Using molten Pb-Sn-Bi alloy, the meniscus shape under high frequency magnetic field of φ100 mm round billet caster was investigated. The effect of some parameters on meniscus shape was studied. The results show that ...Using molten Pb-Sn-Bi alloy, the meniscus shape under high frequency magnetic field of φ100 mm round billet caster was investigated. The effect of some parameters on meniscus shape was studied. The results show that for a mold with 12 segments, the meniscus shape is relatively stable. With increasing power input, the menis- cus height increases with intensification of fluctuation. For the given caster, the reasonable power input is about 70 kW. The coil should be near to the top of mold and/or the initial meniscus should be near to the center of the coil. The lower the frequency, the higher is the meniscus height. With increasing frequency, the free surface is more flattened and meniscus becomes more stable. In practice, the power input should be increased simultaneously with frequency. The optimal frequency is about 20 kHz.展开更多
In this paper, coupling the quasi-3D numerical simulation of electromagnetic field and the experiments of continuous casting with soft-contacted mould with some metals such as tin, aluminum, copper and steel, the elec...In this paper, coupling the quasi-3D numerical simulation of electromagnetic field and the experiments of continuous casting with soft-contacted mould with some metals such as tin, aluminum, copper and steel, the electromagnetic characteristics of continuous casting with soft-contacted mould is analyzed. It is shown that the electromagnetic pressure on the surface of billet is increasing with the rising of power frequency as a logarithmically parabolic function, with that of electric conductivity of billet as a power junction, and with that of the current in inductor as a parabolic junction.展开更多
A comprehensive mathematical model of annulus-electromagnetic direct chill (A-EMDC) casting of A357 aluminum alloy was established with corresponding experimental verification. The model was based on a combination o...A comprehensive mathematical model of annulus-electromagnetic direct chill (A-EMDC) casting of A357 aluminum alloy was established with corresponding experimental verification. The model was based on a combination of the commercial finite element package ANSYS and the commercial finite volume package FLUENT. The effects of structural parameters on fluid flow, temperature field and solidification during A-EMDC process were investigated numerically. The results show that structural parameters such as annulus gap width, annulus gap position, and centre pipe length influence the flow and temperature fields. The smaller the annulus gap width is, the more uniform the temperature is, and the smaller the temperature gradient is. With increasing the centre pipe length, the circular flow would decrease due to the dislocation of centre pipe. Specially, when the annulus gap is located at periphery of the billet, the temperature gradient of the longitudinal direction in the solidification region falls evidently.展开更多
Heat transfer behaviors of AZ80?1%Y alloy during low frequency electromagnetic casting (LFEC) and direct chilling casting were studied by in-situ temperature measurement. The results demonstrated that the low frequenc...Heat transfer behaviors of AZ80?1%Y alloy during low frequency electromagnetic casting (LFEC) and direct chilling casting were studied by in-situ temperature measurement. The results demonstrated that the low frequency electromagnetic field (EM) caused forced convection in the melt during LFEC. The forced convection led to uniform solidification velocity and temperature field. EM frequency, excitation current intensity and casting temperature could control the heat transfer behavior. The forced convection could improve the microstructure and degrade the difference in microstructure between the edge and center of billet. Appropriate parameters of low frequency EM for casting Mg alloy are 20 Hz of frequency and 60 A of electric current intensity.展开更多
The effects of low frequency electromagnetic field on the macro-physical fields in the semi-continuous casting process of aluminum alloys and the microstructure and crack in the billets were studied and analyzed by th...The effects of low frequency electromagnetic field on the macro-physical fields in the semi-continuous casting process of aluminum alloys and the microstructure and crack in the billets were studied and analyzed by the numerical and experimental methods.Comparison of the results for the macro-physical fields in the low frequency electromagnetic casting(LFEC) process with the conventional DC casting process indicates the following characters due to the application of electromagnetic field:an entirely changed direction and remarkably increased velocity of melt flow;a uniform distribution and a decreased gradient of temperature;elevated isothermal lines;a reduced sump depth;decreased stress and plastic deformation.Further,the microstructure of the billets is refined remarkably and the crack in the billets is eliminated in LFEC process because of modification of the macro-physical fields induced by the application of low frequency electromagnetic field.展开更多
