离心铸造Al-60Si合金的数值模拟与实验研究

高硅铝合金由于具有较低的热膨胀系数、低密度、导热性能好等良好的物理化学性能,已成为最具有潜力的金属基电子封装材料。然而,高硅铝合金常规制备方法,如粉末冶金等,制备出的合金存在致密度低、合金内部容易产生气孔、组织粗大等问题,且成本较高。本文以Al-60Si超高硅铝合金作为研究对象,采用ProCast数值模拟的方法,计算了不同浇注温度、离心转速等工艺条件下,合金凝固过程中温度场和流场等分布规律,确定最优工艺参数为离心转速800 r/min,浇注温度1200℃,浇注速度16.5 mm/s;并制备了高性能的细晶Al-60Si合金环形铸件,发现铸环外层、中层和内层分布不同尺寸的初生硅相,外层部分大多数是块状初生硅相;中层及内层部分是粗大的板条状初生硅相;通过表征热膨胀系数发现,离心后的Al-60Si热膨胀系数整体小,其中铸环外层区域热膨胀系数最小,性能较好。

Effect of Ti on microstructure and properties of electromagnetic stirred Al-18wt.%Mg_(2)Si alloy

By adding different amounts of Ti into the electromagnetic stirred Al-18wt.%Mg_(2)Si alloy,the effect of Ti element on the microstructure and mechanical properties of the alloy was studied.The experimental results show that the microstructure is refined after modification with Ti,which is related to the heterogeneous nucleation of TiAl_(3) particles on theα-Al matrix.With the increase of Ti content and holding time after stirring,the primary Mg_(2)Si phase is refined firstly and then coarsened,and correspondingly,the mechanical properties of the alloy show a trend of increasing at first and then decreasing.When the addition of Ti is 0.5wt.%and the holding time is about 20 min,the refinement effect of primary Mg_(2)Si phase is the most significant and the mechanical properties of the alloy are optimal.

Investigation of the Laser Powder Bed Fusion Process of Ti-6.5Al-3.5Mo-1.5Zr-0.3Si Alloy

Laser powder bed fusion(LPBF)is an advanced manufacturing technology;however,inappropriate LPBF process parameters may cause printing defects in materials.In the present work,the LPBF process of Ti-6.5Al-3.5Mo-1.5Zr-0.3Si alloy was investigated by a two-step optimization approach.Subsequently,heat transfer and liquid flow behaviors during LPBF were simulated by a well-tested phenomenological model,and the defect formation mechanisms in the as-fabricated alloy were discussed.The optimized process parameters for LPBF were detected as laser power changed from 195 W to 210 W,with scanning speed of 1250 mm/s.The LPBF process was divided into a laser irradiation stage,a spreading flow stage,and a solidification stage.The morphologies and defects of deposited tracks were affected by liquid flow behavior caused by rapid cooling rates.The findings of this research can provide valuable support for printing defect-free metal components.

Effects of Yttrium Ion on Formation Mechanism of ZrO_2-Y_2O_3 Ceramic Coatings Formed by Plasma Electrolytic Oxidation on Al-12Si Alloy

ZrO2-Y2O3 ceramic coating was produced by plasma electrolytic oxidation （PEO） on ZAlSil2Cu3Ni2 alloy. The microstructure and phase composition of the coating were investigated by SEM and XRD.： The results show that adding an appropriate amount of yttrium ion can improve the growing rate of ceramic coating at different oxidation stages and decrease arc voltage. The thickness of ZrO2-Y2O3 coating is 16 μn thicker than that of ZrO2 coating and the maximum oxidation rate improves by 0.6 μm/min. In addition, the arc voltage decreases from 227 to 172 V. It can be seen that the rate of oxidation firstly increases to some extent and then decreases with the content of yttrium ion increasing. The growth rate reaches the maximum while the content of yttrium ion is 0.05 g-L-1The maximum thickness is 90 μm.Compared to ZrO2 coating, the micropores of ZrO2-Y2O3 coating are less and the ceramic layer is repeatedly deposited by ZrO2 and Y2O3 ceramic particles. Meanwhile, the binding force between coating and substrate is better and the coating is uniform and compact. The ceramic layer is mainly composed of c-Y0.15Zr0.85O1.93□0.07, m-ZrO2, α-Al2O3, ,γ-Al2O3 and Y2O3. It is indicated that ZrO2 has beert fully stabilized by yttrium ion through the formation of solid solution.

