镁合金半固态触变射铸技术研究进展

姜巨福; 张金泽; 崔竞波; 王迎; 张晓东

doi:10.13700/j.bh.1001-5965.2025.0584

镁合金半固态触变射铸技术研究进展

doi: 10.13700/j.bh.1001-5965.2025.0584

姜巨福^{1, 2, ,},
张金泽^{1, 2},
崔竞波^{1, 2},
王迎³,
张晓东^{1, 2}

1.
哈尔滨工业大学材料科学与工程学院，哈尔滨 150001
2.
哈尔滨工业大学精密热成形全国重点实验室，哈尔滨 150001
3.
哈尔滨工业大学机电工程学院，哈尔滨 150001

基金项目:

国家自然科学基金(52431004)；东莞市重点领域研发项目(20241200300012)

详细信息

通讯作者:
E-mail：jiangjufu@hit.edu.cn

中图分类号: TG146.22
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- 文章访问数: 291
- HTML全文浏览量: 129
- PDF下载量: 9
- 被引次数: 0
出版历程
- 收稿日期: 2025-08-21
- 录用日期: 2025-10-10
- 网络出版日期: 2025-11-06
- 整期出版日期: 2026-10-01

Research progress in semi-solid thixomolding technology of magnesium alloys

JIANG Jufu^{1, 2
, ,},
ZHANG Jinze^{1, 2},
CUI Jingbo^{1, 2},
WANG Ying³,
ZHANG Xiaodong^{1, 2}

1.
School of Materials Science and Engineering，Harbin Institute of Technology，Harbin 150001，China
2.
National Key Laboratory of Precision Hot Forming，Harbin Institute of Technology，Harbin 150001，China
3.
School of Mechatronics Engineering，Harbin Institute of Technology，Harbin 150001，China

Funds:

National Natural Science Foundation of China (52431004); Dongguan City Key Field Research and Development Projects (20241200300012)

More Information

Corresponding author: E-mail：jiangjufu@hit.edu.cn

摘要

摘要:
镁合金因其低密度特性，在交通设施轻量化领域具有重要的战略意义，但传统铸造工艺面临缩孔、气孔及氧化等技术瓶颈，基于半固态加工原理的创新成形工艺——触变射铸技术，为有效突破上述瓶颈提供了可行途径。为此，系统阐述了触变射铸技术的基本原理，揭示了非枝晶结构的形成机制与半固态浆料的制备方法，并重点分析了该技术对AZ系及AM系镁合金综合性能的提升作用。目前，该技术已在消费电子及交通运输载具领域实现规模化应用。依托新一代大吨位成形设备，其应用领域逐步拓展至大型结构件制造领域，在新能源汽车产业中展现出突出的发展潜力。未来研究需重点关注新型半固态触变射铸镁合金的成分设计、成形过程的多物理场耦合模拟及大型构件缺陷控制机制等方面。
- 镁合金 /
- 半固态成形 /
- 触变射铸 /
- 力学性能 /
- 轻量化
Abstract:
Because of their low density, magnesium alloys are strategically valuable for lightweight transportation equipment. Nevertheless, conventional casting processes encounter technical challenges, including shrinkage porosity, gas porosity, and oxidation. Thixomolding—an innovative forming process based on semi-solid processing principles-provides a viable approach to overcome these limitations. This work systematically elucidates the fundamental mechanisms of thixomolding, reveals the formation principles of non-dendritic microstructures and preparation methodologies for semi-solid slurries, and comprehensively analyzes the technology’s enhancement effects on the comprehensive properties of AZ-series and AM-series magnesium alloys. Currently, this technology has achieved industrial-scale implementation in consumer electronics and transportation equipment sectors. Supported by next-generation higher-tonnage forming systems, its applications are progressively expanding to large-scale structural component manufacturing, demonstrating exceptional development potential within the new energy vehicle industry. Among other crucial areas, future research should focus on defect control mechanisms for large-scale components, multi-physics coupled modeling of the forming process, and composition design of innovative thixomolded magnesium alloys.
- magnesium alloy /
- semi-solid forming /
- thixomolding /
- mechanical properties /
- lightweight

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图 1 半固态加工原理示意图^[18]

Figure 1. Schematic diagram of semi-solid forming^[18]

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图 2 剪切速率和湍流强度对凝固过程中生长模式影响的示意图^[25]

Figure 2. Schematic diagram of influence of shear rate and turbulence intensity on growth patterns in solidification process^[25]

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图 3 第2个三次枝晶臂脱落过程中溶质富集的演变^[29]

Figure 3. Evolution of solute-enrichment during fragmentation of a second tertiary dendrite arm^[29]

