Tuning the Planar-Flow Melt-Spinning Process Subject to Operability Conditions

Su, Yu Guang; Chen, Falin; Chang, Chia Ming; Wu, Chung Yung; Chang, Ming Wen; Chung, C. A.

doi:10.1007/s11837-014-0982-3

Cited by 9 publications

(6 citation statements)

References 28 publications

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“…Convective heat transfer coefficient 'h' is the proportionality constant between the heat flux and the temperature difference. The convective heat transfer coefficient was usually assumed as an average value when heat transfer during PFC process was concerned [1,2,9,11,22]. However, it disagrees with the facts and is not reliable or accurate.…”

Section: Convective Heat Transfer Coefficient Distributionmentioning

confidence: 99%

Three-dimensional temperature and stress field simulation with all-hexahedral element mesh in a high efficiency cooling structure for the fabrication of amorphous ribbons

Chen

Shen

et al. 2022

Mater. Res. Express

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Planar flow casting is an advanced technology to produce amorphous and nanocrystalline ribbons in electrical application. At present, the utilization rate of roller surface is generally under 20% in industrial production. This work reports a new cooling structure that is designed to produce ribbons width 65mm with the utilization rate of roller surface up to 65%. The cooling structure is simulated with the software ANSYS by employing three-dimensional temperature and stress field mathematic model incorporating actual production conditions with all-hexahedral element mesh. It is shown that the liquid velocity is uniform with consistent distribution of convective heat transfer coefficient in width direction between cooling water and rotating roller. The thermal expansion difference in the new cooling structure is only 0.0042mm at the ribbon edge. In this case, it is unnecessary to make the slit with an upward bend. The new cooling structure is expected to be applied for industrial production at an ideal level.

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Section: Convective Heat Transfer Coefficient Distributionmentioning

confidence: 99%

Three-dimensional temperature and stress field simulation with all-hexahedral element mesh in a high efficiency cooling structure for the fabrication of amorphous ribbons

Chen

Shen

et al. 2022

Mater. Res. Express

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“…Wu et al 35 performed three-dimensional numerical analysis on the effect of the gas distribution on the characteristics inside a COREX shaft furnace. Chen et al 36 studied the tuning of the planar-flow melt-spinning process.…”

Section: 23mentioning

confidence: 99%

Optimization of Metallurgical Reactors Using Mathematical and Physical Modeling

Zhang

2014

JOM

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Because of the tremendous cost of pilot-plantscale metal industrial trials, previous attempts to develop new metallurgical processes have generally relied on scaling up small bench-scale experiments. Because of the lack of true understanding of the rate constants, mixing phenomena, and geometric effects that control the success of the real process, many previous pilot-plant operations have been unsuccessful. Water modeling and mathematical modeling instead have become the main approaches to optimize the metallurgical reactors. To achieve success, the model must accurately predict the phenomena of true interest, including the following: -Multiphase and turbulent fluid flow within each vessel in the process, incorporating the effects of gas stirring and including transient variations, which are the main source of variability in the product -Mixing phenomena in each vessel, including solidification, heating, and remelting of a metal layer around alloy particle additions, which directly controls the success of alloying, and is important to other reactions as well -Heat-transfer phenomena, including temperature drops between each vessel -Evolution of composition during each vessel, including the thermodynamics and kinetics of the reactions between the molten metal and interfaces with the top slag and bubble surfaces, coupled with fluid flow and mixing phenomena -Effects of the true three-dimensional features of the vessel shape (including location of inlet and outlet launder), gas injection location and flow rates, and other operating conditions on the above phenomenaExtensive past work has employed physical water models to successfully investigate fluid flow phenomena in metallurgical processes such as the steel refining and casting process 1-5 and the aluminum remelting process.6-10 The first water modeling for the fluid flow in a continuous casting mold study was carried out by Afanas'Eva et al.11 for a straight bore nozzle system. Physical water models can model single-phase fluid flow because of the simulation of kinematic viscosity of steel and water. However, it is hard to use water modeling to simulate the solidification of molten metals.With the tremendous increases in the power of computer hardware and modeling software, computational modeling offers a better design tool for creating new processes. Numerical simulation has the potential to quantify the phenomena taking place in a commercial-scale process before it is constructed. Mathematical models can yield added insight into flow phenomena. Computational models based on finite-volume or finite-element solution of the Navier-Stokes equations can include phenomena such as heat transfer, multiphase flow, and solidification in steel casting without the inaccuracies inherent in a water model. Extensive research focused on the design of the metallurgical reactors using mathematical modeling such as for molten steel system 2,12-22 and molten aluminum system. 6,23THE CURRENT JOM TOPICThe current JOM topic addresses the optimization of metallurgical reactors, suc...

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“…This can be exemplified in processes such as rapid solidification and severe plastic deformation, where amorphous and nanostructured metals can be produced, respectively. Within the area of melt processing, planar-flow melt spinning (PFMS) and splat quenching [1,2] have been used to produce thick films and coatings for a variety of materials. PFMS involves the deposition of molten metal through a nozzle onto the surface of a rotating cold wheel, on which the metal solidifies into a thick film or ribbon.…”

Section: Introductionmentioning

confidence: 99%

“…Typical film thicknesses obtained in PFMS for metals can range from 8 lm to a few hundred micrometers, depending on the material being cast as well as on the processing conditions. [1,6] Moreover, cooling rates have been reported to range between 10 4 and 10 6 K/s, [7] while splat quenching can have cooling rates of 10 4 to 10 10 K/s, again depending on conditions, [8] but typically produces ''coat'' thicknesses of 30 lm and above. In PFMS, the film thickness has been found to be inversely proportional to wheel speed.…”

Section: Introductionmentioning

confidence: 99%

Novel Ballistic Processing of Thick Films: Structural Evolution and Mechanical Behavior

Hille

Youssef

Azadfallah

et al. 2020

Metall Mater Trans A

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Ballistic processing (BP) is a new process that promises almost instantaneous processing of thick and thin films, through the acceleration of a carrier through a molten metal stream. The mechanisms by which such films are produced are difficult to study due to the ultrarapid processing speeds involved. In this article, we use the thermal properties of the carrier to reveal the mechanisms of formation of these films. High-speed imaging and extensive postprocessing characterization were used to arrive at a fundamental understanding of the microstructural evolution of thick films in BP. Results show that the thermal characteristics of the carrier material play a role in the morphology, topography, structure, and mechanical behavior of the processed films. An increase in carrier thermal conductivity generally resulted in an increase in film thickness and apparent elastic modulus. Increasing the carrier speed beyond the current limit is forecasted to decrease the thickness and improve the properties.

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Tuning the Planar-Flow Melt-Spinning Process Subject to Operability Conditions

Cited by 9 publications

References 28 publications

Three-dimensional temperature and stress field simulation with all-hexahedral element mesh in a high efficiency cooling structure for the fabrication of amorphous ribbons

Three-dimensional temperature and stress field simulation with all-hexahedral element mesh in a high efficiency cooling structure for the fabrication of amorphous ribbons

Optimization of Metallurgical Reactors Using Mathematical and Physical Modeling

Novel Ballistic Processing of Thick Films: Structural Evolution and Mechanical Behavior

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