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Metals
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Advanced Simulation Technologies of Metallurgical Processing
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Advanced Simulation Technologies of Metallurgical Processing

A special issue of Metals (ISSN 2075-4701).

Deadline for manuscript submissions: closed (30 September 2019) | Viewed by 57849

Special Issue Editor

Prof. Dr. Bernhard Peters

E-Mail Website
Guest Editor
University of Luxembourg, Maison du Nombre 6, Avenue de la Fonte L-4364 Esch-sur-Alzette, Luxembourg
Interests: fluid dynamics; thermodynamics and combustion; granular materials; simulation (CFD)

Special Issue Information

Dear Colleagues,

Traditional models describing metallurgical processes such as sintering, roasting, smelting, leaching, precipitation, electrolysis, refining, solidification, etc., range from turbulent flow to multi-phase flow models, including heat transfer. However, at the heart of these processes, very complex multi-phase and multi-physics processes, including complex chemistry, often spanning multiple time and length scales, take place. Under these circumstances, empirical data is difficult to obtain and modelling is a complementary and promising path to follow. In conjunction with experimental data, an analysis of predicted results provides a deeper insight into the physics of these processes. Furthermore, modelling and simulation is a useful tool employed to analyse metallurgical processes in depth, such as those of a blast furnace, which are usually characterized by high costs and energy consumption. In fact, process simulations derived from versatile mathematical, physical, or data-driven models have the potential to provide effective analysis tools to improve metallurgical processes, resulting in enhanced quality at lower costs and often contributing to better sustainability. Therefore, this Special Issue is intended to collect and present the latest developments in advanced simulation technologies for metallurgical processes, as well as to identify any research gaps.

The present Special Issue aims to bring together engineers and researchers from the applicable industries and scientific community, as well as to provide a lively exchange of ideas regarding state-of-the-art and future needs for simulation technologies. Therefore, topics covered in this Special Issue will include:

  • mathematical formulation;
  • numerical methods and implementation issues;
  • solution strategies;
  • multi-scale techniques;
  • multi-physics approaches;
  • artificial intelligence, e.g., machine learning;
  • validation, verification, and uncertainty quantification (VVUQ);
  • metallurgical models;
  • large-scale simulation, and industrial applications and their requirements.

Prof. Dr.-Ing. Bernhard Peters
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

  • mathematical modelling
  • numerical approaches
  • machine learning
  • continuous and discrete methods
  • coupling
  • uncertainty quantification
  • multi-physics
  • high-performance computing

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Published Papers (15 papers)

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Editorial

Jump to: Research, Review

3 pages, 157 KiB  
Editorial
Advanced Simulation Technologies of Metallurgical Processing
by Bernhard Peters
Metals 2020, 10(6), 829; https://doi.org/10.3390/met10060829 - 23 Jun 2020
Cited by 1 | Viewed by 2145
Abstract
Although the design and performance of metallurgical processes are still carried out on an experimental basis, numerical methods and simulation software—either commercial or open-source—have developed into a standard for these processes [...] Full article
(This article belongs to the Special Issue Advanced Simulation Technologies of Metallurgical Processing)

