Since the as-cast microstructure benefits dynamic recrystallization(DRX)nucleation,the present research is focused on the microstructure evolution associated with the dendrites and precipitates during the thermal defo...Since the as-cast microstructure benefits dynamic recrystallization(DRX)nucleation,the present research is focused on the microstructure evolution associated with the dendrites and precipitates during the thermal deformation of an ingot without homogenization treatment aiming at exploring a new efficient strategy of ingot cogging for superalloys.The as-cast samples were deformed at the sub-solvus temperature,and the DRX evolution from dendritic arms(DAs)to inter-dendritic regions(IDRs)was discussed based on the observation of the fishnet-like DRX microstructures and the gradient of DRX grain size at IDRs.The difference in the precipitates at DAs and IDRs played an essential role during the deformation and DRX process,which finally resulted in very different microstructures in the two areas.A selective straininduced grain boundary bulging(SIGBB)mechanism was found to function well and dominate the DRX nucleation at DAs.The grain boundary was able to migrate and bulge to nucleate on the condition that the boundary was located at DAs and had a great difference in dislocation density between its opposite sides at the same time.As for DRX nucleation at IDRs,the particle-stimulated nucleation(PSN)mechanism played a leading role,and the progressive subgrain rotation(PSR)and geometric DRX were two important supplementary mechanisms.The dislocation accumulation around the coarse precipitates at IDR resulted in progressive orientation rotation,which would generate DRX nuclei once the maximum misorientation there was sufficient to form a high-angle boundary with the matrix.The PSR or geometric DRX functioned at the severely elongated IDRs at the later stage of deformation,depending on the thickness of the elongated IDRs.The uniform microstructure was obtained by the deformation without homogenization and the subsequent annealing treatment.The smaller strain,the lower annealing temperature,and the much shorter soaking time requested in the above process lead to a smaller risk of cracking and a lower consumption of energy during the ingot-cogging process.展开更多
Three-layer composite ingot of 4045/3004/4045 aluminum alloys was prepared by direct-chill semi-continuous casting process,the temperature field distribution near the composite interface,macro-morphology,microstructur...Three-layer composite ingot of 4045/3004/4045 aluminum alloys was prepared by direct-chill semi-continuous casting process,the temperature field distribution near the composite interface,macro-morphology,microstructure and composition distribution of the composite interface were investigated.The results show that semi-solid layer with a certain thickness forms near the interface due to the effect of cooling plate,which ensures successful implementation of casting the composite ingot.Two different aluminum alloys are well bonded metallurgically.The mechanical properties of composite interface were measured,the tensile and shearing strengths of composite interface are 105 and 88 MPa,respectively,which proves that the composite interface is a kind of metallurgical bonding.展开更多
In order to improve the quality of clad ingots, diverse physical fields including electromagnetic stirring, power ultrasonic and compound field of ultrasonic and electromagnetic stirring were attempted to prepare clad...In order to improve the quality of clad ingots, diverse physical fields including electromagnetic stirring, power ultrasonic and compound field of ultrasonic and electromagnetic stirring were attempted to prepare clad ingots of 3003/4004 alloys. The solidification structures near the interface in clad ingots were investigated. The experiment results indicate that the solidification structure of 4004 alloy changes from dendritic crystals to petal-like grains when the clad ingot is treated by electromagnetic stirring. With the effect of power ultrasonic, the solidified microstructure of 4004 alloy exhibits the refinement of both primary a（A1） and eutectic silicon. Under the compound field, the primary a（A1） is refined, the morphology of eutectic silicon has a transition from a coarse plate-like form without treatment or thin acicular-like form with power ultrasonic to fine coral-like form.展开更多
Inclusion distribution in ingots was studied by dissection of a 16.8 t P12 ingot and a 5.0 t H13 ingot, with the analysis of T[O], original position statistic distribution analysis （OPA）, metallographic microscope s...Inclusion distribution in ingots was studied by dissection of a 16.8 t P12 ingot and a 5.0 t H13 ingot, with the analysis of T[O], original position statistic distribution analysis （OPA）, metallographic microscope static analysis and small sample electrolysis. The results showed that the inclusions in ingots were uneven; a positive segregation area was found in the center and lower part of the ingot, while a negative segregation area was present in the central part of ingot top; inclusion segregation in a large size ingot was severer than that in a small one. A new con cept, named inclusion segregation index, was put forward to quantify the segregation degree of inclusion. It was found that the segregation indexes drawn from T[O] analysis and OPA fit well, but they were different from those obtained by metallograpbic microscope static analysis and small sample electrolysis in the investigation of Pl 2 ingot, which contained a higher sulfur content; while the segregation index drawn from T[O] analysis was close to that from metallographic microscope static analysis in the H13 ingot with a lower sulfur content.展开更多
