ZK系列镁合金高应变速率锻造工艺及机理的研究
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摘要
镁合金是最轻的金属结构材料,具有比强度和比刚度高、导热性和阻尼减振性能好、电磁屏蔽性能和机加工性能优异等优点,被誉为“二十一世纪最具发展前景的绿色工程材料”。尤其是锻造镁合金,由于其优异的静态和动态强度,可在航空航天、汽车等领域大幅减轻设备的自重,进而实现节能减排的目的。但由于镁合金锻造温度区间窄、对应变速率敏感,锻造成形困难,极大地制约了镁合金锻件的广泛应用。因此,开发一种有效的锻造工艺制备高性能镁合金锻件具有重要的理论意义和工程应用价值。本文以ZK(Mg-Zn-Zr)系镁合金为研究对象,通过高应变速率变形诱发孪生再结晶,从根本上提高合金的可锻性,并结合多向锻造细化晶粒、软化织构的特点,提出了高应变速率多向锻造工艺,围绕锻造工艺和合金成分对锻坯组织和力学性能的影响开展了镁合金高应变速率锻造的研究。
1、基于变形温度和应变速率在镁合金锻造过程中的重要作用,开展了ZK系镁合金热压缩模拟的研究,分析了变形温度和应变速率对合金显微组织和流变行为的影响规律,验证了镁合金高应变速率变形的可行性,探讨了高应变速率压缩条件下的动态再结晶机制,初步优化了合金最佳热加工工艺范围,结果表明：
(1)应变速率ε≤1s-1时,合金主要晶粒细化机制为晶界再结晶；而应变速率ε≥10s-1时,孪生的作用明显增强,在初始晶粒内形成大量的孪晶,并在孪晶上形成再结晶晶粒,合金主要晶粒细化机制为孪生诱发动态再结晶。
(2)ZK系列镁合金热加工性能随应变速率的增大而提高；其最佳热加工工艺参数范围为：250℃-350℃,应变速率≥10s-1。
(3)ZK系列合金高应变速率压缩变形时,晶界的再结晶为典型的非连续动态再结晶,其过程包括晶界弓出、弓出晶界附近形成亚晶界、亚晶界演变成大角度晶界；晶内的孪生诱发动态再结晶为典型的连续动态再结晶,其过程包括：位错塞积形成位错胞、位错重排形成亚晶、亚晶界吸收位错形成大角度晶界。
2、以提高合金的可锻性和锻坯的力学性能为目的,开展了ZK21镁合金高应变速率锻造工艺的研究,研究了单向、双向和三向锻造的变形特征和规律,分析了应变速率、道次变形量和锻后冷却对三向锻造变形的影响规律,进一步优化了锻造工艺,结果表明：
(1)单向锻造合金再结晶机制为晶界再结晶和孪生诱发动态再结晶,由于合金单向变形所能承受的极限变形量有限,经单向锻造的合金未能获得完全的再结晶组织,锻坯性能较差；双向锻造合金再结晶机制为孪生诱发动态再结晶,经双向锻造的合金可以获得均匀细小的再结晶组织,锻坯强度和屈强比较高、延伸率较差；三向锻造合金再结晶机制为旋转再结晶和孪生诱发动态再结晶,经三向锻造的合金组织由蜂窝状粗大再结晶晶粒和岛状细小再结晶晶粒组成,具有良好的综合力学性能,其抗拉强度和延伸率分别为341MPa和25.1%。
(2)三向锻造过程中,降低应变速率和增大道次应变会在一定程度上降低合金的晶粒细化能力,使锻坯的力学性能下降,因此小道次应变高应变速率多向锻造是合金较为理想的锻造工艺；而加快锻坯的冷却速度则会在提高强度的同时牺牲一定的塑性,因此空冷是较为理想的冷却方式。
3、以优化的三向锻造工艺为基础,研究了ZK系列镁合金高应变速率多向锻造显微组织及力学性能演变,分析了Zn含量对孪生和动态再结晶的影响规律,并对锻坯的强化机制进行了深入的探讨,结果表明：
(1)ZK系列镁合金经高应变速率多向锻造后均可获得蜂窝状粗大再结晶组织和岛状细小再结晶组织混合而成的组织,其晶粒细化效果与合金元素密切相关,Zn含量的高低将决定粗大再结晶组织和细小再结晶组织的晶粒大小,Zn元素的分布将决定粗大再结晶组织和细小再结晶组织的组分比例。
(2)高应变速率多向锻造可以大幅提高合金的综合力学性能,晶粒细化、孪晶强化和第二相强化是锻坯的主要强化机制,晶粒细化和孪晶对力学性能的贡献随Zn含量的提高而减弱,而第二相对力学性能的贡献则随Zn含量的提高而增强。
4、以优化的合金成分和锻造工艺为基础,开展了ZK系列镁合金组织均匀性和各向异性的研究,探讨了高应变速率多向锻造的工业应用可行性,结果表明：
(1)由于外摩擦的影响,锻坯各部位的组织具有一定的不均匀性；但当累积应变为3.3时,ZK21和ZK60合金不同部位的抗拉强度分别为315.2-325.6MPa和313.1-326.5MPa,而延伸率分别为19.4-24.3%和20.7-27.6%,表明高应变速率多向锻造锻坯具有较好的力学性能均匀性。
(2)累积应变为3.3时,ZK21和ZK60合金各方向的抗拉强度分别为299.3-325.3MPa和310.6-323.9MPa,而延伸率分别为20.5-36.6%和21.9-29.7%,表明高应变速率多向锻造可以避免强烈的各向异性。
(3)高应变速率多向锻造是制备大尺寸高性能镁合金的理想工艺,具有重要的工业应用价值。
Magnesium alloys are the lightest metallic structure materials with high specific strength and stiffiness, superior properties for absorbing vibration or shock energy, insulating electromagnetic interference, and excellent machining property, etc, which have been considered as the environment-friendly engineering nviterial with the greatest prospects for development in the21st century. Especially, forged magnesim alloy have broad application prospects in aircraft and automobile industries where energy conservation and emissions reduction need to be achieved ascribe to their excellent combination properties. However, the undesirable forgeability because of the narrow range of forging temperature and high sensitivity of forging strain rate in magnesium has limited their widespread application. Therefore, it is of important values both in theory and engineering to develop a more reliable forging process for magnesium alloys with high excellent combination properties. High strain rate forging was carried out on ZK (Mg-Zn-Zr) series alloys in the present study, and the forgeability should be significantly improved by twin induced dynamic recrystallization (TDRX) during high strain rate forging. A forging technique of the high strain rate multiple forging (HSRMF) was developed on the basis of grain refinement and texture weaken during multiple forging (MF), and the influence of forging technics and alloy element on HSRMF were also investigated in this paper.
