素偏析严重,导致铸坯和热轧开坯易开裂,严重限制了其使用和发展。强制均匀凝固技术通过对合金熔体施加物理外场,促进熔体剪切流动,形成均匀分布的温度场、成分场和细小的异质颗粒基底,合金熔体整体爆发形核,最终可以有效的细化晶粒、减少偏析。因此本文进行7075铝合金强制均匀凝固技术及应用研究。
首先研究了双螺旋机械搅拌技术对7075铝合金凝固行为的影响。在双螺旋机械搅拌条件下合金熔体的流动速度和剪切速率非常高,温度场和成分场非常均匀,强制均匀效果非常好。通过理论和实验分析确定了双螺旋机械搅拌的最优工艺参数为：搅拌强度100rpm,搅拌时间60s,浇注温度650℃。在该工艺条件下,7075铝合金晶粒组织十分细小均匀,平均晶粒尺寸约为55μm;而且合金的化学成分偏析大大减弱,Zn、Mg和Cu元素的偏析率分别降为0.71%、0.87%和2.1%。然而双螺旋机械搅拌不足之处主要是容易污染合金熔体,维护成本高,不适宜高温金属(熔点超过1000℃)的研究与应用。
电磁搅拌具有能量的高密度性和清洁性、优越的响应性和可控性、易于自动化、能量利用率高等优点,率先实现产业化并获得较为广泛的商业应用。本文研究了环缝电磁搅拌技术对7075铝合金凝固行为的影响。相比普通电磁搅拌,环缝电磁搅拌技术避开了磁感应强度较低的部分,充分利用趋肤效应层磁感应强度高的优点,使合金熔体在缝隙内搅拌,熔体剪切速率增大,同时增加了熔体心部的散热面积,使熔体获得更加均匀的温度场和成分场,合金凝固组织更加细小均匀。但由于电磁搅拌的电磁力在熔体中主要是按周向分布,熔体周向流动为主,而轴向流和径向流较弱,产生了沿轴向和径向分布的温度梯度和成分梯度,同时熔体剪切速率相对于双螺旋机械搅拌弱很多,对合金熔体的强制均匀效果差很多,晶粒组织细化效果也就差很多。
在以上研究的基础上,本文提出了螺旋电磁搅拌技术。螺旋电磁搅拌技术克服了机械搅拌易污染、难应用和环缝电磁搅拌不均匀、剪切速率低的缺点,实现了在电磁搅拌条件下熔体流动速度和剪切速率明显增加、紊流更加剧烈、温度场和成分场更加均匀,对合金熔体的强制均匀效果与双螺旋机械搅拌大幅接近。通过理论和实验分析获得了螺旋腔体的最优结构和螺旋电磁搅拌的最优工艺参数,分别为：螺旋腔体的螺杆直径40mm、螺纹高度12mm、螺纹斜度65。及螺纹螺距55mmm：搅拌电流30A、搅拌频率50Hz、浇注温度650℃。在该腔体结构和工艺参数条件下,7075铝合金凝固组织演变为细小均匀的等轴晶组织,晶粒尺寸约为68gm,而且合金的化学成分偏析大大减弱,Zn、Mg和Cu元素的偏析率分别降为1.5%、3.3%和3.4%。
以上述的实验研究为基础,深化丰富了强制均匀凝固技术对合金凝固行为的影响,建立了强制均匀凝固作用下控制形核及长大的描述模型。强制均匀凝固技术可以有效控制熔体温度场和成分场的均匀性,增加了合金熔体的形核过冷度,缩小甚至消除成分过冷区,从而显著增加了合金熔体的有效均匀形核率、非均匀形核率及核心存活率,使熔体整体爆发形核,并削弱甚至消除了枝晶生长的条件,最终使凝固组织变为细小均匀的等轴晶粒。
最后进行了螺旋电磁搅拌技术在7075铝合金流变压铸成型中的应用研究,研究结果表明：相比于普通压铸成型,螺旋电磁搅拌条件下7075铝合金流变压铸零件显微组织分布均匀细小,不同位置的组织差别不大；布氏硬度显著提高且分布均匀；零件裂纹倾向性降低明显；凝固组织和性能均接近双螺旋机械搅拌流变压铸的零件,而且生产效率明显增加。同时针对螺旋电磁搅拌技术自动化程度不高的缺点,设计出自动化螺旋电磁搅拌技术原型,集熔体自动收集、自动处理和自动浇注于一体,为最终实现产业化生产奠定基础。
7075aluminum alloy with high strength is widely used in the aerospace, aviation and military industry. Due to the high content of alloy elements, the solidification structure is non-uniform and coarse and alloy elements segregation is serious, resulting in being craze when casting and hot rolling, which seriously limits its use and development. By applying physical fields on alloy melt, mandatory uniform solidification technology can promote the melt flowing and shearing and make the temperature field, component field and tiny heterogeneous particles uniformly distribute in the melt, which will make the alloy melt overall nucleate, effectively refine the grain and reduce segregation. So this paper was concerned on the technology and application research on mandatory uniform solidification of7075aluminium alloy.
