磁场对二元合金凝固过程中糊状层稳定性的影响

利用线性稳定性方法研究了外加磁场对二元合金凝固过程中糊状层稳定性的影响,且模型同时考虑了温度场、浓度场和流动的耦合作用.利用计算得出的色散关系式分析了磁场对糊状层稳定性的影响,其中包括直接模式和振荡模式.给出了不同情况下外加磁场对糊状层稳定性的影响,发现磁洛伦兹力可以减小由浮力引起的失稳效应.振荡模式下外加磁场对糊状层产生稳定作用,但直接模式下外加磁场对糊状层的稳定作用具有不确定性.本文所给出结果为工业中利用外加磁场改善产品的质量提供了重要的理论参考.     

3D Analysis of Crystal/Melt Interface Shape and Marangoni Flow Instability in Solidifying Liquid Bridges

Solidification of gallium (Pr=0.02) in liquid bridges in zero-gravity conditions is investigated by numerical solutions of the three-dimensional and time-dependent flow-field equations. A single region (continuum) formulation based on the enthalpy method is adopted to model the phase-change problem. This paper analyzes the influence of the azimuthally asymmetric and steady first bifurcation of the Marangoni flow on the shape of the solid/melt interface during the crystal growth process. The numerical results show that this interface is distorted in the azimuthal direction. The distortion is related to the sinusoidal three-dimensional temperature disturbances due to the instability of the Marangoni flow. The three-dimensional flow field organization, related to the wave number, changes during the solidification process; this behavior is explained according to the variation of the aspect ratio of the solidifying liquid bridge. A correlation law is found for the azimuthal wave number of the instability as function of the melt zone aspect ratio.     

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.     

强磁场作用下Cu熔体中富Fe颗粒的迁移与排列

凝固界面前沿颗粒间的相互作用决定了颗粒的运动轨迹、分布和材料的性能,控制熔体中颗粒的迁移可用于材料的净化和提纯.在Cu-30%Fe合金液固两相区施加不同的强磁场条件,富Fe颗粒的分布和排列不尽相同.当无强磁场作用时,富Fe颗粒较均匀地分布在Cu熔体中;随着施加稳恒强磁场磁感应强度的增加,富Fe颗粒向远离重力方向的试样上端迁移,样品底部几乎无富Fe颗粒;而施加向下的梯度磁场作用后,富Fe颗粒沿重力方向向下迁移.结合强磁场作用下颗粒的受力情况,分析了Fe颗粒的迁移行为.不同磁场条件和不同区域的颗粒直径统计分析表明,随磁感应强度增加,Fe颗粒聚合增加,但施加梯度强磁场后颗粒的团聚又逐渐减弱,对此从影响颗粒运动的Stokes和Marangoni凝并速度进行了讨论.从能量最低的角度解释了富Fe相沿平行磁场方向的取向排列.     

温度梯度区域熔化作用下熔池迁移的元胞自动机模拟

本文采用耦合凝固和熔化效应的二维元胞自动机(cellular automaton, CA)模型,对温度梯度区域熔化(temperature gradient zone melting, TGZM)效应引起的熔池在固液两相区中的迁移现象进行模拟研究.模拟分析了抽拉速度、熔池初始位置、温度梯度和合金成分等因素对TGZM动力学的影响,并将模拟结果与解析模型的预测结果进行比较验证.通过模拟发现,在温度梯度作用下,熔池总是向着高温方向迁移;当抽拉速度低于或高于临界抽拉速度时,熔池朝向移动的液相线或固相线迁移;对于给定的抽拉速度,位于糊状区内临界位置以上的熔池会迁移进入液相,而位于临界位置以下的熔池会逐步靠近固相线.此外,温度梯度越高,合金成分越低,熔池的迁移速度越快.     

Heat transfer and diffusion-controlled kinetics of liquid–solid phase in titanium matrix composite during selective laser melting

This study describes a self-consistent theoretical model of simulating diffusion-controlled kinetics on the liquid–solid phase boundary during high-speed solidification in the melt pool after the selective laser melting (SLM) process for titanium matrix composite based on Ti–TiC system. The model includes the heat transfer equation to estimate the temperature distribution in the melt pool and during crystallization process for some deposited layers. The temperature field is used in a micro region next to solid–liquid boundary, where solute micro segregation and dendrite growth are calculated by special approach based on transient liquid phase bonding. The effect of the SLM process parameters (laser power, scanning velocity, layer thickness and substrate size) on the microstructure solidification is being discussed.     

