Abstract
The control of the carbon macrosegregation level in steel ingots is important for the structural integrity of the final component. Previous studies using the SOLID® multiscale modelling software have shown that in order to obtain predictive results for the macrosegregation and the grain structure (CET, grain morphology) in steel ingots, a model needs to account for fragmentation of columnar dendrites as a source of equiaxed grains. The goal of this study is to show that a numerical model that takes into account fragmentation can describe the formation of the structures and the macrosegregation during solidification of a large steel ingot. The present article describes how fragmentation is taken into account in the multiphase numerical model used in the simulations. The simulation results are compared to experimental data from a 9.8 tonne ingot cast in A5/6 steel by ArcelorMittal Industeel. The model correctly reproduces the major features of the experimentally observed structure and macrosegregation. We show that the structures are formed very early on during solidification, whereas macrosegregation develops much more gradually. Our results also underline the importance of liquid flow and grain movement in order to correctly predict the final structure and macrosegregation.
Highlights
Achieving homogeneous mechanical properties for large cast ingots is an industrial challenge because of the segregation of alloying elements during solidification
Segregation is the result of the complex interaction of the solidification structures and liquid flow
Convection is much more pronounced due to the heat exchange between the liquid and the exothermal powder
Summary
Achieving homogeneous mechanical properties for large cast ingots is an industrial challenge because of the segregation of alloying elements during solidification. This is due to an enrichment of the liquid in alloying elements as solidification progresses. This can lead to large-scale inhomogeneity (macrosegregation) which will affect the local mechanical properties. The prediction of the structures requires taking into account the fragmentation of the columnar dendrites in the model [1]. The present study uses the SOLID® multiscale and multiphysics model to predict the structure and macrosegregation of a 1.44 m diameter, 9.8 tonne steel ingot by taking into account the fragmentation during solidification. The originality of this study lies in the prediction and description of the formation of the structures and the macrosegregation, which is not commonly found in literature for such large products
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