【作者】 周毅；

【导师】 张卫文；

【作者基本信息】 华南理工大学 ， 材料加工工程， 2012， 硕士

【摘要】 铜水套是一种用于冶金炉上的冷却设备，其突出特点是具有优异的冷却能力，有利于保护炉体和延长冶金炉使用寿命。本文利用砂型铸造方法制备了Cu/Ni、Cu/Monel水套材料，并分析了不同浇注温度下铸件界面的组织和性能；模拟了Cu/Monel水套不同铸造工艺下的铸造充型和凝固过程，并预测了可能产生的缺陷；采用三种雨淋式铸造工艺制备了尺寸为1058mm×300mm×76mm的Cu/Monel水套，分析了水套的组织和性能。主要结论如下：研究了Cu/Ni、Cu/Monel水套材料不同浇注温度下的组织和性能。结果表明：随着浇注温度从1100℃升高到1300℃，Cu/Ni、Cu/Monel水套材料界面处的扩散层厚度增加，显微硬度增大，但剪切强度先增大后减小；在1200℃浇注时，Cu/Ni、Cu/Monel水套材料分别获得了162MPa、199MPa的最佳界面剪切强度；相同浇注温度下，Cu/Monel水套材料的界面组织和剪切强度都要优于Cu/Ni水套材料，主要原因是Monel合金的熔点与Cu更接近，因而扩散熔合更充分。模拟了Cu/Monel水套六种不同铸造工艺下的铸造充型和凝固过程。结果表明：工艺Ⅰ（立浇底注式）、工艺Ⅱ（立浇反雨淋式）、工艺Ⅳ（平浇底注式）充型过程中易发生起伏、飞溅、紊流、涡流等现象，温度场分布不均匀，在埋管间存在温度偏低区域。工艺Ⅲ（立浇雨淋式）、工艺Ⅴ（平浇雨淋式）、工艺Ⅵ（平浇多孔雨淋式）充型过程平稳，铜液自下而上逐步充满型腔，且温度场变化比较平缓。工艺Ⅰ、工艺Ⅱ、工艺Ⅳ中铸件最后凝固区在冒口正下方及埋管间，虽然气孔缺陷数量较少，但在冒口下方及埋管间可能存在大范围缩孔缩松缺陷。工艺Ⅲ、工艺Ⅴ、工艺Ⅵ中铸件最后凝固区域位于雨淋孔下方，且处于铸件的表面处，铸件的埋管附近虽然存在集中气孔，但由于雨淋孔下方的补缩作用，避免了缩孔缩松缺陷的产生。研究了三种铸造工艺下Cu/Monel水套的组织和性能。结果表明：工艺1（立浇雨淋式）、工艺2（平浇雨淋式）、工艺3（平浇多孔雨淋式）中铸件的无间隙率分别为94.5%、95.5%、98.9%；铸件心部位置的界面扩散层最厚，显微硬度过渡区最宽；三种工艺下铸件的最大平均剪切强度分别为175MPa、162MPa和189MPa，最小平均剪切强度分别为52MPa、47MPa和80MPa；对比分析三个铸件的组织和缺陷特征以及界面处的结合强度，工艺3获得的水套铸件综合质量最好。更多还原

【Abstract】 Copper water jacket is a kind of cooling equipment applied in metallurgical furnaces. Itcan protect the metallurgical furnace and extend its service life due to the excellent coolingcapacity. In this paper, Cu/Ni and Cu/Monel water jacket materials were prepared by sandcasting, then the interface structure and property of the ingots prepared at different pouringtemperatures were analyzed. The filling and solidification of the Cu/Monel water jackets bysix kinds of casting processing were simulated and some possible defects were also predicted.The Cu/Monel water jackets with industrial sizes were prepared by three raining pouringprocess and the structure and property of the matrix and interface were studied. The mainconclusions are as follows:The structure and property of Cu/Ni and Cu/Monel water jackets casting at differentpouring temperatures were analyzed. The results show that the thickness of diffusion layerincreases and the interface micro-hardness increases as the pouring temperature increasesfrom1100℃to1300℃, while the shear strength increases first and then reduces. When thepouring temperature is1200℃, Cu/Ni and Cu/Monel water jackets get the best interfaceshear strength, which is162Mpa and199MPa, respectively. Furthermore, at the pouringtemperature of1200℃, the Cu/Monel water jacket gets better microstructure and shearstrength at the interface, because the melting point of Monel alloy is closer to that of Cu thanNi, which results in more fully diffusion.The filling and solidification of the Cu/Monel water jackets with the size of1058mm×300mm×76mm were simulated for six kinds of casting processing. The results show thatthe fluctuation, spattering, turbulence and vortex flow during melt filling process occur inProcess I (vertically placed and bottom gating), Process II (vertically placed and anti-showergating) and Process IV (horizontally placed and bottom gating) with the uneven velocitydistribution. In addition, the temperature distribution is inhomogeneous. There is a lowtemperature region between the pipes. However, the velocity field of Process III (verticallyplaced and shower gating), Process V (horizontally placed and shower gating) and Process VI(horizontally placed and porous-shower gating) is even, and the temperature field is relativelyhomogeneous. Solidification occures from the wall to the core part of the ingots in Process I,Process II and Process IV and some isolated liquid regions are found below the riser andbetween the pipes. However, the final solidification region exists below the pouring holes andthe surface of the ingots in Process III, Process V and Process VI. Although the centralizedhole is found near the embedded pipes, the shrinkage cavity and porosity are vanished due to the the feeding of the raining-pouring gating system.The structure and property of Cu/Monel water jackets with the size of1058mm×300mm×76mm were studied. The results show that the gapless rates of ingots cast by Process1(vertically placed and shower gating), Process2(horizontally placed and shower gating) andProcess3(horizontally placed and porous-shower gating) are94.5%,95.5%and98.9%,respectively. Furthermore, the thickest interface diffusion layer and the widest transitionalzone of micro-hardness are located in the ingots cores. The maximum shear strength of175Mpa,162MPa and189MPa and the minimum shear strength of52MPa,47MPa and80MPa, respectively, are achieved for the ingots prepared by process1, process2and process3.It is concluded that the Cu/Monel water jacket prepared by Process3possesses the bestcomprehensive quality.更多还原