Research

Jump to: Editorial, Review

15 pages, 4818 KiB  
Article
A Stochastic Model Approach for Copper Heap Leaching through Bayesian Networks
by Manuel Saldaña, Javier González, Ricardo I. Jeldres, Ángelo Villegas, Jonathan Castillo, Gonzalo Quezada and Norman Toro
Metals 2019, 9(11), 1198; https://doi.org/10.3390/met9111198 - 7 Nov 2019
Cited by 19 | Viewed by 2958
Abstract
Multivariate analytical models are quite successful in explaining one or more response variables, based on one or more independent variables. However, they do not reflect the connections of conditional dependence between the variables that explain the model. Otherwise, due to their qualitative and [...] Read more.
Multivariate analytical models are quite successful in explaining one or more response variables, based on one or more independent variables. However, they do not reflect the connections of conditional dependence between the variables that explain the model. Otherwise, due to their qualitative and quantitative nature, Bayesian networks allow us to easily visualize the probabilistic relationships between variables of interest, as well as make inferences as a prediction of specific evidence (partial or impartial), diagnosis and decision-making. The current work develops stochastic modeling of the leaching phase in piles by generating a Bayesian network that describes the ore recovery with independent variables, after analyzing the uncertainty of the response to the sensitization of the input variables. These models allow us to recognize the relations of dependence and causality between the sampled variables and can estimate the output against the lack of evidence. The network setting shows that the variables that have the most significant impact on recovery are the time, the heap height and the superficial velocity of the leaching flow, while the validation is given by the low measurements of the error statistics and the normality test of residuals. Finally, probabilistic networks are unique tools to determine and internalize the risk or uncertainty present in the input variables, due to their ability to generate estimates of recovery based upon partial knowledge of the operational variables. Full article
(This article belongs to the Special Issue Advanced Simulation Technologies of Metallurgical Processing)
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18 pages, 6007 KiB  
Article
Process-Structure-Properties-Performance Modeling for Selective Laser Melting
by Tatu Pinomaa, Ivan Yashchuk, Matti Lindroos, Tom Andersson, Nikolas Provatas and Anssi Laukkanen
Metals 2019, 9(11), 1138; https://doi.org/10.3390/met9111138 - 24 Oct 2019
Cited by 37 | Viewed by 7294
Abstract
Selective laser melting (SLM) is a promising manufacturing technique where the part design, from performance and properties process control and alloying, can be accelerated with integrated computational materials engineering (ICME). This paper demonstrates a process-structure-properties-performance modeling framework for SLM. For powder-bed scale melt [...] Read more.
Selective laser melting (SLM) is a promising manufacturing technique where the part design, from performance and properties process control and alloying, can be accelerated with integrated computational materials engineering (ICME). This paper demonstrates a process-structure-properties-performance modeling framework for SLM. For powder-bed scale melt pool modeling, we present a diffuse-interface multiphase computational fluid dynamics model which couples Navier–Stokes, Cahn–Hilliard, and heat-transfer equations. A computationally efficient large-scale heat-transfer model is used to describe the temperature evolution in larger volumes. Phase field modeling is used to demonstrate how epitaxial growth of Ti-6-4 can be interrupted with inoculants to obtain an equiaxed polycrystalline structure. These structures are enriched with a synthetic lath martensite substructure, and their micromechanical response are investigated with a crystal plasticity model. The fatigue performance of these structures are analyzed, with spherical porelike defects and high-aspect-ratio cracklike defects incorporated, and a cycle-amplitude fatigue graph is produced to quantify the fatigue behavior of the structures. The simulated fatigue life presents trends consistent with the literature in terms of high cycle and low cycle fatigue, and the role of defects in dominating the respective performance of the produced SLM structures. The proposed ICME workflow emphasizes the possibilities arising from the vast design space exploitable with respect to manufacturing systems, powders, respective alloy chemistries, and microstructures. By digitalizing the whole workflow and enabling a thorough and detailed virtual evaluation of the causal relationships, the promise of product-targeted materials and solutions for metal additive manufacturing becomes closer to practical engineering application. Full article
(This article belongs to the Special Issue Advanced Simulation Technologies of Metallurgical Processing)
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18 pages, 9684 KiB  
Article
Model-Based Analysis of Factors Affecting the Burden Layer Structure in the Blast Furnace Shaft
by Haifeng Li, Henrik Saxén, Weiqiang Liu, Zongshu Zou and Lei Shao
