Heat transfer behaviors of AZ80?1%Y alloy during low frequency electromagnetic casting (LFEC) and direct chilling casting were studied by in-situ temperature measurement. The results demonstrated that the low frequenc...Heat transfer behaviors of AZ80?1%Y alloy during low frequency electromagnetic casting (LFEC) and direct chilling casting were studied by in-situ temperature measurement. The results demonstrated that the low frequency electromagnetic field (EM) caused forced convection in the melt during LFEC. The forced convection led to uniform solidification velocity and temperature field. EM frequency, excitation current intensity and casting temperature could control the heat transfer behavior. The forced convection could improve the microstructure and degrade the difference in microstructure between the edge and center of billet. Appropriate parameters of low frequency EM for casting Mg alloy are 20 Hz of frequency and 60 A of electric current intensity.展开更多
With the aid of ANSYS software, the effect of different mould external part materials on magnetic flux density in the aluminum melt and magnetic field interaction of four coils applied with same currents were investig...With the aid of ANSYS software, the effect of different mould external part materials on magnetic flux density in the aluminum melt and magnetic field interaction of four coils applied with same currents were investigated. Calculating results showed that magnetic flux density in the aluminum melt was greatly improved and the magnetic field interaction among different coils was decreased when external part of mould is made of soft magnetic material. Based on the finding, a four-strand low-frequency electromagnetic casting 6063 aluminum alloy experiment was carried out in the laboratory . The experiment showed that the surface of the billet was smooth and had no exudations and cold shuts, the as-cast microstructures were fine, uniform, equiaxed, net-globular or globular under low-frequency electromagnetic field. The microstructure becomes finer with increased current value.展开更多
The super high strength aluminum alloy ingots with 100 mm in diameter were cast by the process of low-frequency electromagnetic horizontal continuous casting (LFEHC) and the effect of electromagnetic field on the as-c...The super high strength aluminum alloy ingots with 100 mm in diameter were cast by the process of low-frequency electromagnetic horizontal continuous casting (LFEHC) and the effect of electromagnetic field on the as-cast microstructure was studied. Results show that microstructure of the sample prepared by the LFEHC process was greatly refined. Microstructures at the border and the center of the ingots were fine, uniform and rosette-shaped. Electromagnetic frequency plays a key role in microstructure refining. Fine and uniform microstructures can be obtained with optimal electromagnetic frequency. In this experiment, under a frequency of 30 Hz the microstructure was the finest and the most uniform.展开更多
The influences of the low frequency electromagnetic field on the horizontal direct chill casting process were investigated experimentally. Ingots of 2024 aluminum alloy with a cross size of 40 mm× 200 mm were pro...The influences of the low frequency electromagnetic field on the horizontal direct chill casting process were investigated experimentally. Ingots of 2024 aluminum alloy with a cross size of 40 mm× 200 mm were produced by the conventional horizontal chill casting process and low frequency electromagnetic horizontal chill casting processre- spectively. The as-cast structures and the mechanical property of the ingots were examined. The results showed that the low frequency electromagnetic field could sub- stantially refine the microstructures and pronouncedly reduce the macrosegregation in the horizontal direct chill casting process. Moreover, the surface quality of the ingot was prominently improved by the low frequency electromagnetic field. The fracture strength and elongation percentage of the ingot was increased with the low frequency electromagnetic field.展开更多
To understand the solidification behavior of austenitic stainless steel in rotary electromagnetic-field, the influence of low-frequency rotary electromagnetic-field on solidification structure of austenitic stainless ...To understand the solidification behavior of austenitic stainless steel in rotary electromagnetic-field, the influence of low-frequency rotary electromagnetic-field on solidification structure of austenitic stainless steel in horizontal continuous casting was investigated based on industrial experiments. The results show that the solidification structure of austenitic stainless steel can be remarkably refined, the central porosity and shrinkage cavity can be remarkably decreased, and the equiaxed grains zone are enlarged by means of application of appropriate low-frequency electromagnetic-field parameters. The industrial trials verify that the stirring intensity of austenitic stainless steel should be higher compared with that of plain carbon steel. Electromagnetic stirring affects the macrostructure even if the average magnetic flux density of the electromagnetic stirring reaches 90 mT (amplitude reaches 141 mT) with the frequency of 3-4 Hz. Due to a higher viscosity, rotating speed of molten stainless steel is 20%-30% lower than that of molten carbon steel in the same magnetic flux density.展开更多
Controlling molten steel flow in the mold and stabilizing the meniscus are critical challenges during the continuous casting,directly impacting the surface quality and internal quality of the final steel slab product....Controlling molten steel flow in the mold and stabilizing the meniscus are critical challenges during the continuous casting,directly impacting the surface quality and internal quality of the final steel slab product.The effects of electromagnetic swirling flow in nozzle(EMSFN)technology on molten steel flow in the mold during slab continuous casting under various casting speeds were investigated.A real-time adjustable EMSFN was developed,and a three-dimensional unsteady Reynolds-averaged Navier–Stokes turbulence mathematical model was established to simulate the flow field within the mold.The results demonstrate that the EMSFN effectively stabilizes the outflow from nozzle,reduces the impact depth and surface velocity of the molten steel,mitigates meniscus fluctuations,and promotes stable flow within the mold.However,a certain matching relationship exists between the casting speed and the current intensity.For the experimental medium-thick slab specifications,the optimal current intensities were found to be 100,130,and 200 A at casting speeds of 1.0,1.5,and 2.0 m/min,respectively.EMSFN can optimize the mold flow field under different casting speeds,providing theoretical support for improving the quality of continuously cast slab products.展开更多
