TC4合金变截面构件熔模铸造工艺优化及缺陷控制

贺同正; 陈玉勇; 吴敬玺; 罗国军; 沈选金; 唐丽英

doi:10.7513/j.issn.1004-7638.2024.03.007

TC4合金变截面构件熔模铸造工艺优化及缺陷控制

doi: 10.7513/j.issn.1004-7638.2024.03.007

贺同正^{1, 2,},
陈玉勇^{2, 3},
吴敬玺³,
罗国军^{1, 2},
沈选金^{1, 2},
唐丽英^{1, 2}

1.
攀钢集团攀枝花钢铁研究院有限公司, 四川攀枝花 617000
2.
四川省航空钛合金精密铸造工程研究中心, 四川攀枝花 617000
3.
哈尔滨工业大学材料科学与工程学院, 黑龙江哈尔滨 150001

详细信息

作者简介:
贺同正，1971年出生，男，河南南阳人，博士研究生，高级工程师，研究方向钛合金精密铸造，E-mail: hetongzheng@163.com

中图分类号: TF823，TG249
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出版历程
- 收稿日期: 2024-02-23
- 刊出日期: 2024-07-02

Optimization of the investment casting process and defect control for variable cross−section components of TC4 alloy

He Tongzheng^{1, 2
,},
Chen Yuyong^{2, 3},
Wu Jingxi³,
Luo Guojun^{1, 2},
Shen Xuanjin^{1, 2},
Tang Liying^{1, 2}

1.
Panzhihua Research Institute of Iron & Steel Co., Ltd., Pangang Group, Panzhihua 617000, Sichuan, China
2.
Sichuan Engineering Research Center of Aerial Titanium Alloy Precision Casting, Panzhihua 617000, Sichuan, China
3.
School of Materials Science and Engineering, Harbin Institute of Technology, Harbin 150001, Heilongjiang, China

摘要

摘要: 以TC4合金变截面构件为研究对象，基于正交试验设计，采用ProCAST软件对铸件的离心熔模铸造工艺进行了优化。同时，对铸件的充型与凝固行为进行了数值分析，并对铸件质量及力学性能进行了表征。结果表明，缩松缩孔集中分布在铸件顶部，少量缩松缩孔离散分布在铸件中部或底部，孤立液相区是导致缩松缩孔形成的主要原因，熔体流动停止表现出窄结晶温度范围合金特征；应力集中主要发生在内浇道与铸件连接处，较大的结构变化是诱使应力集中产生的主要原因。对铸件内部质量及尺寸进行表征分析，发现铸件内部无缩松缩孔存在，铸件尺寸可以较好地满足设计要求，未发生明显变形。热等静压态铸件的室温抗拉强度为953.5 MPa、屈服强度为835.0 MPa、断后伸长率为10.0%，可以较好地满足实际服役要求。
- TC4合金 /
- 变截面构件 /
- 熔模铸造 /
- ProCAST数值分析 /
- 缺陷控制
Abstract: In this study, the centrifugal investment casting process was optimized using ProCAST software based on an orthogonal experiment for TC4 alloy variable cross−section components. Simultaneously, the mold filling and solidification behaviors of the castings were investigated in detail, and the quality and mechanical properties of the castings were characterized. The results show that a small amount of shrinkage porosity is discretely distributed in the middle and bottom of the casting, while a large concentration is discretely distributed at the top. The formation of isolated liquid phase zones is the main reason for the shrinkage porosity, and the termination of melt metal flow exhibits the characteristics of a narrow crystallization temperature range. At the same time, the stress concentration mainly occurs at the connection between the inner sprue and the casting, and the major cause of it is the large structural change. The internal quality and dimensions of the casting were characterized, and it was discovered that there is no shrinkage porosity, the casting dimensions better satisfy the design requirements, and there is no visible deformation. The room-temperature tensile strength (UTS) of the hot isostatic pressing (HIPed) castings is 953.5 MPa, the yield strength (YS) is 835.0 MPa, and the elongation (EL) is 10.0%, which can better meet the actual service demands.
- TC4 alloy /
- variable cross−section components /
- investment casting /
- ProCAST numerical simulation /
- defect control

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图 1 铸件的三维模型

Figure 1. Three−dimensional models of the casting

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图 2 拉伸试样尺寸(单位：mm)

