挤压铸造SiC_w/Al-18Si复合材料凝固行为的研究
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摘要
金属基复合材料的凝固过程影响其组织结构,特别是界面结合状态。采用液相法制备金属基复合材料的过程中,基体金属在增强相存在情况下的凝固过程是影响其组织结构的关键。复合材料的凝固行为至今还没有一个统一的认识,因此复合材料组分和凝固条件对其凝固行为的影响需要进一步研究。本文以典型的铝硅合金为研究对象,研究了增强相、变质剂、冷却速度和冷却压力对复合材料凝固过程中形核、长大和组织结构的影响。
利用纯铝和单晶硅配制Al-18Si合金,采用Al-10Sr合金作为变质剂进行变质处理。以变质前后的Al-18Si合金作为基体,以碳化硅晶须(SiC_w)作为增强相,采用挤压铸造法制备体积分数分别为15%、20%和25%的复合材料(SiC_w/Al-18Si)。采用金相显微镜、扫描电子显微镜(SEM)、透射电子显微镜(TEM)、能谱分析(EDS)、差示扫描量热法(DSC)等分析手段,研究了压铸态、重熔态和定向凝固状态下复合材料的显微组织,分析了复合材料的初晶硅和铝硅共晶相的形核与长大过程。
组织观察和理论计算表明,SiC_w作为SiC_w/Al-18Si复合材料中初晶硅相的形核衬底。初晶硅相沿着SiC_w表面生长,初晶硅相与SiC_w的界面结合较好。通过计算,(211)SiC∥(110)Si之间的面错配度为6.18%,(110)SiC∥(111)Si之间的面错配度为7.65%。SiC_w含量、变质剂Sr、重熔温度、冷却速度、冷却压力等不改变复合材料基体合金中初晶硅相的形核位置。
随着SiC_w体积分数不断增加,压铸态SiC_w/Al-18Si复合材料的初晶硅、铝硅共晶相的尺寸逐渐变小,分布趋于均匀。SiC_w对初晶硅相的影响大于对铝硅共晶相的影响。初晶硅凝固起始温度和峰值温度随SiC_w含量的增加而降低,且初晶硅的数量逐渐减少。以未变质铝硅合金为基体的复合材料的初晶硅凝固起始温度和峰值温度随SiC_w含量变化的幅度大于以变质铝硅合金为基体的复合材料相应的温度变化幅度。
变质剂Sr的加入使SiC_w/Al-18Si复合材料中的初晶硅由片状或雪花状转变为块状或颗粒状,平均尺寸缩小为原来的1/10~1/6。变质剂Sr使复合材料中铝硅共晶组织由粗条状、短棒状且成堆密集状态,转变为细短条状或颗粒状且均匀弥散分布,共晶组织尺寸分布范围缩小。变质剂Sr使复合材料初晶硅凝固起始温度和峰值温度降低,初晶硅数量减少。
变质剂Sr与SiC_w协同作用时,基体合金的细化效果更加明显。变质剂Sr的加入使由SiC_w形成的小块熔融区对基体合金凝固组织的限制作用减弱。同时SiC_w减弱了变质剂Sr对复合材料凝固温度、过冷度以及初晶硅相分布的影响。
随着冷却速度的增加,SiC_w/Al-18Si复合材料中初晶硅明显被细化,形貌由树枝状和雪花状逐渐转变为团絮状和颗粒状。当冷却速度为100~1000℃/min时,初晶硅呈颗粒状和棒状的混合态。随着冷却速度的增加,颗粒状的初晶硅数量减少,棒状初晶硅数量增加、长径比逐渐增大。当冷却速度达到3570℃/min时,初晶硅均呈现长棒状。冷却速度对铝硅共晶组织影响不大。随着冷却速度的增加,SiC_w/Al-18Si复合材料中初晶硅和铝硅共晶相的形核过冷度增大,凝固潜热逐渐增加。变质后复合材料的凝固潜热大于未变质的复合材料的凝固潜热。随着SiC_w体积百分含量的逐渐增加,复合材料凝固潜热逐渐变小。
冷却压力改变了SiC_w/Al-18Si复合材料中初晶硅和铝硅共晶相的大小。压力为0~30MPa时,初晶硅和铝硅共晶相的尺寸随着压力增加不断减小;当压力为30~50MPa时,随着压力的逐渐增加,初晶硅和铝硅共晶相的尺寸逐渐变大。随着压力的增加,SiC_w含量对复合材料铝硅共晶组织的影响逐渐减弱。压力对变质剂Sr作用的发挥没有影响。
The microstructure of metal matrix composites (MMCs), especially the interfacial condition, was affected by their solidification processing. Solidification processing of matrix alloys with the presence of reinforcement is crucial in determining the matrix microstructure during the solid state processing of MMCs. However, at present the solidification theory of MMCs is not consistent. More studies need to be carried out in the effect of matrix alloys, cooling conditions on the MMCs solidification. In this paper, the influence of the reinforcement, modifier, cooling rate and cooling pressure on the nucleation, growth and microstructure will be investigated based on the common Al-Si matrix alloys.
