Quantification of temperature, stress, and strain fields during the start-up phase of direct chill casting process by using a 3D fully coupled thermal and stress model for AA5182 ingots

Sengupta, Joydeep; Cockcroft, S. L.; Maijer, Daan M.; Larouche, André

doi:10.1016/j.msea.2005.02.011

Cited by 59 publications

(38 citation statements)

References 7 publications

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“…In 2005, J. Sengpta et al 4) used the tensile properties obtained from Gleeble tensile test by Colley et al 8) to obtain the viscoplastic properties in a semisolid state to predict hot tearing in a AA5182 DC casting slab. In the test during partial remelting such as the Gleeble tensile test, the as-cast specimen is reheated and held at a target temperature.…”

Section: +1mentioning

confidence: 99%

Development of an Elasto-Viscoplastic Constitutive Equation for an Al-Mg Alloy Undergoing a Tensile Test during Partial Solidification

et al. 2015

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Predicting hot tearing during direct chill casting using thermal stress analysis requires constitutive equations in both semi-solid state and below the solidus of the alloy. However, numerous difficulties have been hindered constitutive equations used heretofore for hot tearing predictions. (1) Testing methods for obtaining material constants were inappropriate. First, the elastic strain reversibility was unconfirmed. Second, a flat distribution of temperature in the specimen gauge length was not guaranteed. Third, strain was measured not from local strain but from cross-head displacement. Fourth, the melt-back phenomenon was unavoidable in test during partial remelting because of homogenization of the segregation structure. (2) Temperature dependence of the strain-rate sensitivity of stress was not considered. (3) Some material constants were inferred, not obtained experimentally. This study developed elasto-viscoplastic constitutive equations (Hooke's and viscoplastic NortonHoff laws) for partially solidified state and below the solidus. To obtain material constants experimentally, two tensile tests for which issue (1) was addressed were conducted using Al-5 mass%Mg alloy. They were a tensile test after partial solidification and high-temperature tensile test with high-frequency induction coil. After the temperature dependence of elastic and viscoplastic properties was investigated, material constants were obtained and were compared with those obtained using earlier testing methods.

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Section: +1mentioning

confidence: 99%

Development of an Elasto-Viscoplastic Constitutive Equation for an Al-Mg Alloy Undergoing a Tensile Test during Partial Solidification

et al. 2015

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“…Moreover, performing hot tearing experiments on an industrial scale by adjusting the process parameters is time consuming and expensive. These limitations have necessitated the development of a number of DC casting process simulations based on finite elements (FE) that have examined various aspects of the casting process (e.g., [3][4][5] ) and are able to predict the thermal fields and stress-strain evolution within the cast body (e.g., [6][7][8][9] . The effect of changes in casting parameters can thus be investigated by examining the concomitant changes in the predictions of stress, strain, and temperature evolution.…”

Section: Introductionmentioning

confidence: 99%

Stress–Strain Predictions of Semisolid Al-Mg-Mn Alloys During Direct Chill Casting: Effects of Microstructure and Process Variables

Jamaly

Phillion

Drezet

2013

Metall Mater Trans B

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The occurrence of hot tearing during the industrial direct chill (DC) casting process results in significant quality issues and a reduction in productivity. In order to investigate their occurrence, a new semisolid constitutive law (Phillion et al.) for AA5182 that takes into account cooling rate, grain size, and porosity has been incorporated within a DC casting finite element process model for round billets. A hot tearing index was calculated from the semisolid strain predictions from the model. This hot tearing index, along with semisolid stress-strain predictions from the model, was used to perform a sensitivity analysis on the relative effects of microstructural features (e.g., grain size, coalescence temperature) as well as process parameters (e.g., casting speed) on hot tearing. It was found that grain refinement plays an important role in the formation of hot cracks. In addition, the combination of slow casting speeds and a low temperature for mechanical coalescence was found to improve hot tearing resistance.

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“…Furthermore, the amount of such deformation can be easily calculated using finite element models of casting processes (e.g. [13,19,20]). …”

Section: Model Development 21 Pore Fraction Hot Tearing Modelmentioning

confidence: 99%

Application of a Pore Fraction Hot Tearing Model to Directionally Solidified and Direct Chill Cast Aluminum Alloys

Dou

Phillion

2016

Metall Mater Trans A

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Hot tearing is strongly linked with the applied semi-solid strain rate. This defect is commonly qualitatively predicted using a pressure drop equation in the mushy zone that includes the effects of both tensile deformation perpendicular to the thermal gradient and shrinkage feeding. In this study, the effect of strain rate parallel to the thermal gradient is additionally introduced in order to assess its effect on hot tearing predictions. The deformation and shrinkage pore fractions are obtained on the basis of the dimensionless Niyama criterion and a scaling variable method. This Pore Fraction hot tearing model is first applied to the binary Al-Cu system under conditions of directional solidification. It is shown that for the same Niyama criterion, a decrease in the cooling rate increases both the deformation and shrinkage pore fractions because of an increase in the time spent in the brittle temperature region. Then, using a finite element simulation, the pore fraction distributions during Direct Chill casting of the AA5182 aluminum alloy are obtained. It is shown that including the strain rate parallel to the thermal gradient significantly improved the predictive quality of hot tearing criteria based on the pressure drop equation. Further, an increase in the casting speed increases the deformation and shrinkage pore fractions and causes the maximum point of pore fraction to move towards the base of the casting.

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Quantification of temperature, stress, and strain fields during the start-up phase of direct chill casting process by using a 3D fully coupled thermal and stress model for AA5182 ingots

Cited by 59 publications

References 7 publications

Development of an Elasto-Viscoplastic Constitutive Equation for an Al-Mg Alloy Undergoing a Tensile Test during Partial Solidification

Development of an Elasto-Viscoplastic Constitutive Equation for an Al-Mg Alloy Undergoing a Tensile Test during Partial Solidification

Stress–Strain Predictions of Semisolid Al-Mg-Mn Alloys During Direct Chill Casting: Effects of Microstructure and Process Variables

Application of a Pore Fraction Hot Tearing Model to Directionally Solidified and Direct Chill Cast Aluminum Alloys

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