固液混合铸造ZA12合金组织与性能研究
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摘要
锌铝合金显示出较高的力学性能、优良的摩擦磨损性能,是一种具有高承载能力的新型减摩材料,其铸造性能优良,且摩擦系数和成本较低,得到了广泛关注与应用。其中ZA12合金是一种多用途合金,具有高致密性,易于机加工,有很多研究表明ZA12合金具有优异的摩擦磨损性能。固液混合铸造技术是一种制备微晶合金的新技术,开展锌铝合金固液混合铸造技术的研究工作对拓展锌铝合金的应用范围具有重要意义。本论文采用固液混合铸造技术制备ZA12合金。主要研究此种制备工艺下不同工艺参数对ZA12合金组织的影响,并与金属型铸造、半固态铸造合金进行对比,研究合金微观组织演变规律。同时还对ZA12合金的力学性能和摩擦磨损性能及机理进行一定的分析。试验研究结果表明:
1)固液混合铸造ZA12合金时,工艺参数对于合金组织有很大影响,在熔体过热度为40℃,粉末加入量为30%,粉末粒度为-200~+400目(38~74μm )条件下,合金的组织细小、分布均匀,初生相含量也较低。
2)固液混合铸造ZA12合金组织相对金属型铸造的铸态组织,后者粗大的枝晶完全被破碎,白色的初生相组织偏向于团球状,平均粒度大幅度减小,且分布较为均匀;同样的搅拌条件下,半固态铸造ZA12合金组织枝晶破碎、细化程度明显不及固液混合铸造的合金组织。固液混合铸造及半固态铸造化程度明显不及固液混合铸造的合金组织。固液混合铸造及半固态铸造合金的致密度低于金属型铸造合金。
3)ZA12金属型铸造铸态组织、半固态铸造组织及固液混合铸造组织中相组成基本一致。它们主要是由η-Zn相、β-AlZn相及少量α-Al相组成。
4)固液混合铸造ZA12合金的抗拉强度较金属型铸造和半固态铸造合金提高幅度较小的情况可能与合金中的杂质、孔洞有关。金属型铸造合金拉伸断口为典型的解理断裂,而固液混合铸造及半固态铸造ZA12合金的拉伸断口呈现解理断裂与准解理断裂相结合的断裂特征。
5)固液混合铸造工艺参数对ZA12合金的布氏硬度有很大影响。
6)摩擦磨损过程中,试验载荷、试环转速及润滑条件对ZA12合金的摩擦磨损性能有很大的影响。固液混合铸造工艺制备ZA12合金在室温干、湿滑动摩擦条件下的耐磨损性能、减摩性能均优于金属型与半固态铸造工艺制备的合金。
Zn-Al alloy shows considerable promise for bearing and wear applications, which is a new kind of antifriction material with high bearing capacity and mechanical properties, fine casting characteristic, low friction coefficient and low cost. There has been a growing interest and application in the use of such alloy.ZA12 alloy is the general-purpose alloy, and it has excellent machinability and high compactability. There is growing evidence that ZA-12 has excellent bearing and wear characteristics. The mixed solid-liquid casting is a new technology used for preparing microcrystal, which has been of real significance in applications of Zn-Al alloys. In this thesis, mixed solid-liquid casting was employed to prepare ZA12 alloy. The effects of processing parameters on the microstructures of mixed solid-liquid casting ZA12 alloy were mainly investigated and compared with ZA12 alloy prepared by other technologies. In addition, the evolution of ZA12 alloy microstructures has been obtained. The mechanical properties, friction and wear characteristic and mechanics of ZA12 alloy prepared by different technologies were also explored.
The results are concluded as below:
1)The processing parameters have important effect on the microstructures and mechanical properties of mixed solid-liquid casting ZA12 alloy. The result shows that homogeneous and finer nodular primary phases could be obtained with 40℃degree of melt superheat, 30% mass ratio of the added power and 38~74μm of powder particle size, at the same time, it has lower content of primary phase.
