CN110111861B - Prediction method for thermal cracks in solidification process of magnesium and aluminum alloy castings - Google Patents

Prediction method for thermal cracks in solidification process of magnesium and aluminum alloy castings Download PDF

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CN110111861B
CN110111861B CN201910440113.6A CN201910440113A CN110111861B CN 110111861 B CN110111861 B CN 110111861B CN 201910440113 A CN201910440113 A CN 201910440113A CN 110111861 B CN110111861 B CN 110111861B
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CN110111861A (en
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王科
付彭怀
彭立明
王迎新
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SHANGHAI LIGHT ALLOY NET FORMING NATIONAL ENGINEERING RESEARCH CENTER CO LTD
Shanghai Jiaotong University
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Abstract

The invention discloses a method for predicting thermal cracks in a magnesium and aluminum alloy casting solidification process; according to LRGnAnd M0Judging whether thermal cracks are generated in the casting process or not, wherein L is the length of a constraint segment in the casting and is m; r is the average cooling rate in units of ℃/s for each point within the constrained segment; g is the temperature gradient at each point in the confinement section, unit ℃/m; n is an influence factor of the temperature gradient and is 1.5; m0Is a critical value; when the casting is in a certain position LRGn>M0Then hot cracks will appear at that location; when all positions of the LRG in the casting are presentn≤M0The casting is not at risk of hot cracking. The prediction method provided by the invention does not need an alloy complete material mechanical property database, L, R and G in the criterion can be directly obtained from casting simulation calculation, and the critical value M0The method can be obtained through simple experiments and simulation calculation, so that the hot cracking prediction method provided by the invention is simpler to operate and has wider applicability.

Description

Prediction method for thermal cracks in solidification process of magnesium and aluminum alloy castings
Technical Field
The invention belongs to the field of metal casting, and particularly relates to a method for predicting thermal cracks in a magnesium and aluminum alloy casting solidification process.
Background
In the actual casting production process, people often perform casting process design by means of a casting numerical simulation technology/software, and casting defects such as shrinkage porosity, shrinkage cavity, oxide skin, cracks and the like in the casting are reduced or even eliminated by optimizing a gating system. Among them, hot cracking is a very serious and irreparable casting defect, which is often found in the production process of steel, aluminum alloy and magnesium alloy castings, and can seriously affect the quality and service life of the castings, and in most cases, hot cracking directly results in the rejection of the castings. Therefore, the prediction of the thermal cracking has important scientific research and practical value.
At present, the prediction of the hot cracks of the casting is mainly established on the basis of the simulation of the stress-strain numerical value in the solidification process of the casting: for example, a criterion HTI provided in the ProCAST of the casting simulation software for predicting the hot crack position of the casting is based on a Gurson model of a theoretical framework of plastic deformation of the porous material, and the thermal cracking sensitivity of the casting at different nodes is measured by calculating the total plastic strain magnitude of the solid phase fraction of each node in a grid during CRITFS (solid fraction when crystal grains are contacted with each other, which is usually between 50% and 99%); the casting simulation software MAGMASoft predicts the formation or non-formation of the thermal crack by a viscoplastic deformation model, wherein the strain comprises elastic strain, thermal strain and viscoplastic strain. In order to predict thermal cracking, a complete mechanical property database of the material is needed to be known by stress-strain simulation calculation, wherein the database comprises the variation conditions of elastic modulus, Poisson's ratio, yield strength, work hardening, strain rate sensitivity index and the like along with temperature, and particularly data near a solidus line. The data detection is time-consuming and labor-consuming, and most alloys do not have such a complete mechanical property database. Therefore, thermal crack prediction based on stress-strain simulation calculations is only applicable to a few alloys with complete material databases. Therefore, there is an urgent need for a simple method for effective prediction of hot cracks in castings, particularly new alloys.
Disclosure of Invention
The existing thermal crack prediction needs a complete material mechanical property database which comprises the quantitative relation of elastic modulus, Poisson's ratio, yield strength, work hardening rate, strain rate sensitive index and the like along with the temperature change, and the conventional novel alloy cannot conveniently obtain the data. Aiming at the technical problem, the invention provides a method for predicting thermal cracks in the solidification process of magnesium and aluminum alloy castings based on numerical simulation of the casting solidification temperature field. As the numerical simulation technology of the casting temperature field is mature and all casting simulation software has the function, the hot crack prediction method provided by the invention has wide application range and can easily realize the hot crack prediction of novel metal.
