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
A coupled computational model of molten steel within the mold was developed,encompassing electromagnetic fields,fluid flow,heat transfer,shell formation,stress,and strain.The model was verified through comparison with...A coupled computational model of molten steel within the mold was developed,encompassing electromagnetic fields,fluid flow,heat transfer,shell formation,stress,and strain.The model was verified through comparison with plant measurements,showing reasonable agreement in electromagnetic field distribution,solidification endpoint,and shell thickness.Results indicate that coordinating the submerged entry nozzle(SEN)and mold electromagnetic stirring(M-EMS)effectively regulates the solidification quality of the initial shell.Adjusting M-EMS current frequency changes the impact position of the molten steel jet from the four-port SEN,while increasing current intensity reduces the jet impact intensity.Adjusting the M-EMS parameters can enhance the initial shell uniformity.Furthermore,in areas directly impacted by the steel jet from the four-port SEN,a relationship between brittle temperature range(BTR)width and total mechanical strain was found,and the larger the BTR width,the smaller the corresponding total mechanical strain.The BTR width provides a discriminant method to avoid hot tearing.Appropriate M-EMS parameters are obtained and applied,and the plant trials show a significant improvement in hot tearing near the surface of round blooms.展开更多
Taking into account the characteristics of non-Newtonian fluids and the influence of latent heat of wax crystallization,this study establishes physical and mathematical models for the synergy of tubular heating and me...Taking into account the characteristics of non-Newtonian fluids and the influence of latent heat of wax crystallization,this study establishes physical and mathematical models for the synergy of tubular heating and mechanical stirring during the waxy crude oil heating process.Numerical calculations are conducted using the sliding grid technique and FVM.The focus of this study is on the impact of stirring rate(τ),horizontal deflection angle(θ1),vertical deflection angle(θ2),and stirring diameter(D)on the heating effect of crude oil.Our results show that asτincreases from 200 rpm to 500 rpm and D increases from 400 mm to 600 mm,there is an improvement in the average crude oil temperature and temperature uniformity.Additionally,heating efficiency increases by 0.5%and 1%,while the volume of the low-temperature region decreases by 57.01 m^(3) and 36.87 m3,respectively.Asθ1 andθ2 increase from 0°to 12°,the average crude oil temperature,temperature uniformity,and heating efficiency decrease,while the volume of the low-temperature region remains basically the same.Grey correlation analysis is used to rank the importance of stirring parameters in the following order:τ>θ1>θ2>D.Subsequently,multiple regression analysis is used to quantitatively describe the relationship between different stirring parameters and heat transfer evaluation indices through equations.Finally,based on entropy generation minimization,the stirring parameters with optimal heat transfer performance are obtained when τ=350 rpm,θ1=θ2=0°,and D=500 mm.展开更多
The Al-Mg_(2)Si in-situ composite is a lightweight material with great potential for application in fields such as automotive lightweighting,aerospace,and electronic components.In this research,the modification,semi-s...The Al-Mg_(2)Si in-situ composite is a lightweight material with great potential for application in fields such as automotive lightweighting,aerospace,and electronic components.In this research,the modification,semi-solid technology coupled with different types of electromagnetic stirring was applied to regulate the undesirable solidified dendritic microstructure and facilitate the composites’mechanical properties.The spheroidization and refinement of Mg_(2)Si andα-Al matrix in SM(semi-solid)+RES(rotate electromagnetic stirring)sample and SM+SHES(single winding helical electromagnetic stirring)sample are realized under the effect of fused dendrite arm,the decreased critical nucleate radius,and the increased nucleation rate and extra supercooling degree induced by electromagnetic stirring.The Mg_(2)Si phase in the SM+RES sample and SM+SHES sample is refined by 73.4%and 75.7%,respectively compared to the AC(as-cast)sample.Besides,the single winding electromagnetic stirring can lead to more homogeneously distributed physical fields,lower temperature gradient,and more significant mass transfer,mainly responsible for the more homogeneous distributed reinforced finer Mg_(2)Si particles in the SM+SHES sample.Moreover,both the tensile properties and hardness of modified semi-solid composites are improved through electromagnetic stirring.Compared with RES,the improvement effect of SHES is more excellent.The SM+SHES sample possesses the highest Brinell hardness(124.7 HB),and its quality index of tensile properties is 5.73%and 82.2%higher than that of the SM+RES and AC samples,respectively.展开更多
The rapid development of magnetic materials provides the possibility for the application of permanent magnet stirring(PMS).Numerical and experimental investigations were employed with respect to the solidification pro...The rapid development of magnetic materials provides the possibility for the application of permanent magnet stirring(PMS).Numerical and experimental investigations were employed with respect to the solidification process of the Al—2Sc alloy controlled by a novel PMS using NdFeB permanent magnets under various rotation speeds(0,50,100 and 150 r/min).The simulated results reveal that the maximum electromagnetic force increases proportionally from 4.14 to 12.39 kN/m^(3)and the maximum tangential velocity increases from 0.13 to 0.36 m/s when the rotation speed of PMS enhances from 50 to 150 r/min in the ingot melt.Besides,the experimental results demonstrate that PMS can achieve a uniform distribution of blocky Al_(3)Sc precipitated phase in the longitudinal direction under the impact of a forced fluid flow.Moreover,increasing rotation speed of PMS is beneficial to refining aluminum grain size significantly and decreasing the texture intensity in the alloy.In addition,the Brinell hardness of Al-2Sc alloy is increased by 33%to 27.8 HB and the tensile strength is enhanced by 34%-128.2 MPa,due to the improved distribution of the strengthening Al_(3)SC phase and the grain refinement of Al matrix under the impact of PMS.This work provides an effective application of NdFeB permanent magnets in the metal cast field.展开更多