Two kinds of argon shroud protection devices with two different basic structures were designed and investigated. Industrial experiments and numerical simulations were used to examine the protection effect, and the mec...Two kinds of argon shroud protection devices with two different basic structures were designed and investigated. Industrial experiments and numerical simulations were used to examine the protection effect, and the mechanism of air entrapment during the casting of steel ingots was analyzed. The influence of the structure of the argon shroud protection device on the protection effect was investigated. An argon shroud protection device mounted to the nozzle holder on the bottom of the ladle does not provide a good protection effect because air can easily flow into the teeming system and cause reoxidation of molten steel during teeming. By contrast, an argon shroud protection device seated on the top of the central trumpet provides an excellent protection effect, where air has little chance of flowing into the teeming system during casting. The feasibilities of the argon shroud protection devices are discussed.展开更多
During the ingot casting process, the parametric changes of the molten steel pouring process often cause both ingot surface and internal quality defects. With the increasingly wide application of computers in industri...During the ingot casting process, the parametric changes of the molten steel pouring process often cause both ingot surface and internal quality defects. With the increasingly wide application of computers in industrial technology ,numerical simulations of the molten steel pouring process enable predictions of the defects that will arise during the pouring and solidification process, especially for the molten steel flow during the early stages of casting. In addition,using a computer to simulate the casting process of a 40 t ingot and solidification can prevent many defects. The simulation results indicate that controlling the pouring speed to less than 80 kg/s, hanging the casting powder in a mold with the hanging height maintained at 100-150 mm, and controlling the taper angle of the mold brick outlet to a suitable level can reduce the probability of slag entrapment and improve the internal and surface quality of the ingot.展开更多
The metallurgical effect of a round tundish used to cast heavy steel ingots in machine works at present was evaluated through water modeling experiments. The flow control devices of the improved oval tundish, which wa...The metallurgical effect of a round tundish used to cast heavy steel ingots in machine works at present was evaluated through water modeling experiments. The flow control devices of the improved oval tundish, which was used instead of the round tundish, had been optimized. The results show that the residence time of the round tundish is short, its inclusion removal efficiency is too low, and it has more dead zones and an unreasonable flow field. Compared with the round tundish, the improved oval tundish with the optimized weir and dam has a better effect： its minimum residence time is prolonged by 38.1 s, the average residence time is prolonged by 233.4 s, its dead volume fraction decreases from 26% to 15%, and the ratio of plug volume fraction to dead volume fraction increases from 0.54 to 1.27. The inclusion removal efficiency also increases by 17.5%.展开更多
A two-phase model for the prediction of macrosegregation formed during solidification is presented. This model incorporates the descriptions of heat transfer, melt convection, solute transport, and solid movement on t...A two-phase model for the prediction of macrosegregation formed during solidification is presented. This model incorporates the descriptions of heat transfer, melt convection, solute transport, and solid movement on the system scale with microscopic relations for grain nucleation and growth. Then the model is used to simulate the solidification of a benchmark industrial 3.3-t steel ingot. Simulations are per- formed to investigate the effects of grain motion and pipe shrinkage formation on the final macrosegregation pattern. The model predictions are compared with experimental data and numerical results from literatures. It is demonstrated that the model is able to express the overall macrosegregation patterns in the ingot. Furthermore, the results show that it is essential to consider the motion of equiaxed grains and the formation of pipe shrinkage in modelling. Several issues for future model improvements are identified.展开更多
The solidification of 4.4 t cold work tool steel ingot type X210Crl2 was simulated by Magma software. By the reduction of ingot height, solidification modeling and pouring of a new 3 t ingot were performed and decreas...The solidification of 4.4 t cold work tool steel ingot type X210Crl2 was simulated by Magma software. By the reduction of ingot height, solidification modeling and pouring of a new 3 t ingot were performed and decreasing the porosity formation potential in 3 t ingot in comparison with 4.4 t ingot on the basis of Niyama criterion was ob-served which was in good accordance with experimental data. In order to produce sound ingot, a new 2.8 t ingot mould was designed which includes some parameteric changes in mould such as mould slope, slenderness ratio, mould concavity radius, fillet radius of mould internal corners and feeding diameter to ingot upper diameter ratio. Furthermore, the effects of insulating between kokil and feeding ring and also insulating the outer surface of feeding ring as well as insulating the outer surface of one third of kokil upper part on eenterline porosity formation were in-vestigated in both 2.8 and 4.4 t ingots. The results show that the ingot which was produced in new designed 2.8 t mould has a better Niyama pattern and the centerline porosities were eliminated.展开更多
Achieving a uniform structure with few defects in heavy steel ingot is of high commercial importance. In this present work, in order to verify the potential of pulsed magneto-oscillation(PMO) applied in the production...Achieving a uniform structure with few defects in heavy steel ingot is of high commercial importance. In this present work, in order to verify the potential of pulsed magneto-oscillation(PMO) applied in the production of heavy ingot, an induction coil was located at the hot top of the steel ingot to develop a novel technique, named hot top pulsed magneto oscillation(HPMO). The influences of HPMO on the solidification structure, macro segregation and compactness of a cylindrical medium carbon steel ingot with the weight of 160 kg were systematically investigated by optical microscope(OM) and laser induced breakdown spectroscopy original position metal analyzer(LIBSOPA-100). The results show that HPMO not only causes significant grain refinement and promotes the occurrence of columnar to equiaxed transition(CET) but also can homogenize the carbon distribution and enhance the compactness of the steel ingot. Therefore, HPMO technique has the potential to be applied in the production of heavy steel ingots on an industrial scale.展开更多
