Numerical microstructure prediction for an aluminium casting and its experimental validation

Virtual manufacturing based on through-process modelling becomes an evolving research area which aims at integrating diverse simulation tools to realize computer-aided design, analysis, prototyping and manufacturing. Numerical prediction of the as-cast microstructure is an initial and critical step in the whole through- process modelling chain for engineering components. A commercial software package with the capability of calculating important microstructure features for aluminium alloys is used to simulate a G-AISi7MgCu0.5 laboratory casting. The simulated microstructure, namely grain size, secondary dendrite arm spacing and diverse phase fractions are verified experimentally. Correspondence and discrepancies are reported and discussed.

Simulation on solidification of an Al-Ni alloy under electromagnetic stirring

The microstructure of AI-Ni alloy has a significant influence on its performance, while electromagnetic stirring is one of the most effective methods for control of solidification structure of AI alloy. To investigate the effect of electromagnetic stirring on the solidification of the ingot, the solidification of the Al-50Ni alloy in vacuum with electromagnetic stirring was described by numerical simulation in this paper; and a three dimensional mathematical model was established. The electromagnetic field was simulated by ANSYS software and the thermal-flow field was simulated by FLUENT software. The coupling between the electromagnetic field and the thermal-flow field was implemented by user-defined subroutines. It is found that the current intensity has significant influences on the fluid flow and the microstructure of the alloy. The simulation results agree well with the experimental results, and the optimum current intensity under the exprimental conditions is 80 A, while the frequency is 50 Hz.

Preface

Hot flat rolling processes, including plate rolling and hot strip rolling, play a key role in integrated steel companies like Baosteel for producing both the final products for customers and the raw materials for further cold rolling or other downstream processing inside the company. Beside cold rolled steel sheets, pickled plates and welded pipes are two main products produced from hot rolled plates or strips in Baosteel.

Effects of Ti-Ce refiners on solidification structure and hot ductility of Fe-36Ni invar alloy

Effects of Ti-Ce refiners on the solidification structure and the hot ductility of Fe-36Ni invar alloy were investigated, the corresponding mechanisms were also discussed. The results showed that the solidification of the alloy was remarkably refined with the addition of 0.05%Ti-0.01%Ce refiners. Not only did the columnar grains become shorter and thinner, but the growth pattern of them changed into staggered growth from linear growth. The alloy had a bad hot ductility below 1050 °C, which was mainly attrib-uted to weaker boundaries and the presence of grain boundary sliding. However, the hot ductility of the alloy was highly enhanced at 850-1000 °C as the addition of 0.05%Ti-0.01%Ce refiners could refine grain sizes, thus hinder grain boundary sliding, strengthen the grain boundary and promote the grain boundary movement. The alloy had a good hot ductility over 1050 °C, dynamic recrys-tallization occurred and was found to be responsible for the better hot ductility. In addition, the average coefficient of thermal ex-pansion of the alloy decreased a little with the addition of 0.05%Ti-0.01%Ce refiners, which met the requirement of material prop-erties.

Norton-Hoff model for deformation of growing solid shell of thin slab casting in funnel-shape mold

A funnel-type mold is commonly used to provide necessary clearance for the submerged entry nozzle in the thin slab casting(TSC).The partially solidified shell is subjected to the mechanical deformations,which can lead to the defects formation and,as a results,to a breakout.Traditionally,the results of the flow simulation,performed by the finite volume method(FVM),are fed to the external package for the finite element analysis of stress and strain.A coupled model was assembled using“creeping solid”approach by blending the Norton-Hoff viscoplastic stress for the solidifying shell with the Newtonian viscous stress of the liquid melt.The FVM was used to combine both liquid and solid stress models within a single solver.The iterative procedure based on the improved both side diffusion method was introduced to treat the nonlinear relation between the viscoplastic stress and the strain rate.The modeled shell thickness was verified by previously published breakout measurements and the simulation results.Temperature distribution,obtained during the TSC simulation,dominantly corresponds to the viscoplastic range.Developed numerical approach is robust and has direct industrial application.

Correction to: Norton-Hoff model for deformation of growing solid shell of thin slab casting in funnel-shape mold

Correction to:J.Iron Steel Res.Int.(2022)29:88-102 https://doi.Org/10.1007/s42243-021-00734-8The original version of this article unfortunately contained mistakes.The assignment of the affiliations was incorrect,and the corrected table is given below.The original article has been corrected.