喷射成形柱状坯生长及传热过程研究
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摘要
喷射成形是二十世纪六十年代发展起来的一种新型的金属成形技术,它既克服了传统铸造过程中存在的晶粒粗大、偏析严重的缺点,又摒弃了粉末冶金工序繁多,氧化严重等不足,同时又兼有粉末冶金技术的优点,是一种极具竞争力的快速凝固工艺。但是影响喷射成形过程的参数很多,直接进行实验研究工作量大、成本高、周期长,采用计算机数值模拟技术对喷射成形过程进行工艺优化可有效的解决这些问题。
本文建立了喷射成形柱状坯生长和传热过程的数学模型。针对宝钢喷射成形沉积室设备利用沉积坯生长过程数学模型模拟了不同工艺参数下沉积坯的生长过程,研究结果表明:采用直喷方式进行单喷嘴喷射成形,当喷嘴喷射夹角为0°时,不能形成柱状沉积坯,喷嘴喷射夹角为20°和35°时,能够形成柱状沉积坯;采用直喷方式进行双喷嘴喷射成形时,均能形成柱状沉积坯,但20°和35°的组合最稳定。采用斜喷方式进行单喷嘴、双喷嘴喷射成形时均能生成柱状沉积坯,但当初始时刻沉积器距喷嘴距离小时,易发生严重的过喷,金属收得率明显下降。
利用沉积坯传热过程数学模型模拟了两组不同工艺参数下得到沉积坯的传热过程,研究结果表明:稳定生长条件下得到的柱状沉积坯除底部区域外各处温度比较均匀,且温度随时间变化趋势相似,因而可得到整体性能良好的沉积坯;非稳定生长条件下得到的沉积坯除中心区域外其余各处温度相差较大,顶部和底部冷却速度明显大于中心部分,因而得到沉积坯整体性能较差。
Spray forming is a new-style technique for metal forming developing from 1960’s. It has overcome the shortcomings of coarse grains and serious segregation in traditional casting process, and get rid of various working procedures and serious oxidation in powder metallurgy process, but also has the advantage of powder metallurgy technology, is a highly competitive rapid solidification process. But because of there are a great many of parameters in spray forming process, study this process through experiment directly is workload, high cost and long cycle. Using computer numerical simulation technology can solve this problem effectively.
The shape evolution and heat transfer model of rod-billet was established in this paper, And use the shape evolution model modeling the shape evolution of rod-billet in different parameters according to the deposition equipment of Baosteel , the following conclusions can be drawn: Use direct injection and single nozzle in spray forming, when the injection angle of nozzle is 0°,can’t form rod-billet, when the injection angle is 20°and 35°can form rod-billet; use direct injection and double nozzle in spray forming, can form rod-billet all, and the combination of nozzles of 20°and 35°is most instability. Use incline injection and single or double nozzle can form rod-billet all, but when the distance from the nozzle to the substrate is small, metal received rate will decreased significantly.
The deposition billet heat transfer process in two different parameters are simulated using heat transfer model established,the following conclusions can be drawn: The temperature of the rod-billet formed by stable growth condition is even everywhere except at the bottom area, and the trend of temperature change to time change is similar, thus the billet has good performance; the temperature of the billet formed by unstable growth condition is difference except center area, and the cooling rate of top area and bottom area is greater than center area, thus the billet has poor performance.
本文建立了喷射成形柱状坯生长和传热过程的数学模型。针对宝钢喷射成形沉积室设备利用沉积坯生长过程数学模型模拟了不同工艺参数下沉积坯的生长过程,研究结果表明:采用直喷方式进行单喷嘴喷射成形,当喷嘴喷射夹角为0°时,不能形成柱状沉积坯,喷嘴喷射夹角为20°和35°时,能够形成柱状沉积坯;采用直喷方式进行双喷嘴喷射成形时,均能形成柱状沉积坯,但20°和35°的组合最稳定。采用斜喷方式进行单喷嘴、双喷嘴喷射成形时均能生成柱状沉积坯,但当初始时刻沉积器距喷嘴距离小时,易发生严重的过喷,金属收得率明显下降。
利用沉积坯传热过程数学模型模拟了两组不同工艺参数下得到沉积坯的传热过程,研究结果表明:稳定生长条件下得到的柱状沉积坯除底部区域外各处温度比较均匀,且温度随时间变化趋势相似,因而可得到整体性能良好的沉积坯;非稳定生长条件下得到的沉积坯除中心区域外其余各处温度相差较大,顶部和底部冷却速度明显大于中心部分,因而得到沉积坯整体性能较差。
Spray forming is a new-style technique for metal forming developing from 1960’s. It has overcome the shortcomings of coarse grains and serious segregation in traditional casting process, and get rid of various working procedures and serious oxidation in powder metallurgy process, but also has the advantage of powder metallurgy technology, is a highly competitive rapid solidification process. But because of there are a great many of parameters in spray forming process, study this process through experiment directly is workload, high cost and long cycle. Using computer numerical simulation technology can solve this problem effectively.