High-performance magnesium alloys are moving towards a trend of being produced on a large scale and in an integrated manner.The foundational key to their successful production is the high-quality cast ingots.Magnesium...High-performance magnesium alloys are moving towards a trend of being produced on a large scale and in an integrated manner.The foundational key to their successful production is the high-quality cast ingots.Magnesium alloys produced through the conventional semi-continuous casting process inevitably contain casting defects,which makes it challenging to manufacture high-quality ingots.The integration of external field assisted controlled solidification technology,which combines physical fields such as electromagnetic and ultrasonic fields with traditional semi-continuous casting processes,enables the production of high-quality magnesium alloy ingots characterized by a homogeneous microstructure and absence of cracks.This article mainly summarizes the technical principles of those external field assisted casting process.The focus is on elaborating the refinement mechanism of different types of electromagnetic fields,ultrasonic fields,and combined physical fields during the solidification of magnesium alloys.Finally,the development prospects of producing highquality magnesium alloy ingots through semi-continuous casting under the external field were discussed.展开更多
A modified horizontal continuous casting process under the electromagnetic field was proposed for preparing AA3003/ AA4045 clad composite hollow billets. To investigate the effect of electromagnetic field on this proc...A modified horizontal continuous casting process under the electromagnetic field was proposed for preparing AA3003/ AA4045 clad composite hollow billets. To investigate the effect of electromagnetic field on this process, a comprehensive three-dimensional model was developed. Two cases with and without electromagnetic field were compared using the simulations. When rotating electromagnetic stirring is applied, the flow pattern of fluid melt is greatly modified; the mushy zone becomes much wider, the temperature profile becomes more uniform, and the solid fraction decreases for both the external and internal alloy melt layers. These modifications are beneficial for the formation of a bimetal interface and fine and uniform grain structure of the clad composite hollow billet. Experiments conducted using the same electrical and casting parameters as the simulations verify that under the electromagnetic field the microstructure of the clad composite hollow billet becomes fine and the diffusion of the elements at the interface is promoted.展开更多
The relationship between electromagnetic frequency and microstructures of continuous casting aluminum alloys was studied. 7075 aluminum alloy ingot of 100 mm in diameter was produced by electromagnetic continuous cast...The relationship between electromagnetic frequency and microstructures of continuous casting aluminum alloys was studied. 7075 aluminum alloy ingot of 100 mm in diameter was produced by electromagnetic continuous casting process, the microstructures of as-cast ingot was examined by scanning electron microscopy (SEM) equipped with energy dispersive spectrometer (EDS). The results showed that electromagnetic frequency greatly influenced segregation and microstructures of as-cast ingot, and product quality can be guaranteed by the application of a proper frequency. Electromagnetic frequency plays a significant role in solute redistribution; low frequency is more efficient for promoting solution of alloying elements.展开更多
The super high strength aluminum alloy ingots with 100 mm in diameter were cast by the process of low-frequency electromagnetic horizontal continuous casting (LFEHC) and the effect of electromagnetic field on the as-c...The super high strength aluminum alloy ingots with 100 mm in diameter were cast by the process of low-frequency electromagnetic horizontal continuous casting (LFEHC) and the effect of electromagnetic field on the as-cast microstructure was studied. Results show that microstructure of the sample prepared by the LFEHC process was greatly refined. Microstructures at the border and the center of the ingots were fine, uniform and rosette-shaped. Electromagnetic frequency plays a key role in microstructure refining. Fine and uniform microstructures can be obtained with optimal electromagnetic frequency. In this experiment, under a frequency of 30 Hz the microstructure was the finest and the most uniform.展开更多