A novel mechanical stirring-assisted double-melt in-situ reaction casting process was developed to prepare Cu-1TiB2(wt%)composites.The effects of preparation parameters(melting reaction temperature,stirring rate and s...A novel mechanical stirring-assisted double-melt in-situ reaction casting process was developed to prepare Cu-1TiB2(wt%)composites.The effects of preparation parameters(melting reaction temperature,stirring rate and stirring time)on the microstructure and properties of Cu-1TiB2 composites were investigated.The melt viscosity and particle motion during stirring process were analyzed.The strong turbulence and shear effects generated by mechanical stirring in the melt not only significantly improve the particle distribution but also contribute to adequate in-situ reactions and precise control of the chemical composition.The optimal preparation parameters were 1200℃,a stirring rate of 100 r·min^(−1) and a stirring time of 1 min.Combined with the cold rolling process,the tensile strength,elongation and electrical conductivity of the composite reached 475 MPa,6.0%and 88.4%IACS,respectively,which were significantly better than the composite prepared by manual stirring.The good plasticity is attributed to the uniform distribution of TiB_(2) particles,effectively retarding the crack propagation.The dispersion of particles promotes heterogeneous nucleation of Cu matrix and inhibits grain growth.On the other hand,dispersed particles contribute to grain shear fracture and dislocation multiplication during cold deformation.Therefore,the composite achieves higher dislocation strengthening and grain boundary strengthening.展开更多
The bottom blowing element is the key equipment to ensure the bottom blowing effect of the converter.Three types of bottom blowing elements,dispersive type(D1),double circular seam(D2)and straight cylinder type(D3),we...The bottom blowing element is the key equipment to ensure the bottom blowing effect of the converter.Three types of bottom blowing elements,dispersive type(D1),double circular seam(D2)and straight cylinder type(D3),were built,and the effects of bottom blowing element type on molten bath flow,wall erosion and furnace bottom erosion were simulated.It was found that when the bottom blowing elements of dispersive type(D1)and double circular seam(D2)were used,the dead zone area in the lower part of the molten bath was smaller,and the high-speed zone area was larger;therefore,the stirring effect on the bottom melt was better.When the straight cylinder type(D3)bottom blowing element was used,the gas penetrated the molten bath at a faster rate to reach the surface of molten bath and failed to disperse in the bottom molten bath,and the wall shear stress near the nozzle outlet was larger.When argon was blown by three different bottom blowing elements,the area of the wall shear stress greater than 3 Pa was 4.8,5.6 and 8.7 cm2,respectively,within 0.2 m of the bottom blowing nozzle outlet.展开更多
Electromagnetic stirring is one of the widely applied techniques to modify the quality of casting billets.Different from conventional rotate stirring,the helical stirring is more professional in assisting multi-dimens...Electromagnetic stirring is one of the widely applied techniques to modify the quality of casting billets.Different from conventional rotate stirring,the helical stirring is more professional in assisting multi-dimensional flow of molten metal and eliminating solidification defects.In this study,the single-winding helical stirring(SWHS)was introduced,offering advantages such as smaller volume and lower electromagnetic shielding compared to traditional helical stirring methods.Following a comprehensive numerical simulation,the stirring parameters of SWHS were adjusted to yoke inclination angle of 43°and frequency of 12 Hz.The higher electromagnetic force and flow velocity in drawing direction,as well as the lower temperature gradient induced by the SWHS,are positive factors for homogeneous solidification of billet.The experimental results on Al-8%Si alloy and 0.4%C-1.1%Mn steel demonstrate that compared to rotate stirring,the SWHS process can induce better billet quality and is more effective in accelerating the equiaxed expansion and reducing element segregation.The SWHS process can enhance the equiaxed ratio of the billet by 58.3%and reduce segregation degree of carbon element by 10.97%.Consequently,SWHS holds great promise as a potential approach for improving the quality of continuous casting billets.展开更多
A surface Ti-WC composite was fabricated on CP-Ti by surface friction stirring(SFS)using a pinless WC-Cotool at a processing window of 800−2500 r/min and 8−50 mm/min.At 1600 r/min-50 mm/min,a defect-free compositelaye...A surface Ti-WC composite was fabricated on CP-Ti by surface friction stirring(SFS)using a pinless WC-Cotool at a processing window of 800−2500 r/min and 8−50 mm/min.At 1600 r/min-50 mm/min,a defect-free compositelayer with an average hardness of~HV 1170 is formed.The hardness was increased by WC and TiN reinforcingparticles,dissolved Co atoms in Ti,and the formation of ultrafine grains.WC particles were incorporated into the Tisubstrate owing to the intense frictional interaction/heating at the tool-plate interface(~1000℃),which led to strengthloss and wear of the tool.The Williamson-Hall analysis of the XRD peaks of the SFSed sample confirmed a significantlysmall crystallite size(~100 nm).Wear tests showed that the wear resistance of the composite structure was about 4.5times higher than that of the CP-Ti.Friction analysis revealed a significant reduction in average value and fluctuations ofthe friction coefficient.展开更多
