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CFD Modeling and Simulation in Materials Processing

CFD Modeling and Simulation in Materials Processing

Laurentiu Nastac (Editor), Lifeng Zhang (Editor), Brian G. Thomas (Editor), Adrian S. Sabau (Editor), Nagy El-Kaddah (Editor), Adam C. Powell (Editor), Herve Combeau (Editor)

ISBN: 978-1-118-36469-7

May 2012

347 pages

Description

Proceedings of a symposium sponsored by Association for Iron and Steel Technology
and
the Process Technology and Modeling Committee of the Extraction and Processing Division
and
the Solidification Committee of the Materials Processing and Manufacturing Division of TMS (The Minerals, Metals & Materials Society)
Held during the TMS 2012 Annual Meeting & Exhibition Orlando, Florida, USA, March 11-15, 2012

Preface xi

Editors xiii

CFD Modeling and Simulation in Materials Processing

CFD Modeling in Materials Processing I

Fluid Flow, Solidification and Inclusion Entrapment during Steel Centrifugal Casting Process 3
L Zhang, Y. Wang, E. Martinez, and K. Peaslee

A Micro-Macro Model of a PEM Fuel Cell System 17
T. Paramadhayalan, H. Pimpalgaonkar, and S. Sundarraj

Modeling the Effects of Tool Geometries on the Temperature Distributions and Material Flow of Friction Stir Aluminum Welds 25
H. Mohanty, M. Mahapatra, P. Kumar, and P. Jha

Understanding Fuming during Metal Refining by CFD 33
J. Olsen, M. Naess, and G. Tranell

CFD-Based Modelling on Interfacial Heat Transfer for Water Quenching 41
G Wang and Y. Rong

Fuzzy Extraction Separation Optimized Process of Tm, Yb and Lu Enriched Oxides by Computer Simulation 49
F. Yang, S. Yang, L. Wu, C. Tong, and M. Li

CFD Modeling in Materials Processing II

Multi-Physics Modeling of Molten Salt Transport in Solid Oxide Membrane (SOM) Electrolysis and Recycling of Magnesium 57
A. Powell, andS. Pati

Numeric Modeling for the Carbothermic Aluminum Process 65
D. Roha

A Coupled CFD-PBE Approach Applied to the Simulation of the Inclusion Behavior in a Steel Ladle. 73
J. Bel lot, V. De Felice, L Us Alves Daoud, A. Jardy, and S. Hans

Multiphysics CFD Modeling of a Free Falling Jet during Melt-Blowing Slag Fiberization 81
D. Gerogiorgis, D. Panias, and I. Paspaliaris

Numerical Simulation of Erosion Using Computational Fluid Dynamics 89
H. Grewal, H. Singh, and A. Agarwal

Modeling of Melting and Remelting Processes

A Multiscale Transient Modeling Approach for Predicting the Solidification Structure in VAR Processed Alloy 718 Ingots 99
L. Nastac

A Multiscale Model for the Simulation of V.A.R. Ingot Solidification 107
M Revil-Baudard, A. Jardy, F. Leclerc, M. Zaloznik, V. Rebeyrolle, and H. Combeau

Mathematical Modeling of Fluid Dynamics and Vessel Vibration in the AOD Process 115
C. Wuppermann, A. Rückert, H. Pfeifer, H. Odenthal, and E. Hovestädt

Solute Redistribution, Liquid/Solid Interface Instability, and Initial Transient Regions during the Unidirectional Solidification of Ti-6-4 and Ti-17 Alloys 123
L. Nastac

Numerical Analysis of Electromagnetic Field in an Electroslag Remelting Process with Three-Phases Electrodes 131
B. Li, F. Wang, and M. Shan

Influence of the Frequency of the Applied AC Current on the Electroslag Remelting Process 139
A. Kharicha, M. Wu, A. Ludwig, M. Ramprecht, and H. Holzgruber

Modeling of Casting and Solidification Processes I

Modeling of Multiscale and Multiphase Phenomena in Material Processing 149
A. Ludwig, A. Kharicha, and M. Wu

