Volume-averaged modeling of multiphase solidification with equiaxed crystal sedimentation in a steel ingot

Macrosegregation is a critical factor that limits the mechanical properties of materials.The impact of equiaxed crystal sedimentation on macrosegregation has been extensively studied,as it plays a significant role in determining the distribution of alloying elements and impurities within a material.To improve macrosegregation in steel connecting shafts,a multiphase solidification model that couples melt flow,heat transfer,microstructure evolution,and solute transport was established based on the volume-averaged Eulerian-Eulerian approach.In this model,the effects of liquid phase,equiaxed crystals,columnar dendrites,and columnar-to-equiaxed transition(CET)during solidification and evolution of microstructure can be considered simultaneously.The sedimentation of equiaxed crystals contributes to negative macrosegregation,where regions between columnar dendrites and equiaxed crystals undergo significant A-type positive macrosegregation due to the CET.Additionally,noticeable positive macrosegregation occurs in the area of final solidification in the ingot.The improvement in macrosegregation is beneficial for enhancing the mechanical properties of connecting shafts.To mitigate the thermal convection of molten steel resulting from excessive superheating,reducing the superheating during casting without employing external fields or altering the design of the ingot mold is indeed an effective approach to control macrosegregation.

Exploration of the coupled lattice Boltzmann model based on a multiphase field model:A study of the solid-liquid-gas interaction mechanism in the solidification process

A multiphase field model coupled with a lattice Boltzmann(PF-LBM)model is proposed to simulate the distribution mechanism of bubbles and solutes at the solid-liquid interface,the interaction between dendrites and bubbles,and the effects of different temperatures,anisotropic strengths and tilting angles on the solidified organization of the SCN-0.24wt.%butanedinitrile alloy during the solidification process.The model adopts a multiphase field model to simulate the growth of dendrites,calculates the growth motions of dendrites based on the interfacial solute equilibrium;and adopts a lattice Boltzmann model(LBM)based on the Shan-Chen multiphase flow to simulate the growth and motions of bubbles in the liquid phase,which includes the interaction between solid-liquid-gas phases.The simulation results show that during the directional growth of columnar dendrites,bubbles first precipitate out slowly at the very bottom of the dendrites,and then rise up due to the different solid-liquid densities and pressure differences.The bubbles will interact with the dendrite in the process of flow migration,such as extrusion,overflow,fusion and disappearance.In the case of wide gaps in the dendrite channels,bubbles will fuse to form larger irregular bubbles,and in the case of dense channels,bubbles will deform due to the extrusion of dendrites.In the simulated region,as the dendrites converge and diverge,the bubbles precipitate out of the dendrites by compression and diffusion,which also causes physical phenomena such as fusion and spillage of the bubbles.These results reveal the physical mechanisms of bubble nucleation,growth and kinematic evolution during solidification and interaction with dendrite growth.

Numerical simulation on the multiphase flow and reoxidation of the molten steel in a two-strand tundish during ladle change

A 3D mathematical model was proposed to investigate the molten steel–slag–air multiphase flow in a two-strand slab continuous casting(CC)tundish during ladle change.The study focused on the exposure of the molten steel and the subsequent reoxidation occurrence.The exposure of the molten steel was calculated using the coupled realizable k–εmodel and volume of fluid(VOF)model.The diffusion of dissolved oxygen was determined by solving the user-defined scalar(UDS)equation.Moreover,the user-defined function(UDF)was used to describe the source term in the UDS equation and determine the oxidation rate and oxidation position.The effect of the refilling speed on the molten steel exposure and dissolved oxygen content was also discussed.Increasing the refilling speed during ladle change reduced the refilling time and the exposure duration of the molten steel.However,the elevated refilling speed enlarged the slag eyes and increased the average dissolved oxygen content within the tundish,thereby exacerbating the reoxidation phenomenon.In addition,the time required for the molten steel with a high dissolved oxygen content to exit the tundish varied with the refilling speed.When the inlet speed was 3.0 m·s^(-1)during ladle change,the molten steel with a high dissolved oxygen content exited the outlet in a short period,reaching a maximum dissolved oxygen content of 0.000525wt%.Conversely,when the inlet speed was 1.8 m·s^(-1),the maximum dissolved oxygen content was 0.000382wt%.The refilling speed during the ladle change process must be appropriately decreased to minimize reoxidation effects and enhance the steel product quality.