Figure 2. Size of tensile specimens

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图 3 铸件正交试验缩松缩孔模拟结果

Figure 3. Results of shrinkage porosity simulation in the orthogonal experiment of the casting

(a) A1B1C1D1; (b) A1B2C2D2; (c) A1B3C3D3; (d) A2B1C2D3; (e) A2B2C3D1; (f) A2B3C1D2; (g) A3B1C3D2; (h) A3B2C1D3; (i) A3B3C2D1

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图 4 充型与凝固过程（优化方案）

(a)～(d) 充型过程；(e)～(h) 充型速度； (i)～(l) 凝固过程

Figure 4. Filling and solidification processes (optimization scheme)

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图 5 缩松缩孔与孤立液相区（优化方案）

(a) 缩松缩孔； (b) 顶部孤立液相区； (c)、(d) 中部和底部的孤立液相区

Figure 5. Shrinkage porosity and the isolated liquid−phase zones (optimization scheme)

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图 6 组织模拟（优化方案）

(a)、(b) 凝固初期； (c)～(e) 凝固中期； (f) 凝固末期; (b1) 图(b)中虚线框部分的局部放大； (d1) 图(d)中虚线框部分的局部放大；(f1) 图(f)中虚线框部分的局部放大

Figure 6. Simulation results of macrostructure (optimization scheme)

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图 7 熔体流动终止示意

(a) 充型过程; (b) 流动终止阶段; (c) 完全凝固阶段

Figure 7. The cessation mechanism of flow

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图 8 有效应力及变形（优化方案）

(a) 有效应力； (b) 网格变形； (c) 间隙宽度

Figure 8. Effective stress and deformation (optimization scheme)

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图 9 陶瓷型壳与铸件的宏观形貌

(a) 型壳; (b) 铸件

Figure 9. Macromorphology of the ceramic shell and the casting

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图 11 热等静压态微观组织（附铸试样）

Figure 11. Microstructure of HIPed (excised bar samples)

(a) OM; (b) SEM

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图 10 铸件质量分析

(a)～(d) X射线无损探伤; (e) 解剖示意; (f) 解剖实物; (g) 铸件变形拟合; (h) 铸件剖面变形拟合

Figure 10. Quality analysis of the casting

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图 12 热等静压态铸件的断口形貌（附铸试样）

Figure 12. Fracture morphology of HIPed castings (excised bar samples)

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表 1 正交试验设计

Table 1. Orthogonal experimental design

序号	A / ℃	B / ℃	C /(kg·s⁻¹)	D/ (r·min⁻¹)	方案
1	1680	300	3	350	A1B1C1D1
2	1680	350	5	450	A1B2C2D2
3	1680	400	7	550	A1B3C3D3
4	1700	300	5	550	A2B1C2D3
5	1700	350	7	350	A2B2C3D1
6	1700	400	3	450	A2B3C1D2
7	1750	300	7	450	A3B1C3D2
8	1750	350	3	550	A3B2C1D3
9	1750	400	5	350	A3B3C2D1
A代表浇注温度（℃）；B代表型壳预热温度（℃）；C代表浇注速率(kg/s)；D代表离心转速(r/min)。

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表 2 正交试验直观分析

Table 2. Intuitive analysis table of orthogonal experiment

序号	A/℃	B/℃	C/ (kg·s⁻¹)	D/(r·min⁻¹)	方案	缩松缩孔 /cm³
1	1680	300	3	350	A1B1C1D1	5.1081
2	1680	350	5	450	A1B2C2D2	5.1409
3	1680	400	7	550	A1B3C3D3	5.2849
4	1700	300	5	550	A2B1C2D3	5.5014
5	1700	350	7	350	A2B2C3D1	5.4112
6	1700	400	3	450	A2B3C1D2	5.1672
7	1750	300	7	450	A3B1C3D2	6.1459
8	1750	350	3	550	A3B2C1D3	5.3232
9	1750	400	5	350	A3B3C2D1	5.4044
K1	15.5339	16.7554	15.5985	15.9237
K2	16.0798	15.8753	16.0467	16.4540
K3	16.8735	15.8565	16.8420	16.1095
R	1.3396	0.8989	1.2435	0.5303

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