Numerical simulation of melt flow and temperature field during DC casting 2024 aluminium alloy under different casting conditions

Casting speed,casting temperature and secondary cooling water flow rate are the main process parameters affecting the DC casting process.These parameters significantly influence the flow and temperature fields during casting,which are crucial for the quality of the ingot and can determine the success or failure of the casting operation.Numerical simulation,with the advantages of low cost,rapid execution,and visualized results,is an important method to study and optimize the DC casting process.In the present work,a simulation model of DC casting 2024 aluminum alloy was established,and the reliability of the model was verified.Then,the influence of casting parameters on flow field and temperature field was studied in detail by numerical simulation method.Results show that with the increase of casting speed,the melt flow becomes faster,the depths of slurry zone and mushy zone increase,and the variation of slurry zone depth is greater than that of mushy zone.With an increase in casting temperature,the melt flow rate increases,the depth of the slurry zone becomes shallower,and the depth of the mushy zone experiences only minor changes.The simulation results further indicate that the increase of the flow rate of the secondary cooling water slightly reduces the depths of both slurry and mushy zone.

Two-dimensional investigation of characteristic parameters and their gradients for the self-generated electric and magnetic fields of laser-induced zirconium plasma

Two-dimensional diagnosis of laser-induced zirconium(Zr)plasma has been experimentally performed using the time-of-flight method by employing Faraday cups in addition to electric and magnetic probes.The characteristic parameters of laser-induced Zr plasma have been evaluated as a function of different laser irradiances ranging from 4.5 to 11.7 GW cm-2 at different axial positions of 1–4 cm with a fixed radial distance of 2 cm.A well-supporting correlation between the plume parameters and the laser-plasma-produced spontaneous electric and magnetic(E and B)fields was established.The measurements of the characteristic parameters and spontaneously induced fields were observed to have an increasing trend with the increasing laser irradiance.However,when increasing the spatial distance in both the axial and radial directions,the plasma parameters(electron/ion number density,temperature and kinetic energy)did not show either continuously increasing or decreasing trends due to various kinetic and dynamic processes during the spatial evolution of the plume.However,the E and B fields were observed to be always diffusing away from the target.The radial component of electron number densities remained higher than the axial number density component,whereas the axial ion number density at all laser irradiances and axial distances remained higher than the radial ion number density.The higher axial self-generated electric field(SGEF)values than radial SGEF values are correlated with the effective charge-separation mechanism of electrons and ions.The generation of a self-generated magnetic field is observed dominantly in the radial direction at increasing laser irradiance as compared to the axial one due to the deflection of fast-moving electrons and the persistence of two-electron temperature on the radial axis.

Numerical Simulation of Coupled Molten Steel Flow and Temperature Fields in Compact Strip Production Casting

Based on the casting manufacture practice of steel slabs by CSP technology, the flow and the temperature fields of the funnel mould and the secondary cooling segment were simulated using the commercial code, CFX4. Compared with other physical investigations, the correlative data of the present simulation results are in good agreement with them. Therefore, a more comprehensive survey for metallurgy characteristic of the flow and the temperature fields in CSP continuous casting process can be achieved.

Causes of geothermal fields and characteristics of ground temperature fields in China

There are many arguments on energy sources and main controlling factors of geothermal fields, so a systematic study on the distribution of ground temperature fields shall be necessary. In this paper the thermal conduction forward method of geothermal field is used to simulate cooling rate of abnormal heat sources and heat transfer of the paleo-uplift model. Combined with a large number of geothermal field exploration cases and oil exploration well temperature curves of domestic and foreign, the following conclusions are drawn:(1) According to the magmatic activity time, the magmatism activities are divided into two categories: Magma active areas(activity time < 500 000 years) and weak/magma inactive areas(activity time > 500 000 years). The latter has a fast cooling rate(the cooling time of the magma pocket buried around 10 km is less than 200 000 years) after it has intruded into the shallow layer and it has no direct contribution to modern geothermal fields;(2) China belongs to a weak/magma inactive area such as Tengchong region and Qinghai-Tibet region because the chronological data of these regions show that its magma activity time is more than 500 000 years;(3) The temperature of most geothermal fields can be obviously divided into three segments in the vertical direction: A high geothermal gradient segment(Segment H) at the surface, then a low geothermal gradient segment(Segment L) at a secondary depth, and finally a lower temperature segment(Segment D) at a deeper depth. The temperature isoline presents a mirror reflection relation on the temperature profile, indicating that geothermal field is dominated by heat conduction, rather than having an abnormally high temperature "heat source" to provide heat;(4) Near-surface(0-5 km) materials' lateral heterogeneity caused by tectonic movement shall probably be the main controlling factor of ground temperature fields.

