基于成分均匀化的层状铸造方法的实验与模拟研究

doi:10.11900/0412.1961.2017.00225

金属学报

2018, Vol. 54

Issue (1): 118-128 DOI: 10.11900/0412.1961.2017.00225

本期目录 | 过刊浏览

基于成分均匀化的层状铸造方法的实验与模拟研究

李军^1,²(

), 王军格¹, 任凤丽¹, 葛鸿浩¹, 胡侨丹¹, 夏明许¹, 李建国¹

1 上海交通大学材料科学与工程学院上海 200240
2 上海交通大学高新船舶与深海开发装备协同创新中心上海 200240

Experimental and Numerical Simulation Study on Layer Casting Method for Composition Homogeneityon Ingot Casting

Jun LI^1,²(

), Junge WANG¹, Fengli REN¹, Honghao GE¹, Qiaodan HU¹, Mingxu XIA¹, Jianguo LI¹

1 School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai 200240, China
2 Collaborative Innovation Center for Advanced Ship and Deep-Sea Exploration, Shanghai Jiao Tong University, Shanghai 200240, China

引用本文:

李军, 王军格, 任凤丽, 葛鸿浩, 胡侨丹, 夏明许, 李建国. 基于成分均匀化的层状铸造方法的实验与模拟研究[J]. 金属学报, 2018, 54(1): 118-128.
Jun LI, Junge WANG, Fengli REN, Honghao GE, Qiaodan HU, Mingxu XIA, Jianguo LI. Experimental and Numerical Simulation Study on Layer Casting Method for Composition Homogeneityon Ingot Casting[J]. Acta Metall Sin, 2018, 54(1): 118-128.

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摘要:

提出了一种可降低铸锭宏观偏析的铸造工艺：层状铸造(layer casting,LC)。将铸锭分为数个甚至数十个浇包逐次间隔浇注,使每包次浇入的金属液依次、逐层凝固,从而达到降低铸锭中宏观偏析的目的。采用实验与数值模拟相结合的手段验证该工艺的可行性和适用性。分别采用传统铸造工艺和层状铸造工艺制备Al-4.0%Cu (质量分数)小铸锭,采用直读光谱仪测量铸锭中心截面处Cu含量并绘制出对应的宏观偏析图。实验结果表明：采用传统铸造工艺制备的铸锭出现明显的宏观偏析,包括铸锭底部严重的负偏析和顶部正偏析;而采用层状铸造工艺制备的铸锭没有出现大范围严重的宏观偏析,铸锭中心线上最小负偏析和最大正偏析分别降低了24.6%和77.2%,说明层状铸造工艺可一定程度改善铸锭宏观偏析。同时,采用柱状晶-等轴晶混合三相凝固模型对100和13 t钢锭的传统铸造工艺以及层状铸造工艺的宏观偏析的形成进行数值模拟预测。模拟结果表明：采用层状铸造工艺可有效改善大型钢锭中的宏观偏析,并且随着钢锭尺寸的增大,该工艺对宏观偏析的改善效果愈加明显。并对层状铸造工艺抑制宏观偏析的作用机理进行了分析。

关键词 ：大型铸锭, 层状铸造, 宏观偏析, 数值模拟

Abstract：

Macrosegregation, or compositional heterogeneity, is a very common and serious defect in large steel ingots, which is hard to remove in the following processing procedures. It not only decides the final properties of the product, but also restricts downstream hot working processing severely. This compositional heterogeneity occurs due to the relative motion between the liquid and solid phases during solidification. Therefore, it is necessary to develop an effective method to manufacture large ingots with less macrosegregation. In this work, a novel casting method was proposed to alleviate macrosegregation of large ingots, i.e., layer casting (LC). With this method, alloy melt will be poured into the mould step by step, so that the melt could be solidified layer by layer and the macrosegregation will be alleviated. Both experimental and numerical studies were carried out to verify the feasibility and effectiveness of LC method. Two small Al-4.0%Cu (mass fraction) ingots were cast using two casting methods, conventional casting method, in which melt was cast into mould in one stage, and LC method, in which melt was cast into mould in several stages. Each ingot was sectioned into two parts along the center line, and then the specimens were measured by optical emission spectrometry to obtain the compositional distribution of Cu. Both severe bottom negative segregation and top positive segregation zones were observed in the ingot fabricated by conventional casting method. More homogeneity of compositional distribution was observed in the ingot fabricated by LC method, and the max negative and positive macrosegregation along the center line decreased by 24.6% and 77.2%, respectively. At the same time, a mixed three-phase (equiaxed, columnar and liquid) solidification model was employed to study the solidification processing in large ingots. The macrosegregation formation processes of 100 t and 13 t steel ingots fabricated by both conventional casting and LC methods were numerically simulated. The simulation results indicated that LC method had the capability of alleviating macrosegregation of large steel ingots significantly, compared with conventional casting method. With the increment of ingot size and amount of ladles, LC method had more significant effect on the alleviation of macrosegregation in large ingots. The mechanism of macrosegregation alleviation of LC method was analyzed.

Key words： large ingot layer casting macrosegregation numerical simulation

收稿日期: 2017-06-09

ZTFLH:

TG244.2

基金资助:国家重点研发计划项目No.2017YFB0305300,国家自然科学基金钢铁联合基金重点项目No.U1660203,国家自然科学基金项目No.51404152和上海市浦江人才支持计划项目No.14PJ1404800

作者简介:

作者简介李军,男,1984年生,博士

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	胡侨丹
	夏明许
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链接本文:

https://www.ams.org.cn/CN/10.11900/0412.1961.2017.00225 或 https://www.ams.org.cn/CN/Y2018/V54/I1/118

图1 层状铸造工艺示意图

图2 采用传统铸造工艺和层状铸造工艺制备的Al-4.0%Cu合金铸锭的宏观组织形貌

图3 采用传统铸造工艺和层状铸造工艺制备的铸锭中心截面处宏观偏析分布图

表1 采用传统铸造工艺和层状铸造工艺制备的铸锭中心线各处宏观偏析分布特征

图4 采用传统铸造工艺和层状铸造工艺制备的铸锭中心线上宏观偏析分布曲线

图5 100 t Fe-0.2%C钢锭尺寸示意图及相关初始条件和边界条件

图6 传统铸造和层状铸造工艺制备的100 t钢锭凝固的宏观偏析分布图的数值模拟

图7 采用传统铸造工艺和层状铸造工艺制备的100 t钢锭中心线上宏观偏析分布曲线的数值模拟

表2 采用传统铸造工艺和层状铸造工艺制备的钢锭中心线上宏观偏析分布特征的数值模拟

图8 采用传统铸造工艺和层状铸造工艺制备的13 t钢锭中心线上宏观偏析分布曲线的数值模拟

图9 浇注0.5 h后传统铸造和层状铸造工艺下凝固过程中钢液流动情况

图10 浇注0.5 h后传统铸造和层状铸造工艺下凝固过程中等轴晶运动情况

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