Supergravity metallurgy: principles, experimental methods, techniques, and applications
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摘要: 超重力顯著增大兩相間的重力差，可用于加速固?液、液?液、液?氣高溫黏稠混和體的相分離速度；超重力具有定向性，避免攪拌等技術產生的熔體湍流返混，可用于深度脫除金屬液中細小夾雜物；超重力條件下固?液界面張力微不足道，可容易實現微孔滲流；超重力條件下進行結晶凝固，按結晶順序實現固?液分離，可用于制備梯度材料；超重力加速固?液分離，可細化凝固組織晶粒，但對非共晶熔體也易產生宏觀偏析。將超重力技術應用于冶金及材料生產過程中，有望解決高溫冶金和材料制備的一些難題，如復雜礦冶金渣有價組分的分離提取、冶煉渣中金屬液的分離回收、多金屬的熔析結晶分離、復雜礦直接還原鐵的渣?金分離；在高端金屬材料方面，應用超重力技術，有望解決近零夾物金屬材料的精煉除雜難題，提高梯度功能材料、金屬?陶瓷復合材料、多孔金屬材料、器件材料表面電沉積修飾的制造水平。此外，在材料科學研究方面，超重力凝固可作為一種材料基因組高通量制備方法。Abstract: Supergravity significantly increases the gravity difference between two phases and thus can accelerate phase separation in solid–liquid mixtures, liquid–liquid mixtures, and liquid–bubble mixtures that have high temperatures and viscosities. Due to its directionality, supergravity avoids turbulent backmixing in melts, typically seen in agitation and other separation techniques, and is applicable toward the deep removal of fine inclusions in liquid metals. Under supergravity, solid–liquid interfacial tension is negligible and microporous seepage is straightforwardly achievable. Particle–liquid separation during crystallization can be performed under supergravity to prepare gradient materials. Supergravity accelerates particle–liquid separation, which refines solidified grains, but can also produce macroscopic segregation in noneutectic melts. Supergravity is widely applicable and beneficial to many fields. In metallurgy and materials production, supergravity can be used to improve the separation and extraction of valuable components from metallurgical slags of complex ores, separation and recovery of molten metal in smelting slags, melt crystallization separation of polymetals, and slag–metal separation of reduced iron from complex ores. In addition, supergravity can also be applied to high-end metal materials to improve the refinement and removal of impurities in metal materials toward near zero inclusion. Furthermore, supergravity can improve the manufacturing of functional gradient materials, metal–ceramic composites, porous metal materials, and device materials via electrodeposition modification. Finally, supergravity solidification can be used as a high-throughput method for the preparation of material genomes.
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Key words:
- supergravity /
- phase separation /
- inclusion removal /
- seepage technology /
- graded materials
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圖 1 重力對固?液界面Marangoni效應的影響，超重力與附加壓力對固?液接觸角影響的區別
Figure 1. Effect of gravity on the interface between solids and liquids, and the effect of supergravity and pressure on the contact angle of solids and liquids
圖 2 擴散系數（a）、擴散邊界層厚度（b）與重力系數關系曲線
Figure 2. Relationship between the diffusion coefficient (a) or thickness of the mass transfer diffusion layer (b) and gravity coefficient
圖 3 攪拌上浮與超重力除雜示意圖。（a）攪拌上浮；（b）超重力除雜
Figure 3. Schematic of inclusion removal by gas bubble stirring compared with supergravity: (a) stirring and floating; (b) impurity removal under supergravity