The fundamental mechanism of the cracking formation was investigated for the as-cast GH4151 superalloy.By analyzing the characteristics of cracking,the cracking mechanism was determined to be the cold crack formed dur...The fundamental mechanism of the cracking formation was investigated for the as-cast GH4151 superalloy.By analyzing the characteristics of cracking,the cracking mechanism was determined to be the cold crack formed during the cooling process.And cold cracking is closely related to severe segregation,complex precipitates and uneven γ'phase distribution.During cooling process,cracks were generated around the precipitates due to their different linear shrinkage coefficients.The annealing treatment process controlling the residual stress,the size and morphology of γ'phase was proposed.The annealing treatment plays a role in reducing residual stress through decreasing the thermal gradient and controlling the size distribution of γ'phase to reduce the strain concentration around the precipitate phases.展开更多
In this paper,a large-sized ingot of Mg–9Gd–3Y–1.5Zn–0.5Zr(wt%) alloy with a diameter of 600 mm was successfully prepared by the semi-continuous casting method.The alloy was subsequently annealed at a relatively l...In this paper,a large-sized ingot of Mg–9Gd–3Y–1.5Zn–0.5Zr(wt%) alloy with a diameter of 600 mm was successfully prepared by the semi-continuous casting method.The alloy was subsequently annealed at a relatively low temperature of 430°C for 12 h as a homogenization treatment.The microstructure and room-temperature mechanical properties of the alloy were investigated systematically.The results show that the as-cast alloy contained a mass of discontinuous lamellar-shaped 18 R long-period stacking ordered(LPSO) phases with a composition of Mg10 Zn Y and an α-Mg matrix,along with net-shaped Mg5(Y,Gd) eutectic compounds at the grain boundaries.Most of the eutectic compounds dissolved after the homogenization treatment.Moreover,the amount and dimensions of the lamellar-shaped LPSO phase obviously increased after the homogenization treatment.The structure of the phase transformed into 14H-type LPSO with composition Mg12Zn(Y,Gd).The mechanical properties of the heat-treated large-sized alloy ingot are uniform.The ultimate tensile strength(UTS) and tensile yield strength(TYS) of the alloy reached 207.2 MPa and 134.8 MPa,respectively,and the elongation was 3.4%.The high performances of the large-sized alloy ingot after the homogenization treatment is attributed to the strengthening of the α-Mg solid solution and to the plentiful LPSO phase distributed over the α-Mg matrix.展开更多
In order to get a better understanding of the vacuum consumable arc remelting(VAR) processes and thus to optimize them,a 3D finite element model was developed for the temperature fields and heat transfer of titanium a...In order to get a better understanding of the vacuum consumable arc remelting(VAR) processes and thus to optimize them,a 3D finite element model was developed for the temperature fields and heat transfer of titanium alloy ingots during VAR process.The results show that the temperature fields obtained by the simulation are well validated through the experiment results.The temperature distribution is different during the whole VAR process and the steady-state molten pool forms at 329 s for d100 mm × 180 mm ingots.At the initial stage of remelting,the heat dissipation of crucible bottom plays an important role in the whole heat dissipation system.At the middle of remelting,the crucible wall becomes a major heat dissipation way.The effect of cooling velocity on the solidification structure of ingots was investigated based on the temperature fields and the results can well explain the macrostructure of titanium alloy ingots.展开更多
The method based on transient heat transfer model is adopted to simulate electro-slag remelting process. The calculated results of the model show that the process is in the quasi-steady state, and the shape of pool re...The method based on transient heat transfer model is adopted to simulate electro-slag remelting process. The calculated results of the model show that the process is in the quasi-steady state, and the shape of pool remains unchanged when the height of ingot is approximately 2.5-3 times the thickness of slab ingot. The change in the shape of pool is found to be strongly dependent on the pattern of melting rate, and hence, the power input; the depth of the molten pool increases with the increase in melting speed. It is concluded that a transient heat transfer model has to be used to obtain reliable input information for the entire, operatina time.展开更多
For steel-making and continuous/ingot casting are the key processes of modern iron and steel enterprises, this paper proposes a batch splitting schedule policy to solve continuous and ingot casting schedule of mixed w...For steel-making and continuous/ingot casting are the key processes of modern iron and steel enterprises, this paper proposes a batch splitting schedule policy to solve continuous and ingot casting schedule of mixed whole/ half charging plan for steel making. First establish the model of continuous and ingot casting schedule of mixed whole/half charging plan according to the complex constraints. Then solve this model by heuristic algorithm. Finally use actual data to prove the proposed algorithmrs validity and analyze the application result in steel plant.展开更多
