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金属学报  2018, Vol. 54 Issue (3): 470-484    DOI: 10.11900/0412.1961.2017.00460
  本期目录 | 过刊浏览 |
Cu-Al复合材料连铸直接成形数值模拟研究
刘新华1,2, 付华栋1,2, 何兴群1, 付新彤1, 江燕青1, 谢建新1,2()
1 北京科技大学新材料技术研究院 北京 100083
2 北京科技大学材料先进制备技术教育部重点实验室 北京 100083
Numerical Simulation Analysis of Continuous Casting Cladding Forming for Cu-Al Composites
Xinhua LIU1,2, Huadong FU1,2, Xingqun HE1, Xintong FU1, Yanqing JIANG1, Jianxin XIE1,2()
1 Institute for Advanced Materials and Technology, University of Science and Technology Beijing, Beijing 100083, China
2 Key Laboratory for Advanced Materials Processing (MOE), University of Science and Technology Beijing, Beijing 100083, China
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摘要: 

建立了Cu-Al复合材料连铸成形的数值模拟模型,确定了模型的边界条件,提出了复合过程处理和结果评价方法。通过与部分实验结果对比表明,模拟结果与实验结果一致。以铜包铝棒坯立式连铸和Cu-Al复合板坯水平连铸过程为例,采用ProCAST软件对其稳态温度场进行了数值模拟分析,得到了各工艺参数对连铸过程的影响规律,给出了合理的工艺参数范围,并结合模拟的参数进行相应的实验研究。结果表明,本工作建立的连铸复合模型、确定的边界条件、提出的复合过程处理和结果评价方法合理,可有效用于连铸复合成形模拟分析。计算结果表明,制备横断面为100 mm×100 mm、Cu包覆层厚度(4~10 mm)的铜包铝棒坯可行的连铸工艺参数为:Cu液温度1250 ℃,Al液温度750 ℃,结晶器长度200 mm,芯棒管长度290 mm,一冷水流量1600~2000 L/h,二冷水流量900~1300 L/h,二冷水距结晶器出口距离30 mm,拉坯速率60~80 mm/min;制备厚度20 mm、宽度75 mm、Cu包覆层厚度(4~7 mm)的Cu-Al复合板坯可行的工艺参数为:Cu液温度1250 ℃,Al液温度760~800 ℃,拉坯速率40~80 mm/min,Al液导流管长度20 mm。

关键词 Cu-Al复合材料连铸复合成形温度场数值模拟    
Abstract

High performance Cu-Al composites have widely applied in aviation, aerospace and other fields, at the same time the continuous casting as one of composite forming technologies has been also developed in recent years. Obviously, it is an effective and cheap way to numerically simulate the solidification process of short process continuous casting for manufacturing Cu-Al composites before fabricating them. To meet the need of simulation, in this work, a numerical method for theoretically describing the Cu-Al composite forming in continuous casting processes was proposed. The vertical continuous casting of copper clad aluminum bar billet and the horizontal continuous casting of copper and aluminum composite plate were performed. Based on this method, the steady state temperature fields in solidification processes in the above two kinds of casting technologies were numerically simulated by using proCAST software package. In this work the effects of the theoretical parameters on the steady state temperature fields and then on the performance of Cu-Al composites fabricated by using the above two casting technologies were carefully discussed. It is found that the experimental and simulated results are in good agreement. For the cases of the copper clad aluminum bar billet with a cross section of 100 mm×100 mm, and the copper or aluminum plate with a thickness of 20 mm and a width of 75 mm (coat thicknesses of 4~7 mm), the feasible parameters for producing high performance Cu-Al composites, for examples, are as follows: for the former the temperature of copper liquid is 1250 ℃, the temperature of aluminum liquid is 750 ℃, the length of crystallizer is 200 mm, the length of graphite mandrel tube is 290 mm, the flux of the first cooling water is 1600~2000 L/h, the flux of the second cooling water is 900~1300 L/h, the distance from the second cooling water to the exit of crystallizer is 30 mm, and the withdrawing speed is 60~80 mm/min. For the latter the temperature of copper melt was 1250 ℃, the temperatures of aluminum melt are 760~800 ℃, the withdrawing speed is 40~80 mm/min, and the length of aluminum duct is 20 mm.

