Effect of process parameters on structure and macrosegregation upon direct chill casting of Mg–Nd–Zn–Zr alloy

Abstract

Direct chill (DC) semicontinuous casting process has been successfully used to produce sound Mg–3·0Nd–0·4Zn–0·4Zr (NZ30K) billets. The influence of process parameters such as casting speed, casting temperature on the microstructure and macrosegregation was studied. The results show that the casting speed affects the macrosegregation greatly while it has a slight influence on the grain size of the billet; the casting temperature has a slight influence on macrosegregation of the billet while the grain size of the billet increases as the casting temperature increases. The optimal process parameters have been experimentally determined as follows: casting temperature 700°C and casting speed 90 mm min^?1. The ultimate tensile strength, yield strength and elongation of billets cast at the optimal casting parameters are 196 MPa, 125 MPa and 16·5% respectively.     

利用电磁超声横波检测二冷区尾端连铸坯壳厚度

使用电磁超声横波对二冷区尾端的连铸坯壳厚度进行检测,并建立了有限元仿真模型。选取Q235连铸小钢坯作为被测对象。为减小永磁铁的提离距离、在被测体内部生成更大的感应涡流,文章利用多物理场有限元仿真软件建立了一种不同于一般结构的电磁超声换能器仿真模型：圆柱形永磁体两侧并行排列螺旋线圈。分析了永磁铁尺寸对磁场涡流的影响以及电磁超声横波在被测钢坯内不同时间、不同位置的传播情况。计算了被测体中的磁通密度模和电流密度模,同时计算了产生的涡流大小及质点位移情况。研究结果表明：该结构的电磁超声换能器可以在连铸坯壳内成功激发并接收电磁超声横波,且横波穿透力强、效率高,能够成功探测连铸钢坯的回波信号并计算出坯壳的厚度。     

Finite element numerical simulation on thermo-mechanical behavior of steel billet in continuous casting mold

The thermo-mechanical behavior of a thin, growing shell during the early stages of solidification in a continuous casting mold is very important to the ultimate quality of the final billet. A two-dimensional, transient finite element model has been developed to treat the heat flow and deformation of the solidifying shell in the continuous casting billet mold as a coupled phenomena. The major application of the model is to predict the extent of the gap between the mold and the shell and focus on the influence of mold taper on the thermo-mechanical behavior of the steel billet to help to understand the formation of off-corner cracks and break-outs in the solidifying shell. The calculations indicate that the gap is initially formed at the corner of the billet, where heat transfer is greatly reduced. Insufficient mold taper contributes to a hot spot in the off-corner region, which corresponds to the lowest shell thickness. At the same time, the solidifying front on the diagonal of the billet is subjected to an excessive mechanical strain, which causes the off-corner cracks and even the break-outs.     

Finite Element Numerical Simulation for Influence of Mold Taper on Thermomechanical Behavior of Steel Billet in Continuous Casting Process

The thermomechanical behavior of the thin, growing shell during the early stages of solidification in the continuous casting mold is very important to the ultimate quality of the final billet. A two-dimensional, transient finite element model has been developed to treat the heat flow and deformation of solidifying shell in the continuous casting billet mold as coupled phenomena. The major application of the model is to predict the extent of the gap between the mold and the shell, and focus on the influence of mold taper on the thermomechanical behavior of the steel billet to help understand the formation of off-corner cracks and breakouts in the solidifying shell. The calculations indicate that the gap is initially formed at the corner of the billet, where heat transfer is greatly reduced. Insufficient mold taper contributes to a hot spot in the off-corner region, which corresponds to the thinnest shell thickness. Meanwhile, the solidifying front along the diagonal of the billet is subjected to an excessive mechanical strain, which causes the off-corner cracks and even the breakouts.     

Finite element numerical simulation on thermo-mechanical behavior of steel billet in continuous casting mold

The thermo-mechanical behavior of a thin, growing shell during the early stages of solidification in a continuous casting mold is very important to the ultimate quality of the final billet. A two-dimensional, transient finite element model has been developed to treat the heat flow and deformation of the solidifying shell in the continuous casting billet mold as a coupled phenomena. The major application of the model is to predict the extent of the gap between the mold and the shell and focus on the influence of mold taper on the thermo-mechanical behavior of the steel billet to help to understand the formation of off-corner cracks and break-outs in the solidifying shell. The calculations indicate that the gap is initially formed at the corner of the billet, where heat transfer is greatly reduced. Insufficient mold taper contributes to a hot spot in the off-corner region, which corresponds to the lowest shell thickness. At the same time, the solidifying front on the diagonal of the billet is subjected to an excessive mechanical strain, which causes the off-corner cracks and even the break-outs.     

