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Remelting and Casting Processes in the Production of Metals and...
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Remelting and Casting Processes in the Production of Metals and Alloys

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Casting, Forming and Heat Treatment".

Deadline for manuscript submissions: 20 October 2024 | Viewed by 6560

Special Issue Editor

Dr. Fengsheng Qi

E-Mail Website
Guest Editor
School of Metallurgy, Northeastern University, Shenyang 110819, China
Interests: refining outside the furnace; thermal engineering and combustion technology of industrial furnaces; intelligent flow and virtual simulation

Special Issue Information

Dear Colleagues,

”Remelting and Casting Processes in the Production of Metals and Alloys" is a Special Issue focused on investigating and analyzing the remelting and casting processes involved in the production of metals and alloys. Remelting plays a crucial role in the recycling and refining of metals and scrap materials to obtain homogeneous materials with desired properties. Various remelting techniques, such as using an electric arc furnace (EAF), electro-slag remelting (ESR), induction melting, and vacuum refining, are evaluated to understand their advantages and limitations. Casting, on the other hand, involves pouring molten metal into molds to obtain specific shapes and forms. Different casting methods, including continuous casting (CC), sand casting, investment casting, and die casting, are explored based on factors such as complexity, cost, and production volume. Furthermore, solidification is the crucial phase in the casting process where the molten metal transitions into a solid state, determining the final shape, microstructure, and properties of the casting. This topic also focuses on the characterization and mitigation of defects that may occur during remelting and casting processes. Factors such as porosity, shrinkage, and inclusions are analyzed, and strategies for defect prevention and reduction are investigated. Advanced techniques such as computer simulations and process optimization are employed to improve casting quality and minimize defects.

This Special Issue aims to present the latest research related to advanced techniques for “Remelting and Casting Processes in the Production of Metals and Alloys”. Research reports associated with novel metallurgical technology are also welcome.

Dr. Fengsheng Qi
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • remelting techniques
  • casting process
  • alloy production
  • defects
  • continuous casting
  • electro-slag remelting
  • numerical simulation
  • optimaization

Published Papers (7 papers)

