Simulation of microstructures in solidification of aluminum twin-roll casting

Based on the research on the solidification of twin-roll continuous casting aluminum thin strip, the analytical model of heterogeneous nucleation, the growth kinetics of tip （KGT） and columnar dendrite transformation to equiaxed dendrite （CET） of twin-roll continuous casting aluminum thin strip solidification was established by means of the principle of metal solidification and modem computer emulational technology. Meantime, based on the cellular automaton, the emulational model of twin-roll continuous casting aluminum thin strip, solidification was established. The foundation for the emulational simulation of twin-roll casting thin strip solidification structure was laid. Meanwhile, the mathematical simulation feasibility was confirmed by using the solidification process of twin-roll continuous casting aluminum thin strip.

Kinetics of recrystallization for twin-roll casting AZ31 magnesium alloy during homogenization

The kinetics of recrystallization for twin-roll casting AZ31 magnesium alloy with different thicknesses during homogenization was analyzed.It is shown that fine grains are first formed at the boundaries of deformed bands in the twin-roll casting slab.The recrystallized grains with no strain are gradually substituted for the deformed microstructure of twin-roll casting AZ31 magnesium alloy.The incubation temperature and time for the recrystallization of a twin-roll casting AZ31 magnesium alloy strip with a thickness of 3 mm are lower and shorter than those of the 6-mm thick strip,respectively.The 3-mm thick twin-roll casting magnesium alloy has finer grains than the 6-mm thick strip.The activation energies of recrystallization for twin-roll casting AZ31 magnesium alloy slabs with the thickness of 3 and 6 mm are 88 and 69 kJ/mol,respectively.The kinetics curves of recrystallization for twin-roll casting AZ31 magnesium alloy were obtained.

Bonding strength of Invar/Cu clad strips fabricated by twin-roll casting process

Based on traditional twin-roll casting process,Invar/Cu clad strips were successfully fabricated by using solid Invar alloy strip and molten Cu under conditions of high temperature,high pressure and plastic deformation.A series of tests including tensile test,bending test,T-type peeling test and scanning electron microscope(SEM)and energy dispersive spectrometer(EDS)measurements were carried out to analyze the mechanical properties of Invar/Cu clad strips and the micro-morphology of tensile fracture surfaces and bonding interfaces.The results indicate that no delamination phenomenon occurs during the compatible deformation of Invar/Cu in bending test and only one stress platform exists in the tensile stress-strain curve when the bonding strength is large.On the contrary,different mechanical properties of Invar and Cu lead to delamination phenomenon during the uniaxial tensile test,which determines that two stress platforms occur on the stress-strain curve of Invar/Cu clad strips when two elements experience necking.The average peeling strength can be increased from13.85to42.31N/mm after heat treatment at800℃for1h,and the observation of the Cu side at peeling interface shows that more Fe is adhered on the Cu side after the heat treatment.All above illustrate that heat treatment can improve the strength of the bonding interface of Invar/Cu clad strips.

Dynamic tensile behaviors of AZ31B magnesium alloy processed by twin-roll casting and sequential hot rolling

The dynamic tensile behavior of twin-roll cast-rolled and hot-rolled AZ31B magnesium alloy was characterized over strainrates ranging from 0.001 to 375 s^-1 at room temperature using an elaborate dynamic tensile testing method, and the relationshipbetween its mechanical properties and microstructures. It is observed that the sheet has a strong initial basal fiber texture andmechanical twinning becomes prevalent to accommodate the high-rate deformation. The yield strength and ultimate tensile strengthmonotonically increase with increasing the strain rate, while the strain hardening exponent proportionally decreases with increasingthe strain rate due to twinning-induced softening. The total elongation at fracture distinctly decreases as the strain rate increasesunder quasi-static tension, while the effect of strain rate on the total elongation is not distinct under dynamic tension. Fractographicanalysis using a scanning electron microscope reveals that the fracture is a mixed mode of ductile and brittle fracture.