A three-dimensional mathematical model coupling electromagnetic,flow,heat transfer,and solidification has been developed to investigate the effect of eccentric mold electromagnetic stirring(EM-EMS)on the flow and heat...A three-dimensional mathematical model coupling electromagnetic,flow,heat transfer,and solidification has been developed to investigate the effect of eccentric mold electromagnetic stirring(EM-EMS)on the flow and heat transfer of molten steel in round blooms with different cross sections.The uneven distribution of the flow field caused by EM-EMS was improved by changing the straight submerged entry nozzle(SEN)to a four-port SEN.The symmetry index was determined by the velocity distributions on the left and right sides of the center cross section of mold electromagnetic stirring(M-EMS),which quantitatively evaluated the symmetry of EM-EMS on the flow field.In the presence of EM-EMS,the maximum temperature difference ofϕ500 mm andϕ650 mm round blooms between the inner and outer curves amounted to 63 and 26 K,respectively.The maximum distinction between the solidified shells in the inner and outer curves was 11.5 and 5.3 mm,respectively.After using the four-port SEN,the temperature and the shell distribution on the inner and outer curves for theϕ500 mm round bloom were almost the same.The symmetry indices ofϕ500 mm andϕ650 mm round blooms were increased from 0.55 and 0.70 to 0.77 and 0.87,respectively.The four-port SEN can be used to mitigate the negative impact of EM-EMS on the steel flow field.展开更多
In gas injection refining processes,wide dispersion of small bubbles in the bath is indispensable for high refining efficiency.Eccentric mechanical stirring with unidirectional impeller rotation was tested using a wat...In gas injection refining processes,wide dispersion of small bubbles in the bath is indispensable for high refining efficiency.Eccentric mechanical stirring with unidirectional impeller rotation was tested using a water model for pursuing better bubble disintegration and dispersion.Effects of various factors on bubble disintegration and dispersion were investigated.These factors were stirring mode,eccentricity and rotation speed,nozzle structure,nozzle immersion depth,and gas flow rate.Gas injection from a nozzle at the end of the impeller shaft and from an immersed lance was studied.Under eccentric stirring,a vortex was formed away from the shaft.Small bubbles were produced in the strong turbulence or high shear stress field near the rotating impeller and moved in the direction to the vortex keeping up with the macroscopic flow induced by the mechanical stirring.Thus small bubbles could disperse widely in the bath under eccentric stirring with unidirectional rotation.展开更多
In the contemporary electric arc furnace(EAF)steelmaking industry,increasing contents and temperature homogenization via fluid flow stirring is found to be an effective method of improving production quality and smelt...In the contemporary electric arc furnace(EAF)steelmaking industry,increasing contents and temperature homogenization via fluid flow stirring is found to be an effective method of improving production quality and smelting efficiency.It is a trend for different factories with bowl-shaped furnaces to apply the bath fluidity enhancement technology.EAF has plenty of advantages in modern steelmaking industry,and the improvements on the EAF steelmaking process have come up with two major tasks,namely reduction in energy consumption and tap-to-tap time.The latter task requires an essential understanding of every phase in EAF steelmaking process.The flat bath phase with poor bath fluid flow was crucial to the product quality and metallurgical efficiency considering EAF’s bowl-shaped structure.The research of three stirring bath methods,oxygen jets injection,electromagnetic stirring,and bottom blowing,were introduced,and then the detailed parameters of each method with their influences on molten bath fluidity were presented.展开更多
Metal foams are usually used as light structural/functional materials.The nucleation,evolution and the solidification behavior of the metal foams can be influenced by the stining mode and the foaming parameters.In thi...Metal foams are usually used as light structural/functional materials.The nucleation,evolution and the solidification behavior of the metal foams can be influenced by the stining mode and the foaming parameters.In this paper,the effects of electromagnetic stirring on metal foaming process were investigated.Comparative tests were carried out and the optimized parameters of the stirring modes were discussed.The stirring effects of the spiral electromagnetic field are better than the travelling wave electromagnetic field.The effects of the spiral electromagnetic-mechanical combined stirring are better than the situations of the single electromagnetic stirring or the single mechanical stirring.展开更多
The effects of pouring temperature, short electromagnetic stirring with low strength and then soaking treatment on the microstructure of AISi7Mg alloy were investigated. The results show that if AlSi7Mg alloy is poure...The effects of pouring temperature, short electromagnetic stirring with low strength and then soaking treatment on the microstructure of AISi7Mg alloy were investigated. The results show that if AlSi7Mg alloy is poured at 630 or 650℃ and meanwhile stirred by an electromagnetic field at a low power for a short time, the pouring process can be easily controlled and most solidified primary α-Al grains become spherical and only a few of them are rosette-like. Weak electromagnetic stirring makes the temperature field more homogeneous and makes the primary α-Al grains disperse in a larger region, which leads to the spherical microstructures of primary α-Al grains. When the AISi7Mg alloy is soaked or reheated at the semisolid state, the primary α-Al grains ripen further and they become more spherical, which is favorable to the semi-solid forming of AlSi7Mg alloy.展开更多
