Development of Universal Mould Geometry for the Teeming of Cylindrical Iron-Base Alloy Ingots
Source abstract
Abstract
The presented work is aimed at developing a mould geometry suitable for casting both low- and high-alloy steel grades into 500 kg experimental ingots. The high Height-to-Diameter (H/D)-ratio mould currently used in COMTES FHT Inc. served as a reference and for finite element method simulations (FEM) of the filling and solidification process. The optimized mould geometry, balancing the porosity and segregations, was determined using MAGMA software. Four different steel grades were defined for the simulation. Case studies were carried out for 34CrNiMo6 (W.Nr. 1.6582), DHQ8, CB2 and borated stainless steel grades ranging from low-alloy steel to high-alloy steel. Extended user-defined criteria and verified boundary conditions were used to predict the formation of A-segregations in cast steel. Both primary (PDAS) and secondary (SDAS) arm spacings were modelled as well. The optimized mould shape and the casting assembly were designed based on the simulation results.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: Metallurgical Processes and Thermodynamics · Aluminum Alloy Microstructure Properties · Metallurgy and Material Forming
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
Affiliations
Department of Material Science and Technology, Faculty of Mechanical Engineering, University of West Bohemia, UWB Plzeň, Univerzitní 22, 301 00 Pilsen, Czech Republic
COMTES FHT Inc., Průmyslová 995, 334 41 Dobřany, Czech Republic
Funding
Technologická Agentura České Republiky
References (23)
Show source-provided references
1. Effect of mould design on the Niyama criteria during solidification of CH3C 80t ingot10.1080/03019233.2019.1583879 ↗
2. Numerical model for prediction of the final segregation pattern of bearing steel ingots10.1016/0921-5093(93)90236-8 ↗
3. Modelling of ingot size effects on macrosegregation in steel castings10.1016/j.jmatprotec.2017.09.004 ↗
4. Influence of Dendritic Morphology on the Calculation of Macrosegregation in Steel Ingot10.4028/www.scientific.net/MSF.790-791.121 ↗
5. Li, J., Wu, M., Ludwig, A., and Kharicha, A. (2012). Modelling macrosegregation in a 2.45 ton steel ingot. IOP Conf. Ser. Mater. Sci. Eng., 33.10.1088/1757-899X/33/1/012091 ↗
6. Modelling of Inclusion Effects on Macrosegregation in Solidifying Steel Ingot with a Multi-phase Approach10.1007/s11661-018-5066-5 ↗
7. Gradual-cooling solidification approach to alleviate macrosegregation in large steel ingots10.1016/j.jmatprotec.2018.06.041 ↗
8. (2020, December 02). MAGMAsoft v.5.4. Reference Manual, MAGMA GmbH, Aachen, Germany. Available online: https://www.magmasoft.com/en/.
9. Hattel, J.H. (2005). Fundamentals of Numerical Modelling of Casting Processes, Polyteknisk Forlag.
10. Prediction of Shrinkage Pore Volume Fraction Using a Dimensionless Niyama Criterion10.1007/s11661-008-9715-y ↗
11. Beckermann, C. (2008). ASM Handbook, ASM Handbook Committee.
12. Beckermann, C., and Schneider, M.C. (1961, January 8–11). Simulation of Convection and Macrosegregation in Steel Casting. Proceedings of the 50th SFSA Technical and Operating Conference, Chicago, IL, USA.
13. Simulation of Micro-/Macrosegregation during the Solidification of a Low-alloy Steel10.2355/isijinternational.35.665 ↗
14. Formation of macrosegregation by multicomponent thermosolutal convection during the solidification of steel10.1007/BF02671251 ↗
15. Macrosegregation in Steel Ingots: The Applicability of Modelling and Characterisation Techniques10.2355/isijinternational.53.935 ↗
16. On the prediction of shrinkage defects by thermal criterion functions10.1007/s00170-014-5995-0 ↗
17. Numerical Modeling and Optimization of Thermal Behaviour and A-segregates in a Load-carrying Steel Ring Casting
18. A Casting Yield Optimization Case Study: Forging Ram
19. Modelling and simulation of A segregates in steel castings using thermal criterion function Part I—Background and validation10.1179/1743284712Y.0000000025 ↗
20. Modelling and simulation of A segregates in steel castings using thermal criterion function Part II—Optimisation of real industrial cast part10.1179/1743284712Y.0000000026 ↗
21. Rayleigh Number Criterion for Formation of A-Segregates in Steel Castings and Ingots10.1007/s11661-013-1761-4 ↗
22. Prediction of dendrite arm spacing for low alloy steel casting processes10.1007/BF02915668 ↗
23. IDS: Thermodynamic–kinetic–empirical tool for modelling of solidification, microstructure and material properties10.1016/j.matcom.2009.11.002 ↗