Solidification cracking that occurs during continuous casting of 1Cr13 stainless steel was investigated with and without final elec- tromagnetic stirring (F-EMS). The results show that cracks initiates and propagate...Solidification cracking that occurs during continuous casting of 1Cr13 stainless steel was investigated with and without final elec- tromagnetic stirring (F-EMS). The results show that cracks initiates and propagates along the grain boundaries where the elements of carbon and sulfur are enriched. The final stirrer should be appropriately placed at a location that is 7.5 m away from the meniscus, and the appropri- ate thickness of the liquid core in the stirring zone is 50 ram. As a stirring current of 250 A is imposed, it can promote colurnnar-equiaxed transition, decrease the secondary dendrite arm spacing, and reduce the segregation of both carbon and sulfur. F-EMS can effectively de- crease the amount of cracks in 1Cr13 stainless steel.展开更多
The hot top EMC (electromagnetic casting) method was put forward, namely, the shape of top liquid column was formed by the hot top in the screen and the semi suspended liquid column was formed by the electromagnetic f...The hot top EMC (electromagnetic casting) method was put forward, namely, the shape of top liquid column was formed by the hot top in the screen and the semi suspended liquid column was formed by the electromagnetic force nearby the liquid solid interface frontier. Using the numerical simulating technique, the temperature distribution was discussed, the effect of parameters such as upper conduct distance (UCD), cooling water rate of flow, pouring temperature and liquid column height on casting velocity were studied, the relationship among them was confirmed finally. According to the calculated results, the hot top EMC shaping system was designed and a lot of experiments were performed. The pure Al thin slabs of 480 mm×20 mm×850 mm were made successfully. The result showed that the casting velocity curve obtained experimentally almost coincides to the calculated one.展开更多
In order to obtain cast metal of high quality, an investigation was carried out by simultaneous imposition of multi electromagnetic fields from the outside of a cold crucible copper mold. Sn 4.5%Pb as a simulator of h...In order to obtain cast metal of high quality, an investigation was carried out by simultaneous imposition of multi electromagnetic fields from the outside of a cold crucible copper mold. Sn 4.5%Pb as a simulator of high melting point metal was continuously cast under different conditions. The results show that multi electromagnetic fields can eliminate surface defects, and coarse columnar grains of the solidification structure is turned into equiaxed crystal with the increase of magnetic flux density. Moreover, finer equiaxed crystal structure is obtained when rapidly solidified sheet is fed into the mold during continuous casting.[展开更多
Heat transfer and deformation of initial solidification shell in soft contact continuous casting mold under high frequency electromagnetic field were analyzed using numerical simulation method; the relative electromag...Heat transfer and deformation of initial solidification shell in soft contact continuous casting mold under high frequency electromagnetic field were analyzed using numerical simulation method; the relative electromagnetic parameters were obtained from the previous studies. Owing to the induction heating of a high frequency electromagnetic field (20 kHz), the thickness of initial solidification shell decreases, and the temperature of strand surface and slit copper mold increases when compared with the case without the electromagnetic filed. The viscosity of flux de- creases because of the induction heating of the high frequency electromagnetic field, and the dimension of the flux channel increases with electromagnetic pressure; thus, the deformation behavior of initial solidification shell was different before and after the action of high frequency electromagnetic field. Furthermore, the abatement mechanism of oscillation marks under high frequency electromagnetic field was explained.展开更多
The microstructures of ZL201 alloy slurry prepared by near-liquidus electromagnetic casting (NLEMC), electromagnetic casting(EMC), and near-liquidus casting(NLC) were investigated by means of electron microscopy...The microstructures of ZL201 alloy slurry prepared by near-liquidus electromagnetic casting (NLEMC), electromagnetic casting(EMC), and near-liquidus casting(NLC) were investigated by means of electron microscopy and image analysis. Mechanical properties of as-cast alloys were determined. The results show that the NLEMC induces a fine, uniform, and equiaxed grain structure with a mean equal-area-circle grain diameter of 32.8μm. The as-cast aUoy has a hardness of HV122.8 and a tensite strength of 368MPa. Both of them are betterthan those of the alloys prepared by EMC and by NLC. The mechanism of grain refinement in the NLEMC alloy slurry was discussed.展开更多