Determination of optimal location to monitor temperature in low pressure die casting process

Abstract

Controlling and eliminating defects, such as macroporosity, in castings is a continuing challenge that manufacturers must continually address. Since the encapsulation of liquid regions by a solid shell and subsequent formation of macroporosity cannot be detected during casting, the die temperature, which is routinely measured, has been used as an indirect indicator of this defect. A finite element model has been developed to predict the evolution of temperature as well as the volume of encapsulated liquid in a casting with a high propensity to form macroporosity. The boundary conditions in the model were iteratively adjusted until the temperature predictions matched the experimental data for a variety of operational conditions. A model based methodology has been developed to analyse the correlation between the die temperature and the encapsulated liquid volume. This methodology is employed to assess the suitability of different in-cycle die temperatures for use as indicators of macroporosity formation, and to help determine the optimal location to monitor temperature for the purpose of minimising macroporosity.     

基于COMSOL连铸坯壳测厚横波EMAT优化

为了研究电磁超声传感器(Electromagnetic Acoustic Transducer,EMAT)横波测量连铸坯壳厚度的机理及横波在连铸坯中的传播情况,选取坯壳厚度为10~50 mm的Q235小方坯为研究对象,利用有限元软件COMSOL建立脉冲电磁铁和螺旋线圈的电磁超声模型,分析在不同EMAT结构参数下,连铸坯中电磁场、力场、声场的分布规律。研究结果表明:脉冲电磁铁和螺旋线圈组成的EMAT能够在连铸坯壳集肤层激发出超声波横波。脉冲电磁铁空心螺线管线圈匝数、内半径、线圈导线半径对换能效率的影响依次减小,且当脉冲电磁铁内半径尺寸大于螺旋线圈尺寸时,产生横波的效率最高。坯壳厚度越小,螺旋线圈最优激励频率越大,测量精度越高,信号衰减越快。因此,坯壳厚度为10~50 mm的Q235小方坯选择1.1 MHz为最佳激励频率。     

Organic fibre modified ceramic shell moulding for investment casting

Abstract

Investment casting research is being carried out by the University of Birmingham sponsored by the EPSRC and a consortium of industrial companies. The programme is aimed at developing a fundamental understanding of the process, with a view to routinely producing sound, net shape castings. The casting of liquid metals to produce solid objects is a manufacturing process, which has been practised for over five thousand years, with investment casting being one of the oldest known metal shaping methods. The technique itself has tremendous advantages in the production of quality components and key benefits of accuracy, versatility and integrity. As a result the process is one of the most economic methods of forming a wide range of metal components. Environmental and economic pressures have, however, resulted in a need for the industry to improve current casting quality, reduce manufacturing costs and explore new markets for the process. Optimisation of the mechanical and physical properties of the ceramic shell will be fundamental to achieving these aims. This paper reports on the work carried out to determine the applicability of the use of fibres as reinforcement media for investment shells and to explore methods by which the use of organic fibres can improve ceramic shell performance.     

Prevention of Scum Formation and Entrapment in High Carbon Steel Billets

Gradual build-up of scum over the liquid steel surface in the mould gives rise to entrapped exogenous inclusions and slag patch in the cast billets. The problem is more commonly observed during the open stream casting of continuous casting of high carbon (C > 0.6 mass%) steel billets. This problem has been quite commonly observed at Tata Steel during its billet casting. Present work aimed at eliminating the problem of scum formation during open stream billet casting of high carbon steel billets. This work involved experiments in the laboratory as well as in the plant. In addition, based on liquid steel composition thermodynamic calculations were carried out for predicting the possible oxide inclusions in Mn-Si deoxidised steels. Water model experiments were carried out in a full-scale billet caster physical model for investigating the influence of tundish outlet nozzle alignment on the entrapment of scum as slag patch over the billet surface. Based on these, cause of scum formation and its exact mechanism of entrapment in cast billets were established. Finally, countermeasures were recommended to the plant. Adequacy of the proposed countermeasures was established through a series of trials in the plant before implementation. Improvement obtained from the implementation over a period of time has been reported in the paper.

