Modeling of Heat Transfer and Interdendritic Strain for Exuded Surface Segregation Layer in the Direct Chill Casting of Aluminum Alloys

详细信息    查看全文

• 作者：Mostafa Omar El-Bealy
• 刊名：Metallurgical and Materials Transactions B
• 出版年：2016
• 出版时间：February 2016
• 年：2016
• 卷：47
• 期：1
• 页码：630-648
• 全文大小：1,773 KB
• 参考文献：1.I. H. Hove, B. Andersson and D. Voss: Proc. 3rd Conf. on aluminium Alloys-Their Physical and Mechanical Properites, L. Arnberg, O. Lohne, E-Nes, and N. Ryum, eds., Trondheim, Norway, 1992, vol. 2, pp. 264–269.
  2.M. O. El-Bealy; in Proceed. Of Light Metals, TMS-Annual meeting, “Cast Shop Technology”, Seattle, Washington, 2010, pp. 683–688.
  3.M. O. El-Bealy: in Proceed. of LMBC, TMS, 2007, New Mexico, Nancy, France.
  4.H. Yu, and D. A. Granger: in Symposium Held at NASA Lewis Research Center, Cleveland, Oh, 1984, pp. 157–168.
  5.L. Ohm and S. Engler; Metall, 1989, vol. 43, pp. 520-524.
  6.C. J. Vreeman, J. D. Schloz, and M. J. M. Krane: J. Heat Transfer, 2002, vol. 124, pp. 947-953.CrossRef
  7.A. Mo; Int. J. Heat and Mass Transfer, 1993, vol. 36, pp. 4335-4340.CrossRef
  8.A. V. Reddy and C. Beckermann; Metall. Trans. B, 1997, vol. 28B, pp. 479-489.CrossRef
  9.M.C. Flemings, ISIJ Int., 2000, vol. 40, pp. 833–841.CrossRef
  10.Q. Du, D. G. Eskin, and, L. Katgerman; Metall. Trans. A., 2007, vol. 38A, pp.180-189.CrossRef
  11.M. O. El-Bealy: Light Metals, “Cast Shop Technology”, 2012, pp. 1107–1112.
  12.R. Nadella, D. G. Eskin, Q. Du and L. Katgerman;, Progress in Materials, 2008, vol. 53, pp. 421-480.CrossRef
  13.M. O. El-Bealy; Can. Metall. Q., 2010, vol. 49, pp. 47-62.CrossRef
  14.A. Jafari, S. H. Seyedein, M. R. Aboutalebi, D. G. Eskin and, L. Katgerman;, Iranian Journal of Materials Science & Engineering, 2010, vol. 7, pp. 39-50.
  15.B.C.H. Venneker and L. Katgerman: J. Light Metals, 2002, vol. 2, pp. 149–159.
  16.A. M. Glenn, S. P. Russo, and P.J.K. Paterson: Metall. Trans. A., 2003, vol. 34A, pp. 1513–23.
  17.C. Y. Wang and, C. Beckermann; Metall. Trans. A, 1996, vol. 27A, pp. 2765-2783.CrossRef
  18.R. Nadella, DG. Eskin and L. Katgerman: Metall. Trans. A., 2008, vol. 39A, pp. 450- 461.CrossRef
  19.M.C. Flemings and, G. E. Nereo; Trans-AIME, 1967, vol. 239, pp. 1449-61.
  20.M.C Flemings, R. Mehrabian and G. E. Nereo; Trans-AIME, 1968, vol. 242, pp. 41-49.
  21.M.C Flemings and G.E. Nereo: Trans-AIME, 1968, vol. 242, pp. 50–55.
  22.Flemings, M. C. and Nereo, G. E.; TMS-AIME, 1969, vol. 245, pp. 2347-48.
  23.Rogberg, B.: High Temperature Properties of Steels and their Influence on the Formation of Defects in Continuous Casting. Ph. D. Thesis, Royal Institute of Technology, Stockholm, Sweden, 1982.
  24.M. El-Bealy and, H. Fredriksson; Scand. J. of Metall., 1994, vol. 23, pp. 140-50.
  25.M. El-Bealy and, H. Fredriksson; Metall. Trans. B., 1996, vol. 27B, pp. 999-1014.CrossRef
  26.M. O. El-Bealy: Steel Res. Int., 2013, vol. 84, pp. 565-583, 584–606.
  27.M. O. El-Bealy; in Proceed. of Light Metals, TMS-Annual meeting, “Cast Shop Technology”, New Orleans, Louisiana, USA, 2008, pp. 721–727.
  28.M. O. El-Bealy; Metall. Trans. B, 2012, vol. 43B, pp. 635-656.CrossRef
  29.J. O. Kristiansson; J. Thermal Stresses, 1982, vol. 5, pp. 315-330.CrossRef
  30.J. H. Weiner and, B. A. Boley; Journal of Mechanical Physics and Solids, 1963, Vol. 11, pp. 145–154.CrossRef
  31.R. H. Tien and, V. Koump; J. Applied Mechanics,1969, vol. 36, pp. 763-67.CrossRef
  32.J. R. Williams, R. W. Lewis, and K. Morgan; International” J. for Numerical Methods in Engineering, 1979, vol. 14, pp. 1–9.CrossRef
  33.B. G. Thomas; ISIJ International, 1995, vol. 35, pp. 737–743.CrossRef
  34.C. Li and B. G. Thomas; Metall. Trans. B., 2004, vol. 35B, pp. 1151-1172.CrossRef
  35.H. J. Thevik, A. Mo, T. Rusten, Met. Trans. B., 1999, vol. 30B, pp. 135-142.CrossRef