2D and 3D Numerical Modeling of Solidification Benchmark of Sn-3wt.% Pb Alloy under Natural Convection 163
R. Boussaa, L. Hachani, B. Saadi, X. Wang, O. Budenkova, K. Zaidat, H. Ben Hadid, and Y. Fautrelle

Numerical Modeling of the Interaction between a Foreign Particle an Solidifying Crystalline Interface 171
E. Agaliotis, M. Rosenberger, A. Ares, and C Schvezov

Optimization of Tensile Test Pattern for Aluminum Alloys 179
E. Tan, A. Riza Tarakcilar, F. Syvertsen, and D. Dispinar

Modeling of Casting and Solidification Processes II

Modeling of Centrifugal Casting Processes with Complex Geometries 189
N. Humphreys, D. McBride, N. Croft, D. Shevchenko, N. Green, and M. Cross

CFD Modeling of Microstructural Development in the Scanning Laser Epitaxy Process 197
R. Acharya, R. Bansal, J. Gambone, and S. Das

Numerical Simulation of Macro-shrinkage and Micro-shrinkage in A356 Sand Mold Castings 205
L. Nastac

Defect Analysis by Casting Simulation Software in Rolling Roll Manufactured by GGG70 213
E. Tan, A. Riza Tarakcilar, and D. Dispinar

SPH Model Approach Used to Predict Skin Inclusions into Semisolid Metal Castings 219
F. Pineau, and G. D'Amours

Vibrations Induced Flow in a Horizontal Centrifugal Casting 227
A. Kharicha, J. Bohacek, A. Ludwig, and M. Wu

Inverse Modeling for Determination of Thermal Properties of the Investment Casting Ceramic Mold 235
M Xu, S. Lekakh, V. Richards, and S. Dutler

Electromagnetic and Ultrasonic Processing of Materials

Modeling Magnetically Excited and Magnetically Damped Liquid Metal Flow 245
V. Bojarevics, and K. Pericleous

Numerical Analysis of the Influence of Melting and Application of Electromagnetic Stirring Prior to Solidification on Macrosegregation Formation during Casting of a Binary Alloy 253
K. Omdal Tveito, M. M'Hamdi, H. Combeau, M. Zaloznik, K. Zaidat, X. Wang, B. Saadi, and Y. Fautrelle

Multiscale Modeling of Ingot Solidification Structure Controlled by Electromagnetic and Ultrasonic Stirring Technologies 261
L. Nastac

Modeling the Case Hardening of Crankshafts 269
T. Munikamal, and S. Sundarraj

Modeling of Steelmaking Processes

Transport and Entrapment of Particles in Steel Continuous Casting 279
B. Thomas, Q. Yuan, R. Liu, S. Mahmood, and R. Chaudhaty

Mathematical Modeling of a Compressible Oxygen Jet Interacting with a Free Surface in a Basic Oxygen Furnace for Steel Production 287
K. Pericleous, B. Lebon, G. Djambazov, and M. Patel

CFD Model for Prediction of Liquid Steel Temperature in Ladle during Steel Making and Casting 295
A. Tripathi, J. Saha, J. Singh, and S. Ajmani

Multiphase Flow in a Steelmaking Converter Using an Unconventional Lance 303
M. Barron, I. Hilerio, and A. de Ita

Fluid Flow and Inclusion Removal in Multi-Strand Tundish with Nozzle Blockage 311
P. Jha, S. Mishra, S. Sharma, S. Ajmani, and M. Mahapatra

CFD Modeling of Fluid Flow Behavior and Bath Surface Deformation in LD Converter 319
T. Kundu, and S. Pal

Effect of Thermal Buoyancy Force on the Flow, Temperature Distribution and Residence Time Distribution of Molten Steel in the Slab Casting Tundish 327
H. Sun, B. Y an, andJ. Zhang

Time Zone Analysis of F-Curve for Intermixing during Ladle Change-Over 335
P. Jha, S. Kant, P. Kumar, and A. Kumar

Author Index 343

Subject Index 345