CN113667910A - Research method for continuous pull rod preparation based on A390 aluminum alloy - Google Patents
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
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- C—CHEMISTRY; METALLURGY
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- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
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Abstract
The invention belongs to the technical field of metal alloy pull rod casting application, and particularly discloses a research method for preparation of an A390 aluminum alloy continuous pull rod, which comprises the following steps of 1, phase diagram research, microstructure uniformity control detection, a heat treatment state A390 alloy microstructure composed of a primary Si phase and (alpha + Si) eutectic, wherein the morphology, the size and the distribution state of the Si phase have great influence on the final performance of a part, and two parts made of A390 alloy are selected for alloy microstructure detection. And 2, a numerical simulation model is used for researching the distribution of the cooling rate of the A390 aluminum alloy round ingot DC semi-continuous casting process on the cross section of the ingot by a numerical simulation method, and the obtained solidification cooling rate distribution of the ingot from the surface to the center is the research on the relation between the cooling rate and the deterioration. The invention has the beneficial effects that: numerical simulation is adopted to analyze the cooling rate distribution of the A390 aluminum alloy round ingot, the deterioration effect under different cooling rates is researched, and the improvement of the casting process is provided.
Description
Technical Field
The invention belongs to the technical field of metal alloy pull rod casting application, and particularly relates to a research method for preparation of an A390 aluminum alloy continuous pull rod.
Background
With the coming of the new energy automobile era, the demand for light weight of automobile parts is increasing due to the bottleneck of mobile energy storage development.
The aluminum-based hypereutectic alloy has the characteristics of mechanical property, low density, high wear resistance and the like which are comparable to those of the iron-based alloy, and is gradually used for replacing the traditional iron-based alloy to prepare automobile parts so as to meet the market demand of the overall light weight of automobiles. Compared with the conventional casting, the casting is lighter than the common iron casting, the structural segregation is eliminated through the nodular treatment of silicon, the uniform structure and fine crystal grains are obtained through the solid solution treatment, the mechanical property and the thermal process property of the alloy can be obviously improved, and the casting is widely applied to the automobile industry, particularly the application of light-weight automobiles and new energy automobiles.
The high-silicon hypereutectic aluminum alloy has the advantages of small thermal expansion coefficient, high volume stability, high strength, wear resistance, corrosion resistance and the like, and is a preferred material for replacing key parts of engine systems, air conditioning systems and braking systems of vehicles such as automobiles and the like. The A390 aluminum alloy is a high-silicon hypereutectic type aluminum alloy with excellent casting performance, and a round ingot is prepared by a DC (direct chill, DC) semi-continuous casting process, and a swash plate and other parts working under a high-temperature condition are manufactured through the procedures of extrusion, forging and the like. The high-silicon aluminum alloy has large solidification latent heat and wide crystallization range, so that the structure of the cast ingot primary silicon is easily thick, the appearance is poor, the structure is uneven, the preparation difficulty is high, and the development of the field of high-performance new energy automobiles is seriously restricted.
Typical structures of A390 aluminum alloys include primary alpha-Al, Al-Si eutectic structures, and small amounts of Mg2Si, CuAl2, and other complex hybrid metallurgical phases containing Fe and Ni. The morphology, size and distribution of eutectic silicon are important factors affecting the mechanical properties of the alloy, especially the elongation. The unmodified eutectic silicon is in a thick lath shape or a long needle shape, and the modified ideal eutectic silicon tissue is in a fine and uniform fibrous shape or a granular shape. The metamorphism of the eutectic silicon can obviously improve the mechanical property, the wear resistance, the electrical property, the heat-conducting property and the like of the A390 aluminum alloy. Therefore, modification treatment is an important process in the production of A390 aluminum alloy.