The semi-solid slurry of a hypoeutectic Al-Si alloy was manufactured by low superheat pouring and weak electromagnetic stirring. The effects of pouting temperature and stirring power on the semi-solid slurry were inve...The semi-solid slurry of a hypoeutectic Al-Si alloy was manufactured by low superheat pouring and weak electromagnetic stirring. The effects of pouting temperature and stirring power on the semi-solid slurry were investigated. The results indicated that the semi-solid slurry to satisfy rheocasting can be manufactured by low superheat pouring and weak electromagnetic stirring. The pouring temperature （or superheat） and the stirring power remarkably affected the morphology of primary α-Al and the size of primary α-Al, and there is no obvious effect of stirring time on primary α-Al. Compared with the samples made by low superheat pouring with no stirring, the nucleation rate, particle morphology and grain size of primary α-Al in A356 were markedly improved by low superheat pouring and weak electromagnetic stirring. On the condition of weak electromagnetic stirring, the pouring temperature with low superheat can be suitably raised to reach the effectiveness obtained from the lower pouring temperature without stirring.展开更多
To investigate the possibility of substituting the mechanical stirring system with electromagnetic stirring (EMS) system for aluminum rheo die-casting, the EMS under the different stirring cooling conditions was carri...To investigate the possibility of substituting the mechanical stirring system with electromagnetic stirring (EMS) system for aluminum rheo die-casting, the EMS under the different stirring cooling conditions was carried out. It was found that in the early period of solidification, the dendrite breakages led to a fine primary phase. When dendrites grew coarsely, the effect of ripening on grain size overwhelmed that of dendrite breakage. It was also found that the high cooling rate favored large nucleation rate, and led to a fine primary phase. But high cooling rate also made the growth rate of the dendrite arm, which prevented the dendrite arm from being sheared off. Therefore there were a suitable stirring time and suitable cooling rate to obtain the best rheo die-casting structure. Qualified semisolid A356 aluminum alloy was successfully manufactured with short time EMS.展开更多
The semi-solid slurry of hypoeutectic Al-Si alloy was manufactured by low superheat pouring and weak electromagnetic stirring. The effects of pouring temperature and stirring power on the semi-solid slurry making proc...The semi-solid slurry of hypoeutectic Al-Si alloy was manufactured by low superheat pouring and weak electromagnetic stirring. The effects of pouring temperature and stirring power on the semi-solid slurry making process were investigated. The results indicate that the semi-solid slurry to satisfy rheocasting requirement can be made by a combination of low superheat pouring and weak electromagnetic stirring. The pouring temperature (or superheat) and the stirring power significantly affect the morphology and the size of primary α-Al, while there is no obvious effect of the stirring time on primary α-Al. Compared with the samples made by low superheat pouring without stirring, the nucleation rate, particle morphology and grain size of primary α-Al in A356 Al alloy are markedly improved by a process of applying both low superheat pouring and weak electromagnetic stirring. Under the condition of weak electromagnetic stirring applied, the pouring temperature with low superheat can be equivalently to reach the effectiveness obtained from the even lower pouring temperature without stirring.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
The semi-solid slurry of A356 alloy, which is grain-refined by Al-Ti-B master alloy, is prepared by low superheat pouring and slight electromagnetic stirring. The effects of grain refining on the morphology and the gr...The semi-solid slurry of A356 alloy, which is grain-refined by Al-Ti-B master alloy, is prepared by low superheat pouring and slight electromagnetic stirring. The effects of grain refining on the morphology and the grain size of the primary α phase in the slurry manufactured are researched. The results indicate that the slurry with particle-like and rosette-like primary α phases can be prepared by low superheat pouring and slight electromagnetic stirring from liquid A356 alloy grain-refined, in which the pouring temperature can be suitably raised. Compared with the A356 samples without grain refining, the grain size and particle morphology of primary α phase as well as the distribution of the grain with particle-like or rosette-like along radial in the ingot in A356 are markedly improved by grain refining.展开更多
The effect of electromagnetic stirring on molten steel flow and heat transfer in a 260 mm× 300 mm bloom mold was investigated by using a method combining both finite element method and finite volume method. The s...The effect of electromagnetic stirring on molten steel flow and heat transfer in a 260 mm× 300 mm bloom mold was investigated by using a method combining both finite element method and finite volume method. The simu lation results related to magnetic fields were consistent with the onsite measured data. The magnetic flux density in creased with increasing the current intensity but decreased with increasing the current frequency. Electromagnetic stirring caused molten steel to flow with rotation on a horizontal section and two sets of recirculation regions with opposite fellow directions in a longitudinal section formed. The maximum tangential velocity increased with increasing the current intensity and frequency. Furthermore, the superheat degree of the molten steel on the outlet cross section of the mold decreased with increasing the current intensity. growth zone of solidified shell in the effective stirring zone. bearing steel, the appropriate values of current intensity and to be 300 A and 3 Hz, respectively. Electromagnetic stirring caused the emergence of a zero For the 260 mm N 300 mm bloom continuous caster of current frequency of electromagnetic stirring were found展开更多
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 Zhongyuan Special Steel Equipment Manufacturing Co.,Ltd.,China.
