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.

Effect of different processing parameters on interfacial heat-transfer behavior in high-pressure die-casting process

Vacuum die casting can reduce the'air entrapment'phenomenon during casting process.Based on the temperature measurements at metal-die interface with different processing parameters,such as slow shot speed(VL),high shot speed(VH),pouring temperature(Tp)and initial die temperature(Tm),inverse method was developed to determine the interfacial heat transfer coefficient(IHTC).The results indicate that a closer contact between the casting and die could be achieved when the vacuum system is used.It is found that the vacuum could strongly increase the values of IHTC and decrease the grain size in castings.The IHTC could have a higher peak value with increasing the Tp from680to720℃or the VL from0.1to0.4m/s.In addition,the influence of the VH and Tm on IHTC could be negligible.

Determination of interfacial heat transfer coefficient and its application in high pressure die casting process

In this paper,the research progress of the interfacial heat transfer in high pressure die casting(HPDC)is reviewed.Results including determination of the interfacial heat transfer coefficient(IHTC),influence of casting thickness,process parameters and casting alloys on the IHTC are summarized and discussed.A thermal boundary condition model was developed based on the two correlations:(a)IHTC and casting solid fraction and(b)IHTC peak value and initial die surface temperature.The boundary model was then applied during the determination of the temperature field in HPDC and excellent agreement was found.

PHYSICAL SIMULATION OF INTERFACIAL CONDITIONS IN HOT FORMING OF STEELS

In the last few years,substantial experimental simulation and mumerical modelling hare been carried out in IMMPETUS to characterise the interfacial heat transfer and friction conditions during hot forging and rolling of steels. Emphasis has been placed on the influence of the oxide scale which forms on the steel workpiece. In the present paper, the experimental methods used for investigating interfacial heat transfer and friction conditions are described. Theses include hot flat rolling of steel slabs and hot axi- symmetric forging of steel cylinders and rings.Temperature measurements and computations demon- strate that for similar conditions, similar conditions, the effective interfacial heat transfer coefficients (IHTC) derived for hot rolling are significantly higher than those for forging, mainly due to the contribution of scale cracking during rolling. On the basis of experimental observations and numerical analysis,physical models for interfacial heat transfer in forging and rolling have been established. In addition, hot' sandwich' rolling and hot tensile tests with finite element modelling have been carried out to evaluate the hot ductility of the oxide scale.The results indicate that the defomation, cracking and decohesion behaviour of the oxide scale depend on deformation temperature, strain and relative strengths of the scale layer and scale - steel interface.Finaly, friction results from hot ring compression tests and from hot rolling with forward/backward slip measurements are reported.

Study on interfacial heat transfer coefficient at metal/die interface during high pressure die casting process of AZ91D alloy

The high pressure die casting (HPDC) process is one of the fastest growing and most efficient methods for the production of complex shape castings of magnesium and aluminum alloys in today's manufacturing industry. In this study, a high pressure die casting experiment using AZ91D magnesium alloy was conducted, and the temperature profiles inside the die were measured. By using a computer program based on solving the inverse heat problem, the metal/die interfacial heat transfer coefficient (IHTC) was calculated and studied. The results show that the IHTC between the metal and die increases right after the liquid metal is brought into the cavity by the plunger, and decreases as the solidification process of the liquid metal proceeds until the liquid metal is completely solidified, when the IHTC tends to be stable. The interfacial heat transfer coefficient shows different characteristics under different casting wall thicknesses and varies with the change of solidification behavior.

Measurement of temperature inside die and estimation of interfacial heat transfer coefficient in squeeze casting

As an advanced near-net shape technology, squeeze casting is an excellent method for producing high integrity castings. Numerical simulation is a very effective method to optimize squeeze casting process, and the interfacial heat transfer coefficient(IHTC) is an important boundary condition in numerical simulation. Therefore, the study of the IHTC is of great significance. In the present study, experiments were conducted and a "plate shape" aluminum alloy casting was cast in H13 steel die. In order to obtain accurate temperature readings inside the die, a special temperature sensor units(TSU) was designed. Six 1 mm wide and 1 mm deep grooves were machined in the sensor unit for the placement of the thermocouples whose tips were welded to the end wall. Each groove was machined to terminate at a particular distance(1, 3, and 6 mm) from the front end of the sensor unit. Based on the temperature measurements inside the die, the interfacial heat transfer coefficient(IHTC) at the metal-die interface was determined by applying an inverse approach. The acquired data were processed by a low pass filtering method based on Fast Fourier Transform(FFT). The feature of the IHTC at the metal-die interface was discussed.