Heat transfer analysis and experimental study of unequal diameter twin-roll casting process for fabricating Cu/Al clad strips

Unequal diameter twin-roll casting(UDTRC)can improve the formability,surface conditions,and production efficiency during the fabrication of clad strips.Using Fluent software,a numerical simulation is used to study the asymmetric heat transfer characteristics of Cu/Al clad strips fabricated by UDTRC.The effects of roller velocity ratio,Cu strip thickness,and inclination angle on the kissing point position,as well as the entire temperature distribution are obtained.The heat transfer model is established,and the mechanism is discussed.The Cu strip and rollers are found to be the main causes of asymmetric heat transfer,indicating that the roller velocity ratio changes the liquid zone proportion in the molten pool.The Cu strip thickness determines the heat absorption capacity and the variations in thermal resistance between the molten Al and the big roller.The inclination angle of the small roller changes the cooling time of big roller to molten Al.Moreover,the microstructure of Al cladding under different roller velocity ratios is examined.The results show significant grain refinement caused by the shear strain along the thickness direction of Al cladding and the intense heat transfer at the moment of contact between the metal Al cladding and Cu strip.

Simulation of critical cooling rate and process conditions for metallic glasses in vertical type twin-roll casting

Critical cooling rates for producing metallic glasses were evaluated based on a calculated continuous cooling transformation(CCT)diagram.Temperature distributions of the melt in molten pool in the vertical type twin-roll casting(VTRC)process of metallic glasses were simulated,and cooling rates under different casting conditions were calculated with the simulated results.By comparing the results obtained by CCT diagrams and simulation,the possibility of producing metallic glasses by the VTRC method and influences of casting conditions on cooling rate were discussed.The results reveal that cooling rate with3or4orders of magnitude by the VTRC process can be attained in producing Mg-based metallic glasses,which is faster than the critical cooling rate calculated by the CCT diagram.One side pouring mode can improve the temperature distributions of casting pool.VTRC process has a good ability in continuous casting metallic glassy thin strips.

Effect of twin-roll casting parameters on microstructure and mechanical properties of AA5083-H321 sheet

Thepurpose of the present paper is to study the mechanical propertiesand microstructureof the twin-roll cast and cold rolled AA5083 aluminum alloy sheet in strain-hardened H321 temper. To reach this goal, first, a sound surface slab of 8.90 mm thick and 1260 mm wide was cast by a 15°; tilt back twin roll caster at a casting speed of 490 mm/min. After homogenization at 520 ℃, the product was cold rolled to two thicknesses of 6.30 mm and 3.85 mm with an intermediate annealing at 370 ℃ and final stabilization at 180 ℃. Opticalmicroscopyand scanning electron microscopy （SEM） investigations of the as-cast state depicted the segregation of intermetallic particles mainly in grain boundaries which wasthe cause of grain removal observed in the fracture surface of tensile test samples. In addition, mechanical properties indicated an increase in total elongation after homogenization heat treatment dueto the elimination of the grain boundary segregations. Finally, it was observed that the properties of the 3.85 mmthick sheet were consistent with the H321 temper requirements according to ASTM B 290M standard due to applying sufficient cold reduction during cold rolling stage.

Interfacial pressure distribution and bonding characteristics in twin-roll casting of Cu/Al clad strip

The mechanical properties and product thickness specifications of bimetallic clad strip prepared by twin-roll casting are tightly related to the mechanical behavior of bonding interface interaction.The thermal−flow coupled simulation and the interface pressure calculation models are established with the cast-rolling velocity as the variable.The results show that the interface temperature decreases,the interface pressure and the proportion of the thickness of the Al side increase with the decrease in cast-rolling velocity.The thinning of Cu strip mainly occurs in the backward slip zone.The higher pressure and longer solid/semi-solid contact time make the interface bonded fully,which provides favorable conditions for atomic diffusion.The inter-diffusion zone with a width of 4.9μm is attained at a cast-rolling velocity of 2.4 m/min,and the Cu side surface is nearly completely covered by aluminum.Therefore,the ductile fracture occurs on the Al side,which prevents the propagation of interface delamination cracks effectively.Meanwhile,shear effect becomes more significant at high interfacial pressure and large plastic strain,and the microstructure on Al side is composed of slender columnar crystals.Thus,the metallurgical bonding and refinement of grains on the Al side can result in higher bonding strength and tensile properties of the clad strip.