Metals 2019, 9(9), 1003; https://doi.org/10.3390/met9091003 - 12 Sep 2019
Cited by 19 | Viewed by 4042
Abstract
The distribution of burden layers in an ironmaking blast furnace strongly influences the conditions in the upper part of the process. The bed permeability largely depends on the distribution of ore and coke in the lumpy zone, which affects the radial gas flow [...] Read more.
The distribution of burden layers in an ironmaking blast furnace strongly influences the conditions in the upper part of the process. The bed permeability largely depends on the distribution of ore and coke in the lumpy zone, which affects the radial gas flow distribution in the shaft. Along with the continuous advancement of technology, more information about the internal conditions of the blast furnace can be obtained through advanced measurement equipment, including 2D profiles and 3D surface maps of the top burden surface. However, the change of layer structure along with the burden descent cannot be directly measured. A mathematical model predicting the burden distribution and the internal layer structure during the descending process is established in this paper. The accuracy of the burden distribution model is verified by a comparison with experimental results. A sensitivity study was undertaken to clarify the role of some factors on the arising layer distribution, including the descent-rate distribution, the initial burden surface profile, and the charging direction through the charging matrix. The findings can be used as a theoretical basis to guide plant operations for optimizing the charging. Full article
(This article belongs to the Special Issue Advanced Simulation Technologies of Metallurgical Processing)
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9 pages, 1539 KiB  
Article
Simulation of the Scale-up Process of a Venturi Jet Pyrolysis Reactor
by Chao Lv, Tingan Zhang and Bo Hao
Metals 2019, 9(9), 979; https://doi.org/10.3390/met9090979 - 3 Sep 2019
Cited by 4 | Viewed by 2526
Abstract
Micro- and nano-sized cerium oxide particles can be prepared through pyrolyzing cerium chloride solution directly in the venturi jet pyrolysis reactor. Micro- and nano-sized cerium oxide particles have better performance and higher application value. To increase the production of micro-and nano-sized cerium oxide, [...] Read more.
Micro- and nano-sized cerium oxide particles can be prepared through pyrolyzing cerium chloride solution directly in the venturi jet pyrolysis reactor. Micro- and nano-sized cerium oxide particles have better performance and higher application value. To increase the production of micro-and nano-sized cerium oxide, it is necessary to scale up the venturi jet pyrolysis reactor. According to the geometric similarity principle, the scale-up of the venturi jet pyrolysis reactors utilize dimensional analysis methods, with FLUENT13.0 and user-defined functions, following the mathematical simulation of the resulting enlarged reactors. After the dimensional analysis, the empirical formula obtained between the reactants and all the parameters is Q = 2.240727 × 10−4P0.004568ρ0.26223d−0.24801V1.25714n0.076479μ−0.26628, and the geometrical scale-up of the reactors needs to follow V = 0.0209d0.196. The results in this study can provide data support for the future optimization and amplification of reactors. Full article
(This article belongs to the Special Issue Advanced Simulation Technologies of Metallurgical Processing)
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11 pages, 1367 KiB  
Article
Development of an Analytical Model for the Extraction of Manganese from Marine Nodules
by Manuel Saldaña, Norman Toro, Jonathan Castillo, Pía Hernández, Emilio Trigueros and Alessandro Navarra
Metals 2019, 9(8), 903; https://doi.org/10.3390/met9080903 - 17 Aug 2019
Cited by 17 | Viewed by 3726
Abstract
Multivariable analytical models provide a descriptive (albeit approximate) mathematical relationship between a set of independent variables and one or more dependent variables. The current work develops an analytical model that extends a design of experiments for the leaching of manganese from marine nodules, [...] Read more.
Multivariable analytical models provide a descriptive (albeit approximate) mathematical relationship between a set of independent variables and one or more dependent variables. The current work develops an analytical model that extends a design of experiments for the leaching of manganese from marine nodules, using sulfuric acid (H2SO4) in the presence of iron-containing tailings, which are both by-products of conventional copper extraction. The experiments are configured to address the effect of time, particle size, acid concentration, Fe2O3/MnO2 ratio, stirring speed and temperature, under typical industrial conditions. The recovery of manganese has been modeled using a first order differential equation that accurately fits experimental results, noting that Fe2O3/MnO2 and temperature are the most critical independent variables, while the particle size is the least influential (under typical conditions). This study obtains representative fitting parameters, that can be used to explore the incorporation of Mn recovery from marine nodules, as part of the extended value chain of copper sulfide processing. Full article