We studied the effect of twin-screw stirring process on the melt physical fields and solidification structure of7075aluminum alloy. The twin-screw stirring process can make the melt flowing rate and shearing rate very high, the temperature and composition fields very uniform, and the effect of mandatory uniform solidification very well. The optimal process parameters of twin-screw stirring were the intensity of100rpm, the stirring time of60s and the pouring temperature of650℃. Under this process condition, the7075alloy grain was very uniformly fine and the average grain size was55μm. The alloy chemical composition segregation greatly abated. The segregation rates of Zn, Mg and Cu elements were0.71%,0.87%and2.1%, respectively. The deficiencies of twin-screw stirring process were that the stirring device was easy to be corroded and expensive to be maintained, and it cannot process high temperature alloy (melting point higher than1000℃). So it is not suitable for mass production of parts, and it is difficult to realize industrialization production.
The electromagnetic stirring has the advantages of high density and cleanliness of energy, superior responsiveness and controllability, easy automation, high energy utilization rate, and etc. So it obtains more widely commercial application. We studied the effect of the annular electromagnetic stirring process on the physical fields and solidification structure of7075aluminum alloy. Compared with the conventional electromagnetic stirring process, annular electromagnetic stirring process can avoid the lower part of magnetic induction intensity, alternate the disadvantage of electromagnetic field skin effect into advantage and make full use of the advantage of high magnetic induction intensity on the skin effect layer. Also it increased the cooling area of the melt center and made the melt temperature and composition fields more uniform. But because of the intrinsic characteristics of electromagnetic stirring, electromagnetic force in the melt showed the circumferential distribution. The melt flow was also the circumferential movement. The circumferential flow was strong, but the axial flow and radial flow were weak. It was inevitable that the temperature gradient and composition gradient distributed along the radial and axial part.
On the basis of the above research, this paper presented the spiral electromagnetic stirring technology which could overcome the shortcomings of mechanical stirring for easy pollution and difficult application. Under the condition of spiral electromagnetic stirring, the flow velocity and shearing rate of melt increased significantly, the temperature gradient significantly decreased, and the turbulence of melt flow became more intensive. The optimal structures of the screw were:the screw diameter of40mm, the screw thread height of12mm, the screw thread angle of65°and the screw thread pitch of55mm. The optimal process parameters of spiral electromagnetic stirring were:the stirring current of30A, the stirring frequency of50Hz and the pouring temperature of650℃. And under this process condition, the7075alloy solidification microstructure became more uniformly fine, and alloy chemical composition segregation greatly abated. The segregation rates of Zn, Mg and Cu elements were1.5%,3.3%and3.4%, respectively.
On the basis of the above experiment research, it was further understood that the effect of mandatory uniform solidification technology on the solidification behavior of alloy melt. It was established that the description of controlled nucleation and growth model under the action of mandatory uniform solidification. Mandatory uniform solidification technology can effectively improve the homogeneous nucleation rate and heterogeneous nucleation rate of the alloy melt, improve the survival rate of the nuclus, make the nucleation outbreak in the whole melt, and reduce or even eliminate the undercooling region in the forefront of alloy solid-liquid interface. Finally, it limited the dendrite growth and made the solidification microstructure become fine equiaxed grains.
Finally on the basis of the above research, the application of the spiral electromagnetic stirring technology on rheo-diecasting was carried on. The results showed that the spiral electromagnetic stirring technology can well applied on the alloy rheo-diecasting forming. Compared with common diecasting forming, under the condition of spiral electromagnetic stirring, the microstructure of rheo-diecasting part distributed uniformly fine and showed little difference in different position. Brinell hardness of rheo-diecasting parts increased significantly, and also showed little difference in different positions. The solidification microstructure and mechanical property were similar with that in the condition of twin-screw mechanical stirring, but the spiral electromagnetic stirring technology obviously increased the production efficiency. In order to overcome the shortcoming of spiral electromagnetic stirring technology for the low automation degree, it was designed that automatic spiral electromagnetic stirring technology prototype, which had the advantages of automatic collection, automatic processing and automatic pouring and laid the foundation for the ultimate realization of industrial production.