The low frequency electromagnetic casting(LFEC)was used to prevent hot cracking during the solidification process of GH4742 superalloy ingot.The effects of LFEC on the solidification macrostructure of the ingot were i...The low frequency electromagnetic casting(LFEC)was used to prevent hot cracking during the solidification process of GH4742 superalloy ingot.The effects of LFEC on the solidification macrostructure of the ingot were investigated through experiments and simulation.The results show that the average grain size decreases after application of LFEC.At the same time,the fraction of equiaxed grains increases compared with the ingots that without LFEC.In addition,the average grain size decreases and the fraction of equiaxed grains increases with increasing the current frequency.When the current frequency increases from 5 Hz to 20 Hz,the average grain size decreases from 5.39 mm to 4.74 mm,and the fraction of equiaxed grains increases from 41.21%to 55.24%.The distribution of Lorentz force,melt flow field and temperature field in the melt was simulated using COMSOL Multiphysics software.It is found that the Lorentz force increases and the forced convection is enhanced with increasing the current frequency,thus the melt flow velocity and heat transfer in the melt are promoted.It can facilitate the heterogenous nucleation in the melt,resulting in grain refinement,and further preventing hot cracking of large size ingots.展开更多
An opposite combined vertical linear electromagnetic stirring(CV-LEMS)was proposed,which is applied in the final solidification zone of bloom continuous casting.The melt flow,heat transfer,and solidification under CV-...An opposite combined vertical linear electromagnetic stirring(CV-LEMS)was proposed,which is applied in the final solidification zone of bloom continuous casting.The melt flow,heat transfer,and solidification under CV-LEMS were investigated by establishing a three-dimensional numerical simulation model and a pilot continuous casting simulation experiment and compared with the conventional rotary electromagnetic stirring(REMS).The results show that a longitudinally symmetric linear magnetic field is formed in the liquid core of the bloom by applying CV-LEMS,which induces a strong longitudinal circulation flow both on the inner arc side and the outer arc side in the liquid core of the bloom.The height of the melt longitudinal effective mixing range under CV-LEMS reaches 0.9 m,which is greater than that of the REMS and makes up for the deficiency of REMS sensitivity to the position of the final solidification zone.CV-LEMS strongly promotes the mixing of upper melt with high temperature and the lower part melt with low temperature in the liquid core,improves the uniformity of melt temperature distribution and significantly increases the melt temperature near the solidification front,and the width of the liquid core increases by 4.2 mm at maximum.This shows that the appliction of CV-LEMS is more helpful to strengthen the feeding effect of the upper melt to the solidification shrinkage of the lower melt than the conventional REMS and inhibits the formation of porosity,shrinkage cavity and crack defects in the center of the bloom.展开更多
The electromagnetic swirling flow in nozzle(EMSFN)technique is designed to mitigate the adverse effects of unstable and uneven flow within the submerged entry nozzle in continuous casting.Utilizing electromagnetic for...The electromagnetic swirling flow in nozzle(EMSFN)technique is designed to mitigate the adverse effects of unstable and uneven flow within the submerged entry nozzle in continuous casting.Utilizing electromagnetic forces,EMSFN stabilizes the flow within the nozzle,leading to a more controlled flow in the mold.Numerical simulations were used to quantitatively analyze the magnetic and flow fields in a slab continuous casting system under EMSFN.Results indicate that EMSFN significantly stabilizes the outflow from the nozzle,with stability increasing with higher current intensity.At 10,000 Ampere-turns(At)of the coil,meniscus fluctuations were unstable.They stabilized at 13,000 At,with minimal changes observed beyond this point.The optimal current intensity for stable mold flow,at a casting speed of 1.56 m/min,is 13,000 At.These findings confirm the effectiveness of EMSFN in stabilizing the internal flow field of the slab mold and determining optimal operational current intensity.展开更多
To address the current issues with the conventional slide gate system utilized in the steel teeming process,a unique electromagnetic induction controlled automated steel teeming(EICAST)technology has been developed.Co...To address the current issues with the conventional slide gate system utilized in the steel teeming process,a unique electromagnetic induction controlled automated steel teeming(EICAST)technology has been developed.Cooling means of spiral coil in this technology is directly related to its service life.Firstly,heat transfer processes of air cooling and spray cooling were compared and analyzed.Secondly,the impacts of water temperature,water flow rate and air flow rate were examined in order to maximize the spray cooling effect.To maintain coil temperature at a low value consistently throughout the entire thermal cycle process of the ladle,a combined cooling mode was finally employed.Numerical simulation was applied to examine the coil temperature variation with different cooling systems and characteristics.Before coil operation,spray cooling is said to be more effective.By controlling the water flow rate and air flow rate,the spray cooling effect is enhanced.However,water temperature has little or no impact when using spray cooling.Air cooling during the secondary refining process and spray cooling prior to coil operation are combined to further lower coil temperature.When the direction of the spray cooling is from bottom to top,the coil temperature is lowered below 165℃.A practical induction coil cooling plan was provided for the EICAST technology’s production process.展开更多