Macrosegregation is the major defect in large steel ingots caused by solute partitioning and melt convection during casting.In this study,a three-phase(liquid,columnar dendrites,and equiaxed grains)model is proposed t...Macrosegregation is the major defect in large steel ingots caused by solute partitioning and melt convection during casting.In this study,a three-phase(liquid,columnar dendrites,and equiaxed grains)model is proposed to simulate macrosegregation in a 36-t steel ingot.A supplementary set of conservation equations are employed in the model such that two types of equiaxed grains,either settling or adhering to the solid shell,are well simulated.The predicted concentration agrees quantitatively with the experimental value.A negative segregation cone was located at the bottom owing to the grain settlement and solute-enriched melt leaving from the mushy zone.The interdendritic liquid flow was carefully analyzed,and the formation of A-type segregations in the mid-height of the ingot is discussed.Negative segregation was observed near the riser neck due to the specific relationship between flow direction and temperature gradient.Additionally,the as-cast macrostructure of the ingot is presented,including the grain size distribution and columnar–equiaxed transition.展开更多
Heavy ingots,especially the ingot of more than 10 t,often contain detrimental heterogeneous defects,such as macrosegregation,shrinkage pipes,and cracks.Hot-top pulsed magneto-oscillation(HPMO)can refine the solidified...Heavy ingots,especially the ingot of more than 10 t,often contain detrimental heterogeneous defects,such as macrosegregation,shrinkage pipes,and cracks.Hot-top pulsed magneto-oscillation(HPMO)can refine the solidified structure of ingot and improve their homogeneity.However,it may exacerbate the positive segregation at the upper part of the ingot body.Thus,a round table HPMO riser with a feeding part was designed,and the microstructure and macrosegregation of Al–Si alloy ingots solidified with and without HPMO were investigated.The simulation and experimental results indicated that round table HPMO riser could enable fine and uniform solidified structures in the whole ingot body;in the meantime,feeding part allowed the melt with enriched solute to gather in the upper part of the riser until the last solidification stage of ingot.This provides an effective approach for obtaining highly homogenized ingots.展开更多
Central shrinkage crack is a common defect encountered in steel ingot casting. It is necessary to limit the degree of crack in case of further propagation in forging. A 234-t steel ingot was dissected to check the int...Central shrinkage crack is a common defect encountered in steel ingot casting. It is necessary to limit the degree of crack in case of further propagation in forging. A 234-t steel ingot was dissected to check the internal quality, and a central shrinkage crack band of 1,400 mm in height and 120 mm in width, was found at a distance of 450 mm under the riser bottom line. Then, thermo-mechanical simulation using an elasto-viscoplastic finite-element model was conducted to analyze the stress-strain evolution during ingot solidification. A new criterion considering mush mechanical property in the brittle temperature range as well as shrinkage porosity was used to identify the shrinkage crack potential, where the degree of shrinkage porosity is regarded as a probability factor using a modified sigmoid function. Different casting processes, such as pouring speed, mould preheating and riser insulation, were optimized with the simulation model. The results show that fast pouring, proper mould preheating and good riser insulation can alleviate shrinkage crack potential in the ingot center.展开更多
Deformation characteristics and range of optimized hot working parameters of a 6.5 tons GH3535 superalloy ingot with an average columnar grain size of over 1 mm in diameter were investigated. Axial compression experim...Deformation characteristics and range of optimized hot working parameters of a 6.5 tons GH3535 superalloy ingot with an average columnar grain size of over 1 mm in diameter were investigated. Axial compression experiments were performed in temperature range of 900-1240 ℃ and strain rate range of 0.001-30 s;at a total strain of 0.8. The hot deformation activation energy of the experimental GH3535 alloy is calculated to be 483.22 kJ/mol. Furthermore, the deformation constitutive equation is established by the peak stresses obtained from the stress-strain curves under various conditions. The hot working window of the alloy ingot at a strain of 0.8 can be preliminarily discussed based on the deformed microstructures and processing maps. The optimized hot working window was thus determined at the strain of 0.95 for 6.5 tons GH3535 alloy ingot by the supplementary compression tests. A large-size GH3535 superalloy ring with a dimension of 03010 mm x 410 mm was ultimately manufactured.展开更多
In present paper, a ladle-tundish-mold CFD model and a macrosegregation model were utilized to investigate the effects of the multiple pouring （MP） process on the macrosegregation in a 438-ton steel ingot. Firstly, ...In present paper, a ladle-tundish-mold CFD model and a macrosegregation model were utilized to investigate the effects of the multiple pouring （MP） process on the macrosegregation in a 438-ton steel ingot. Firstly, the model was partially proved as compared to the measured carbon distributions along the transverse sections in the riser of ingot. Then, the comparison between the single pouring （SP） and MP process has been carried out to study their influences on the macrosegregation in ingot. Besides, the predicted macrosegregation results in MP process which introduced the improved riser fixed with an insulating sleeve were compared with that in traditional MP process. The traditional MP process leads to certain favorable initial carbon distribution in the mold, which has some favorable influence on suppressing the positive segregation in ingot. The holding time of the low carbon in the riser is the main factor to suppress the positive segregation in ingot. Improved insulating sleeve can prolong the holding time of the low carbon in the riser and release the positive segregation in the riser of ingot. Improvement of the insulating effect of the riser is an efficient method to control macrosegregation in large steel ingot.展开更多
基金supported by the Natural Science Foundation of Shaanxi Province of China(No.2023-JC-QN-0466)the National Natural Science Foundation of China(Nos.52305421 and 52175363)+1 种基金the General Research Fund of Hong Kong(No.15223520)the project No.1-ZE1W from the Hong Kong Polytechnic University.
