强迫对流影响二元合金非等温凝固枝晶生长的相场法模拟

在二元合金相场模型的研究基础上,建立了耦合溶质场、温度场和流场的相场模型,采用Simple算法求解质量和动量守恒方程,用交替隐式有限差分法求解温度控制方程,模拟了流场作用下二元合金等温和非等温凝固过程中枝晶的生长过程,研究了流场对枝晶生长形貌、溶质场和温度场分布情况的影响,将流场作用下二元合金等温和非等温凝固枝晶生长过程进行比较,分析了由于凝固潜热的释放对流场作用下凝固枝晶生长的影响． 关键词： 相场法 对流 非等温凝固 枝晶生长     

Phase field simulation of the columnar dendritic growth and microsegregation in a binary alloy

This paper applies a phase field model for polycrystalline solidification in binary alloys to simulate the formation and growth of the columnar dendritic array under the isothermal and constant cooling conditions. The solidification process and microsegregation in the mushy zone are analysed in detail. It is shown that under the isothermal condition solidification will stop after the formation of the mushy zone, but dendritic coarsening will progress continuously, which results in the decrease of the total interface area. Under the constant cooling condition the mushy zone will solidify and coarsen simultaneously. For the constant cooling solidification, microsegregation predicted by a modified Brody- Flemings model is compared with the simulation results. It is found that the Fourier number which characterizes microsegregation is different for regions with different microstructures. Dendritic coarsening and the larger area of interface should account for the enhanced Fourier number in the region with well developed second dendritic arms.     

纯物质枝晶凝固的元胞自动机模型

采用元胞自动机模型模拟了纯物质凝固微观组织演化行为. 与以往采用KGT模型简化考虑不同,采用界面能量守恒方程来自洽地确定液固界面的生长动力学,考察了模型的网格尺寸相关性和时间相关性,并对模型的稳定性进行了验证. 采用这个模型模拟了纯丁二腈在过冷熔体中的自由枝晶生长,并与Glicksman的等温枝晶生长实验(isothermal dendritic growth experiment,IDGE)和LM-K临界稳定性原理进行了对比. 模拟的形貌再现了实验形貌的特征,并且特征参数与理论结果及实验结果符合得很好. 关键词： 元胞自动机 界面 凝固 临界稳定性原理     

晶体取向对定向凝固枝晶生长的影响

采用类金属透明模型合金丁二腈-1.0 wt%乙醇(SCN-1.0 wt% Eth)合金, 考察了晶体取向对定向凝固过程中晶粒的平界面失稳孕育时间、枝晶形态演化以及枝晶一次间距的影响. 结果表明, 随着枝晶择优生长方向与温度梯度方向夹角的增大, 晶粒的平界面失稳孕育时间增加, 界面的稳定性增强; 对于不同晶体取向的枝晶形态演化, 枝晶择优生长方向与温度梯度方向夹角越大, 枝晶二次臂不对称生长越严重, 同时, 具有生长优势的枝晶二次臂对相邻枝晶的生长的抑制越强烈; 至于不同晶体取向的枝晶一次间距, 随着枝晶择优生长方向与温度梯度方向夹角的增大, 枝晶一次间距增大. 关键词： 定向凝固 平界面失稳 枝晶间距 晶体取向     

基于元胞自动机方法的定向凝固枝晶竞争生长数值模拟

通过耦合温度场模型、溶质扩散方程以及枝晶生长动力学方程等重要因素,建立了一种改进的元胞自动机模型.该模型通过采用偏心算法消除网格各向异性,实现了二维尺度上任意角度枝晶生长的模拟,同时适用于模拟三维尺度上枝晶的生长过程.利用建立的模型开展了定向凝固枝晶竞争生长过程的数值模拟.为了体现本模型的有效性,模拟了透明合金的竞争生长过程,并与实验结果符合良好.镍基高温合金汇聚竞争和发散竞争的模拟结果清楚地展现了不同抽拉速度和枝晶优先生长角度下枝晶的竞争生长过程,并且模拟结果与理论模型相符合.三维枝晶生长的模拟结果表明本模型可以用来模拟三维枝晶一次臂间距的调整过程.     

Rapid solidification and dendrite growth of ternary Fe-Sn-Ge and Cu-Pb-Ge monotectic alloys

The phase separation and dendrite growth characteristics of ternary Fe-43.9%Sn- 10%Ge and Cu-35.5%Pb-5%Ge monotectic alloys were studied systematically by the glass fluxing method under substantial undercooling conditions. The maximum undercoolings obtained in this work are 245 and 257 K, respectively, for these two alloys. All of the solidified samples exhibit serious macrosegregation, indicating that the homogenous alloy melt is separated into two liquid phases prior to rapid solidification. The solidification structures consist of four phases including α-Fe, (Sn), FeSn and FeSn2 in Fe-43.9%Sn-10%Ge ternary alloy, whereas only (Cu) and (Pb) solid solution phases in Cu-35.5%Pb-5%Ge alloy under different undercoolings. In the process of rapid monotectic solidification, α-Fe and (Cu) phases grow in a dendritic mode, and the transition "dendrite→monotectic cell" happens when alloy undercoolings become sufficiently large. The dendrite growth velocities of α-Fe and (Cu) phases are found to increase with undercooling according to an exponential relation.     

