Modelling macrosegregation modification in dc casting of aluminium alloys in sheet ingots accounting for inlet melt flow, equiaxed grain morphology and transport
Macrosegregation is a severe defect present in direct-chill (DC) cast aluminium ingots and billets. In the recent years, experimental studies were conducted to modify and to an extent optimize macrosegregation formation by modifying the inlet melt flow. Due to several limitations, the grain settling...
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| creator | Pakanati, A M'Hamdi, M Combeau, H Založnik, M |
| description | Macrosegregation is a severe defect present in direct-chill (DC) cast aluminium ingots and billets. In the recent years, experimental studies were conducted to modify and to an extent optimize macrosegregation formation by modifying the inlet melt flow. Due to several limitations, the grain settling behavior and corresponding liquid flow pattern is difficult to analyze using experiments. Simulations on the other hand can provide this insight. However, conducting 2D sheet ingot simulations, as has been previously done, provides an incomplete description of flow pattern. To avoid this and as a first qualitative study, full scale 3D sheet ingot simulation results with two different inlets are presented in this paper. A simplified three-phase multiscale solidification model accounting for solidification shrinkage, natural convection and equiaxed grain growth and transport is used to conduct this study. We show that modification of inlet flow results in modification of grain settling and eventually leading to modification of macrosegregation. The impact of grain morphology is also additionally analyzed. |
| doi_str_mv | 10.1088/1757-899X/861/1/012040 |
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In the recent years, experimental studies were conducted to modify and to an extent optimize macrosegregation formation by modifying the inlet melt flow. Due to several limitations, the grain settling behavior and corresponding liquid flow pattern is difficult to analyze using experiments. Simulations on the other hand can provide this insight. However, conducting 2D sheet ingot simulations, as has been previously done, provides an incomplete description of flow pattern. To avoid this and as a first qualitative study, full scale 3D sheet ingot simulation results with two different inlets are presented in this paper. A simplified three-phase multiscale solidification model accounting for solidification shrinkage, natural convection and equiaxed grain growth and transport is used to conduct this study. We show that modification of inlet flow results in modification of grain settling and eventually leading to modification of macrosegregation. The impact of grain morphology is also additionally analyzed.</description><identifier>ISSN: 1757-8981</identifier><identifier>EISSN: 1757-899X</identifier><identifier>DOI: 10.1088/1757-899X/861/1/012040</identifier><language>eng</language><publisher>Bristol: IOP Publishing</publisher><subject>Aluminum base alloys ; Billet casting ; Casting alloys ; Chill casting ; Computational fluid dynamics ; Direct chill casting ; Engineering Sciences ; Flow distribution ; Free convection ; Grain growth ; Ingot casting ; Ingots ; Inlet flow ; Inlets ; Liquid flow ; Materials ; Morphology ; Pattern analysis ; Reactive fluid environment ; Settling ; Simulation ; Solidification</subject><ispartof>IOP conference series. Materials Science and Engineering, 2020-05, Vol.861 (1), p.12040</ispartof><rights>Published under licence by IOP Publishing Ltd</rights><rights>2020. This work is published under http://creativecommons.org/licenses/by/3.0/ (the “License”). 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Materials Science and Engineering</title><addtitle>IOP Conf. Ser.: Mater. Sci. Eng</addtitle><description>Macrosegregation is a severe defect present in direct-chill (DC) cast aluminium ingots and billets. In the recent years, experimental studies were conducted to modify and to an extent optimize macrosegregation formation by modifying the inlet melt flow. Due to several limitations, the grain settling behavior and corresponding liquid flow pattern is difficult to analyze using experiments. Simulations on the other hand can provide this insight. However, conducting 2D sheet ingot simulations, as has been previously done, provides an incomplete description of flow pattern. To avoid this and as a first qualitative study, full scale 3D sheet ingot simulation results with two different inlets are presented in this paper. A simplified three-phase multiscale solidification model accounting for solidification shrinkage, natural convection and equiaxed grain growth and transport is used to conduct this study. We show that modification of inlet flow results in modification of grain settling and eventually leading to modification of macrosegregation. The impact of grain morphology is also additionally analyzed.