The purpose of the invention is realized by the following technical scheme:
the invention relates to a method for predicting thermal cracks in a magnesium and aluminum alloy casting solidification process, which comprises the following steps:
s1, according to formula M ═ LRGnCalculating an M value; wherein L is the length of the constraint segment in the casting, in m; r is the average cooling rate in units of ℃/s for each point within the constrained segment; g is the temperature gradient at each point in the confinement section, unit ℃/m; n is an influence factor of the temperature gradient and is 1.5;
s2, passing M and M0Judging whether thermal cracks are generated in the casting process of the magnesium and aluminum alloy castings: when the casting is at a certain position M>M0Then hot cracks will appear at that location; when all positions M in the casting are less than or equal to M0The casting has no risk of hot cracking; wherein M is0Is the critical value of the casting for generating hot cracks.
The method for determining the length L of the constraint segment comprises the following steps: the metal liquid is solidified in the casting mould, the liquid-solid phase change causes the metal volume to shrink, the casting mould does not shrink along with the metal volume, the contradiction is generated between the two, when the contradiction between the two can not pass through strain coordination, the stress is immediately generated, when the stress exceeds a critical value, the thermal crack is generated, therefore, the constraint of the mould on the metal volume shrinkage is a necessary condition for generating the thermal crack, and the length L of the constraint section is a quantitative index of the necessary condition. The constraint points are positions for hindering the shrinkage of the casting, are mostly positions with sudden changes of the wall thickness of the casting, and are also the maximum value positions of the temperature gradient G generally, so that the positions of the constraint points can be determined through the maximum value of G, and the distance between the two constraint points is the length L of the constraint segment. Specifically, in the numerical simulation, an extreme point, namely a constraint point, is determined by calculating the temperature gradient G in the casting solidification process, and the length L of the constraint segment is determined by calculating the distance between the two extreme points.
The length L of the constraint segment provided by the invention is the distance between two maximum value positions of the temperature gradient G at a certain temperature in a temperature range corresponding to the casting solid phase ratio of 0.85-1.0.
More preferably, the restriction section length L is a distance between two maximum positions of the temperature gradient G at which the casting solid fraction is 0.95.
Method for calculating cooling rate R: all current casting simulation software can calculate the cooling rate of a certain grid point, and the temperature range of the cooling rate calculation is from the liquidus line to the solidus line.
The cooling rate R provided by the invention is the average cooling rate of each point in the constraint section in the temperature range corresponding to the solid fraction of 0.74-1.0.
Calculation method of temperature gradient G: all casting software today is able to calculate the temperature gradient between a certain grid point and an adjacent grid point.
The temperature gradient G provided by the invention is the temperature gradient of each point in the constraint section at a certain temperature in a temperature range corresponding to the solid fraction of 0.85-1.0.
More preferably, the temperature gradient G is a temperature gradient corresponding to a solid fraction of 0.95.
Critical value M0The confirmation method comprises the following steps: the critical value M is determined by adopting a restrained bar casting (figure 1) for conventional hot cracking behavior research0。
The critical value M provided by the invention0The method is determined by combining a restrained bar casting test and casting simulation, and the specific method comprises the following steps:
a1, respectively pouring the restraining bar castings under the conditions of preset pouring temperature and different mold temperatures aiming at specific alloys, and determining the critical mold temperature at which all restraining positions of the restraining bar castings do not generate thermal cracks; (specifically, by observing the surface appearance of the restrained bar casting, finding out the critical mold temperature at which all restrained positions of the restrained bar casting do not generate thermal cracks)
A2, simulation software by casting and M ═ L R G1.5Calculating the M value of the position of the longest test bar of the constraint bar casting which is most easy to generate thermal cracks at the critical mould temperature, wherein the M value is M0。
The restraining bar casting comprises an inverted frustum-shaped casting top gate and a cylindrical casting body; test bars 1-4 vertical to the central axis of the casting body are uniformly arranged on the casting body at intervals, and the distance between the test bars is 38 mm; the test rods 1-4 are cylinders with the same diameter, the diameter of the cylinder is 9.5mm, and the lengths of the cylinders are sequentially increased and are respectively 27 mm, 65 mm, 103 mm and 141 mm; the end parts of the test rods 1-4 are respectively provided with spheres with the same diameter, and the diameter of each sphere is 19 mm; the end part of the cylindrical casting body is a hemisphere, and the diameter of the sphere is 29 mm.