液态三元Fe-Cr-Ni合金中快速枝晶生长与溶质分布规律

采用落管方法实现了液态三元Fe-Cr-Ni合金的深过冷与快速凝固,合金液滴的冷却速率和过冷度均随液滴直径的减小而迅速增大.两种成分合金近平衡凝固组织均为粗大板条状α相.在快速凝固过程中,不同直径Fe_(81.4)Cr_(13.9)Ni_(4.7)合金液滴凝固组织均为板条状α相,其固态相变特征很明显,随着过冷度增大,初生δ相由具有发达主干的粗大枝晶转变为等轴晶.Fe_(81.4)Cr_(4.7)Ni_(13.9)合金液滴凝固组织由α相晶粒组成,随着过冷度增大,初生γ相由具有发达主干的粗大枝晶转变为等轴晶,其枝晶主干长度和二次分枝间距均显著下降,晶粒内溶质的相对偏析度也明显减小,溶质Ni的相对偏析度始终大于溶质Cr.理论计算表明,与γ相相比,δ相枝晶生长速度更大.在实验获得的过冷度范围内,两种Fe-Cr-Ni合金枝晶生长过程均由热扩散控制.     

In situ observation of NaBi(WO4)2 dendrite growth and the study on microstructure of solidification

The dendrite growth process of transparent NaBi(WO4)2 with small prandtl and high melting point was studied by using the in-situ observation system. According to the dynamic images and detailed information, there are two kinds of restriction effect on the dendrite growth, the competition between arms and branches and the convection in the melt. The dendrite growth rate was time dependent, and the rate of arm growth reached the maximum 5.8 mm/s in the diffusive-advective region and rapidly decreased in the diffusive-convective region. The growth rate of branch had the same change trends as the arm's. Based on the EPMA-EDS data of solidification structure of quenched NaBi(WO4)2 melt, it was found that there were component differences from stoichiometric concentration in the melt near the interface during the growth process.     

On array models theoretical predictions versus measurements for the growth of cells and dendrites in the transient solidification of binary alloys

Most of the theoretical studies of the growth of cells/dendrites in the literature are based on the assumption that it is a steady-state phenomenon. The analysis of cells/dendritic structures in the unsteady-state regime is very important, since it encompasses the majority of industrial solidification processes. The aim of the present investigation was to validate the predictions furnished by the cellular and primary dendritic growth models in the literature for unsteady-state conditions against a large spectrum of experimental data, which includes those for a variety of Al alloys (Al–Cu, Al–Si, Al–Fe, Al–Bi, Al–Ni, Al–Sn) and low thermal diffusivity alloys, such as Sn–Pb and Pb–Sb. The predictions furnished by the Hunt–Lu model do not match the cellular experimental scatter for any examined alloy system. However, this model matches well with the primary dendritic growth of Al alloys, with the exception of Al–Sn alloys, for which the Hunt–Thomas approach has to be applied. The primary dendritic predictions of Bouchard–Kirkaldy's model, performed with the originally suggested a ₁ calibration factors are, in most cases, located above the experimental points. Experimental growth laws relating cellular and dendritic spacings with the tip growth rate and the cooling rate, respectively, are established.     

Solute distribution in KNbO3 melt-solution and its effect on dendrite growth during rapid solidification

This paper reports that the rapid solidification of mixed Li 2 B 4 O 7 and KNbO 3 melted in a Pt loop heater has been performed experimentally by the method of quenching, and various morphologies of KNbO 3 crystals have been observed in different regions of the quenched melt-solution. Dendrites were formed in the central region where mass transfer is performed by diffusion, whereas polygonal crystals with smooth surface grew in the marginal region where convection dominates mass transport. Based on measurement of KNbO 3 concentration along crystal interface by electronic probe analysis, it finds the variety of crystal morphologies, which is the result of different solute distributions: in the central region the inhomogeneity of solute concentration is much sharper and morphological instability is easier to take place; nevertheless in the marginal region the concentration homogeneity has been greatly enhanced by convection which prevents the occurrence of morphological instability. Additional solute distribution in the melt along the primary dendrite trunk axis as well as that in mushy zones has also been determined. Results show that the solute concentration in the liquid increases linearly with distance from the trunk tip and more solutes were found to be concentrated in mushy zones. The closer the mushy zone is to trunk tip, the lower the solute concentration will be there.     