The influences of the low frequency electromagnetic field on the horizontal direct chill casting process were investigated experimentally. Ingots of 2024 aluminum alloy with a cross size of 40 mm× 200 mm were pro...The influences of the low frequency electromagnetic field on the horizontal direct chill casting process were investigated experimentally. Ingots of 2024 aluminum alloy with a cross size of 40 mm× 200 mm were produced by the conventional horizontal chill casting process and low frequency electromagnetic horizontal chill casting processre- spectively. The as-cast structures and the mechanical property of the ingots were examined. The results showed that the low frequency electromagnetic field could sub- stantially refine the microstructures and pronouncedly reduce the macrosegregation in the horizontal direct chill casting process. Moreover, the surface quality of the ingot was prominently improved by the low frequency electromagnetic field. The fracture strength and elongation percentage of the ingot was increased with the low frequency electromagnetic field.展开更多
The low frequency electromagnetic field was applied during direct chill(DC) semi-continuous casting of the ZK60 magnesium alloy billets. Effects of low frequency electromagnetic field on surface quality, microstructur...The low frequency electromagnetic field was applied during direct chill(DC) semi-continuous casting of the ZK60 magnesium alloy billets. Effects of low frequency electromagnetic field on surface quality, microstructure and hot-tearing tendency of Φ500 mm ZK60 magnesium alloy billets were investigated. The results showed that with the application of the low frequency electromagnetic field, the surface quality of the ZK60 magnesium alloy billets is markedly improved and the depth of cold fold is decreased. The microstructure of the billets is also significantly refined. Besides, the distribution of the grain size is relatively uniform from the billet surface towards its center, where the average grain size is 42 μm at surface and 50 μm at center. It also shows that the hot-tearing tendency of DC semi-continuous casting ZK60 magnesium alloy billets is significantly reduced under low frequency electromagnetic field.展开更多
Recently, a semi-solid metal processing has been acknowledged as a cost-effective technique to be able to manufacture high quality product for the transportation industry. In this study a hypo-eutectic Al alloy was fa...Recently, a semi-solid metal processing has been acknowledged as a cost-effective technique to be able to manufacture high quality product for the transportation industry. In this study a hypo-eutectic Al alloy was fabricated by means of an electromagnetic stirrer in continuous casting process and the microstructural change during solidification due to a fluid flow by electromagnetic stirring was examined. Due to the forced fluid flow during solidification a dendritic phase of primary α phase of Al alloy was turned into a globular phase, which can make the Al alloy get a thixotropic behavior in the semi-solid region. In order to establish the quantitative relationship between microstructure and the process parameters, the morphology shape, a silicon distribution and a size of primary α phase were observed according to casting speed in continuous casting machine. The primary α phase was turned into the degenerate dendrites approaching a spherical configuration with increasing casting speed. The fine-grained and equiaxed microstructure appeared at higher casting speed. A segregation behavior of Si element was declined with increasing casting speed and a very uniform distribution of Si element was observed on the billet at a casting speed of 600 mm·min-1. A thickness of the solidifying shell of the billet was shortened with increasing the casting speed.展开更多
The electromagnetic direct chill (EMDC) casting process is a welt-established production route for aluminum alloy ingot, however, the skin effect restricts the casting diameter. In order to avoid this problem, annul...The electromagnetic direct chill (EMDC) casting process is a welt-established production route for aluminum alloy ingot, however, the skin effect restricts the casting diameter. In order to avoid this problem, annulus electromagnetic direct chill (A-EMDC) casting process has been developed. A three-dimension finite element computational model of A-EMDC casting process was established by using ANSYS Magnetic-Nodal programs and FLOTRAN CFD programs. Microstruetures of A-EMDC casting semi-solid Al-6Si-3Cu-Mg alloy billets were investigated. Two pairs of vortexes occur within the crystallizer with opposite direction in A-EMDC. The annulus gap is advantageous to increasing circulate flow, reducing the temperature gradient as well as shallowing liquid sump depth. The microstructure obtained by A-EMDC is globular or rosette-like, and the microstructure is homogeneous in the billet.展开更多