Firstly, hot compression was carried out on ZK series alloy in the consideration that temperature and strain rate play the most important role during forging process. The influence of temperature and strain rate on microstructure and flow behavior was analysed, and the processing parameters were optimized. Moreover, the dynamic recrystallization (DRX) mechanism during high strain rate compression was also investigated, the result showed that:
(1) During low strain rate (ε≤1s-1) compression, DRX initiated mainly at original grain boundaries and resulted in grain refinement. During high strain rate(ε≥10s-1) compression, DRX initiated maily at the extensively developed twins in original grain cores, and the TDRX was the main grain refinement mechanism.
(2) The hot workability of ZK series alloys increased with the strain rate increasing, the optimum processing parameters for the three alloys were temperature range of250℃～350℃and strain rate range of ε≥10s-1.
(3) During High strain rate compression of ZK series alloy, the DRX at intial grain boundaries was characteristic of dis-continuous DRX mechanism which including grain boundary bulging, the formation of suh-grain at the place bulging out and the development of high-angle grain boundaries, while the DRX at intial grain cores was characteristic of continuous DRX mechanism which including the formation of dislocation cells due to dislocation pile-ups, the development of sub-grain caused by dislocation rearrangement and the formation of high-angle grain boundaries.
Secondly, high strain rate forging at different conditions were studied to improve the forgeability and mechanical properties of ZK21alloy. The forging technics were further optimized by the investigation of deformation characteristics and regularities of different forging routes (uniaxial, biaxial and triaxial). Moreover, the influence forging parameters (including strain rates, pass strain and colling rates) during multiple forging were also investigated, the results showed that:
(1) DRX at initial grain boundaries and twin induced DRX (TDRX) were the main grain refinement mechanism during uniaxial forging, which resulted in an incomplete DRX structure and small improvement of mechanical properties due to the limited deformation limit under uniaxial load. In biaxial forging samples, TDRX was the main DRX mechanism. A homogeneous ultrafine grained structure formed after biaxial forging wich show high strength but low ductility. In triaxial forging samples, TDRX and rotation DRX were the main grain mechanisms. A novel mixed structure of honeycomb-like coarse DRX grains and island-like ultrafine grains formed after triaxial forging. This novel mixed structure show substantial improvements in mechanical properties, and tenslie testing gave an ultimate tensile strength (UTS) of341MPa and an elongation of25%.