宏微观耦合模拟熔池不同区域中枝晶竞争生长过程

针对熔化焊过程建立了宏微观耦合模型,模拟了熔池内不同区域凝固过程中随机取向枝晶的竞争生长过程. 通过宏观三维有限元模型计算熔池中瞬态的传热传质过程,利用双线性插值算法将凝固参数传递给微观组织模型. 采用元胞自动机法模拟随机取向的枝晶在熔池凝固条件下的竞争生长过程. 模拟结果表明,所建立的微观模型能够精确模拟任意生长取向的枝晶. 凝固条件中最大温度梯度方向对枝晶竞争过程有明显选择作用,生长方向与最大温度梯度方向相同或接近的枝晶在竞争中具有更大优势. 焊缝中的晶粒组织由枝晶簇发展形成,晶粒组织的形貌演变取决于相邻枝晶簇之间的竞争过程,具有择优取向的枝晶簇会逐渐排挤非择优取向的枝晶簇并最终将其阻挡在凝固组织内部,宏观晶粒的取向与其内部枝晶簇的生长方向并不一定相同. 熔池中心线附近区域在焊接过程中具有更小的温度梯度、更大的凝固速率以及更大的局部冷却速率,凝固后可以获得更加细小的焊缝枝晶组织. 枝晶间距的模拟结果与相应凝固条件下的试验数据符合较好. 关键词： 焊接熔池 枝晶形貌 竞争生长 元胞自动机     

脉冲磁场下金属熔体凝固流场的数值模拟

用ANSYS55有限元数值模拟软件对铝合金熔体凝固过程中的流场作了数值模拟，模拟结果和实验现象相符合.通过数值模拟发现，用数值模拟的方法不仅可以初步了解凝固过程中熔体的流动状态，而且可以了解凝固组织细化和产生缺陷的原因.因此，是一个值得注意的研究方向，有较大的实用价值.     

Numerical simulation on dendritic growth of Al-Cu alloy under convection based on the cellular automaton lattice Boltzmann method

A numerical model is developed by coupling the cellular automaton (CA) method and the lattice Boltzmann method (LBM) to simulate the dendritic growth of Al-Cu alloy in both two and three dimensions. An improved decentered square algorithm is proposed to overcome the artificial anisotropy induced by the CA cells and to realize simulation of dendritic growth with arbitrary orientations. Based on the established CA-LBM model, effects of forced convection and gravity-driven natural convection on dendritic growth are studied. The simulation results show that the blocking effect of dendrites on melt flow is advanced with a larger number of seeds. The competitive growth of the converging columnar dendrites is determined by the interaction between heat flow and forced convection. Gravity-driven natural convection leads to highly asymmetric growth of equiaxed dendrites. With sinking downwards of the heavy solute, chimney-like or mushroom-like solute plumes are formed in the melt in front of the columnar dendrites when they grow along the gravitational direction. More details on dendritic growth of Al-Cu alloy under convection are revealed by 3D simulations.     

基于MeshTV界面重构算法的二元合金自由枝晶生长元胞自动机模型

本文基于MeshTV界面重构算法, 发展了二元合金凝固自由枝晶生长的元胞自动机 (cellular automaton, CA) 模型. 通过采用MeshTV界面重构算法, 在细化的界面元胞内重构出了固液界面的位置. 在此基础上, 发展了一种同时适合描述纯物质与合金凝固界面生长的动力学模型. 与非界面重构的CA模型相比, 本文所发展的模型可以在较大的网格尺寸下实现模型的收敛, 同时网格各向异性不明显, 且能够反映界面能各向异性参数ε 对自由枝晶生长的影响. 在ε =0.02时, 通过与描述自由枝晶生长的LGK理论模型相比较, 发现计算的枝晶尖端速度与LGK理论模型的预测符合较好, 而计算的枝晶尖端半径比LGK理论预测值大于约20%.     

用元胞自动机方法模拟镁合金薄带双辊铸轧过程凝固组织

用元胞自动机方法模拟铸轧凝固组织,采用有限元方法模拟铸轧过程中熔池内部的宏观传输现象,将二者耦合模拟了镁合金铸轧薄带凝固过程中晶粒的形核与长大过程.阐明了薄带铸轧工艺过程中的主要工艺参数（浇注温度、铸轧速度等）对镁合金薄带凝固组织中晶粒大小、取向等的影响规律.这为通过工艺优化来控制铸轧薄带的凝固组织提供了理论依据. 关键词： 双辊铸轧 镁合金 凝固组织 元胞自动机     

