The effect of low-frequency electromagnetic fields on the micro-structure and macro-segregation of 5A90 alloy ingots during the semi-continuous casting process were quantitatively investigated. The ingots of a 5A90 alloy with a diameter 170 mm were p...
This paper presents a numerical simulation of the steel grade transition from the ladle nozzle to the solidification end of the bloom. The simulation is based on models encompassing fluid flow, solidification, heat transfer, an electromagnetic field,...
The prediction and controlling of the solidification structure and macro-segregation in heavy steel casting, which is usually produced in limited quantities, was a conundrum in the foundry field. In this work, the cooling and solidification processes...
Gas tungsten arc (GTA) weldability of rolled CoCrFeMnNi high-entropy alloys (HEAs) was conducted using stainless steel (STS) 308L and HEA fillers. Microstructure and mechanical properties of the welds were examined to determine GTA weldability of the...
Using magnetic stirring during solidification provides a good opportunity to control the microstructure of alloys, thus controlling their physical properties. However, magnetic stirring is often accompanied by a change in local concentrations, and ne...
This paper presents the detailed comparisons of solute macro-segregation pictures predicted by different meso-macroscopic simulations, based on the single-domain enthalpy–porosity approach coupled with distinct models of flow resistance in the...
The effects of ultrasonic introduced by L-shaped sonotrodes made of high-temperature-resistant ceramic on the microstructure and macro-segregation of solidifying 15t AA2219 aluminum alloy ingots have been examined in the present study. The macroscopi...
C110 oil well casing tubes should have high strength and corrosion resistance which is commonly used for deep wells operation containing corrosive media. In this paper, the microstructure evolution of a kind of semi-macro segregation originated bande...
The effect of filling velocity on positive macrosegregation in large size steel ingots was studied. Macrosegregation and macro/microstructures were characterized on the hot-tops and a portion of the upper section of two ingots. The measurements revea...
Conductive polymer composites with carbonaceous fillers are very attractive and play a significant role in the field of electric heaters owing to their lightweight, corrosion resistance, and easy processing as well as low manufacturing cost. In this...
Macrosegregation, serving as a major defect in billets, can severely degrade material homogeneity. Better understanding of the physical characteristics of macrosegregation through numerical simulation could significantly contribute to the segregation...
In this study, the relationship between macro segregation and the equiaxed zone in high-carbon grades with continuous casting parameters was investigated and optimized at the İsdemir iron and steel plant. The work was conducted for the 1080 qual...
The process of symmetrical multidirectional pressure was adopted to inhibit the macrosegregation of eutectic Si in squeeze cast A356 alloy. Five pressure modes were applied to study the effects of multidirectional pressure and the timing of pressure...
The influence of hot-top designs with different heat capacities on the distribution of positive and negative macrosegregation was investigated on a 12 metric tonne (MT) cast ingot made using Cr-Mo low-alloy steel. The three-dimensional finite element...
A mathematical model of the macrosegregation of continuous cast high carbon steel billet was developed based upon a representative volume element, considering the flow of enriched liquid, solidification rate, and solidification shrinkage as well. It...
Macrosegregation is commonly seen and has been extensively studied in large ingots in a variety of alloy systems. In comparison, this defect is rarely investigated in small aluminum shape castings. To address this shortcoming, a numerical model was d...
In the present work, the influence of filling rate on macrosegregation in a 40-Metric Ton (MT) ingot of a high-strength low-carbon steel was studied using finite element (FE) simulation. The modelling of the filling and solidification processes were...
Macrosegregation is a very common problem for the quality control of all cast ingots. The effect of current on the structure and macrosegregation in dual alloy ingot processed by electroslag remelting (ESR) was investigated experimentally with variou...
In this study, large-sized Al–Zn–Mg–Cu alloy billets were prepared by direct chill casting imposed with annular electromagnetic stirring and intercooling; a process named uniform direct chill casting. The effects of uniform direct chill casting on gr...
Grain structure and macrosegregation are two main factors determining mechanical properties of components and are strongly coupled during alloy solidification. A two-dimensional (2D) cellular automaton (CA)–finite element (FE) model is develope...
Grain structure and macrosegregation are two important aspects to assess the quality of direct chill (DC) cast billets, and the phenomena responsible for their formation are strongly interacted. Transient modeling of grain structure and macrosegregat...
Macrosegregation, a serious defect formed during the solidification of steel ingots, impairs the performance of the final components. To predict macrosegregation caused by thermal-solutal convection and solid deformation, a volume-averaged single-pha...
A Cellular Automaton-Finite Element (CAFE) model and a secondary dendrite arm spacing (SDAS) model are established to study the evolutionary behavior of the macrostructure and the secondary dendrites on a 295 × 2270 mm2 slab cross-section of ex...
The effect of the hot top height on the formation of positive and negative macrosegregation patterns, the ingot quality, and the material yield during solidification of a 12 MT cast ingot made of a Cr-Mo-low alloy steel was investigated. A 3D numeric...
In this study, 8Cr4Mo4V steel was selected as the research material to develop a numerical model of the macrosegregation phenomenon during vacuum arc remelting (VAR). The accuracy of the model was validated by comparing it with the literature and exp...
