Validation of the Physical Simulations of a Stirred Molten Metal Using Particle Image Velocimetry Data

De-Ironing of Aluminium Alloy Melts by High Shear Melt Conditioning Technology: An Overview

“…The size and design of the chamber and the processing section account for maximizing the level of melt shear rate and mass flow as these are restricted to the close vicinity of the mixing head [50]. The implementation of the technology on large vessels requires an increase in the size of the unit and still further analysis, by computational fluid dynamic (CFD) modelling [51] and experimental validation [52], on the fluid flow and key features of the high shear processing. At this stage, the oxide agglomerates in the melt are finely dispersed because of the intensive melt shearing [35][36][37] and the composition and temperature are quickly homogenized by the strong macroscopic flow provided by the rotor-stator unit.…”

“…At this stage, the oxide agglomerates in the melt are finely dispersed because of the intensive melt shearing [35][36][37] and the composition and temperature are quickly homogenized by the strong macroscopic flow provided by the rotor-stator unit. dynamic (CFD) modelling [51] and experimental validation [52], on the fluid flow and key features of the high shear processing. At this stage, the oxide agglomerates in the melt are finely dispersed because of the intensive melt shearing [35][36][37] and the composition and temperature are quickly homogenized by the strong macroscopic flow provided by the rotor-stator unit.…”

Enhancement of chip breakability of aluminium alloys by controlling the solidification during direct chill casting

“…The advantage of MC-DC casting is that it provides both dispersive and distributive mixing in the sump, while keeping the melt surface relatively stable. The region of intense mixing around the mixer is toroidal [18] and is denoted as a pseudo-cavern by the literature [19]. In MC-DC casting, grain nucleation is also initiated in the slurry zone, however, which is characterized by a high thermal gradient and high undercooling compared to conventional DC casting, due to an enhanced rate of heat extraction by the intensive forced convection.…”

Numerical Assessment of In-Line Rotor–Stator Mixers in High-Shear Melt Conditioning (HSMC) Technology

“…The high-speed rotor moves within the small gap and entrains melt, resulting in time-dependent flow features such as the high-speed jets ejected from the stator, trailing vortices inside the mixer, vortices below the rotor, and large re-circulation regions in the crucible. 13 Optimization of HSMC necessitates understanding of the dynamics of mixing and the flow inside stirred vessels, calling for both experimental investigations 12,[14][15][16] and numerical simulations. 9,10 HSMC technology has proven successful in reducing grain sizes in direct-chill (DC) cast billets, 1,4 a process called melt-conditioned direct-chill (MCDC) casting, and in controlling the size of secondary JOM https://doi.org/10.1007/s11837-020-04320-3 Ó 2020 The Author(s) dendrite arm spacings (SDAS).…”