文摘Since the as-cast microstructure benefits dynamic recrystallization(DRX)nucleation,the present research is focused on the microstructure evolution associated with the dendrites and precipitates during the thermal deformation of an ingot without homogenization treatment aiming at exploring a new efficient strategy of ingot cogging for superalloys.The as-cast samples were deformed at the sub-solvus temperature,and the DRX evolution from dendritic arms(DAs)to inter-dendritic regions(IDRs)was discussed based on the observation of the fishnet-like DRX microstructures and the gradient of DRX grain size at IDRs.The difference in the precipitates at DAs and IDRs played an essential role during the deformation and DRX process,which finally resulted in very different microstructures in the two areas.A selective straininduced grain boundary bulging(SIGBB)mechanism was found to function well and dominate the DRX nucleation at DAs.The grain boundary was able to migrate and bulge to nucleate on the condition that the boundary was located at DAs and had a great difference in dislocation density between its opposite sides at the same time.As for DRX nucleation at IDRs,the particle-stimulated nucleation(PSN)mechanism played a leading role,and the progressive subgrain rotation(PSR)and geometric DRX were two important supplementary mechanisms.The dislocation accumulation around the coarse precipitates at IDR resulted in progressive orientation rotation,which would generate DRX nuclei once the maximum misorientation there was sufficient to form a high-angle boundary with the matrix.The PSR or geometric DRX functioned at the severely elongated IDRs at the later stage of deformation,depending on the thickness of the elongated IDRs.The uniform microstructure was obtained by the deformation without homogenization and the subsequent annealing treatment.The smaller strain,the lower annealing temperature,and the much shorter soaking time requested in the above process lead to a smaller risk of cracking and a lower consumption of energy during the ingot-cogging process.
基金Project (2005CB623707) supported by the National Basic Research Program of China
文摘Three-layer composite ingot of 4045/3004/4045 aluminum alloys was prepared by direct-chill semi-continuous casting process,the temperature field distribution near the composite interface,macro-morphology,microstructure and composition distribution of the composite interface were investigated.The results show that semi-solid layer with a certain thickness forms near the interface due to the effect of cooling plate,which ensures successful implementation of casting the composite ingot.Two different aluminum alloys are well bonded metallurgically.The mechanical properties of composite interface were measured,the tensile and shearing strengths of composite interface are 105 and 88 MPa,respectively,which proves that the composite interface is a kind of metallurgical bonding.
基金Project(51074031)supported by the National Natural Science Foundation of ChinaProject supported by the Korea National Project
文摘In order to improve the quality of clad ingots, diverse physical fields including electromagnetic stirring, power ultrasonic and compound field of ultrasonic and electromagnetic stirring were attempted to prepare clad ingots of 3003/4004 alloys. The solidification structures near the interface in clad ingots were investigated. The experiment results indicate that the solidification structure of 4004 alloy changes from dendritic crystals to petal-like grains when the clad ingot is treated by electromagnetic stirring. With the effect of power ultrasonic, the solidified microstructure of 4004 alloy exhibits the refinement of both primary a（A1） and eutectic silicon. Under the compound field, the primary a（A1） is refined, the morphology of eutectic silicon has a transition from a coarse plate-like form without treatment or thin acicular-like form with power ultrasonic to fine coral-like form.
文摘Inclusion distribution in ingots was studied by dissection of a 16.8 t P12 ingot and a 5.0 t H13 ingot, with the analysis of T[O], original position statistic distribution analysis （OPA）, metallographic microscope static analysis and small sample electrolysis. The results showed that the inclusions in ingots were uneven; a positive segregation area was found in the center and lower part of the ingot, while a negative segregation area was present in the central part of ingot top; inclusion segregation in a large size ingot was severer than that in a small one. A new con cept, named inclusion segregation index, was put forward to quantify the segregation degree of inclusion. It was found that the segregation indexes drawn from T[O] analysis and OPA fit well, but they were different from those obtained by metallograpbic microscope static analysis and small sample electrolysis in the investigation of Pl 2 ingot, which contained a higher sulfur content; while the segregation index drawn from T[O] analysis was close to that from metallographic microscope static analysis in the H13 ingot with a lower sulfur content.