Microstructure and mechanical properties of a cast TRIP-assisted multiphase stainless steel

Stainless steels are used in a wide range of complex environments due to their excellent corrosion resistance.Multiphase stainless steels can offer an excellent combination of strength,toughness and corrosion resistance due to the coexistence of different microstructures.The microstructure and mechanical properties of a novel cast multiphase stainless steel,composed of martensite,ferrite,and austenite,were investigated following appropriate heat treatment processes:solution treatment at 1,050℃ for 0.5 h followed by water quenching to room temperature,and aging treatment at 500℃ for 4 h followed by water quenching to room temperature.Results show reversed austenite is formed by diffusion of Ni element during aging process,and the enrichment of Ni atoms directly determines the mechanical stability of austenite.The austenite with a lower Ni content undergoes a martensitic transformation during plastic deformation.The tensile strength of the specimen exceeds 1,100 MPa and the elongation exceeds 24%after solid solution,and further increases to 1,247 MPa and 25%after aging treatment.This enhancement is due to the TRIP effect of austenite and the precipitation of the nanoscale G-phase pinning dislocations in ferrite and martensite.

A new interacting capillary bundle model on the multiphase flow in micropores of tight rocks

Surfactants are widely used in the fracturing fluid to enhance the imbibition and thus the oil recovery rate. However, current numerical models cannot capture the physics behind capillary imbibition during the wettability alteration by surfactants. Although the interacting capillary bundle(ICB) model shows potential in characterizing imbibition rates in different pores during wettability alteration, the existing ICB models neglect the influence of wettability and viscosity ratio on the imbibition behavior, making it difficult to accurately describe the oil-water imbibition behavior within the porous media. In this work,a new ICB mathematical model is established by introducing pressure balance without assuming the position of the leading front to comprehensively describe the imbibition behavior in a porous medium under different conditions, including gas-liquid spontaneous imbibition and oil-water imbibition.When the pore size distribution of a tight rock is known, this new model can predict the changes of water saturation during the displacement process in the tight rock, and also determine the imbibition rate in pores of different sizes. The water saturation profiles obtained from the new model are validated against the waterflooding simulation results from the CMG, while the imbibition rates calculated by the model are validated against the experimental observations of gas-liquid spontaneous imbibition. The good match above indicates the newly proposed model can show the water saturation profile at a macroscopic scale while capture the underlying physics of the multiphase flow in a porous medium at a microscopic scale. Simulation results obtained from this model indicate that both wettability and viscosity ratio can affect the sequence of fluid imbibition into pores of different sizes during the multiphase flow, where less-viscous wetting fluid is preferentially imbibed into larger pores while more-viscous wetting fluid tends to be imbibed into smaller pores. Furthermore, this model provides an avenue to calculate the imbibition rate in pores of different sizes during wettability alteration and capture the non-Darcy effect in micro-and nano-scale pores.

Influence of pressure disturbance wave on dynamic response characteristics of liquid film seal for multiphase pump

Slug flow or high GVF(Gas Volume Fraction)conditions can cause pressure disturbance waves and alternating loads at the boundary of mechanical seals for multiphase pumps,endangering the safety of multiphase pump units.The mechanical seal model is simplified by using periodic boundary conditions and numerical calculations are carried out based on the Zwart-Gerber-Belamri cavitation model.UDF(User Define Function)programs such as structural dynamics equations,alternating load equations,and pressure disturbance equations are embedded in numerical calculations,and the dynamic response characteristics of mechanical seal are studied using layered dynamic mesh technology.The results show that when the pressure disturbance occurs at the inlet,as the amplitude and period of the disturbance increase,the film thickness gradually decreases.And the fundamental reason for the hysteresis of the film thickness change is that the pressure in the high-pressure area cannot be restored in a timely manner.The maximum value of leakage and the minimum value of axial velocity are independent of the disturbance period and determined by the disturbance amplitude.The mutual interference between enhanced waves does not have a significant impact on the film thickness,while the front wave in the attenuated wave has a promoting effect on the subsequent film thickness changes,and the fluctuation of the liquid film cavitation rate and axial velocity under the attenuated wave condition deviates from the initial values.Compared with pressure disturbance conditions,alternating load conditions have a more significant impact on film thickness and leakage.During actual operation,it is necessary to avoid alternating load conditions in multiphase pump mechanical seals.