圖 5 超重力分離富集含鈦高爐渣中鈣鈦礦(CaTiO3)。（a）含鈦高爐渣熔析結晶規律；（b）超重力分離富集鈣鈦礦的掃描電鏡與能譜圖
Figure 5. Separation of perovskites (CaTiO3) in a titanium-bearing blast furnace slag by supergravity: (a) crystallization behavior of the titanium-bearing blast furnace slag; (b) energy dispersive spectroscopy (EDS) and scanning electron microscopy (SEM) of separation of the perovskites by supergravity
圖 6 不同條件下熔析結晶?超重力分離含鈦高爐渣中富鈦相
Figure 6. Selective crystallization and separation of titanium-rich phases in a titanium-bearing blast furnace slag by supergravity
圖 7 超重力分離轉爐釩渣中釩鐵尖晶石(FeV2O4)
Figure 7. Separation of vanadium–iron spinel (FeV2O4) in a vanadium-bearing converter slag by supergravity
圖 8 超重力梯級分離稀土精礦熔渣中不同稀土相
Figure 8. Stepwise separation scheme of different rare-earth phases in a rare earth melt by supergravity
圖 9 超重力分步分離含硼渣中遂安石(Mg2B2O5)。（a）步驟 I: T=1443K, G=1000；（b）步驟 II: T=1523K, G=1000；（c）相應的電鏡圖及X射線衍射圖
Figure 9. Two-step separation of suanite (Mg2B2O5) in a boron-bearing slag by supergravity: (a) step I: T = 1443 K, G = 1000; (b) step II: T = 1523 K, G = 1000; (c) SEM and XRD
圖 10 超重力渣/鐵低溫分離。（a）高磷鮞狀赤鐵礦；（b）稀土共生鐵礦
Figure 10. Separation of slag and iron at low-temperature by supergravity: (a) high-phosphorus oolitic hematite; (b) rare earth symbiotic iron ore
圖 11 超重力分離冶煉渣中金屬液滴。（a）銅渣；（b）鋼渣；（c）二次鋁灰
Figure 11. Separation of various metal droplets from smelting slags by supergravity: (a) copper slag; (b) steel-making slag; (c) secondary aluminum ash
圖 12 超重力處理危固冶煉渣。（a）鋁鎂合金精煉渣；（b）不銹鋼冶煉渣
Figure 12. Treatment of hazardous smelting slags by supergravity: (a) reuse of an aluminum–magnesium alloy; (b) stainless steel slag for chromium fixation
圖 13 有色冶金多金屬超重力分離富集。（a）Pb?Sb二元合金；（b）貴鉛Pb?Sb?Bi?Ag多步分離示意圖
Figure 13. Separation and enrichment of nonferrous metals by supergravity technology: (a) Pb–Sb alloy; (b) schematic process of a Pb–Sb–Bi–Ag alloy
圖 14 超重力強化分離廢舊線路板中各類金屬。（a）超重力分步熔融分離；（b）混合金屬超重力凝固
Figure 14. Supergravity-enhanced separation of metals from waste printed circuit boards (WPCBs): (a) stepwise separation of metals by supergravity; (b) solidification of WPCB alloys in supergravity fields
圖 15 超重力脫除鋼水中夾雜物。（a）重力系數對鋼水中SiO2夾雜脫除所需時間的影響（夾雜物上浮30 mm）；（b）718高溫合金樣超重力處理前后夾雜物分布情況
Figure 15. Removal of inclusions in liquid steel by supergravity: (a) effect of the gravity coefficient on the time required for removing SiO2 inclusions from liquid steel (depth 30 mm); (b) distribution of inclusions in 718 superalloy specimens before and after supergravity treatment
圖 16 Al?2.8%Fe鋁液自然沉降除雜和超重力除雜效果對比
Figure 16. Macro and microstructures of an Al?2.8%Fe alloy solidified in normal-gravity and supergravity fields
圖 17 超重力熔析分離Al?Si熔體中結晶硅
Figure 17. Separation of silicon crystals from an Al–Si melt by supergravity-induced liquidation
圖 18 重力系數對不同金屬凝固晶粒尺寸及力學性能的影響。（a）純鋁；（b）Cr12鋼；（c）Al?6%Cu合金；（d）Cu?11%Sn合金
Figure 18. Effect of the gravity coefficient on the grain size and mechanical properties of solidified metals: (a) pure Al; (b) Cr12 steel; (c) Al?6%Cu alloy; (d) Cu?11%Sn alloy
圖 19 超重力凝固制備梯度功能材料。 （a）離心凝固Al/Al3Zr功能梯度材料示意圖；（b）超重力輔助自蔓延高溫合成FeCrNi/TiC梯度金屬陶瓷復合材料
