Simulation of As‐Cast Steel Ingots

Wu, Menghuai; Ludwig, Andreas; Kharicha, Abdellah

doi:10.1002/srin.201700037

Cited by 19 publications

(14 citation statements)

References 78 publications

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“…This four phase mixed columnar-equiaxed solidification model was described elsewhere [114]. Figures 8-10 display a modeling result for a 36-ton steel ingot, and comparison with the experiment [125]. Experimental analysis of this ingot was recently published by Duan et al [126].…”

Section: Application Of Mixed Columnar-equiaxed Solidification Modelmentioning

confidence: 98%

“…To solve this problem, an additional phase (the phase number 4), i.e., gas phase (or covering liquid slag phase), is introduced into the model. The gas phase has no mass and species exchange with the metal phases, but it is coupled with them by taking into account the Figures 8-10 display a modeling result for a 36-ton steel ingot, and comparison with the experiment [125]. Experimental analysis of this ingot was recently published by Duan et al [126].…”

Section: Application Of Mixed Columnar-equiaxed Solidification Modelmentioning

confidence: 99%

“…When incorporating a dendritic morphology into the multiphase volume-averaged solidification models, it is necessary to consider different phase regions. For example, the liquid melt, which is enclosed in the deep dendrite (interdendritic melt), has a far different solute concentration than the This mixed columnar-equiaxed solidification model was mostly applied to study macrosegregation in steel ingots [69,124,125,[127][128][129], but it was also used analyze solidification during direct chill casting of copper alloys [130,131] and continuous casting of steel [132]. In the meantime, this model is being continuously improved by considering the multicomponent alloy [69,70] and the fragmentation rates [133].…”

Section: Incorporation Of Dendritic Morphologymentioning

confidence: 99%

“…The macrosegregation, both simulated (a) and experimental (b), is shown for the carbon segregation index in % (cindex = 100x(cmix-co)/co). cmix is the mixture concentration of all metal phases: Reproduced from[125], with permission from John Wiley and Sons, 2019.…”

mentioning

confidence: 99%

“…Comparison of the numerically-simulated macrosegregation profiles along the centerline (left) and across the diameter of three different horizontal sections (right: see section A, B, C inFigure 9a) with the experimental specimen (36-ton ingot). Reproduced from reference[125], with permission from John Wiley and Sons, 2019.…”

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confidence: 99%

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Volume-Averaged Modeling of Multiphase Flow Phenomena during Alloy Solidification

Ludwig

Kharicha

2019

Metals

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The most recent developments and applications in volume-averaged modeling of solidification processes have been reviewed. Since the last reviews of this topic by Beckermann and co-workers [Applied Mech. Rev. 1993, p. 1; Annual Rev. Heat Transfer 1995, p. 115], major progress in this area has included i) the development of a mixed columnar-equiaxed solidification model; ii) further consideration of moving crystals and crystal dendritic morphology; and iii) the model applications to analyze the formation mechanisms of macrosegregation, as-cast structure, shrinkage cavity and porosity in different casting processes. The capacity of computer hardware is still a limiting factor. However, many calculation examples, as verified by the laboratory casting experiments, or even by the casting processes at a small industrial scale, show great application potential. Following the trend of developments in computer hardware (projection according to Moore’s law), a full 3D calculation of casting at the industry scale with the multiphase volume-averaged solidification models will become practically feasible in the foreseeable future.

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Section: Application Of Mixed Columnar-equiaxed Solidification Modelmentioning

confidence: 98%

Section: Application Of Mixed Columnar-equiaxed Solidification Modelmentioning

confidence: 99%

Section: Incorporation Of Dendritic Morphologymentioning

confidence: 99%

mentioning

confidence: 99%

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confidence: 99%

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Volume-Averaged Modeling of Multiphase Flow Phenomena during Alloy Solidification

Ludwig

Kharicha

2019

Metals

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Spatial Characterization of Internal Defects in Medium Carbon Steel via X‐Ray Computed Tomography

Ali

Zhang

Sui

et al. 2022

steel research int.

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Herein, the 3D characterization of internal defects in medium carbon steel with different soft reduction (SR) parameters is investigated, as regards its spatial morphology and size distribution using X‐ray computed tomography. The size of defects and their shape complexity increase from the equiaxed toward the center of the ingot, and the total number of defects is larger at the equiaxed region, which exhibits the aggregation and growth of small spherical pores into the large defects from equiaxed toward the center region. The two types of shrinkage defects, including island and net shrinkage, are identified. With the minimum reduction amount of 2 and 4 mm, the number and size of defects along with the carbon macrosegregation in the equiaxed region and center of the ingot are less as compared to the high reduction amount of 6 mm and without SR technology. The size of gas pores with sphericity >0.6 is <70 um with different reduction amounts and exceeds up to 150 um without SR. Therefore, minimum reduction amounts can easily regulate the internal defects in medium carbon steel.

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Numerical Simulation on the Fluid Flow, Air Entrainment, Heat Transfer, and Solidification during Top Pouring and Cooling of a 303 Ton Heavy Ingot

Wei

Zhou

Chen

et al. 2023

steel research int.

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Herein, a mathematical model combined with the k–ε turbulence model, volume of fluid multiphase model, and heat transfer and solidification model is established to investigate the steel–air two‐phase flow and solidification during the filling process of a 303 ton heavy steel ingot. The measured temperatures at different times are employed to validate the current mathematical model. The results show that the predicted results are in good agreement with the measured results. At the initial stage of the filling process, a double‐roll flow pattern is formed near the junction between the liquid surfaces due to the high speed of the jet flow. The maximum impinging depth of the jet flow is 1.8 m and the maximum splash height of the molten steel is 0.3 m. An empirical formula for the variation of the entrained air volume with time is proposed. The maximum growth rate in the horizontal direction is 0.08 mm s−1. In the vertical direction, the maximum growth rate of the solidified shell on the central axis is 0.12 mm s−1. The distribution of primary dendrite arm spacing and secondary dendrite arm spacing is obtained by combining the predicted cooling rate.

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Simulation of As‐Cast Steel Ingots

Cited by 19 publications

References 78 publications

Volume-Averaged Modeling of Multiphase Flow Phenomena during Alloy Solidification

Volume-Averaged Modeling of Multiphase Flow Phenomena during Alloy Solidification

Spatial Characterization of Internal Defects in Medium Carbon Steel via X‐Ray Computed Tomography

Numerical Simulation on the Fluid Flow, Air Entrainment, Heat Transfer, and Solidification during Top Pouring and Cooling of a 303 Ton Heavy Ingot

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