银包铝棒材立式连铸复合成形制备工艺
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摘要
以直径20 mm,包覆比50%的银包铝细棒为研究对象,通过有限元数值模拟以及相应的实验验证,得出了银包铝复合材料立式连铸复合成形工艺的边界条件.采用Pro CAST软件模拟了立式连铸成形过程,得出各工艺参数对连铸结果的影响规律,给出了可行的连铸工艺参数范围及工艺调控策略,以模拟结果为指导,制备出表面质量高、复合界面效果良好的银包铝复合棒材.实验结果表明,芯管长度、连铸速度对结果的影响最大,芯管长度影响了芯管出口处双金属的接触温度、接触时间,并直接改变了铝芯固液界面的相对位置.当芯管长度过短时,银铝界面反应较强烈,当芯管长度过长时,芯棒冷却强度大,芯部铝产生明显的冷隔.随着连铸速度的增大,银的固液界面到芯管出口距离逐渐减小,铝的固液界面距出口距离逐渐增大;铝液铸造温度升高,冷却水减少也会带来相似的作用.结果显示,芯管长度30 mm,速度37～67 mm·min-1,银的铸造温度1225～1325℃,铝的铸造温度800℃,冷却水流量约300 L·h-1是可行的银包铝连铸工艺.
Silver clad aluminum composite wire,which combines the high electrical conductivity of silver-coated metal,good welding performance,and low density,has wide application prospects in aerospace and other fields. The preparation of silver clad aluminum bars with high surface quality and good combination of interfaces is an important step in the preparation of silver clad aluminum wire with excellent performance. Continuous casting composite forming is a short,high-efficiency material-forming process,which provides methods for the preparation of silver clad aluminum. The boundary conditions of the vertical continuous casting process of silver clad aluminum composite rod that has a diameter of 20 mm and cladding ratio of 50% were established through finite element numerical simulation using the Pro CAST software and corresponding experiments. The effect of each process parameter on continuous composite casting was analyzed,based on which the optimized control method was obtained. A silver clad aluminum composite rod with high surface quality and excellent bonding interface was prepared on the basis of the simulation results. The length of the core tube and the speed of continuous casting are considered to be the most important factors affecting the formation process. The length of the core tube is assumed to affect the contact temperature and time of the aluminum liquid and silver tube at the end of the core tube,and result in the variation of the relative position of the solid-liquid interface of the aluminum. The interface reaction is severe when the core tube is too short. Conversely,significant cold separation occurs in aluminum because of the high cooling intensity when length of the core tube is too large. The actual casting temperature increases with the high continuous casting speed,which can be attributed to the reduction in the distance between solid-liquid interface and the outlet of the core tube for silver and the increase for aluminum. The increase in aluminum casting temperature and reduction in the flow rate of cooling water are found to have a similar effect to that of the increase in continuous casting speed. A series of optimized casting parameters was obtained in this study,i. e.,length of the core tube 30 mm,the casting speed is 37-67 mm·min~(-1),the casting temperature of silver is in the range between 1225 ℃ and 1325 ℃,casting temperature of aluminum is 800 ℃,and the flow rate of cooling water is 300 L·h~(-1).
Silver clad aluminum composite wire,which combines the high electrical conductivity of silver-coated metal,good welding performance,and low density,has wide application prospects in aerospace and other fields. The preparation of silver clad aluminum bars with high surface quality and good combination of interfaces is an important step in the preparation of silver clad aluminum wire with excellent performance. Continuous casting composite forming is a short,high-efficiency material-forming process,which provides methods for the preparation of silver clad aluminum. The boundary conditions of the vertical continuous casting process of silver clad aluminum composite rod that has a diameter of 20 mm and cladding ratio of 50% were established through finite element numerical simulation using the Pro CAST software and corresponding experiments. The effect of each process parameter on continuous composite casting was analyzed,based on which the optimized control method was obtained. A silver clad aluminum composite rod with high surface quality and excellent bonding interface was prepared on the basis of the simulation results. The length of the core tube and the speed of continuous casting are considered to be the most important factors affecting the formation process. The length of the core tube is assumed to affect the contact temperature and time of the aluminum liquid and silver tube at the end of the core tube,and result in the variation of the relative position of the solid-liquid interface of the aluminum. The interface reaction is severe when the core tube is too short. Conversely,significant cold separation occurs in aluminum because of the high cooling intensity when length of the core tube is too large. The actual casting temperature increases with the high continuous casting speed,which can be attributed to the reduction in the distance between solid-liquid interface and the outlet of the core tube for silver and the increase for aluminum. The increase in aluminum casting temperature and reduction in the flow rate of cooling water are found to have a similar effect to that of the increase in continuous casting speed. A series of optimized casting parameters was obtained in this study,i. e.,length of the core tube 30 mm,the casting speed is 37-67 mm·min~(-1),the casting temperature of silver is in the range between 1225 ℃ and 1325 ℃,casting temperature of aluminum is 800 ℃,and the flow rate of cooling water is 300 L·h~(-1).