Three-dimensional modeling of effect of surface intermetallic phase on surface defects of Al-Fe-Si aluminum foils during twin-roll casting

Scanning electron microscopy and X-ray energy dispersive spectrum analysis show that the clusters of intermetallic AlFeSi particle are distributed on or near the aluminum foil stock surfaces heterogeneously. 3D finite element modeling shows that these clusters of hard particles induce the fracture of the nano-scale lubricant oil film at first and further lead to severe deformation in the nearby aluminum foil substrate along the rolling direction. Consequently, the optical property in this region differs from that in the surroundings, resulting in surface defects.

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.

3D stress simulation and parameter design during twin-roll casting of 304 stainless steel based on the Anand model

This study first investigated cracks on the surface of an actual steel strip. Formulating the Anand model in ANSYS software, we then simulated the stress field in the molten pool of type 304 stainless steel during the twin-roll casting process. Parameters affecting the stress distribution in the molten pool were analyzed in detail and optimized. After twin-roll casting, a large number of transgranular and intergranular cracks resided on the surface of the thin steel strip, and followed a tortuous path. In the molten pool, stress was enhanced at the exit and at the roller contact positions. The stress at the exit decreased with increasing casting speed and pouring temperature. To ensure high quality of the fabricated strips, the casting speed and pouring temperature should be controlled above 0.7 m/s and 1520℃, respectively.

Simulation of microstructures in solidification of aluminum twin-roll casting based on CA

The microstructures in the solidification process of aluminum twin-roll casting was simulated based on CA(Cellular Automation Method),and the nucleation model based on the normal distribution and KUZR-GIOVANOLS-TRIVEDI(KGT) growth model were used in the calculation. FDM(Finite Difference Method) combined with relative motion was used,and dynamic evolution of microstructures in the process of aluminum twin-roll casting was achieved. Visual Fortran programming language was adopted to calculate and realize the image post-processing. Moreover,the effect of different casting process parameters on the formation of the microstructures was simulated. The results are helpful to explaining the dendritic segregation and size segregation as well as shrinkage-porosity defects. Columnar grains mainly distribute near the casting roller while equiaxed grains distributed far away from the casting roller.

Microstructure of aluminum twin-roll casting based on Cellular Automation

Nucleation and growth model based on Cellular Automation(CA) incorporated with macro heat transfer calculation was presented to simulate the microstructure of aluminum twin-roll casting. The dynamics model of dendrite tip (KGT model) was amended in view of characteristics of aluminum twin-roll casting. Through the numerical simulation on solidification structure under different casting speeds, it can be seen that when the casting speed is 1.3 m/min, that is, under conditions of conventional roll casting, coarse columnar grains dominate the solidification structure, and equiaxed grains exist in the center of aluminum strip. When the casting speed continuously increases to 8 m/min, that is, under the conditions of thin-gauge high-speed casting, columnar grains in solidification structure all convert into equiaxed grains. Experimental and numerical results agree well.

Effect of casting parameters and deformation on microstructure evolution of twin-roll casting magnesium alloy AZ31

Twin roll casting method is a promising route to directly produce magnesium alloy strip. It is a rapid solidification process with high temperature gradient combined with thermal flow and rolling deformation in the casting region. As-cast strip with proper microstructure is requested to serve as next rolling feedstock. However the microstructure of as-cast strip is sensitive for casting conditions during the casting process and the as-cast microstructure greatly affects the mechanical properties. In this work, the effect of casting speed, pouring temperature, deformation as well as anneal process on microstructure and mechanical properties were investigated. The results revels that twin-roll casting process can effectively refine the grain size, improve the morphology and distribution states of Mg17Al12. The homogenization treatment time can be shorted for the fine microstructure and lower the cost dramatically for the next forming process.

