热等静压在铸造高温合金领域的应用

采用适当热等静压工艺处理铸造高温合金,利用高温高压实现铸件内部疏松孔洞的蠕变扩散,达到闭合疏松和均匀合金组织的目的,使铸造高温合金的综合力学性能,尤其是疲劳性能、塑性及合金力学性能的稳定性显著提高,大大提高了铸件使用的安全性和可靠性.介绍了热等静压工艺处理高温合金铸件的致密化原理、工艺因素及其对合金组织和性能的影响,同时概述了热等静压技术的应用成果及发展状况.     

船用柴油机涡轮增压器叶片材料的研制

根据船用柴油机涡轮增压器叶片的使用要求,研制了一种高钛型铁基铸造高温合金——2O8合金。文中介绍了合金化学成份的选择,列举了合金全面性能的研究结果。在严格控制钛、铝、碳元素含量的前提下,适当选择合理的浇注和热处理工艺,可以获得较稳定的合金组织。     

TiAl合金增压器涡轮研究进展

采用轻质TiAl合金代替较重的镍基高温合金制作内燃机增压器涡轮,是改善内燃机加速响应性、实现轻量化的有效技术途径之一.围绕TiAl合金增压器涡轮的工程化应用,分析了TiAl合金增压器涡轮的合金及组织设计、涡轮制备技术、涡轮连接技术、母合金制备技术、应用考核试验等方面的国内外研究现状和研究进展.认为我国铸造技术和连接技术...     

铸造高温合金真空感应熔炼过程的研究

本文主要介绍铸造高温合金真空感应熔炼工艺的基本原理和过程。利用实验证明了熔炼过程中精炼期、合金化期、浇注期对铸造高温合金材料纯净度、显微组织、力学性能及表面质量等方面所产生的影响。实验证明:精炼期对材料中杂质元素Pb、Bi,气体元素N、O有良好的去除作用;以γ′相为强化的高温合金,合金化过程中,Al的过量添加,将产生大量的β-Ni Al脆相,使材料塑性大幅下降;浇注过程,温度过高致使铸件晶粒粗大,易产生缩孔。浇注温度过低致使铸件表面产生大量冷隔等缺陷。     

工业燃气轮机涡轮叶片用铸造高温合金研究及应用进展

工业燃气轮机具有热效率高、污染低等突出优点,成为未来发电机组与大型水面舰船动力的首选设备。铸造高温合金是工业燃气轮机涡轮叶片等热端部件的关键材料,其性能和制备水平在一定程度上决定了先进燃气轮机的功率、效率、寿命等性能。本文重点综述了工业燃气轮机及其涡轮叶片用铸造高温合金材料的研究及应用现状,并对工业燃气轮机涡轮叶片用铸造高温合金及涡轮叶片制造技术的发展趋势进行了展望。未来,先进定向凝固,“材料基因工程”等技术将逐渐应用到工业燃气轮机涡轮叶片用铸造高温合金的研制中;此外,先进工业燃气轮机上定向/单晶高温合金的应用将越来越广泛。     

铸造工艺对K424合金涡轮组织和性能的影响

研究了不同铸造工艺对K424合金涡轮铸件组织和性能的影响,实验结果表明:浇注温度和模壳温度越高,铸件晶粒越大,越容易在靠近浇口部位产生缩孔缺陷;反之,晶粒越小,组织越均匀,铸件成型和补缩越困难,内部显微疏松越严重,力学性能波动越大;通过采用一定的强化控制凝固冷却措施,有利于涡轮铸件轮盘部位的凝固补缩.当模壳温度为950℃、浇注温度为1470℃,并采用适当的强化控制凝固冷却措施时,K424合金涡轮铸件获得较理想的显微组织、优良的综合力学性能.     

ZL205A热壳精密铸造工艺研究

ZL2 0 5A合金以其优良的综合力学性能在航空航天工业中得到广泛的应用 ,但ZL2 0 5A合金的铸造工艺性能较差 ,一般适用于带冷铁的砂型铸造 ,在热壳精密铸造生产铸件时 ,对浇注工艺的要求很高 ,否则很容易出现疏松、缩松、气泡、表面缩陷等铸造缺陷 ,导致铸件质量和力学性能不合格 .本研究结合ZL2 0 5A的铸造性能特点 ,进行了ZL2 0 5A合金的热壳精密铸造研究 ,总结了浇注工艺参数和加压凝固工艺对ZL2 0 5A热壳精密铸件质量的影响 .     