(2) During high strain strain rate multiple forging, the decrease of strain rate and increase of pass strain could decrease the strength owing to the reduction of grain refinement, small pass strain HSRMF has therefore identified as an effective technique for producing high strength ZK21alloy. On the other hand, the increase of colling rate after HSRMF could decrease the ductility while simultaneous preserving even high strength, therefore air colling was more feasible for producing stronger and more ductile ZK21alloy.
Thirdly, microstructure and mechanical properties of the HSRMFed ZK series alloy were studied based on the optimized forging parameters, then the influence of Zn content on twinning and DRX was analysed, moreover, the strengthen mechanism was also investigated. The results showed that:
(1) The initial grains were refined significantly ater HSRMF. A novel mixed structure of honeycomb-like coarse DRX grains and island-like ultrafine grains formed, and the grain refinement was inflenced by alloy element Zn. The grain size of the coarse grains and ultrafine grains were determined by Zn content, while the fraction of the coarse grains and ultrafine grains were determined by the distribution of Zn element.
(2) The mechanical properties improved substantially after HSRMF, and grain refinement, twins and second phase were the main strengthen mechanism. Increasing of Zn content in ZK series alloy coule reduce the contribution of grain refinement and twins decrease on strengthen materials, but increase the contribution of second phase.
Fourthly, HSRMF was carried out based on the optimizd forging paramenter and alloy content, and the microstructure homogeneity and mechanical anisotropy was studied. The results showed that:
(1) Micro structural imhomogenity was detected in the HSRMF samples owing to the friction. However, The UTS and ductility of the HSRMFed ZK21and ZK60alloys in different positions at the accumulated strain of3.3were315.2-325.6MPa,19.4～24.3%and313.1～326.5MPa,20.7-27.6%, respectively.
(2) The UTS and ductility of the HSRMFed ZK21and ZK60alloys in different directions at the accumulated strain of3.3were299.3-325.3MPa,20.5～36.6%and310.6～323.9MPa,21.9-29.7%, respectively. HSRMF was therefore identified as a potential technique for producing magnesium alloy with low anisotropy.
(3) HSRMF was a potential technique for producing stronger and more ductile magnesium alloy.
1、基于变形温度和应变速率在镁合金锻造过程中的重要作用,开展了ZK系镁合金热压缩模拟的研究,分析了变形温度和应变速率对合金显微组织和流变行为的影响规律,验证了镁合金高应变速率变形的可行性,探讨了高应变速率压缩条件下的动态再结晶机制,初步优化了合金最佳热加工工艺范围,结果表明：
(1)应变速率ε≤1s-1时,合金主要晶粒细化机制为晶界再结晶；而应变速率ε≥10s-1时,孪生的作用明显增强,在初始晶粒内形成大量的孪晶,并在孪晶上形成再结晶晶粒,合金主要晶粒细化机制为孪生诱发动态再结晶。
(2)ZK系列镁合金热加工性能随应变速率的增大而提高；其最佳热加工工艺参数范围为：250℃-350℃,应变速率≥10s-1。
