Numerical and Experimental Study on the Direct Chill Casting of Large-Scale AA2219 Billets via Annular Coupled Electromagnetic Field

Zhao, Haodong; Zhang, Zhifeng; Bai, Yang; Li, Bao; Gao, Mingwei

doi:10.3390/ma15051802

Cited by 3 publications

(3 citation statements)

References 28 publications

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“…Gross compositional defects such as the formation of freckles or segregated chimneys is caused by macrosegregation. This is associated with the following causes: solidification shrinkage [189][190][191][192], natural and forced convection [193][194][195], grain movement [196], mushy deformation [195], and cavitation bubbles [197]. Fragmentation has been researched as an important phenomenon using large-scale simulations as it is responsible for grain refinement [198][199][200][201].…”

Section: Solute Transport and Segregationmentioning

confidence: 99%

A Review of Large-Scale Simulations of Microstructural Evolution during Alloy Solidification

Cusato,

Nabavizadeh,

Eshraghi

2023

Metals

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During the past two decades, researchers have shown interest in large-scale simulations to analyze alloy solidification. Advances in in situ X-ray observations of the microstructural evolution of dendrites have shown defects that can be very costly for manufacturers. These simulations provide the basis for understanding applied meso-/macro-scale phenomena with microscale details using various numerical schemes to simulate the morphology and solve for transport phenomena. Methods for simulating methodologies include cellular automaton, phase field, direct interface tracking, level set, dendritic needle networks, and Monte Carlo while finite element, finite difference, finite volume, and lattice Boltzmann methods are commonly used to solve for transport phenomena. In this paper, these methodologies are explored in detail with respect to simulating the dendritic microstructure evolution and other solidification-related features. The current research, from innovations in algorithms for scaling to parallel processing details, is presented with a focus on understanding complex real-world phenomena. Topics include large-scale simulations of features with and without convection, columnar to equiaxed transition, dendrite interactions, competitive growth, microsegregation, permeability, and applications such as additive manufacturing. This review provides the framework and methodologies for achieving scalability while highlighting the areas of focus that need more attention.

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Section: Solute Transport and Segregationmentioning

confidence: 99%

A Review of Large-Scale Simulations of Microstructural Evolution during Alloy Solidification

Cusato,

Nabavizadeh,

Eshraghi

2023

Metals

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“…There have many reports about the effect of electromagnetic stirring on the large-sized aluminium alloy billets DC-casting process. Zhao et al [15] proposed an internal coupled electromagnetic melt treatment (ICEMT) to produce AA2219 billets with a diameter of 440 mm. As a result, grains are much refined and uniformly distributed, and the severe positive macrosegregation in the centre was promoted significantly.…”

Section: Introductionmentioning

confidence: 99%

Effects of PMMT on microstructure and macrosegregation of large-sized 6061 alloy billet

Bao

Rui-yin³

et al. 2023

Materials Science and Technology

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The pulsed magnetic field melt treatment (PMMT) was applied in the direct chill (DC) casting of 6061 alloy billets with a diameter of 430 mm. The results indicated that the billet solidification structure was refined and homogenised. The grain size was reduced by 20.4% in the billet centre. Meanwhile, the PMMT can reduce the addition of grain refiner. The negative macrosegregation in the billet centre was reduced significantly. This can be attributed to the melt structure being changed by the energy of the pulsed magnetic field, which leads to the temperature of the melt variation and increased nucleation rate. This study may offer a promising method for the high-quality large-sized 6061 alloy billets preparation with less grain refiner.

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“…Many researchers have demonstrated that applying external fields is an effective method to improve the metallurgical quality of DC casting billets [15][16][17]. With the advantages of contactless, pollution-free, low-cost and easy operation, the application of electromagnetic fields, such as low-frequency electromagnetic fields and AC and DC combined magnetic fields, in the aluminum alloy DC casting process has become a research hotspot [18][19][20]. Recently, pulsed magnetic field treatment has gained attention due to its advantages of energy conservation and weakening of the skin effect.…”

Section: Introductionmentioning

confidence: 99%

Effects of Pulsed Magnetic Field Melt Treatment on Grain Refinement of Al-Si-Mg-Cu-Ni Alloy Direct-Chill Casting Billet

Bao

Xing

et al. 2022

Metals

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Al-Si-Mg-Cu-Ni alloy is widely used in the manufacture of high-performance car engine parts. Coarse, dendritic α-Al and large primary Si are common in Al-Si-Mg-Cu-Ni alloy DC casting billet, which is harmful to the performance of the final product. In this paper, a pulsed magnetic field melt treatment technique was applied to the melt in the launder of a DC casting platform to modify the α-Al and primary Si in the billet. A transient numerical model was established to analyze the electromagnetic field, flow field and temperature field in the melt during the pulsed magnetic field treatment. The effect of the magnetic energy on the clusters in the melt was analyzed. We found that during the pulsed magnetic field melt treatment, the number of clusters close to the critical size was increased due to the cluster formation work being reduced by the magnetic energy, which facilitated nucleation and refined the solidification structure. Furthermore, the flow velocity increased, and temperature homogenized in the melt during the pulsed magnetic field melt treatment, which benefitted the clusters close to the critical size distributed and maintained in the melt uniformly. The experimental results show that the α-Al and primary Si were small and homogeneous following the pulsed magnetic field melt treatment. The size of α-Al and primary Si was reduced by 25.6–44.4% and 32.2–54.1%, respectively, in the billet center compared to the conventional process.

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Numerical and Experimental Study on the Direct Chill Casting of Large-Scale AA2219 Billets via Annular Coupled Electromagnetic Field

Cited by 3 publications

References 28 publications

A Review of Large-Scale Simulations of Microstructural Evolution during Alloy Solidification

A Review of Large-Scale Simulations of Microstructural Evolution during Alloy Solidification

Effects of PMMT on microstructure and macrosegregation of large-sized 6061 alloy billet

Effects of Pulsed Magnetic Field Melt Treatment on Grain Refinement of Al-Si-Mg-Cu-Ni Alloy Direct-Chill Casting Billet

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