2) Mixed solid-liquid casting ZA12 alloy has obviously cracked dendrites, homogeneous and fine nodular no-dendritic primary phases and reduced mean size compared with as-cast structure; and it is also much better than semi-solid structure which was agitated without powder added. The density of the ZA12 alloys prepared by mixed solid-liquid casting and semi-solid casting is lower than that prepared by metal mold casing.
3)All of the alloys prepared the three technologies are composed byη-Zn phase,β-AlZn phase and a small quality ofα-Al phase.
4)Because of impurity and gas cavity induced by smart agitating, the tensile strength has not been increased. The metal mold casting alloys exhibit mainly cleavage fracture, and the mixed solid-liquid casting and semi-solid casting consist of cleavage fracture and quasi-cleavage fracture.
5)The processing parameters of Mixed solid-liquid casting play an important part in Brinell hardness of ZA12 alloys.
6)The testing load, rotational speed of friction ring and lubricating conditions have great influence on friction and wear characteristic of ZA12 alloys. At room-temperature, the mixed solid-liquid casting ZA12 alloy has the more excellent the friction and wear characteristic than metal mold casting and semi-solid casting alloys.
1)固液混合铸造ZA12合金时,工艺参数对于合金组织有很大影响,在熔体过热度为40℃,粉末加入量为30%,粉末粒度为-200~+400目(38~74μm )条件下,合金的组织细小、分布均匀,初生相含量也较低。
2)固液混合铸造ZA12合金组织相对金属型铸造的铸态组织,后者粗大的枝晶完全被破碎,白色的初生相组织偏向于团球状,平均粒度大幅度减小,且分布较为均匀;同样的搅拌条件下,半固态铸造ZA12合金组织枝晶破碎、细化程度明显不及固液混合铸造的合金组织。固液混合铸造及半固态铸造化程度明显不及固液混合铸造的合金组织。固液混合铸造及半固态铸造合金的致密度低于金属型铸造合金。
3)ZA12金属型铸造铸态组织、半固态铸造组织及固液混合铸造组织中相组成基本一致。它们主要是由η-Zn相、β-AlZn相及少量α-Al相组成。
4)固液混合铸造ZA12合金的抗拉强度较金属型铸造和半固态铸造合金提高幅度较小的情况可能与合金中的杂质、孔洞有关。金属型铸造合金拉伸断口为典型的解理断裂,而固液混合铸造及半固态铸造ZA12合金的拉伸断口呈现解理断裂与准解理断裂相结合的断裂特征。
5)固液混合铸造工艺参数对ZA12合金的布氏硬度有很大影响。
6)摩擦磨损过程中,试验载荷、试环转速及润滑条件对ZA12合金的摩擦磨损性能有很大的影响。固液混合铸造工艺制备ZA12合金在室温干、湿滑动摩擦条件下的耐磨损性能、减摩性能均优于金属型与半固态铸造工艺制备的合金。
Zn-Al alloy shows considerable promise for bearing and wear applications, which is a new kind of antifriction material with high bearing capacity and mechanical properties, fine casting characteristic, low friction coefficient and low cost. There has been a growing interest and application in the use of such alloy.ZA12 alloy is the general-purpose alloy, and it has excellent machinability and high compactability. There is growing evidence that ZA-12 has excellent bearing and wear characteristics. The mixed solid-liquid casting is a new technology used for preparing microcrystal, which has been of real significance in applications of Zn-Al alloys. In this thesis, mixed solid-liquid casting was employed to prepare ZA12 alloy. The effects of processing parameters on the microstructures of mixed solid-liquid casting ZA12 alloy were mainly investigated and compared with ZA12 alloy prepared by other technologies. In addition, the evolution of ZA12 alloy microstructures has been obtained. The mechanical properties, friction and wear characteristic and mechanics of ZA12 alloy prepared by different technologies were also explored.