(3)ZK系列合金高应变速率压缩变形时,晶界的再结晶为典型的非连续动态再结晶,其过程包括晶界弓出、弓出晶界附近形成亚晶界、亚晶界演变成大角度晶界；晶内的孪生诱发动态再结晶为典型的连续动态再结晶,其过程包括：位错塞积形成位错胞、位错重排形成亚晶、亚晶界吸收位错形成大角度晶界。
2、以提高合金的可锻性和锻坯的力学性能为目的,开展了ZK21镁合金高应变速率锻造工艺的研究,研究了单向、双向和三向锻造的变形特征和规律,分析了应变速率、道次变形量和锻后冷却对三向锻造变形的影响规律,进一步优化了锻造工艺,结果表明：
(1)单向锻造合金再结晶机制为晶界再结晶和孪生诱发动态再结晶,由于合金单向变形所能承受的极限变形量有限,经单向锻造的合金未能获得完全的再结晶组织,锻坯性能较差；双向锻造合金再结晶机制为孪生诱发动态再结晶,经双向锻造的合金可以获得均匀细小的再结晶组织,锻坯强度和屈强比较高、延伸率较差；三向锻造合金再结晶机制为旋转再结晶和孪生诱发动态再结晶,经三向锻造的合金组织由蜂窝状粗大再结晶晶粒和岛状细小再结晶晶粒组成,具有良好的综合力学性能,其抗拉强度和延伸率分别为341MPa和25.1%。
(2)三向锻造过程中,降低应变速率和增大道次应变会在一定程度上降低合金的晶粒细化能力,使锻坯的力学性能下降,因此小道次应变高应变速率多向锻造是合金较为理想的锻造工艺；而加快锻坯的冷却速度则会在提高强度的同时牺牲一定的塑性,因此空冷是较为理想的冷却方式。
3、以优化的三向锻造工艺为基础,研究了ZK系列镁合金高应变速率多向锻造显微组织及力学性能演变,分析了Zn含量对孪生和动态再结晶的影响规律,并对锻坯的强化机制进行了深入的探讨,结果表明：
(1)ZK系列镁合金经高应变速率多向锻造后均可获得蜂窝状粗大再结晶组织和岛状细小再结晶组织混合而成的组织,其晶粒细化效果与合金元素密切相关,Zn含量的高低将决定粗大再结晶组织和细小再结晶组织的晶粒大小,Zn元素的分布将决定粗大再结晶组织和细小再结晶组织的组分比例。
(2)高应变速率多向锻造可以大幅提高合金的综合力学性能,晶粒细化、孪晶强化和第二相强化是锻坯的主要强化机制,晶粒细化和孪晶对力学性能的贡献随Zn含量的提高而减弱,而第二相对力学性能的贡献则随Zn含量的提高而增强。
4、以优化的合金成分和锻造工艺为基础,开展了ZK系列镁合金组织均匀性和各向异性的研究,探讨了高应变速率多向锻造的工业应用可行性,结果表明：
(1)由于外摩擦的影响,锻坯各部位的组织具有一定的不均匀性；但当累积应变为3.3时,ZK21和ZK60合金不同部位的抗拉强度分别为315.2-325.6MPa和313.1-326.5MPa,而延伸率分别为19.4-24.3%和20.7-27.6%,表明高应变速率多向锻造锻坯具有较好的力学性能均匀性。
(2)累积应变为3.3时,ZK21和ZK60合金各方向的抗拉强度分别为299.3-325.3MPa和310.6-323.9MPa,而延伸率分别为20.5-36.6%和21.9-29.7%,表明高应变速率多向锻造可以避免强烈的各向异性。
(3)高应变速率多向锻造是制备大尺寸高性能镁合金的理想工艺,具有重要的工业应用价值。
Magnesium alloys are the lightest metallic structure materials with high specific strength and stiffiness, superior properties for absorbing vibration or shock energy, insulating electromagnetic interference, and excellent machining property, etc, which have been considered as the environment-friendly engineering nviterial with the greatest prospects for development in the21st century. Especially, forged magnesim alloy have broad application prospects in aircraft and automobile industries where energy conservation and emissions reduction need to be achieved ascribe to their excellent combination properties. However, the undesirable forgeability because of the narrow range of forging temperature and high sensitivity of forging strain rate in magnesium has limited their widespread application. Therefore, it is of important values both in theory and engineering to develop a more reliable forging process for magnesium alloys with high excellent combination properties. High strain rate forging was carried out on ZK (Mg-Zn-Zr) series alloys in the present study, and the forgeability should be significantly improved by twin induced dynamic recrystallization (TDRX) during high strain rate forging. A forging technique of the high strain rate multiple forging (HSRMF) was developed on the basis of grain refinement and texture weaken during multiple forging (MF), and the influence of forging technics and alloy element on HSRMF were also investigated in this paper.