引文
[1] Su S,Liu X H,Liu X F,et al. Fabrication processing of silver clad aluminum composite wire. Chin J Nonferrous Met,2007,17(12):1960(苏顺,刘新华,刘雪峰,等.银包铝复合丝材的制备工艺.中国有色金属学报,2007,17(12):1960)
[2] Zhang J,Wang B H,Chen G H,et al. Formation and growth of Cu-Al IMCs and their effect on electrical property of electroplated Cu/Al laminar composites. Trans Nonferrous Met Soc China,2016,26(12):3283
[3] Zu G Y,Li X B,Ding M M,et al. Investigating deformation behavior of asymmetrically rolled Cu/Al bimetal clad sheets. J Northeastern Univ Nat Sci,2011,32(5):675(祖国胤,李小兵,丁明明,等.异步轧制铜/铝双金属复合板变形行为的研究.东北大学学报(自然科学版),2011,32(5):675)
[4] Gulenc B. Investigation of interface properties and weldability of aluminum and copper plates by explosive welding method. Mater Des,2008,29(1):275
[5] Durgutlu A,Gülenc B,Findik F. Examination of copper/stainless steel joints formed by explosive welding. Mater Des,2005,26(6):497
[6] Raghukandan K. Analysis of the explosive cladding of cu--low carbon steel plates. J Mater Process Technol,2003,139(1-3):573
[7] Liu X Y,Ma X X,Fan H,et al. Preparation of Cu-Ag composite alloy bonding wire. Gold,2017,38(8):4(刘希云,马晓霞,范红,等. Cu-Ag复合合金丝的制备.黄金,2017,38(8):4)
[8] Xie S K,Chen J P,Wan J X,et al. Manufacture process and mechanical performance of CCA bimetal wire. Mater Rev,2008,22(5):83(谢世坤,陈京平,万建新,等.双金属铜包铝线的制备工艺与力学性能.材料导报,2008,22(5):83)
[9] Chen J M,Zhang X M,Deng Y L,et al. Analysis of causes of fracture of special long continuously cast stell during explosive cladding. World Nonferrous Met,2002(7):35(陈健美,张新明,邓运来,等.特长连铸钢坯爆炸焊接包覆发生断裂的原因分析.世界有色金属,2002(7):35)
[10] Dai Y K,Wang Y K,Liu P J,et al. Mechanism study of cladwelding and drawing method for copper clad aluminum wire metallurgical bonding. Electr Wire Cable,2003(6):1(戴雅康,王玉凯,刘丕家,等.包覆焊接--拉拔法铜包铝线冶金结合机理的探讨.电线电缆,2003(6):1)
[11] Xie J X. Developing situation and prospects of materials processing technologies. J Mech Eng,2003,39(9):29(谢建新.材料加工技术的发展现状与展望.机械工程学报,2003,39(9):29)
[12] Wu Y F,Liu X H,Xie J X,et al. Copper cladding aluminum composite materials with rectangle section fabricated by horizontal core-filling continuous casting. Chin J Nonferrous Met,2012,22(9):2500(吴永福,刘新华,谢建新,等.矩形断面铜包铝复合材料的水平连铸直接复合成形.中国有色金属学报,2012,22(9):2500)
[13] Zhang J Y,Zeng X Y,Han Y Q,et al. Formation mechanism of interface in copper cladding aluminum composites fabricated by core-filling continuous casting. Chin J Nonferrous Met,2014,24(11):2755(张建宇,曾祥勇,韩艳秋,等.充芯连铸铜包铝复合材料的界面形成机理.中国有色金属学报,2014,24(11):2755)
[14] Xue Z Y,Wu C J,Xie J X. Effects of processing variables on the surface quality of Cu-cladding Al rod in continuous casting with core-filling. Special Casting Nonferrous Alloys,2006,26(2):121(薛志勇,吴春京,谢建新.充芯连铸铜包铝棒坯工艺参数对表面质量的影响.特种铸造及有色合金,2006,26(2):121)
