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金属学报  2021, Vol. 57 Issue (4): 515-528    DOI: 10.11900/0412.1961.2020.00414
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块体非晶合金铸造成形的研究新进展
刘日平(), 马明臻(), 张新宇
燕山大学 亚稳材料制备技术与科学国家重点实验室 秦皇岛 066004
New Development of Research on Casting of Bulk Amorphous Alloys
LIU Riping(), MA Mingzhen(), ZHANG Xinyu
State Key Laboratory of Metastable Materials Preparation Technology and Science, Yanshan University, Qinhuangdao 066004, China
引用本文:

刘日平, 马明臻, 张新宇. 块体非晶合金铸造成形的研究新进展[J]. 金属学报, 2021, 57(4): 515-528.
Riping LIU, Mingzhen MA, Xinyu ZHANG. New Development of Research on Casting of Bulk Amorphous Alloys[J]. Acta Metall Sin, 2021, 57(4): 515-528.

全文: PDF(3422 KB)   HTML
摘要: 

块体非晶合金的亚稳态结构特点，决定了其难于用常规的锻压或焊接等工艺手段进行构件或零件的加工制造，但利用块体非晶合金熔体的流动性进行铸造成形，是制造块体非晶合金构件或零件的有效技术手段。本文基于块体非晶合金的铸造成形，简要介绍了块体非晶合金熔体的流动性与充型能力，真空压铸、真空吸铸、以及水冷铜坩埚重力铸造与相变制冷铸造成形的技术方法与应用，探讨了非晶合金铸造成形过程需要解决的理论问题和需要攻克的技术瓶颈，展望了块体非晶合金的工程应用前景。
关键词 ： 块体非晶合金,  流动性,  铸造成形,  真空压铸,  真空吸铸    
Abstract：

Bulk amorphous alloys possess a metastable structure, which is difficult to process and manufacture into components or parts by conventional forging or welding. Instead, components or parts from bulk amorphous alloys can be fabricated by vacuum casting with the fluidity of bulk amorphous-alloy melts. Based on the casting forming of bulk amorphous alloys, this paper briefly introduces the fluidity and filling ability of bulk amorphous-alloy melts. In addition, the technical methods and applications of vacuum die casting, vacuum suction casting, gravity casting in a water-cooled copper crucible, and phase-change refrigeration casting are also mentioned. The theoretical problems and technical bottlenecks to be resolved in the forming process of bulk amorphous alloys are then discussed. Finally, the engineering application prospects of bulk amorphous alloys are suggested.
Key words： bulk amorphous alloy    fluidity    casting forming    vacuum die casting    vacuum suction casting
收稿日期: 2020-10-20     
ZTFLH:  TG139  
基金资助:国家自然科学基金项目(52071278);国家重点研发计划项目(2018YFA0703603)
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https://www.ams.org.cn/CN/10.11900/0412.1961.2020.00414      或      https://www.ams.org.cn/CN/Y2021/V57/I4/515