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图 4 双螺杆流变成形工艺示意图^[34]

Figure 4. Schematic illustration of twin-screw rheomolding process^[34]

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图 5 电磁搅拌装置结构示意图^[35]

Figure 5. Schematic diagram of electromagnetic stirring device^[35]

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图 6 凝固速率R与熔体流动速度v对晶粒形貌影响的模拟结果^[40]

Figure 6. Simulated grain morphologies under different solidification velocities R and liquid flow velocities v^[40]

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图 7 SIMA法工艺路线图^[50]

Figure 7. Process map of SIMA^[50]

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图 8 采用新SIMA法制备的AZ80合金半固态浆料在不同温度下的显微组织^[62]

Figure 8. Microstructure of AZ80 alloy semisolid billet fabricated by new SIMA at different temperatures^[62]

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图 9 镁合金触变射铸设备及其关键部件^[2,69-70]

Figure 9. Magnesium alloy thixomolding equipment and its key components^[2,69-70]

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图 10 镁合金切削前后显微组织^[74]

Figure 10. Microstructure of magnesium alloy before and after cutting^[74]

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图 11 冷室压铸、热室压铸和触变射铸试样的微观结构^[20]

Figure 11. Microstructures of cold-chamber die-casting, hot-chamber die-casting, and thixomolding samples^[20]

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图 12 常规铸态与触变射铸态AM系镁合金的微观组织特征

Figure 12. Microstructure characteristics of AM series magnesium alloys prepared by conventional casting and thixomolding

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图 13 触变射铸镁合金试样的TEM图像^[67]

Figure 13. TEM images of thixomolding magnesium alloy specimens^[67]

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图 14 不同工艺的镁合金试样在室温下经5×10⁻⁴ mol/L NaCl溶液浸泡约4.5天后的顶面腐蚀形貌与横截面SEM图像^[122]

Figure 14. Top surface corrosion morphology and cross-sectional SEM images of magnesium alloy specimens with different processes after immersion in 5×10⁻⁴ mol/L NaCl solution at room temperature for approximately 4.5 days^[122]

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图 15 触变射铸AM60B镁合金与不同工艺制备同系镁合金的疲劳性能对比^[124]

Figure 15. Comparison of fatigue properties between thixomolding AM60B magnesium alloy and counterpart Mg alloys fabricated by conventional processes^[124]

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图 16 Mg-Al-Ca合金体系富Mg角的液相线投影图^[128]

Figure 16. Phase line projection of Mg rich angle in Mg-Al-Ca alloy system^[128]

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图 17 AZ91-xRE(Ce、Y、Gd，x = 0, 0.3, 0.6, 0.9)合金中Mg₁₇Al₁₂化合物的质量分数^[132]

Figure 17. Mass fraction of Mg₁₇Al₁₂ compound in AZ91-xRE (Ce, Y, Gd, x = 0, 0.3, 0.6, 0.9) alloys^[132]

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图 18 大型镁合金触变射铸成形设备^{[70,136,140-142]}

Figure 18. Large magnesium alloy thixomolding equipment^{[70,136,140-142]}

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图 19 消费电子结构件、外壳件^[145,147]

Figure 19. Structural components and housings for consumer electronics^[145,147]

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图 20 户外运动产品结构件、外壳件^[145]

Figure 20. Structural components and housings for outdoor sports products^[145]

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图 21 汽车结构件^[68,145,147]

Figure 21. Structural components for automobiles^[68,145,147]

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图 22 汽车关键大型结构件^{[140,142,148-149]}

Figure 22. Critical large structural components for automobiles^{[140,142,148-149]}

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表 1 半固态浆料组织形成机制的主要假说

Table 1. Major hypotheses on formation mechanism of semi-solid slurries microstructure

假说	特点及适用范围	主导因素	对实际生产的指导
枝晶臂破碎与枝晶臂根部重熔理论	应用广泛，解释了晶核增殖过程的机制，对实际生产有重要指导意义，但尚无法解释枝晶到蔷薇状晶、近球状晶的转变路径	破碎枝晶	机械搅拌法、电磁搅拌法等成熟制浆工艺
生长控制理论	解释了枝晶在剪切作用下，向蔷薇状晶、近球状晶的转变机制	剪切速率	双螺杆挤出机等
有效持续形核机制	半固态浆料微观结构主要依赖于湍流而不是剪切速率，湍流的作用提高了浆料的形核速率	形核速率	双螺杆剪切制浆、流变压铸等工艺
自由晶核生成机制	利用临界密度的游离晶核在凝固过程中直接诱导近球状晶形核	游离晶核	液相线铸造、剪切低温浇注法等新型工艺