Interactions between a cavitation bubble and solidification front under the effects of ultrasound: Experiments and lattice Boltzmann modeling

The phenomena of melting and dendritic fragmentation are captured by using an in-situ device during the ultrasound-assisted solidification of a succinonitrile-acetone (SCN-ACE) alloy. The experimental results show that the dendrite arms detach from primary trunk due to the melting of the solid phase, which is caused by a moving ultrasound cavitation bubble. To quantify the interactions between the ultrasound cavitation bubble and the solidification front, a coupled lattice Boltzmann (LB) model is developed for describing the fields of temperature, flow, and solid fraction, and their interactions. The multi-relaxation-time (MRT) scheme is applied in the LB model to calculate the liquid-gas flow field, while the Bhatnagar–Gross–Krook (BGK) equation is executed to simulate the evolution of temperature. The kinetics of solidification and melting are calculated according to the lever rule based on the SCN-ACE phase diagram. After the validation of the LB model by an analytical model, the morphologies of the cavitation bubble and solidification front are simulated. It is revealed that the solidification interface melts due to the increase of the temperature nearby the cavitation bubble in ultrasonic field. The simulated morphologies of the cavitation bubble and solidification front are compared well with the experimental micrograph. Quantitative investigations are carried out for analyzing the melting rate of the solidification front under different conditions. The simulated data obtained from LB modeling and theoretical predictions reasonably accord with the experimental results, demonstrating that the larger the ultrasonic intensity, the faster the melting rate. The present study not only reveals the evolution of the solidification front shape caused by the cavitation bubbles, which is invisible in the ultrasound-assisted solidification process of practical alloys, but also reproduces the complex interactions among the temperature field, acoustic streaming, and multi-phase flows.     

Fourier thermal analysis of solidification kinetics in molten aluminium and in presence of ultrasonic field

In this paper a comparison between the Newtonian and Fourier method analysis available in thermal analysis techniques is reported. The experimental solidification of liquid aluminium under various conditions has been studied. Thermal analysis is a tool in elucidating the thermal events involved in liquid to solid transformation. The Newtonian method predicts a maximum in heat generation at the onset of solidification, while the Fourier method incorporates the effect of thermal gradient and predicts two heat generation peaks during the solidification process. This comparison between the Fourier and Newtonian method indicates that their predictions are appreciably different. In order to elucidate the effect of ultrasonic waves on solidification process, the measurements were carried out under similar conditions both with and without sonication. Our studies have shown that in presence of the ultrasonic field the kinetics of solidification is changed, leading namely to a decreased undercooling degree of the melt and thermal diffusivity.     

高能超声制备碳纳米管增强AZ91D复合材料的声场模拟

建立了高能超声制备碳纳米管增强AZ91D复合材料的声场计算模型, 并采用有限元方法计算了20 kHz超声直接作用下AZ91D熔体的声场分布, 熔体声场呈辐射状分布, 距离声源越远, 声压幅值越低. 采用超声作用下单一气泡变化模型描述超声作用下AZ91D 熔体中的空化效应, 通过对Rayleigh-Plesset方程的求解, 得到了不同声压作用下气泡的变化规律, 获得了声压幅值与熔体空化效应的关系, 声压幅值越大, 气泡溃灭半径阈值越小, 熔体发生空化效应越容易. 计算了固定坩埚尺寸、不同超声探头没入熔体深度情况下的声场, 得到了超声探头最优没入深度为30 mm左右. 将声场计算结果以及AZ91D熔体中空化效应的发生规律进行综合分析, 得到了超声功率对有效空化区域的影响规律, 超声功率较大时, 有效空化区域体积随超声功率近似成线性增大. 最后, 通过甘油水溶液超声处理实验, 验证了模拟计算的准确性.     

液体材料超声处理过程中声场和流场的分布规律研究

针对合金熔体等液体材料的超声处理过程,选取水作为透明模型材料,采用数值模拟计算和示踪粒子实验方法,研究了20和490 kHz两种频率超声作用下水中的声场和流场分布.结果表明,增大变幅杆半径能够提高水中声压水平,扩大空化效应的发生区域.当超声频率为20 kHz时,水中声压最大值出现在超声变幅杆下端面处,且声压沿传播距离的增大而显著减小.如果超声频率增加至490 kHz,水中的声压级相比于20 kHz时明显提高,且声压沿着超声传播方向呈现出周期性振荡特征.两种频率超声作用下水中的流场呈现相似的分布特征,且平均流速均随着变幅杆半径增大表现出先升高后降低的趋势.变幅杆半径相同时,20 kHz频率超声作用下水中的平均流速高于490 kHz频率超声.采用示踪粒子图像测速技术实时观察和测定了水中的流速分布,发现其与计算结果基本一致.     

Study of ultrasonic melt treatment on the quality of horizontal continuously cast Al-1%Si alloy

The fluctuation of the melt temperature in a tundish was measured during casting and experiments were conducted to investigate the effects of ultrasonic melt treatment on the surface quality and solidification structures of Al-1%Si ingots. The results show that the uniformity of melt temperature was enhanced with the application of ultrasonic melt treatment. When the ultrasonic power is 1,000W, the surface quality was evidently improved and grains of cast ingots were refined. Moreover, EPMA analysis was adopted to study the relationship between the ultrasonic power and boundary segregation of Si element. The result shows that boundary segregation is suppressed with the increase of ultrasonic power and the phenomenon was theoretically interpreted.     