基金supported by the National Natural Science Foundation of China(Grant No.51404018)the State Key Laboratory of Advanced Metallurgy Foundation(No.41614014)
文摘Two kinds of argon shroud protection devices with two different basic structures were designed and investigated. Industrial experiments and numerical simulations were used to examine the protection effect, and the mechanism of air entrapment during the casting of steel ingots was analyzed. The influence of the structure of the argon shroud protection device on the protection effect was investigated. An argon shroud protection device mounted to the nozzle holder on the bottom of the ladle does not provide a good protection effect because air can easily flow into the teeming system and cause reoxidation of molten steel during teeming. By contrast, an argon shroud protection device seated on the top of the central trumpet provides an excellent protection effect, where air has little chance of flowing into the teeming system during casting. The feasibilities of the argon shroud protection devices are discussed.
文摘During the ingot casting process, the parametric changes of the molten steel pouring process often cause both ingot surface and internal quality defects. With the increasingly wide application of computers in industrial technology ,numerical simulations of the molten steel pouring process enable predictions of the defects that will arise during the pouring and solidification process, especially for the molten steel flow during the early stages of casting. In addition,using a computer to simulate the casting process of a 40 t ingot and solidification can prevent many defects. The simulation results indicate that controlling the pouring speed to less than 80 kg/s, hanging the casting powder in a mold with the hanging height maintained at 100-150 mm, and controlling the taper angle of the mold brick outlet to a suitable level can reduce the probability of slag entrapment and improve the internal and surface quality of the ingot.
基金financially supported by the Key Special Project in the National Science & Technology Program during the Eleventh Five-Year Plan Period (No.2009ZX04014-061-7)
文摘The metallurgical effect of a round tundish used to cast heavy steel ingots in machine works at present was evaluated through water modeling experiments. The flow control devices of the improved oval tundish, which was used instead of the round tundish, had been optimized. The results show that the residence time of the round tundish is short, its inclusion removal efficiency is too low, and it has more dead zones and an unreasonable flow field. Compared with the round tundish, the improved oval tundish with the optimized weir and dam has a better effect： its minimum residence time is prolonged by 38.1 s, the average residence time is prolonged by 233.4 s, its dead volume fraction decreases from 26% to 15%, and the ratio of plug volume fraction to dead volume fraction increases from 0.54 to 1.27. The inclusion removal efficiency also increases by 17.5%.
基金supported by the National Science and Technology Major Project of China (No.2011ZX04014-052)the National Basic Research Priorities Program of China (No.2011CB012900)
文摘A two-phase model for the prediction of macrosegregation formed during solidification is presented. This model incorporates the descriptions of heat transfer, melt convection, solute transport, and solid movement on the system scale with microscopic relations for grain nucleation and growth. Then the model is used to simulate the solidification of a benchmark industrial 3.3-t steel ingot. Simulations are per- formed to investigate the effects of grain motion and pipe shrinkage formation on the final macrosegregation pattern. The model predictions are compared with experimental data and numerical results from literatures. It is demonstrated that the model is able to express the overall macrosegregation patterns in the ingot. Furthermore, the results show that it is essential to consider the motion of equiaxed grains and the formation of pipe shrinkage in modelling. Several issues for future model improvements are identified.
文摘The solidification of 4.4 t cold work tool steel ingot type X210Crl2 was simulated by Magma software. By the reduction of ingot height, solidification modeling and pouring of a new 3 t ingot were performed and decreasing the porosity formation potential in 3 t ingot in comparison with 4.4 t ingot on the basis of Niyama criterion was ob-served which was in good accordance with experimental data. In order to produce sound ingot, a new 2.8 t ingot mould was designed which includes some parameteric changes in mould such as mould slope, slenderness ratio, mould concavity radius, fillet radius of mould internal corners and feeding diameter to ingot upper diameter ratio. Furthermore, the effects of insulating between kokil and feeding ring and also insulating the outer surface of feeding ring as well as insulating the outer surface of one third of kokil upper part on eenterline porosity formation were in-vestigated in both 2.8 and 4.4 t ingots. The results show that the ingot which was produced in new designed 2.8 t mould has a better Niyama pattern and the centerline porosities were eliminated.
基金financially supported by the National Natural Science Foundation of China(Granted No.U1760204,51504048)the National Key Research Program of China(Granted No.2017YFB0701800)
文摘Achieving a uniform structure with few defects in heavy steel ingot is of high commercial importance. In this present work, in order to verify the potential of pulsed magneto-oscillation(PMO) applied in the production of heavy ingot, an induction coil was located at the hot top of the steel ingot to develop a novel technique, named hot top pulsed magneto oscillation(HPMO). The influences of HPMO on the solidification structure, macro segregation and compactness of a cylindrical medium carbon steel ingot with the weight of 160 kg were systematically investigated by optical microscope(OM) and laser induced breakdown spectroscopy original position metal analyzer(LIBSOPA-100). The results show that HPMO not only causes significant grain refinement and promotes the occurrence of columnar to equiaxed transition(CET) but also can homogenize the carbon distribution and enhance the compactness of the steel ingot. Therefore, HPMO technique has the potential to be applied in the production of heavy steel ingots on an industrial scale.
