Three-Dimensional Simulation of Macrosegregation in a 36-Ton Steel Ingot Using a Multicomponent Multiphase Model

Tu, Wutao; Duan, Zhenhu; Shen, Bingzhen; Shen, Houfa; Liu, Baicheng

doi:10.1007/s11837-016-2023-x

Cited by 14 publications

(9 citation statements)

References 15 publications

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“…It is worth mentioning that the casting was recently made, and more reliable process conditions and precise segregation measurement of the as-cast ingot were provided. [73,74] The result was a very promising simulation-experiment agreement, either regarding the segregation map (Figure 8) or the segregation profiles along different lines (Figure 9). It also provides reasonable shrinkage cavity and porosity information.…”

Section: Macrosegregationmentioning

confidence: 77%

“…Major improvements of the model in comparison with the previous three‐phase models are: (i) including the dendritic morphology of the equiaxed crystals, (ii) including the solidification shrinkage and its interaction with the formation of macrosegregation. It is worth mentioning that the casting was recently made, and more reliable process conditions and precise segregation measurement of the as‐cast ingot were provided . The result was a very promising simulation‐experiment agreement, either regarding the segregation map (Figure ) or the segregation profiles along different lines (Figure ).…”

Section: Capabilities and Limitationsmentioning

confidence: 80%

“…A four‐phase mixed columnar‐equiaxed solidification model is used to simulate macrosegregation in a 36‐ton ingot. a) The macrosegregation map of the as‐cast ingot in the longitudinal section was determined chemically using infrared carbon‐sulfur analyzer (only half of the section was analyzed, another half is mirrored); (b) Numerically‐simulated segregation maps in different vertical and horizontal sections, as presented in the similar color scale as the experiment; (c) as‐predicted shrinkage cavity (top surface profile) and probability of the centerline shrinkage porosity according to the CBN‐criterion . The macrosegregation, both experimental a) and simulated b), is shown for the carbon segregation index ( c index = 100 × ( c mix – c o )/ c o ).…”

Section: Capabilities and Limitationsmentioning

confidence: 99%

See 2 more Smart Citations

Simulation of As‐Cast Steel Ingots

Ludwig²,

Kharicha

2017

steel research int.

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Some of the most recent examples of simulations of as‐cast steel ingots are presented in this paper, focusing on discussions concerning available simulation/modeling tools and their capacities and limitations. Although, there has been some success from implementing criterion functions into commercial codes to predict shrinkage porosity and hot tearing, large‐scale ingot sectioning experiments, similar to what is done a century ago, are still needed to investigate other issues, such as macrosegregation, since models are currently unable to predict such issues well. Models with more sophisticated features for macrosegregation prediction that incorporate multiphase transport phenomena are already under development. A limiting factor in application of these models for simulating steel ingots is the demand on large computation resources. Following the recent development trend and the projection of Moore's law (computer hardware), in the foreseeable future, it is predicted that multiphase models will to a great extent reduce the need for the experimental pouring‐sectioning trials.

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Section: Macrosegregationmentioning

confidence: 77%

Section: Capabilities and Limitationsmentioning

confidence: 80%

Section: Capabilities and Limitationsmentioning

confidence: 99%

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Simulation of As‐Cast Steel Ingots

Ludwig²,

Kharicha

2017

steel research int.

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“…Therefore, the region of carbon enrichment moved gradually to the hot top. [ 29–32 ] The Δ C values were clearly unstable in the inserted insulation board. The lower values appeared for the 39, 43, and 45 ton ingots.…”

Section: Resultsmentioning

confidence: 99%

Effects of Weight‐Compatible Design on Ingot Solidification

Zhang

Liu

et al. 2021

steel research int.

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The problem of complex and various ingot moulds has bothered special steel enterprises. Herein, three ingot‐weight‐compatible (IWC) designs are described. The 39 tons mould is adapted to cast at most 45 tons of molten steel. The effect of three IWC designs on shrinkage cavity, porosity and macrosegregation is studied. The simulation is based on a polyphase coupled model for momentum, energy, and mass conservation equations. On the basis of the experimental results and previous literature, the interfacial heat transfer coefficient is established. Through finite difference method (FDM) simulation, the effect of the three IWC designs on the solidification is studied. The predictions of shrinkage porosity and macrosegregation are obtained. With the increase of ingot weight, the shrinkage cavity from the hot top is deeper in the three IWC designs. The Niyama criterion is found to be the condition under G/L0.5 < constant (G and L are the temperature gradient and cooling rate, respectively). With this criterion, the extent of centerline shrinkage porosity is predicted. Subsequently, utilizing the three compatible designs, the simulated results uncover that the centerline shrinkage porosity is serious. In addition, it is significant to note that the macrosegregation shows different characteristics.

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“…These models have been combined with a modified volume of fluid (VOF) method [6] or arbitrary Lagrangian-Eulerian (ALE) method [7] to couple the effect of solidification shrinkage. During recent years, more advanced two-phase or multi-phase models have been developed [8][9][10][11][12][13]. In these models, macroscopic transport phenomena, including the melt flow and grain sedimentation, are coupled with a microscopic solidification mechanism.…”

Section: Introductionmentioning

confidence: 99%

Numerical Simulation of Macrosegregation with Solid Deformation During the Solidification of Steel Ingots Using a Single-Phase/Two-Phase Integrated Model

Chen

Shen

2019

Metals

Self Cite

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Macrosegregation, a serious defect formed during the solidification of steel ingots, impairs the performance of the final components. To predict macrosegregation caused by thermal-solutal convection and solid deformation, a volume-averaged single-phase/two-phase integrated model is developed. During the deformation stage, the two-phase model coupling the solid deformation and liquid flow in the mushy zone is utilized. Before or after the deformation stage, the motion of the solid phase is neglected, and the single-phase model is solved. A 450 kg steel ingot punching test is considered for application. The results show that when the solid shell of the ingot is being punched, the solid phase in the mushy core at punching height is compressed, and a relative liquid flow is induced. This in turn causes a transition of positive segregation to negative segregation in the compressed mushy core of the ingot. According to numerical sensitivity tests of different punching parameters, as the punching start time and punching velocity increase, the effect of punching on macrosegregation will be smaller. It is demonstrated that the single-phase/two-phase integrated model can predict macrosegregation in the steel ingots which are deformed during solidification.

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Three-Dimensional Simulation of Macrosegregation in a 36-Ton Steel Ingot Using a Multicomponent Multiphase Model

Cited by 14 publications

References 15 publications

Simulation of As‐Cast Steel Ingots

Simulation of As‐Cast Steel Ingots

Effects of Weight‐Compatible Design on Ingot Solidification

Numerical Simulation of Macrosegregation with Solid Deformation During the Solidification of Steel Ingots Using a Single-Phase/Two-Phase Integrated Model

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