Compared with the prior art, the hot crack prediction method provided by the invention has the following beneficial effects:
(1) the applicability is wide: the hot crack prediction method is suitable for all magnesium and aluminum alloy materials, including the existing magnesium and aluminum alloy with a complete material mechanical property database and the novel magnesium and aluminum alloy which is just developed and has an incomplete mechanical property database;
(2) the operation method is simple and convenient: except for a critical value M0Besides the determination by combining the experiment and the simulation (only one group of experiments are needed for the same alloy), the rest can be obtained by casting simulation, and time and labor are saved.
Drawings
Other features, objects and advantages of the invention will become more apparent upon reading of the detailed description of non-limiting embodiments with reference to the following drawings:
FIG. 1 is a drawing of a test bar restraint bar casting and a die for researching hot cracking behavior of magnesium and aluminum alloys;
FIG. 2 shows the temperature gradient G of a casting of a restraint bar0.95Numerical valueA simulation result graph;
FIG. 3 is a casting temperature gradient G of 14-inch magnesium alloy automobile hub according to process parameter 1#0.95A numerical simulation result graph;
FIG. 4 shows the thermal crack prediction of a 14-inch magnesium alloy automobile hub: (a) technological parameter 1#, rim part, L ═ 0.11 m; (b) technological parameter 1#, spoke part, L is 0.04 m; (c) the technological parameter 2#, L ═ 0.11 m;
FIG. 5 shows crack criterion (L.R.G)1.5﹥M0) And (3) comparing the predicted result with the 1# experimental result of the technological parameter of the 14-inch magnesium alloy automobile hub.
Detailed Description
In order to make the technical problems, technical solutions and advantageous effects solved by the present invention more clearly apparent, the present invention is further described in detail with reference to the accompanying drawings and embodiments. The magnesium alloy Mg-3Nd-0.2Zn-0.5Zr (NZ30K, wt.%) is used as a test material, and the validity of the automobile hub test criterion of certain metal mold low-pressure casting is selected. ProCAST is selected as casting simulation software. The simulation parameters, except for casting process parameters (pouring temperature, mold temperature, pouring speed, etc.), are software default or recommended values. The cooling rate R is a solid phase fraction fsThe average cooling speed in the temperature range corresponding to 0.74-1; temperature gradient G is solid fraction fsTemperature gradient corresponding to 0.95, denoted as G0.95. It should be understood that the specific examples described herein are intended to be illustrative only and are not intended to be limiting.
Examples
1. Critical value M0Is determined by
(1) Preparing a test tool: the heating resistance furnace comprises a casting ladle, a constraint rod casting mould and a casting ladle/constraint rod casting mould. The casting ladle is a barrel-shaped body with the outer diameter of 90mm, the inner diameter of 80mm and the height of 250mm, the bottom of the casting ladle is provided with a plug with the diameter of 30mm, and the casting ladle is made of stainless steel. The dimensions of the restraint bar casting and the die are shown in figure 1, and the material is H13 steel. During pouring, the casting ladle and the restraining rod mold are heated in situ by an external heat-preservation resistance furnace, the heating furnace is respectively positioned outside the casting ladle/the restraining rod mold, the casting ladle and the casting ladle heating furnace are positioned right above the restraining rod mold and the restraining rod mold heating furnace, and the bottom of the casting ladle is 50mm away from the upper surface of the restraining rod mold.
(2) The constraint rod casting pouring process: firstly, setting a casting ladle and the temperature of a restraint bar mold; after the temperature reaches the set temperature, the temperature is 1% SF 6/99% CO2Pouring 260 +/-10 cm under the protection of gas3The magnesium alloy melt is put into a casting ladle; after the temperature of the melt in the casting ladle reaches the set temperature, opening the plug, and filling the magnesium alloy melt into the restraint rod mold under the action of gravity; after the magnesium alloy is completely solidified, taking out the restraint bar mold from the heat preservation furnace, and opening the mold to take out a restraint bar casting; and when the restraining bar casting is cooled to the room temperature, observing whether cracks exist on the surface of the restraining bar.