首先研究了双螺旋机械搅拌技术对7075铝合金凝固行为的影响。在双螺旋机械搅拌条件下合金熔体的流动速度和剪切速率非常高,温度场和成分场非常均匀,强制均匀效果非常好。通过理论和实验分析确定了双螺旋机械搅拌的最优工艺参数为：搅拌强度100rpm,搅拌时间60s,浇注温度650℃。在该工艺条件下,7075铝合金晶粒组织十分细小均匀,平均晶粒尺寸约为55μm;而且合金的化学成分偏析大大减弱,Zn、Mg和Cu元素的偏析率分别降为0.71%、0.87%和2.1%。然而双螺旋机械搅拌不足之处主要是容易污染合金熔体,维护成本高,不适宜高温金属(熔点超过1000℃)的研究与应用。
电磁搅拌具有能量的高密度性和清洁性、优越的响应性和可控性、易于自动化、能量利用率高等优点,率先实现产业化并获得较为广泛的商业应用。本文研究了环缝电磁搅拌技术对7075铝合金凝固行为的影响。相比普通电磁搅拌,环缝电磁搅拌技术避开了磁感应强度较低的部分,充分利用趋肤效应层磁感应强度高的优点,使合金熔体在缝隙内搅拌,熔体剪切速率增大,同时增加了熔体心部的散热面积,使熔体获得更加均匀的温度场和成分场,合金凝固组织更加细小均匀。但由于电磁搅拌的电磁力在熔体中主要是按周向分布,熔体周向流动为主,而轴向流和径向流较弱,产生了沿轴向和径向分布的温度梯度和成分梯度,同时熔体剪切速率相对于双螺旋机械搅拌弱很多,对合金熔体的强制均匀效果差很多,晶粒组织细化效果也就差很多。
在以上研究的基础上,本文提出了螺旋电磁搅拌技术。螺旋电磁搅拌技术克服了机械搅拌易污染、难应用和环缝电磁搅拌不均匀、剪切速率低的缺点,实现了在电磁搅拌条件下熔体流动速度和剪切速率明显增加、紊流更加剧烈、温度场和成分场更加均匀,对合金熔体的强制均匀效果与双螺旋机械搅拌大幅接近。通过理论和实验分析获得了螺旋腔体的最优结构和螺旋电磁搅拌的最优工艺参数,分别为：螺旋腔体的螺杆直径40mm、螺纹高度12mm、螺纹斜度65。及螺纹螺距55mmm：搅拌电流30A、搅拌频率50Hz、浇注温度650℃。在该腔体结构和工艺参数条件下,7075铝合金凝固组织演变为细小均匀的等轴晶组织,晶粒尺寸约为68gm,而且合金的化学成分偏析大大减弱,Zn、Mg和Cu元素的偏析率分别降为1.5%、3.3%和3.4%。
以上述的实验研究为基础,深化丰富了强制均匀凝固技术对合金凝固行为的影响,建立了强制均匀凝固作用下控制形核及长大的描述模型。强制均匀凝固技术可以有效控制熔体温度场和成分场的均匀性,增加了合金熔体的形核过冷度,缩小甚至消除成分过冷区,从而显著增加了合金熔体的有效均匀形核率、非均匀形核率及核心存活率,使熔体整体爆发形核,并削弱甚至消除了枝晶生长的条件,最终使凝固组织变为细小均匀的等轴晶粒。
最后进行了螺旋电磁搅拌技术在7075铝合金流变压铸成型中的应用研究,研究结果表明：相比于普通压铸成型,螺旋电磁搅拌条件下7075铝合金流变压铸零件显微组织分布均匀细小,不同位置的组织差别不大；布氏硬度显著提高且分布均匀；零件裂纹倾向性降低明显；凝固组织和性能均接近双螺旋机械搅拌流变压铸的零件,而且生产效率明显增加。同时针对螺旋电磁搅拌技术自动化程度不高的缺点,设计出自动化螺旋电磁搅拌技术原型,集熔体自动收集、自动处理和自动浇注于一体,为最终实现产业化生产奠定基础。
7075aluminum alloy with high strength is widely used in the aerospace, aviation and military industry. Due to the high content of alloy elements, the solidification structure is non-uniform and coarse and alloy elements segregation is serious, resulting in being craze when casting and hot rolling, which seriously limits its use and development. By applying physical fields on alloy melt, mandatory uniform solidification technology can promote the melt flowing and shearing and make the temperature field, component field and tiny heterogeneous particles uniformly distribute in the melt, which will make the alloy melt overall nucleate, effectively refine the grain and reduce segregation. So this paper was concerned on the technology and application research on mandatory uniform solidification of7075aluminium alloy.