文摘A coupled computational model of molten steel within the mold was developed,encompassing electromagnetic fields,fluid flow,heat transfer,shell formation,stress,and strain.The model was verified through comparison with plant measurements,showing reasonable agreement in electromagnetic field distribution,solidification endpoint,and shell thickness.Results indicate that coordinating the submerged entry nozzle(SEN)and mold electromagnetic stirring(M-EMS)effectively regulates the solidification quality of the initial shell.Adjusting M-EMS current frequency changes the impact position of the molten steel jet from the four-port SEN,while increasing current intensity reduces the jet impact intensity.Adjusting the M-EMS parameters can enhance the initial shell uniformity.Furthermore,in areas directly impacted by the steel jet from the four-port SEN,a relationship between brittle temperature range(BTR)width and total mechanical strain was found,and the larger the BTR width,the smaller the corresponding total mechanical strain.The BTR width provides a discriminant method to avoid hot tearing.Appropriate M-EMS parameters are obtained and applied,and the plant trials show a significant improvement in hot tearing near the surface of round blooms.
基金supported by the National Natural Science Foundation of China(Grant no.52304065)China Postdoctoral Science Foundation(Grant no.2022MD723759).
文摘Taking into account the characteristics of non-Newtonian fluids and the influence of latent heat of wax crystallization,this study establishes physical and mathematical models for the synergy of tubular heating and mechanical stirring during the waxy crude oil heating process.Numerical calculations are conducted using the sliding grid technique and FVM.The focus of this study is on the impact of stirring rate(τ),horizontal deflection angle(θ1),vertical deflection angle(θ2),and stirring diameter(D)on the heating effect of crude oil.Our results show that asτincreases from 200 rpm to 500 rpm and D increases from 400 mm to 600 mm,there is an improvement in the average crude oil temperature and temperature uniformity.Additionally,heating efficiency increases by 0.5%and 1%,while the volume of the low-temperature region decreases by 57.01 m^(3) and 36.87 m3,respectively.Asθ1 andθ2 increase from 0°to 12°,the average crude oil temperature,temperature uniformity,and heating efficiency decrease,while the volume of the low-temperature region remains basically the same.Grey correlation analysis is used to rank the importance of stirring parameters in the following order:τ>θ1>θ2>D.Subsequently,multiple regression analysis is used to quantitatively describe the relationship between different stirring parameters and heat transfer evaluation indices through equations.Finally,based on entropy generation minimization,the stirring parameters with optimal heat transfer performance are obtained when τ=350 rpm,θ1=θ2=0°,and D=500 mm.
基金supported by the National Key R&D Projects(No.2021YFB3702000)the Institute Projects of Ansteel Beijing Research Institute(No.2023BJC-06)the Regional Company Projects in Ansteel Beijing Research Institute(No.2022BJB-18BG&No.2022BJB-13GF).
文摘The Al-Mg_(2)Si in-situ composite is a lightweight material with great potential for application in fields such as automotive lightweighting,aerospace,and electronic components.In this research,the modification,semi-solid technology coupled with different types of electromagnetic stirring was applied to regulate the undesirable solidified dendritic microstructure and facilitate the composites’mechanical properties.The spheroidization and refinement of Mg_(2)Si andα-Al matrix in SM(semi-solid)+RES(rotate electromagnetic stirring)sample and SM+SHES(single winding helical electromagnetic stirring)sample are realized under the effect of fused dendrite arm,the decreased critical nucleate radius,and the increased nucleation rate and extra supercooling degree induced by electromagnetic stirring.The Mg_(2)Si phase in the SM+RES sample and SM+SHES sample is refined by 73.4%and 75.7%,respectively compared to the AC(as-cast)sample.Besides,the single winding electromagnetic stirring can lead to more homogeneously distributed physical fields,lower temperature gradient,and more significant mass transfer,mainly responsible for the more homogeneous distributed reinforced finer Mg_(2)Si particles in the SM+SHES sample.Moreover,both the tensile properties and hardness of modified semi-solid composites are improved through electromagnetic stirring.Compared with RES,the improvement effect of SHES is more excellent.The SM+SHES sample possesses the highest Brinell hardness(124.7 HB),and its quality index of tensile properties is 5.73%and 82.2%higher than that of the SM+RES and AC samples,respectively.