[15] Wu Y F,Liu X H,Xie J X. Interface of copper cladding aluminum composite materials with rectangle section fabricated by horizontal core-filling continuous casting and its evolvement in rolling process. Chin J Nonferrous Met,2013,23(1):191(吴永福,刘新华,谢建新.连铸直接成形矩形断面铜包铝复合材料界面及其在轧制中的变化.中国有色金属学报,2013,23(1):191)
[16] Zhang H A,Chen G. Fabrication of Cu/Al compound materials by solid-liquid bonding method and interface bonding mechanism. Chin J Nonferrous Met,2008,18(3):414(张红安,陈刚.铜/铝复合材料的固—液复合法制备及其界面结合机理.中国有色金属学报,2008,18(3):414)
[17] Li H,Long P,Niu Y S,et al. Fabrication of Al/Cu composite:theoretical and technological progresses. Mater Rev,2016,30(4):148(李慧,龙萍,牛永胜,等. Al/Cu复合材料制备中理论与工艺研究进展.材料导报,2016,30(4):148)
[18] Xie J X,Sun D Q,Wu C J,et al. Fabrication of bimetallic composite materials with duel-mold continuous casting technique. J Mater Eng,2000(4):38(谢建新,孙德勤,吴春京,等.双金属复合材料双结晶器连铸工艺研究.材料工程,2000(4):38)
[19] Su Y J,Liu X H,Wu Y F,et al. Microstructure and properties of copper cladding aluminum rod fabricated by horizontal core-filling continuous casting. Special Casting Nonferrous Alloys,2011,31(9):785(苏亚军,刘新华,吴永福,等.水平连铸直接复合成形铜包铝复合材料的组织与性能.特种铸造及有色合金,2011,31(9):785)
[20] Mei J,Liu X H,Xie J X. Solidification temperature field simulation of BFe10 cupronickel tube during heating-cooling combined mold continuous casting. Chin J Nonferrous Met,2012,22(5):1430(梅俊,刘新华,谢建新. BFe10白铜管材热冷组合铸型水平连铸凝固温度场模拟.中国有色金属学报,2012,22(5):1430)
[21] Liu X H,Fu X T,Fu H D,et al. Numerical simulation analysis of effects of processing parameters on forming process of vertical continuous core-filling casting for copper clad aluminum billets with large section. Chin J Nonferrous Met,2017,27(3):514(刘新华,付新彤,付华栋,等.大断面铜包铝棒坯立式连铸成形工艺参数对连铸复合过程影响的数值模拟.中国有色金属学报,2017,27(3):514)
[22] Ning Y T,Zhao H Z. Silver. Changsha:Central South University Press,2005(宁远涛,赵怀志.银.长沙:中南大学出版社,2005)
[23] Xue B. Engineering Thermodynamics. Xi'an:Shanxi Science&Technology Press,2005(薛兵.工程热力学.西安:陕西科学技术出版社,2005)
[24] Zhang X J,Liu X H,Wu Y F,et al. Simulation on temperature field for solidification process of horizontal core-filling continuous casting of copper clad aluminum bars. Foundry Eng,2013,37(3):10(张小军,刘新华,吴永福,等.铜包铝扁坯水平连铸直接复合成形过程温度场的数值模拟.铸造工程,2013,37(3):10)
[25] Li Y L. Engineering Thermodynamics and Heat Transfer. 2nd Ed. Beijing:China Communications Press,2013(李岳林.工程热力学与传热学. 2版.北京:人民交通出版社,2013)
[26] Zhang L W,Zhang Y,Zhang J Z,et al. Analysis on the macrostructure of 600 mm 35CrMo round steel billet produced by vertical continuous casting. J Univ Sci Technol Liaoning,2018,41(1):14(张连望,张羽,张佳正,等. 600 mm 35CrMo钢立式连铸圆坯宏观组织分析.辽宁科技大学学报,2018,41(1):14)
[27] Zhao Z G,Yan H C,Qiu S T,et al. Pilot processing ofΦ100mm billet of high speed steel W6Mo5Cr4V2 by vertical continuous casting. Special Steel,2015,36(1):41(赵志刚,颜慧成,仇圣桃,等.立式连铸高速钢W6Mo5Cr4V2Φ100 mm坯的工艺试验.特殊钢,2015,36(1):41)
[28] Qiao J S,Nie S C,Zhang H,et al. Microstructure and mechanical properties of interfaces of extruded cladding Mg--Al rods.Chin J Rare Met,2015,39(6):481(乔及森,聂书才,张涵,等.铝镁包覆挤压材料界面微观组织与力学性能研究.稀有金属,2015,39(6):481)