文摘Using molten Pb-Sn-Bi alloy, the meniscus shape under high frequency magnetic field of φ100 mm round billet caster was investigated. The effect of some parameters on meniscus shape was studied. The results show that for a mold with 12 segments, the meniscus shape is relatively stable. With increasing power input, the menis- cus height increases with intensification of fluctuation. For the given caster, the reasonable power input is about 70 kW. The coil should be near to the top of mold and/or the initial meniscus should be near to the center of the coil. The lower the frequency, the higher is the meniscus height. With increasing frequency, the free surface is more flattened and meniscus becomes more stable. In practice, the power input should be increased simultaneously with frequency. The optimal frequency is about 20 kHz.
文摘In this paper, coupling the quasi-3D numerical simulation of electromagnetic field and the experiments of continuous casting with soft-contacted mould with some metals such as tin, aluminum, copper and steel, the electromagnetic characteristics of continuous casting with soft-contacted mould is analyzed. It is shown that the electromagnetic pressure on the surface of billet is increasing with the rising of power frequency as a logarithmically parabolic function, with that of electric conductivity of billet as a power junction, and with that of the current in inductor as a parabolic junction.
基金Project (2009AA03Z534) supported by the Hi-tech Research and Development Program of China Project (2006CB605203) supported by National Basic Research Program of China
文摘A comprehensive mathematical model of annulus-electromagnetic direct chill (A-EMDC) casting of A357 aluminum alloy was established with corresponding experimental verification. The model was based on a combination of the commercial finite element package ANSYS and the commercial finite volume package FLUENT. The effects of structural parameters on fluid flow, temperature field and solidification during A-EMDC process were investigated numerically. The results show that structural parameters such as annulus gap width, annulus gap position, and centre pipe length influence the flow and temperature fields. The smaller the annulus gap width is, the more uniform the temperature is, and the smaller the temperature gradient is. With increasing the centre pipe length, the circular flow would decrease due to the dislocation of centre pipe. Specially, when the annulus gap is located at periphery of the billet, the temperature gradient of the longitudinal direction in the solidification region falls evidently.
基金Project(2013CB632203)supported by the National Basic Research and Development Program of ChinaProject(2014028027)supported by the Liaoning Provincial Natural Science Foundation,China
文摘Heat transfer behaviors of AZ80?1%Y alloy during low frequency electromagnetic casting (LFEC) and direct chilling casting were studied by in-situ temperature measurement. The results demonstrated that the low frequency electromagnetic field (EM) caused forced convection in the melt during LFEC. The forced convection led to uniform solidification velocity and temperature field. EM frequency, excitation current intensity and casting temperature could control the heat transfer behavior. The forced convection could improve the microstructure and degrade the difference in microstructure between the edge and center of billet. Appropriate parameters of low frequency EM for casting Mg alloy are 20 Hz of frequency and 60 A of electric current intensity.
基金Project(2005CB623707)supported by National Basic Research Project of China
文摘The effects of low frequency electromagnetic field on the macro-physical fields in the semi-continuous casting process of aluminum alloys and the microstructure and crack in the billets were studied and analyzed by the numerical and experimental methods.Comparison of the results for the macro-physical fields in the low frequency electromagnetic casting(LFEC) process with the conventional DC casting process indicates the following characters due to the application of electromagnetic field:an entirely changed direction and remarkably increased velocity of melt flow;a uniform distribution and a decreased gradient of temperature;elevated isothermal lines;a reduced sump depth;decreased stress and plastic deformation.Further,the microstructure of the billets is refined remarkably and the crack in the billets is eliminated in LFEC process because of modification of the macro-physical fields induced by the application of low frequency electromagnetic field.