铸造Al-Cu合金凝固缺陷研究现状

铸造Al-Cu合金的凝固缺陷严重影响了铸件的性能,控制或消除凝固缺陷对提高铸件成品率有重大意义。综述了铸造Al-Cu合金在工程中出现的常见凝固缺陷,如偏析、热裂、显微疏松、缩孔等。重点分析了各类缺陷的形成机理与特点,从合金化、熔铸工艺、热处理工艺、数值模拟等角度提出了减少铸造Al-Cu合金凝固缺陷的方法。     

离心铸造高强耐热铜镍合金的组织和性能研究EI北大核心

高镍含量的Cu-Ni-Al合金由于具有优异的高温耐磨特性,可应用于航空、航天等领域中,制造具有耐腐蚀、高温耐磨、高导热性能的关键零部件。本工作采用离心铸造工艺制备了一种复杂合金化的高温耐磨铜合金。重点分析了不同铸造工艺参数对铸件组织特征和力学性能的影响。同时与常用耐磨铝青铜合金QAl10-4-4的性能进行了比较。结果表明:浇注温度显著影响铸件横截面上的等轴晶比例,为了使铸件获得全部的等轴晶,浇注温度必须控制在1250℃左右。在最佳工艺参数下,合金的室温抗拉强度为810MPa,500℃下的高温抗拉强度为435MPa,分别比QAl10-4-4合金提高了14%和110%。     

铸件热裂缺陷预测及其工艺优化

以解决铸件热裂为目的,以生产中遇到的典型铸件为例,利用ProCAST铸造模拟软件,对不同铸件结构和不同浇注工艺条件下的铸件热裂缺陷形成倾向进行了系统研究,得到了优化后的铸件结构和铸造工艺,并进行了生产验证,其结果基本吻合.     

热等静压技术在镍基铸造高温合金领域的应用研究

镍基铸造高温合金是航空发动机与燃气轮机生产制造过程中应用的主要材料之一,在航空航天、能源工业、船舶舰艇等领域有着广泛的应用。现代航空工业的飞速发展离不开高温合金综合性能的快速提升,而热等静压技术在镍基铸造高温合金领域的应用对镍基铸造高温合金综合性能的改进方面发挥了举足轻重的作用。本文介绍了热等静压技术的工作原理与应用发展历史,总结了热等静压技术在镍基铸造高温合金领域的研究应用现状,重点阐述了热等静压技术对铸造高温合金的致密化作用机理与组织性能影响、热等静压对长期服役镍基铸造高温合金组织修复研究以及实现两种镍基高温合金扩散连接的应用优势与研究成果。同时指出热等静压技术研究中存在的一些问题及国内热等静压技术在镍基铸造高温合金领域的发展趋势。     

高温合金电磁软接触近净成形定向凝固研究

传统高温合金叶片类铸件制备过程中,熔体长时间受到陶瓷模壳材料的污染,性能难以提高,借助于电磁软接触成形技术中的电磁压力使高温合金熔体呈半悬浮状态,减少了熔体与磁模结晶器的接触面积和时间,提高了合金熔炼和成形的纯净度,同时将该技术和定向凝固技术相结合开发了一种实现高温合金复杂形状电磁软接触成形定向凝固的工艺,并探讨了该工艺下3种结晶器材料（陶瓷、磁模和石墨）中磁感应强度的分布规律,结果表明,石墨套高度对磁模结晶器磁感应强度的大小和分布以及熔体温度场有很大影响。通过调整上下线圈功率和抽拉速度等工艺参数成功地制备了大小两种近叶片形状的高温合金电磁软接触成形的定向凝固样件。．     