</description><subject>Aluminum base alloys</subject><subject>Billet casting</subject><subject>Casting alloys</subject><subject>Chill casting</subject><subject>Computational fluid dynamics</subject><subject>Direct chill casting</subject><subject>Engineering Sciences</subject><subject>Flow distribution</subject><subject>Free convection</subject><subject>Grain growth</subject><subject>Ingot casting</subject><subject>Ingots</subject><subject>Inlet flow</subject><subject>Inlets</subject><subject>Liquid flow</subject><subject>Materials</subject><subject>Morphology</subject><subject>Pattern analysis</subject><subject>Reactive fluid environment</subject><subject>Settling</subject><subject>Simulation</subject><subject>Solidification</subject><issn>1757-8981</issn><issn>1757-899X</issn><fulltext>true</fulltext><rsrctype>article</rsrctype><creationdate>2020</creationdate><recordtype>article</recordtype><sourceid>O3W</sourceid><sourceid>ABUWG</sourceid><sourceid>AFKRA</sourceid><sourceid>AZQEC</sourceid><sourceid>BENPR</sourceid><sourceid>CCPQU</sourceid><sourceid>DWQXO</sourceid><recordid>eNqFkd9qFDEUxgdRsFZfQQLeKHTdJJOdZC9LqVbY0osqeBfO5M9sSmYyTTLqPk7f1ExHVoSCVzk55_d9J-SrqrcEfyRYiDXhG74S2-33tWjImqwxoZjhZ9XJcfD8WAvysnqV0h3GDWcMn1QP10Eb793QoR5UDMl00XSQXRhQH7SzTi0XNyCtkIKUZzZYBH7q3eCmvlQ-HNJMpL0xuRRdyAmBUmEaHnEbYun6MuuNz8j68PMMmfvJwS-jURfBzdviuA8-dAcEg0Y5wpDGEPPr6oUFn8ybP-dp9e3T5deLq9Xu5vOXi_PdSjFG8oqqFphqNau1FQqLtmZAGBe0JXXLuRaNtgpqTLFpBNcMswYsYLDCgKrVtj6tPiy-e_ByjK6HeJABnLw638m5h-mWC97UP0hh3y3sGMP9ZFKWd2GKQ3mepJuGbijjmBWqWaj5X1M09mhLsJyjk3Mqck5IlugkkUt0RUgXoQvjX-f_it4_Ibq-vfwHk6O29W8zqay0</recordid><startdate>20200501</startdate><enddate>20200501</enddate><creator>Pakanati, A</creator><creator>M'Hamdi, M</creator><creator>Combeau, H</creator><creator>Založnik, M</creator><general>IOP Publishing</general><scope>O3W</scope><scope>TSCCA</scope><scope>AAYXX</scope><scope>CITATION</scope><scope>8FE</scope><scope>8FG</scope><scope>ABJCF</scope><scope>ABUWG</scope><scope>AFKRA</scope><scope>AZQEC</scope><scope>BENPR</scope><scope>BGLVJ</scope><scope>CCPQU</scope><scope>D1I</scope><scope>DWQXO</scope><scope>HCIFZ</scope><scope>KB.</scope><scope>L6V</scope><scope>M7S</scope><scope>PDBOC</scope><scope>PIMPY</scope><scope>PQEST</scope><scope>PQQKQ</scope><scope>PQUKI</scope><scope>PRINS</scope><scope>PTHSS</scope><scope>1XC</scope><scope>VOOES</scope><orcidid>https://orcid.org/0000-0002-5038-8029</orcidid><orcidid>https://orcid.org/0000-0001-9810-2360</orcidid></search><sort><creationdate>20200501</creationdate><title>Modelling macrosegregation modification in dc casting of aluminium alloys in sheet ingots accounting for inlet melt flow, equiaxed grain morphology and transport</title><author>Pakanati, A ; 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In the recent years, experimental studies were conducted to modify and to an extent optimize macrosegregation formation by modifying the inlet melt flow. Due to several limitations, the grain settling behavior and corresponding liquid flow pattern is difficult to analyze using experiments. Simulations on the other hand can provide this insight. However, conducting 2D sheet ingot simulations, as has been previously done, provides an incomplete description of flow pattern. To avoid this and as a first qualitative study, full scale 3D sheet ingot simulation results with two different inlets are presented in this paper. A simplified three-phase multiscale solidification model accounting for solidification shrinkage, natural convection and equiaxed grain growth and transport is used to conduct this study. We show that modification of inlet flow results in modification of grain settling and eventually leading to modification of macrosegregation. 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| subjects | Aluminum base alloys Billet casting Casting alloys Chill casting Computational fluid dynamics Direct chill casting Engineering Sciences Flow distribution Free convection Grain growth Ingot casting Ingots Inlet flow Inlets Liquid flow Materials Morphology Pattern analysis Reactive fluid environment Settling Simulation Solidification |
| title | Modelling macrosegregation modification in dc casting of aluminium alloys in sheet ingots accounting for inlet melt flow, equiaxed grain morphology and transport |
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