基金supported by the National Natural Science Foundation of China(No.52274377 and No.52304391)the Natural Science Foundation of Liaoning Province(No.2023-MSBA-133)the Fundamental Research Funds for the Central Universities(No.N2402010).
文摘High-performance magnesium alloys are moving towards a trend of being produced on a large scale and in an integrated manner.The foundational key to their successful production is the high-quality cast ingots.Magnesium alloys produced through the conventional semi-continuous casting process inevitably contain casting defects,which makes it challenging to manufacture high-quality ingots.The integration of external field assisted controlled solidification technology,which combines physical fields such as electromagnetic and ultrasonic fields with traditional semi-continuous casting processes,enables the production of high-quality magnesium alloy ingots characterized by a homogeneous microstructure and absence of cracks.This article mainly summarizes the technical principles of those external field assisted casting process.The focus is on elaborating the refinement mechanism of different types of electromagnetic fields,ultrasonic fields,and combined physical fields during the solidification of magnesium alloys.Finally,the development prospects of producing highquality magnesium alloy ingots through semi-continuous casting under the external field were discussed.
基金Projects(51274054,U1332115,51271042,51375070,51401044)supported by the National Natural Science Foundation of ChinaProject(313011)supported by the Key Grant Project of Ministry of Education of China+4 种基金Project(2013A16GX110)supported by the Science and Technology Planning Project of Dalian,ChinaProject(2014M551075)supported by the China Postdoctoral Science FoundationProject supported by the Fundamental Research Funds for the Central Universities,China
文摘A modified horizontal continuous casting process under the electromagnetic field was proposed for preparing AA3003/ AA4045 clad composite hollow billets. To investigate the effect of electromagnetic field on this process, a comprehensive three-dimensional model was developed. Two cases with and without electromagnetic field were compared using the simulations. When rotating electromagnetic stirring is applied, the flow pattern of fluid melt is greatly modified; the mushy zone becomes much wider, the temperature profile becomes more uniform, and the solid fraction decreases for both the external and internal alloy melt layers. These modifications are beneficial for the formation of a bimetal interface and fine and uniform grain structure of the clad composite hollow billet. Experiments conducted using the same electrical and casting parameters as the simulations verify that under the electromagnetic field the microstructure of the clad composite hollow billet becomes fine and the diffusion of the elements at the interface is promoted.
基金This research was supported by Major State Basic Research Projects of China, Grant No.:G1999064905 and the National Natural Science Foundation of China, No.59974009.
文摘The relationship between electromagnetic frequency and microstructures of continuous casting aluminum alloys was studied. 7075 aluminum alloy ingot of 100 mm in diameter was produced by electromagnetic continuous casting process, the microstructures of as-cast ingot was examined by scanning electron microscopy (SEM) equipped with energy dispersive spectrometer (EDS). The results showed that electromagnetic frequency greatly influenced segregation and microstructures of as-cast ingot, and product quality can be guaranteed by the application of a proper frequency. Electromagnetic frequency plays a significant role in solute redistribution; low frequency is more efficient for promoting solution of alloying elements.
基金National "863" project (NO.2001AA332030) of China
文摘The super high strength aluminum alloy ingots with 100 mm in diameter were cast by the process of low-frequency electromagnetic horizontal continuous casting (LFEHC) and the effect of electromagnetic field on the as-cast microstructure was studied. Results show that microstructure of the sample prepared by the LFEHC process was greatly refined. Microstructures at the border and the center of the ingots were fine, uniform and rosette-shaped. Electromagnetic frequency plays a key role in microstructure refining. Fine and uniform microstructures can be obtained with optimal electromagnetic frequency. In this experiment, under a frequency of 30 Hz the microstructure was the finest and the most uniform.