Microstructure and Thermal-protective Property of CPED Coating with ZrO2 Nanoparticles Addition on Al-12Si Alloy

A novel thermal-protective coating has been successfully prepared by CPED process on a cast Al-12%Si alloy with the addition of ZrO2 nano-particles in the electrolyte. The microstructures and phase composition of the coatings were analyzed by SEM and XRD, and the heat insulation performance and the thermal shock resistance of the coatings were investigated. With ZrO2 nanoparticles addition, the cathode plasma discharge on the coating surface is more obvious than that without ZrO2 nanoparticles addition, the coating is more uniform and compact, and the thickness of the coating increases. Furthermore, the content of Zr and Y elements increases and the degree of crystallization of the coating is more complete. The formation of the solid solution of yttrium stabilized zirconia is promoted by cathode plasma discharge. In addition, the thermal insulation temperature increases as ZrO2 nano-particles are added to the electrolyte. After 1 000 cycles of thermal shock, there was no cracking in the coating surface layer, which indicated that the CPED coating with ZrO2 nanoparticles addition possessed a good thermal shock resistance.

Efects of Al-Mn-Ti-P-Cu master alloy on microstructure and properties of Al-25Si alloy

To obtain a higher microstructural refining efficiency,and improve the properties and processing ability of hypereutectic Al-25Si alloy,a new environmentally friendly Al-20.6Mn-12Ti-0.9P-6.1Cu(by wt.%)master alloy was fabricated;and its modification and strengthening mechanisms on the Al-25Si alloy were studied.The mechanical properties of the unmodified,modified and heat treated alloys were investigated.Results show that the optimal addition amount of the Al-20.6Mn-12Ti-0.9P-6.1Cu master alloy is 4wt.%.In this case,primary Si and eutectic Si as well asα-Al phase were clearly refined,and this refining effect shows an excellent long residual action as it can be heat-retained for at least 5 h.After being T6 heat treated,the morphology of primary and eutectic Si in the Al-25Si alloys with the addition of 4wt.%Al-20.6Mn-12Ti-0.9P-6.1Cu alloy changes into particles and short rods.The average grain size of the primary and eutectic Si decreases from 250μm(unmodified)to 13.83μm and 35μm(unmodified)to 7μm;theα-Al becomes obviously finer and the distribution of Si phases tends to be uniform and dispersed.Meanwhile,the tensile properties are improved obviously;the tensile strengths at room temperature and 300 oC reach 241 MPa and127 MPa,increased by 153.7%and 67.1%,respectively.In addition,the tensile fracture mechanism changes from brittle fracture for the alloy without modification to ductile fracture after modification.Modifying the morphology of Si phase and strengthening the matrix can effectively block the initiation and propagation of cracks,thus improving the strength of the hypereutectic Al-25Si alloy.

DIFFUSION OF La IN LIQUID Al-Si ALLOY

The diffusion coefficients of lanthnum in liquid Al-Si alloy have been measured successfully by the anodic chronopotentiometry. At 973K, the diffusion coefficient of lanthanum (D_(La(Al-Si))) in liquid Al-5.2wt-%Si alloy equals (0.91±0.01)×10^(-5) cm^2 s^(-1) . In the range of temperatures 953-1053K, the relationship between the diffusion coefficient and the tem- perature is represented by 1gD_(La(Al-Si))=-1.78×10^(-3)-4909/T. The activation energy is Q=94.00kJ·mol^(-1). Using the diffusion data of lanthanum and strontium, the effect of the diffusion of the modifier on the incubation period of modification and cooling rate has been discussed.

