Special Issue "Optimization of Industrial Casting Processes"

A special issue of Metals (ISSN 2075-4701).

Deadline for manuscript submissions: 31 August 2018

Special Issue Editor

Guest Editor
Prof. Dr. Steve Cockcroft

Univ British Columbia, Dept Mat Engn, Vancouver, BC V5Z 1M9, Canada
Website | E-Mail
Interests: Physical phenomena in non-ferrous casting: hot tearing; Continuous Casting, EB Melting and Refining, Vaccuum Casting; Finite element-based heat flow and stress codes; Optimization of industrial casting processes; Mathematical modeling

Special Issue Information

Dear Colleagues,

Casting processes have seen continuous technological development for close to 5000 years, largely through a process of trial-and-error improvement. While modern casting is a sophisticated, technologically-advanced process capable of producing high quality parts economically, there remain significant opportunities for the optimization of the existing technologies.

In the context of casting technology, and for a given alloy chemistry, optimization may be thought of as obtaining a desired design objective(s) through manipulation of the process parameters and/or altering the geometry of the mould system.  The design objective may include for example, elimination of shrinkage porosity above a certain size threshold, minimization of the overall solidification time, achieving a target secondary dendrite arm spacing at a given location, or minimization the metal contained within the feeding system (process scrap).

Given the sophisticated state of the commercial solidification software now available, and the availability of significant computational resources at reasonable cost, we are starting to see an increase in the application of numerical optimization methodologies to casting processes, both from the commercial software vendors and from academia.  The ability to optimize industrial casting processes at scale represents a formidable challenge, requiring highly accurate simulation capabilities, fast simulation capabilities, effective optimization algorithms, and the identification of suitable process objective functions and design constraints.

This Special Issue aims to present some of the latest research devoted to exploring the application of numerical optimization methodologies to casting. Suitable subjects include, but are not limited to, optimization algorithms and their application to example casting problems, case studies in process parameter optimization, case studies in geometry optimization, advances in cooling or heating technologies and their optimization in casting processes and objective functions and design constraints in casting optimization problems.

Prof. Dr. Steve Cockcroft
Guest Editor

Manuscript Submission Information

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Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 1200 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • Casting Technology
  • Casting Optimization
  • Numerical Optimization
  • Casting Simulation
  • Process Optimization
  • Geometry Optimization

Published Papers (2 papers)

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Research

Open AccessArticle Hydrodynamic Modeling and Mathematical Simulation on Flow Field and Inclusion Removal in a Seven-Strand Continuous Casting Tundish with Channel Type Induction Heating
Metals 2018, 8(6), 374; https://doi.org/10.3390/met8060374
Received: 12 April 2018 / Revised: 9 May 2018 / Accepted: 19 May 2018 / Published: 23 May 2018
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Abstract
The tundish with heating instrumentation is attracting more and more attention in continuous casting processes for maintaining a pre-determined constant pouring temperature under a given casting speed, which is beneficial for an improved and consistent steel product quality. However, the fluid flow, temperature
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The tundish with heating instrumentation is attracting more and more attention in continuous casting processes for maintaining a pre-determined constant pouring temperature under a given casting speed, which is beneficial for an improved and consistent steel product quality. However, the fluid flow, temperature distribution and the removal behaviors of non-metallic inclusions in it will be much different from that in a conventional tundish, due to the implementation of the heating practice. In the present work, to reduce the non-metallic inclusion amounts in billets of the second and sixth strands in a seven-strand tundish with channel type induction heating, the flow field profiles and temperature profiles of molten steel in this tundish have been investigated using hydrodynamic modeling coupled with mathematical simulation under isothermal and non-isothermal situations, respectively. The results of the isothermal experiment indicate that the prototype tundish has severe “short-circuiting flow” in the second and sixth strands, which might have caused the increased inclusion amounts in the billets of the two strands. The flow field of the tundish can be greatly improved by changing the channel design and adding two high dams at each side of the tundish. Compared with the prototype structure A0, the average residence time of the optimized case C5 is prolonged by 55.49% (from 501 to 779 s); the dead zone volume fraction is reduced by 66.18% (from 45.57% to 15.41%); and the flow of each strand becomes more consistent with lower standard deviation. The non-isothermal experiments show that the fluid presents an obvious rising tendency when it flows out from the heating induction channel. The larger the temperature difference inside and outside the channel is, the more consistent the fluid flow between different strands and the more homogeneous the flow field in the whole tundish. For the prototype tundish structure, when the temperature difference is 5 °C, the dead zone is basically eliminated, and the minimum residence time is prolonged by 789% (from 38 to 338 s), compared with the 0 °C of temperature difference. A mathematic model has been proposed accordingly, which can explain well the hydraulic phenomena. The inclusion removal rates of different cases were compared by mathematical simulation, and their removal mechanism was studied, as well. Full article
(This article belongs to the Special Issue Optimization of Industrial Casting Processes)
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Open AccessArticle Optimizing the Gating System for Steel Castings
Metals 2018, 8(4), 266; https://doi.org/10.3390/met8040266
Received: 17 March 2018 / Revised: 4 April 2018 / Accepted: 10 April 2018 / Published: 13 April 2018
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Abstract
The article presents the attempt to optimize a gating system to produce cast steel castings. It is based on John Campbell’s theory and presents the original results of computer modelling of typical and optimized gating systems for cast steel castings. The current state-of-the-art
[...] Read more.
The article presents the attempt to optimize a gating system to produce cast steel castings. It is based on John Campbell’s theory and presents the original results of computer modelling of typical and optimized gating systems for cast steel castings. The current state-of-the-art in cast steel casting foundry was compared with several proposals of optimization. The aim was to find a compromise between the best, theoretically proven gating system version, and a version that would be affordable in industrial conditions. The results show that it is possible to achieve a uniform and slow pouring process even for heavy castings to preserve their internal quality. Full article
(This article belongs to the Special Issue Optimization of Industrial Casting Processes)
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