(This article belongs to the Special Issue Advanced Simulation Technologies of Metallurgical Processing)
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14 pages, 3493 KiB  
Article
Effect of Differentiated Injection Ratio, Gas Flow Rate, and Slag Thickness on Mixing Time and Open Eye Area in Gas-Stirred Ladle Assisted by Physical Modeling
by Luis E. Jardón-Pérez, Daniel R. González-Morales, Gerardo Trápaga, Carlos González-Rivera and Marco A. Ramírez-Argáez
Metals 2019, 9(5), 555; https://doi.org/10.3390/met9050555 - 12 May 2019
Cited by 17 | Viewed by 2911
Abstract
In this work, the effects of equal (50%/50%) or differentiated (75%/25%) gas flow ratio, gas flow rate, and slag thickness on mixing time and open eye area were studied in a physical model of a gas stirred ladle with dual plugs separated by [...] Read more.
In this work, the effects of equal (50%/50%) or differentiated (75%/25%) gas flow ratio, gas flow rate, and slag thickness on mixing time and open eye area were studied in a physical model of a gas stirred ladle with dual plugs separated by an angle of 180°. The effect of the variables under study was determined using a two-level factorial design. Particle image velocimetry (PIV) was used to establish, through the analysis of the flow patterns and turbulence kinetic energy contours, the effect of the studied variables on the hydrodynamics of the system. Results revealed that differentiated injection ratio significantly changes the flow structure and greatly influences the behavior of the system regarding mixing time and open eye area. The Pareto front of the optimized results on both mixing time and open eye area was obtained through a multi-objective optimization using a genetic algorithm (NSGA-II). The results are conclusive in that the ladle must be operated using differentiated flow ratio for optimal performance. Full article
(This article belongs to the Special Issue Advanced Simulation Technologies of Metallurgical Processing)
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14 pages, 4304 KiB  
Article
Numerical Simulation of Solidification Behavior and Solute Transport in Slab Continuous Casting with S-EMS
by Dongbin Jiang, Miaoyong Zhu and Lifeng Zhang
Metals 2019, 9(4), 452; https://doi.org/10.3390/met9040452 - 17 Apr 2019
Cited by 21 | Viewed by 4393
Abstract
A 3D numerical model was built to investigate the transport phenomena in slab continuous casting process with secondary electromagnetic stirring (S-EMS). In the model, the columnar grain grew from strand surface and it should be treated as a porous media. While for the [...] Read more.
A 3D numerical model was built to investigate the transport phenomena in slab continuous casting process with secondary electromagnetic stirring (S-EMS). In the model, the columnar grain grew from strand surface and it should be treated as a porous media. While for the equiaxed zone, the nucleated grain moves with fluid flow in the earlier stage and it was regarded as a slurry. The model was validated by measured strand surface temperature and magnetic induction intensity. The results show that the solidification end near the 1/4 width of slab was postponed, due to the liquid flow from a submerged entry nozzle injected to the strand’s narrow face. As the linear stirring in the same direction is applied, liquid moves from side B to side A and then penetrates deep downward with higher temperature. In the later stage, the solidification end near the side A is postponed and the solute element is concentrated. When linear stirring in the opposite direction is used, the solidification end near the side A moves backward, while that near the side B moves forward. Moreover, it is found that the solute segregation in the side B is deteriorated, but that in the side A is reduced. As rotational stirring mode is applied, the evenness of solidification end profile is improved and the centerline segregation is reduced, especially with higher current intensity. Therefore, it is concluded that the linear stirring mode is not appropriated for slab casting, while the rotational stirring mode is more suitable. Full article
(This article belongs to the Special Issue Advanced Simulation Technologies of Metallurgical Processing)
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13 pages, 5978 KiB  
Article
Modeling of the Melting of Aluminum Particles during the RH Refining Process
by Chang Liu, Haojian Duan and Lifeng Zhang
Metals 2019, 9(4), 442; https://doi.org/10.3390/met9040442 - 15 Apr 2019
Cited by 12 | Viewed by 3867
Abstract
The aluminum content in oriented silicon steel obviously influences its magnetic properties. In the current work, the movement and melting process of added aluminum particles during Ruhrstahl-Heraeus (RH) treatment were simulated using a mathematical approach, considering the effect of the multiphase fluid flow [...] Read more.