Development of Mathematical Model of Slag Flow Field and Temperature Field in ESR System

The heat transfer phenomena and driving forces of slag bath flow in ESR process were analyzed, and the mathematical models in ESR system were reviewed and evaluated. The electromagnetic force is the main driving force for the flow formation in the ESR slag pool, and the temperature difference in the pool creates a convective flow in the system. The shape of the electrode tip has an effect on electromagnetic field distribution in slag pool, thus affects the flow pattern. Finally an improved mathematical model of slag pool flow was proposed.

Flow and Temperature Fields in Slab Continuous Casting Molds

In order to develop super-board and super-thick slabs, the flow and temperatur fields were studied in slab continuous casting molds under different practical conditions, such as slab dimensions, with-drawing slab speed, design of nozzles, and superheat tempera-ture. The results showed that it is preferred to incline nozzle bores downwards and the submerged depth of the nozzles is best kept be-tween 250-300 mm. In addition, the solidified shell is thicker at the wide face than that at the narrow face, while the thin points alongthe wide face ekist both in the center and in the some area toward each respective end.

The influence of charge characteristics of suspension droplets on the ion flow field in different temperatures and humidity

In order to clarify the charging characteristics of suspension droplets in ion flow field under different temperatures and humidity,the effective charging factor used to characterize the charging characteristics of suspension droplets is introduced in this paper,and a calculation method of charging factor is proposed based on the upstream finite element method(FEM).Then,the charging factor under different temperatures and humidity is calculated,and the analytic expression of the charging factor considering the influence of temperature and humidity is obtained by fitting the calculation results.The influence of suspension droplets on the ion flow field is analyzed.The results show that the charging factor is small and increases little with the relative humidity when the relative humidity is less than 60%,and the charging factor is large and increases rapidly with the relative humidity when the relative humidity is more than 60%.At the same relative humidity,the charging factor increases linearly with the temperature.The influence of charged suspension droplets on the ion flow field can be ignored when the relative humidity is less than 60%and must be considered under high temperature and humidity.The calculation method and analytic expression of the charging factor proposed in this paper can be used to model of ion flow field considering the influence of temperature and humidity and provide technical support for the construction of HVDC transmission lines across high temperature and humidity.

Numerical Investigation on the Flow and Temperature Fields in an Inductively Coupled Plasma Reactor

This paper gives a numerical study on the flow and temperature fields in an induced plasma reactor, which worked in 0.5 ATM with air as a working gas. We employed a two-dimensional mode of an inductively coupled plasma to calculate the temperature and flow field of the reactor as well as the generator. The algorithm is based on the solutions of the two-dimensional continuity, momentum, and energy equations in term of vorticity, stream function and enthalpy. An upwind finite-difference scheme was adopted to solve those equations with appropriate boundary conditions. The computed results show that there is a flat region with little parameter change in the reactor, that the diameter of the region is not much larger than that of the generator and that a deep change of parameter exists in the outer side of the region.

THE NEAR TIP FIELDS AND TEMPERATURE DISTRIBUTION AROUND A CRACK IN A BODY OF HARDENING MATERIAL CONTAINING SMALL DAMAGE

In this paper, the following conclusions are reached: The influence of damage on the stress and strain feilds can be neglected in an asymptotic sense for the solutions of damage field in a plastic solid containing small damage. The formulation of the problem is simplified with an uncoupled approach. Based on experimental results of plastic damage, most of the damage in the material are con- sidered as small damage with the critacal damage variable ω_c<<1. Using this approach, closed form ex- pressions of the near tip damage fields for mode Ⅲ, mode I and the temperature distribution induced by plastic dissipation in a hardening material containing damage are deduced. We point out that the temperature distribution in the process zone is strongly dependent on the damage of materials even for the small damage case. The results of the predicted value of the temperature rise near the tip region ignoring the damage effect is appreciably higher than the observed data. The main reason of this discrepancy is the presence of damage dissipation and the fact that its influence on the calculation of plas- tic dissipation have not been appropriately taken account of. The calculation is improved by taking in- to account the damage effect on the temperature rise, then the T_(max) value is in better accord with the experimental value.

Simulation of Temperature and Flow Field by Three Dimension Finite ElementMethod for Castex Process of AS Wire

Castex of AS wire is a new technology of near net shape. To study the variation of temperature and velocity of liquid (or semisolid) aluminum during dynamic solidification the numerical simulation was carried out with the theory of heat-transfer and hydrodynamics by means of 3-dimensional finite element method. From simulation results, it is found that the variation of temperature and velocityis mainly influenced by the casting temperature of aluminum, rotating speed of Castex wheel and flow of cooling water. Among theseinfluencing factors, the casting temperature distributes most to the length of liquid phase metal. Moreover, the faster the metal solidifies,the higher the metal there moves with the overall trend of descending from the bottom of the wheel to the shoe wall as well as from sidewalls to the center of wheel groove. In comparison with the practical value, the simulation is reliable.

