镁合金自孕育凝固过程及其半固态流变成形的研究
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摘要
随着人们对节能减排及对产品性能要求日益提高,镁合金在以轻量化为发展方向的交通、电子等领域具有广阔应用前景。传统铸造得到的镁合金产品晶粒及析出相粗大且分布不均衡,使其力学性能和耐腐蚀性能不够理想,难以满足高性能结构件需求；压铸是镁合金零件主要成形工艺,但也存在气孔缺陷严重、难以热处理强化等问题。金属半固态成形技术采用了含有细小、球状初生固相的固液混合浆料,能有效改善产品微观组织并减少铸造缺陷,有望进一步解决限制镁合金应用的瓶颈问题。本文以镁合金凝固组织控制技术为基础,以实现半固态流变加工为主要目的,选择目前广泛使用的Mg-Al系合金为研究对象,开展了镁合金铸态组织细化、非枝晶固液混合浆料快速制备、流变压铸成形及后续热处理强化方面较系统的实验室基础研究,研究结果对进一步完善和创新镁合金细晶坯料制备技术、推动镁合金半固态流变成形进一步应用具有一定指导意义。主要研究内容和获得的成果如下：
从金属凝固组织控制理论基本原理出发,结合现有金属晶粒细化技术的特点,发展了一种新型的凝固组织控制技术—自孕育铸造(Self-inoculation method, SIM),设计制造了SIM相关设备并进行了一系列熔铸实验。结果表明：相比常规凝固,SIM对AM60和AZ31合金晶粒大小及二次相形貌均有较好细化效果,铸件组织及成分均匀性得到改善；揭示了工艺参数对SIM铸造过程的影响规律和本质：熔体处理温度、孕育剂加入量和导流器倾斜角度共同影响合金熔体的激冷强度和导流器出口处的温度,只要上述参数匹配使熔体出口温度处于液相线附近,便可以极大促进晶粒增殖,获得较好晶粒细化效果。在此基础上提出了描述孕育剂熔化状态的数学模型,建立了SIM工艺参数和熔体出口温度之间的数学关系,为优化不同合金SIM工艺参数提供了基础；
对SIM条件下镁合金半固态组织形成及演变过程研究认为,SIM促进了合金凝固初期的晶粒增殖,缓慢冷却时合金温度场较为均匀,所得半固态组织细小、圆整,因此高晶粒密度和均匀温度场是从液相中直接获得球晶组织的两个条件；研究了SIM参数对半固态组织中初生α-Mg形貌影响规律,发现三个主要参数影响规律基本一致,在保证浆料质量的前提下,都具有较宽的可操作范围,一定程度上提高了制浆的灵活性和可操作性；对非枝晶初生相形核和生长特点分析认为,孕育剂创造了熔体非均质形核所需的热力学和动力学条件,导流器使熔体整体过冷并产生激冷晶游离,两者结合促进了熔体“晶粒倍增”,晶粒生长时由于液体强迫对流使合金温度场均匀,减小了生长前沿实际过冷,避免了择优生长；浆料冷却和保温时初生相在界面曲率和表面张力作用分离并逐渐球化,高晶粒密度下晶粒浓度场叠加减小了成分过冷度,使固相在很大程度上保持稳定生长而不失稳,延长保温时间初生相在合并长大和Ostwald熟化机制下粗化长大。
不同成形参数的流变压铸成形结果表明：半固态浆料液相的凝固行为可以分为二次α-Mg依附长大、独立形核长大及共晶反应三个阶段；增大压射速度使产品内α-Mg尺寸、形状系数下降,均匀性提高,降低浆料固相率或增大压射速度有利于减轻铸件表层液相偏析；浆料保存时间越长,产品固相率和初生相尺寸越大,同时圆整度提高,浆料保存温度越高,产品液相率越高,初生相颗粒尺寸和圆整度下降；气孔是流变压铸AM60产品的主要缺陷,降低压射速度和提高固相率有利于减少气孔缺陷,提高产品致密度；产品缺陷较少时,AM60合金断裂方式主要为沿二次凝固区β相的断裂分离,AZ31合金断裂分离既发生在初生相表面,也发生在初生相内部；缺陷较多时,两种合金裂纹均首先在气孔、缩松处产生,之后沿依附生长的二次α-Mg扩展。
热处理结果表明,固溶处理时流变压铸AM60组织演变可分为两个阶段：β-Mg17A112相快速溶解及颗粒快速粗化阶段和颗粒正常长大阶段。第一阶段β相溶解使二次颗粒迅速长大,同时初生颗粒合并二次颗粒快速长大；第二阶颗粒以合并机制缓慢长大；过饱和AM60时效时以不连续析出胞形式析出β相,时效温度升高,相同时间内不连续析出胞数量增多,且在晶界处聚集粗化；AM60抗拉强度和延伸率随固溶时间延长先增大,后减小,400℃固溶16h时达到最大值237MPa和13.9%,但时效强化效果不明显；流变压铸AZ31具备一定可固溶强化性,固溶时力学性能峰值较AM60提前,400℃固溶1h时抗拉强度和延伸率达到最大值220MPa,14.7%。
Magnesium alloys present a great potential in automobile and electronic industries with the human's increasingly strict demand on energy conservation and emission reduction and the product quality. The grain in microstructure of Mg alloys under conventional solidification is coarse and the precipitated phase is nonuniform, thus the mechanical properties and corrosion resistance of Mg alloy cannot meet the requirement of structural components; die-casting is the main shaping technology for Mg products, but the castings always involve in voids and cannot be strengthened by heat treatment. Semisolid forming uses semisolid slurry contains fine and spherical solid grains, thus the bottleneck of widely application of Mg alloy is able to solve with the development of SSF. This research focuses on the microstructure control of Mg alloy and with the objective of realizing SSF of Mg alloy. The research content contains solidification microstructure refining, non-dendritic slurry preparation, rheo-diecasting and the heat treatment of semisolid die-castings. The results of this research have guiding significance on further improvement and innovation of Mg alloy refining technology, and promoting the further application of SSF in Mg production. The main results are as follows:
A novel solidification controlling method called as self-inoculation method (SIM) is developed on the basis of microstructure control theory and the features of current refining technologies, the equipment of SIM was manufactured and a series of cast experiments were carried out. Results indicate that compared to conventional solidification, SIM has favorable refining effect on grain size and the morphology of secondary phase of both AM60and AZ31alloy, thus the microstructure and composition uniformity of alloy were enhanced. The essential effect of SIM parameters on solidification process was verified:the melt treatment temperature, addition amount of self-inoculants and slope angle of fluid director collectively effect on the melt temperature at the exit of fluid director, the fine refining effect can be achieved due to the grain breeding if the above parameters were better matched. The model which describes the melting conditions of self-inoculants and the mathematic relation between different parameters of SIM were developed, which proposes a rule for the further optimizing of SIM parameters for other alloys.
The research on formation mechanism and evolution process of semisolid microstructure under SIM indicate that:SIM promotes the grain multiplication in initial solidification of alloy melt, the temperature guidance was uniform in the continuous cooling stage, and the resulted microstructure is fine and spherical, thus the high grain density and uniform temperature field are the basic conditions for directly formation of spherical microstructure from alloy melt; the result from slurry preparation experiments indicate that the main parameters of SIM have similar effect on morphology of primary a-Mg, there is a wide operable parameter range of SIM thus the flexibility and operability of slurry preparation were enhanced; the analysis of nucleation and growth feature of a-Mg considered that self-inoculants create the appropriate thermodynamics dynamics conditions for heterogeneous nucleation, and the fluid director promote undercooling of bulk melt and created the free crystals; the grain grow in a uniform temperature field due to the liquid convection, the actual undercooling in front of interface was weakened thus the preferred growth was suppressed. In continuous cooling and isothermal holding of slurry, the particle separation occurred under the function of interface curvature and surface tension, the undercooling was decreased because of concentration field overlying, mergence and Ostwald ripening is the main coarsening mechanism of primary during prolonged isothermal holding.
Results of rheo-diecasting experiments indicate that:the solidification behavior of semisolid slurry can be divided into three stages:dependent growth of secondary a-Mg, independent nucleation of secondary a-Mg and the final eutectic reaction. The size and shape factor of a-Mg decreases with the increase of injection speed, and the liquid segregation at the edge of castings decreases with the reducing of slurry solid fraction and the increase of injection speed. The solid fraction and particle size increases with the prolonging holding time, and the particle size and roundness reduces with the increase of holding temperature. Voids is the main defect of AM60alloy produced by RDC, reducing injection speed and increasing solid fraction are helpful for improving the density of castings; the fracture occurred along the β phase in the secondary solidification area when the defects is less, and in this condition the fracture of AZ31occurred both in and on the surface of primary phase. When the defects are frequent, the crack generated in voids and then extended along the secondary a-Mg.
