玻璃粒子在半固态铝合金液中搅拌分散过程模拟的研究
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摘要
在日常生活和生产中,玻璃和铝的消费量剧增,随之产生了大量的废铝和废玻璃。传统的再生利用方式主要是回炉重熔,利用价值不高。利用铝的韧性和玻璃的硬度,用半固态机械搅拌法制备废玻璃/铝基复合材料是高附加值利用这两类材料的有效途径。前期实验发现,在搅拌槽结构确定的条件下,搅拌工艺参数对制得材料的性能优劣有很大影响。为了解决前期实验中出现的问题,使以废玻璃和废铝料作为原料制备的复合材料尽可能均质化,本文采用数值模拟和实验验证相结合的方法研究了搅拌工艺参数对废玻璃粒子在半固态废铝液中分散的影响,探索玻璃粒子在半固态铝硅熔体的湍流场中分散、碰撞、团聚的机理,提出优化的搅拌工艺参数。
主要的研究内容和结论有：
1.对国内外废铝、废玻璃的回收利用以及颗粒增强复合材料,特别是玻璃/铝基复合材料的研究近况,以及流体力学软件应用于两相体系的研究进展进行了综述；
2.前期实验利用废玻璃和废铝制备了玻璃/铝基复合材料,实验过程中发现搅拌工艺参数的选取会影响玻璃在半固态铝硅合金液是均匀分散还是团聚上浮；
3.利用同轴双筒流变仪研究了以废旧铝料为原料的半固态铝硅合金浆料的稳态流变性能,并获得了半固态铝硅合金浆料的流变性的表征方程；
4.借助CFD流场模拟软件FLUENT,对搅拌槽内单相及两相半固态铝硅合金液的流场进行了数值模拟,模拟计算的研究表明：流场的分布信息以及玻璃颗粒混合的机理可以用来指导和调整搅拌工艺参数,如搅拌桨旋转速度、半固态铝硅熔体温度、玻璃粒子粒度、玻璃粒子掺入速度、搅拌时间等；
5.将在优化工艺条件下制得的复合材料各个部位取样后,在金相显微镜下观察到玻璃颗粒分布均匀,表明数值模拟对筛选工艺参数是可行和有效的。
6.通过讨论玻璃颗粒在半固态铝硅液中的受力情况及在半固态铝硅液中的形态,得出了半固态搅融复合机理是浸润和摩擦包裹。当玻璃颗粒加入搅拌中的半固态浆料中,与浆料中的固相颗粒摩擦,在摩擦中表面逐渐得到润湿,玻璃颗粒被浸润后,被固相颗粒捕获、包围,避免了颗粒的团聚；根据搅融复合机理,讨论了颗粒团聚原因主要是由于搅拌槽内温度不均匀,局部过热导致玻璃颗粒表面会出现熔融的液相,玻璃颗粒粒度越小,越容易熔融,熔融后的小粒度玻璃颗粒相互间的吸引力大于斥力,颗粒间容易粘结在一起形成疏松的大颗粒,疏松大颗粒受到大的浮力就会团聚浮到液面；由于半固态浆料中结晶颗粒的固相数一定,因此玻璃颗粒的加入量有个上限,加入的玻璃太多,浆料中的固相粒子不足以包裹玻璃颗粒,多余的玻璃颗粒容易相互粘结在一起浮在液面。根据玻璃团聚上浮的原因,提出了防止颗粒团聚上浮的相应措施。
In daily life and production, it is resulted in a large number of scrap aluminum and waste glass with glass and aluminum consumption surging. Traditional recycling methods are mainly remelting. The use value is not high. Using semi-solid mechanical stirring method in preparation of waste glass/aluminum matrix composites is high added value utilization of the two kinds of materials effectively. In our early experiment, we find that mixing process parameters have a great influence on the material performance under the determined stirrer structure. In the paper, we studied the mixing process parameters'effect on glass particles dispersion in semi-solid slurry using simulation and experiment. We also explored the mechanism of glass particles dispersion、collision and agglomeration in semi-solid slurry. The optimized mixing process parameters are advanced. The main thesis research contents and conclusions are as follows:
1.In this paper, the author reviewed the domestic and foreign scrap, waste glass recycling conditions, particle-reinforced composite materials, especially glass/aluminum composites research recently, as well as fluid mechanics software used in two-phase system research progress;
2. Waste glass/aluminum matrix composites were prepared in early experiment. During the process of experiment, we find whether glass particles dispersed in semi-solid of aluminum alloy or particle agglomeration influenced by the selection of mixing process parameters;
3.The rheological behavior of the semi-solid slurry based on scrap aluminum materials has been measured through a couette-type viscometer. The semi-solid slurry of aluminum-silicon alloy's equation of rheological properties was founded;
4. With the CFD flow simulation software FLUENT, the semi-solid slurry of aluminum-silicon alloy liquid's flow field in stirrer has been studied. Simulation studies show that the distribution of flow field and mixing mechanism of glass particles can be used to guide and adjust the mixing process parameters,for example, stirrer speed, semi-solid slurry temperature,glass particles granularity, glass particles adding speed,stirrer times etc;
5. The glass/aluminum matrix composites are made under the optimized mixing process parameters. The metallograph of cross-section of glass/aluminum matrix composites show that glass particles dispersion equably in composites. The simulation is effective in selecting the mixing process parameters;