Spatial interfacial heat transfer and surface characteristics during gravity casting of A356 alloy

As one of the key boundary conditions during casting solidification process, the interfacial heat transfer coefficient (IHTC) affects the temperature variation and distribution. Based on the improved nonlinear estimation method (NEM), thermal measurements near both bottom and lateral metal-mold interfaces throughout A356 gravity casting process were carried out and applied to solving the inverse heat conduction problem (IHCP). Finite element method (FEM) is employed for modeling transient thermal fields implementing a developed NEM interface program to quantify transient IHTCs. It is found that IHTCs at the lateral interface become stable after the volumetric shrinkage of casting while those of the bottom interface reach the steady period once a surface layer has solidified. The stable value of bottom IHTCs is 750 W/(m^2·℃), which is approximately 3 times that at the lateral interface. Further analysis of the interplay between spatial IHTCs and observed surface morphology reveals that spatial heat transfer across casting-mold interfaces is the direct result of different interface evolution during solidification process.

A study of metal/die interfacial heat transfer behavior of vacuum die cast pure copper

High pressure die casting copper is used to produce rotors for induction motors to improve efficiency.Experiments were carried out for a special"step-shape"casting with different step thicknesses.Based on the measured temperature inside the die,the interfacial heat transfer coefficient(IHTC)at the metal/die interface during vacuum die casting was evaluated by solving the inverse problem.The IHTC peak value was 4.5×10^3-11×10^3 W·m^-2·K^-1 under the basic operation condition.The influences of casting pressure,fast shot speed,pouring temperature and initial die surface temperature on the IHTC peak values were investigated.Results show that a greater casting pressure and faster shot speed could only increase the IHTC peak values at the location close to the ingate.An increase of pouring temperature and/or initial die surface temperature significantly increases the IHTC peak values.

Optimal Experiment Design for the Identification of the Interfacial Heat Transfer Coefficient in Sand Casting

The interfacial heat transfer coefficient(IHTC)is one of the main input parameters required by casting simulation software.It plays an important role in the accurate modeling of the solidification process.However,its value is not easily identifiable by means of experimental methods requiring temperature measurements during the solidification process itself.For these reasons,an optimal experiment design was performed in this study to determine the optimal position for the temperature measurement and the optimal thickness of the rectangular cast iron part.This parameter was identified using an inverse technique.In particular,two different algorithms were used:Levenberg Marquard(LM)and Monte Carlo(MC).A numerical model of the solidification process was associated with the optimization algorithm.The temperature was measured at different positions from the mould/metal interface at d=0 mm(mould/metal interface),30 mm,60 mm and 90 mm.the thicknesses of the cast part were:L1=40 mm,60 mm and 80 mm.A comparative study on the IHTC identification was then carried out by varying the initial value of the IHTC between 500 Wm^(-2)K^(-1) and 1050 Wm^(-2)K^(-1).Results showed that the MC algorithm used for estimating the IHTC gives the best results,and the optimal position was at d=30 mm,the position closest to the mould/metal interface,for the lowest thickness L1=40 mm.