Ultrasound cavitation induced nucleation in metal solidification: An analytical model and validation by real-time experiments

Microstructural refinement of metallic alloys via ultrasonic melt processing (USMP) is an environmentally friendly and promising method. However, so far there has been no report in open literature on how to predict the solidified microstructures and grain size based on the ultrasound processing parameters.In this paper, an analytical model is developed to calculate the cavitation enhanced undercooling and the USMP refined solidification microstructure and grain size for Al-Cu alloys. Ultrafast synchrotron X-ray imaging and tomography techniques were used to collect the real-time experimental data for validating the model and the calculated results. The comparison between modeling and experiments reveal that there exists an effective ultrasound input power intensity for maximizing the grain refinement effects for the Al-Cu alloys, which is in the range of 20-45 MW/m². In addition, a monotonous increase in temperature during USMP has negative effect on producing new nuclei, deteriorating the benefit of microstructure refinement due to the application of ultrasound.     

Numerical simulation of dendrite growth and microsegregation formation of binary alloys during solidification process

The dendrite growth and solute microsegregation of Fe-C binary alloy are simulated during solidification process by using cellular automaton method. In the model the solid fraction is deduced from the relationship among the temperature, solute concentration and curvature of the solid/liquid interface unit, which can be expressed as a quadric equation, instead of assuming the interface position and calculating the solid fraction from the interface velocity. Then by using this model a dendrite with 0 and 45 degree of preferential growth direction are simulated respectively. Furthermore, a solidification microstructure and solute microsegregation are simulated by this method. Finally, different Gibbs-Thomson coefficient and liquid solute diffusing coefficient are adopted to investigate their influences on the morphology of dendrite.     

Influences of travelling magnetic field on the dendritic structures of Sn–1.8Cd peritectic alloy during directional solidification

The effects of melt flow driven by a travelling magnetic field (TMF) on solidification structures of Sn–1.8 wt.% Cd peritectic alloy have been investigated numerically and experimentally. Numerical results indicate that the flow velocity at the solid–liquid interface under a downward TMF is smaller than that under an upward TMF. The experimental results show that the growth directions of dendrites are chaotic, and several crotches among the dendrites are observed at the solid–liquid interface in the case of no field. It is concluded from TMF results that the ordered growth of dendrites at two different directions occurs, and only one crotch among the dendrites appears at the solid–liquid interface. The location of the crotch gradually approaches the interface center with increasing magnetic field intensity (B≤10.3 mT). Moreover, the growth of high-order branches occurs at the crotch under a downward TMF. A simple model is established for explanation and it well corresponds to the experimental results.     

Modelling of the solid–liquid interface during laser processing using an inverse methodology

This study presents a methodology for estimating the melt depth during laser processing of solid materials. The determination of the melt depth is treated as an inverse heat conduction problem, which includes the solid and liquid phases. The conjugate gradient method is applied to treat the inverse problem using the available temperature measurements. Without the inverse methodology the melt depth is very difficult to obtain with precision. The proposed method can also be applied during microthermal machining to determine the location of the solid–liquid interface and the temperature distributions of the two phases by using scanning thermal microscopy.     

离心力场中伴随瞬态固化与再熔现象的渗流传热过程

针对离心渗铸充型过程中金属铝熔液的瞬态固化与再熔现象,建立了旋转多孔介质内的渗流传热理论模型。通过理论分析,获得了复合管离心渗铸充型过程中伴随有瞬态固化与再熔现象的压力分布以及渗透界面与再熔界面移动速度计算公式,建立了界面移动速度与温度间的耦合关系,分析了流场变化规律。结果表明:多孔预型体内发生的液固共融现象对流场分布具有重要的影响,增大孔隙率和离心转速,有利于提高流场局部温度,缩短液固两相熔融区的长度,降低熔融区内固化率。由于渗透前沿发生瞬态固化导致该区域的空隙率减小,熔液的有效流通截面变窄,使得流场局部压力和速度发生波动。     

定向凝固宏微观热质传递及双扩散流作用

针对氯化铵水溶液定向凝固实验,从枝晶微尺度到宏观尺度耦合模拟了相变热质传递过程,并考察了双扩散流的影响.研究结果表明,NH4CI-H2O溶液的枝晶微界面浓度变化与非平衡态的谢尔方程趋于一致.两相区内液相率较高,易于流动的产生;热浮升力形成逆时针回流,溶质浮升力形成顺时针回流;热浮升力作用大于溶质浮升力.但双扩散流几乎不影响凝固沿着结晶室高度方向进行的一维定向特性.数值模拟中低估了两相区的渗透率,是造成两相区厚度模拟结果小于实验值的原因.     

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.     

Improving the property of calcium ferrite using a sonochemical method

Power ultrasonic vibration was applied to the solidification of calcium ferrite (CF) melt in this study. The results indicated that power ultrasound can promote the formation of CF by accelerating the solidification process. Ultrasonic vibration greatly refined the CF grains, resulting the grain size decreased from 1893 to 437 μm. Meanwhile, ultrasonic vibration significantly enhanced the compressive strength, reduced the reduction time and improved the reducibility of CF slags. With ultrasonic treatment, the ultimate compressive strength of samples increased from 37.5 to 67.8 MPa, and the reduction time decreased from 225 to 136 min.