Key wordsCu-Al composites    continuous casting composite forming    temperature field    numerical simulation
收稿日期: 2017-11-01     
基金资助:资助项目 国家高技术研究发展计划项目No.2013AA030706,北京市科技计划项目No.Z141100004214003,云南省科技合作项目No.2015IB012
作者简介:

作者简介 刘新华,男,1975年生,研究员,博士

引用本文:

刘新华, 付华栋, 何兴群, 付新彤, 江燕青, 谢建新. Cu-Al复合材料连铸直接成形数值模拟研究[J]. 金属学报, 2018, 54(3): 470-484.
Xinhua LIU, Huadong FU, Xingqun HE, Xintong FU, Yanqing JIANG, Jianxin XIE. Numerical Simulation Analysis of Continuous Casting Cladding Forming for Cu-Al Composites. Acta Metall Sin, 2018, 54(3): 470-484.

链接本文:

https://www.ams.org.cn/CN/10.11900/0412.1961.2017.00460      或      https://www.ams.org.cn/CN/Y2018/V54/I3/470

图1  铜包铝立式连铸直接复合成形工艺原理示意图
图2  铜包铝立式连铸复合几何模型示意图
图3  Cu包Al立式连铸温度场稳态模拟边界条件(左)和界面条件(右)示意图
图4  模拟得到的典型温度场分布图及模拟结果的评价指标物理意义示意图
L0 / mm s / mm h / mm v / (mm?min-1) L2 / mm
80 50 180 130 132.0
100 50 180 130 120.8
100 10 180 130 72.2
100 50 180 130 70.8
100 50 180 100 93.8
100 50 190 130 106.9
150 50 180 130 47.7
150 10 180 130 47.5
150 10 240 130 8.1
150 10 180 100 30.5
150 10 240 100 -12.2
200 50 270 130 99.8
200 50 310 100 35.4
200 10 270 130 48.3
200 10 310 100 16.8
250 50 310 130 103.5
250 50 380 100 16.2
250 10 310 130 64.5
250 10 380 100 -5.8
表1  结晶器长度对Cu和Al凝固固/液界面位置的影响
h
mm
Q1
Lh-1
Q2
Lh-1
TAl
v
mmmin-1
L1
mm
L2
mm
L3
mm
Ts
250 1600 900 750 60 73.5 78.15 67.08 740
270 1600 900 750 60 73.5 69.26 47.61 710
290 1600 900 750 60 73.5 35.82 27.92 685
310 1600 900 750 60 73.5 18.62 5.93 650
330 1600 900 750 60 73.4 6.43 -3.24 630
表2  芯棒管长度对Cu和Al凝固固/液界面位置的影响
No. h
mm
Q1
Lh-1
Q2
Lh-1
TAl
v
mmmin-1
L1
mm
L2
mm
L3
mm
Ts
1 290 1400 900 750 60 72.5 37.94 28.95 690
2 290 1600 900 750 60 74.0 35.82 27.92 685
3 290 1800 900 750 60 74.5 34.95 26.83 683
4 290 2000 900 750 60 74.5 33.86 26.82 680
表3  一冷水流量对Cu和Al凝固固/液界面位置的影响
No. h
mm
Q1
Lh-1
Q2
Lh-1
TAl
v
mmmin-1
L1
mm
L2
mm
L3
mm
Ts
1 290 1600 700 750 60 75.5 35.94 27.93 690
2 290 1600 900 750 60 75.0 35.82 27.92 685
3 290 1600 1100 750 60 73.5 35.12 26.83 687
4 290 1600 1300 750 60 73.5 34.95 26.83 684
5 290 1600 1500 750 60 73.5 33.84 25.83 680
表4  二冷水流量对Cu和Al凝固固/液界面位置的影响
No. h
mm
Q1
Lh-1
Q2
Lh-1
TAl
v
mmmin-1
L1
mm
L2
mm
L3
mm
Ts
1 290 1600 900 750 40 55.5 -11.51 0 -
2 290 1600 900 750 60 75.0 35.82 27.92 685
3 290 1600 900 750 80 80.0 59.07 51.85 725
4 290 1600 900 750 100 81.0 76.93 62.97 770
5 290 1600 900 750 120 82.5 87.49 70.39 790
表5  连铸速率对Cu和Al凝固固/液界面位置的影响
图5  不同冷却水流量下试样的截面形貌
图6  水平连铸成形制备Cu-Al复合薄板坯原理示意图
图7  Cu-Al复合板坯水平连铸几何模型
图8  Al液导流管长度对Cu和Al凝固位置的影响
图9  拉坯速率对Cu和Al凝固位置的影响
图10  Al液温度对Cu和Al凝固位置的影响
图11  不同拉坯速率下的板坯形貌
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