An improved simulation modelling on the heat transfer process of wire-feeding spheroidization in iron melt

Abstract

The wire-feeding spheroidization treatment is important research and how to realize visual control of the process is an unsolved problem all along. In this work, an improved model of cored wire-feeding spheroidization coupled with more proper boundary conditions was developed, in which both the heat transfer effect of Mg-core and steel shell are considered. In our simulation, an implicit time integration scheme was given in the framework of FVM to ensure the convergence of calculations. The reliability performance of the presented model was verified by comparing it with the test of the artificial insertion method. Particularly, the relationship among the temperature of the iron melt, the speed of wire-feeding and melt-explosion depth of cored wire was investigated using our model. In addition, we also study the temperature variation rules at different positions of the cross-section of cored wire, and the effects of parameters on the microstructures and properties of ductile iron could provide theoretical guidance for industrial production.

Study of Assimilation of Cored Wire into Liquid Steel Baths

“…Most of the cited works on the modeling of cored wire [30,[32][33][34][35][36][37]39,40] have relied, for model validation, on published data on the assimilation of static cylindrical metal rods, which are simpler constructions than cored wires themselves. In the work of Du Terrail et al [31], a method in which a cored wire is fitted with thermocouples and metal detectors to determine the wire assimilation time is discussed.…”

“…The number of published studies in which the assimilation of cored wire is discussed is comparatively smaller. Modeling works by different groups such as Bannenberg et al [30], Du Terrail et al [31], Sanyal et al [32,33], Castro et al [34][35][36], Huang et al [37], Jingang et al [38], Guo et al [39], and Wang et al [40] have presented various modeling work frames, allowing for the description of possible assimilation routes during the injection of cored wires. These routes are summarized schematically by the present authors in Figure 1, considering that the wire filler can be released in a solid, liquid, or gaseous state.…”

“…The different wire assimilation routes are a function of the wire design parameters (e.g., wire core and casing materials, casing thickness) and processing conditions (e.g., bath material, bath superheat, wire injection speed). Most of the cited works on the modeling of cored wire [30,[32][33][34][35][36][37]39,40] have relied, for model validation, on published data on the assimilation of static cylindrical metal rods, which are simpler constructions than cored wires themselves. In the work of Du Terrail et al [31], a method in which a cored wire is fitted with thermocouples and metal detectors to determine the wire assimilation time is discussed.…”

Heat Transfer and Melting Characteristics of Calcium‐Cored Wire in Molten Steel

“…[26,27] The heat transfer process of the cored wire was characterized by a numerical simulation using Ansys software, and the melting time and optimal wire feeding speed of the cored wire in the molten steel were determined. [28] The influence of the size and shape of the cored wire on the melting behavior was studied. [29,30] The cylindrical-cored wire provides better heat transfer characteristics; however, the temperature distribution of the cored wire at different melting periods cannot be explained.…”