     

基于前置反射器的多波长铸坯表面测温方法

钢铁冶金现场的连铸铸坯表面温度是重要的工艺参数,针对铸坯表面温度难以测量,研究一种前置反射器与多波长结合红外辐射测温方法,该方法分别建立有反射器和无反射器的多波长辐射能量方程,在线求解被测铸坯表面的发射率和铸坯表面温度。利用蒙特卡洛方法建立铸坯表面的多层模型和光波的多次反射-吸收的仿真模型,模型分析表明该方法可实现准确的铸坯表面温度测量。     

The influence of mould pre-heat temperature and casting size on the interaction between a Ti–46Al–8Nb–1B alloy and the mould comprising an Al2O3 face coat

Alumina has been used as a mould face coat material for investment casting titanium alloys for many years; the interaction between the Al₂O₃ and the alloys are exemplified by a hardened layer formed at the alloy interface. In this research, the interaction between the Al₂O₃ face coat and a Ti–46Al–8Nb–1B alloy was investigated by modelling the cooling profile of the mould during casting. The interaction between the mould and metal was identified from the hardened layer thickness and metal/shell interface microstructural changes. Results showed that a high mould pre-heat temperature and large bar diameter will enhance the interaction between the shell and the TiAl alloy. During the casting process, not only was oxygen observed penetrating into the metal through the decomposition of the face coat materials, but also silicon from the backup coat was found to interact with the metal during the casting process.     

Computer model of unidirectional solidification of single crystals of high temperature alloys

Abstract

I t has been common practice to use mould withdrawal unidirectional solidification to produce single crystal castings. To grow single crystals successfully, it is important to control several solidification parameters, such as the morphology of the solidification front (solid/liquid interface), thermal gradient, and growth rate during solidification. It is the aim of this study to develop a solidification model that can predict such solidification parameters for various design and operating conditions. The solidification phenomena in the process modelled are basically controlled by two heat transfer mechanisms: conduction and radiation. A set of heat transfer equations and boundary conditions were employed to describe mathematically the heat transfer phenomena. Then the finite difference method was used numerically to solve these equations for specified boundary conditions to obtain the temperature distribution and temperature variation in the casting. The solidification parameters can subsequently be deduced from these temperature data. Several thin plate castings were tested using the model developed. The following design and operating conditions were evaluated: susceptor temperature (power input), withdrawal speed, changes of cross-sectional area in the casting, and geometrical arrangement of the casting tree.

MST/1422     

一种薄芯冷却叶片熔铸工艺的研究

为了解决某薄芯气冷叶片断芯、疏松等影响铸件合格率的问题,开展了铸件浇注工艺研究。找出了浇注温度、型壳温度、浇注速度、浇注系统等主要工艺因素与铸件晶粒尺寸、铸件断芯等缺陷的关系。设计出一种可有效防止钢水冲击断芯并对铸件良好补缩的浇注系统。研究表明,提高型壳温度、降低浇注速度有利于晶粒细化、防止钢水冲击断芯;底注式浇注系统和交汇式补缩系统对减少铸件断芯有利。实践证明,这种铸造工艺有效提高了铸件合格率。     

Analysis of solidification in Bridgman furnace as simulation of DC casting of aluminium alloy slabs

Abstract

The vertical Bridgman directional solidification equipment has been used in several investigations to simulate direct chill casting of wrought aluminium alloys. As a basis for such investigations and alloy developments, it is important to have an understanding of the performance of the furnace used during simulation of the casting conditions. In this investigation the thermal conditions in the furnace have been analysed in detail, both by measurements and by mathematical modelling. The growth characteristics of the furnace, such as gradient, growth rates and cooling rates have been compared to conditions in large ingots. The direct chill casting conditions, which the simulations have been compared to, are casting of slabs of 330 and 600 mm thickness of an aluminium AA3003 type alloy. The results show that the experiments are able to simulate the cooling conditions in the ingots except from the surface zone. Comparisons of the microstructures have been made and a good agreement has been obtained for structure parameters such as grain size and DAS.     

