Abstract
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 realized with a two-phase (liquid-solid) multiscale 3D model. The liquid flow induced by the pouring jet, the thermosolutal convection, and the thermomechanical deformation of the solid phase were taken into consideration. Two filling rates were examined, representing the upper and lower manufacturing limits for casting of large size ingots made of high strength steels for applications in energy and transportation industries. The evolution of solute transport, as well as its associated phenomena throughout the filling and cooling stages, were also investigated. It was found that increasing the filling rate reduced macrosegregation intensity in the upper section, along the centerline and in the mid-radius regions of the ingot. The results were analyzed in the framework of heat and mass transfer theories, liquid flow dynamics, and macrosegregation formation mechanisms.
Highlights
In recent years, there is an increasing demand for large size forged steel ingots in energy and transportation industries for applications in turbine shafts, trains, ships, and windmills [1]
Considering that a fully experimental-based approach is very costly, time-consuming, and difficult in the pursuit of the solidliquid interface evolution involved in large size ingot filling and solidification, numerical simulation is a valuable tool for the casting process analyses [3]
It is seen that the variation of filling rate gave rise to different large-scale compositional distribution in the course of solidification
Summary
There is an increasing demand for large size forged steel ingots in energy and transportation industries for applications in turbine shafts, trains, ships, and windmills [1]. In most of the reported literature on ingot solidification modelling, the filling rate effects are neglected by assuming the occurrence of no phase changes in the filling stage [9], or instantaneous completion of filling [10]. Kermanpur et al [14] simulated the effect of bottom pouring rate and mold dimensions on solidification behavior of a low alloy steel in a 6-Metric Ton (MT) ingot. Yadav et al [11] modeled the filling and solidification of a Pb-Sn alloy in a small side-cooled cavity (50 × 60 mm2) They found that residual flow, due to filling, significantly modified the shape of the mushy zone and delayed the development of solutal convection. The results were analyzed in the framework of heat and mass transfer theories, liquid flow dynamics and macrosegregation formation mechanisms
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