基金Project supported by the Natural Science Foundation of Hunan Province(2024JJ4056)the Key Project of Guangxi Zhuang Autonomous Region(AB22080089)the Government of Chongzuo,Guangxi Zhuang Autonomous Region(FA20210716)。
文摘The rapid development of magnetic materials provides the possibility for the application of permanent magnet stirring(PMS).Numerical and experimental investigations were employed with respect to the solidification process of the Al—2Sc alloy controlled by a novel PMS using NdFeB permanent magnets under various rotation speeds(0,50,100 and 150 r/min).The simulated results reveal that the maximum electromagnetic force increases proportionally from 4.14 to 12.39 kN/m^(3)and the maximum tangential velocity increases from 0.13 to 0.36 m/s when the rotation speed of PMS enhances from 50 to 150 r/min in the ingot melt.Besides,the experimental results demonstrate that PMS can achieve a uniform distribution of blocky Al_(3)Sc precipitated phase in the longitudinal direction under the impact of a forced fluid flow.Moreover,increasing rotation speed of PMS is beneficial to refining aluminum grain size significantly and decreasing the texture intensity in the alloy.In addition,the Brinell hardness of Al-2Sc alloy is increased by 33%to 27.8 HB and the tensile strength is enhanced by 34%-128.2 MPa,due to the improved distribution of the strengthening Al_(3)SC phase and the grain refinement of Al matrix under the impact of PMS.This work provides an effective application of NdFeB permanent magnets in the metal cast field.
基金supported by the National Natural Science Foundation of China(Nos.U2202255 and 52371038)the Science and Technology Innovation Program of Hunan Province(No.2023RC1019).
文摘A novel mechanical stirring-assisted double-melt in-situ reaction casting process was developed to prepare Cu-1TiB2(wt%)composites.The effects of preparation parameters(melting reaction temperature,stirring rate and stirring time)on the microstructure and properties of Cu-1TiB2 composites were investigated.The melt viscosity and particle motion during stirring process were analyzed.The strong turbulence and shear effects generated by mechanical stirring in the melt not only significantly improve the particle distribution but also contribute to adequate in-situ reactions and precise control of the chemical composition.The optimal preparation parameters were 1200℃,a stirring rate of 100 r·min^(−1) and a stirring time of 1 min.Combined with the cold rolling process,the tensile strength,elongation and electrical conductivity of the composite reached 475 MPa,6.0%and 88.4%IACS,respectively,which were significantly better than the composite prepared by manual stirring.The good plasticity is attributed to the uniform distribution of TiB_(2) particles,effectively retarding the crack propagation.The dispersion of particles promotes heterogeneous nucleation of Cu matrix and inhibits grain growth.On the other hand,dispersed particles contribute to grain shear fracture and dislocation multiplication during cold deformation.Therefore,the composite achieves higher dislocation strengthening and grain boundary strengthening.
基金funded by the Joint Fund Project of Shaanxi(Grant No.2021JLM-32)the General Project of National Natural Science Foundation of China(Grant No.52374346).
文摘The bottom blowing element is the key equipment to ensure the bottom blowing effect of the converter.Three types of bottom blowing elements,dispersive type(D1),double circular seam(D2)and straight cylinder type(D3),were built,and the effects of bottom blowing element type on molten bath flow,wall erosion and furnace bottom erosion were simulated.It was found that when the bottom blowing elements of dispersive type(D1)and double circular seam(D2)were used,the dead zone area in the lower part of the molten bath was smaller,and the high-speed zone area was larger;therefore,the stirring effect on the bottom melt was better.When the straight cylinder type(D3)bottom blowing element was used,the gas penetrated the molten bath at a faster rate to reach the surface of molten bath and failed to disperse in the bottom molten bath,and the wall shear stress near the nozzle outlet was larger.When argon was blown by three different bottom blowing elements,the area of the wall shear stress greater than 3 Pa was 4.8,5.6 and 8.7 cm2,respectively,within 0.2 m of the bottom blowing nozzle outlet.
基金financially supported by the National Key R&D Projects(No.2021YFB3702000)the Regional Company Projects in Ansteel Beijing Research Institute(No.2022BJB07GF&No.2022BJB-13GF)。
文摘Electromagnetic stirring is one of the widely applied techniques to modify the quality of casting billets.Different from conventional rotate stirring,the helical stirring is more professional in assisting multi-dimensional flow of molten metal and eliminating solidification defects.In this study,the single-winding helical stirring(SWHS)was introduced,offering advantages such as smaller volume and lower electromagnetic shielding compared to traditional helical stirring methods.Following a comprehensive numerical simulation,the stirring parameters of SWHS were adjusted to yoke inclination angle of 43°and frequency of 12 Hz.The higher electromagnetic force and flow velocity in drawing direction,as well as the lower temperature gradient induced by the SWHS,are positive factors for homogeneous solidification of billet.The experimental results on Al-8%Si alloy and 0.4%C-1.1%Mn steel demonstrate that compared to rotate stirring,the SWHS process can induce better billet quality and is more effective in accelerating the equiaxed expansion and reducing element segregation.The SWHS process can enhance the equiaxed ratio of the billet by 58.3%and reduce segregation degree of carbon element by 10.97%.Consequently,SWHS holds great promise as a potential approach for improving the quality of continuous casting billets.