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Research

18 pages, 10455 KiB  
Article
Study on Al Evaporation during AlV55 Melting and Alloy Preparation
by Bin Sun, Heli Wan, Baoqiang Xu, Xianjun Lei and Lanjie Li
Metals 2024, 14(4), 466; https://doi.org/10.3390/met14040466 - 16 Apr 2024
Viewed by 529
Abstract
Vacuum induction melting is a commonly used method for preparing AlV55 alloys. However, this method results in high Al evaporation losses, leading to poor cost control. Moreover, the influence of the process parameters on the alloy composition remains unclear. In this study, the [...] Read more.
Vacuum induction melting is a commonly used method for preparing AlV55 alloys. However, this method results in high Al evaporation losses, leading to poor cost control. Moreover, the influence of the process parameters on the alloy composition remains unclear. In this study, the evaporation pattern of Al in the melting and preparation processes of AlV55 alloys is studied, and measures for controlling the system pressure are proposed to effectively reduce Al evaporation. The experimental results show that smelting under an Ar gas atmosphere of 2000 Pa can reduce the evaporation loss of Al from 11.48% under vacuum conditions (60 Pa) to 0.58% of the amount of raw material added, effectively improving the metal utilization rate and reducing production costs. The influence of various process parameters on the alloy composition and Al volatilization are investigated to enable the effective control of the compositional uniformity and impurity content of the resulting alloys. Under optimal conditions, the impurity contents of C, O, and N are 0.03%, 0.0073%, and 0.013%, respectively; this reduces the amount of Al lost by evaporation compared to conventional methods, and the alloy produced meets commercial standards. Full article
(This article belongs to the Special Issue Remelting and Casting Processes in the Production of Metals and Alloys)
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16 pages, 3638 KiB  
Article
Optimization of the Circular Channel Size and the A.C. Magnetic Field Parameters for Application in a Channel-Type Induction-Heating Tundish
by Qi Zhang, Guangye Xu and Kazuhiko Iwai
Metals 2024, 14(4), 420; https://doi.org/10.3390/met14040420 - 03 Apr 2024
Viewed by 481
Abstract
In this paper, the appropriate channel design and operating conditions for the simultaneous operation of the inclusion removal and the induction heating of the molten steel by imposing the A.C. magnetic field around the circular channel have been studied. (1) The effect of [...] Read more.
In this paper, the appropriate channel design and operating conditions for the simultaneous operation of the inclusion removal and the induction heating of the molten steel by imposing the A.C. magnetic field around the circular channel have been studied. (1) The effect of the lift force and the turbulence force on the inclusion in the transition zone of the channel has been computed; the results show that when the diameter of the inclusion is not less than 0.1 mm, both forces can be neglected because they are less than the electromagnetic pinch force, especially when the shielding parameter is not less than 5.0. (2) The minimal channel length to remove the inclusions out of the dead zone was computed without the lift force and the turbulence force; the shielding parameter of 10.0~15.9 is optimal to obtain the shortest channel length. Furthermore, the slow velocity of the molten steel is desirable. (3) The molten steel temperature increase per unit channel length by the induction heating can be controlled by the A.C. magnetic field frequency; a high frequency condition is better for the efficient thermal supply in this calculation condition. (4) When the flow velocity of the molten steel in the channel with a length of 1 m and a radius of 0.075 m is 0.1 m/s, the shielding parameter of 15.9 is the optimal parameter to simultaneously remove the inclusions and heat up the molten steel in the circular channel. And when the non-dimensional magnetic field intensity of the A.C. magnetic field is 31.7, the removal rate of the 0.1 mm inclusion in the channel can reach more than 95% and the molten steel temperature can be heated over 10 K. Full article
(This article belongs to the Special Issue Remelting and Casting Processes in the Production of Metals and Alloys)
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14 pages, 10053 KiB  
Article
Effect Mechanism of α-Ferrite Sustained Precipitation on High-Temperature Properties in Continuous Casting for Peritectic Steel
by Songyuan Ai, Yifan Li, Mujun Long, Haohao Zhang, Dengfu Chen, Huamei Duan, Danbin Jia and Bingzhi Ren
Metals 2024, 14(3), 350; https://doi.org/10.3390/met14030350 - 18 Mar 2024
Viewed by 652
Abstract
Exploring the mechanism of the α-ferrite precipitation process on high-temperature properties plays an important guiding role in avoiding slab cracks and effectively regulating quality. In this work, in situ observation of the α-ferrite sustained precipitation behavior for peritectic steel during the austenitic [...] Read more.