AlN Precipitates and Microstructure in Non-oriented Electrical Steels Produced by Twin-roll Casting Process

Aluminum nitride （AIN） precipitates and microstructure of 4 wt.% （Si＋AI） non-oriented electrical steel were investigated. The 2.0 mm thick cast strips with three different silicon/aluminum （Si/AI） ratios were produced by twin-roll casting process, then the strips were reheated, warm rolled, cold rolled and annealed. The microstructure and AIN precipitates were characterized using optical microscopy, scanning electron microscopy and transmission electron microscopy. The results showed that with the increase of Si/AI ratio, on the one hand, the casting microstructure changed from columnar grains to equiaxed grains, and the uniformity of annealed microstructure was improved; On the other hand, the number of AIN precipitates in cast strips reduced meanwhile the distribution became dispersed. By the reheat treatment, the size and distribution of the AIN precipitates can be changed. Moreover, the grain size of the annealed strips is in the range of 20-50 #m, at the same time, many AIN precipitates were located at grain boundaries. Therefore, controlling the Si/AI ratio is a simple method to obtain desired microstructure. Then AIN precipitates in non-oriented electrical steel prepared by twin-roll casting process hinder markedly the recrystallized grains growth, A compatible reheat treatment can be an approach worth exploring to control the behavior of AIN precipitates.

A Decoupling Control Model on Perturbation Method for Twin-Roll Casting Magnesium Alloy Sheet

To better understand the twin-roll casting process,based on the analysis of the solidification phenomenon,the geometry shape of the molten metal pool,the continuity of metal and the balance of energy and momentum,five critical partial equations were established separately including the equations of pool level,solidification process,roll separating force,roll gap and casting speed.Meanwhile,to obtain a uniform sheet thickness and keep a constant roll separating force,a decoupling control model was built on the perturbation method to eliminate the interference of process parameters.The simulation results show that the control model is valuable to quickly and accurately determine the control parameters.Moreover,Mg alloy sheets with high quality were cast by applying this model.

Application of non-equilibrium dendrite growth model considering thermo-kinetic correlation in twin-roll casting

Upon non-equilibrium solidifications, dendrite growth, generally as precursor of as-solidified structures,has severe effects on subsequent phase transformations. Considering synergy of thermodynamics and kinetics controlling interface migration and following conservation of heat flux in solid temperature field, a more flexible modeling for the dendrite growth is herein developed for multi-component alloys,where, two inherent problems, i.e. correlation between thermodynamics and kinetics(i.e. the thermokinetic correlation), and theoretical connection between dendrite growth model and practical processing,have been successfully solved. Accordingly, both the thermodynamic driving force G and the effective kinetic energy barrier Qeffhave been found to control quantitatively the dendrite growth(i.e. especially the growth velocity, V), as reflected by the thermo-kinetic trade-off. Compared with previous models, it is the thermo-kinetic correlation that guarantees quantitative connection between the practical processing parameters and the current theoretical framework, as well as more reasonable description for kinetic behaviors involved. Applied to the vertical twin-roll casting(VTC), the present model, realizes a good prediction for kissing points, which influences significantly alloy design and processing optimization.This work deduces quantitatively the thermo-kinetic correlation controlling the dendrite growth, and by proposing the parameter-triplets(i.e. G-Qeff-V), further opens a new beginning for connecting solidification theories with industrial applications, such as the VTC.

Generalized stability criterion for controlling solidification segregation upon twin-roll casting