Results of heat treatment indicate that, the microstructure evolution of AM60during solid solution can be divided into three stages:rapidly dissolution of β phase combined with rapidly a-Mg coarsening and the normal coarsening of a-Mg particles. In the first stage, the β phase dissolve in a-Mg rapidly results in a rapid coarsening of secondary a-Mg, and at the same time the primary a-Mg grow rapidly by combining secondary particles. In the secondary stage the a-Mg particles grow with a low rate under the combination mechanism. In ageing process, the β phase precipitates from a-Mg in the form of discontinuous precipitation cell, the amount of β phase increases with the increase of ageing temperature and the morphology presents a coarsening tendency. The tensile strength and elongation increase with the prolonging of solid solution and then decreased at the excessive treatment time, the peak value of237MPa and13.9%was achieved when solid solution treated operated at430℃with16hours. The ageing strength effect of AM60was not obvious. The rheo-diecasted AZ31alloy has certain solid solution strength ability, and the peak value of mechanical properties was obtained during a shorter solid solution time compared to AM60alloy, the peak value of220MPa and14.7%was obtained when the solid solution operated at400℃withlh.
从金属凝固组织控制理论基本原理出发,结合现有金属晶粒细化技术的特点,发展了一种新型的凝固组织控制技术—自孕育铸造(Self-inoculation method, SIM),设计制造了SIM相关设备并进行了一系列熔铸实验。结果表明：相比常规凝固,SIM对AM60和AZ31合金晶粒大小及二次相形貌均有较好细化效果,铸件组织及成分均匀性得到改善；揭示了工艺参数对SIM铸造过程的影响规律和本质：熔体处理温度、孕育剂加入量和导流器倾斜角度共同影响合金熔体的激冷强度和导流器出口处的温度,只要上述参数匹配使熔体出口温度处于液相线附近,便可以极大促进晶粒增殖,获得较好晶粒细化效果。在此基础上提出了描述孕育剂熔化状态的数学模型,建立了SIM工艺参数和熔体出口温度之间的数学关系,为优化不同合金SIM工艺参数提供了基础；
对SIM条件下镁合金半固态组织形成及演变过程研究认为,SIM促进了合金凝固初期的晶粒增殖,缓慢冷却时合金温度场较为均匀,所得半固态组织细小、圆整,因此高晶粒密度和均匀温度场是从液相中直接获得球晶组织的两个条件；研究了SIM参数对半固态组织中初生α-Mg形貌影响规律,发现三个主要参数影响规律基本一致,在保证浆料质量的前提下,都具有较宽的可操作范围,一定程度上提高了制浆的灵活性和可操作性；对非枝晶初生相形核和生长特点分析认为,孕育剂创造了熔体非均质形核所需的热力学和动力学条件,导流器使熔体整体过冷并产生激冷晶游离,两者结合促进了熔体“晶粒倍增”,晶粒生长时由于液体强迫对流使合金温度场均匀,减小了生长前沿实际过冷,避免了择优生长；浆料冷却和保温时初生相在界面曲率和表面张力作用分离并逐渐球化,高晶粒密度下晶粒浓度场叠加减小了成分过冷度,使固相在很大程度上保持稳定生长而不失稳,延长保温时间初生相在合并长大和Ostwald熟化机制下粗化长大。
不同成形参数的流变压铸成形结果表明：半固态浆料液相的凝固行为可以分为二次α-Mg依附长大、独立形核长大及共晶反应三个阶段；增大压射速度使产品内α-Mg尺寸、形状系数下降,均匀性提高,降低浆料固相率或增大压射速度有利于减轻铸件表层液相偏析；浆料保存时间越长,产品固相率和初生相尺寸越大,同时圆整度提高,浆料保存温度越高,产品液相率越高,初生相颗粒尺寸和圆整度下降；气孔是流变压铸AM60产品的主要缺陷,降低压射速度和提高固相率有利于减少气孔缺陷,提高产品致密度；产品缺陷较少时,AM60合金断裂方式主要为沿二次凝固区β相的断裂分离,AZ31合金断裂分离既发生在初生相表面,也发生在初生相内部；缺陷较多时,两种合金裂纹均首先在气孔、缩松处产生,之后沿依附生长的二次α-Mg扩展。
热处理结果表明,固溶处理时流变压铸AM60组织演变可分为两个阶段：β-Mg17A112相快速溶解及颗粒快速粗化阶段和颗粒正常长大阶段。第一阶段β相溶解使二次颗粒迅速长大,同时初生颗粒合并二次颗粒快速长大；第二阶颗粒以合并机制缓慢长大；过饱和AM60时效时以不连续析出胞形式析出β相,时效温度升高,相同时间内不连续析出胞数量增多,且在晶界处聚集粗化；AM60抗拉强度和延伸率随固溶时间延长先增大,后减小,400℃固溶16h时达到最大值237MPa和13.9%,但时效强化效果不明显；流变压铸AZ31具备一定可固溶强化性,固溶时力学性能峰值较AM60提前,400℃固溶1h时抗拉强度和延伸率达到最大值220MPa,14.7%。
Magnesium alloys present a great potential in automobile and electronic industries with the human's increasingly strict demand on energy conservation and emission reduction and the product quality. The grain in microstructure of Mg alloys under conventional solidification is coarse and the precipitated phase is nonuniform, thus the mechanical properties and corrosion resistance of Mg alloy cannot meet the requirement of structural components; die-casting is the main shaping technology for Mg products, but the castings always involve in voids and cannot be strengthened by heat treatment. Semisolid forming uses semisolid slurry contains fine and spherical solid grains, thus the bottleneck of widely application of Mg alloy is able to solve with the development of SSF. This research focuses on the microstructure control of Mg alloy and with the objective of realizing SSF of Mg alloy. The research content contains solidification microstructure refining, non-dendritic slurry preparation, rheo-diecasting and the heat treatment of semisolid die-castings. The results of this research have guiding significance on further improvement and innovation of Mg alloy refining technology, and promoting the further application of SSF in Mg production. The main results are as follows:
A novel solidification controlling method called as self-inoculation method (SIM) is developed on the basis of microstructure control theory and the features of current refining technologies, the equipment of SIM was manufactured and a series of cast experiments were carried out. Results indicate that compared to conventional solidification, SIM has favorable refining effect on grain size and the morphology of secondary phase of both AM60and AZ31alloy, thus the microstructure and composition uniformity of alloy were enhanced. The essential effect of SIM parameters on solidification process was verified:the melt treatment temperature, addition amount of self-inoculants and slope angle of fluid director collectively effect on the melt temperature at the exit of fluid director, the fine refining effect can be achieved due to the grain breeding if the above parameters were better matched. The model which describes the melting conditions of self-inoculants and the mathematic relation between different parameters of SIM were developed, which proposes a rule for the further optimizing of SIM parameters for other alloys.
The research on formation mechanism and evolution process of semisolid microstructure under SIM indicate that:SIM promotes the grain multiplication in initial solidification of alloy melt, the temperature guidance was uniform in the continuous cooling stage, and the resulted microstructure is fine and spherical, thus the high grain density and uniform temperature field are the basic conditions for directly formation of spherical microstructure from alloy melt; the result from slurry preparation experiments indicate that the main parameters of SIM have similar effect on morphology of primary a-Mg, there is a wide operable parameter range of SIM thus the flexibility and operability of slurry preparation were enhanced; the analysis of nucleation and growth feature of a-Mg considered that self-inoculants create the appropriate thermodynamics dynamics conditions for heterogeneous nucleation, and the fluid director promote undercooling of bulk melt and created the free crystals; the grain grow in a uniform temperature field due to the liquid convection, the actual undercooling in front of interface was weakened thus the preferred growth was suppressed. In continuous cooling and isothermal holding of slurry, the particle separation occurred under the function of interface curvature and surface tension, the undercooling was decreased because of concentration field overlying, mergence and Ostwald ripening is the main coarsening mechanism of primary during prolonged isothermal holding.
Results of rheo-diecasting experiments indicate that:the solidification behavior of semisolid slurry can be divided into three stages:dependent growth of secondary a-Mg, independent nucleation of secondary a-Mg and the final eutectic reaction. The size and shape factor of a-Mg decreases with the increase of injection speed, and the liquid segregation at the edge of castings decreases with the reducing of slurry solid fraction and the increase of injection speed. The solid fraction and particle size increases with the prolonging holding time, and the particle size and roundness reduces with the increase of holding temperature. Voids is the main defect of AM60alloy produced by RDC, reducing injection speed and increasing solid fraction are helpful for improving the density of castings; the fracture occurred along the β phase in the secondary solidification area when the defects is less, and in this condition the fracture of AZ31occurred both in and on the surface of primary phase. When the defects are frequent, the crack generated in voids and then extended along the secondary a-Mg.
Results of heat treatment indicate that, the microstructure evolution of AM60during solid solution can be divided into three stages:rapidly dissolution of β phase combined with rapidly a-Mg coarsening and the normal coarsening of a-Mg particles. In the first stage, the β phase dissolve in a-Mg rapidly results in a rapid coarsening of secondary a-Mg, and at the same time the primary a-Mg grow rapidly by combining secondary particles. In the secondary stage the a-Mg particles grow with a low rate under the combination mechanism. In ageing process, the β phase precipitates from a-Mg in the form of discontinuous precipitation cell, the amount of β phase increases with the increase of ageing temperature and the morphology presents a coarsening tendency. The tensile strength and elongation increase with the prolonging of solid solution and then decreased at the excessive treatment time, the peak value of237MPa and13.9%was achieved when solid solution treated operated at430℃with16hours. The ageing strength effect of AM60was not obvious. The rheo-diecasted AZ31alloy has certain solid solution strength ability, and the peak value of mechanical properties was obtained during a shorter solid solution time compared to AM60alloy, the peak value of220MPa and14.7%was obtained when the solid solution operated at400℃withlh.
引文
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