4045／3003铝合金包覆铸造工艺的数值模拟研究

Study on Numerical Simulation of 4045/3003 Aluminium Alloy Cladding Casting Process

采用数值模拟和实验研究相结合的方法,研究了φ140 mm×φ110 mm的4045/3003铝合金包覆铸造过程中分流方式、铸造温度、铸造速度对温度场、流场及凝固过程的影响规律。结果表明:密集不均匀分流方式可最大化的使芯材支撑层四周温度分布和熔体流速趋于均匀一致,复合面上边缘温差在5℃内;3003铝合金铸造温度从720℃提高到760℃对整个温度场几乎没有影响,但在适当的温度范围较高的浇注温度有利于提高支撑层表面光滑度和铸锭表面质量;铸造速度过慢会出现卡锭现象,铸造速度过快会导致漏铝,因此铸造速度应保持在100 mm/min左右,以保证试验顺利进行。模拟结果可为进一步优化包覆铸造工艺和工业化提供理论基础。

The effects of split-flow way, casting temperature and casting speed on temperature field, flow field and solidification process during the casting process of 4045/3003 cladding ingots with section of φ4140mm×φ110mm were studied by using the method of numerical simulation combined with experiments. The results show that concentrated uneven split-flow way could make the temperature and flow rate of melt around the supporting layer uniform, and the temperature difference of the upper edge on composite surface is less than 5 ℃. When the casting temperature of 3003 aluminum alloy increases from 720℃ to 760 ℃, the temperature field changes scarcely, but in a reasonable range, higher casting temperature contributes to improving the smoothness of supporting layer and the quality of cladding ingots. A too high or too low casting speed would lead to locking and remelting, respectively. Therefore, the reasonable casting speed is about 100mm/min to ensure that the experiment goes smoothly. Simulation results could provide theoretical foundation for optimizing further cladding casting process and industrialization.