Preparation process of silver clad aluminum bars by vertical continuous casting composite forming
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摘要: 以直徑20 mm, 包覆比50%的銀包鋁細棒為研究對象, 通過有限元數值模擬以及相應的實驗驗證, 得出了銀包鋁復合材料立式連鑄復合成形工藝的邊界條件.采用ProCAST軟件模擬了立式連鑄成形過程, 得出各工藝參數對連鑄結果的影響規律, 給出了可行的連鑄工藝參數范圍及工藝調控策略, 以模擬結果為指導, 制備出表面質量高、復合界面效果良好的銀包鋁復合棒材.實驗結果表明, 芯管長度、連鑄速度對結果的影響最大, 芯管長度影響了芯管出口處雙金屬的接觸溫度、接觸時間, 并直接改變了鋁芯固液界面的相對位置.當芯管長度過短時, 銀鋁界面反應較強烈, 當芯管長度過長時, 芯棒冷卻強度大, 芯部鋁產生明顯的冷隔.隨著連鑄速度的增大, 銀的固液界面到芯管出口距離逐漸減小, 鋁的固液界面距出口距離逐漸增大; 鋁液鑄造溫度升高, 冷卻水減少也會帶來相似的作用.結果顯示, 芯管長度30 mm, 速度37~67 mm·min-1, 銀的鑄造溫度1225~1325℃, 鋁的鑄造溫度800℃, 冷卻水流量約300 L·h-1是可行的銀包鋁連鑄工藝.Abstract: Silver clad aluminum composite wire, which combines the high electrical conductivity of silver-coated metal, good welding performance, and low density, has wide application prospects in aerospace and other fields. The preparation of silver clad aluminum bars with high surface quality and good combination of interfaces is an important step in the preparation of silver clad aluminum wire with excellent performance. Continuous casting composite forming is a short, high-efficiency material-forming process, which provides methods for the preparation of silver clad aluminum. The boundary conditions of the vertical continuous casting process of silver clad aluminum composite rod that has a diameter of 20 mm and cladding ratio of 50% were established through finite element numerical simulation using the ProCAST software and corresponding experiments. The effect of each process parameter on continuous composite casting was analyzed, based on which the optimized control method was obtained. A silver clad aluminum composite rod with high surface quality and excellent bonding interface was prepared on the basis of the simulation results. The length of the core tube and the speed of continuous casting are considered to be the most important factors affecting the formation process. The length of the core tube is assumed to affect the contact temperature and time of the aluminum liquid and silver tube at the end of the core tube, and result in the variation of the relative position of the solid-liquid interface of the aluminum. The interface reaction is severe when the core tube is too short. Conversely, significant cold separation occurs in aluminum because of the high cooling intensity when length of the core tube is too large. The actual casting temperature increases with the high continuous casting speed, which can be attributed to the reduction in the distance between solid-liquid interface and the outlet of the core tube for silver and the increase for aluminum. The increase in aluminum casting temperature and reduction in the flow rate of cooling water are found to have a similar effect to that of the increase in continuous casting speed. A series of optimized casting parameters was obtained in this study, i.e., length of the core tube 30 mm, the casting speed is 37-67 mm·min-1, the casting temperature of silver is in the range between 1225℃ and 1325℃, casting temperature of aluminum is 800℃, and the flow rate of cooling water is 300 L·h-1.
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圖 1 銀包鋁立式連鑄原理圖
1—銀熔液; 2—感應線圈; 3—鋁熔液; 4—銀包覆層; 5—鋁芯; 6—水冷銅套; 7—二次冷卻
Figure 1. Schematic diagram of the vertical continuous casting of SCA
圖 2 銀包鋁立式連鑄模型
1—石墨模具; 2—銀包覆層; 3—鋁芯; 4—水冷銅套; a, b, c—測溫點
Figure 2. Vertical continuous casting model of SCA
圖 3 銀包鋁立式連鑄穩態溫度場模擬界面和邊界條件示意圖
1~10為邊界; Ⅰ~Ⅳ為界面
Figure 3. Interface and boundary conditions of the steady-state temperature field simulation of the vertical continuous casting of SCA
圖 4 Ⅰ組實驗. (a) 模擬結果; (b) 實驗結果
Figure 4. Group Ⅰ experiment: (a) simulation results; (b) experimental results
圖 6 Ⅱ組實驗結果. (a) 外表面; (b) 縱截面; (c) 橫截面