A comprehensive mathematical model of annulus-electromagnetic direct chill （A-EMDC） casting of A357 aluminum alloy was established with corresponding experimental verification. The model was based on a combination o...A comprehensive mathematical model of annulus-electromagnetic direct chill （A-EMDC） casting of A357 aluminum alloy was established with corresponding experimental verification. The model was based on a combination of the commercial finite element package ANSYS and the commercial finite volume package FLUENT. The effects of structural parameters on fluid flow, temperature field and solidification during A-EMDC process were investigated numerically. The results show that structural parameters such as annulus gap width, annulus gap position, and centre pipe length influence the flow and temperature fields. The smaller the annulus gap width is, the more uniform the temperature is, and the smaller the temperature gradient is. With increasing the centre pipe length, the circular flow would decrease due to the dislocation of centre pipe. Specially, when the annulus gap is located at periphery of the billet, the temperature gradient of the longitudinal direction in the solidification region falls evidently.展开更多
The effects of low frequency electromagnetic field on the macro-physical fields in the semi-continuous casting process of aluminum alloys and the microstructure and crack in the billets were studied and analyzed by th...The effects of low frequency electromagnetic field on the macro-physical fields in the semi-continuous casting process of aluminum alloys and the microstructure and crack in the billets were studied and analyzed by the numerical and experimental methods.Comparison of the results for the macro-physical fields in the low frequency electromagnetic casting（LFEC） process with the conventional DC casting process indicates the following characters due to the application of electromagnetic field：an entirely changed direction and remarkably increased velocity of melt flow;a uniform distribution and a decreased gradient of temperature;elevated isothermal lines;a reduced sump depth;decreased stress and plastic deformation.Further,the microstructure of the billets is refined remarkably and the crack in the billets is eliminated in LFEC process because of modification of the macro-physical fields induced by the application of low frequency electromagnetic field.展开更多
A modified horizontal continuous casting process under the electromagnetic field was proposed for preparing AA3003/ AA4045 clad composite hollow billets. To investigate the effect of electromagnetic field on this proc...A modified horizontal continuous casting process under the electromagnetic field was proposed for preparing AA3003/ AA4045 clad composite hollow billets. To investigate the effect of electromagnetic field on this process, a comprehensive three-dimensional model was developed. Two cases with and without electromagnetic field were compared using the simulations. When rotating electromagnetic stirring is applied, the flow pattern of fluid melt is greatly modified; the mushy zone becomes much wider, the temperature profile becomes more uniform, and the solid fraction decreases for both the external and internal alloy melt layers. These modifications are beneficial for the formation of a bimetal interface and fine and uniform grain structure of the clad composite hollow billet. Experiments conducted using the same electrical and casting parameters as the simulations verify that under the electromagnetic field the microstructure of the clad composite hollow billet becomes fine and the diffusion of the elements at the interface is promoted.展开更多
The precise tuning of magnetic nanoparticle size and magnetic domains,thereby shaping magnetic properties.However,the dynamic evolution mechanisms of magnetic domain configurations in relation to electromagnetic(EM)at...The precise tuning of magnetic nanoparticle size and magnetic domains,thereby shaping magnetic properties.However,the dynamic evolution mechanisms of magnetic domain configurations in relation to electromagnetic(EM)attenuation behavior remain poorly understood.To address this gap,a thermodynamically controlled periodic coordination strategy is proposed to achieve precise modulation of magnetic nanoparticle spacing.This approach unveils the evolution of magnetic domain configurations,progressing from individual to coupled and ultimately to crosslinked domain configurations.A unique magnetic coupling phenomenon surpasses the Snoek limit in low-frequency range,which is observed through micromagnetic simulation.The crosslinked magnetic configuration achieves effective low-frequency EM wave absorption at 3.68 GHz,encompassing nearly the entire C-band.This exceptional magnetic interaction significantly enhances radar camouflage and thermal insulation properties.Additionally,a robust gradient metamaterial design extends coverage across the full band(2–40 GHz),effectively mitigating the impact of EM pollution on human health and environment.This comprehensive study elucidates the evolution mechanisms of magnetic domain configurations,addresses gaps in dynamic magnetic modulation,and provides novel insights for the development of high-performance,low-frequency EM wave absorption materials.展开更多
The relationship between electromagnetic frequency and microstructures of continuous casting aluminum alloys was studied. 7075 aluminum alloy ingot of 100 mm in diameter was produced by electromagnetic continuous cast...The relationship between electromagnetic frequency and microstructures of continuous casting aluminum alloys was studied. 7075 aluminum alloy ingot of 100 mm in diameter was produced by electromagnetic continuous casting process, the microstructures of as-cast ingot was examined by scanning electron microscopy (SEM) equipped with energy dispersive spectrometer (EDS). The results showed that electromagnetic frequency greatly influenced segregation and microstructures of as-cast ingot, and product quality can be guaranteed by the application of a proper frequency. Electromagnetic frequency plays a significant role in solute redistribution; low frequency is more efficient for promoting solution of alloying elements.展开更多