The Al-18Si alloy was prepared by high purity aluminum and single crystal silicon and was modified by Al-10Sr. The SiC whisker reinforced Al-18Si alloy matrix composites (SiC_w/Al-18Si composites) were prepared by squeeze casting method. The alloys used are Al-Si alloy and Al-Si alloy with Sr addition, respectively. The volume fractions of SiC whisker (SiC_w) are 15%, 20% and 25%. The microstructure of the composite matrix alloys was studied by optical microscope, Scanning Electron Microscopy (SEM), Transmission Electron Microscopy (TEM), Energy Dispersive Spectrometer (EDS) etc. The nucleation and growth behavior were also analyzed.
The microstructure observation and theoretical calculation show that the primary Si nucleates on the SiC_w surface. SiC_w is surrounded by Si phase. The interfacial bonding between Si phase and SiC_w is strong. Calculations show that the mismatch between (211)SiC and (110)Si is 6.18% and the mismatch between (110)SiC and (111)Si is 7.65%. SiC_w content, Sr modifier, remelting temperature, cooling rate and cooling pressure do not affect the nucleation site of primary Si.
With the increase of SiC_w volume fraction, the size of primary Si and Al-Si eutectic of MMCs prepared by squeeze casting decreases, distribution of these phases change from non-uniform to uniform state. The amplitude of primary Si size is greater than that of Al-Si eutectic. The onset and peak temperatures of primary Si decrease with increasing of whisker content and the quantity of primary Si decreases as well. The change of the onset and peak temperatures of primary Si in the SiC_w/Al-18Si composites is greater than that of the SiC_w/Al-18Si-Sr composites.
The morphology of primary Si in SiC_w/Al-18Si-Sr composites changes from snow-like to platelet, even to particle shape. The size of primary Si reduces to 1/10~1/6 of the original size. The morphology of Al-Si eutectic varies from rodlike to nodular, and distribution shifts from close-packed to diffusion. The size distribution of Al-Si eutectic reduces. Sr make the onset and peak temperature of primary Si decreases and quantity of primary Si reduces in the SiC_w/Al-18Si composites.
Synergism of SiC_w and Sr refines the primary Si and Al-Si eutectic deeply. Sr addition weakens the restriction of SiC_w on the solidification. SiC_w weaken the effect of Sr on the solidification temperature, undercooling and distributing of primary Si.
The primary Si of the composites is refined and distribute evenly with the increasing of cooling rate. The primary Si of the composites changes from tree-like to granular. When the cooling rate is 100~1000℃/min, some primary Si are granular, others are rodlike. With the increasing of cooling rate, the number granular Si reduced gradually and the aspect ratio of the rodlike Si increased. When the cooling rate is 3570℃/min, the aspect ratio of rodlike Si increases. The cooling rate has no effect on the Al-Si eutectic morphology. The undercooling of primary Si and Al-Si eutectic in SiC_w/Al-18Si composites increases with increasing of cooling rate. The latent heat increases with increasing of cooling rate. The latent heat of SiC_w/Al-18Si-Sr composites is greater than that of SiC_w/Al-18Si composites. The latent heat of composites with lower volume fraction of SiC_w is larger than that of composites with higher volume fraction SiC_w.