(3) Pouring a restraint bar casting: and pouring the molten magnesium alloy melt into a constraint rod casting at the pouring temperature of 730 ℃ and at different mold temperatures (150, 250, 350 and 450 ℃). And carefully observing the surface crack condition of the restraint bar casting, and determining the minimum mold temperature at which no crack is generated at all restraint positions. For the NZ30K magnesium alloy, the minimum mold temperature is 350 ℃, i.e., the critical mold temperature is 350 ℃.
(4) A constrained distance L is determined. Calculating the temperature gradient G of the restraint bar casting at the pouring temperature of 730 ℃ and the die temperature of 150 ℃ by ProCast software0.95The calculation results of (2) are shown in fig. 2. And selecting two extreme points of the temperature gradient on each test bar to calculate the constraint distance L, wherein the constraint distances of the test bars 1, 2, 3 and 4 are respectively 0.025 m, 0.067 m, 0.101 m and 0.137 m.
(5) Determining a threshold value M0. At the critical mold temperature, by ProCast software and M ═ LRG1.5Calculating the M value of the longest test bar 4 of the restrained bar casting at the position C (shown in figure 1) which is most easy to generate hot cracks, wherein the M value is M0The value is obtained. For the NZ30K alloy, when the casting temperature is 730 ℃ and the mould temperature is 350 ℃, the M at the C is 765 DEG C2.5/(sm0.5) Critical value M for heat cracking of NZ30K alloy0765 deg.C2.5/(sm0.5). When in a certain position M>M0When the position is hot, hot cracks are generated at the position; otherwise, no thermal cracking occurs at this location.
2. Prediction of thermal cracks of NZ30K magnesium alloy low-pressure casting automobile hub
Two groups of typical process parameters of the trial production of the NZ30K magnesium alloy 14-inch hub are selected as comparison to prove the effectiveness of the hot cracking criterion. The NZ30K magnesium alloy 14-inch hub is formed by low-pressure casting through a metal die, the die is made of H13 steel and consists of 1 upper die, 4 side dies and 1 lower die, and the average wall thickness of the die is 20 mm. 1# of process parameters: the temperature of the upper die is 200 ℃, the temperature of the side die is 300 ℃ and the temperature of the bottom die is 500 ℃, and the trial production result shows that a plurality of thermal cracks are generated at the rim of the hub and the spoke does not have thermal cracks. Process parameter 2 #: the temperature of the upper die is 350 ℃, the temperature of the side die is 450 ℃, the temperature of the bottom die is 500 ℃, and the hub is trial-manufactured without thermal cracks.
(1) And obtaining the thermophysical parameters during calculation simulation of the NZ30K magnesium alloy. Mg-3Nd-0.2Zn-Zr (NZ30K, wt.%) is a novel magnesium rare earth alloy, the database of thermophysical property parameters is incomplete, thermophysical property parameters related to materials can be calculated according to the components of the alloy through a 'Thermodynamic Databases' carried in ProCAST software, and a Scheil model is selected during calculation.
The quantitative relation of alloy density, enthalpy, thermal conductivity, solid fraction and viscosity along with temperature change can be obtained through calculation, and the calculation results can be used for temperature field simulation of the casting process. These parameters can also be obtained experimentally. The calculation results of ProCAST software are used in this embodiment.
(2) Casting simulation of the 14-inch magnesium alloy hub and determination of the length L of the constraint segment. Setting pouring temperature, mold temperature and pouring rate (0.2m/s), calculating temperature gradient G of each position of the hub in the pouring and solidification process of the 14-inch hub by adopting software recommended values of other parameters0.95The temperature gradient distribution under the process parameter 1# is as shown in fig. 3, the temperature gradient on the longitudinal section of the hub has 8 extreme values (the calculation of the distance between these extreme values can be realized by software programming), wherein the maximum distance of the extreme values (the length L of the constraint segment) on the rim is the distance between the extreme value 2 and the extreme value 4, and is 0.11 m; the maximum extremum distance at the spoke is the distance between extremum 4 and extremum 6, which is 0.04 m. Because the existing software can not completely realize the independent assignment of the length L of each region constraint segmentFor convenience of calculation, in this embodiment, the maximum value of all the constraint segment lengths L on the rim is 0.11m, and the maximum value of the constraint segment length at the rim is 0.04 m.