The method widely adopted in the current industrial production is to add the alterant into the melt to carry out the modification treatment on the A390 aluminum alloy, because the method of adding the alterant has the advantages of stable modification effect, strong operability, no need of additionally adding equipment and the like, and is suitable for industrial production. Commonly used alterants are sodium (Na), strontium (Sr), antimony (Sb), calcium (Ca), barium (Ba) and rare earth alterants, which have the alteration effect on eutectic silicon and are closely related to the solidification cooling rate. Under the condition of the same addition amount of the alterant, the higher the cooling rate is, the finer the eutectic silicon structure is, the better the modification effect is, and the sensibility of each modification element to the cooling rate is obviously different. Due to the influence of the cooling rate on the deterioration of the eutectic silicon, it is necessary to study the cooling rate of the ingot during casting in order to obtain a high-quality ingot with good deterioration effect and uniform structure. Especially when DC semi-continuous casting is used for producing large-size ingots, the cooling rates at different positions of the cross section of the ingot have large difference. .
Therefore, based on the problems, the invention provides a research method for preparing the continuous pull rod based on the A390 aluminum alloy.
Disclosure of Invention
The purpose of the invention is as follows: the invention aims to provide a research method for preparing an A390 aluminum alloy continuous pull rod, which analyzes the cooling rate distribution of an A390 aluminum alloy round ingot by numerical simulation and researches the deterioration effect under different cooling rates.
The technical scheme is as follows: the invention relates to a research method based on preparation of an A390 aluminum alloy continuous pull rod, which comprises the following steps of 1, phase diagram research, microstructure uniformity control detection, wherein a heat treatment state A390 alloy microstructure consists of a primary Si phase and (alpha + Si) eutectic, wherein the morphology, the size and the distribution state of the Si phase can generate great influence on the final performance of a part, and the part made of two A390 alloys is selected for alloy microstructure detection. And 2, a numerical simulation model is used for researching the distribution of the cooling rate of the A390 aluminum alloy round ingot DC semi-continuous casting process on the cross section of the ingot by a numerical simulation method, and the obtained solidification cooling rate distribution of the ingot from the surface to the center is the research on the relation between the cooling rate and the deterioration.
In the technical scheme, in the step 1, a Japanese-produced A390 part and a domestic A390 alloy trial-made part are selected for detection.
In the step 2, the solid-phase ratio fs of the model is 0.3 as a boundary point for distinguishing a slurry region from a paste region, the temperature at this time is defined as a solidification lap temperature Tcoh, the temperature above the solidification lap temperature Tcoh is the slurry region, and the temperature below the solidification lap temperature fs is the paste region; according to the strong coupling relation between a flow field and a temperature field in the DC semi-continuous casting process, a DC semi-continuous casting unsteady flow field temperature field coupling model is established by adopting Fluent software, two phases are divided into a slurry area (slurry zone) and a mushy area (mushy zone), the material behavior in the slurry area is closer to that of a fluid, and the material behavior in the mushy area is closer to that of a solid; the cooling rate is the average cooling rate in the interval from the solidification and lapping temperature Tcoh of the alloy to the solidus temperature Ts, and Rc-delta T-Tcoh-Ts; Δ t tco-ts; in the formula: rc is the cooling rate, K/s; Δ T is the temperature difference, K; Δ t is the time difference, s; tcoh is the solidification lap temperature, K; ts is solidus temperature, K; tcoh is the time for the temperature to fall to the solidification lap temperature, s; ts is the time for the temperature to fall to the solidus temperature.
Compared with the prior art, the research method based on the A390 aluminum alloy continuous pull rod preparation has the beneficial effects that: numerical simulation is adopted to analyze the cooling rate distribution of the A390 aluminum alloy round ingot, the deterioration effect under different cooling rates is researched, and a casting process improvement suggestion is proposed.
Drawings
FIG. 1 is a schematic representation of the alloy microstructure of a part made of two A390 alloys (conventional casting method);
FIG. 2 is a schematic illustration of a semi-solid ingot;
FIG. 3 is a schematic diagram of the main boundary conditions of the inventive research method based on the preparation of A390 aluminum alloy continuous pull rod;
FIG. 4 is a schematic diagram showing the heat transfer coefficient setting of the secondary cooling water;
FIGS. 5, 6 and 7 are schematic illustrations of parts cast using the present method compared to parts made of the Japanese A390 alloy;
FIG. 8 is a hardness analysis comparison.