CFD-Based Evaluation of Flowand Temperature Characteristics of Airflow in an Aircraft Cockpit

The rational design of airflow distribution is of great importance for comfort and energy conservation.Several numerical investigations of flow and temperature characteristics in cockpits have been performed to study the distinct airflow distribution.This study developed the coupled heat transfer model of radiation,convection,and heat conduction for the cockpit flight environment.A three-dimensional physical model was created and a shear stress transfer(SST)k-w turbulence model was well verified with a high prediction accuracy of 91%for the experimental data.The strong inhomogeneous flow and temperature distribution were captured for various initial operating conditions(inlet temperature,inlet pressure,and gravitational acceleration).The results indicated that the common feature of the flow field was stable in the middle part of the cockpit,while the temperature field showed a large temperature gradient near the cockpit’s top region.It was also found that there was remarkable consistency in the distributed features,regardless of the applied initial operating conditions.Additionally,the mass flux and the top heat source greatly affected the flow and temperature characteristics.This study suggests that an optimized operating condition does exist and that this condition makes the flow and temperature field more stable in the cockpit.The corresponding results can provide necessary theoretical guidance for the further design of the cockpit structure.

Study on application and numerical simulation of the airflow temperature distribution rule in drifting tunnel

According to the law of conservation in the state of turbulent flow, the differential equation describing the airflow temperature distribution in drifting tunnel is derived, By theoretical analysis and field measurement of the airflow and thermal process in mine, theoretical analysis and systematic flow are developed. By PHONENICS program, the numerical simulation is processed, and the changing rule of airflow temperature with various parameters in drifting tunnel is derived. The airflow temperature in drifting tunnel decreases as the airflow velocity increases in a way of negative power exponent, and elevates linearly as the temperature of the incoming airflow elevates.

Fluid Flow and Heat Transfer Characteristic of Outer and Inner Half Coil Jackets

The physical models of the outer and inner half coil jackets were simplified to two types of coiled ducts.The mathematic models of incompressible fluid at the condition of laminar flow and heat transfer in the two types of jackets for cooling process reactor were set up and solved by the semi-implicit method for pressure linked equa-tions consistent （SIMPLEC） algorithm based on a control volume method.The flow and temperature fields were given and the effects of Dean and Prandtl numbers on flow and heat transfer were studied.The results show that flow in the inner half coil jacket is found to exhibit transition of secondary flow pattern from two vortices to four vortices when the Dean number increases,but that in the outer half coil jacket is not found.The critical Dean num-ber is about 96.The inner half coil jacket has stronger heat transfer ability than the outer half coil jacket and this superiority is more evident with larger Prandtl number.However,as the Dean number is greater than 105,the flow resistance enhances more severely in the inner jacket than the outer jacket.For both jackets,the centers of the heated wall are the poorest for heat transfer.

Mathematical modeling of fluid flow, heat transfer and inclusion transport in a four strand tundish

Mathematical simulation was used for trouble-shooting and optimization. By the mathematical simulation, fluid flow and beat transfer of molten-steel in a four-strand tundish of a billet caster under different conditions （bare tundish and tundish with flow control device） were analyzed, The results showed that （1） the tundish with flow control device （FCD） has an important effect on the fluid pattern and temperature distribution; （2） the unsteady, solving method was used to model the inclusion motions at different time perthds, and it showed that the FCD is advantageous to separate the nonmetallic inclusions. According to the simulation results, the main problem existing in the industry preduction was found, and some helpful rneasurements were executed. Consequently, the large nonmetallic inclusions were separated, and the content of total oxygen was reduced. The qualily of steel was greatly improved.

Numerical prediction of vortex flow and thermal separation in a subsonic vortex tube

This work was aimed at gaining understanding of the physical behaviours of the flow and temperature separation process in a vortex tube. To investigate the cold mass fraction’s effect on the temperature separation, the numerical calculation was carried out using an algebraic Reynolds stress model (ASM) and the standard k-ε model. The modelling of turbulence of com-pressible, complex flows used in the simulation is discussed. Emphasis is given to the derivation of the ASM for 2D axisymmet-rical flows, particularly to the model constants in the algebraic Reynolds stress equations. The TEFESS code, based on a staggered Finite Volume approach with the standard k-ε model and first-order numerical schemes, was used to carry out all the computations. The predicted results for strongly swirling turbulent compressible flow in a vortex tube suggested that the use of the ASM leads to better agreement between the numerical results and experimental data, while the k-ε model cannot capture the stabilizing effect of the swirl.