The aluminum content in oriented silicon steel obviously influences its magnetic properties. In the current work, the movement and melting process of added aluminum particles during Ruhrstahl-Heraeus (RH) treatment were simulated using a mathematical approach, considering the effect of the multiphase fluid flow on the evolution of aluminum particles and the dissolved aluminum distribution. The current model was validated by the [Al] content in the molten steel measured by an industry experiment. Most of the added aluminum particles were melted within 5 s after they connected with the molten steel under the superheat of 28 K. The statistics of the melting time and trajectory length showed a normal distribution. Furthermore, both the melting time and the trajectory length of aluminum particles decreased as the superheat increased. Since the maximum mixing time may go up when the superheat is excessive, the suggested superheat should range from 20 K to 30 K during the RH refining process. Besides, an appropriate sampling position with a short mixing time was proposed. Full article
(This article belongs to the Special Issue Advanced Simulation Technologies of Metallurgical Processing)
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12 pages, 2298 KiB  
Article
Analysis of Heat Insulation for Coil in the Electromagnetic Induction Controlled Automated Steel-Teeming System
by Xian-Liang Li, Ming He, Xiao-Wei Zhu, Qing-Wei Wang and Qiang Wang
Metals 2019, 9(4), 434; https://doi.org/10.3390/met9040434 - 12 Apr 2019
Cited by 7 | Viewed by 3862
Abstract
Due to heat transfer of liquid steel, ambient temperature of induction coil in the electromagnetic induction controlled automated steel-teeming (EICAST) system is extremely high, which causes the coil damage and seriously restricts development of the EICAST technology. To solve the problem, a numerical [...] Read more.
Due to heat transfer of liquid steel, ambient temperature of induction coil in the electromagnetic induction controlled automated steel-teeming (EICAST) system is extremely high, which causes the coil damage and seriously restricts development of the EICAST technology. To solve the problem, a numerical simulation method was used to study the heat insulation effect of using different kinds, different thicknesses and different positions of heat insulation materials on induction coil. Finally, the optimum heat insulation method of induction coil was obtained and validated by experiments. The results show that after 10 mm heat insulation coating or 5 mm insulation coating +5 mm insulation felt was arranged on the outside of induction coil, the ambient temperature of the coil could be reduced to 614 °C and 589 °C, respectively. The two methods above can get the ideal heat insulation effect and meet the life requirements of induction coil for the EICAST technology. Full article
(This article belongs to the Special Issue Advanced Simulation Technologies of Metallurgical Processing)
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13 pages, 4599 KiB  
Article
Mold Nonsinusoidal Oscillation Mode and Its Effect on Slag Infiltration for Lubrication and Initial Shell Growth during Steel Continuous Casting
by Xiaobo Yan, Boran Jia, Qiangqiang Wang, Shengping He and Qian Wang
Metals 2019, 9(4), 418; https://doi.org/10.3390/met9040418 - 7 Apr 2019
Cited by 10 | Viewed by 3995
Abstract
The effect of nonsinusoidal oscillation at different modification ratios (α) on slag lubrication was investigated during mold oscillation. A validated and reliable multiphase model was employed, which involved flow and solidification of the molten steel and mold slag. The main results [...] Read more.
The effect of nonsinusoidal oscillation at different modification ratios (α) on slag lubrication was investigated during mold oscillation. A validated and reliable multiphase model was employed, which involved flow and solidification of the molten steel and mold slag. The main results revealed that a large amount of liquid slag at the entrance of the mold–strand channel reflowed into the slag pool at the middle of the negative strip period. The phenomenon was more distinct, with an increase in the modification ratio. The modification ratio had no obvious effect on the average thickness of the liquid film at different depths below the meniscus. A modification ratio of 0.5 caused less fluctuation of the transient liquid film. Quantitative prediction of slag consumption indicated that as the modification ratio increased from 0.2 to 0.5 to 0.8, the average values were 0.278, 0.286, and 0.279 kg/m2, respectively. Shell solidification and growth near the meniscus mainly occurred when the mold was descending, which not only depended on the heat flux, but also on the liquid slag flow, the pressure driven by slag rim, and the mold oscillation. Optimization of the modification ratio of nonsinusoidal oscillation could be an alternative to delay growth of the initial shell towards the molten steel. A modification ratio of 0.5 had the least robust shell tip at the meniscus, thereby reducing entrapment of inclusions and bubbles by the shell tip. Full article
(This article belongs to the Special Issue Advanced Simulation Technologies of Metallurgical Processing)
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12 pages, 9365 KiB  
Article
Physical Modelling of Splashing Triggered by the Gas Jet of an Oxygen Lance in a Converter
by Bo Zhang, Kai Chen, Ruifang Wang, Chengjun Liu and Maofa Jiang
Metals 2019, 9(4), 409; https://doi.org/10.3390/met9040409 - 3 Apr 2019
Cited by 19 | Viewed by 3405
Abstract