基金Project(50974016)supported by the National Natural Science Foundation of China。
文摘The fundamental mechanism of the cracking formation was investigated for the as-cast GH4151 superalloy.By analyzing the characteristics of cracking,the cracking mechanism was determined to be the cold crack formed during the cooling process.And cold cracking is closely related to severe segregation,complex precipitates and uneven γ'phase distribution.During cooling process,cracks were generated around the precipitates due to their different linear shrinkage coefficients.The annealing treatment process controlling the residual stress,the size and morphology of γ'phase was proposed.The annealing treatment plays a role in reducing residual stress through decreasing the thermal gradient and controlling the size distribution of γ'phase to reduce the strain concentration around the precipitate phases.
基金supported by the Youth Science Fund Project of the National Natural Science Fund of China(No.51401070)the Program for New Century Excellent Talents in Universities(No.NCET-12-0849)the Fundamental Research Funds for the Central Universities(No.2014ZZD03)
文摘In this paper,a large-sized ingot of Mg–9Gd–3Y–1.5Zn–0.5Zr(wt%) alloy with a diameter of 600 mm was successfully prepared by the semi-continuous casting method.The alloy was subsequently annealed at a relatively low temperature of 430°C for 12 h as a homogenization treatment.The microstructure and room-temperature mechanical properties of the alloy were investigated systematically.The results show that the as-cast alloy contained a mass of discontinuous lamellar-shaped 18 R long-period stacking ordered(LPSO) phases with a composition of Mg10 Zn Y and an α-Mg matrix,along with net-shaped Mg5(Y,Gd) eutectic compounds at the grain boundaries.Most of the eutectic compounds dissolved after the homogenization treatment.Moreover,the amount and dimensions of the lamellar-shaped LPSO phase obviously increased after the homogenization treatment.The structure of the phase transformed into 14H-type LPSO with composition Mg12Zn(Y,Gd).The mechanical properties of the heat-treated large-sized alloy ingot are uniform.The ultimate tensile strength(UTS) and tensile yield strength(TYS) of the alloy reached 207.2 MPa and 134.8 MPa,respectively,and the elongation was 3.4%.The high performances of the large-sized alloy ingot after the homogenization treatment is attributed to the strengthening of the α-Mg solid solution and to the plentiful LPSO phase distributed over the α-Mg matrix.
基金Project(2007CB613802) supported by the National Basic Research Program of China
文摘In order to get a better understanding of the vacuum consumable arc remelting(VAR) processes and thus to optimize them,a 3D finite element model was developed for the temperature fields and heat transfer of titanium alloy ingots during VAR process.The results show that the temperature fields obtained by the simulation are well validated through the experiment results.The temperature distribution is different during the whole VAR process and the steady-state molten pool forms at 329 s for d100 mm × 180 mm ingots.At the initial stage of remelting,the heat dissipation of crucible bottom plays an important role in the whole heat dissipation system.At the middle of remelting,the crucible wall becomes a major heat dissipation way.The effect of cooling velocity on the solidification structure of ingots was investigated based on the temperature fields and the results can well explain the macrostructure of titanium alloy ingots.
文摘The method based on transient heat transfer model is adopted to simulate electro-slag remelting process. The calculated results of the model show that the process is in the quasi-steady state, and the shape of pool remains unchanged when the height of ingot is approximately 2.5-3 times the thickness of slab ingot. The change in the shape of pool is found to be strongly dependent on the pattern of melting rate, and hence, the power input; the depth of the molten pool increases with the increase in melting speed. It is concluded that a transient heat transfer model has to be used to obtain reliable input information for the entire, operatina time.
基金Sponsored by National Basic Research Program of China (2009CB320601)National Natural Science Foundation of China (7102061,60974091,61020106003)Program for New Century Excellent Talents in University (NCET-08-0105)
文摘For steel-making and continuous/ingot casting are the key processes of modern iron and steel enterprises, this paper proposes a batch splitting schedule policy to solve continuous and ingot casting schedule of mixed whole/ half charging plan for steel making. First establish the model of continuous and ingot casting schedule of mixed whole/half charging plan according to the complex constraints. Then solve this model by heuristic algorithm. Finally use actual data to prove the proposed algorithmrs validity and analyze the application result in steel plant.