The grain refinement and macrosegregation control of GCrl5 bearing steel were investigated under a type of rarely-used electromagnetic stirring, vertical electromagnetic stirring （V-EMS）, in continuous casting. V-EM...The grain refinement and macrosegregation control of GCrl5 bearing steel were investigated under a type of rarely-used electromagnetic stirring, vertical electromagnetic stirring （V-EMS）, in continuous casting. V-EMS can create an upward electromagnetic force and generate longitudinal loop convection, which ena- bles the better mixing of the upper part with the lower part of the liquid steel. The results showed that ap- plying V-EMS can enlarge the region of the equiaxed grain, decrease the secondary dendrite arm spacing （SDAS） and reduce the segregation of both carbon and sulfur. After applying V-EMS, liquid steel with a high solute concentration is brought to the dendrite tips, making the dendrite arms partially melt. The length of the dendrite fragment is approximately 1.8 mm, 10 to 12 times the SDAS. Upon increasing the amount of cooling water from 2.0 to 3.5 m3/h, the dendrite fragments exhibit an obvious aggregation fol- lowing V-EMS. Finally, a criterion for dendrite fragmentation under V-EMS was derived based on the dendrite fragmentation theory of Campanella et al.展开更多
Solidification cracking that occurs during continuous casting of 1Cr13 stainless steel was investigated with and without final elec- tromagnetic stirring （F-EMS）. The results show that cracks initiates and propagate...Solidification cracking that occurs during continuous casting of 1Cr13 stainless steel was investigated with and without final elec- tromagnetic stirring （F-EMS）. The results show that cracks initiates and propagates along the grain boundaries where the elements of carbon and sulfur are enriched. The final stirrer should be appropriately placed at a location that is 7.5 m away from the meniscus, and the appropri- ate thickness of the liquid core in the stirring zone is 50 ram. As a stirring current of 250 A is imposed, it can promote colurnnar-equiaxed transition, decrease the secondary dendrite arm spacing, and reduce the segregation of both carbon and sulfur. F-EMS can effectively de- crease the amount of cracks in 1Cr13 stainless steel.展开更多
The hot top EMC (electromagnetic casting) method was put forward, namely, the shape of top liquid column was formed by the hot top in the screen and the semi suspended liquid column was formed by the electromagnetic f...The hot top EMC (electromagnetic casting) method was put forward, namely, the shape of top liquid column was formed by the hot top in the screen and the semi suspended liquid column was formed by the electromagnetic force nearby the liquid solid interface frontier. Using the numerical simulating technique, the temperature distribution was discussed, the effect of parameters such as upper conduct distance (UCD), cooling water rate of flow, pouring temperature and liquid column height on casting velocity were studied, the relationship among them was confirmed finally. According to the calculated results, the hot top EMC shaping system was designed and a lot of experiments were performed. The pure Al thin slabs of 480 mm×20 mm×850 mm were made successfully. The result showed that the casting velocity curve obtained experimentally almost coincides to the calculated one.展开更多
The magnetic,heat transfer and flow phenomenon occurring in the continuous casting process under the mold electromagnetic stirring was further analyzed by solving the 3-D electromagnetic field mathematical model and f...The magnetic,heat transfer and flow phenomenon occurring in the continuous casting process under the mold electromagnetic stirring was further analyzed by solving the 3-D electromagnetic field mathematical model and flow solidification model with finite element method and finite volume method,respectively.The results indicate that the solidified shell thickness located in the effective stirring region fluctuates because of the unsteady scouring under the mold electromagnetic stirring.The maximum rotational velocity is a key parameter to the solidification of the billet when controlling the stirring intensity.When the rotational velocity reaches 0.32 m/s,the mush zone enlarges significantly and the solidification rate is further accelerated.The number of vortexes in the lower recirculation zone is not only two and depends on the stirring parameters.Besides,the secondary flow is closely associated with the solidification.Compared with the results of the model ignoring the influence of solidification on the flow of molten steel,the flow pattern within the lower recirculation region changes dramatically,and thus a coupling analysis of the flow,heat transfer,and solidification is essential when simulating the electromagnetic continuous casting process.展开更多
In order to obtain cast metal of high quality, an investigation was carried out by simultaneous imposition of multi electromagnetic fields from the outside of a cold crucible copper mold. Sn 4.5%Pb as a simulator of h...In order to obtain cast metal of high quality, an investigation was carried out by simultaneous imposition of multi electromagnetic fields from the outside of a cold crucible copper mold. Sn 4.5%Pb as a simulator of high melting point metal was continuously cast under different conditions. The results show that multi electromagnetic fields can eliminate surface defects, and coarse columnar grains of the solidification structure is turned into equiaxed crystal with the increase of magnetic flux density. Moreover, finer equiaxed crystal structure is obtained when rapidly solidified sheet is fed into the mold during continuous casting.[展开更多
基金Project(2013CB632203)supported by the National Basic Research and Development Program of ChinaProject(2014028027)supported by the Liaoning Provincial Natural Science Foundation,China
文摘Heat transfer behaviors of AZ80?1%Y alloy during low frequency electromagnetic casting (LFEC) and direct chilling casting were studied by in-situ temperature measurement. The results demonstrated that the low frequency electromagnetic field (EM) caused forced convection in the melt during LFEC. The forced convection led to uniform solidification velocity and temperature field. EM frequency, excitation current intensity and casting temperature could control the heat transfer behavior. The forced convection could improve the microstructure and degrade the difference in microstructure between the edge and center of billet. Appropriate parameters of low frequency EM for casting Mg alloy are 20 Hz of frequency and 60 A of electric current intensity.
