Prediction of Hot Tear Formation in Vertical DC Casting of Aluminum Billets Using a Granular Approach

Sistaninia, M.; Drezet, Jean‐Marie; Phillion, A.B.; Rappaz, M.

doi:10.1007/s11837-013-0662-8

Cited by 13 publications

(8 citation statements)

References 11 publications

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“…Within each grain, deformation is rather homogeneous and modeled using a continuum FE method, whilst, within the entire domain, discontinuous deformation is modeled using the discrete element method. As shown previously, the SDM requires a domain containing a minimum of 700 grains in order to accurately model semi-solid deformation [27]. Above this number, the behavior of the domain does not depend on the number and/or the distribution of grains, i.e.…”

Section: The Semi-solid Deformation Modulementioning

confidence: 94%

A 3-D coupled hydromechanical granular model for simulating the constitutive behavior of metallic alloys during solidification

et al. 2012

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A three-dimensional (3-D) coupled hydromechanical granular model has been developed and validated to directly predict, for the first time, hot tear formation and stress-strain behavior in metallic alloys during solidification. This granular model consists of four separate 3-D modules: (i) the solidification module is used to generate the solid-liquid geometry at a given solid fraction; (ii) the fluid flow module (FFM) is used to calculate the solidification shrinkage and deformation-induced pressure drop within the intergranular liquid; (iii) the semi-solid deformation module (SDM) simulates the rheological behavior of the granular structure; and (iv) the failure module (FM) simulates crack initiation and propagation. Since solid deformation, intergranular flow and crack initiation are deeply linked together, the FFM, SDM and FM are coupled processes. This has been achieved through the development of a new three-phase interactive technique that couples the interaction between intergranular liquid, solid grains and growing voids. The results show that the pressure drop, and consequently hot tear formation, depends also on the compressibility of the mushy zone skeleton, in addition to the well-known contributors (lack of liquid feeding and semi-solid deformation).

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Section: The Semi-solid Deformation Modulementioning

confidence: 94%

A 3-D coupled hydromechanical granular model for simulating the constitutive behavior of metallic alloys during solidification

et al. 2012

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“…The granular model can provide the inputs for hot tearing criteria at the microstructure scale, along with the spatial variations in these parameters [169]. This allows the formation of hot tearing in grain boundaries by considering both the stochastic variations in grain morphology and the process parameters in DC casting [166,170]. As shown in Fig.…”

Section: Kou's Criterionmentioning

confidence: 99%

“…5.10. 3D granular model predictions of the liquid pressure in a representative volume located at the centre of a round billet at two casting speeds [170].…”

Section: Kou's Criterionmentioning

confidence: 99%

Recent advances in hot tearing during casting of aluminium alloys

Katgerman

et al. 2021

Progress in Materials Science

133

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Hot tearing is one of the most severe and irreversible casting defects for many metallic materials. In 2004, Eskin et al. published a review paper in which the development of hot tearing of aluminium alloys was evaluated . Sixteen years have passed and this domain has undergone considerable development. Nevertheless, an updated systematic description of this field has not been presented. Therefore, this article presents the latest research status of the hot tearing during the casting of aluminium alloys. The first part explains the hot tearing phenomenon and its occurrence mechanism. The second part presents a detailed description and analysis of the characterisation methods of the mushy zone mechanical properties and hot tearing susceptibility. The third part presents considerable data pertaining to the mushy zone behaviour, including those of the linear contraction and load behaviour during solidification, semi-solid strength and ductility, and characteristic points related to hot tearing. The fourth part examines the effect of the composition and casting process parameters on the hot tearing susceptibility of aluminium alloys. The fifth part describes the hot tearing simulations and the associated criteria and mechanisms. Finally, recommendations for the further development of hot tearing research are presented.

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“…Such cracks can form during manufacturing processes of the materials [21][22][23][24] or installation processes. It could also be associated with the surface roughness.…”

Section: Rve With a Pre-existing Crackmentioning

confidence: 99%