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表 2 国内外镁合金触变射铸与传统半固态制浆法的组织参数对比

Table 2. Comparison of microstructural parameters between domestic and international magnesium alloy thixomolding and traditional semi-solid slurry processing methods

镁合金成分	固相晶粒尺寸/μm	形状因子	工艺	参考文献
AZ91D	32.0	0.72	触变射铸	[67]
AM60	50.0		触变射铸	[77]
AZ91D	66.6		触变射铸	[78]
AZ91D	30.0		触变射铸	[79]
AZ91	10.5		触变射铸	[80]
AZ91	50.0		触变射铸	[81]
AZ91D	70.0		触变射铸	[82]
AZ91D	45.3	0.65	触变射铸	[83]
AZ61	60.0	0.70	半固态等温处理	[53]
AM60B	200.6	0.71	半固态等温处理	[63]
AZ80	62.0	0.71	半固态等温处理	[84]
Mg-10Gd-3Y-0.5Zr	90.0	0.70	半固态等温处理	[85]
Mg-3Nd-0.2Zn-0.4Zr	46.0	0.59	电磁搅拌	[86]
AZ91D	77.2	0.59	气泡诱导法	[87]
AZ91-2Ca	50.0	0.70	气泡诱导法	[88]
Mg-2.5Gd-1Zn	180.0	0.29	低频电磁搅拌	[37]
Mg-Gd-Zn	501.0	0.30	低频电磁搅拌	[89]
Mg-6Zn-1.4Y	32.0	0.76	超声振动法	[90]
Mg-11Gd-3Y-1Zn-0.2Zr	63.0		旋转热焓平衡装置法	[91]
AZ91	50.0	0.81	剪切低温浇注法	[92]
AZ91D	45.3	0.85	内部快速冷却搅拌工艺	[93]
AM60	65.0		自孕育法	[94]
AM60	100.0	0.70	再结晶重熔	[53]
Mg-8.20Gd-4.48Y-3.34Zn-0.36Zr	62.0		SIMA法	[95]
AZ80	12.5	0.89	新SIMA法	[62]
AM60B	15.1	0.88	新SIMA法	[63]
AZ80	15.6	0.87	新SIMA法	[96]

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表 3 国内外半固态触变射铸Mg-Al系镁合金力学性能分析

Table 3. Analysis of mechanical properties of domestic and foreign semi-solid thixomolding Mg-Al series magnesium alloys

镁合金成分	屈服强度/MPa	抗拉强度/MPa	延伸率/%	成形方法	参考文献
AZ91D	169	299	8.0	触变射铸	[15]
AZ91D	192	279	10.0	触变射铸	[20]
AZ91D		240	4.5	触变射铸	[67]
AZ91D	180	230	4.4	触变射铸	[77]
AZ91D		245	3.9	触变射铸	[110]
AZ91D		285	7.6	触变射铸	[111]
AZ91D		253	4.3	触变射铸	[112]
AZ91D		170	3.0	触变射铸	[113]
AZ91D	170	273	7.2	触变射铸	[71]
AZ91D	158	256	6.0	触变射铸	[114]
AZ91D	145	248	7.4	流变射铸	[34]
AZ91D	138	225	4.5	流变压铸	[115]
AZ91D	144	200	2.5	高压压铸	[115]
AM60	127	192	5.0	触变射铸	[15]
AM50A	138	268	20.0	触变射铸	[22]
AM60B	147	278	18.8	触变射铸	[22]
AM60B	160	240	7.2	触变射铸	[77]
AM60	140	210	5.4	触变射铸	[116]
AM60B	146	269	11.0	触变射铸	[117]
AM50A	140	269	7.8	触变射铸	[118]
AM60B	102	155	8.0～9.0	高压压铸	[103]
AM60B		141	5.3	高压压铸	[119]
AM50A		103	5.5	高压压铸	[120]

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表 4 国内外部分设备制造商旗下3000～4000 t级镁合金触变射铸成形机参数^{[70,136,139-143]}

Table 4. Parameters of 3000−4000 t thixomolding machines from selected domestic and international equipment manufacturers^{[70,136,139-143]}

设备厂家	型号	设备吨位/t	锁模机构	螺杆直径/mm	最大理论注射量/kg	已公布下一代设备吨位/t
日本制钢所	JLM3000-MGIIeL	3000	三板式	130	8
海天金属	HMG3000	3000	三板式	150	10	5000
伊之密	UN3200MGII	3200	三板式	160	11	6600
伯乐智能	MTX4000D	4000	二板式	170	17

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