A 2-D FINITE ELEMENT MODEL SIMULATION OF THE MELTING PROCESS OF Al-Ti ALLOY IN VACUUM INDUCTION FURNACE WITH COLD CRUCIBLE(VIFCC)

The development of a numerical model for the melting process of Al--Ti alloy targetmaterial in vacuum induction furnace with cold crucible (VIFCC)was described. It isa two--dimensional computational methodology to calculate electromagnetic field, heattransfer field and fluid flow field. Based on the aid of the finite element method withthe commercial software--ANSYS, a superimposition method of a layer of copper anda slit to simulate the VIFCC melting process was used. The method was effectiveto save large quantity of memory and computing time. Meanwhile, a temperaturedistribution profile during the melting process was obtained. Validity of the model wasconfirmed by comparison between the result from calculation and those from directmeasurement by optical pyrometer and indirect investigation by ingot macrostructure.A relatively good agreement was found. Further, a nearly directional solidificationstrvcture was obtained under properly controlling the cooling rate and heating power.Therefore, such model d     

NUMERICAL SIMULATION OF INDUCTION SKULL MELTING PROCESS FOR TITANIUM-ALUMINIUM BASE ALLOY

The mathematics model for temperature field of water-cooling copper crucible induction skull melting process was established. The program for simulating temperature field of melting process was developed with finite element method. The temperature field of the melting process for Ti-47Al-2Cr-2Nb aUoy was calculated. During melting period, the temperature is raised gradually along radius augmentation direction. The elements of the charge near the crucible wall are molten first. The center elements of the charge are molten last. The melting time of the center element is just that of all the charge melting. The melting time of Ti-47Al-2Cr-2Nb alloy is 15min. In which, the charge was heated by low power 80kW for 9min and by high power 300kW for 6min. When melting Ti-47AI-2Cr-2Nb aUoy,the loading power is nearly direct proportion to melt temperature. Increasing loading power may raise melt temperature. The best melting power of Ti-47Al-2Cr-2Nb alloy is 305-310kW. This is identical with the melting test and has guidance sense to the melting process of actual titanium aUoy.     

Serrated Flow Model for Metallic Glasses under Compressive Loading

A rheological model is proposed that incorporates the serrated flow nature of metallic glasses. It involves the process of the nucleation, propagation and the arrest of a shear bands in the samples subjected to compressive deformation at room temperature. Numerical resolution of the constitutive equations resulting from the model is compared with the stress-strain curve obtained from in-situ nano-compression test in SEM of Zrbased metallic glass. Parametric identification method was applied and enabled us to release the physical parameters of the model. The obtained results showed that the model is adequately valid to describe the experimental data and the almost adjustable model parameters are physically meaningful and comparable to literature.     

Dynamic simulation of resistance spot welding of zinc-coated steels

A model was developed to simulate the temperature distribution and nugget formation during resistance spot welding （ RS1V） of zinc-coated steels. It employs a coupled thermal-electrical-mechanical analysis simulating the dynamic RSW process. Temperature-dependent thermal-electrical-mechanical material properties were considered including contact-resistance. The contact area was determined from a coupled thermal-mechanical analysis. A layer of transition elements was used to represent the change of contact area by killing or activating elements. The heat generation and temperature field were computed in a coupled thermal-electrical model. All these analyses were solved using the commercial finite element method （FEM） based on ANSYS code, and some advanced functions were used by writing a paragraph of codes by the authors. Compared with the results from only coupled thermal-electrical model in which contact area was uniform during the whole process, the result matches better to the experimental results.     

Numerical simulation of facet dendrite growth

Numerical simulation based on phase field method was performed to describe the solidification of silicon. The effect of anisotropy, undercooling and coupling parameter on dendrite growth shape was investigated. It is indicated that the entire facet dendrite shapes are obtained by using regularized phase field model. Steady state tip velocity of dendrite drives to a fixed value when γ≤0.13. With further increasing the anisotropy value, steady state tip velocity decreases and the size is smaller. With the increase in the undercooling and coupling parameter, crystal grows from facet to facet dendrite. In addition, with increasing coupling parameter, the facet part of facet dendrite decreases gradually, which is in good agreement with Wulfftheory.     

Numerical simulation of tungsten alloy in powder injection molding process

The flow behavior of feedstock for the tungsten alloy powder in the mold cavity was approximately described using Hele-Shaw flow model. The math model consisting of momentum equation, consecutive equation and thermo-conduction equation for describing the injection process was established. The equations are solved by the finite element/finite difference hybrid method that means dispersing the feedstock model with finite element method, resolving the model along the depth with finite difference methgd, and tracking the movable boundary with control volume method, then the pressure equation and energy equation can be resolved in turn. The numerical simulation of the injection process and the identification of the process parameters were realized by the Moldflow software. The results indicate that there is low temperature gradient in the cavity while the pressure and shear rate gradient are high at high flow rate. The selection of the flow rate is affected by the structure of the gate. The shear rate and the pressure near the gate can be decreased by properly widening the dimension of the gate. There is a good agreement between the process parameters obtained by the numerical simulation and the actual ones.     