基金financially supported by the National Natural Science Foundation of China (No. 50834009)the Key Project of the Ministry of Education of China (No. 311014)the 111 Project of China (No. B07015)
文摘Solidification cracking that occurs during continuous casting of 1Cr13 stainless steel was investigated with and without final elec- tromagnetic stirring (F-EMS). The results show that cracks initiates and propagates along the grain boundaries where the elements of carbon and sulfur are enriched. The final stirrer should be appropriately placed at a location that is 7.5 m away from the meniscus, and the appropri- ate thickness of the liquid core in the stirring zone is 50 ram. As a stirring current of 250 A is imposed, it can promote colurnnar-equiaxed transition, decrease the secondary dendrite arm spacing, and reduce the segregation of both carbon and sulfur. F-EMS can effectively de- crease the amount of cracks in 1Cr13 stainless steel.
文摘The hot top EMC (electromagnetic casting) method was put forward, namely, the shape of top liquid column was formed by the hot top in the screen and the semi suspended liquid column was formed by the electromagnetic force nearby the liquid solid interface frontier. Using the numerical simulating technique, the temperature distribution was discussed, the effect of parameters such as upper conduct distance (UCD), cooling water rate of flow, pouring temperature and liquid column height on casting velocity were studied, the relationship among them was confirmed finally. According to the calculated results, the hot top EMC shaping system was designed and a lot of experiments were performed. The pure Al thin slabs of 480 mm×20 mm×850 mm were made successfully. The result showed that the casting velocity curve obtained experimentally almost coincides to the calculated one.
文摘In order to obtain cast metal of high quality, an investigation was carried out by simultaneous imposition of multi electromagnetic fields from the outside of a cold crucible copper mold. Sn 4.5%Pb as a simulator of high melting point metal was continuously cast under different conditions. The results show that multi electromagnetic fields can eliminate surface defects, and coarse columnar grains of the solidification structure is turned into equiaxed crystal with the increase of magnetic flux density. Moreover, finer equiaxed crystal structure is obtained when rapidly solidified sheet is fed into the mold during continuous casting.[
基金Item Sponsored by National Natural Science Foundation of China (59734080)
文摘Heat transfer and deformation of initial solidification shell in soft contact continuous casting mold under high frequency electromagnetic field were analyzed using numerical simulation method; the relative electromagnetic parameters were obtained from the previous studies. Owing to the induction heating of a high frequency electromagnetic field (20 kHz), the thickness of initial solidification shell decreases, and the temperature of strand surface and slit copper mold increases when compared with the case without the electromagnetic filed. The viscosity of flux de- creases because of the induction heating of the high frequency electromagnetic field, and the dimension of the flux channel increases with electromagnetic pressure; thus, the deformation behavior of initial solidification shell was different before and after the action of high frequency electromagnetic field. Furthermore, the abatement mechanism of oscillation marks under high frequency electromagnetic field was explained.
基金This work was supported by the National Natural Science Foundation of China(No.50374031)National High Technical Reasearch and Development Programme of China(No.2003AA305090)Liaoning Provincial Natural Science Foundation of China(No.20031011).
文摘The microstructures of ZL201 alloy slurry prepared by near-liquidus electromagnetic casting (NLEMC), electromagnetic casting(EMC), and near-liquidus casting(NLC) were investigated by means of electron microscopy and image analysis. Mechanical properties of as-cast alloys were determined. The results show that the NLEMC induces a fine, uniform, and equiaxed grain structure with a mean equal-area-circle grain diameter of 32.8μm. The as-cast aUoy has a hardness of HV122.8 and a tensite strength of 368MPa. Both of them are betterthan those of the alloys prepared by EMC and by NLC. The mechanism of grain refinement in the NLEMC alloy slurry was discussed.