Firstly, hot compression was carried out on ZK series alloy in the consideration that temperature and strain rate play the most important role during forging process. The influence of temperature and strain rate on microstructure and flow behavior was analysed, and the processing parameters were optimized. Moreover, the dynamic recrystallization (DRX) mechanism during high strain rate compression was also investigated, the result showed that:
(1) During low strain rate (ε≤1s-1) compression, DRX initiated mainly at original grain boundaries and resulted in grain refinement. During high strain rate(ε≥10s-1) compression, DRX initiated maily at the extensively developed twins in original grain cores, and the TDRX was the main grain refinement mechanism.
(2) The hot workability of ZK series alloys increased with the strain rate increasing, the optimum processing parameters for the three alloys were temperature range of250℃～350℃and strain rate range of ε≥10s-1.
(3) During High strain rate compression of ZK series alloy, the DRX at intial grain boundaries was characteristic of dis-continuous DRX mechanism which including grain boundary bulging, the formation of suh-grain at the place bulging out and the development of high-angle grain boundaries, while the DRX at intial grain cores was characteristic of continuous DRX mechanism which including the formation of dislocation cells due to dislocation pile-ups, the development of sub-grain caused by dislocation rearrangement and the formation of high-angle grain boundaries.
Secondly, high strain rate forging at different conditions were studied to improve the forgeability and mechanical properties of ZK21alloy. The forging technics were further optimized by the investigation of deformation characteristics and regularities of different forging routes (uniaxial, biaxial and triaxial). Moreover, the influence forging parameters (including strain rates, pass strain and colling rates) during multiple forging were also investigated, the results showed that:
(1) DRX at initial grain boundaries and twin induced DRX (TDRX) were the main grain refinement mechanism during uniaxial forging, which resulted in an incomplete DRX structure and small improvement of mechanical properties due to the limited deformation limit under uniaxial load. In biaxial forging samples, TDRX was the main DRX mechanism. A homogeneous ultrafine grained structure formed after biaxial forging wich show high strength but low ductility. In triaxial forging samples, TDRX and rotation DRX were the main grain mechanisms. A novel mixed structure of honeycomb-like coarse DRX grains and island-like ultrafine grains formed after triaxial forging. This novel mixed structure show substantial improvements in mechanical properties, and tenslie testing gave an ultimate tensile strength (UTS) of341MPa and an elongation of25%.
(2) During high strain strain rate multiple forging, the decrease of strain rate and increase of pass strain could decrease the strength owing to the reduction of grain refinement, small pass strain HSRMF has therefore identified as an effective technique for producing high strength ZK21alloy. On the other hand, the increase of colling rate after HSRMF could decrease the ductility while simultaneous preserving even high strength, therefore air colling was more feasible for producing stronger and more ductile ZK21alloy.
Thirdly, microstructure and mechanical properties of the HSRMFed ZK series alloy were studied based on the optimized forging parameters, then the influence of Zn content on twinning and DRX was analysed, moreover, the strengthen mechanism was also investigated. The results showed that:
(1) The initial grains were refined significantly ater HSRMF. A novel mixed structure of honeycomb-like coarse DRX grains and island-like ultrafine grains formed, and the grain refinement was inflenced by alloy element Zn. The grain size of the coarse grains and ultrafine grains were determined by Zn content, while the fraction of the coarse grains and ultrafine grains were determined by the distribution of Zn element.
(2) The mechanical properties improved substantially after HSRMF, and grain refinement, twins and second phase were the main strengthen mechanism. Increasing of Zn content in ZK series alloy coule reduce the contribution of grain refinement and twins decrease on strengthen materials, but increase the contribution of second phase.
Fourthly, HSRMF was carried out based on the optimizd forging paramenter and alloy content, and the microstructure homogeneity and mechanical anisotropy was studied. The results showed that:
(1) Micro structural imhomogenity was detected in the HSRMF samples owing to the friction. However, The UTS and ductility of the HSRMFed ZK21and ZK60alloys in different positions at the accumulated strain of3.3were315.2-325.6MPa,19.4～24.3%and313.1～326.5MPa,20.7-27.6%, respectively.
(2) The UTS and ductility of the HSRMFed ZK21and ZK60alloys in different directions at the accumulated strain of3.3were299.3-325.3MPa,20.5～36.6%and310.6～323.9MPa,21.9-29.7%, respectively. HSRMF was therefore identified as a potential technique for producing magnesium alloy with low anisotropy.
(3) HSRMF was a potential technique for producing stronger and more ductile magnesium alloy.
引文
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