Effects of electrode immersion depth and remelting rate on electroslag remelting process

In the electroslag remelting process, the electrode molten state is a critical factor determining the ingot quality, while the electrode immersion depth and melting rate are key factors for the stability of the electroslag re-melting process. Studies were carried out to investigate the microscopic and macroscopic effects of electrode immersion depth and melting rate on the potential distribution and heat density in the slag bath, and on the depth and shape of the molten bath. Based on the finite element method and the numerical solution method, the effect of the electrode immersion depth on the slag bath heat density was researched; the relationship between the electrode immersion depth and the slag resistance was obtained; and the unsteady-state model of the solidification process of the re-melting ingot was solved using the finite difference method. The mathematical model and physical model of the electrode melting process were established and solved; and the corresponding curves between the electrode molten-state and slag-bath physical parameters were obtained. The experimental results verified the simulated results studied in this paper.     

NUMERICAL ANALYSIS OF HEAT TRANSFER DURING LASER CLADDING TO SYNTHESIZE TiCp／Al COMPOSITE

Based on the continuum model for binary solid-liquid phase change system, the mathematic model to simulate the process of laser cladding in situ synthesis TiCp/Al composite on the surface of aluminum alloy was formulated. The additive source method was employed to treat with the heat release of synthetic reaction in powder mixture at certain temperatures, and also to solve the momentum and heat transfer caused by the relative movement between laser beam and the specimen. Two different types of driving forces for)flow were considered in the model, i.e., the buoyancy force and the surface tension gradient at the laser pool surface. The three-dimensional transient temperature field simulation program was developed being based upon the commercial software PHOENICS. The calculated and observed fusion boundaries were compared and very good agreement was obtained.     

Synthesis and characterization of Sm^3＋-doped CeO2 powders

Sm^3＋-doped Ce02 （denoted as Ce1-xSmxO2） powders with different morphologies were successfully synthesized via a precursor-growth-calcination approach, in which precursor was first synthesized by a hydrothermal method and Ce1-xSmxO2 powders were finally obtained through a calcination process. The products were characterized with X-ray diffractometry（XRD）, field emission scanning electron microscopy（FE-SEM） and fluorescence spectroscopy. The results reveal that the Ce1-xSmxO2 powders obtained by calcining the precursors prepared in the absence and presence of poly（vinyl pyrrolidone） （PVP） exhibit bundle-and sphere-like morphology, respectively. The possible growth process was proposed by preparing a series of intermediate morphologies during the shape evolution of CeO2 based on the SEM image observation. It is also found that the luminescence intensity of bundle-like Ce1-xSmxO2 is enhanced in comparison with that of sphere-like one due to its special morphology.     

Numerical model and experimental observation for distribution of SiCp in electromagnetic-centrifugally cast composites

A two-phase numerical model coupled with heat transfer was presented to describe the radial distribution of SiC particles on centrifugally-cast metal matrix composite,and a transverse static magnetic field was concurrently imposed to induce electromagnetic stirring of the melt as it revolved with the mold.Meanwhile,experimental observations were also carried out to examine the radial distribution of SiC particles in pure aluminum.The effects of the imposed magnetic field,particle size and the matrix metals were discussed.The computational results show that the particles tend to be congregated by the centrifugal force,and both increasing the imposed magnetic field and decreasing the particle size tend to result in even distribution of the particles.With the magnetic field varying from 0 to 1 T and the particle size from 550 to 180 μm,a uniform distribution of the particles in the aluminum matrix can be obtained among the computational results.The matrix metal can also influence the particle distributions due to the difference in physical properties of metals.Experimental observation shows similar tendency of particle distributions in aluminum matrix influenced by magnetic field and particle size.However,the chilling effect from the mold wall results in an outer particle-free zone,which is not involved in the numerical model.     