切向流动作用下SCN-3wt% H2O枝晶定向生长过程研究

实时观察了切向流动作用下SCN-3wt% H₂O合金的定向凝固过程,研究了该合金枝晶生长方向、尖端半径、枝晶一次臂间距以及二次臂生长速度的变化规律.实验观察到能够代表枝晶尖端溶质边界层的“亮带”,该亮带在流动作用下的非对称性证实了切向流动能够改变枝晶前沿溶质的对称分布,使溶质边界层厚度沿背流侧向迎流侧逐渐减薄,枝晶生长发生迎流偏转,且偏转角度随抽拉速度的提高而减小.同时,流场与浓度场的耦合促进枝晶间的优胜劣汰,枝晶一次臂间距显著增大.固液界面处的强迫流动还能够引发相邻枝晶间环流,加速迎流处二次臂生长而抑制背流处生长. 关键词： 定向凝固 枝晶生长 切向流动     

凝固前沿和气泡相互作用的大密度比格子玻尔兹曼方法模拟

建立了二维双组分两相流的大密度比格子玻尔兹曼方法 (lattice Boltzmann method, LBM)模型. 该模型基于改进的Shan-Chen伪势多相流LBM模型, 结合采用不同时间步长的方法, 实现密度比达800以上的气液两相流模拟. 为了对模型进行验证, 模拟了在不同气液相互作用系数和密度比条件下气泡内外压力差与其半径之间的关系, 其结果满足Laplace定律. 将所建立的大密度比LBM与介观尺度的元胞自动机(cellular automaton, CA)和有限差分法(FDM)相耦合, 用LBM模拟气液两相流, 用CA方法模拟固相生长, 用有限差分法模拟温度场, 采用LBM-CA-FDM耦合模型对定向凝固过程中凝固前沿的气泡与液-固界面之间的相互作用进行模拟研究. 结果表明, 绝热气泡的存在影响了温度场分布, 使得凝固前沿接近气泡时, 液-固界面凸起, 在不同的固相生长速度条件下, 出现凝固前沿淹没气泡或气泡脱离凝固前沿的不同情况, 模拟结果与实验结果符合良好. 关键词： 格子玻尔兹曼方法 元胞自动机 凝固 气泡     

Phase-field modeling of faceted growth in solidification of alloys

A regularization of the surface tension anisotropic function used in vapor-liquid-solid nanowire growth was introduced into the quantitative phase-field model to simulate the faceted growth in solidification of alloys. Predicted results show that the value of δ can only affect the region near the tip, and the convergence with respect to δ can be achieved with the decrease of δ near the tip. It can be found that the steady growth velocity is not a monotonic function of the cusp amplitude, and the maximum value is approximately at ε=0.8 when the supersaturation is fixed. Moreover, the growth velocity is an increasing function of supersaturation with the morphological transition from facet to dendrite.     

枝晶生长和气泡形成的数值模拟

本文建立了二维的格子玻尔兹曼方法-元胞自动机(lattice Boltzmann method-cellular automaton, LBM-CA)耦合模型, 对凝固过程中枝晶生长和气泡形成进行模拟研究. 本模型采用CA方法模拟枝晶的生长, 根据界面溶质平衡法计算枝晶生长的驱动力. 采用基于Shan-Chen多相流的LBM模拟气泡在液相中的生长和运动. 在LBM-CA的耦合模型中包含了固-液-气三相之间的相互作用. 应用Laplace定理和模拟气-液-固三相之间的润湿现象对模型进行了验证. 应用所建立的LBM-CA耦合模型模拟研究了气-液相互作用系数对单气泡生长的影响. 发现单气泡的生长速度和平衡半径随气-液相互作用系数的增大而增大. 定向凝固过程中枝晶和气泡生长的模拟结果再现了枝晶的择优生长、 气泡的优先形核位置、气泡的长大、合并、在枝晶间受挤变形以及在液相通道中的运动等物理现象, 与实验结果符合良好. 此外, 初始气体含量越高, 凝固结束时气泡的体积分数也相对较高. 本模型的模拟结果可以揭示在凝固过程中气泡形核、 生长和运动演化以及与枝晶生长相互作用的物理机理.     

Ti-45at.% Al合金定向凝固过程中显微组织演化的计算机模拟

采用基于溶质扩散控制模型CA方法对Ti-45at.% Al合金定向凝固过程中显微组织演化过程进行了数值模拟.模拟结果表明,在温度梯度较高时,初生晶核间距无论大小,均可通过分枝或竞争生长而使一次胞晶/枝晶间距得到调整.在抽拉速度一定情况下,随着温度梯度增加,胞晶/枝晶间距减小,在温度梯度一定情况下,随着抽拉速度增大,观察到胞晶/枝晶混合结构,混合结构区随温度梯增大而增大,模拟结果与实验观察相符合. 关键词： Ti-45at.% Al合金 定向凝固 组织演化 数值模拟