The results are concluded as below:
1)The processing parameters have important effect on the microstructures and mechanical properties of mixed solid-liquid casting ZA12 alloy. The result shows that homogeneous and finer nodular primary phases could be obtained with 40℃degree of melt superheat, 30% mass ratio of the added power and 38~74μm of powder particle size, at the same time, it has lower content of primary phase.
2) Mixed solid-liquid casting ZA12 alloy has obviously cracked dendrites, homogeneous and fine nodular no-dendritic primary phases and reduced mean size compared with as-cast structure; and it is also much better than semi-solid structure which was agitated without powder added. The density of the ZA12 alloys prepared by mixed solid-liquid casting and semi-solid casting is lower than that prepared by metal mold casing.
3)All of the alloys prepared the three technologies are composed byη-Zn phase,β-AlZn phase and a small quality ofα-Al phase.
4)Because of impurity and gas cavity induced by smart agitating, the tensile strength has not been increased. The metal mold casting alloys exhibit mainly cleavage fracture, and the mixed solid-liquid casting and semi-solid casting consist of cleavage fracture and quasi-cleavage fracture.
5)The processing parameters of Mixed solid-liquid casting play an important part in Brinell hardness of ZA12 alloys.
6)The testing load, rotational speed of friction ring and lubricating conditions have great influence on friction and wear characteristic of ZA12 alloys. At room-temperature, the mixed solid-liquid casting ZA12 alloy has the more excellent the friction and wear characteristic than metal mold casting and semi-solid casting alloys.
引文
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[2] ASM International Handbook Committee. ASM metals handbook volume2. Ohio: ASM International, 1992: 1625-1641
[3] Nilsson A, Gabrielson P, St?hl J E. Zinc-alloys as tool materials in short-run sheet-metal forming processes experimental analysis of three different zinc alloys. Journal of Materials Processing Technology, 2002(125-126): 806-813
[4] 陈体军,郝远.铸造锌基复合材料的研究现状.材料导报,2000,14(3):29-31
[5] 顾春雷,张伟强,金花子等.锌及锌铝合金研究及应用现状.有色金属,2003, 55(4):44-47
[6] 刘 永 红 ,张 忠 明 ,刘 宏 昭 等 .锌 铝 合 金 的 研 究 现 状 及 应 用 概 况 .铸 造 技术,2001(1):42-44
[7] Gervais E, Barnhurst R J, Loong C A. An analysis of selected properties of ZA alloys. Journal of Metals, 1985, 37(11): 43-47
[8] 张福全,舒震.高铝锌合金加铈变质的研究.特种铸造及有色合金,1992(2): 1-4
[9] 侯平均.高铝锌合金凝固特性与变质机理研究:[洛阳工学院硕士学位论文].洛阳:洛阳工学院,2002:2-5
[10] 陈体军,郝远,狄杰建等.变质剂对ZA27合金半固态等温热处理组织的影响.热加工工艺,2001(4):25
[11] 许广济,陆松,陈体军.硼、钛对半固态ZA27组织演变的影响.甘肃工业大学学报,2000,26(1):19-22
[12] 唐孝杰,王晓沛.ZA27合金网状η和ε相的形成.特种铸造及有色合金, 1991(3):8-9
[13] Prasad B K, Patwardhan A K, Yegneswaran A H. Microstructure property characterization of some Zn-Al alloy: effect of heat treatment parameters. Zeitschriftfür Metallkunde, 1996, 87(12): 967-971
[14] 于海朋.挤压铸造ZA43合金的研究:[沈阳工业大学硕士学位论文].沈阳:沈阳工业大学,2000:62-65
[15] Arikan R, Murphy S. Anisotropic wear of planar-random metal matrix composites with zinc alloy matrix. Wear, l991, 143(1): 149-157
[16] 赵浩峰,王玲.铸造锌铝合金及其复合材料.北京:中国标准出版社,2002: 11-99
[17] ASM International Handbook Committee. ASM metals handbook volume9. Ohio: ASM International, 1992, 1087-1090
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