旋流数对铝熔炼炉熔炼过程的影响

针对现有的圆形铝熔炼炉,结合铝熔炼炉熔炼过程的特点,在铝熔炼炉热平衡测试的基础上,建立了合理的铝熔炼炉数学模型,并运用计算流体力学软件FLUENT实现燃烧空间和熔池的耦合物理场的数值模拟。同时分析了不同旋流数对铝熔炼炉熔炼过程的影响,依据提出的优化准则,确实旋流数大于0.6时能够获得最佳的熔炼性能。     

基于有限元法的钒合金电子束熔炼过程数值模拟研究

基于ANSYS有限元软件建立了钒合金电子束熔炼过程的数理模型,对V-4Cr-4Ti合金电子束熔炼过程进行了数值模拟,研究了不同熔炼工艺参数下的熔炼过程温度场分布规律以及熔池形状。结果表明:熔炼过程温度场分布及熔池形状受到熔炼功率及扫描半径的影响。随着熔炼功率的增大,熔池最高温度将会线性增大,熔池宽度和深度将会逐渐增大。随着扫描半径的增大,熔池最高温度将会先增大后减小,通过分析获得了V-4Cr-4Ti合金电子束熔炼的最佳工艺参数。实验结果表明,在优化后的工艺条件下,钒合金电子束熔炼铸锭质量得到一定提升。     

自保护药芯焊丝焊接工艺参数的敏感性分析

自保护药芯焊丝是一种适合于野外作业的焊接材料,广泛应用于船舶、钻井平台、石油管道、集装箱等结构件焊接及修复. 采用自保护药芯焊丝在Q235钢板表面进行单层单道平板堆焊试验,运用二次回归通用旋转组合设计方法建立了电弧电压、送丝速度、焊接速度与熔宽、余高、熔高的二次回归数学模型,分析了工艺参数与熔敷几何尺寸的关系. 结果表明,该模型能够预测稳定工艺区间内工艺参数变化对熔敷层几何尺寸的影响规律;当电压较低时,送丝速度是影响熔宽和余高的主要因素,电压较高时,焊接速度是影响熔宽和余高的主要因素.     

Modeling of an aluminum melting process using constructive polynomial functions

Constantly increasing quality requirements and ever-stricter conditions pose difficult challenges for the foundry industry. They must produce the high-quality components demanded by the market at a reasonable cost. Modern technologies and innovative methods help to master this challenge. Until recently, production, from the design of the aluminum melting furnace to daily process, relied largely on traditional methods and experience. However, important data and information about the melting process—for example, the temperatures and the shape of the aluminum block in the furnace—can hardly be obtained with conventional experimental methods, as the temperatures exceed 700 °C. Therefore, this research project investigates the method of monitoring a melting process by means of optical sensors for the first time. The purpose of this paper is to predict the surface shape of the block during the melting process, as it is not possible to maintain a constant monitoring due to the heat and energy loss during measurement Behrens (Einsatz einer Lichtfeldkamera im Hochtemperaturbereich beim Schmelzvorgang von Aluminium, wt Werkstattstechnik online, 2016). To generate the necessary data, a 3D light-field camera is installed on top of an aluminum melting furnace in order to monitor the process. The basic idea is to find a general method for curve modeling from scattered range data on the aluminum surface in 3D space. By means of the (x, y, z) data from the 3D camera, the aluminum surface is modeled as a polynomial function with coefficient derived using various interpolation and approximation methods. This study presents an attempt to find the optimal polynomial function model that describes the aluminum surface during the melting process by interpolation or approximation methods. The best method for curve fitting will be extended and implemented for surface modeling. Based on this method, the melting process can be better controlled while the furnace operates continuously under stable conditions and the efficiency can therefore be increased. The proposed model can be modified for a wide variety of melting furnaces.     

烧嘴对蓄热式铝熔炼炉熔炼过程的影晌

结合蓄热式铝熔炼炉熔炼过程的特点,运用FLUENTUDF和FLUENTScheme混合编程,耦合用户自定义熔化模型和燃烧器换向及燃烧量变化模型,实现了蓄热式铝熔炼炉熔炼过程的数值模拟。依据优化原则,获得了熔炼时间随影响因子的变化规律：熔炼时间随着旋流数、燃烧器倾角、空气预热温度或天然气流量的增加而缩短;熔炼时间随着燃烧器间水平夹角或空燃比的延长,先减小而后增加：熔炼时间随着燃烧器高度的增加而延长。     

铝熔炼过程温度场的数值模拟研究

根据物料平衡方程、能量守恒方程、动量方程建立熔炼炉内熔炼过程中熔体温度的数学模型;以能量平衡测试中得到的数据为边界条件,在概率密度函数(PDF)仿真基础上,运用Fluent6.3流体力学软件对熔炼过程温度场进行数值模拟,模拟结果与实际情况相符。本研究为现场实际生产过程控制提供重要依据,为熔炼炉的设计、研究提供了有效的方法和途径。     

ELECTROMAGNETIC MODEL OF LEVITATION MELTING WITH COLD CRUCIBLE

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