6.The semi-solid stirring mechanism is infiltration and friction swallow trap. Adding glass particles in the mixing semi-solid slurry, Aggregation of the particles can follow and scattered, and dispersed glass particles can move with the slurry in the stirrer at the same time. Dispersed glass particles scrub with the slurry particles, and the friction wet the surface gradually. Due to the distribution of a large number of solid-phase particles suspended in semi-solid slurry, glass particles are infiltration, and the solid particles are captured, surrounded. It is like the glass particles are trapped swallow by solid particles, which to avoid agglomeration of the particles. We explored the cause of particle agglomeration:When the surface of the glass particles appears melting liquid phase, the surface energy of glass particles melted and the solid surface can have difference. Its function is to make the glass surface area tends to shrink. During glass particles melting, collision and bonding process, molten particle is captured by more other molten glass particles close to it, which form into large particles of loose bonding. The buoyancy on the loosely bonded particles is far greater than the downward force of stirrer, so less than140particles added into stirrer can float in the liquid level, which can not enter the semi-solid slurry of aluminum-silicon. While the semi-solid slurry has maximum solubility as solvent, when the number of crystalline particles unsufficient to wrap up excess glass particles, resulting in increasing opportunities for glass particle collision, so the excess glass particles can easily reunion and float on liquid surface. The measure of avoiding paticle agglomeration are advanced according as agglomeration causes forementioned.
主要的研究内容和结论有：
1.对国内外废铝、废玻璃的回收利用以及颗粒增强复合材料,特别是玻璃/铝基复合材料的研究近况,以及流体力学软件应用于两相体系的研究进展进行了综述；
2.前期实验利用废玻璃和废铝制备了玻璃/铝基复合材料,实验过程中发现搅拌工艺参数的选取会影响玻璃在半固态铝硅合金液是均匀分散还是团聚上浮；
3.利用同轴双筒流变仪研究了以废旧铝料为原料的半固态铝硅合金浆料的稳态流变性能,并获得了半固态铝硅合金浆料的流变性的表征方程；
4.借助CFD流场模拟软件FLUENT,对搅拌槽内单相及两相半固态铝硅合金液的流场进行了数值模拟,模拟计算的研究表明：流场的分布信息以及玻璃颗粒混合的机理可以用来指导和调整搅拌工艺参数,如搅拌桨旋转速度、半固态铝硅熔体温度、玻璃粒子粒度、玻璃粒子掺入速度、搅拌时间等；
5.将在优化工艺条件下制得的复合材料各个部位取样后,在金相显微镜下观察到玻璃颗粒分布均匀,表明数值模拟对筛选工艺参数是可行和有效的。
6.通过讨论玻璃颗粒在半固态铝硅液中的受力情况及在半固态铝硅液中的形态,得出了半固态搅融复合机理是浸润和摩擦包裹。当玻璃颗粒加入搅拌中的半固态浆料中,与浆料中的固相颗粒摩擦,在摩擦中表面逐渐得到润湿,玻璃颗粒被浸润后,被固相颗粒捕获、包围,避免了颗粒的团聚；根据搅融复合机理,讨论了颗粒团聚原因主要是由于搅拌槽内温度不均匀,局部过热导致玻璃颗粒表面会出现熔融的液相,玻璃颗粒粒度越小,越容易熔融,熔融后的小粒度玻璃颗粒相互间的吸引力大于斥力,颗粒间容易粘结在一起形成疏松的大颗粒,疏松大颗粒受到大的浮力就会团聚浮到液面；由于半固态浆料中结晶颗粒的固相数一定,因此玻璃颗粒的加入量有个上限,加入的玻璃太多,浆料中的固相粒子不足以包裹玻璃颗粒,多余的玻璃颗粒容易相互粘结在一起浮在液面。根据玻璃团聚上浮的原因,提出了防止颗粒团聚上浮的相应措施。
In daily life and production, it is resulted in a large number of scrap aluminum and waste glass with glass and aluminum consumption surging. Traditional recycling methods are mainly remelting. The use value is not high. Using semi-solid mechanical stirring method in preparation of waste glass/aluminum matrix composites is high added value utilization of the two kinds of materials effectively. In our early experiment, we find that mixing process parameters have a great influence on the material performance under the determined stirrer structure. In the paper, we studied the mixing process parameters'effect on glass particles dispersion in semi-solid slurry using simulation and experiment. We also explored the mechanism of glass particles dispersion、collision and agglomeration in semi-solid slurry. The optimized mixing process parameters are advanced. The main thesis research contents and conclusions are as follows:
1.In this paper, the author reviewed the domestic and foreign scrap, waste glass recycling conditions, particle-reinforced composite materials, especially glass/aluminum composites research recently, as well as fluid mechanics software used in two-phase system research progress;
2. Waste glass/aluminum matrix composites were prepared in early experiment. During the process of experiment, we find whether glass particles dispersed in semi-solid of aluminum alloy or particle agglomeration influenced by the selection of mixing process parameters;
3.The rheological behavior of the semi-solid slurry based on scrap aluminum materials has been measured through a couette-type viscometer. The semi-solid slurry of aluminum-silicon alloy's equation of rheological properties was founded;
4. With the CFD flow simulation software FLUENT, the semi-solid slurry of aluminum-silicon alloy liquid's flow field in stirrer has been studied. Simulation studies show that the distribution of flow field and mixing mechanism of glass particles can be used to guide and adjust the mixing process parameters,for example, stirrer speed, semi-solid slurry temperature,glass particles granularity, glass particles adding speed,stirrer times etc;
5. The glass/aluminum matrix composites are made under the optimized mixing process parameters. The metallograph of cross-section of glass/aluminum matrix composites show that glass particles dispersion equably in composites. The simulation is effective in selecting the mixing process parameters;
6.The semi-solid stirring mechanism is infiltration and friction swallow trap. Adding glass particles in the mixing semi-solid slurry, Aggregation of the particles can follow and scattered, and dispersed glass particles can move with the slurry in the stirrer at the same time. Dispersed glass particles scrub with the slurry particles, and the friction wet the surface gradually. Due to the distribution of a large number of solid-phase particles suspended in semi-solid slurry, glass particles are infiltration, and the solid particles are captured, surrounded. It is like the glass particles are trapped swallow by solid particles, which to avoid agglomeration of the particles. We explored the cause of particle agglomeration:When the surface of the glass particles appears melting liquid phase, the surface energy of glass particles melted and the solid surface can have difference. Its function is to make the glass surface area tends to shrink. During glass particles melting, collision and bonding process, molten particle is captured by more other molten glass particles close to it, which form into large particles of loose bonding. The buoyancy on the loosely bonded particles is far greater than the downward force of stirrer, so less than140particles added into stirrer can float in the liquid level, which can not enter the semi-solid slurry of aluminum-silicon. While the semi-solid slurry has maximum solubility as solvent, when the number of crystalline particles unsufficient to wrap up excess glass particles, resulting in increasing opportunities for glass particle collision, so the excess glass particles can easily reunion and float on liquid surface. The measure of avoiding paticle agglomeration are advanced according as agglomeration causes forementioned.
引文
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