文摘With the aid of ANSYS software, the effect of different mould external part materials on magnetic flux density in the aluminum melt and magnetic field interaction of four coils applied with same currents were investigated. Calculating results showed that magnetic flux density in the aluminum melt was greatly improved and the magnetic field interaction among different coils was decreased when external part of mould is made of soft magnetic material. Based on the finding, a four-strand low-frequency electromagnetic casting 6063 aluminum alloy experiment was carried out in the laboratory . The experiment showed that the surface of the billet was smooth and had no exudations and cold shuts, the as-cast microstructures were fine, uniform, equiaxed, net-globular or globular under low-frequency electromagnetic field. The microstructure becomes finer with increased current value.
基金National "863" project (NO.2001AA332030) of China
文摘The super high strength aluminum alloy ingots with 100 mm in diameter were cast by the process of low-frequency electromagnetic horizontal continuous casting (LFEHC) and the effect of electromagnetic field on the as-cast microstructure was studied. Results show that microstructure of the sample prepared by the LFEHC process was greatly refined. Microstructures at the border and the center of the ingots were fine, uniform and rosette-shaped. Electromagnetic frequency plays a key role in microstructure refining. Fine and uniform microstructures can be obtained with optimal electromagnetic frequency. In this experiment, under a frequency of 30 Hz the microstructure was the finest and the most uniform.
文摘The influences of the low frequency electromagnetic field on the horizontal direct chill casting process were investigated experimentally. Ingots of 2024 aluminum alloy with a cross size of 40 mm× 200 mm were produced by the conventional horizontal chill casting process and low frequency electromagnetic horizontal chill casting processre- spectively. The as-cast structures and the mechanical property of the ingots were examined. The results showed that the low frequency electromagnetic field could sub- stantially refine the microstructures and pronouncedly reduce the macrosegregation in the horizontal direct chill casting process. Moreover, the surface quality of the ingot was prominently improved by the low frequency electromagnetic field. The fracture strength and elongation percentage of the ingot was increased with the low frequency electromagnetic field.
基金Project(CSTC2007BB4216) supported by the Natural Science Foundation of Chongqing,China
文摘To understand the solidification behavior of austenitic stainless steel in rotary electromagnetic-field, the influence of low-frequency rotary electromagnetic-field on solidification structure of austenitic stainless steel in horizontal continuous casting was investigated based on industrial experiments. The results show that the solidification structure of austenitic stainless steel can be remarkably refined, the central porosity and shrinkage cavity can be remarkably decreased, and the equiaxed grains zone are enlarged by means of application of appropriate low-frequency electromagnetic-field parameters. The industrial trials verify that the stirring intensity of austenitic stainless steel should be higher compared with that of plain carbon steel. Electromagnetic stirring affects the macrostructure even if the average magnetic flux density of the electromagnetic stirring reaches 90 mT (amplitude reaches 141 mT) with the frequency of 3-4 Hz. Due to a higher viscosity, rotating speed of molten stainless steel is 20%-30% lower than that of molten carbon steel in the same magnetic flux density.
基金National Natural Science Foundation of China(Nos.U21A20117,52104347 and 52272078)the Fundamental Research Funds for the Central Universities(No.N2409006)Natural Science Foundation of Liaoning Province(2023-MSBA-135)for the financial support.
文摘Controlling molten steel flow in the mold and stabilizing the meniscus are critical challenges during the continuous casting,directly impacting the surface quality and internal quality of the final steel slab product.The effects of electromagnetic swirling flow in nozzle(EMSFN)technology on molten steel flow in the mold during slab continuous casting under various casting speeds were investigated.A real-time adjustable EMSFN was developed,and a three-dimensional unsteady Reynolds-averaged Navier–Stokes turbulence mathematical model was established to simulate the flow field within the mold.The results demonstrate that the EMSFN effectively stabilizes the outflow from nozzle,reduces the impact depth and surface velocity of the molten steel,mitigates meniscus fluctuations,and promotes stable flow within the mold.However,a certain matching relationship exists between the casting speed and the current intensity.For the experimental medium-thick slab specifications,the optimal current intensities were found to be 100,130,and 200 A at casting speeds of 1.0,1.5,and 2.0 m/min,respectively.EMSFN can optimize the mold flow field under different casting speeds,providing theoretical support for improving the quality of continuously cast slab products.
