Effect of phosphorus content on interfacial heat transfer and film deposition behavior during the high-temperature simulation of strip casting

The interfacial wettability and heat transfer behavior are crucial in the strip casting of high phosphorus-containing steel.A hightemperature simulation of strip casting was conducted using the droplet solidification technique with the aims to reveal the effects of phosphorus content on interfacial wettability,deposited film,and interfacial heat transfer behavior.Results showed that when the phosphorus content increased from 0.014wt%to 0.406wt%,the mushy zone enlarged,the complete solidification temperature delayed from1518.3 to 1459.4℃,the final contact angle decreased from 118.4°to 102.8°,indicating improved interfacial contact,and the maximum heat flux increased from 6.9 to 9.2 MW/m2.Increasing the phosphorus content from 0.081wt%to 0.406wt%also accelerated the film deposition rate from 1.57 to 1.73μm per test,resulting in a thickened naturally deposited film with increased thermal resistance that advanced the transition point of heat transfer from the fifth experiment to the third experiment.

Solidification microstructure of Ti-43Al alloy by twin-roll strip casting

As a near-net-shape technology,the twin-roll strip casting(TRC)process can be considered to apply to the fabrication of TiAl alloy sheets.However,the control of the grain distribution is very important in strip casting because the mechanical properties of strips are directly determined by the solidification microstructure.A three-dimensional(3D)cellular automation finite-element(CAFE)model based on ProCAST software was established to simulate the solidification microstructure of Ti-43Al alloy.Then,the influence of casting temperature and the maximum nucleation density(nmax)on the solidification microstructure was investigated in detail.The simulation results provide a good explanation and prediction for the solidification microstructure in the molten pool before leaving the kissing point.Experimental and simulated microstructure show the common texture<001>orientation in the columnar grains zone.Finally,the microstructure evolution of the Ti-43Al alloy was analyzed and the solidification phase transformation path during the TSC process was determined,i.e.,L→L+β→β→β+α→α+γ+β/B2 phase under a faster cooling rate and L→L+β→β→β+α→γ+lamellar(α_(2)+γ)+β/B2 phase under a slower cooling rate.

Coupled Simulation of Flow and Thermal Field of Twin-Roll Strip Casting Process

The first micro-segregation under conditions of twin roll strip casting was simulated.The relationship between the temperature and solid fraction in the mushy zone was given.The temperatures such as ZDT,LIT were got from this simulation.Then using the turbulent model,the flow field and thermal field in the pool of twin-roll strip caster was simulated.The speed and temperature at different casting speed was given,and the results were also explained.By these two simulations,the appropriate casting speed can be found.These simulations can provide effective data for controlling the twin-roll strip casting process.

Numerical simulation of the temperature fields of stainless steel with different roller parameters during twin-roll strip casting

The temperature field of stainless steel during twin-roll strip casting was simulated by experiment and a finite element （FE） model. By comparing the measured result with the simulated values, it is found that they fit close to each other, which indicates this FE model is effective. Based on this model, the effects of roll gap （t） and roll radius （R） on solidification were simulated. The simulated results give the relationship between t or R and the position of the freezing point. The larger the t is and the smaller the R is, the closer the position of the freezing point is to the exit.

Solidification Structure of Low Carbon Steel Strips with Different Phosphorus Contents Produced by Strip Casting

In the present paper, low carbon steel strips with different phosphorus contents were produced using a twin roll strip casting process. The solidification structure was studied and its features were analyzed in detail. It was found that the strips possessed a fine microstructure compared with the mould cast steels. With increasing phosphorus content more ferrite has been formed with finer grains.

Water Modeling of Twin-Roll Strip Casting

Twin-roll strip casting is regarded as a prospective technology of near net shape continuous casting. The fluid flow field and level fluctuation in the pool have a strong influence not only on composition and temperature homogeneity of pool, but also on the strip quality. A 1 ： 1 water model of a twin-roll strip caster was set up based on the criteria of Froude number and Reynold number similarity. The level fluctuation was measured. The influence of pool depth, casting speed and feeding system configuration on level fluctuation in the pool was studied. The experimental results provided a basis for the optimization of feeding system and process parameters.

Effects of Strip Casting and Annealing on Electrochemical Properties of LPCNi_(3.55)Co_(0.75)Mn_(0.4)Al_(0.3) Hydrogen Storage Alloys

The effect of thickness (1 similar to 10 mm) of the ingots on the electrochemical properties of as-cast and annealed strip cast LPCNi3.55Co0.75Mn0.4Al0.3 hydrogen storage alloys was investigated. It is found that the 0.2 C discharge capacity of as-cast LPCNi3.55Co0.75Mn0.4Al0.3 alloy increases with the increase of the thickness of the ingots. As-east alloy with the thickness of 10 mm shows better activation property, higher 1C discharge capacity and better cyclic stability than others. It is mainly contributed to its larger unit cell volume and less internal stress. Annealed LPCNi3.55Co0.75Mn0.4Al0.3 alloy with the thickness of 3 mm shows much better comprehensive electrochemical properties than as-east one; The cyclic. stability of the alloy with the thickness of 6 mm and the activation properties of the alloys with the thickness of 3 similar to 6 mm are improved after annealing. It is mainly owing to the great release of internal stress and the decrease of the segregation of Mn in the alloys.