Figure 6. Experimental results of group Ⅱ: (a) external surface; (b) longitudinal section; (c) cross section
圖 8 不同工藝參數下的模擬結果. (a) 連鑄速度; (b) 芯管長度; (c) 冷卻水流量; (d) 銀熔化溫度
Figure 8. Simulation results: (a) withdrawing speeds; (b) lengths of the mandrel tube; (c) flow rates of cooling water; (d) silver melting temperatures
圖 9 不同連鑄速度下的溫度場. (a) 15 mm·min-1; (b) 45 mm·min-1; (c) 75 mm·min-1
Figure 9. Temperature fields at different casting speeds: (a) 15 mm·min-1; (b) 45 mm·min-1; (c) 75 mm·min-1
圖 10 不同芯管長度下的溫度場. (a) 25 mm; (b) 30 mm; (c) 45 mm
Figure 10. Temperature fields at different lengths of the mandrel tube: (a) 25 mm; (b) 30 mm; (c) 45 mm
圖 11 銀包鋁圖片. (a) 外表面; (b) 截面; (c) 鋁組織; (d) 銀組織; (e) 界面
Figure 11. Picture of SCA: (a) external surface; (b) sectional view; (c) aluminum structure; (d) silver structure; (e) interface layer
圖 12 不同銀層鑄造溫度下銀鋁界面層. (a) 1280 ℃; (b) 1260 ℃; (c) 1250 ℃
Figure 12. Interface layer of silver and aluminum at different casting temperatures of silver: (a) 1280 ℃; (b) 1260 ℃; (c) 1250 ℃
圖 13 銀鋁界面形成示意圖. (a) 銀的擴散; (b) 界面形成; (c) 銀與鋁互擴散; (d) 凸起結構形成
Figure 13. Schematic diagram showing the formation of the silver-clad aluminum interface: (a) silver diffuses; (b) the interface forms; (c) silver and aluminum interdiffuse; (d) protruding structures form
表 1 棒材與模具的換熱系數
Table 1. Heat transfer coefficient between casting billet and molds
溫度/℃ 空氣熱導率/(W·m-1·K-1) 氣縫寬度/mm 換熱系數/(W·m-2·K-1) 100 0.0321 0.1683 190.75 300 0.0461 0.1293 356.58 500 0.0575 0.0903 636.87 700 0.0671 0.0513 1308.40 800 0.0717 0.0318 2255.80 900 0.0767 0.0123 2500.00 
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表 2 驗證實驗中的工藝參數選擇
Table 2. Process parameters of the validation experiment
組別 冷卻水流量/(L·h-1) 連鑄速度/(mm·min-1) 芯管長度/mm 鋁連鑄溫度/℃ 合金連鑄溫度/℃ Ⅰ 300 30 40 720 600 Ⅱ 300 30 30 720 600 Ⅲ 300 45 30 720 600
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表 3 三組測試點模擬與實測溫度比較
Table 3. Comparison of the simulated/measured temperatures of the test points
組別 a點溫度(實測/模擬)/℃ b點溫度(實測/模擬)/℃ c點溫度(實測/模擬)/℃ 1 850/850 762/760 471/470 2 820/820 752/760 449/431 3 810/820 745/750 483/420
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表 4 各組實驗的工藝參數
Table 4. Experimental parameters of every group
組別 冷卻水流量，w/(L·h-1) 連鑄速度，v/(mm·min-1) 芯管長度，l/mm 銀熔化溫度，T1/℃ 鋁熔化溫度，T2/℃ A 300 45 20, 25, 30, 35, 40 1250 800 B 300 15, 30, 45, 60, 75 30 1250 800 C 200, 250, 300, 350, 400 45 30 1250 800 D 300 45 30 1250 700, 800, 900 E 300 45 30 1175, 1200, 1225, 1250, 1270 800
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表 5 銀包鋁連鑄復合模擬結果
Table 5. Simulation results of the continuous casting of SCA
組別 實驗編號 參數 模擬結果 名稱 數值 L1/mm L2/mm L3/mm t/s ΔT/℃ 1 20 1.5 31.4 18.5 42 61 2 25 17 13.5 8 18 211 A 3 芯管長度/mm 30 22 6.5 8 8.7 259 4 35 27.5 -1 7.5 — 311 5 40 32.5 -5 7.5 — 354 6 15 24 1 6 4 287 7 30 23 4 7 8 272 B 8 連鑄速度/(mm·min-1) 45 22 6.5 8 8.7 259 9 60 21.5 8.5 8.5 8.5 248 10 75 20.5 11.4 9.5 9.12 234 11 200 22 7 8 9.3 256 12 250 22 7 8 9.3 257 C 13 冷卻水流量/(L·h-1) 300 22 6.5 8 8.7 259 14 350 22.5 6 7.5 8 260 15 400 22.5 6 7.5 8 260 16 700 22 6.2 8 8.3 261 D 17 鋁熔化溫度/℃ 800 22 6.5 8 8.7 259 18 900 22 6.8 8 8.7 257 19 1175 40 2 - 2.7 284 20 1200 26 4 4 5.4 275 E 21 銀熔化溫度/℃ 1225 24 5 6 6.7 268 22 1250 22 6.5 8 8.7 259 23 1275 21 7 9 9.3 255
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表 6 銀鋁界面層成分分布
Table 6. Composition distribution of the silver-clad aluminum interface layer
圖 12中測試點 Ag(1280 ℃)
質量分數/%Ag(1260 ℃)
質量分數/%Ag(1250 ℃)
質量分數/%圖 12中測試點 Ag(1280 ℃)
質量分數/%Ag(1260 ℃)
質量分數/%Ag(1250 ℃)
質量分數/%1 97.14 97.40 96.97 7 85.13 81.90 85.44 2 97.14 97.89 96.94 8 84.78 35.86 84.65 3 97.14 97.52 96.41 9 84.30 28.66 33.65 4 88.63 87.28 96.29 10 33.42 38.49 25.32 5 86.57 85.50 87.20 11 48.74 43.25 40.99 6 85.75 83.71 85.84 12 35.99 47.54 33.55
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