文摘A surface Ti-WC composite was fabricated on CP-Ti by surface friction stirring(SFS)using a pinless WC-Cotool at a processing window of 800−2500 r/min and 8−50 mm/min.At 1600 r/min-50 mm/min,a defect-free compositelayer with an average hardness of~HV 1170 is formed.The hardness was increased by WC and TiN reinforcingparticles,dissolved Co atoms in Ti,and the formation of ultrafine grains.WC particles were incorporated into the Tisubstrate owing to the intense frictional interaction/heating at the tool-plate interface(~1000℃),which led to strengthloss and wear of the tool.The Williamson-Hall analysis of the XRD peaks of the SFSed sample confirmed a significantlysmall crystallite size(~100 nm).Wear tests showed that the wear resistance of the composite structure was about 4.5times higher than that of the CP-Ti.Friction analysis revealed a significant reduction in average value and fluctuations ofthe friction coefficient.
基金supported by the National Natural Science Foundation of China(No.52074207).
文摘A three-dimensional mathematical model coupling electromagnetic,flow,heat transfer,and solidification has been developed to investigate the effect of eccentric mold electromagnetic stirring(EM-EMS)on the flow and heat transfer of molten steel in round blooms with different cross sections.The uneven distribution of the flow field caused by EM-EMS was improved by changing the straight submerged entry nozzle(SEN)to a four-port SEN.The symmetry index was determined by the velocity distributions on the left and right sides of the center cross section of mold electromagnetic stirring(M-EMS),which quantitatively evaluated the symmetry of EM-EMS on the flow field.In the presence of EM-EMS,the maximum temperature difference ofϕ500 mm andϕ650 mm round blooms between the inner and outer curves amounted to 63 and 26 K,respectively.The maximum distinction between the solidified shells in the inner and outer curves was 11.5 and 5.3 mm,respectively.After using the four-port SEN,the temperature and the shell distribution on the inner and outer curves for theϕ500 mm round bloom were almost the same.The symmetry indices ofϕ500 mm andϕ650 mm round blooms were increased from 0.55 and 0.70 to 0.77 and 0.87,respectively.The four-port SEN can be used to mitigate the negative impact of EM-EMS on the steel flow field.
基金Projects (50974035,51074047) supported by the National Natural Science Foundation of ChinaProject (20090407) supported by the Doctoral Fund of Ministry of Education,ChinaProject (200921007) supported by Liaoning Key Science and Technology,China
文摘In gas injection refining processes,wide dispersion of small bubbles in the bath is indispensable for high refining efficiency.Eccentric mechanical stirring with unidirectional impeller rotation was tested using a water model for pursuing better bubble disintegration and dispersion.Effects of various factors on bubble disintegration and dispersion were investigated.These factors were stirring mode,eccentricity and rotation speed,nozzle structure,nozzle immersion depth,and gas flow rate.Gas injection from a nozzle at the end of the impeller shaft and from an immersed lance was studied.Under eccentric stirring,a vortex was formed away from the shaft.Small bubbles were produced in the strong turbulence or high shear stress field near the rotating impeller and moved in the direction to the vortex keeping up with the macroscopic flow induced by the mechanical stirring.Thus small bubbles could disperse widely in the bath under eccentric stirring with unidirectional rotation.
基金the National Natural Science Foundation of China(No.51804345)is gratefully acknowledged.
文摘In the contemporary electric arc furnace(EAF)steelmaking industry,increasing contents and temperature homogenization via fluid flow stirring is found to be an effective method of improving production quality and smelting efficiency.It is a trend for different factories with bowl-shaped furnaces to apply the bath fluidity enhancement technology.EAF has plenty of advantages in modern steelmaking industry,and the improvements on the EAF steelmaking process have come up with two major tasks,namely reduction in energy consumption and tap-to-tap time.The latter task requires an essential understanding of every phase in EAF steelmaking process.The flat bath phase with poor bath fluid flow was crucial to the product quality and metallurgical efficiency considering EAF’s bowl-shaped structure.The research of three stirring bath methods,oxygen jets injection,electromagnetic stirring,and bottom blowing,were introduced,and then the detailed parameters of each method with their influences on molten bath fluidity were presented.
基金Item Sponsored by the Program of New Century Excellent Talents of the Ministry of Education of China (NCET-08-0080) the Fundamental Research Funds for the Central Universities (DUT11ZD115) the"Liaoning BaiQianWan Talents Program" (2011921065)
文摘Metal foams are usually used as light structural/functional materials.The nucleation,evolution and the solidification behavior of the metal foams can be influenced by the stining mode and the foaming parameters.In this paper,the effects of electromagnetic stirring on metal foaming process were investigated.Comparative tests were carried out and the optimized parameters of the stirring modes were discussed.The stirring effects of the spiral electromagnetic field are better than the travelling wave electromagnetic field.The effects of the spiral electromagnetic-mechanical combined stirring are better than the situations of the single electromagnetic stirring or the single mechanical stirring.
基金The work was supported by the National Hitech Research Foundation of China under grant No. G2002AA336080 by the National Natural Science Foundation of China under grant No. 50374012.
