基于体积平均法模拟铸锭凝固过程的可靠性分析

The reliability analysis of using the volume averaging method to simulate the solidification process in a ingot

采用欧拉方法和体积平均思想,建立了以液相为主相、等轴晶和柱状晶视为两类不同第二相的三相模型,耦合凝固过程质量、动量、能量、溶质的守恒方程和晶粒的传输方程.以Al-4.7 wt.%Cu二元合金铸锭为例,模拟了合金铸锭二维的流场、温度场、溶质场、柱状晶向等轴晶转变过程以及等轴晶的沉积过程,并将模拟的铸锭组织和偏析结果与实验所得结果对比.温度场、流场和组织的模拟结果与理论基本一致,但由于模型没有考虑收缩以及浇注时的强迫对流,导致铸锭外层的偏析模拟值比实测值低,内层的模拟值比实测值高.所以收缩和逆偏析在模拟中是不可忽略的,这也是本文模型的改进方向.另外在所得模拟结果的基础上分析了体积平均法计算铸锭凝固过程的优点和不足之处.

Adopting the Euler and the volume averaging methods, a three-phase mathematical model with parent melt as the primary phase, columnar dendrites and equiaxed grains as two different secondary phases is developed, and the coupled macroscopic mass, momentum, energy and species conservation equations are obtained separately. Taking the Al-4.7 wt%Cu binary alloy ingots for example, the flow field, temperature field, solute field, columnar-to-equiaxed-transition and grain sedimentation in two-dimension are simulated, and the simulated result of ingot and macrosegregation result are compared with their experimental values. The simulation results of temperature field, flow field and structure are basically consistent with the theoretical results, but the result of solute field shows that the simulated values is lower than the measured value on the edge, this is because the model does not take the shrinkage and forced convection into account, and the inner results is higher than the results on edge. The shrinkage and inverse segregation therefore should not be neglected. This model are still necessarily improved. Besides, based on the analysis of simulation results, the advantages and the disadvantages of the volume averaging method to simulate the solidification in a ingot are evaluated.