基金financially supported by the Major Projects in Aviation Engines and Gas Turbines (Grant No.2019-VI-0020-0136)the National Key Research and Development Program of China (Grant Nos.2022YFB3705101&2022YFB3705102)+1 种基金the National Natural Science Foundation of China (Grant No.U1708253)the Fundamental Research Funds for the Central Universities,China (Grant No.N2302005)。
文摘The low frequency electromagnetic casting(LFEC)was used to prevent hot cracking during the solidification process of GH4742 superalloy ingot.The effects of LFEC on the solidification macrostructure of the ingot were investigated through experiments and simulation.The results show that the average grain size decreases after application of LFEC.At the same time,the fraction of equiaxed grains increases compared with the ingots that without LFEC.In addition,the average grain size decreases and the fraction of equiaxed grains increases with increasing the current frequency.When the current frequency increases from 5 Hz to 20 Hz,the average grain size decreases from 5.39 mm to 4.74 mm,and the fraction of equiaxed grains increases from 41.21%to 55.24%.The distribution of Lorentz force,melt flow field and temperature field in the melt was simulated using COMSOL Multiphysics software.It is found that the Lorentz force increases and the forced convection is enhanced with increasing the current frequency,thus the melt flow velocity and heat transfer in the melt are promoted.It can facilitate the heterogenous nucleation in the melt,resulting in grain refinement,and further preventing hot cracking of large size ingots.
基金the National Natural Science Foundation of China(Grant No.U1760206 and Grant No.51574083)the 111 Project(2.0)of China(No.BP0719037)for the financial support。
文摘An opposite combined vertical linear electromagnetic stirring(CV-LEMS)was proposed,which is applied in the final solidification zone of bloom continuous casting.The melt flow,heat transfer,and solidification under CV-LEMS were investigated by establishing a three-dimensional numerical simulation model and a pilot continuous casting simulation experiment and compared with the conventional rotary electromagnetic stirring(REMS).The results show that a longitudinally symmetric linear magnetic field is formed in the liquid core of the bloom by applying CV-LEMS,which induces a strong longitudinal circulation flow both on the inner arc side and the outer arc side in the liquid core of the bloom.The height of the melt longitudinal effective mixing range under CV-LEMS reaches 0.9 m,which is greater than that of the REMS and makes up for the deficiency of REMS sensitivity to the position of the final solidification zone.CV-LEMS strongly promotes the mixing of upper melt with high temperature and the lower part melt with low temperature in the liquid core,improves the uniformity of melt temperature distribution and significantly increases the melt temperature near the solidification front,and the width of the liquid core increases by 4.2 mm at maximum.This shows that the appliction of CV-LEMS is more helpful to strengthen the feeding effect of the upper melt to the solidification shrinkage of the lower melt than the conventional REMS and inhibits the formation of porosity,shrinkage cavity and crack defects in the center of the bloom.
基金supported by the Application Technology of Automotive Steels(No.2021040300048)the National Natural Science Foundation of China(No.52304347)+2 种基金Hebei Provincial Natural Science Foundation(No.E2019501008),China Baowu Low Carbon Metallurgy Innovation Foundation(BWLCF202320)Natural Science Foundation of Liaoning Province(Nos.2023-MSBA-135 and 2023-BSBA-107)Fundamental Research Funds for the Central Universities(Nos.N2409008 and N2409006).
文摘The electromagnetic swirling flow in nozzle(EMSFN)technique is designed to mitigate the adverse effects of unstable and uneven flow within the submerged entry nozzle in continuous casting.Utilizing electromagnetic forces,EMSFN stabilizes the flow within the nozzle,leading to a more controlled flow in the mold.Numerical simulations were used to quantitatively analyze the magnetic and flow fields in a slab continuous casting system under EMSFN.Results indicate that EMSFN significantly stabilizes the outflow from the nozzle,with stability increasing with higher current intensity.At 10,000 Ampere-turns(At)of the coil,meniscus fluctuations were unstable.They stabilized at 13,000 At,with minimal changes observed beyond this point.The optimal current intensity for stable mold flow,at a casting speed of 1.56 m/min,is 13,000 At.These findings confirm the effectiveness of EMSFN in stabilizing the internal flow field of the slab mold and determining optimal operational current intensity.
基金supported by the Startup Foundation of Shenyang Agriculture University(No.X2023050)the Fundamental Research Funds for the Central Universities(No.N2209006)the National Natural Science Foundation of China(No.U22A20173).