Effect of La addition on microstructure and mechanical properties of hypoeutectic Al-7Si aluminum alloy

The effect of La addition(0,0.1,0.2,0.4,wt.%)on the microstructure,tensile properties and fracture behavior of Al-7Si alloy was investigated systematically.It is found that the La appears in the Al-7Si alloy in the form of Al4La and Al2Si2La phases.La addition can refine the secondary dendrite arm spacing(SDAS)and eutectic Si particles,which are decreased by 7.9%and 7%,respectively,with the optimal La content of 0.1wt.%.Because when 0.1wt.%La is added,a relatively higher nucleation undercooling of 37.47℃ is observed.Higher undercooling degree suggests that nucleation is accelerated and subsequent growth is restrained.After T6 heat treatment,compared with the without La,the ultimate tensile strength of the alloy with 0.1wt.%La is enhanced by 5.2%from 333 MPa to 350.2 MPa and the elongation increases by 73%from 7.37%to 12.75%,correspondingly.The fracture mode evolves from the ductile-brittle mixed fracture to ductile fracture mode.However,when La element content reaches a certain value of 0.4wt.%,serious segregation takes place during the solidification process.The formed brittle phases deteriorate the tensile properties of the alloy and the fracture mode of Al-7Si-0.2/0.4 La changes to mixed ductile-brittle fracture mode.

Characteristics of Faigue Crack Initiation in Ti-5Al-4Sn-2Zr-1Mo-0.7Nd-0.25Si Alloy

The characteristics of fatigue crack initiation in Ti-5AI-4Sn-2Zr1Mo-O.7Nd-O.25Si alloy wereStudied. Two modes Of fatigue crack initiation were found. The Nd-rich phase particles displaybetter resistance to fatigue crack initiation than the matrix at lower stress.

机械合金化Fe_(60)Si_(40)体系的XAFS研究

利用XAFS技术研究Fe60 Si40 二元合金体系中Fe原子周围配位环境随球磨时间的变化 .结果表明 ,球磨过程中 ,首先发生晶态α Fe和Si的晶格较大的畸变和颗粒破碎 ,致使Fe和Si原子近邻配位的无序度增大 ,进而Si原子通过活化的界面向Fe晶格扩散 ,形成亚稳的Fe3 Si和Fe5 Si3 替位固溶体 .

Optimization of processing parameters for preparation of Al-3Ti-1B grain refiner

Al-3Ti-1B master alloys were prepared at different processing parameters by the reaction of halide salts,and the grain refining response of Al-7Si alloy was investigated with Al-3Ti-B master alloy.The microstructure of master alloy and its grain refining effect on Al-7Si alloy were investigated by means of OM,XRD and SEM.Experimental results show that,the size of Al3Ti particles presented in Al-3Ti-1B master alloys increases with the increase of reaction temperature and decreases with the increase of cooling rate.The grain refining efficiency of Al-3Ti-1B master alloy on Al-7Si alloy is mainly attributed to heterogeneous nucleation of Al3Ti particles,and the morphology ofα(Al)changes from coarse dendritic to fine equiaxed.As a result,Al-3Ti-1B master alloy is prepared by permanent mold,and holding at 800 ℃for 30min,which has better grain refining performance on Al-7Si alloy.

Effects of cerium and phosphorus on microstructures and properties of hypereutectic Al-21%Si alloy

The influences of P and rare earth （RE） complex modifier on the microstructure and mechanical properties of hypereutectic Al-21%Si alloy were studied. The ingots were made by metal mold casting and the proportion of Ce＋P ingredient was different. The result showed that the size of grains could be refined obviously by the Ce＋P modifier and the effect of phosphorus was more intensive The primary silicon crystal was refined, while the needle-like eutectic silicon was turned fibrous or short. The alloy mechanical prop- erties had the best performance when 0.08% P and 0.6% Ce were added. The modification of primary silicon grains mainly depended on the heterogeneous nucleation mechanism, and the metamorphic mechanism of eutectic silicon was explained by adsorbing-twirming theory. The strengthening mechanism of experimental alloy was also discussed. The σb, 20 ℃ increases from 236.2 to 287.6 MPa and σb, 300 ℃ increases from 142.5 to 210 MPa.

Grain growth behavior of Ti-6.5Al-3.5Mo-1.5Zr-0.3Si alloy during isothermal β heat treatments

Isothermal β heat treatments of Ti-6.5 Al-3.5 Mo-1.5 Zr-0.3 Si alloy were performed at the temperature of1040-1240 ℃ to examine the influence of heating conditions on grain growth of the alloy. The results show that the grain size increases with heating temperature and holding time increasing. Rapid β grain growth of the alloy takes place at the temperature of over 1140 ℃. The grain growth kinetics for the alloy follows the classical isothermal grain growth law.The growth time exponent(n) of 0.5651 and activation energy(Q) of 129.6 kJ mol-1 are determined. Finally, in order to determine the grain size under different heating conditions,the grain growth model of the alloy was established.

