Investigation on the Manufacture of a Large‐Scale Aluminum Alloy Ingot: Microstructure and Macrosegregation

Abstract

A large-scale cylindrical 2219 Al alloy ingot (1 250 mm in diameter and 3 300 mm in length) is manufactured using a special DC casting facility. Macrosegregation of major element (Cu) at different casting stages is determined on three cross-sections of as-cast ingot. Meanwhile, the evolution of temperature filed in the sump is simulated at different casting stages. Further, the relationships, between macrosegregation, temperature field, and grain structures, are investigated. These work provide some insights in the macrosegregation formation during large-scale casting or solidification, further promoting to manufacture the large-scale metallic ingots for potential application.

Effect of Multi-Source Ultrasonic on Segregation of Cu Elements in Large Al–Cu Alloy Cast Ingot

“…However, the casting ingot in group I was significantly higher than the grain size in group II when in the heart location.The maximum deviation of the grain size in group I was 282 μm (Δ r ), which was higher than the same size in group II. The value of the ultrasonically untreated ingot is 300 μm [20]. …”

“…The maximum deviation of the grain size in group I was 282 μm (Δ r ), which was higher than the same size in group II. The value of the ultrasonically untreated ingot is 300 μm [20].…”

A new approach to improving the macrosegregation in zirconium‐containing magnesium‐lithium alloy

“…Regardless of the particles size under 0.1 mm, the dominated size of zirconium particles is about 0.4 mm, Figure 2b2. Magnesium and dark b-Lithium are observed [18], and the grain morphology transforms from equiaxed to dendritic with the average grain size about 100 mm, Figure 3a, c, e. For particle master alloy addition, the average grain size at different positions basically maintains consistent about 70 mm, and dual-phase structure has not been observed, Figure 3b, d, f. These results indicate that the inhomogeneous microstructures exist in the ingot for the block master alloy addition and the grain size rapidly increases along the axial direction. While more homogeneous microstructure along the axial direction can be found for the particle master alloy addition.…”

Effect of Ultrasonic Bending Vibration Introduced by the L-shaped Ultrasonic Rod on Solidification Structure and Segregation of Large 2A14 Ingots

“…In particular, the grain refinement effect at the edge of the ingot was the best, the secondary phase was smaller, more solute elements can be dissolved into the α-Al matrix, and the ability of the L-shaped ultrasonic wave guide rod to restrain segregation was stronger at the edge of the ingot. macro-segregation directly affects the quality of ingots and the subsequent finished products ratio of forging, and increases the material processing loss and production cost [10][11][12][13].At present, applying appropriate ultrasonic vibration in the process of metal solidification is a good method to reducing casting defects, obtaining good structure and improving mechanical properties of materials [14][15][16][17]. Abramov V et al [18] studied the effect of the ultrasonic treatment of the water-cooled transducer on the microstructure and properties of different industrial aluminum based alloy.…”

“…In particular, the grain refinement effect at the edge of the ingot was the best, the secondary phase was smaller, more solute elements can be dissolved into the α-Al matrix, and the ability of the L-shaped ultrasonic wave guide rod to restrain segregation was stronger at the edge of the ingot. macro-segregation directly affects the quality of ingots and the subsequent finished products ratio of forging, and increases the material processing loss and production cost [10][11][12][13].…”