文摘The influences of the low frequency electromagnetic field on the horizontal direct chill casting process were investigated experimentally. Ingots of 2024 aluminum alloy with a cross size of 40 mm× 200 mm were produced by the conventional horizontal chill casting process and low frequency electromagnetic horizontal chill casting processre- spectively. The as-cast structures and the mechanical property of the ingots were examined. The results showed that the low frequency electromagnetic field could sub- stantially refine the microstructures and pronouncedly reduce the macrosegregation in the horizontal direct chill casting process. Moreover, the surface quality of the ingot was prominently improved by the low frequency electromagnetic field. The fracture strength and elongation percentage of the ingot was increased with the low frequency electromagnetic field.
基金financially supported by the Major State Basic Research Development Program of China(Grant No.2013CB632203)the Liaoning Provincial Natural Science Foundation of China(Grant No.201202072)+1 种基金the Program for Liaoning Excellent Talents in University(Grant No.LJQ2012023)the Fundamental Research Foundation of Central Universities(Grant Nos.N120509002 and N120309003)
文摘The low frequency electromagnetic field was applied during direct chill(DC) semi-continuous casting of the ZK60 magnesium alloy billets. Effects of low frequency electromagnetic field on surface quality, microstructure and hot-tearing tendency of Φ500 mm ZK60 magnesium alloy billets were investigated. The results showed that with the application of the low frequency electromagnetic field, the surface quality of the ZK60 magnesium alloy billets is markedly improved and the depth of cold fold is decreased. The microstructure of the billets is also significantly refined. Besides, the distribution of the grain size is relatively uniform from the billet surface towards its center, where the average grain size is 42 μm at surface and 50 μm at center. It also shows that the hot-tearing tendency of DC semi-continuous casting ZK60 magnesium alloy billets is significantly reduced under low frequency electromagnetic field.
基金This work was financiallysupported bythe KISTProgram(No.2E19470)and by the Components&Materials Technology Development Program of Ministry of Commerce,Industry and Energy of Korea.
文摘Recently, a semi-solid metal processing has been acknowledged as a cost-effective technique to be able to manufacture high quality product for the transportation industry. In this study a hypo-eutectic Al alloy was fabricated by means of an electromagnetic stirrer in continuous casting process and the microstructural change during solidification due to a fluid flow by electromagnetic stirring was examined. Due to the forced fluid flow during solidification a dendritic phase of primary α phase of Al alloy was turned into a globular phase, which can make the Al alloy get a thixotropic behavior in the semi-solid region. In order to establish the quantitative relationship between microstructure and the process parameters, the morphology shape, a silicon distribution and a size of primary α phase were observed according to casting speed in continuous casting machine. The primary α phase was turned into the degenerate dendrites approaching a spherical configuration with increasing casting speed. The fine-grained and equiaxed microstructure appeared at higher casting speed. A segregation behavior of Si element was declined with increasing casting speed and a very uniform distribution of Si element was observed on the billet at a casting speed of 600 mm·min-1. A thickness of the solidifying shell of the billet was shortened with increasing the casting speed.
基金Project(2009AA03Z534) supported by the National Hi-tech Research and Development Program of ChinaProject(2006CB605203) supported by the National Basic Research Program of China
文摘The electromagnetic direct chill (EMDC) casting process is a welt-established production route for aluminum alloy ingot, however, the skin effect restricts the casting diameter. In order to avoid this problem, annulus electromagnetic direct chill (A-EMDC) casting process has been developed. A three-dimension finite element computational model of A-EMDC casting process was established by using ANSYS Magnetic-Nodal programs and FLOTRAN CFD programs. Microstruetures of A-EMDC casting semi-solid Al-6Si-3Cu-Mg alloy billets were investigated. Two pairs of vortexes occur within the crystallizer with opposite direction in A-EMDC. The annulus gap is advantageous to increasing circulate flow, reducing the temperature gradient as well as shallowing liquid sump depth. The microstructure obtained by A-EMDC is globular or rosette-like, and the microstructure is homogeneous in the billet.