Detailed Description
The invention is further elucidated with reference to the drawings and the embodiments.
The invention relates to a research method based on preparation of an A390 aluminum alloy continuous pull rod, which comprises the following steps of 1, phase diagram research, microstructure uniformity control detection, wherein a microstructure of the A390 alloy in a heat treatment state consists of a primary Si phase and (alpha + Si) eutectic, wherein the morphology, the size and the distribution state of the Si phase have great influence on the final performance of a part, and the part made of two A390 alloys is selected for alloy microstructure detection (as shown in figures 1, 5, 6 and 7). And 2, a numerical simulation model is used for researching the distribution of the cooling rate of the A390 aluminum alloy round ingot DC semi-continuous casting process (shown in figure 2) on the cross section of the ingot by a numerical simulation method, and the obtained solidification cooling rate distribution of the ingot from the surface to the center is the research on the relation between the cooling rate and the deterioration.
According to the invention, the preferable research method based on the preparation of the A390 aluminum alloy continuous pull rod is that in the step 1, a Japanese-produced A390 part and a domestic A390 alloy trial-made part are selected for detection.
Preferably, in the step 2, the solid phase ratio fs of the model is 0.3 as a dividing point for dividing the slurry region from the paste region, the temperature at this time is defined as the solidification lap temperature Tcoh, the temperature above the solidification lap temperature Tcoh is the slurry region, and the temperature below the solidification lap temperature Tcoh is the paste region; according to the strong coupling relation between a flow field and a temperature field in the DC semi-continuous casting process, a DC semi-continuous casting unsteady flow field temperature field coupling model is established by adopting Fluent software, two phases are divided into a slurry area (slurry zone) and a mushy area (mushy zone), the material behavior in the slurry area is closer to that of a fluid, and the material behavior in the mushy area is closer to that of a solid; the cooling rate is the average cooling rate in the interval from the solidification and lapping temperature Tcoh of the alloy to the solidus temperature Ts, and Rc-delta T-Tcoh-Ts; Δ t tco-ts; in the formula: rc is the cooling rate, K/s; Δ T is the temperature difference, K; Δ t is the time difference, s; tcoh is the solidification lap temperature, K; ts is solidus temperature, K; tcoh is the time for the temperature to fall to the solidification lap temperature, s; ts is the time for the temperature to fall to the solidus temperature.
Examples
The main boundary conditions of the research method based on the A390 aluminum alloy continuous pull rod preparation of the invention are as follows (as shown in figure 3):
1: a symmetric boundary;
2: the inlet boundary is set as the inlet speed (unit: m/s) and the pouring temperature (unit: K) of the aluminum liquid;
3: the heat dissipating capacity of the hot top part is small and can be ignored relative to the heat exchanging capacity of the water-cooled mould in the hot top area,
is arranged as an adiabatic boundary;
4: a cold heat exchange region for setting the heat exchange coefficient h of the interface between the primary cooling water region mold and the ingot
The bit is W (m 2. K) -1,
in a cold heat exchange area, the heat exchange coefficient h between the cast ingot and the mold changes along with the change of the solid phase ratio f, when fs is 0, the contact between a liquid phase and the mold is good, and at the moment, the heat exchange coefficient is the highest value; when the solid phase rate fs reaches 100 percent, namely the solid phase rate fs is completely solidified, an air gap is generated between the cast ingot and the mold due to solidification and shrinkage, the heat exchange coefficient between the cast ingot and the mold is reduced to the lowest value, and h1 is 3000 x (1-fs) +50 xfs; 5: and the secondary cooling heat exchange area is provided with a water spraying cooling heat exchange coefficient h between secondary cooling water and the casting, the unit is W (m 2K) -1, the outlet boundary is provided with the moving speed of the base, namely the casting speed, and the comprehensive heat exchange coefficient h3 of the base and the environment. In two cold heat transfer areas, between the ingot casting temperature interval of difference, the heat transfer mechanism between secondary cooling water and the ingot casting is different, and the boiling heat transfer mechanism of high temperature interval plays a role, and the heat transfer of low temperature interval convection current heat transfer mechanism plays a role, and the heat transfer of this border is simplified and is handled, sets for comprehensive heat transfer coefficient: h is a constant value of 500W (m 2K) -1, and the heat exchange coefficient of the secondary cooling water is set (as shown in FIG. 4);
results and analysis: under the same DC semi-continuous casting process conditions, the high cooling rate of more than 4K/s can still be maintained in the range of 60mm from the surface of the ingot along with the increase of the diameter of the ingot, but the cooling rate of the core of the ingot is obviously reduced.