Effect of combined application of electromagnetic fields on horizontal direct chill casting of 7050 aluminium alloy

Abstract

Influence of combined electromagnetic field application on horizontal direct chill casting of 7050 aluminium alloy is investigated. Temperature measurement and structure observation are carried out to analyse the casting process under different electromagnetic fields. Combined electromagnetic field can reduce the harmful gravitational thermal effect in the horizontal direct chill casting process and improve the ingot properties. With application of combined electromagnetic field, temperature distribution in the melt is more uniform, sump of the ingot becomes flat and symmetric, surface quality of ingot improves markedly, grain morphology changes from feathery grains to equiaxed grains and grain size decreases. Distribution of copper and zinc in the transverse section of the ingot becomes more uniform.     

Mathematical model of extrusion preheater

Abstract

An effective numerical model has been developed to simulate the thermal behaviour of extrusion preheating processes for metals. The model utilises a finite difference scheme to predict the temperature profile of the billet during and subsequent to heating. The model is versatile and has been applied to show that a three zone induction preheater, especially designed to provide taper heating for isothermal extrusion, can achieve the desired taper temperature profile for aluminium alloys. Applications of the present model to other types of preheater are also discussed.

MST/399     

Influence of alloying elements on central billet quality of continuous casting

Abstract

The influence of carbon content and alloying elements on the central billet quality of continuous casting has been studied. In plain carbon steels the higher central equiaxed zone (CEZ) value (the area, expressed as a percentage, of equiaxed crystals) is obtained for medium carbon content. For lower and higher carbon contents, this value becomes smaller. However, the decrease is more pronounced in the latter situation than in the former and it is associated with a deterioration of the central quality of the billet. A difference in the CEZ behaviour was found between plain carbon steel and low alloy steels. This difference can be explained by the modification that alloying elements produce in the percentage of material that transforms from δ-ferrite into austenite during the peritectic reaction.

MST/796     

Drying conditions and their effect on ceramic shell investment casting process

Abstract

The ceramic shell investment casting process has gained an important position in the family of precision casting techniques owing to the scientific advances in many of its aspects, such as binder solutions, refractory materials, pattern materials, and in the manufacturing process. In this endeavour an effort was made to investigate the effect of drying conditions on the performance of ceramic shell moulds. The binder used in this work was an acetone based polysilicic acid, which had been considered as an alternative to the conventionally used binders (namely, ethyl silicate, colloidal silica aquasols etc.). The effects of drying conditions were observed on ceramic wafers, prepared from the slurry, made of fused silica and the binder. The wafers were dried at different temperatures and relative humidity conditions. The effect of drying conditions was observed through the measurement of compressive strength of the ceramic shell wafers. The binder was also subjected to various drying conditions and the characteristic changes of the binder solutions were investigated.     

Role of grain refining in hot cracking and macrosegregation in direct chill cast AA 7075 billets

Abstract

Direct chill (DC) casting experimental results are presented for an Al–Zn–Mg–Cu alloy with and without grain refining by attempting the inoculant addition either in the furnace or in the launder at two different casting speeds. Despite considerable structural refinement macro segregation remains unchanged with grain refining at a lower casting speed. Hot cracking, on the other hand, is totally prevented at this casting speed. Depending on the grain refining practice, either hot tears do not appear at all or prior cracks existing in the non-grain refined billet are completely healed. At a higher casting speed, the severity of segregation increases. The hot cracking tendency, however, has shown a distinct difference with grain refining method, with furnace-refined alloy resulting in a crack-free billet. But the billet grain refined in the launder exhibited hot cracking. Overall, these experimental results confirm the beneficiary effect of grain refining on hot cracking.     

精铸型壳的增材制造技术研究进展

增材制造技术用于精密铸造领域,可以满足市场对精密铸件的短周期、个性化、多样化、柔性制造的需求.增材制造技术可以制作树脂模型代替蜡模进行精密铸造,但更高效的方法是用增材制造技术直接制备精铸型壳.目前可用于制备精铸型壳的增材制造技术主要有三维打印法(3DP)、选择性激光烧结法(SLS)、光固化成形法(SLA)以及浆料挤出法...