The shape evolution and heat transfer model of rod-billet was established in this paper, And use the shape evolution model modeling the shape evolution of rod-billet in different parameters according to the deposition equipment of Baosteel , the following conclusions can be drawn: Use direct injection and single nozzle in spray forming, when the injection angle of nozzle is 0°,can’t form rod-billet, when the injection angle is 20°and 35°can form rod-billet; use direct injection and double nozzle in spray forming, can form rod-billet all, and the combination of nozzles of 20°and 35°is most instability. Use incline injection and single or double nozzle can form rod-billet all, but when the distance from the nozzle to the substrate is small, metal received rate will decreased significantly.
The deposition billet heat transfer process in two different parameters are simulated using heat transfer model established,the following conclusions can be drawn: The temperature of the rod-billet formed by stable growth condition is even everywhere except at the bottom area, and the trend of temperature change to time change is similar, thus the billet has good performance; the temperature of the billet formed by unstable growth condition is difference except center area, and the cooling rate of top area and bottom area is greater than center area, thus the billet has poor performance.
引文
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[3]杨留栓,杨根仓,周尧和.喷雾沉积快速凝固技术的发展与展望[J].材料科学与工程.1994,12(2):29-33.
[4]王文明,潘复生,Lu Yun,曾苏民.喷射成形技术的发展概况及展望[J].重庆大学学报.2004,27(1):101-106.
[5]杨卯生,钟雪友.金属喷射成形原理及其应用.包头钢铁学院学报.2000,19 (2):175-180.
[6] Leatham A.G, Lawely A. The osprey process: principles and placations[J].The International Journal of Powder Metallurgy,1993,29(4),321-329.
[7] Lavemia E.J, Grant N.J. Spray deposition of metals[J]. A review materials Science andEngineering,1998,98,381-384.
[8] Brooks R.G, Moore C, Leatham A.G. The osprey process[J].Powder Metallurgy,1999,(2),100-120.
[9]张永昌.金属喷射成形的进展[J].粉末冶金工业. 2001,11(6):17-22.
[10]孙剑飞,沈军,贾均,李庆春.喷射成形一种先进的金属热成形技术[J].材料开发与应用. 1999,14(2):42-45.
[11]李阳,杨滨.金属雾化喷射沉积技术.云南大学学报(自然科学版).2002,24(1A):228-235.
[12]霍光,谢明,邓德国,符世继,陈力,陈江.喷射成形制造工艺[J].金属成形工艺.2002,20(6):41-42.
[13]杨卯生,钟雪友.金属喷射成形原理及其应用.包头钢铁学院学报.2000,19 (2):175-180.
[14]崔成松,李庆春,沈军,等.喷射沉积快速凝固材料的研究及应用概况[J].材料导报,1996.10(1):21-26.
[15]王军,严彪,徐政.喷射成形技术的发展应用[J].上海有色金属.2002,23(3):133-138.
[16]吴成义,张丽英.粉体成形力学原理[M].冶金工业出版社.2003
[17]美H.A.库恩A.劳利编著任崇信译,粉末冶金工艺新技术及其分析[M].1982
[18]陈文哲,彭开萍,钱匡武.离心喷射沉积钛铝金属间化合物的研究[J].福建工程学院学报.2003,1(1):9-14.
[19] Yu Fuxiao, Cui Jianzhong, S.Ranganathan, E.S.Dwarakadasa. Fundamental differences between spray forming and other semisolid processes[J]. Materials Science and Engineering. 2001,304(306):621-626.
[20]王建强.喷射成形技术的研究发展及展望[J]. 21世纪青年学者论坛. 2000,22(1):62-65.
[21]康福伟,孙剑飞,沈军,李庆春.喷射成形工艺的发展及应用[J].稀有金属. 2004,28(2):402-407.
[22]熊柏青.喷射成形技术的产业化现状及应用发展方向[J].稀有金属.1999,3(6):425-430.
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