[2] Zhang J,Wang B H,Chen G H,et al. Formation and growth of Cu-Al IMCs and their effect on electrical property of electroplated Cu/Al laminar composites. Trans Nonferrous Met Soc China,2016,26(12):3283
[3] Zu G Y,Li X B,Ding M M,et al. Investigating deformation behavior of asymmetrically rolled Cu/Al bimetal clad sheets. J Northeastern Univ Nat Sci,2011,32(5):675(祖国胤,李小兵,丁明明,等.异步轧制铜/铝双金属复合板变形行为的研究.东北大学学报(自然科学版),2011,32(5):675)
[4] Gulenc B. Investigation of interface properties and weldability of aluminum and copper plates by explosive welding method. Mater Des,2008,29(1):275
[5] Durgutlu A,Gülenc B,Findik F. Examination of copper/stainless steel joints formed by explosive welding. Mater Des,2005,26(6):497
[6] Raghukandan K. Analysis of the explosive cladding of cu--low carbon steel plates. J Mater Process Technol,2003,139(1-3):573
[7] Liu X Y,Ma X X,Fan H,et al. Preparation of Cu-Ag composite alloy bonding wire. Gold,2017,38(8):4(刘希云,马晓霞,范红,等. Cu-Ag复合合金丝的制备.黄金,2017,38(8):4)
[8] Xie S K,Chen J P,Wan J X,et al. Manufacture process and mechanical performance of CCA bimetal wire. Mater Rev,2008,22(5):83(谢世坤,陈京平,万建新,等.双金属铜包铝线的制备工艺与力学性能.材料导报,2008,22(5):83)
[9] Chen J M,Zhang X M,Deng Y L,et al. Analysis of causes of fracture of special long continuously cast stell during explosive cladding. World Nonferrous Met,2002(7):35(陈健美,张新明,邓运来,等.特长连铸钢坯爆炸焊接包覆发生断裂的原因分析.世界有色金属,2002(7):35)
[10] Dai Y K,Wang Y K,Liu P J,et al. Mechanism study of cladwelding and drawing method for copper clad aluminum wire metallurgical bonding. Electr Wire Cable,2003(6):1(戴雅康,王玉凯,刘丕家,等.包覆焊接--拉拔法铜包铝线冶金结合机理的探讨.电线电缆,2003(6):1)
[11] Xie J X. Developing situation and prospects of materials processing technologies. J Mech Eng,2003,39(9):29(谢建新.材料加工技术的发展现状与展望.机械工程学报,2003,39(9):29)
[12] Wu Y F,Liu X H,Xie J X,et al. Copper cladding aluminum composite materials with rectangle section fabricated by horizontal core-filling continuous casting. Chin J Nonferrous Met,2012,22(9):2500(吴永福,刘新华,谢建新,等.矩形断面铜包铝复合材料的水平连铸直接复合成形.中国有色金属学报,2012,22(9):2500)
[13] Zhang J Y,Zeng X Y,Han Y Q,et al. Formation mechanism of interface in copper cladding aluminum composites fabricated by core-filling continuous casting. Chin J Nonferrous Met,2014,24(11):2755(张建宇,曾祥勇,韩艳秋,等.充芯连铸铜包铝复合材料的界面形成机理.中国有色金属学报,2014,24(11):2755)
[14] Xue Z Y,Wu C J,Xie J X. Effects of processing variables on the surface quality of Cu-cladding Al rod in continuous casting with core-filling. Special Casting Nonferrous Alloys,2006,26(2):121(薛志勇,吴春京,谢建新.充芯连铸铜包铝棒坯工艺参数对表面质量的影响.特种铸造及有色合金,2006,26(2):121)
[15] Wu Y F,Liu X H,Xie J X. Interface of copper cladding aluminum composite materials with rectangle section fabricated by horizontal core-filling continuous casting and its evolvement in rolling process. Chin J Nonferrous Met,2013,23(1):191(吴永福,刘新华,谢建新.连铸直接成形矩形断面铜包铝复合材料界面及其在轧制中的变化.中国有色金属学报,2013,23(1):191)