Numerical simulation study on multiphase flow pattern of hydrate slurry

The research on the multiphase flow characteristics of hydrate slurry is the key to implementing the risk prevention and control technology of hydrate slurry in deep-water oil and gas mixed transportation system.This paper established a geometric model based on the high-pressure hydrate slurry experimental loop.The model was used to carry out simulation research on the flow characteristics of gas-liquid-solid three-phase flow.The specific research is as follows:Firstly,the effects of factors such as slurry flow velocity,hydrate particle density,hydrate particle size,and hydrate volume fraction on the stratified smooth flow were specifically studied.Orthogonal test obtained particle size has the most influence on the particle concentration distribution.The slurry flow velocity is gradually increased based on stratified smooth flow.Various flow patterns were observed and their characteristics were analyzed.Secondly,increasing the slurry velocity to 2 m/s could achieve the slurry flow pattern of partial hydrate in the pipeline transition from stratified smooth flow to wavy flow.When the flow rate increases to 3 m/s,a violent wave forms throughout the entire loop.Based on wave flow,as the velocity increased to 4 m/s,and the flow pattern changed to slug flow.When the particle concentration was below 10%,the increase of the concentration would aggravate the slug flow trend;if the particle concentration was above 10%,the increase of the concentration would weaken the slug flow trend,the increase of particle density and liquid viscosity would weaken the tendency of slug flow.The relationship between the pressure drop gradients of several different flow patterns is:slug flow>wave flow>stratified smooth flow.

Flow Pattern and Temperature Distribution in HMCZ Silicon Melt

The axial and radial convective flow,temperature fluctuation and distribution in the HMCZ silicon melt are studied tentatively.The experimental results show that the axial and radial convective speeds,the tempera- ture variation and the radial temperature gradient,parallel to magnetic field and near melt surface,all decrease,but the axisymmetry of temperature distribution no longer exists when the magnetic field is applied.

An improved CFD model of gas flow and particle interception in a fiber material

An improved CFD model of gas flow and particle interception in a fiber material which fiber size is Y-shape was developed in this work. The porous medium model was used to build the model of the whole size of fiber filter medium. Mixture model was adopted. The algorithm of particle interception in the whole size of fiber filter medium was derived and UDF(User Defined Function) that described kinds of particle filtering mechanisms in filter fibrous media was added to the Fluent default conservation equation as source term for simulation. The inertial resistance of the filter was taken into consideration, which provided a more precise measurement of the smoke flow and the particle interception in the filter under higher smoke speed conditions. The commercial software, Fluent 6.3, was used to simulate the smoke flow and particle interception in the filter in a single suction. The velocity and pressure profiles of smoke or nicotine particle in the filter, as well as nicotine particle volume fraction profile were well simulated. Finally, the comparisons of nicotine particle filtration efficiency between Fluent simulation results in this work and experimental results, as well as the model prediction in the literature were made to validate the simulation model. The comparisons showed that the particle entrapment model from simulation results was in good agreement with that from the experimental results. In addition, the Fluent simulation results are closer to reality both at the beginning and the end of the smoke process comparing with the model predicted results in the literature.

Thermal and induced flow characteristics of radio frequency surface dielectric barrier discharge plasma actuation at atmospheric pressure

Thermal and induced flow velocity characteristics of radio frequency（RF） surface dielectric barrier discharge（SDBD）plasma actuation are experimentally investigated in this paper. The spatial and temporal distributions of the dielectric surface temperature are measured with the infrared thermography at atmospheric pressure. In the spanwise direction, the highest dielectric surface temperature is acquired at the center of the high voltage electrode, while it reduces gradually along the chordwise direction. The maximum temperature of the dielectric surface raises rapidly once discharge begins.After several seconds（typically 100 s）, the temperature reaches equilibrium among the actuator＇s surface, plasma, and surrounding air. The maximum dielectric surface temperature is higher than that powered by an AC power supply in dozens of k Hz. Influences of the duty cycle and the input frequency on the thermal characteristics are analyzed. When the duty cycle increases, the maximum dielectric surface temperature increases linearly. However, the maximum dielectric surface temperature increases nonlinearly when the input frequency varies from 0.47 MHz to 1.61 MHz. The induced flow velocity of the RF SDBD actuator is 0.25 m/s.

Flow Field and Temperature Field in GaN-MOCVD Reactor Based on Computational Fluid Dynamics Modeling

Metal organic chenlical vapor deposition （AIOCVD） growth systems arc one of the. main types of equipment used for growing single crystal materials, such as GaN. To obtain fihn epitaxial materials with uniform performanee, the flow field and ternperature field in a GaN-MOCVD reactor are investigated by modeling and simulating. To make the simulation results more consistent with the actual situation, the gases in the reactor are considered to be compressible, making it possible to investigate the distributions of gas density and pressure in the reactor. The computational fluid dynamics method is used to stud,v the effects of inlet gas flow velocity, pressure in the reactor, rotational speed of graphite susceptor, and gases used in the growth, which has great guiding~ significance for the growth of GaN fihn materials.