(3) And predicting the hot cracking condition of the hub. In this embodiment, the user opening tool M ═ aU in ProCAST software is usedoCnGmCalculating the value of M, where a, o, n, and M are parameters that can be defined by the user, U is the solidification rate, C is the cooling rate, and G is the temperature gradient, and setting "a ═ L, o ═ 0, n ═ 1, M ═ 1.5, and C ═ R" is the thermal cracking criterion M ═ LRG provided by the present invention1.5. The calculation results for Process parameter # 1 and Process parameter # 2 are shown in FIG. 4, where the maximum value of the color band is M0Thus, the red region is a region where thermal cracking is likely to occur; specifically, under the condition of the process parameter 1#, thermal cracks are generated at the positions 2, 3 and 4 of the rim, and the thermal cracks are not generated at the spoke; no thermal cracks are generated on the whole hub under the condition of the process parameter 2 #.
(4) The thermal cracking prediction is compared with the experimental results. The predicted thermal cracking and the experimental results are shown in FIG. 5. The thermal cracks are cracks formed in the later stage of alloy solidification, the fracture surfaces of the cracks are seriously oxidized and are black due to high temperature during forming, and the positions of the actual thermal cracks on the rim can be found to be quite consistent with the result of simulation calculation by comparing the conditions of the thermal cracks on seven sections of the rim, namely the thermal cracks exist at the predicted crack positions in the figure 4 during low-pressure casting, so that the effectiveness of the thermal crack prediction method is verified.
The foregoing description of specific embodiments of the present invention has been presented. It is to be understood that the present invention is not limited to the specific embodiments described above, and that various changes and modifications may be made by one skilled in the art within the scope of the appended claims without departing from the spirit of the invention.

Claims (7)

1. A method for predicting thermal cracks in a magnesium and aluminum alloy casting solidification process is characterized by comprising the following steps:
s1, according to formula M ═ LRGnCalculating an M value; wherein L is castThe length of the constraint segment in the piece, in m; r is the average cooling rate in units of ℃/s for each point within the constrained segment; g is the temperature gradient at each point in the confinement section, unit ℃/m; n is an influence factor of the temperature gradient and is 1.5;
s2, passing M and M0Judging whether thermal cracks are generated in the casting process of the magnesium and aluminum alloy castings: when the casting is in a certain position LRGn>M0Then hot cracks will appear at that location; when all positions of the LRG in the casting are presentn≤M0The casting has no risk of hot cracking; wherein M is0Is the critical value of the casting for generating hot cracks.
2. The method for predicting the thermal cracks in the solidification process of the magnesium and aluminum alloy castings according to claim 1, wherein the length L of the constrained section is the distance between two maximum positions of the temperature gradient G at a temperature corresponding to a temperature range of 0.85-1.0 of the solid fraction of the castings.
3. The method of predicting thermal cracking in the course of solidification of a magnesium-aluminum alloy casting according to claim 2, wherein the constrained segment length L is the distance between two maximum positions of the temperature gradient G at a casting solid fraction of 0.95.
4. The method for predicting the thermal cracks in the solidification process of the magnesium and aluminum alloy castings according to claim 1, wherein the cooling rate R is the average cooling rate of each point in the constrained section in the temperature range corresponding to the solid fraction of 0.74-1.0.
5. The method for predicting the thermal cracking in the solidification process of a magnesium-aluminum alloy casting according to claim 1, wherein the temperature gradient G is a temperature gradient at each point in the restraint section at a temperature corresponding to a temperature range of the solid fraction of 0.85 to 1.0.
6. The method of predicting thermal cracking in the solidification process of magnesium-aluminum alloy castings according to claim 5, wherein the temperature gradient G is a temperature gradient having a solid fraction of 0.95 corresponding to a temperature.
7. The method for predicting thermal cracking in the process of solidifying the magnesium-aluminum alloy casting as recited in claim 1, wherein the critical value M is0The method is determined by combining a restrained bar casting test and casting simulation, and the specific method comprises the following steps:
a1, respectively pouring the restraint bar casting under the conditions of preset pouring temperature and different mold temperatures, and determining the critical mold temperature at which all restraint positions of the restraint bar casting do not generate thermal cracks;
a2, simulation software by casting and M ═ L R G1.5Calculating the M value of the position of the longest test bar of the constraint bar casting which is most easy to generate thermal cracks at the critical mould temperature, wherein the M value is M0。
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