Development of superalloys

Abstract

The development of what are now termed superalloys is reviewed from the early days of high-temperature alloys in the light of the demands of engineers for materials to serve under differing conditions of stress, temperature, and environment. Before the introduction of the aircraft gas turbine the main interest lay in the field of low-alloy creep resisting steels for steam raising plant or in heat resistant alloys for relatively low-stressed furnace components. Piston aeroengines posed two problems – the exhaust valve and the turbo supercharger rotor – and special materials for these components were introduced, largely on the basis of high-temperature tensile strength. The gas turbine demanded high creep resistance and two main lines of alloy development were followed: carbide-hardened iron or cobalt-base alloys and γ′-hardened nickel-base alloys. The latter type has surpassed the former and now, either in wrought form or, predominantly for the most severe conditions, as castings, is the mainstay of superalloy applications. In recent years, progress has mainly been sought by the improvement of macrostructure: in castings by directional solidification to give columnar crystals or single crystals and in wrought products by powder technology. Severe hot corrosion has been combated by the application of protective surface coatings and the development of a series of wrought and cast high-chromium nickel-base alloys. It is anticipated that future progress in high-temperature materials technology will be sought in the application of a variety of metallurgical and physical techniques to specific engineering components in much the same manner as was done with the aeroengine exhaust valve of 50 years ago.

MST/511     

有利于铸造TiAl合金增压器涡轮叶片可靠性的组织设计

针对增压器涡轮应用背景,详细分析定向层片组织铸造TiAl合金的室温拉伸塑性、断裂韧度以及高温热暴露后的剩余塑性等反映叶片抗损伤能力的性能,并讨论在叶片中形成这种定向层片组织的工艺可行性,以获得一种有利于增压器涡轮可靠性的组织设计。结果表明:定向层片组织铸造TiAl合金具有优异的室温拉伸塑性和断裂韧度,并且在高温热暴露后仍能保持较高的室温拉伸塑性,这些优异性能均依赖于定向层片取向一致性特征。通过控制凝固冷却条件和Ti/Al原子比,在增压器涡轮叶片中可以获得层片界面近似平行叶片表面的定向层片组织,有利于提高叶片的抗损伤能力,从而改善TiAl合金增压器涡轮的使用可靠性。     

Study of hot tearing of A206 aluminum alloy using Instrumented Constrained T-shaped Casting method

The hot tearing susceptibility of A206 aluminum alloy was investigated using Instrumented Constrained T-shaped Casting method and the effect of the casting temperature on hot tearing was studied. The Instrumented Constrained T-shaped Casting apparatus enabled real-time measurements of the contraction load developed in the casting and the temperature variations during solidification as a function of time. Critical temperatures and points during solidification of the castings were extracted from these data. The contraction load developed at the coalescence point of the castings was identified as a comparative criterion for predicting the hot tearing susceptibility of the alloys which could be utilized even when no visual tearing had occurred. The results showed that hot tearing susceptibility increased with the casting temperature. This was associated with reduced cooling rate, increased solute segregation and more localized hot spot formation at the T-junction area. Increase in the casting temperature also increased the grain size which may in turn have affected the initiation of the hot tears. The visual observations were further validated with radiographic tests.     

Mechanical properties of conventionally cast,directionally solidified,and single-crystal superalloys

Abstract

In this paper the authors compare the creep and low-cycle fatigue properties of conventional, directionally solidified, and single-crystal castings produced from nickel-base superalloys. A brief historical review describes the reasons for the evolution from wrought to cast product through directionally solidified to modern single-crystal (‘monocrystal’) castings. The influence of microstructural variations produced by the casting conditions, such as porosity and grain size, on creep and low-cycle fatigue properties are illustrated. The important aspects of postsolidification heat treatment, hot isostatic pressing, and the damaging effects of impurities are described for conventional castings. The results of controlling the microstructures produced by directional solidification especially by high temperature gradient solidification are demonstrated by comparing the creep properties of directionally solidified materials with those of the conventionally cast alloys in long-term tests. The creep and low-cycle fatigue properties depend on the stress direction relative to the crystallographic directions of the material for both directionally solidified and single-crystal castings. For single crystals, individual alloys show variable dependences of properties on the crystallographic directions. Directionally solidified materials show advantages in thin sections and are less sensitive to the effects of impurities compared to conventional castings.