Simulation of Fluid Flow, Heat Transfer and Micro-Segregation in Twin-roll Strip Casting of Stainless Steel

In twin-roll strip casting process, metal flow and temperature distribution in the molten pool directly affect the stability of the process and the quality of products. In this paper, a 3D coupled thermal-flow fenite element modeling （FEM） simulation for twin-roll strip casting of stainless steel was performed. Influences of the pouring temperature and casting speed on the temperature fields were obtained from the numerical simulation. The micro-segregation of the solutes during the strip casting process of stainless steel was also simulated. A developed micro-segregation model was used to calculate the micro-segregation of solutes in twin-roll casting of stainless steel. The relationship between the solidus fraction in solidification and temperature was given, which was used to determine the LIT （liquid impermeable temperature）, ZST （zero strength temperature） and ZDT （zero ductility temperature） in the period of non-equilibrium solidification. The effect of temperature on the micro-segregation was discussed. According to the computational results, the solidification completion temperature in the twin-roll strip casting of stainless steel was then determined, which can provide a basis for controlling the location of solidification completion temperature and analysing the crack of the casting strip.

Investigation of Coercivity Mechanism for Nd-Fe-B Magnets Prepared by Combination of Strip-Casting with Hydrogen Decrepitation Techniques

The coercivity mechanism of Nd Fe B magnets prepared by combination of strip casting with hydrogen decrepitation techniques was investigated. The microstructure of (Nd 0.935 Dy 0.065 ) 14.5 Fe 79.4 B 6.1 magnet was observed. The average grain size is about 6～12 μm. The magnetizing field dependence of the hardmagnetic properties for the (Nd 0.935 Dy 0.065 ) 14.5 Fe 79.4 B 6.1 and the temperature dependence of the coercivity for the Nd 14.5 Fe 79.4 B 6.1 were investigated. Results show that the coercivity for magnets prepared by the combination of strip casting with hydrogen decrepitation techniques is controlled by the nucleation mechanism.

Microstructural Characterization of Novel Ni-Containing Nd-Fe-B Strips by Strip Casting

The characteristics of novel Nd-Fe （Ni, Co, Al ）-B microstructure prepared by strip casting technique were studied. The novel microstructure was observed using scanning electron microscope （SEM） and transmission electron microscope （TEM）. Along the direction of heat flow, there are two kinds of different microstructures. Close to the wheel side, there is a thick layer containing many polygonal Nd2Fe14B grains. Near the free surface side, however, there are relative uniform platelike Nd2Fe14B grains whose growth direction is not completely the direction of the heat flow during solidification. The formation of the novel microstructure is presumed to be the contribution of the special temperature field and Ni component.

NUMERICAL SIMULATION OF MOLTEN POOL AND CONTROL STRATEGY OF KISS POINT IN A TWIN-ROLL STRIP CASTING PROCESS

Coupled turbulent flow, temperature fields of the twin-roll casting strip process were simulated by three-dimensional finite element method. Based on the heat balance calculation and using inverse methods between the simulations and real experiments, the relational models among casting speed, location, and coefficient of heat transfer between molten metal and rolls in different regions are given. In the simulation, the calculated surface temperatures are in good agreement with the measured values. An on-line model of kiss point is derived by simulations and the geometry of molten pool, corresponding control strategy is also proposed.

Microstructure analysis of AISI 304 stainless steel produced by twin-roll thin strip casting process

The microstructure of AISI 304 austenlte stainless steel fabricated by the thin strip casting process were investigated using optical microscope, scanning electron microscope （SEM）, transmission electron microscope （TEM）, and X-ray diffraction （XRD）. The microstructures of the casting strips show a duplex structure consisting of delta ferrite and austenite. The volume fraction of the delta ferrite is about 9.74vo1% at the center and 6.77vo1% at the surface of the casting thin strip, in vermicular and hand shapes. On account of rapid cooling and solidification in the continuous casting process, many kinds of inclusions and precipitates have been found. Most of the inclusions and precipitates are spherical complex compounds consisting of oxides, such as, SiO2, MnO, Al2O3, Cr2O3, and FeO or their multiplicity oxides of MnO.Al2O3, 2FeO.SiO2, and 2MnO.SiO2. Many defects including dislocations and stacking faults have also formed during the rapid cooling and solidification process, which is helpful to improve the mechanical properties of the casting strips.