A transient production prediction method for tight condensate gas wells with multiphase flow

Considering the phase behaviors in condensate gas reservoirs and the oil-gas two-phase linear flow and boundary-dominated flow in the reservoir,a method for predicting the relationship between oil saturation and pressure in the full-path of tight condensate gas well is proposed,and a model for predicting the transient production from tight condensate gas wells with multiphase flow is established.The research indicates that the relationship curve between condensate oil saturation and pressure is crucial for calculating the pseudo-pressure.In the early stage of production or in areas far from the wellbore with high reservoir pressure,the condensate oil saturation can be calculated using early-stage production dynamic data through material balance models.In the late stage of production or in areas close to the wellbore with low reservoir pressure,the condensate oil saturation can be calculated using the data of constant composition expansion test.In the middle stages of production or when reservoir pressure is at an intermediate level,the data obtained from the previous two stages can be interpolated to form a complete full-path relationship curve between oil saturation and pressure.Through simulation and field application,the new method is verified to be reliable and practical.It can be applied for prediction of middle-stage and late-stage production of tight condensate gas wells and assessment of single-well recoverable reserves.

Tribological properties of nanostructured Al_2O_3-40%TiO_2 multiphase ceramic particles reinforced Ni-based alloy composite coatings

The Ni-based alloy composite coatings reinforced by nanostructured Al2O3-40%TiO2 multiphase ceramic particles were prepared on the surface of 7005 aluminum alloy by plasma spray technology. The microstructure and tribological properties of the composite coatings were researched. The results show that the composite coatings mainly consist of γ-Ni, α-Al2O3, γ-Al2O3 and rutile-TiO2 etc, and exhibit lower friction coefficients and wear losses than the Ni-based alloy coatings at different loads and speeds. The composite coating bears low contact stress at 3 N and its wear mechanism is micro-cutting wear. As loads increase to 6-12 N, the contact stress is higher than the elastic limit stress of worn surface, and the wear mechanisms change into multi-plastic deformation wear, micro-brittle fracture wear and abrasive wear. With the increase of speeds, the contact temperature of worn surface increases. The composite coating experiences multi-plastic deformation wear, fatigue wear and adhesive wear.

Experimental verification of mathematical model for multiphase flow in air-agitated seed precipitation tank

In order to check the validity of the mathematical model for analyzing the flow field in the air-agitated seed precipitation tank,a scaled down experimental apparatus was designed and the colored tracer and KCl tracer were added in the apparatus to follow the real flow line.Virtue tracers were considered in the mathematical model and the algorithm of tracers was built.The comparison of the results between the experiment and numerical calculation shows that the time of the tracer flows out of stirring tube are 40 s in the experiment and 42 s in numerical calculated result.The transient diffusion process and the solution residence time of the numerical calculation are in good agreement with the experimental results,which indicates that the mathematical model is reliable and can be used to predict the flow field of the air-agitated seed precipitation tank.

Thermodynamic consistent phase field model for sintering process with multiphase powders

A thermodynamic consistent phase field model is developed to describe the sintering process with multiphase powders. In this model, the interface region is assumed to be a mixture of different phases with the same chemical potential, but with different compositions. The interface diffusion and boundary diffusion are also considered in the model. As an example, the model is applied to the sintering process with Fe-Cu powders. The free energy of each phase is described by the well-developed thermodynamic models, together with the published optimized parameters. The microstructure and solute distribution during the sintering process can both be obtained quantitively.

PYRAMIDAL MULTIPHASE LEVEL SET FRAMEWORK FOR BRAIN TUMOR DETECTION USING GENERALIZED TECHNIQUE OF PAINTING BACKGROUND

The pyramidal multiphase level set framework （PMLSF） based on the technique of painting background （TPBG） and the Chan-Vese model can detect multiple objects on a given image. However, the boundaries of the sub-object obtained by PMLSF-TPBG are not variable since a specialcolor parameter is used in TPBG. To solve the problem, a new technique utilizing a varying parameter is proposed to ensure that PMLSF is effective for the detection of the desired boundaries of the sub-object. The interval of the variable color parameter is proved and the effects of the parameter are also discussed. Experimental results for the brain tumor detection show that different boundaries of the brain tumors can be detected with different color parameters. It is especially useful for clinical diagnoses.