Exploring the mechanism of the α-ferrite precipitation process on high-temperature properties plays an important guiding role in avoiding slab cracks and effectively regulating quality. In this work, in situ observation of the α-ferrite sustained precipitation behavior for peritectic steel during the austenitic phase transition process has been investigated using high-temperature confocal scanning laser microscopy. Meanwhile, the high-temperature evolution of the phase fractions during the phase transition process was quantitatively analyzed based on the high-temperature expansion experiment using the peak separation method. Furthermore, the high-temperature properties variations of the casting slab during the α-ferrite sustained precipitation process were investigated with the Gleeble thermomechanical simulator. The results show that the film-like ferrite precipitated along the austenite grain boundaries at the initial stage of phase transition, then needle-like ferrite initiates rapid precipitation on film-like ferrite when the average thickness reaches 15~20 μm. Hot ductility reached a minimum at the ferrite phase fraction fα = 10~15%, while high-temperature properties returned to a higher level after fα > 40~45%. The appearance of a considerable amount of needle-like ferrite and grain refinement effectively improves the high-temperature properties with the α-ferrite precipitation process advances. Full article
(This article belongs to the Special Issue Remelting and Casting Processes in the Production of Metals and Alloys)
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15 pages, 2602 KiB  
Article
Numerical Simulation of Electromagnetic Field in Slab Electroslag Remelting Process with Double Electrode Series
by Qi Li, Zhenquan Jing and Yanhui Sun
Metals 2024, 14(1), 37; https://doi.org/10.3390/met14010037 - 28 Dec 2023
Viewed by 790
Abstract
In this paper, a mathematical model of an electromagnetic field during an electroslag remelting process of industrial-scale slab was established using a Maxwell 3D module in Ansys Electromagnetics Suite. The distribution characteristics of the magnetic field intensity, current density and Joule heat density [...] Read more.
In this paper, a mathematical model of an electromagnetic field during an electroslag remelting process of industrial-scale slab was established using a Maxwell 3D module in Ansys Electromagnetics Suite. The distribution characteristics of the magnetic field intensity, current density and Joule heat density during the electroslag remelting process were analyzed in detail. On this basis, the influence of the current frequency on the electroslag remelting process of an industrial scale is studied, and the influence of process parameters such as the slag pool depth, electrode insertion depth and ingot height on the electromagnetic field is also considered. The results show that the Joule heat generated in the slag pool is much greater than that of the electrode and the ingot. The maximum Joule heat is located at the contact between the electrode corner and the slag pool, and the Joule heat near the middle of the two electrodes is greater than the rest. With the increase in the current frequency, the current density distribution in the slag cell is basically unchanged. The current density inside the two electrodes increases obviously with the current frequency. When the current frequency increases from 10 Hz to 50 Hz, the maximum current density at the inner surface of the electrode increases by 14.7%. The current distribution at the lower side of the electrode in the slag pool is relatively uniform, and the current density in this region decreases with the increase in the height of the slag pool and the increase in the depth of the electrode inserted into the slag pool. Full article
(This article belongs to the Special Issue Remelting and Casting Processes in the Production of Metals and Alloys)
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19 pages, 26133 KiB  
Article
Influence of Oxy-Fuel Lance Parameters on the Scrap Pre-Heating Temperature in the Hot Metal Ladle
by Shenglei Zhuang, Dongping Zhan, Taotao Wang, Peng Li and Yongkun Yang
Metals 2023, 13(5), 847; https://doi.org/10.3390/met13050847 - 25 Apr 2023
Viewed by 1541
Abstract
As one of the vital ways to improve the converter heat balance and increase the scrap ratio, scrap pre-heating technology has attracted much attention from researchers. The aim of this paper is to reveal the effect of the oxy-fuel lance parameters on the [...] Read more.