基金financially supported by the project to strengthen industrial development at the grassroots level of the Ministry of Industry and Information Technology (MIIT), China (No. TC160A310/21)
文摘Macrosegregation is the major defect in large steel ingots caused by solute partitioning and melt convection during casting.In this study,a three-phase(liquid,columnar dendrites,and equiaxed grains)model is proposed to simulate macrosegregation in a 36-t steel ingot.A supplementary set of conservation equations are employed in the model such that two types of equiaxed grains,either settling or adhering to the solid shell,are well simulated.The predicted concentration agrees quantitatively with the experimental value.A negative segregation cone was located at the bottom owing to the grain settlement and solute-enriched melt leaving from the mushy zone.The interdendritic liquid flow was carefully analyzed,and the formation of A-type segregations in the mid-height of the ingot is discussed.Negative segregation was observed near the riser neck due to the specific relationship between flow direction and temperature gradient.Additionally,the as-cast macrostructure of the ingot is presented,including the grain size distribution and columnar–equiaxed transition.
基金This work was financially supported by the National Key Research and Development Program of China(Nos.2020YFB2008400 and 2017YFB0701800)the National Natural Science Foundation of China(No.U1760204)In addition,the authors would liketo thankHui Shaoand Zi-hao Yin from Centerfor Advanced Solidification Technology,Shanghai University for their help in the experiment and data analysis.
文摘Heavy ingots,especially the ingot of more than 10 t,often contain detrimental heterogeneous defects,such as macrosegregation,shrinkage pipes,and cracks.Hot-top pulsed magneto-oscillation(HPMO)can refine the solidified structure of ingot and improve their homogeneity.However,it may exacerbate the positive segregation at the upper part of the ingot body.Thus,a round table HPMO riser with a feeding part was designed,and the microstructure and macrosegregation of Al–Si alloy ingots solidified with and without HPMO were investigated.The simulation and experimental results indicated that round table HPMO riser could enable fine and uniform solidified structures in the whole ingot body;in the meantime,feeding part allowed the melt with enriched solute to gather in the upper part of the riser until the last solidification stage of ingot.This provides an effective approach for obtaining highly homogenized ingots.
基金supported by the NSFC-Liaoning Joint Fund(U1508215)the project to strengthen industrial development at the grass-roots level of MIIT China(TC160A310/21)
文摘Central shrinkage crack is a common defect encountered in steel ingot casting. It is necessary to limit the degree of crack in case of further propagation in forging. A 234-t steel ingot was dissected to check the internal quality, and a central shrinkage crack band of 1,400 mm in height and 120 mm in width, was found at a distance of 450 mm under the riser bottom line. Then, thermo-mechanical simulation using an elasto-viscoplastic finite-element model was conducted to analyze the stress-strain evolution during ingot solidification. A new criterion considering mush mechanical property in the brittle temperature range as well as shrinkage porosity was used to identify the shrinkage crack potential, where the degree of shrinkage porosity is regarded as a probability factor using a modified sigmoid function. Different casting processes, such as pouring speed, mould preheating and riser insulation, were optimized with the simulation model. The results show that fast pouring, proper mould preheating and good riser insulation can alleviate shrinkage crack potential in the ingot center.
基金supported by the Strategic Priority Research Program of the Chinese Academy of Sciences(Grant No.XDA02004210)
文摘Deformation characteristics and range of optimized hot working parameters of a 6.5 tons GH3535 superalloy ingot with an average columnar grain size of over 1 mm in diameter were investigated. Axial compression experiments were performed in temperature range of 900-1240 ℃ and strain rate range of 0.001-30 s;at a total strain of 0.8. The hot deformation activation energy of the experimental GH3535 alloy is calculated to be 483.22 kJ/mol. Furthermore, the deformation constitutive equation is established by the peak stresses obtained from the stress-strain curves under various conditions. The hot working window of the alloy ingot at a strain of 0.8 can be preliminarily discussed based on the deformed microstructures and processing maps. The optimized hot working window was thus determined at the strain of 0.95 for 6.5 tons GH3535 alloy ingot by the supplementary compression tests. A large-size GH3535 superalloy ring with a dimension of 03010 mm x 410 mm was ultimately manufactured.
基金financially supported by the National Basic Research Program of China (No. 2011CB012900)the National Science and Technology Major Project of the Ministry of Science and Technology of China (No. 2012ZX04012011)
文摘In present paper, a ladle-tundish-mold CFD model and a macrosegregation model were utilized to investigate the effects of the multiple pouring （MP） process on the macrosegregation in a 438-ton steel ingot. Firstly, the model was partially proved as compared to the measured carbon distributions along the transverse sections in the riser of ingot. Then, the comparison between the single pouring （SP） and MP process has been carried out to study their influences on the macrosegregation in ingot. Besides, the predicted macrosegregation results in MP process which introduced the improved riser fixed with an insulating sleeve were compared with that in traditional MP process. The traditional MP process leads to certain favorable initial carbon distribution in the mold, which has some favorable influence on suppressing the positive segregation in ingot. The holding time of the low carbon in the riser is the main factor to suppress the positive segregation in ingot. Improved insulating sleeve can prolong the holding time of the low carbon in the riser and release the positive segregation in the riser of ingot. Improvement of the insulating effect of the riser is an efficient method to control macrosegregation in large steel ingot.