  36.D.R. Poirier, P.J. Nandapurkar and S. Ganesan; Metall. Trans. B., 1991, vol. 22B, pp. 889-900.CrossRef
  37.M. O. El-Bealy: On the Formation of Exuded Surface Segregation Layer in the Direct Chill Casting of Aluminum Sheet Ingots, Technical Report of Jernkontoret, Stockholm, Sweden, 2013.
  38.C. A. Muojekwu, I.V. Samarasekera, and J. K. Brimacombe: Metall. Trans. B., 1995, vol. 26B, pp. 361–82.
  39.M. O. El-Bealy, and R. M. Hammouda; Steel Research International, 2007, vol. 78, pp. 602-611.
  40.T. L. Finn, M. G. Chu, and W. D. Bennon: Micro/Macro Scale Phenomena in Solidification, C. Beckermann, L.A. Bertram, S. J. Pien, and R. E. Smelser, eds., ASME, New York, NY, HTD- 218/AMD-139, 1992, pp. 17–26.
  41.K. Ho and R. D. Pehlke; Metall. Trans. B.,1985, vol. 16B, pp.585-594.CrossRef
  42.G. Fortin, P. Louchez, F. H. Samuel; AFS Trans., 1982, vol. 100, pp. 863–871.
  43.G. L. Chai, L. Bäackerud and, L. Arnberg; Mat. Sci. Tech.,1995, vol. 11, pp. 1099-1103.CrossRef
  44.M. O. El-Bealy: Metall. Trans. B, 2000, vol. 31B, pp. 331–43, 345–55.
  45.S. Vernède, P. Jarry and M. Rappaz; Acta Materialia, 2006, vol. 54, pp. 4023-4034.CrossRef
  46.O. Ludwig, J. M. Drezet, Ch. Martin and M. Suèry; Metall. Trans. A., 2005, vol. 36A, pp. 1525-1535.CrossRef
  47.Y. Langsrud: The Use of Phase Diagrams for Calculating Solidification Paths, F. H. Hayes ed., The Institute of Metals, 1991, pp. 90–100.
  48.A. Mo, B. R. Henriksen, E. K. Jensen, and O. R. Myhr: Light Metals, 1994, pp. 889–896.
  49.M. M. Hamdi, S. Benum, D. Mortensen, H. G. Fjaer, and J-M. Drezet: Mertall. Trans. A., 2003, vol. 34A, pp. 1941–52.
  50.D. Mortensen, Metall. Trans. B, 1999, vol. 30B, pp. 119-133.CrossRef
  51.K. Miyazawa, and K. Schwerdedteger; Ironmaking & Steelmaking, 1979, vol. 6, pp. 68-74.
  52.M. O. El-Bealy; Can. Metall. Q., 1997, vol. 36, pp. 49-56.CrossRef
  53.R. M. Hammouda: Studying Formation Under Unidirectional Heat Transfer and Prosperities. Ph. D Thesis, Ain Shams University, Faculty of Engineering, Cairo, Egypt, 1998.
  54.M. O. El-Bealy; J. Materials Science Research, 2013, vol. 2, pp.1-22.
  55.R. M. Hammouda: Studying of Dendritic morphology by Directional Solidification and its Simulation. Master Thesis, Ain Shams University, Faculty of Engineering, Cairo, Egypt, 1989.
  56.A. Ohno; “Solidification”, Springer-Verlag Berlin, Heidelberg, New York, 1987.CrossRef
  57.W. Reif: Nucleation Separation Theory and Natural Convection Streams During Dendritic Equiaxed Solidification Processes, Technical commutations. Institut für Metallforsung Metallkunde, TU-Berlin, Germany, 1990.
  58.S. K. Das: “Modeling and Optimization of Direct Chill Casting to Reduce Ingot Cracking” Final Technical Report, ORNL/TM-2006/56, U.S. Department of Energy, Industrial Technologies Program “Aluminum Industry of the Future”, pp. 21–23.
  59.H. Sandberg; Scand. J. Metall.,1973,vol. 2, pp. 233-39.
  60.M. Easton, H. Wang, J. Grandfield, D. H. StJohn, and, E. Sweet: Materials Forum, 2004, pp. 224–229.
  61.Honeycombe, R. W. K.; 1984, “The Plastic Deformation of Metals”, 2nd ed., Edward Arnold, London, pp. 236-37.
  62.L. Arnberg, L. Bäckerud, and G. Chai: in American Foundrymen’s Society, S. P. Thomas, ed., Des Plaines, IL, 1996, vol. 3, pp. 231–232.
  63.M.C. Flemings: Solidification Processing, McGraw-Hill, New York, NY, 1974, vol. 148, pp. 255–256.
  64.B. Gariepy and Y. Caron: Light Metals, TMS, Warrendale, 1991, pp. 961-71.
  65.A. M. Glenn, S. P. Russo and P. J. K. Paterson; Metall. Trans. A, 2003, vol. 34A, pp. 1513-1523.CrossRef
  66.R. S. Rana, R. Purohit, and S. Das; Int. J. Scientific and Research Publications, 2012, vol. 2, pp. 1-7.CrossRef
  67.S.G. Shabestari and H. Moemeni; Journal of Materials Processing Technology, 2004,153–154, pp. 193–198.CrossRef
  