The size of primary Si changes with cooling pressure. When the pressure is 0~30MPa, the size of primary Si becomes smaller with the increasing of pressure. When the pressure is 30~50MPa, the size of primary Si changes to larger with the increasing of pressure. The changes of Al-Si eutectic with pressure is the same as primary Si. With the increase of pressure, the effect of SiC_w on the size of Al-Si eutectic is weakened gradually, but the role of Sr does not change yet.
利用纯铝和单晶硅配制Al-18Si合金,采用Al-10Sr合金作为变质剂进行变质处理。以变质前后的Al-18Si合金作为基体,以碳化硅晶须(SiC_w)作为增强相,采用挤压铸造法制备体积分数分别为15%、20%和25%的复合材料(SiC_w/Al-18Si)。采用金相显微镜、扫描电子显微镜(SEM)、透射电子显微镜(TEM)、能谱分析(EDS)、差示扫描量热法(DSC)等分析手段,研究了压铸态、重熔态和定向凝固状态下复合材料的显微组织,分析了复合材料的初晶硅和铝硅共晶相的形核与长大过程。
组织观察和理论计算表明,SiC_w作为SiC_w/Al-18Si复合材料中初晶硅相的形核衬底。初晶硅相沿着SiC_w表面生长,初晶硅相与SiC_w的界面结合较好。通过计算,(211)SiC∥(110)Si之间的面错配度为6.18%,(110)SiC∥(111)Si之间的面错配度为7.65%。SiC_w含量、变质剂Sr、重熔温度、冷却速度、冷却压力等不改变复合材料基体合金中初晶硅相的形核位置。
随着SiC_w体积分数不断增加,压铸态SiC_w/Al-18Si复合材料的初晶硅、铝硅共晶相的尺寸逐渐变小,分布趋于均匀。SiC_w对初晶硅相的影响大于对铝硅共晶相的影响。初晶硅凝固起始温度和峰值温度随SiC_w含量的增加而降低,且初晶硅的数量逐渐减少。以未变质铝硅合金为基体的复合材料的初晶硅凝固起始温度和峰值温度随SiC_w含量变化的幅度大于以变质铝硅合金为基体的复合材料相应的温度变化幅度。
变质剂Sr的加入使SiC_w/Al-18Si复合材料中的初晶硅由片状或雪花状转变为块状或颗粒状,平均尺寸缩小为原来的1/10~1/6。变质剂Sr使复合材料中铝硅共晶组织由粗条状、短棒状且成堆密集状态,转变为细短条状或颗粒状且均匀弥散分布,共晶组织尺寸分布范围缩小。变质剂Sr使复合材料初晶硅凝固起始温度和峰值温度降低,初晶硅数量减少。
变质剂Sr与SiC_w协同作用时,基体合金的细化效果更加明显。变质剂Sr的加入使由SiC_w形成的小块熔融区对基体合金凝固组织的限制作用减弱。同时SiC_w减弱了变质剂Sr对复合材料凝固温度、过冷度以及初晶硅相分布的影响。
随着冷却速度的增加,SiC_w/Al-18Si复合材料中初晶硅明显被细化,形貌由树枝状和雪花状逐渐转变为团絮状和颗粒状。当冷却速度为100~1000℃/min时,初晶硅呈颗粒状和棒状的混合态。随着冷却速度的增加,颗粒状的初晶硅数量减少,棒状初晶硅数量增加、长径比逐渐增大。当冷却速度达到3570℃/min时,初晶硅均呈现长棒状。冷却速度对铝硅共晶组织影响不大。随着冷却速度的增加,SiC_w/Al-18Si复合材料中初晶硅和铝硅共晶相的形核过冷度增大,凝固潜热逐渐增加。变质后复合材料的凝固潜热大于未变质的复合材料的凝固潜热。随着SiC_w体积百分含量的逐渐增加,复合材料凝固潜热逐渐变小。
冷却压力改变了SiC_w/Al-18Si复合材料中初晶硅和铝硅共晶相的大小。压力为0~30MPa时,初晶硅和铝硅共晶相的尺寸随着压力增加不断减小;当压力为30~50MPa时,随着压力的逐渐增加,初晶硅和铝硅共晶相的尺寸逐渐变大。随着压力的增加,SiC_w含量对复合材料铝硅共晶组织的影响逐渐减弱。压力对变质剂Sr作用的发挥没有影响。
The microstructure of metal matrix composites (MMCs), especially the interfacial condition, was affected by their solidification processing. Solidification processing of matrix alloys with the presence of reinforcement is crucial in determining the matrix microstructure during the solid state processing of MMCs. However, at present the solidification theory of MMCs is not consistent. More studies need to be carried out in the effect of matrix alloys, cooling conditions on the MMCs solidification. In this paper, the influence of the reinforcement, modifier, cooling rate and cooling pressure on the nucleation, growth and microstructure will be investigated based on the common Al-Si matrix alloys.