生成式人工智能赋能本科生科研能力培养——ChatGPT支持的CUREs教学模式

为促进高等教育中高素质创新人才培养,构建以学生为中心的科研训练与课程教学整合模式是有效途径。当前基于课程的本科生科研体验(CUREs)教学模式虽在增强学生对科学本质的理解等方面具有一定优势,但在激发学生研究动机方面存在一些不足。将支持高效反馈的生成式人工智能ChatGPT引入人机协作研究过程中,有助于改善学生的科研体验,推动科研项目化学习。通过对ChatGPT支持的CUREs教学模式的设计与实施,发现该模式有助于培养学生的科研能力,提升他们的科研知识水平、科研技能水平和科研情感水平。尽管学生认同该教学模式的有效性和易用性,但其实际效果的发挥仍需人类智慧的参与。未来需要持续升级和优化生成式人工智能技术,确保技术应用高效且符合伦理标准;应用生成式人工智能技术重构教学模式,并通过长周期、跨场域实践检验其应用效果;强调人工智能与人类智慧的互补协作,真正实现生成式人工智能赋能学生科研能力提升。

Quantitative Modelling of Multiphase Lithospheric Stretching and Deep Thermal History of Some Tertiary Rift Basins in Eastern China

The stretching process of some Tertiary rift basins in eastern China is characterized by multiphase rifting. A multiple instantaneous uniform stretching model is proposed in this paper to simulate the formation of the basins as the rifting process cannot be accurately described by a simple (one episode) stretching model. The study shows that the multiphase stretching model, combined with the back-stripping technique, can be used to reconstruct the subsidence history and the stretching process of the lithosphere, and to evaluate the depth to the top of the asthenosphere and the deep thermal evolution of the basins. The calculated results obtained by applying the quantitative model to the episodic rifting process of the Tertiary Qiongdongnan and Yinggehai basins in the South China Sea are in agreement with geophysical data and geological observations. This provides a new method for quantitative evaluation of the geodynamic process of multiphase rifting occurring during the Tertiary in eastern China.

Uncertainty analysis of flow rate measurement for multiphase flow using CFD

The venturi meter has an advantage in its use,because it can measure flow without being much affected by the type of the measured fluid or flow conditions.Hence,it has excellent versatility and is being widely applied in many industries.The flow of a liquid containing air is a representative example of a multiphase flow and exhibits complex flow characteristics.In particular,the greater the gas volume fraction（GVF）,the more inhomogeneous the flow becomes.As a result,using a venturi meter to measure the rate of a flow that has a high GVF generates an error.In this study,the cause of the error occurred in measuring the flow rate for the multiphase flow when using the venturi meter for analysis by CFD.To ensure the reliability of this study,the accuracy of the multiphase flow models for numerical analysis was verified through comparison between the calculated results of numerical analysis and the experimental data.As a result,the Grace model,which is a multiphase flow model established by an experiment with water and air,was confirmed to have the highest reliability.Finally,the characteristics of the internal flow Held about the multiphase flow analysis result generated by applying the Grace model were analyzed to find the cause of the uncertainty occurring when measuring the flow rate of the multiphase flow using the venturi meter.A phase separation phenomenon occurred due to a density difference of water and air inside the venturi,and flow inhomogeneity happened according to the flow velocity difference of each phase.It was confirmed that this flow inhomogeneity increased as the GVF increased due to the uncertainty of the flow measurement.

Annular multiphase flow behavior during deep water drilling and the effect of hydrate phase transition

It is very important to understand the annular multiphase flow behavior and the effect of hydrate phase transition during deep water drilling. The basic hydrodynamic models, including mass, momentum, and energy conservation equations, were established for annular flow with gas hydrate phase transition during gas kick. The behavior of annular multiphase flow with hydrate phase transition was investigated by analyzing the hydrate-forming region, the gas fraction in the fluid flowing in the annulus, pit gain, bottom hole pressure, and shut-in casing pressure. The simulation shows that it is possible to move the hydrate-forming region away from sea floor by increasing the circulation rate. The decrease in gas volume fraction in the annulus due to hydrate formation reduces pit gain, which can delay the detection of well kick and increase the risk of hydrate plugging in lines. Caution is needed when a well is monitored for gas kick at a relatively low gas production rate, because the possibility of hydrate presence is much greater than that at a relatively high production rate. The shut-in casing pressure cannot reflect the gas kick due to hydrate formation, which increases with time.

Toughening mechanism of lined Al_2O_3-ZrO_2 multiphaseceramics in SHS composite pipes

Hypoeutectic and hypereutectic Al2O3-ZrO2 multiphase ceramics-lined composite pipes were produced by using the gravitational separation self-propagate high-temperature synthesis （SHS） process. The microstructure of the ceramics was observed by means of SEM and EPMA. The fracture toughness of the multiphase ceramics was tested by using the Vickers indentation method. The fracture toughness of hypoeutectic Al2O3-ZrO2 multiphase ceramics is 15.96 MPa·m^1/2 and that of hypoeutectic Al2O3-ZrO2 multiphase ceramics is 15.23 MPa·m^1/2. The toughening mechanisms were systematically investigated by means of SEM and XRD. The results show that the bridging toughening mechanism, stress induced ZrO2 transformation toughening mechanism, and microcrack toughening mechanism are the predominant toughening mechanism.