图1  流动性测试装置示意图和水冷模具的照片[38]
图2  不同直径、不同温度和压力差对流动长度的影响及不同条件时纵截面剖面图[38]
Temperature / KΔp / MPa
0.0200.0250.0300.035
1073●●◘◘
1123●◘◘◘
1173◘◘◘◘
1223◘☆☆☆
1273◘☆☆☆
表1  直径6 mm流动性测试纵截面缺陷存在数量[38]
图3  高压铸造装置示意图、模具的三维模型及由耐热钢和铜合金制成的铸造模具[40]
图4  在1353 K下铸造的钥匙的SEM像[40](a) taken at the core of the key, showing a completely crystalline region(b) taken between the core and the outer surface, revealing the interface between the glassy and crystalline parts(c) taken close to the outer surface, showing a completely glassy part of the key
图5  EPV-HPDC设备和操作模式说明[41](a) loading materials and melting(b) pouring liquid metal into the shot sleeve and filling die (V—speed)(c) solidifying under pressure (p—pressure)
图6  Zr55Cu30Ni5Al10块体非晶合金(BMG)智能手机框架和相应的浇注系统图像，及其孔隙率的3D分布[41]
图7  形状各异、用于不同领域的BMG部件[41](a) BMG transmission used in a notebook computer fabricated by Vit106(b) thin-walled and hollow BMG earphones (Vit106)(c) Vit106 thin-walled BMG samples coated in different colors (d-f) biomedical implants fabricated using Vit105 BMGs
图8  块体非晶合金柔轮的制作过程，及DSC曲线和XRD谱[46](a) suction casting over brass inserts was used to create a cup from a Ti-based BMG(b) comparing the outer shape of the BMG cup to a machined steel flexspline(c) the minimum thickness of the cup using suction pressure was 2 mm. The wall was thinned via conventional machining(d) electrial discharge machining (EDM) was used to machine the teeth in the flexspline resulting in the final shape(e) attempts were made to cast the teeth of the flexspline using and EDMed mold (inset)(f) comparison of fully prototyped BMG flexspline with a steel version(g) an assembled, functioning strain wave gear (SWG) utilizing a BMG flexspline from Fig.8f(h) DSC traces of three BMG alloys cast into flexsplines. The lower two plots were prototyped using lab-grade material while the other plot is from a commercially cast part(i) XRD spectra of three BMG alloys cast into flexsplines, showing mostly amorphous microstructure even in fairly large parts
图9  商业化生产铸造的BMG柔轮[46](a, b) 50 mm and 20 mm diameter BMG flexsplines cast to near net shape from the alloy LM1b. After casting, the samples have been de-gated and holes machined into the bottom (c, d) inserting the BMG flexspline into a commercial steel outer spline (e) a fully assembled hybrid CSG-20 SWG with a BMG flexspline (f) a still from a video of the BMG flexspline being driven by the wave generator after submersion in liquid nitrogen (g, h) testing a fully assembled SWG with a BMG flexspline at liquid nitrogen temperatures (i) example of different BMG alloys cast into flexsplines. In total, four alloys were fabricated commercially, as shown (j) optimal micrographs from the larger 50 mm diameter flexspline comparing the steel part to the cast BMG part (k) images of 20 mm diameter flexsplines from machined steel, machined BMG and two cast BMG (l) a schematic showing approximate cost associated with machining steel flexsplines and casting > 1.0 × 104 BMG flexsplines. BMGs can be cast down to ~20 mm in diameter before thermoplastic forming techniques must be used to achieve micro-sized flexsplines. Multi-part casting is possible at small flexspline dimensions
图10  水冷铜坩埚熔炼与金属铜模具铸造的锆基块体非晶合金铸件(a) angle casting (b) Olympic icon casting
Casting moldingCast amorphous alloyAdvantageDisadvantage
technologycasting
Vacuum die castingThin-walled castings such asNear net shape casting, fastLimited casting thickness
phone shells, watch shells,speed, high efficiency(0.5-2.0 mm), low process
notebook computeryield, and there are tiny
accessories, etc.pores
Vacuum suction castingSimple cylinder, disk, ring,Stable filling, controllableNot suitable for casting of
or plate-like castingflow state of alloy meltcomplex shaped castings
Water-cooled copperSuitable for casting moldingAmorphous alloy melt does notThe low overheat of the alloy
crucible meltingof various shapes and sizesreact with the crucible, the alloymelt affects the filling ability
copper mold castingcastingsmelt is clean, and it does notand is prone to produce defects
affect the amorphous formingof insufficient pouring
ability
Ceramic or graphiteSuitable for casting moldingAlloy melt with a largeThe alloy melt reacts with the
crucible melting copperof various shapes and sizescontrollable range of overheat,crucible to reduce the amorphous
mold castingcastingsgood filling ability, easy toforming ability, and it is only
obtain complete castingssuitable for alloy systems with
strong forming ability
Phase transformationSuitable for casting moldingControllable cooling rateAdditional cooling medium is
refrigeration castingof various shapes and sizesrequired and is difficult to
castingsoperate
表2  不同铸造成形技术的适用性及优缺点
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