To characterize the splashing behavior under the impact of the top-blown gas jet in converter, in this paper a physical model is developed with the prototype of a 200 t converter in China. We captured the impact cavity morphology triggered by the top-blown [...] Read more.
To characterize the splashing behavior under the impact of the top-blown gas jet in converter, in this paper a physical model is developed with the prototype of a 200 t converter in China. We captured the impact cavity morphology triggered by the top-blown gas jet of the oxygen lance, and found that the impact cavity shape gradually changed following the sequence of “disc” → “bowl” → “cone” with the increase in the gas flow, leading to the variation of the splashing modes. Moreover, the splashing inside and outside the converter was characterized quantitatively under the different top-blown gas jet conditions. The results showed that the splashing on the furnace inner wall concentrated at the region adjacent to the molten bath surface, implying severe flushing of the furnace lining of this region. The critical gas flow of splashing outside the converter is 32.3 Nm3·h−1, corresponding to a gas flow of 39,000 Nm3·h−1 in the prototype. In addition, the foaming slag can suppress the splashing during the smelting process. The statistics of the splashing flux provide a reference for maintaining the safety of the workers and the converter equipment. Full article
(This article belongs to the Special Issue Advanced Simulation Technologies of Metallurgical Processing)
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13 pages, 15327 KiB  
Article
Thermal Simulation Study on the Solidification Structure and Segregation of a Heavy Heat-Resistant Steel Casting
by Biao Wang, Honggang Zhong, Xihao Li, Xiebin Wang, Tieming Wu, Qingmei Liu and Qijie Zhai
Metals 2019, 9(2), 249; https://doi.org/10.3390/met9020249 - 20 Feb 2019
Cited by 8 | Viewed by 3443
Abstract
The prediction and controlling of the solidification structure and macro-segregation in heavy steel casting, which is usually produced in limited quantities, was a conundrum in the foundry field. In this work, the cooling and solidification processes of a 16 t CB2 ferritic heat-resistant [...] Read more.
The prediction and controlling of the solidification structure and macro-segregation in heavy steel casting, which is usually produced in limited quantities, was a conundrum in the foundry field. In this work, the cooling and solidification processes of a 16 t CB2 ferritic heat-resistant steel (FHRS) valve casting were reproduced by studying the solidification behavior of three typical units through a thermal simulation method. The results indicate that the types of casting without chilling have the most uneven distribution of solutes and hardness, while those types of casting in which parts are solidified by chilling are much more uniform. The macro-segregation degrees of B, C, Nb, P, Cr, Mo, Si, V and Mn decrease gradually during heavy casting of CB2 ferritic heat-resistant steel. Of them, B, C, Nb, and P are solutes prone to segregation, and the maximum macro-segregation index of B can even reach 15. The macro-segregation tendencies of Cr, Mo, Si, V, and Mn are relatively small. Further studies on the last solidification portion of samples taken by electron microprobe reveal that large-sized precipitates such as MnS and NbxC are easily formed due to solute enrichment, and the sizes of these precipitates were distributed from dozens to hundreds of micrometers. Full article
(This article belongs to the Special Issue Advanced Simulation Technologies of Metallurgical Processing)
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13 pages, 3798 KiB  
Article
Dynamic Bath Mixing during an Ingot Casting Process
by Xiaobin Zhou, Liangcai Zhong, Peiyuan Ni and Nanyang Deng
Metals 2019, 9(2), 238; https://doi.org/10.3390/met9020238 - 17 Feb 2019
Cited by 4 | Viewed by 2589
Abstract
This paper presents the results of a bath stirring investigation using a physical model for an uphill ingot casting process. A new method of mixing time measurement that overcomes the drawback of the conventional measurement method was developed. The method was used to [...] Read more.
This paper presents the results of a bath stirring investigation using a physical model for an uphill ingot casting process. A new method of mixing time measurement that overcomes the drawback of the conventional measurement method was developed. The method was used to investigate bath stirring for a dynamic-volume bulk bath in which the liquid volume increases over time during the teeming process. The results show that the new method can be successfully applied to reveal the relationship between gas blowing schemes, gas blowing flowrates, and bath depths. It is demonstrated that blowing bubbles causes the flow of the bath to increase when the bath depth is increased. By applying the new data analysis method, three different bottom blowing schemes were explored to study the mixing behaviors under different operating conditions. The results suggest that the concentric circular annulus is more favorable than both the eccentric blowing scheme and symmetrical scheme to achieve efficient mixing. Full article
(This article belongs to the Special Issue Advanced Simulation Technologies of Metallurgical Processing)
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Review

