Abstract
Control of chemistry and shrinkage void in the final stages of the consolidation processes employed to produce Ti alloy ingots is critical from the standpoint of productivity as there is a direct correlation to the amount of material that must be removed prior to further downstream processing. The application of power to the top surface during this stage allows the raising of the depth of shrinkage voids; however, it can also cause excessive evaporation of volatile elements within the alloy. The balancing of these two factors represents a classic optimization problem. A mathematical model describing the final stage of a commercial consolidation process has been developed to assist in the optimization of the process. The model solves the coupled thermal-fluid flow problem including solute conservation and evaporation. Experimental measurements consisting of the sump depth, pool profile marking, and local composition analysis have been used to validate the model predictions under various casting conditions.
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