We studied the effect of twin-screw stirring process on the melt physical fields and solidification structure of7075aluminum alloy. The twin-screw stirring process can make the melt flowing rate and shearing rate very high, the temperature and composition fields very uniform, and the effect of mandatory uniform solidification very well. The optimal process parameters of twin-screw stirring were the intensity of100rpm, the stirring time of60s and the pouring temperature of650℃. Under this process condition, the7075alloy grain was very uniformly fine and the average grain size was55μm. The alloy chemical composition segregation greatly abated. The segregation rates of Zn, Mg and Cu elements were0.71%,0.87%and2.1%, respectively. The deficiencies of twin-screw stirring process were that the stirring device was easy to be corroded and expensive to be maintained, and it cannot process high temperature alloy (melting point higher than1000℃). So it is not suitable for mass production of parts, and it is difficult to realize industrialization production.
The electromagnetic stirring has the advantages of high density and cleanliness of energy, superior responsiveness and controllability, easy automation, high energy utilization rate, and etc. So it obtains more widely commercial application. We studied the effect of the annular electromagnetic stirring process on the physical fields and solidification structure of7075aluminum alloy. Compared with the conventional electromagnetic stirring process, annular electromagnetic stirring process can avoid the lower part of magnetic induction intensity, alternate the disadvantage of electromagnetic field skin effect into advantage and make full use of the advantage of high magnetic induction intensity on the skin effect layer. Also it increased the cooling area of the melt center and made the melt temperature and composition fields more uniform. But because of the intrinsic characteristics of electromagnetic stirring, electromagnetic force in the melt showed the circumferential distribution. The melt flow was also the circumferential movement. The circumferential flow was strong, but the axial flow and radial flow were weak. It was inevitable that the temperature gradient and composition gradient distributed along the radial and axial part.
On the basis of the above research, this paper presented the spiral electromagnetic stirring technology which could overcome the shortcomings of mechanical stirring for easy pollution and difficult application. Under the condition of spiral electromagnetic stirring, the flow velocity and shearing rate of melt increased significantly, the temperature gradient significantly decreased, and the turbulence of melt flow became more intensive. The optimal structures of the screw were:the screw diameter of40mm, the screw thread height of12mm, the screw thread angle of65°and the screw thread pitch of55mm. The optimal process parameters of spiral electromagnetic stirring were:the stirring current of30A, the stirring frequency of50Hz and the pouring temperature of650℃. And under this process condition, the7075alloy solidification microstructure became more uniformly fine, and alloy chemical composition segregation greatly abated. The segregation rates of Zn, Mg and Cu elements were1.5%,3.3%and3.4%, respectively.
On the basis of the above experiment research, it was further understood that the effect of mandatory uniform solidification technology on the solidification behavior of alloy melt. It was established that the description of controlled nucleation and growth model under the action of mandatory uniform solidification. Mandatory uniform solidification technology can effectively improve the homogeneous nucleation rate and heterogeneous nucleation rate of the alloy melt, improve the survival rate of the nuclus, make the nucleation outbreak in the whole melt, and reduce or even eliminate the undercooling region in the forefront of alloy solid-liquid interface. Finally, it limited the dendrite growth and made the solidification microstructure become fine equiaxed grains.
Finally on the basis of the above research, the application of the spiral electromagnetic stirring technology on rheo-diecasting was carried on. The results showed that the spiral electromagnetic stirring technology can well applied on the alloy rheo-diecasting forming. Compared with common diecasting forming, under the condition of spiral electromagnetic stirring, the microstructure of rheo-diecasting part distributed uniformly fine and showed little difference in different position. Brinell hardness of rheo-diecasting parts increased significantly, and also showed little difference in different positions. The solidification microstructure and mechanical property were similar with that in the condition of twin-screw mechanical stirring, but the spiral electromagnetic stirring technology obviously increased the production efficiency. In order to overcome the shortcoming of spiral electromagnetic stirring technology for the low automation degree, it was designed that automatic spiral electromagnetic stirring technology prototype, which had the advantages of automatic collection, automatic processing and automatic pouring and laid the foundation for the ultimate realization of industrial production.
引文
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