In the present work macrosegregation during solidification of a 2.45 ton steel ingot is simulated with a pure equiaxed model, which was tested previously via modeling of a benchmark experiment. While the columnar structure is not taken into account,...
The material properties of P91 steel, a critical high-temperature heat-resistant steel, are critically dependent on the uniformity of its macro-composition distribution. This paper presents the first application of Spark Mapping Analysis for Large Sa...
Four-point bending fatigue tests were performed on semi-solid Al–7Si–Mg castings with varying magnesium contents and heat treatment conditions. Additionally, the effect of anodising on the fatigue resistance of semi-solid Al–7Si&nda...
Understanding the Si segregation behavior in hypereutectic Al-Si alloys is important for controlling the micro- and macrostructures of ingots. The macrosegregation mechanism and morphological evolution of the primary Si phase were investigated during...
A Ni-based superalloy CMSX-6 was directionally solidified at various drawing speeds (5–20 μm·s−1) and diameters (4 mm, 12 mm) under a 0.5 T weak transverse magnetic field. The results show that the application of a weak transverse magnetic field sign...
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In this study, a three-dimensional (3D) solidification model was developed that uses a SOLA algorithm to solve momentum equations and accelerate iterative convergence. The macrosegregation behavior of a sand-cast Sn-6 wt.% Pb alloy was numerically in...
Segregation defects greatly affect the service performance and working life of castings during the vacuum arc remelting (VAR) process. However, the corresponding research on the prediction of segregation defects is still not comprehensive. Through co...
A simple Lagrangian travelling slice model has been successfully used to predict the relations between the process parameters and the strand temperatures in the continuous casting of steel. The present paper aims to include a simple macrosegregation,...
The microstructures and hardness of the as cast and heat treated (1400 °C/100 h) alloys Nb-24Ti-18Si-5Ge-5Cr-5Al (ZF6) and Nb-24Ti-18Si-5Ge-5Cr-5Al-5Hf (ZF9) were studied. Both alloys were compared with refractory metal bcc solid solution + inter...
Macrosegregation remains one of main defects affecting metal materials properties, which is mainly caused by interdendritic fluid flow during solidifying. However, as for controlling actual specific segregation, it is still difficult to effectively m...
Some cast metallic alloys for ultra-high-temperature structural applications can have better mechanical properties compared with Ni-based superalloys. Research on the directional solidification (DS) of such alloys is limited. The production of DS com...
The internal coupled electromagnetic melt treatment (ICEMT) method is firstly proposed to produce high-quality and large-sized aluminum alloy billets. A three-dimensional model was established to describe the ICEMT process of direct chill casting (DC...
The most recent developments and applications in volume-averaged modeling of solidification processes have been reviewed. Since the last reviews of this topic by Beckermann and co-workers [Applied Mech. Rev. 1993, p. 1; Annual Rev. Heat Transfer 1995...
The impact of microsegregation models on thermophysical properties and solidification behaviors of a high strength steel was investigated. The examined microsegregation models include the classical equilibrium Lever rule, the extreme non-equilibrium...
The solidification and micro- and macro-segregation behaviors of as-cast INCONEL 718 (IN718) alloy at different temperatures under a slow cooling rate (5 °C/min) were investigated in this study. The results indicate that the solid-liquid interfac...
An alternating magnetic field (AMF) was applied during the solidification process of the Cu-14Fe alloy and the effect of the electromagnetic parameter, which impact the model and solidification technique of the solidification structure that were anal...
In this paper, water quenching of large ingots was simulated using FORGE NxT 1.1® Finite Element code. Simulations were carried out for as-forged medium-carbon low-alloy steel. A novel method is proposed to simulate the different parts of a large...
Macrosegregation in continuous casting slabs remains a critical defect that adversely affects the homogeneity and mechanical properties of the final rolled products. Industrial experiments were conducted on E355 steel continuous casting slabs to inve...
In order to achieve long-term and stable ultrasonic treatment in the direct chill semi-continuous casting process, a new L-shaped ceramic ultrasonic wave guide rod is designed to introduce ultrasonic bending vibration into 2A14 aluminum alloy melt. T...
A digital-twin-model-based optimal control system is presented for the steel continuous casting process. The system is designed for the coordinated optimization and dynamic control of secondary cooling and final electromagnetic stirring (FEMS), and i...
Continuous casting is a dominant steelmaking process due to its steady-state nature, enhanced yield of steel production, and low consumption of energy and manpower. However, the production of defect-free cast products is still a big challenge, as the...
In this work, a Al-Cu-Li alloy plate with outstanding mechanical properties was successfully prepared with electromagnetic twin-roll casting (TRC) technology. The microstructure of Al-Cu-Li alloy manufactured by conventional mold casting, TRC, and el...
Due to the high computational costs of the Eulerian multiphase model, which solves the conservation equations for each considered phase, a two-phase mixture model is proposed to reduce these costs in the current study. Only one single equation for ea...
This paper presents the changes in microstructure and mechanical properties that occurred across the wall cross-section of a massive slag ladle casting due to service conditions. The slag ladle was made of low-carbon cast steel. Based on the test res...
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