• 作者单位：Mostafa Omar El-Bealy (1) (2) (3) (4)
  
  1. Military Technical College (MTC), Khalifa El-Maamon St., Kobri Al-kobaa, Cairo, 11566, Egypt
  2. Clausthal Technical University (CTU), 38678, Clausthal-Zellerfeld, Germany
  3. Kungliga Tekniska högskolan (KTH), 100 44, Stockholm, Sweden
  4. Materials Processing Center (MPC), University Materials Council, Massachusetts Institute of Technology (MIT), Cambridge, MA, 02139, USA
  
• 刊物类别：Chemistry and Materials Science
• 刊物主题：Chemistry
  Materials Science
  Manufacturing, Machines and Tools
  Metallic Materials
  Operating Procedures and Materials Treatment
  Characterization and Evaluation Materials
  Numerical and Computational Methods in Engineering
  
• 出版者：Springer Boston
• ISSN：1543-1916

文摘

This investigation on the formation of exuded surface segregation layer “ESSL” is intended to provide experimental and simulated comparison to verify the model developed previously by El-Bealy. Preliminary verification and calibration of the previous 2D mathematical model are demonstrated by quantitative errors between the previous measurements and predictions of temperature and macrosegregation. Also, the results from these comparisons reveal that the errors are in the reasonable and within allowable limits. These comparisons lead to the fact that the exuded surface segregation layer mostly forms on the middle slice of broad sheet ingot face and in the early stages of mold zone. The model predictions point out also that the different interdendritic strain hypotheses associated with fluctuations of mold cooling conditions. This affects the interdendritic liquid flow between the equiaxed crystals which influences the severity of ESSL formation and its macrosegregation level. The mechanism of ESSL with heat flow and interdendritic strain generation has been analyzed and discussed. The quantitative comparisons between the pervious experimental results and numerical simulation in this investigation reveal also several solutions to prevent this defect for future work. Manuscript submitted March 12, 2015.