Jump to: Editorial, Research

43 pages, 10412 KiB  
Review
Volume-Averaged Modeling of Multiphase Flow Phenomena during Alloy Solidification
by Menghuai Wu, Andreas Ludwig and Abdellah Kharicha
Metals 2019, 9(2), 229; https://doi.org/10.3390/met9020229 - 14 Feb 2019
Cited by 37 | Viewed by 5604
Abstract
The most recent developments and applications in volume-averaged modeling of solidification processes have been reviewed. Since the last reviews of this topic by Beckermann and co-workers [Applied Mech. Rev. 1993, p. 1; Annual Rev. Heat Transfer 1995, p. 115], major progress in this [...] Read more.
The most recent developments and applications in volume-averaged modeling of solidification processes have been reviewed. Since the last reviews of this topic by Beckermann and co-workers [Applied Mech. Rev. 1993, p. 1; Annual Rev. Heat Transfer 1995, p. 115], major progress in this area has included (i) the development of a mixed columnar-equiaxed solidification model; (ii) further consideration of moving crystals and crystal dendritic morphology; and (iii) the model applications to analyze the formation mechanisms of macrosegregation, as-cast structure, shrinkage cavity and porosity in different casting processes. The capacity of computer hardware is still a limiting factor. However, many calculation examples, as verified by the laboratory casting experiments, or even by the casting processes at a small industrial scale, show great application potential. Following the trend of developments in computer hardware (projection according to Moore’s law), a full 3D calculation of casting at the industry scale with the multiphase volume-averaged solidification models will become practically feasible in the foreseeable future. Full article
(This article belongs to the Special Issue Advanced Simulation Technologies of Metallurgical Processing)
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