Evolution of interfacial heat transfer,contact behavior and microstructure during sub-rapid solidification of molten steel with different hydrogen contents

Typical Q235 low-carbon steel samples with different hydrogen contents(0.0004,0.0008,and 0.0013 wt.%)were prepared by adjusting the environment humidity and moisture.The effects of hydrogen on interfacial heat transfer,contact behavior,and microstructure evolution were investigated using a novel droplet solidification technique.The results revealed that when the hydrogen content increases from 0.0004 to 0.0013 wt.%,the maximum heat flux between the molten steel and cooling substrate decreases from 8.01 to 6.19 MW/m^(2),and the total heat removed in the initial 2 s reduces from 10.30 to 8.27 MJ/m^(2).Moreover,the final contact angle between the molten steel and substrate increases from 103.741°to 113.697°,and the number of pores on the droplet bottom surface increases significantly from 21 to 210 with the increase in hydrogen.The surface roughness of the droplet bottom surface increases from 20.902 to 49.181 pm.In addition,the average grain size of the droplet increases from 14.778 to 33.548 pm with the increase in the hydrogen content.The interfacial contact condition becomes worse due to the escape of hydrogen from the steel matrix during the cooling process,which leads to the reduction in the interfacial heat transfer and the increase in the grain size.

Thermal Response of Mould in High Speed Casting of Stainless Steel Billet

The hot rolling of slab was studied with the aid of elastic plastic and thermomechanical couple FEM. On the basis of experiment and numerical analysis, the physical models for interfacial heat transfer during hot rolling were established. The results indicated that the deformation, cracking and decohesion behavior of the oxide scale have considerable effects on temperature distribution of slab during hot rolling.

Heat Transfer between Casting and Die during High Pressure Die Casting Process of AM50 Alloy-Modeling and Experimental Results

A method based on die casting experiments and mathematic modeling is presented for the determination of the heat flow density （HFD） and interfacial heat transfer coefficient （IHTC） during the high pressure die casting （HPDC） process.Experiments were carried out using step shape casting and a commercial magnesium alloy,AM50.Temperature profiles were measured and recorded using thermocouples embedded inside the die. Based on these temperature readings,the HFD and IHTC were successfully determined and the calculation results show that the HFD and IHTC at the metal-die interface increases sharply right after the fast phase injection process until approaching their maximum values,after which their values decrease to a much lower level until the dies are opened.Different patterns of heat transfer behavior were found between the die and the casting at different thicknesses.The thinner the casting was,the more quickly the HFD and IHTC reached their steady states.Also,the values for both the HFD and IHTC values were different between die and casting at different thicknesses.

Determination of Interfacial Heat Flux of Stainless Steel Solidification on Copper Substrate During the First 0.2 s

Interfacial heat transfer is a key issue in many solidification processes.In the paper,a novel experimental apparatus has been designed and on this basis,the instantaneous interfacial heat transfer between molten steel or solidified shell and copper substrate during the first 0.2 s has been studied.The investigated parameters include melt superheat,substrate temperature and surface roughness.The results show that the peak value of the interfacial heat flux in the first stage of liquid/solid contact increases with melt superheat and changes slightly with substrate temperature and surface roughness.The interfacial heat flux in the stage of solid/solid contact has a similar trend of slow decrease in most conditions.

Research methods and influencing factors of interfacial heat transfer during sub-rapid solidification process of strip casting

Interfacial heat transfer behavior between the molten steel and twin-rolls is a key issue in the strip casting process,and it has already attracted wide attention from industrial and academic communities of steel.The research methods and influencing factors on the interfacial heat transfer were summarized.Numerical simulation models,semi-industrial scale,and laboratory equipment have been developed in this field,and these methods were also improved by worldwide researchers based on the development of computer,automatic,and visual technologies.Coating properties,naturally deposited film,and casting parameters are the main factors which affect the heat transfer significantly.Although lots of research has been carried out,the internal relations among these influencing factors,interfacial heat transfer,and the quality of the strip are still worth to be further explored.Keywords Strip casting Interfacial heat transfer Simulation method Coating property Naturally deposited film Casting parameter.

