Abstract
A mathematical model for a unidirectionally solidified ingot cooled with a multi-set water-cooling system was established with ProCAST software. Temperature and heat flux fields in a 45 t ingot during solidification under the influences of a traditional water-cooled stool and an improved one were predicted by using this model. The results of temperature distribution and heat flux field show that the proposed chassis cooling system can improve the vertical temperature gradient. Uniform columnar grains from the top to the bottom of the ingot were revealed by the modeling results indicating that improved mechanical properties of the cast product could be achieved.
Highlights
Directional solidification has been widely used in manufacturing the advanced material with special orientation of internal structure and excellent performance
Tamaguchi Miyuki et al [1] consider that it is costly if, after service, the whole thick chassis is replaced with a new one and the whole thick chassis should be divided into two parts: an upper part and a lower part
Yuanyingshi et al [2] think that in general directional solidification processes, the bottom of the ingot will have a reverse contraction, forming an air gap between the ingot and the chassis, which can significantly reduce the thermal conductivity between the chassis and the steel ingot, so that the height of directional solidification layer of the ingot becomes limited
Summary
Directional solidification has been widely used in manufacturing the advanced material with special orientation of internal structure and excellent performance. Through controlling and optimizing the cooling intensity in different blocks of the chassis, a stronger cooling intensity in the center zone (B1) but a weaker cooling intensity in the outer zone (B3) can be achieved resulting in appropriate distributions of the cooling intensity consistent with air gap formation and yielding nearly uniform solidification in the vertical direction of the ingot and avoiding local contraction (buckling) in the ingot bottom. In order to optimize the chassis cooling parameters, a mathematical model was established to predict the temperature field and heat flux field inside a 45 t heavy steel ingot and numerical simulations on the solidification of the ingot cooled with both the conventional water-cooled stool and the improved one were carried out, respectively
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