Numerical Simulation of Temperature Field and Thermal Stress in ZTAp/HCCI Composites DuringSolidification Process

doi:10.11900/0412.1961.2017.00351

Acta Metall Sin

2018, Vol. 54

Issue (2): 314-324 DOI: 10.11900/0412.1961.2017.00351

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Numerical Simulation of Temperature Field and Thermal Stress in ZTA_p/HCCI Composites DuringSolidification Process

Xiaoyu CHONG^1,², Guangchi WANG^1,², Jun DU³, Yehua JIANG^1,²(

), Jing FENG^1,²

1 School of Materials Science and Engineering, Kunming University of Science and Technology, Kunming 650093, China
2 National Engineering Laboratory of Advanced Metal Solidification/Forming and Technology of Equipment, Kunming University of Science and Technology, Kunming 650093, China
3 Technology Center, Magang (Group) Holding Co., Ltd., Ma'anshan 243000, China

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Xiaoyu CHONG, Guangchi WANG, Jun DU, Yehua JIANG, Jing FENG. Numerical Simulation of Temperature Field and Thermal Stress in ZTA_p/HCCI Composites DuringSolidification Process. Acta Metall Sin, 2018, 54(2): 314-324.

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Abstract

As advanced wear-resistant materials, it is important to promote the process and application of high chromium cast iron (HCCI) matrix composite reinforced by zirconia toughened alumina ceramic particles (ZTA_p/HCCI composite). For the purpose of wider applications of this kind of composite, it is urgent to optimize the process parameters of casting process for it. Based on the finite element software the temperature field and thermal stress in ZTA_p/HCCI composite during casting process were simulated. The temperature fields of castings are investigated using the uniform initial temperature and the non-uniform initial temperature at the beginning of solidification. It is more appropriate to the actual situation at the end of mold filling process when the initial temperature of solidification is considered as an unstable temperature field. The influence from performs with different honeycomb shapes is considered in the calculations of temperature fields of castings. In this work, the thermo-elastic plastic model was used to accurately describe the thermal stress in the castings with different honeycomb shapes of preforms, and the results indicate that the thermal stress in them decreases with the increase of edge number of holes in preforms. Finally, the hot crack in castings is predicted and the shakeout process is optimized. It is concluded that the simulated results are in good agreement with the experimental results.

Key words: ZTA_p/HCCI composite heat transfer temperature field thermal stress numerical simulation

Received: 24 August 2017

Fund: Supported by National Natural Science Foundation of China (Nos.51571103 and 51561018)

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	Xiaoyu CHONG
	Guangchi WANG
	Jun DU
	Yehua JIANG
	Jing FENG

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https://www.ams.org.cn/EN/10.11900/0412.1961.2017.00351 OR https://www.ams.org.cn/EN/Y2018/V54/I2/314

Fig.1 The actual castings of a high chromium cast iron (HCCI) matrix composite reinforced by zirconia toughened alumina (ZTA) ceramic particles (ZTA_p/HCCI) (a) and a preform of ZTA ceramic particles (b)

Fig.2 The entity solid model of ZTA_p/HCCI composites designed according to the real casting conditions

Fig.3 Schematics of preforms with different honeycomb shapes(a) regular triangle hole(b) square hole(c) regular pentagon hole(d) regular hexagon hole(e) circle hole

Table 1 Mechanical properties of high chromium cast iron at different temperatures

Table 2 Mechanical properties of ZTA performs

Fig.4 Temperature field changes of casting sections containing performs with time (t)(a) t=0.588 s (b) t=1.708 s (c) t=3.811 s (d) t=5.805 s (e) t=8.179 s (f) t=11.339 s

Fig.5 Overall temperature distribution in pouring system after fully filling

Fig.6 Convection coef?cient between inner surface of sand mould and casting

Fig.7 Temperature ?elds of solidification at 20 s (a, b), 311 s (c, d), 1211 s (e, f) 2411 s (g, h), 3600 s (i, j) and 7200 (k, l) under uniform initial temperature (a, c, e, g, i, k) and non-uniform initial temperture (b, d, f, h, j, l)

Fig.8 Temperature fields of casting including performs with regular triangle hole (a~c), square hole (d~f), regular pentagon hole (g~i), regular hexagon hole (j~l) and circle hole (m~o) at 2 s (a, d, g, j, m), 600 s (b, e, h, k, n) and 18000 s (c, f, i, l, o) under non-uniform initial temperatures

Fig.9 Distribution of temperature in sand mould

Fig.10 Influence of preform's shape on casting thermal stress

Fig.11 Temperature field in casting at 14400 s (a) and cracks in actual casting (b)

Fig.12 Thermal stress fields in preforms included in casting at different time after casting shakeout(a) t=7200 s (b) t=9000 s(c) t=12600 s (d) t=14400 s

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