Antibacterial evaporator based on reduced graphene oxide/polypyrrole aerogel for solar-driven desalination

Solar-driven water evaporation is a sustainable method to purify seawater.Nevertheless,traditional volumetric water-evaporation systems suffer from the poor sunlight absorption and inefficient light-to-thermal conversion.Also,their anti-bacterial and antifouling performances are crucial for the practical application.Herein,we introduce reduced graphene oxide(RGO)with broadband absorbance across the entire solar spectrum,and polypyrrole(PPy),an antibacterial polymer with efficient solar absorption and low thermal conductivity,to develop integrated RGO/PPy aerogel as both the solar absorber and evaporator for highly efficient solar-driven steam generation.As a result,the RGO/PPy aerogel shows strong absorption and good photothermal performance,leading to an evaporation rate of 1.44 kg·m^(−2)·h^(−1)and high salt rejection(up to 99.99%)for real seawater,with photothermal conversion efficiency>90%under one sun irradiation.The result is attributed to the localized heat at the air-water interface by the RGO/PPy and its porous nature with functional groups that facilitates the water evaporation.Moreover,the RGO/PPy demonstrates excellent durability and antibacterial efficiency close to 100%for 12 h,crucial characteristics for longterm application.Our well-designed RGO/PPy aerogel with efficient water desalination performance and antibacterial property provides a straightforward approach to improve the solar-driven evaporation performance by multifunctional materials integration,and offers a viable route towards practical seawater desalination.

Directional solidification behavior of turbine blades in DZ125 alloy:design of blade numbers on assembly

The influence of blades assembly,i.e.,the blade number on the solidification process,heat exchange and grain structure on a directionally solidified Ni-based superalloy DZ125 was investigated by combining the experimental and simulation results.The casting process was simulated thermodynamically by ProCAST software,where the interface heat transfer coefficient was precisely determined by a measurement with thermocouples.There is a good agreement between experimental and simulation results.It was interestingly found that with the number of blades increasing from 6 to 10,due to the decrease in radiation absorption efficiency,the maximum temperature and the heating rate decrease in the mold,during the preheat process.During the withdrawal procedure,increased assembly numbers reduce the radiation exchange from mold to the enclosure,resulting in the decrease in cooling rate and temperature gradient of the blades.At the end of withdrawal,the slower cooling rate of the outside balances the temperature distribution of internal and external surfaces on the rabbet of blade.

Theoretical and experimental advances on heat transfer and flow characteristics of metal foams

Open cell metal foam can be applied to greatly improve thermal performance of heat sink and heat exchanger,so that it has been widely used in the fields of thermal(or heat)control system of aerospace vehicle and energy utilization system and become a very important topic for research in the aerospace thermophysics field,and more and more attentions have been attracted.The optimal design of metal foam heat transfer devices is based on the understanding the flow and heat transfer characteristics in metal foam.This article reviews some recent progresses of theoretical and experimental researches on heat transfer enhancement and flow characteristics of metal foam.We found that the pore cell simplification models of metal foams generally fall into four categories,among which the most commonly used cell model is Kelivin model.Some exploratory works performed by the current authors are also introduced,such as the effect of boundary conditions on the heat transfer enhancement;the theoretical modelling of interfacial convective heat transfer taking into account heat conduction between foam ligaments;and the flow characteristics under relatively high velocity.The analytical results show that the flow characteristics of metal foam at relatively high speed are completely different from those at low speed,a further thorough study of the heat transfer and flow characteristics of metal foam is necessarily required.In this paper,two types of partial filling techniques are discussed.The heat transfer performance of partially filled tubes was evaluated by both the performance evaluation criteria and the performance evaluation plot of enhanced heat transfer techniques oriented for energy-saving.The results show that the filling type of metal foam have a significant impact on its heat transfer enhancement performance.Therefore,the filling method of metal foam should be further studied,in order to optimize the thermophysical properties of heat transfer devices.

A Comprehensive Review for Micro/Nanoscale Thermal Mapping Technology Based on Scanning Thermal Microscopy

Thermal characterization becomes challenging as the material size is reduced to micro/nanoscales.Based on scanning probe microscopy(SPM),scanning thermal microscopy(STh M)is able to collect thermophysical characteristics of the microscopic domain with high spatial resolution.Starting from its development history,this review introduces the operation mechanism of the instrument in detail,including working principles,thermal probes,quantitative study,and applications.As the core principle of STh M,the heat transfer mechanism section is discussed emphatically.Additionally,the emerging technologies based on the STh M platform are clearly reviewed and corresponding examples are presented in detail.Finally,the current challenges and future opportunities of STh M are discussed.