The Al-18Si alloy was prepared by high purity aluminum and single crystal silicon and was modified by Al-10Sr. The SiC whisker reinforced Al-18Si alloy matrix composites (SiC_w/Al-18Si composites) were prepared by squeeze casting method. The alloys used are Al-Si alloy and Al-Si alloy with Sr addition, respectively. The volume fractions of SiC whisker (SiC_w) are 15%, 20% and 25%. The microstructure of the composite matrix alloys was studied by optical microscope, Scanning Electron Microscopy (SEM), Transmission Electron Microscopy (TEM), Energy Dispersive Spectrometer (EDS) etc. The nucleation and growth behavior were also analyzed.
The microstructure observation and theoretical calculation show that the primary Si nucleates on the SiC_w surface. SiC_w is surrounded by Si phase. The interfacial bonding between Si phase and SiC_w is strong. Calculations show that the mismatch between (211)SiC and (110)Si is 6.18% and the mismatch between (110)SiC and (111)Si is 7.65%. SiC_w content, Sr modifier, remelting temperature, cooling rate and cooling pressure do not affect the nucleation site of primary Si.
With the increase of SiC_w volume fraction, the size of primary Si and Al-Si eutectic of MMCs prepared by squeeze casting decreases, distribution of these phases change from non-uniform to uniform state. The amplitude of primary Si size is greater than that of Al-Si eutectic. The onset and peak temperatures of primary Si decrease with increasing of whisker content and the quantity of primary Si decreases as well. The change of the onset and peak temperatures of primary Si in the SiC_w/Al-18Si composites is greater than that of the SiC_w/Al-18Si-Sr composites.
The morphology of primary Si in SiC_w/Al-18Si-Sr composites changes from snow-like to platelet, even to particle shape. The size of primary Si reduces to 1/10~1/6 of the original size. The morphology of Al-Si eutectic varies from rodlike to nodular, and distribution shifts from close-packed to diffusion. The size distribution of Al-Si eutectic reduces. Sr make the onset and peak temperature of primary Si decreases and quantity of primary Si reduces in the SiC_w/Al-18Si composites.
Synergism of SiC_w and Sr refines the primary Si and Al-Si eutectic deeply. Sr addition weakens the restriction of SiC_w on the solidification. SiC_w weaken the effect of Sr on the solidification temperature, undercooling and distributing of primary Si.
The primary Si of the composites is refined and distribute evenly with the increasing of cooling rate. The primary Si of the composites changes from tree-like to granular. When the cooling rate is 100~1000℃/min, some primary Si are granular, others are rodlike. With the increasing of cooling rate, the number granular Si reduced gradually and the aspect ratio of the rodlike Si increased. When the cooling rate is 3570℃/min, the aspect ratio of rodlike Si increases. The cooling rate has no effect on the Al-Si eutectic morphology. The undercooling of primary Si and Al-Si eutectic in SiC_w/Al-18Si composites increases with increasing of cooling rate. The latent heat increases with increasing of cooling rate. The latent heat of SiC_w/Al-18Si-Sr composites is greater than that of SiC_w/Al-18Si composites. The latent heat of composites with lower volume fraction of SiC_w is larger than that of composites with higher volume fraction SiC_w.
The size of primary Si changes with cooling pressure. When the pressure is 0~30MPa, the size of primary Si becomes smaller with the increasing of pressure. When the pressure is 30~50MPa, the size of primary Si changes to larger with the increasing of pressure. The changes of Al-Si eutectic with pressure is the same as primary Si. With the increase of pressure, the effect of SiC_w on the size of Al-Si eutectic is weakened gradually, but the role of Sr does not change yet.
引文
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