MST/329     

Use of vacuum for counter-gravity casting of metals

 The use of vacuum to fill molds to form investment castings in a countergravity casting fashion was started in the early 1970s. This paper describes how the processes work and the reasons for their advantages in cost, quality, and process control. Countergravity casting is being done in sand, permanent, and investment (lost wax) ceramic molds and alloys are cast in air and inert atmospheres. The process started with common steels, was extended to heat resistant superalloys, and recently even titanium alloys are being cast routinely using ceramic crucibles. The use of a unique mold design enables a great reduction in metal cast to yield a given part, thereby greatly reducing the energy use in making such castings. Computerized control of the rate of vacuum application enables complete control of filling rates, permitting casting of very high quality castings in very viscuous metals, such as metal matrix composites of aluminum. These processes are used to produce more than $200  million worth of castings annually and this will greatly increase in the next few years due to the production of automotive exhaust manifolds in stainless steel. Received: 21 July 1998 / Accepted: 10 September 1998     

K403合金铸造涡轮叶片热裂的研究

研究表明，热裂是合金枝晶间液体处于不连通状态的温度与合金完全凝固温度范围内产生，铸造涡轮叶片热裂最常出现的部位是叶冠与叶身或者榫根与叶身的连接段，热裂在外貌上呈弯曲不规则形状，通常是不连续的，常有几条裂纹沿枝晶间或晶界向相同的方向扩展，热裂严重区断口呈光滑的“土豆”状，在热裂扩展出现光滑区与撕裂并存。降低合金初熔温度的微量合金化元素（如Ｂ，Ｚｒ）明显增加了热裂的敏感性。     

On the tensile creep behaviour of a directionally-solidified Ni3Al-based alloy

High temperature tensile creep behaviour of a directionally-solidified Ni₃Al-based alloy is presented. The study involved selection of nine alloy systems based on Ni₃Al. The alloys contained varying amounts of Cr and Ta, fixed amounts of 1·5 at.% Hf and 0·5 at.% Zr and doped with 0·2 at.% each of C and B. The alloys were vacuum arc-melted into buttons and homogenized at 1050°C for 68 h. The test pieces of the alloys were hot compression tested at 600, 700, 800 and 900°C. The yield strength data of some of the alloys were superior to conventionally cast Mar-M 200, a cast nickel-base superalloy widely used in gas turbine structural applications. The best alloy system was chosen based on consistent performance in the hot compression studies. The alloy so chosen was directionally solidified and vacuum-homogenization-treated for 20 h at various selected temperatures. Optimum creep properties were observed at 1120°C, 20 h treatment. The minimum creep rate data of the DS alloy showed relatively higher values even at lower temperatures and stress levels as compared to Mar-M 200. Hence, the alloy is less promising in replacing nickel-based superalloys used as structural materials in gas turbine applications.     

Ru对镍基单晶高温合金凝固特性、TCP相析出及蠕变性能影响的研究进展EI北大核心CSCD

镍基单晶高温合金因优异的高温力学性能而被广泛应用于航空发动机和地面燃气轮机的涡轮叶片等关键热端部件。Ru元素作为第四代、第五代镍基单晶高温合金的主要特征元素,其添加对合金从凝固特性到最终的服役性能都起到关键的影响。本文从镍基单晶高温合金的凝固特性、凝固组织、TCP相析出及蠕变性能等方面出发,综述了Ru元素对镍基单晶高温合金影响的研究进展,系统分析了Ru的添加对合金凝固路径、凝固特征温度、微观偏析等凝固特性及共晶、碳化物等凝固组织的影响规律,并重点探究了Ru的添加能抑制TCP相析出及提高合金蠕变性能的原因。目前由于多组元交互作用对组织与性能影响机理的复杂性,使得含Ru高温合金的成分设计与优化具有更高的挑战,建议未来含Ru高温合金的相关研究从富Ru新相的析出原因及抑制、Ru添加对凝固缺陷的影响及Ru与其他元素交互作用对“逆分配”效应及TCP相析出的影响机制等方面做进一步探究,为发展新型高性能含Ru高温合金的设计提供思路。