Multiphase Flow and Wear in the Cutting Head of Ultra-high Pressure Abrasive Water Jet

Abrasive water jet cutting technology is widely applied in the materials processing today and attracts great attention from scholars, but many phenomena concerned are not well understood, especially in the internal jet flow of the cutting head at the condition of ultra-high pressure. The multiphase flow in the cutting head is numerically simulated to study the abrasive motion mechanism and wear inside the cutting head at the pressure beyond 300 MPa. Visible predictions of the particles trajectories and wear rate in the cutting head are presented. The influences of the abrasive physical properties, size of the jewel orifice and the operating pressure on the trajectories are discussed. Based on the simulation, a wear experiment is carried out under the corresponding pressures. The simulation and experimental results show that the flow in the mixing chamber is composed of the jet core zone and the disturbance zone, both affect the particles trajectories. The mixing efficiency drops with the increase of the abrasive granularity. The abrasive density determines the response of particles to the effects of different flow zones, the abrasive with medium density gives the best general performance. Increasing the operating pressure or using the jewel with a smaller orifice improves the coherency of p articles trajectories but increases the wear rate of the jewel holder at the same time. Walls of the jewel holder, the entrance of the mixing chamber and the convergence part of the mixing tube are subject to wear out. The computational and experimental results give a qualitative consistency which proves that this numerical method can provide a reliable and visible cognition of the flow characteristics of ultra-high pressure abrasive water jet. The investigation is benefit for improving the machining properties of water jet cutting systems and the optimization design of the cutting head.

Lagrangian-based investigation of multiphase flows by finite-timeLyapunov exponents

Multiphase flows are ubiquitous in our daily life and engineering applications. It is important to investigate the flow structures to predict their dynamical behaviors ef- fectively. Lagrangian coherent structures （LCS） defined by the ridges of the finite-time Lyapunov exponent （FTLE） is utilized in this study to elucidate the multiphase interactions in gaseous jets injected into water and time-dependent turbu- lent cavitation under the framework of Navier-Stokes flow computations. For the gaseous jets injected into water, the highlighted phenomena of the jet transportation can be observed by the LCS method, including expansion, bulge, necking/breaking, and back-attack. Besides, the observation of the LCS reveals that the back-attack phenomenon arises from the fact that the injected gas has difficulties to move toward downstream re- gion after the necking/breaking. For the turbulent cavitating flow, the ridge of the FTLE field can form a LCS to capture the front and boundary of the re-entraint jet when the ad- verse pressure gradient is strong enough. It represents a bar- rier between particles trapped inside the circulation region and those moving downstream. The results indicate that the FFLE field has the potential to identify the structures of mul- tiphase flows, and the LCS can capture the interface/barrier or the vortex/circulation region.

DIRECT NUMERICAL SIMULATIONS OF MULTIPHASE FLOWS

Direct numerical simulations have recently emerged as a viable tool to study finite Reynolds number multiphase flows. The approach parallels direct numerical simulations of turbulent flows, but the unsteady motion of a deformable phase boundary adds considerable complexity. Here, a front tracking method that has been used to study several multiphase flow problems is described. The Navier Stokes equations are solved by a finite difference/front tracking technique that allows the inclusion of fully deformable interfaces and surface tension, in addition to inertial and viscous effects. A parallel version of the method makes it possible to use large grids and resolve flows containing a few hundred bubbles.

Influence of Hot Deformation and Subsequent Austempering on the Mechanical Properties of Hot Rolled Multiphase Steel

Influence of hot deformation and subsequent austempering on the mechanical properties of hot rolled multiphase steel was investigated. Thermo-mechanical control processing （TMCP） was conducted by using a laboratory hot rolling mill, where three different kinds of finishing rolling reduction, and austemperings with various isothermal holding duration were applied. The results have shown that a multiphase microstructure consisting of polygonal ferrite, granular bainite and larger amount of stabilized retained austenite can be obtained by controlled rolling processes. Mechanical properties increase with increasing the amount of deformation because of the stabilization of retained austenite. Ultimate tensile strength （σb）, total elongation （σ） and the product of ultimate tensile strength and total elongation （σb-σ） reach the maximum values （791 MPa, 36% and 28476 MPa%, respectively） at optimal processes.