Abstract
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-phase/two-phase integrated model is developed. During the deformation stage, the two-phase model coupling the solid deformation and liquid flow in the mushy zone is utilized. Before or after the deformation stage, the motion of the solid phase is neglected, and the single-phase model is solved. A 450 kg steel ingot punching test is considered for application. The results show that when the solid shell of the ingot is being punched, the solid phase in the mushy core at punching height is compressed, and a relative liquid flow is induced. This in turn causes a transition of positive segregation to negative segregation in the compressed mushy core of the ingot. According to numerical sensitivity tests of different punching parameters, as the punching start time and punching velocity increase, the effect of punching on macrosegregation will be smaller. It is demonstrated that the single-phase/two-phase integrated model can predict macrosegregation in the steel ingots which are deformed during solidification.
Highlights
Macrosegregation refers to a non-uniform distribution in local solute composition during the solidification of metal alloys
To simulate macrosegregation formed during the whole process of the ingots which are deformed during solidification, a single-phase/two-phase integrated model is extended from the two-phase model
The convection thermal-solutal macrosegregation in steel ingots which are deformed during solidification
Summary
Macrosegregation refers to a non-uniform distribution in local solute composition during the solidification of metal alloys. In the four-phase model, three factors for the relative motion which had a significant impact on macrosegregation in steel ingots were considered, including the thermal-solutal convection, solidification shrinkage, and grain sedimentation. Except for the direct modeling of macrosegregation in the continuous casting process, ingot bending or ingot punching tests were developed to analyze macrosegregation and hot tearing phenomena caused by deformation of the solid phase These tests consisted of deforming the external solid shell during the solidification of steel ingots [16,17]. Much progress has been achieved regarding the development of a model for macrosegregation in steel ingots, considering the combined effect of the thermal-solutal convection, solidification shrinkage, and grain sedimentation.
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