Research Progress on the Numerical Simulation of Liquid Phase Sintering in the Mesoscopic Scale
DAI Wenjie1, PAN Shiyan1,2, SHEN Xiaoping2, XU Chi1, FAN Cang1
1 The Department of Materials Science and Engineering, Nanjing University of Science and Technology, Nanjing 210014 2 The Department of Engineering Training Center, Nanjing University of Science and Technology, Nanjing 210014
Abstract: Liquid phasesintering (LPS) is a key technology in powder metallurgy for manufacturing high performance materials.LPS provides an innovative and efficient way for manufacturing nearly fully dense components made of refractory alloys, hard alloys, cermets, etc.The microstructure evolution and densification during LPS directly determine the mechanical properties and dimensional accuracy of the part. Numerical simulation at the mesoscopic/grain scale offers direct insights into the microstructure evolution of the sintered body, and also deals with complex densification mechanisms and their interplays. Hence, numerical simulations of LPS in the mesoscopic scale have gained enormous attentions inrecent years. LPS,involving grain growth and motion, solid-liquid transition and multi-phase flow, etc., presents a great challenge to the numerical simulation and its further applicationin industry. One common way, performing the numerical simulation of LPS, is based on a general assumption that LPS could be resolved into the three stages of grain rearrangement, grain dissolution/precipitation, and skeleton formation. Therefore, each stage of LPS is independently studied for simplification to still reveal some of the microstructure evolution mechanisms and affecting factors. In all the regarding findings, those on grain rearrangement and grain dissolution/precipitation are most fruitful.For grain rearrangement, studies were carried out based on the discrete element method, the liquid bridge coalescence model, etc. During rearrangement, the displacement of each particle was simulated in the viscous liquid under various forces, including inter-particle collision force, sliding force, sintering force and capillary force, etc. In these simulations, the grain motion, pore evolution and densification during grain rearrangement were usually described ignoring the grain growth and coarsening mechanisms. Phase field method and Monte-Carlo method were often adopted to simulate the grain dissolution/precipitation stage, which was treated as the classic Ostwald ripening. Large-scale three-dimensional simulations carried out by phase field method and Monte-Carlo method provided the particle size distribution and the growth kinetics very identical to the experimental observations. However, the simulations focusing on each independent stage is not applicable to describe the whole LPS process and the mechanisms under the experimental conditions, since the ranges overlapped for the three stages of LPS. Recently, the coupling strategies were presented to simulate LPS involving the liquid flow, grain rearrangement and grain growth simultaneously. The quantitative results of microstructure evolution and the sintering kinetics were successfully achieved by several coupled models for LPS, and the results showed higher accuracy than the models simulating only one stage. However, efficient numerical solutions for the three-dimensional simulations and experimental validations are required to promote the industry application of coupled simulations in the future. This paper reviews the recent developments in numerical modeling of LPS in the mesoscopic/grain scale.The reliabilities, accuracies, advantages and disadvantages of each model/method for describing liquid redistribution pore evolution, grain growth and densification are compared and evaluated. Some advice about the future developments of the numerical simulation for LPS is thus given.
作者简介: 代文杰,2013年6月毕业于重庆大学,获得工学学士学位。现为南京理工大学材料学院的博士研究生,在范沧教授和潘诗琰老师的指导下进行研究。目前主要研究领域为基于相场法研究液相烧结过程的机理和现象。 潘诗琰,男,博士,南京理工大学工程训练中心讲师。于2007年从合肥工业大学获得学士学位,于2013年从东南大学取得博士学位,长期从事合金凝固组织演化的相场模拟研究。关于凝固过程微观组织的数值研究方面的工作成绩得到了国内外同行的认可,相关成果先后发表在Acta Materialia、Scripta Materialia、Scientific Reports、Computational Materials Science、Calphad、ISIJ International、Intermetallics和《物理学报》等国际、国内权威期刊,其中SCI收录20篇次、EI收录25篇次,并多次参加国际、国内学术会议。主持国家自然科学基金青年基金项目1项,作为主要参与人参加国家自然科学基金面上项目2项。Journal of Applied Physics、Advances in Mathematical Physics、Computational Materials Science、China Foundry期刊审稿人。
引用本文:
代文杰,潘诗琰,申小平,徐驰,范沧. 介观尺度下液相烧结过程的数值模拟研究进展[J]. 材料导报, 2019, 33(17): 2929-2938.
DAI Wenjie, PAN Shiyan, SHEN Xiaoping, XU Chi, FAN Cang. Research Progress on the Numerical Simulation of Liquid Phase Sintering in the Mesoscopic Scale. Materials Reports, 2019, 33(17): 2929-2938.
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2019, Vol. 33 
