Abstract
The article considers issues related to the efficiency of metal melts’ filtration depending on the size of non-metallic inclusions, parameters of ceramic foam filters and their location options. Studies of influence of the main structural elements on the filtration processes of nickel melts during casting in a vacuum induction installation were carried out on low-temperature physical models. Modeling of melt filtration processes is based on the hydrodynamic similarity of the processes of motion of melt flows and nonmetallic inclusions in casting tanks. A modeling technique has been developed, the scale has been determined and a model installation has been made. Influence of the arrangement of filtration and dividing walls on the dynamics of metal flows, non-metallic inclusions and filtration efficiency is considered. The efficiency of nickel melts filtration is described depending on the technical parameters both on the filter itself (effective filtration surface, filter thickness, channel dimensions, number of channels per unit area), as well as on the type and size of non-metallic inclusions, design features of the casting device and filter layouts. It was found that the overall filtration efficiency is influenced by the rate and uniformity of the melt flows’ distribution in front of the filter. To ensure uniform distribution of the melt flow rates, a dividing wall with bypass holes is installed in front of the filter, the location of which and their number was also the subject of research. As a result of the studies, the relationships were established between the filtration efficiency, the size and type of non-metallic inclusions when using vertical and horizontal foam ceramic filters during the casting of nickel melts in an intermediate casting tank of a vacuum induction installation. It was found that with a vertical arrangement of the filter, its efficiency is higher than with a horizontal one. An additional means of increasing efficiency of the filtration system is the use of a dividing wall. The optimal number of holes and the location of the baffle in the casting tank were determined, ensuring a uniform distribution of melt flows along the height in front of the filter and an increase in its operation time.
Highlights
Modeling of melt filt ration processes is based on the hydrodynamic similarity of the processes of motion of melt flows and nonmetallic inclusions in casting tanks
The efficiency of nickel melts filtration is described depending on the technical parameters both on the filter itself, as well as on the type and size of non-metallic inclusions, design features of the casting device and filter layouts
It was found that the overall filtration efficiency is influenced by the rate and uniformity of the melt flows’ distribution in front of the filter
Summary
Однако остаются не решенными вопросы, связанные с рациональным расположением фильтра в разливочной емкости, возможностью использования дополнительных устройств для стабилизации процесса разливки, их влияния на эффективность процесса фильтрации и ресурс работы фильтра. В случае сложности получения достоверной математической модели явления или процесса для решения ряда конкретных технологических задач можно воспользоваться методом физического моделирования, основанного на теории подобия [19 – 20], который в настоящее время успешно используется для проектирования разливочных устройств МНЛЗ. Целью данной работы являлась разработка на основе теории физического моделирования методики исследования процессов фильтрации металлических расплавов с учетом динамики потоков металла и НВ, геометрии разливочного устройства, схемы расположения фильтрационных перегородок, а также определение эффективности фильтрации никелевых расплавов в процессе разливки в вакуумно-индукционной установке. Для стабилизации процесса фильтрации перед пенокерамическим фильтром устанавливалась керамическая перегородка с последовательностью круглых отверстий определенного диа метра. В задачи исследований входило так же определение оптимального расположения ПКФ и перегородки, количество и расположение отверстий
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