Macro-and micro-segregation formed upon twin-roll casting(TRC)can be inherited from sub-rapid solid-ification to solid-state transformation,even to plastic deformation,thus deteriorating drastically mechan-ical properties of as-produced thin sheets.Although many works focusing mainly on controlling fields of thermal,concentration and convection have been reported,how to control artificially and quantitatively the segregation using a theoretical connection between processing parameters and solidification models,has not been realized,yet.Regarding it,a systematical framework integrating non-equilibrium dendritic growth and overall solidification kinetics with the TRC parameters,was constructed applying a general-ized stability(GS)conception deduced from transient thermodynamic driving force△G^(t)and transient ki-netic energy barrier Q_(eff)^(t)evolving upon solidification.Departing from this framework considering synergy of thermodynamics and kinetics(i.e.,thermo-kinetic synergy),a criterion of high△G^(t)-high GS guaranteed that the macro(i.e.,the centerline)and the micro(i.e.,the edge)segregation can be suppressed by in-creasing△G^(t)and GS at the beginning and the ending stage of sub-rapid solidification,respectively.This typical thermo-kinetic combination producing the microstructure can be inherited into the plastic de-formation,as reflected by corresponding strength-ductility combinations.This work realized quantitative controlling of TRC by a theoretical connection between processing parameters and solidification models,where,an optimization for sub-rapid solidification segregation using the GS conception including△G^(t)and Q_(eff)^(t)has been performed.

Microstructure,tensile properties and free bulge formability of Sr-and Y-containing AZ31 alloy sheet produced by twin-roll casting and sequential hot rolling

The effects of Sr and Y on microstructure,tensile property and free bulge formability of AZ31 alloy sheet produced by twin-roll casting and sequential hot rolling were investigated to improve the mechanical properties and formability of the AZ31 alloy.Sr and Y addition can form Al4 Sr,Al2 Y and Al3 Y phases which can impede dislocation movement and promote dynamic recrystallization during the rolling deformation and decrease the lattice resistance to dislocation motion by decreasing Al solubility in the alloy,resulting in finer grains,lower dislocation density and no twinning generating in the twin-roll casting and sequential hot rolling(TRC-HR)AZ31-1.3 Sr-1.0 Y alloy.The maximum stress and elongation of the alloy increase significantly after adding Sr and Y.The average cavity and grain sizes of the TRC-HR AZ31-1.3 Sr-1.0 Y alloy are smaller,resulting in higher elongation in the alloy.The addition of Y and Sr can effectively improve the free bulge formability and the thickness uniform of the alloy.The Al4 Sr,Al2 Y and A13 Y phases can inhibit the grain growth by obstructing dislocation motion or grain boundary slip,resulting in smaller grain size of AZ31-1.3 Sr-1.0 Y alloy bulge parts.

Wettability and Interfacial Reactions Between Metallic Glass Melts and Cu/Mo Used as Roller Materials for Twin-Roll Casting

Twin-roll casting has been recently revealed to be an effi cient technique to produce rejuvenated metallic glass(MG)strips.Due to the high melting point and high hardness,pure Mo is considered as a good roller material as pure Cu.However,the wettability and interfacial reactions between MG melts and Cu or Mo remain largely unknown.In this work,a series of sessile droplet wetting experiments are designed to investigate the wettability and reactions between Zr_(41.2)Ti_(13.8)Cu_(12.5)Ni_(10)Be_(22.5)(Vit.1)or(Zr 0.401 Ti_(0.133)Cu_(0.118)Ni_(0.101)Be_(0.247))_(99)Nb_(1)(Nb1)MG melts and Cu/Mo substrates at temperatures of 1073,1123 and 1173 K.It is found that the wettability and interfacial reactions of the Vit.1 and Nb1 MG melts on the Cu substrates are very similar.The equilibrium contact angles are~30°at 1073 K and~25°-27°at 1123 K.The MG melts completely spread out on the Cu substrates at 1173 K.Cu substrates are slightly dissolved in the MG melts event at 1073 K,and a transitional reaction layer exists between the droplet and the Cu substrate.In comparison,the Vit.1 MG melt exhibits a much improved wettability on the Mo substrate.The equilibrium contact angle of the Vit.1/Mo is only 6°at 1073 K and 5°at 1123 K.No signifi cant diff usion of Mo into the droplet occurs even at 1173 K with a holding time of~30 min.The interfaces of the Vit.1/Mo samples are sharp,and no interfacial reaction layers form.These fi ndings indicate that pure Mo can be a good roller material for twin-roll casting at high temperatures,and the Mo-made rollers are expected of capability to produce MG strips with good quality.