Influences of residual stress and micro-deformation on microstructures and mechanical properties for Ti-6.5Al-3.5Mo-1.5Zr-0.3Si alloy produced by laser powder bed fusion

Laser powder bed fusion(LPBF)yields unique advantages during the fabrication of titanium alloys.In the present work,Ti-6.5 Al-3.5 Mo-1.5 Zr-0.3 Si alloy specimens with excellent mechanical performances were fabricated by LPBF.The as-built specimens displayed relatively high strength and ductility under modest volume energy densities(VEDs),whereas they manifested high strength with low ductility under high VEDs.To investigate the key reason of this phenomenon,the specimens were designed with two VEDs ranges of 60 J/mm^(3) and 85 J/mm^(3).Special attention was paid to the influences of residual stress and micro-deformation on microstructures and mechanical properties for the first time.The results indicated that the residual stresses and relative density of the 60 J/mm^(3) range specimens were higher than that of the 85 J/mm3 range specimens.Dislocation multiplication and dislocation movement promoted by the residual stress were hindered by the initialα’phase grain boundary(prior-α’GB),leading to the formation ofα’metastable structures.The mean tensile strength and elongation of the 60 J/mm^(3) range specimens were 1248.1 MPa and 12.3%,respectively,whereas the corresponding values for the 85 J/mm^(3) range specimens were 1405.3 MPa,5.0%,respectively.During deformation,the strength and ductility of the specimens were first improved by lamellar structures generated from prior-α’phases,and then effectively enhanced by the interaction between the{10–12}twins and dislocations.However,pores significantly reduced the ductility;hence,high VED specimens with large twins and numerous large pores increased the strength and reduce the ductility.

In Situ Investigation of Si-Poisoning Effect in Al-Cu-Si Alloys Inoculated by Al-5Ti-1B

In situ synchrotron X-radiography was carried out on Al-13 Cu and Al-13 Cu-7 Si alloys with and without addition of Al-5 Ti-1 B master alloy.The effects of Si content on grain growth and the solute-suppressed nucleation zone(SSNZ)were quantitatively studied.The average grain size can be refined to 164μm of Al-13 Cu alloy inoculated by Al-5 Ti-1B.After addition of 7%Si content,a large number of TiB 2 sites in the melt lost the inoculating ability due to"Si poisoning."The radius of the dendrite tip curvature of Al-13 Cu is more than two times as large as that of Al-13 Cu-7 Si.The sharper tip is able to disperse the solute more effectively and thus grains can grow more rapidly.This causes that the dendrite arm growth rate with addition of 7%Si solute is about 2.6 times that of no Si addition.In addition,the solute enrichment in the SSNZ of Al-13 Cu is faster,and the area change of SSNZ is slower than that of Al-13 Cu-7 Si.Thus more nucleation sites in the SSNZ cannot be activated with addition of Si.This study will shed light on the understanding of Si poisoning in casting Al-Cu-Si alloys.

Modification Mechanism and Uniaxial Fatigue Performances of A356.2 Alloy Treated by Al-Sr-La Composite Refinement-Modification Agent

Modification mechanism and uniaxial fatigue properties of A356.2 alloy treated by Al-6Sr-7La and traditional Al-5Ti-1B/Al-10Sr(hereinafter refers to traditional treated alloy) were investigated by constant stress amplitude method. Microstructure, dislocation and Si twinning of the alloys were studied by thermal analysis, scanning electron microscopy(SEM) and transmission electron microscopy(TEM). The results showed that Al-6Sr-7La possesses better refining and modification effect than Al-5Ti-1B/Al-10Sr. Meanwhile, fatigue properties of the alloy treated by Al-6Sr-7La are higher than traditional treated alloy, and this is mainly owing to that Al-6Sr-7La treated alloy has more twins in eutectic Si and lower twin spacing. In addition, higher density of nanophases formed on twin faces and La-rich clusters appear at multiple twin intersections. Stacking faults and entrapped nanophases appeared on growing Si twin faces. Impurity induced twinning(IIT) mechanism and twin plane re-entrant edge(TPRE) mechanism are valid for eutectic Si which are important for mechanical optimization of A356.2 alloy.