文摘To address the current issues with the conventional slide gate system utilized in the steel teeming process,a unique electromagnetic induction controlled automated steel teeming(EICAST)technology has been developed.Cooling means of spiral coil in this technology is directly related to its service life.Firstly,heat transfer processes of air cooling and spray cooling were compared and analyzed.Secondly,the impacts of water temperature,water flow rate and air flow rate were examined in order to maximize the spray cooling effect.To maintain coil temperature at a low value consistently throughout the entire thermal cycle process of the ladle,a combined cooling mode was finally employed.Numerical simulation was applied to examine the coil temperature variation with different cooling systems and characteristics.Before coil operation,spray cooling is said to be more effective.By controlling the water flow rate and air flow rate,the spray cooling effect is enhanced.However,water temperature has little or no impact when using spray cooling.Air cooling during the secondary refining process and spray cooling prior to coil operation are combined to further lower coil temperature.When the direction of the spray cooling is from bottom to top,the coil temperature is lowered below 165℃.A practical induction coil cooling plan was provided for the EICAST technology’s production process.
基金Project (2009AA03Z534) supported by the Hi-tech Research and Development Program of China Project (2006CB605203) supported by National Basic Research Program of China
文摘A comprehensive mathematical model of annulus-electromagnetic direct chill （A-EMDC） casting of A357 aluminum alloy was established with corresponding experimental verification. The model was based on a combination of the commercial finite element package ANSYS and the commercial finite volume package FLUENT. The effects of structural parameters on fluid flow, temperature field and solidification during A-EMDC process were investigated numerically. The results show that structural parameters such as annulus gap width, annulus gap position, and centre pipe length influence the flow and temperature fields. The smaller the annulus gap width is, the more uniform the temperature is, and the smaller the temperature gradient is. With increasing the centre pipe length, the circular flow would decrease due to the dislocation of centre pipe. Specially, when the annulus gap is located at periphery of the billet, the temperature gradient of the longitudinal direction in the solidification region falls evidently.
基金Project(2005CB623707)supported by National Basic Research Project of China
文摘The effects of low frequency electromagnetic field on the macro-physical fields in the semi-continuous casting process of aluminum alloys and the microstructure and crack in the billets were studied and analyzed by the numerical and experimental methods.Comparison of the results for the macro-physical fields in the low frequency electromagnetic casting（LFEC） process with the conventional DC casting process indicates the following characters due to the application of electromagnetic field：an entirely changed direction and remarkably increased velocity of melt flow;a uniform distribution and a decreased gradient of temperature;elevated isothermal lines;a reduced sump depth;decreased stress and plastic deformation.Further,the microstructure of the billets is refined remarkably and the crack in the billets is eliminated in LFEC process because of modification of the macro-physical fields induced by the application of low frequency electromagnetic field.
基金Projects(51274054,U1332115,51271042,51375070,51401044)supported by the National Natural Science Foundation of ChinaProject(313011)supported by the Key Grant Project of Ministry of Education of China+4 种基金Project(2013A16GX110)supported by the Science and Technology Planning Project of Dalian,ChinaProject(2014M551075)supported by the China Postdoctoral Science FoundationProject supported by the Fundamental Research Funds for the Central Universities,China
文摘A modified horizontal continuous casting process under the electromagnetic field was proposed for preparing AA3003/ AA4045 clad composite hollow billets. To investigate the effect of electromagnetic field on this process, a comprehensive three-dimensional model was developed. Two cases with and without electromagnetic field were compared using the simulations. When rotating electromagnetic stirring is applied, the flow pattern of fluid melt is greatly modified; the mushy zone becomes much wider, the temperature profile becomes more uniform, and the solid fraction decreases for both the external and internal alloy melt layers. These modifications are beneficial for the formation of a bimetal interface and fine and uniform grain structure of the clad composite hollow billet. Experiments conducted using the same electrical and casting parameters as the simulations verify that under the electromagnetic field the microstructure of the clad composite hollow billet becomes fine and the diffusion of the elements at the interface is promoted.
基金supported by the National Natural Science Foundation of China(22265021,52231007,and 12327804)the Aeronautical Science Foundation of China(2020Z056056003)Jiangxi Provincial Natural Science Foundation(20232BAB212004).
文摘The precise tuning of magnetic nanoparticle size and magnetic domains,thereby shaping magnetic properties.However,the dynamic evolution mechanisms of magnetic domain configurations in relation to electromagnetic(EM)attenuation behavior remain poorly understood.To address this gap,a thermodynamically controlled periodic coordination strategy is proposed to achieve precise modulation of magnetic nanoparticle spacing.This approach unveils the evolution of magnetic domain configurations,progressing from individual to coupled and ultimately to crosslinked domain configurations.A unique magnetic coupling phenomenon surpasses the Snoek limit in low-frequency range,which is observed through micromagnetic simulation.The crosslinked magnetic configuration achieves effective low-frequency EM wave absorption at 3.68 GHz,encompassing nearly the entire C-band.This exceptional magnetic interaction significantly enhances radar camouflage and thermal insulation properties.Additionally,a robust gradient metamaterial design extends coverage across the full band(2–40 GHz),effectively mitigating the impact of EM pollution on human health and environment.This comprehensive study elucidates the evolution mechanisms of magnetic domain configurations,addresses gaps in dynamic magnetic modulation,and provides novel insights for the development of high-performance,low-frequency EM wave absorption materials.