[16] Zhang H A,Chen G. Fabrication of Cu/Al compound materials by solid-liquid bonding method and interface bonding mechanism. Chin J Nonferrous Met,2008,18(3):414(张红安,陈刚.铜/铝复合材料的固—液复合法制备及其界面结合机理.中国有色金属学报,2008,18(3):414)
[17] Li H,Long P,Niu Y S,et al. Fabrication of Al/Cu composite:theoretical and technological progresses. Mater Rev,2016,30(4):148(李慧,龙萍,牛永胜,等. Al/Cu复合材料制备中理论与工艺研究进展.材料导报,2016,30(4):148)
[18] Xie J X,Sun D Q,Wu C J,et al. Fabrication of bimetallic composite materials with duel-mold continuous casting technique. J Mater Eng,2000(4):38(谢建新,孙德勤,吴春京,等.双金属复合材料双结晶器连铸工艺研究.材料工程,2000(4):38)
[19] Su Y J,Liu X H,Wu Y F,et al. Microstructure and properties of copper cladding aluminum rod fabricated by horizontal core-filling continuous casting. Special Casting Nonferrous Alloys,2011,31(9):785(苏亚军,刘新华,吴永福,等.水平连铸直接复合成形铜包铝复合材料的组织与性能.特种铸造及有色合金,2011,31(9):785)
[20] Mei J,Liu X H,Xie J X. Solidification temperature field simulation of BFe10 cupronickel tube during heating-cooling combined mold continuous casting. Chin J Nonferrous Met,2012,22(5):1430(梅俊,刘新华,谢建新. BFe10白铜管材热冷组合铸型水平连铸凝固温度场模拟.中国有色金属学报,2012,22(5):1430)
[21] Liu X H,Fu X T,Fu H D,et al. Numerical simulation analysis of effects of processing parameters on forming process of vertical continuous core-filling casting for copper clad aluminum billets with large section. Chin J Nonferrous Met,2017,27(3):514(刘新华,付新彤,付华栋,等.大断面铜包铝棒坯立式连铸成形工艺参数对连铸复合过程影响的数值模拟.中国有色金属学报,2017,27(3):514)
[22] Ning Y T,Zhao H Z. Silver. Changsha:Central South University Press,2005(宁远涛,赵怀志.银.长沙:中南大学出版社,2005)
[23] Xue B. Engineering Thermodynamics. Xi'an:Shanxi Science&Technology Press,2005(薛兵.工程热力学.西安:陕西科学技术出版社,2005)
[24] Zhang X J,Liu X H,Wu Y F,et al. Simulation on temperature field for solidification process of horizontal core-filling continuous casting of copper clad aluminum bars. Foundry Eng,2013,37(3):10(张小军,刘新华,吴永福,等.铜包铝扁坯水平连铸直接复合成形过程温度场的数值模拟.铸造工程,2013,37(3):10)
[25] Li Y L. Engineering Thermodynamics and Heat Transfer. 2nd Ed. Beijing:China Communications Press,2013(李岳林.工程热力学与传热学. 2版.北京:人民交通出版社,2013)
[26] Zhang L W,Zhang Y,Zhang J Z,et al. Analysis on the macrostructure of 600 mm 35CrMo round steel billet produced by vertical continuous casting. J Univ Sci Technol Liaoning,2018,41(1):14(张连望,张羽,张佳正,等. 600 mm 35CrMo钢立式连铸圆坯宏观组织分析.辽宁科技大学学报,2018,41(1):14)
[27] Zhao Z G,Yan H C,Qiu S T,et al. Pilot processing ofΦ100mm billet of high speed steel W6Mo5Cr4V2 by vertical continuous casting. Special Steel,2015,36(1):41(赵志刚,颜慧成,仇圣桃,等.立式连铸高速钢W6Mo5Cr4V2Φ100 mm坯的工艺试验.特殊钢,2015,36(1):41)
[28] Qiao J S,Nie S C,Zhang H,et al. Microstructure and mechanical properties of interfaces of extruded cladding Mg--Al rods.Chin J Rare Met,2015,39(6):481(乔及森,聂书才,张涵,等.铝镁包覆挤压材料界面微观组织与力学性能研究.稀有金属,2015,39(6):481)
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