Figure 19. Fabrication of functionally gradient materials (FGMs) by supergravity solidification: (a) schematic illustration of Al/Al3Zr FGM rings prepared by the centrifugal solid-particle method; (b) FeCrNi/TiC gradient composite materials prepared by supergravity-enhanced self-propagating high-temperature synthesis
圖 20 基因組材料高通量制備及材料成分優化設計. （a）Mg56Al30Li7Cu7合金超重力凝固后不同區域的微觀組織;（b）Al2.0CrCuFeNi2高熵合金超重力凝固后不同區域的微觀組織及抗壓強度
Figure 20. High-throughput fabrication of genomic materials and optimization of material compositions: (a) microstructure from different regions of a Mg56Al30Li7Cu7 alloy solidified in supergravity fields; (b) microstructure and compressive strength in different regions of an Al2.0CrCuFeNi2 high-entropy alloy solidified in supergravity fields
圖 21 超重力滲流法制備的80%W?Cu合金宏觀與微觀形貌以及重力系數對合金性能的影響
Figure 21. Macro and microstructure of an 80%W?Cu alloy fabricated by supergravity-induced infiltration, and the effect of the gravity coefficient on its properties
圖 22 超重力滲流制備的Al–SiC梯度復合材料宏觀及微觀形貌
Figure 22. Macro and microstructure of Al–SiC gradient composite materials fabricated by supergravity-induced infiltration
圖 23 以氯化鈉顆粒、空芯玻璃漂珠、PU海綿-石膏為預制體經超重力滲流制備的泡沫鋁及重力系數對泡沫鋁相對密度和結構的影響
Figure 23. Aluminum foams fabricated by supergravity-induced infiltration using NaCl particles, glass cenospheres, and a PU sponge-plaster as preforms, and the effect of the gravity coefficient on the relative density and structure of the prepared aluminum foams
圖 24 超重力場中離子傳遞方向與銅電沉積電流效率產物結構的相互關系
Figure 24. Current efficiencies and deposited structure of Cu electrodeposition in a supergravity field with different mass-transfer directions
圖 25 鎳鍍膜的AFM表面形貌圖及重力系數對鎳鍍膜的粗糙度、硬度、韌性和抗拉強度的影響
Figure 25. AFM image, roughness, hardness, toughness, and tensile strength of nickel foils prepared under supergravity electrodeposition
圖 26 常重力與超重力條件下，NiMo鍍膜的截面微觀結構比較，以及超重力條件下多孔金屬鍍膜的形成機理
Figure 26. Crosssection of NiMo films electrodeposited at different gravity coefficients, and the formation mechanism of porous metal films in supergravity fields
圖 27 超重力與常重力條件下鎳基表面NiO薄膜的SEM和AFM照片
Figure 27. Scanning electron and atomic force microscopy images of the coated NiO layer on a nickel base by electrophoretic deposition under supergravity compared with a control sample
圖 28 金屬液除雜凈化設備結構原理圖。（a）立式批處理；（b）臥式連續處理；（c）滲流過濾或溢流
Figure 28. Schematic of instruments used for the purification of liquid metal: (a) vertical batch reactor; (b) horizontal continuous processing reactor; (c) percolation filtration or overflow reactor
圖 29 冶金熔渣分離有價組分設備結構原理圖。（a）臥式連續處理；（b）臥式批處理
Figure 29. Schematic of instruments used for separating valuable components from metallurgical slags: (a) horizontal continuous processing reactor; (b) horizontal batch reactor
圖 30 廢舊線路板金屬富集料多金屬分步分離設備結構原理設計圖
Figure 30. Schematic of a stepwise centrifugal separation apparatus for separating metals from waste printed circuit boards
圖 31 離心超重力滲流鑄造裝置示意圖
Figure 31. Schematic of filtration casting by a centrifugal device
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