基金This research was supported by Major State Basic Research Projects of China, Grant No.:G1999064905 and the National Natural Science Foundation of China, No.59974009.
文摘The relationship between electromagnetic frequency and microstructures of continuous casting aluminum alloys was studied. 7075 aluminum alloy ingot of 100 mm in diameter was produced by electromagnetic continuous casting process, the microstructures of as-cast ingot was examined by scanning electron microscopy (SEM) equipped with energy dispersive spectrometer (EDS). The results showed that electromagnetic frequency greatly influenced segregation and microstructures of as-cast ingot, and product quality can be guaranteed by the application of a proper frequency. Electromagnetic frequency plays a significant role in solute redistribution; low frequency is more efficient for promoting solution of alloying elements.
基金supported by the National Natural Science Foundation of China(No.50834009)the Key Project of the Ministry of Education of China(No.311014)the 111 Project of China(No.B07015)
文摘The grain refinement and macrosegregation control of GCrl5 bearing steel were investigated under a type of rarely-used electromagnetic stirring, vertical electromagnetic stirring （V-EMS）, in continuous casting. V-EMS can create an upward electromagnetic force and generate longitudinal loop convection, which ena- bles the better mixing of the upper part with the lower part of the liquid steel. The results showed that ap- plying V-EMS can enlarge the region of the equiaxed grain, decrease the secondary dendrite arm spacing （SDAS） and reduce the segregation of both carbon and sulfur. After applying V-EMS, liquid steel with a high solute concentration is brought to the dendrite tips, making the dendrite arms partially melt. The length of the dendrite fragment is approximately 1.8 mm, 10 to 12 times the SDAS. Upon increasing the amount of cooling water from 2.0 to 3.5 m3/h, the dendrite fragments exhibit an obvious aggregation fol- lowing V-EMS. Finally, a criterion for dendrite fragmentation under V-EMS was derived based on the dendrite fragmentation theory of Campanella et al.
基金financially supported by the National Natural Science Foundation of China (No. 50834009)the Key Project of the Ministry of Education of China (No. 311014)the 111 Project of China (No. B07015)
文摘Solidification cracking that occurs during continuous casting of 1Cr13 stainless steel was investigated with and without final elec- tromagnetic stirring （F-EMS）. The results show that cracks initiates and propagates along the grain boundaries where the elements of carbon and sulfur are enriched. The final stirrer should be appropriately placed at a location that is 7.5 m away from the meniscus, and the appropri- ate thickness of the liquid core in the stirring zone is 50 ram. As a stirring current of 250 A is imposed, it can promote colurnnar-equiaxed transition, decrease the secondary dendrite arm spacing, and reduce the segregation of both carbon and sulfur. F-EMS can effectively de- crease the amount of cracks in 1Cr13 stainless steel.
文摘The hot top EMC (electromagnetic casting) method was put forward, namely, the shape of top liquid column was formed by the hot top in the screen and the semi suspended liquid column was formed by the electromagnetic force nearby the liquid solid interface frontier. Using the numerical simulating technique, the temperature distribution was discussed, the effect of parameters such as upper conduct distance (UCD), cooling water rate of flow, pouring temperature and liquid column height on casting velocity were studied, the relationship among them was confirmed finally. According to the calculated results, the hot top EMC shaping system was designed and a lot of experiments were performed. The pure Al thin slabs of 480 mm×20 mm×850 mm were made successfully. The result showed that the casting velocity curve obtained experimentally almost coincides to the calculated one.
文摘The magnetic,heat transfer and flow phenomenon occurring in the continuous casting process under the mold electromagnetic stirring was further analyzed by solving the 3-D electromagnetic field mathematical model and flow solidification model with finite element method and finite volume method,respectively.The results indicate that the solidified shell thickness located in the effective stirring region fluctuates because of the unsteady scouring under the mold electromagnetic stirring.The maximum rotational velocity is a key parameter to the solidification of the billet when controlling the stirring intensity.When the rotational velocity reaches 0.32 m/s,the mush zone enlarges significantly and the solidification rate is further accelerated.The number of vortexes in the lower recirculation zone is not only two and depends on the stirring parameters.Besides,the secondary flow is closely associated with the solidification.Compared with the results of the model ignoring the influence of solidification on the flow of molten steel,the flow pattern within the lower recirculation region changes dramatically,and thus a coupling analysis of the flow,heat transfer,and solidification is essential when simulating the electromagnetic continuous casting process.
文摘In order to obtain cast metal of high quality, an investigation was carried out by simultaneous imposition of multi electromagnetic fields from the outside of a cold crucible copper mold. Sn 4.5%Pb as a simulator of high melting point metal was continuously cast under different conditions. The results show that multi electromagnetic fields can eliminate surface defects, and coarse columnar grains of the solidification structure is turned into equiaxed crystal with the increase of magnetic flux density. Moreover, finer equiaxed crystal structure is obtained when rapidly solidified sheet is fed into the mold during continuous casting.[