Application of Fuzzy Logic Controller to Level Control of Twin-Roll Strip Casting

An intelligent fuzzy-PID controller consisting of fuzzy logic controller and PID controller was developed to control the molten steel level of twin-roll strip caster.Additionally,a feedforward differential PID controller was used for stopper position control in order to avoid differential kick.It is proved by simulation that the proposed intelligent controller is able to obtain zero steady state error asymptotically and the control system is robust due to its fuggy behavior of the controller.

Effect of Oscillation Parameters to Flow Field in the Pool during the Oscillating Twin-Roll Strip Casting Process

During the oscillating twin?roll strip casting process, the quality of final products is directly influenced by the flow field distribution of molten metal in the pool. The variation in the flow field is caused by oscillating roller benefits, for homogeneous distribution of strip impurity, and decreasing the grain size. Thus, the quality of the strip could be improved. A numerical model was developed using the multiphase flow technology, coupled with heat transfer, fluid flow, solidification, and oscillation. Furthermore, a transient algorithm was adopted for simulating the oscillating twin?roll strip casting process of AlSi9Cu3 and 3104 aluminum alloy. This paper focuses on the flow distribution in the pool, in comparison with the traditional vertical twin?roll strip casting process, while the amplitude or frequency is chang?ing with the definite value of casting velocity, roller diameter, nozzle angle, and the strip thickness. Consequently, the conclusions were experimentally validated by oscillating twin?roll 3104 aluminum alloy strip casting. Vibrating casting technology can change the flow field in the pool by vibration, which can improve the quality of the strip core.

Heat Transfer Characteristic of Molten Pool for Twin-Roll Strip Casting

Body-fitted coordinate transformation equation was deduced and used to generate the body-fitted grids of molten pool for twin-roll strip casting.The orthogonality of the grids on the boundary was modified by adjusting source item.The energy equation and the boundary conditions were transformed from physical space to computational space.The velocity field model proposed by Hirohiko Takuda was used to calculate the temperature field of molten steel,and the influence of technical factors was also discussed.

Solidification in Soft-Contact Continuous Casting Mold with Alternating Electromagnetic Field

The mechanical behavior of the mushy zone was studied in detail. Based on the analysis of conventional high temperature mechanical model, considering the physical phenomenon in casting process, a mechanical model suitable for describing the mechanical behavior of the casting material in twin roll casting process was built. Comparing experimental results to the numerical simulated ones, the mechanical model was proved to be correct.

Investigation of the solute transportation coupled with heat transfer and fluid flow during twin-roll strip casting process

Mathematical model of solute [C] distribution in twin-roll strip casting process has been setup successfully with Calcosoft for the first time. Simulation result shows that in the center of the molten steel pool between the two rolls there is a vortex flow, which is a solute enriched area. But the highest solute concentration position is at the solidification front of the columnar grain zone near the cooling roll surface. Another solute enriched position is in the back flow above the nip point. Combined with the formation mechanism of microstruoture in final as cast strip, analysis shows that solute enriched area is in the transitional area between columnar and equiaxed grain zone.

Electrochemical Properties of Strip Casting LPCNi_(3.55) Co_(0.75) Mn_(0.4) Al_(0.3) Hydrogen Storage Alloys

LPCNi 3.55 Co 0.75 Mn 0.4 Al 0.3 hydrogen storage alloy was investigated, and the effects of thickness of its strip casting ingots(as cast) on the electrochemical performances were discussed. It was found that the 0.2 C discharge capacity increased with the increase of the thickness (from 1 mm to 10 mm) of the ingots, mainly due to the enlargement of the unit cell volume; Among the thickness of the ingots in our study, 10 mm sample showed a better activation property; LPCNi 3.55 Co 0.75 Mn 0.4 Al 0.3 alloy with 10mm showed higher comprehensive properties than those with other thickness under 1C rate.

Mathematical modeling of fluid flow and level profile during twin-roll strip casting process

In twin-roll strip casting process,transport phenomena of fluid in the molten pool directly affect the process stability and the quality of products.In order to elucidate the fundamental transport phenomena in twin-roll casting,a commercial software called ProCAST was employed to simulate the transient fluid flow and level profile behaviors during the early stage of the process in this study.The coupled set of governing differential equations for mass,momentum and energy balance were solved with the finite element method and the transient free surface problem was treated with a volume of fluids(VOF) approach.The effect of different delivery systems configuration on flow pattern,level profile in the pool was studied and analyzed in this paper. The new wedge metal delivery systems have been optimized for the twin-roll strip caster.It was shown that new type metal delivery systems had a preferable effect on the uniform distribution of fluid and level fluctuation in the pool.The simulation results also provide a valuable basis for the optimization of delivery system and process parameters during the initial pouring stage.

Morphological Variation of Eutectic Carbide in Twin-Roll Casting Strip of W9Cr4Mo2

The netlike eutectic carbide in twin-roll casting strip of W9Cr4V2 was dissolved and broken up gradually with increasing heating temperature during annealing treatment.Almost all eutectic carbides exist in granular form with heating temperature up to 950 ℃.It is considered that the refining of lamellar spacing made it possible for eutectic carbide to be granulated.