The lowest cooling rate of the phi 120mm ingot at the center of the ingot is also as high as 4.1K/s, the 300mm ingot is reduced to 1.9K/s, and the phi 500mm ingot is further reduced to 1.0K/s.
As the diameter of the cast ingot is larger, the isotherm of the liquidus temperature Tl, the lap joint temperature Tcoh and the solidus temperature Ts is larger when the heat transfer resistance of the heat inside to the surface through the solidified metal is larger, so that the liquid cavity morphology is described. As can be seen from the liquid pocket morphology, as the ingot diameter increases, the liquid pocket gradually deepens, the slope of the isotherm of the solidus temperature Ts increases, and the distance between the isotherms of the liquidus temperature Tl, the lap joint temperature Tcoh, and the solidus temperature Ts increases, indicating that the solidification time increases.
The size of the phi 120mm ingot is relatively small, the cooling rate from the surface of the ingot to the center of the ingot is not greatly different, and the cooling rate from the surface of the ingot to the center of the ingot is only reduced from 4.7K/s to 4.1K/s. The cooling rates of the ingots with the diameter of 300mm and the diameter of 500mm are consistent in distribution rule on the cross section. The cooling rate is rapidly increased from the surface of the cast ingot to the subsurface layer, the cooling rate reaches the maximum value at the subsurface layer, and the cooling rate is gradually reduced along with the increase of the distance from the subsurface layer to the core part, because the part of metal from the surface of the cast ingot to the subsurface layer is solidified in the die area to form a blank shell, and particularly because the cooling water is indirectly acted by the die, an air gap is rapidly formed between the blank shell and the die due to solidification shrinkage after the surface layer is solidified, and the cooling strength is not large; the secondary cooling water directly acts on the ingot blank shell along with the downward movement of the ingot, the cooling intensity is the maximum at the moment, and the corresponding solidification front position is the ingot subsurface layer with the highest cooling rate; from the subsurface layer of the ingot to the center of the ingot, along with the increase of the diameter of the ingot, the heat inside the ingot needs to be transmitted to the surface through the heat conduction of the solidified shell on the surface layer, and then is radiated through surface cooling water, so that the cooling intensity of the metal inside is reduced along with the increase of the distance from the surface.
Under the same DC semi-continuous casting process conditions, the cooling rate of the core of the ingot is obviously reduced while the cooling rate of the surface of the ingot is still kept to be higher than 4K/s within 60mm from the surface along with the increase of the diameter of the ingot. The lowest cooling rate of 120mm phi ingots at the center of the ingot was also as high as 4.1K/s, with a 300mm phi ingot being reduced to 1.9K/s and a 500mm phi ingot being further reduced to 1.0K/s. The cooling rate inside the ingot is lower because the larger the diameter of the ingot, the greater the thermal resistance to heat transfer from the inside to the surface through the solidified metal.
The simulated bar drawing speed is 100mm/min, when the diameter of the bar is between 50mm and 500mm, the influence of the heat exchange of water on the alloy microstructure is small, and the influence of the heat exchange of water on the alloy microstructure is obvious when the diameter of the bar exceeds 500 mm; when the diameter of the rod of the pull rod is between 50mm and 120mm, the downward pulling speed and the casting temperature have obvious influence on the alloy microstructure, namely, the good alloy microstructure (primary Si phase and (alpha + Si) eutectic) is obtained and is increased by 30 to 40 ℃ compared with the preset temperature.