文摘The effects of pouring temperature, short electromagnetic stirring with low strength and then soaking treatment on the microstructure of AISi7Mg alloy were investigated. The results show that if AlSi7Mg alloy is poured at 630 or 650℃ and meanwhile stirred by an electromagnetic field at a low power for a short time, the pouring process can be easily controlled and most solidified primary α-Al grains become spherical and only a few of them are rosette-like. Weak electromagnetic stirring makes the temperature field more homogeneous and makes the primary α-Al grains disperse in a larger region, which leads to the spherical microstructures of primary α-Al grains. When the AISi7Mg alloy is soaked or reheated at the semisolid state, the primary α-Al grains ripen further and they become more spherical, which is favorable to the semi-solid forming of AlSi7Mg alloy.
基金The project was financially supported by the Hi-tech Research and Development Program of China (No. G2002AA336080) and the National Natural Science Foundation of China (No. 50374012)
文摘The semi-solid slurry of a hypoeutectic Al-Si alloy was manufactured by low superheat pouring and weak electromagnetic stirring. The effects of pouting temperature and stirring power on the semi-solid slurry were investigated. The results indicated that the semi-solid slurry to satisfy rheocasting can be manufactured by low superheat pouring and weak electromagnetic stirring. The pouring temperature （or superheat） and the stirring power remarkably affected the morphology of primary α-Al and the size of primary α-Al, and there is no obvious effect of stirring time on primary α-Al. Compared with the samples made by low superheat pouring with no stirring, the nucleation rate, particle morphology and grain size of primary α-Al in A356 were markedly improved by low superheat pouring and weak electromagnetic stirring. On the condition of weak electromagnetic stirring, the pouring temperature with low superheat can be suitably raised to reach the effectiveness obtained from the lower pouring temperature without stirring.
文摘To investigate the possibility of substituting the mechanical stirring system with electromagnetic stirring (EMS) system for aluminum rheo die-casting, the EMS under the different stirring cooling conditions was carried out. It was found that in the early period of solidification, the dendrite breakages led to a fine primary phase. When dendrites grew coarsely, the effect of ripening on grain size overwhelmed that of dendrite breakage. It was also found that the high cooling rate favored large nucleation rate, and led to a fine primary phase. But high cooling rate also made the growth rate of the dendrite arm, which prevented the dendrite arm from being sheared off. Therefore there were a suitable stirring time and suitable cooling rate to obtain the best rheo die-casting structure. Qualified semisolid A356 aluminum alloy was successfully manufactured with short time EMS.
基金The paper is supported by the Hi-tech Research and Develop-ment Program of China (Authorized No.: G2002AA336080), andthe National Natural Science Foundation of China (AuthorizedNo.: 50374012).
文摘The semi-solid slurry of hypoeutectic Al-Si alloy was manufactured by low superheat pouring and weak electromagnetic stirring. The effects of pouring temperature and stirring power on the semi-solid slurry making process were investigated. The results indicate that the semi-solid slurry to satisfy rheocasting requirement can be made by a combination of low superheat pouring and weak electromagnetic stirring. The pouring temperature (or superheat) and the stirring power significantly affect the morphology and the size of primary α-Al, while there is no obvious effect of the stirring time on primary α-Al. Compared with the samples made by low superheat pouring without stirring, the nucleation rate, particle morphology and grain size of primary α-Al in A356 Al alloy are markedly improved by a process of applying both low superheat pouring and weak electromagnetic stirring. Under the condition of weak electromagnetic stirring applied, the pouring temperature with low superheat can be equivalently to reach the effectiveness obtained from the even lower pouring temperature without stirring.
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.
基金financially supported by National High Technical Research and Development Program of China(No.G2002AA336080)National Natural Science Foundation of China(No.50374012)Natural Science Foundation of Jiangxi Province(No.0650047).
文摘The semi-solid slurry of A356 alloy, which is grain-refined by Al-Ti-B master alloy, is prepared by low superheat pouring and slight electromagnetic stirring. The effects of grain refining on the morphology and the grain size of the primary α phase in the slurry manufactured are researched. The results indicate that the slurry with particle-like and rosette-like primary α phases can be prepared by low superheat pouring and slight electromagnetic stirring from liquid A356 alloy grain-refined, in which the pouring temperature can be suitably raised. Compared with the A356 samples without grain refining, the grain size and particle morphology of primary α phase as well as the distribution of the grain with particle-like or rosette-like along radial in the ingot in A356 are markedly improved by grain refining.
基金Sponsored by National Natural Science Foundation of China(51074023)
文摘The effect of electromagnetic stirring on molten steel flow and heat transfer in a 260 mm× 300 mm bloom mold was investigated by using a method combining both finite element method and finite volume method. The simu lation results related to magnetic fields were consistent with the onsite measured data. The magnetic flux density in creased with increasing the current intensity but decreased with increasing the current frequency. Electromagnetic stirring caused molten steel to flow with rotation on a horizontal section and two sets of recirculation regions with opposite fellow directions in a longitudinal section formed. The maximum tangential velocity increased with increasing the current intensity and frequency. Furthermore, the superheat degree of the molten steel on the outlet cross section of the mold decreased with increasing the current intensity. growth zone of solidified shell in the effective stirring zone. bearing steel, the appropriate values of current intensity and to be 300 A and 3 Hz, respectively. Electromagnetic stirring caused the emergence of a zero For the 260 mm N 300 mm bloom continuous caster of current frequency of electromagnetic stirring were found