As one of the vital ways to improve the converter heat balance and increase the scrap ratio, scrap pre-heating technology has attracted much attention from researchers. The aim of this paper is to reveal the effect of the oxy-fuel lance parameters on the temperature field, flow field, and scrap pre-heating temperature in the ladle by means of numerical simulations. For this, a three-dimensional mathematical model containing the turbulence model, the porous medium heat balance model, and other models has been developed. The research results show that the rational and correct choice of gas flow rate, lance position, and nozzle angle has an important influence on the temperature field and the average scrap temperature. When the gas flow rate increases, the internal annular combustion zone of the scrap gradually expands, the cold zone at the bottom of the scrap continues to decrease, and the average scrap temperature keeps increasing. When the gas flow rate is 5000 m3/h, and the average scrap temperature reaches 1197 K, the pre-heating time is 9.98 min. Lowering the oxy-fuel lance position helps to reduce the cold zone at the bottom of the scrap and increases the average temperature in the cold zone. Reasonable selection of the nozzle angle is conducive to improving the uniformity of the flow field. When the angle of the nozzle is 15°, the gas circulation zone is the largest, and the time to reach an average scrap temperature of 1197 K is the shortest. Full article
(This article belongs to the Special Issue Remelting and Casting Processes in the Production of Metals and Alloys)
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15 pages, 3912 KiB  
Article
Effect of CaO-MgO-FeO-SiO2-xNa2O Slag System on Converter Dephosphorization
by Bin Geng, Dongping Zhan, Zhouhua Jiang and Yongkun Yang
Metals 2023, 13(5), 844; https://doi.org/10.3390/met13050844 - 25 Apr 2023
Cited by 2 | Viewed by 1128
Abstract
Na2O is an alkaline oxide, which can significantly improve the dephosphorization ability of converter slag. The effect of Na2O on the dephosphorization of converter slag was analyzed with a high-temperature dephosphorization experiment in a MoSi2 resistance furnace. We [...] Read more.
Na2O is an alkaline oxide, which can significantly improve the dephosphorization ability of converter slag. The effect of Na2O on the dephosphorization of converter slag was analyzed with a high-temperature dephosphorization experiment in a MoSi2 resistance furnace. We found that the dephosphorization rate increased with the increase of (Na2O) in the dephosphorization slag. The elements of Ca, Si, O, and P in the dephosphorization slag are distributed in the same area, mainly in the form of phosphate minerals, such as Ca2SiO4·0.05Ca3(PO4)2 and 6Ca2SiO4·Ca3(PO4)2. After adding Na2O, part of the Na will replace the Ca in the phosphorus-containing phase to form Ca2SiO4·Ca2Na2(PO4)2. The industrial test showed that the average dephosphorization rate in the early stage of the test heats with the CaO-MgO-FeO-SiO2-0.5%Na2O slag system could reach 62.39%, which was 19.62% higher than that of the conventional heats. The average basicity of the final slag was 0.19% lower than that of the conventional heats, while w(P2O5) increased by 0.36%, and T.Fe decreased by 0.69%. The average consumption of the slagging materials was 35.93 kg/t, which was 7.24 kg/t less than that of the conventional heats. Through thermodynamic calculation, we found that with the increase of (Na2O), the phosphorus distribution ratio between slag and steel increased significantly, the area of the liquid phase zone of the slag system increased continuously, and the viscosity decreased continuously. Full article
(This article belongs to the Special Issue Remelting and Casting Processes in the Production of Metals and Alloys)
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16 pages, 7838 KiB  
Article
Effect of Basicity and Al2O3 Content in Slag on Cleanliness of Electroslag Ingot
by Xiaofang Shi, Yu Wang, Bingjie Wang and Lizhong Chang
Metals 2023, 13(4), 642; https://doi.org/10.3390/met13040642 - 23 Mar 2023
Cited by 1 | Viewed by 1030
Abstract
In order to clarify the mechanism for the increase in oxygen content during electroslag remelting, this paper analyzes in detail the effect of slag components on the gas content and number, size and composition of inclusions in electroslag ingots. The results show that, [...] Read more.
In order to clarify the mechanism for the increase in oxygen content during electroslag remelting, this paper analyzes in detail the effect of slag components on the gas content and number, size and composition of inclusions in electroslag ingots. The results show that, when the CaF2-MgF2-CaO-MgO-SiO2 slag system is used for electroslag remelting, the oxygen content in electroslag ingots decreases clearly with the increase in slag basicity. When the basicity is 14~3.3, the oxygen content in electroslag ingots is only 9~11 ppm. When the basicity drops to 2.3, the oxygen content increases to 20 ppm. The slag with high basicity also leads to a decrease in the number and size of inclusions with high Ca content. When the CaF2-MgF2-CaO-MgO-SiO2-Al2O3 slag system is used for electroslag remelting, with the increase in the Al2O3 content in slag with the same basicity, the oxygen content and inclusions in electroslag ingots gradually increase. However, the Al content in inclusions increases and the Ca content decreases. The decomposition of SiO2 and Al2O3 in slag is the main reason for the decrease in the cleanliness of electroslag ingots. Full article
(This article belongs to the Special Issue Remelting and Casting Processes in the Production of Metals and Alloys)
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