As shown in fig. 5, 6 and 7, the parts cast by the method are compared with parts made of the japanese a390 alloy. As shown in fig. 8, which is a comparison of hardness analysis, (1) in the semi-continuous casting process of a390 a aluminum alloy round ingot, the cooling rate is in a whole descending trend from the surface to the center of the ingot, and the cooling rate of the central part of the ingot is remarkably reduced along with the increase of the size of the ingot; (2) sr is used as an eutectic silicon modifier, the cooling rate has obvious influence on the modification effect, and the Sr modification can obtain higher eutectic silicon modification effect under the condition that the cooling rate is higher than 2K/s; (3) in the research range, the technological parameters which have the greatest influence on the cooling rate distribution of the phi 50 mm-phi 120mm ingot are casting speed, secondary pouring temperature and minimum influence on cooling strength, but the casting speed only influences the cooling rate distribution within a distance less than R/2 from the surface of the ingot, the influence on the interior of the ingot is very limited, and the cooling rate of the core of the ingot cannot be obviously improved.
The foregoing is only a preferred embodiment of this invention and it should be noted that modifications can be made by those skilled in the art without departing from the principle of the invention and these modifications should also be considered as the protection scope of the invention.
Claims (3)
1. A390 aluminum alloy continuous pull rod preparation-based research method is characterized in that: comprises the following steps
In the step of,
step 1, phase diagram research, microstructure uniformity control detection, wherein a microstructure of the A390 alloy in a heat treatment state consists of a primary Si phase and (alpha + Si) eutectic, wherein the morphology, the size and the distribution state of the Si phase have great influence on the final performance of the part, and the part made of two A390 alloys is selected for alloy microstructure detection;
and 2, a numerical simulation model is used for researching the distribution of the cooling rate of the A390 aluminum alloy round ingot DC semi-continuous casting process on the cross section of the ingot by a numerical simulation method, and the obtained solidification cooling rate distribution of the ingot from the surface to the center is the research on the relation between the cooling rate and the deterioration.
2. The research method for the preparation of the A390 aluminum alloy continuous pull rod according to claim 1, wherein the research method comprises the following steps: in the step 1, a Japanese A390 part and a domestic A390 alloy trial part are selected for detection.
3. The research method for the preparation of the A390 aluminum alloy continuous pull rod according to claim 1, wherein the research method comprises the following steps: in the step 2, the solid phase rate fs of the model is 0.3 as a dividing point for dividing the slurry region and the paste region, the temperature at this time is defined as the solidification lap temperature Tcoh, the temperature above is the slurry region, and the temperature below is the paste region;
according to the strong coupling relation between a flow field and a temperature field in the DC semi-continuous casting process, a DC semi-continuous casting unsteady flow field temperature field coupling model is established by adopting Fluent software, two phases are divided into a slurry area (slurry zone) and a mushy area (mushy zone), the material behavior in the slurry area is closer to that of a fluid, and the material behavior in the mushy area is closer to that of a solid;
the cooling rate is the average cooling rate in the interval from the solidification lap temperature Tcoh of the alloy to the solidus temperature Ts,
Rc＝ΔT＝Tcoh-Ts；
Δt tcoh-ts；
in the formula: rc is the cooling rate, K/s; Δ T is the temperature difference, K; Δ t is the time difference, s; tcoh is the solidification lap temperature, K; ts is solidus temperature, K; tcoh is the time for the temperature to fall to the solidification lap temperature, s; ts is the time for the temperature to fall to the solidus temperature.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN115921801A (en) * | 2023-03-14 | 2023-04-07 | 中铝材料应用研究院有限公司 | Method for modifying eutectic structure of large-size 4000-series aluminum alloy cast ingot |
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2021
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| CN115921801A (en) * | 2023-03-14 | 2023-04-07 | 中铝材料应用研究院有限公司 | Method for modifying eutectic structure of large-size 4000-series aluminum alloy cast ingot |
| CN115921801B (en) * | 2023-03-14 | 2023-10-10 | 中铝材料应用研究院有限公司 | Method for modifying eutectic structure of large-size 4000-series aluminum alloy cast ingot |
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