CFD modeling and simulation in materials processing 2016: proceedings of a symposium sponsored by the Process Technology and Modeling Committee of the Extraction and Processing Division and the Solidification Committee of the Materials Processing and Manu

282 Pages·2016·36.511 MB·English

by  Nastac, Laurentiu

JWBT1823-NastacCFD_Modeling.indd i 3 December 2015 1:44 PM
FEBRUARY 14-18
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TENNESSEE MUSIC CITY CENTER
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Proceedings of a symposium sponsored by
the Process Technology and Modeling Committee
of the Extraction and Processing Division
and the Solidification Committee of
the Materials Processing and Manufacturing Division
of The Minerals, Metals & Materials Society (TMS)
held during
FEBRUARY 14-18 DOWNTOWN NASHVILLE,
TENNESSEE MUSIC CITY CENTER
Edited by:
Laurentiu Nastac, Lifeng Zhang, Brian G. Thomas, Miaoyong
Zhu, Andreas Ludwig, Adrian S. Sabau, Koulis Pericleous,
and Hervé Combeau
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Copyright © 2016 by The Minerals, Metals & Materials Society.
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TaBle oF ConTenTS
CFD Modeling and Simulation in
Materials Processing 2016
Preface .....................................................................................................................ix
Editors .....................................................................................................................xi
Iron and Steelmaking (Tundish, Casting,
Converter, Blast Furnace)
On the Importance of Modeling 3D Shrinkage Cavities for the Prediction of
Macrosegregation in Steel Ingots .............................................................................3
A. Ludwig, M. Wu, and A. Kharicha
Computational Fluid Dynamics Simulations of a Laboratory Flash Reactor
Relevant to a Novel Ironmaking Process ...............................................................11
Deqiu Fan, Yousef Mohassab, and H.Y. Sohn
Fluid Flow and Inclusion Motion in a Five-Strand Continuous Casting
Tundish ...................................................................................................................19
Abulikemu Yasen and Dongteng Pan
Liquid Steel Flow and Interactions with Nonmetallic Phases in the
Continuous Casting Tundish Using CFD & Physical Modeling ...........................27
Christopher Eastman Jr., Peter Glaws, and Dongbu Cao
Simulation of Fluid Flow and Heat Transfer in Plasma Arc Region of
AC Electric Arc Furnace ........................................................................................35
Qipeng Dong and Jiongming Zhang
Simulation of Heat Transfer in Slab Continuous Casting Mold and
New Formation Mechanism of Shell Hot Spots ....................................................43
Zhaozhen Cai and Miaoyong Zhu
v
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Computational Investigation of Splashing Behaviors in
Steelmaking Converter ...........................................................................................51
Qiang Li, Mingming Li, Mingxia Feng, and Zongshu Zou
Simulation of Air Entrainment in High Pressure Die Casting Applications ..........59
Juergen Jakumeit, Herfried Behnken, Frank Schmidt, Julian Gänz, Bastian
Thorwald, and Michael Mathes
Numerical Simulation of the Multiphase Flow in the Single-Tundish
System ....................................................................................................................67
Shupei Liu, Bo Wang, Zhiliang Yang, Shuai Feng, Kongfang Feng, Jinyin Xie,
and Jieyu Zhang
CFD Analysis of Blast Furnace Operating Condition Impacts on
Operational Efficiency ...........................................................................................75
Tyamo Okosun, Armin K. Silaen, Guangwu Tang, Bin Wu, and
Chenn Q. Zhou
Microstructure evolution
Validation of a Model for the Columnar to Equiaxed Transition with
Melt Convection .....................................................................................................85
Mahdi Torabi Rad and Christoph Beckermann
Modeling the Multicomponent Columar-to-Equiaxed Transition
of Alloy 625 ...........................................................................................................93
Kyle Fezi and Matthew J.M. Krane
Performance Optimization and Evaluation of a 3D CA-FVM Model for
Dendritic Growth of Fe-C Alloy ..........................................................................101
Weiling Wang, Sen Luo, and Miaoyong Zhu
Multiscale Modeling of the Solidification Structure Evolution of
Continuously Cast Steel Blooms and Slabs .........................................................109
Laurentiu Nastac, Mikko Kärkkäinen, Pilvi Hietanen, and Seppo Louhenkilpi
Numerical Simulation of Dendritic Growth of Fe-C Binary Alloy with
Natural Convection ..............................................................................................117
Sen Luo, Weiling Wang, and Miaoyong Zhu
vi
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Localized Strengthening of Al-Based Casting Alloys by Automatized
Optimization of Laser Heat Treatment ................................................................125
A. Ludwig and T. Holzmann
Casting with external Field Interaction
A High-Order Acoustic Cavitation Model for the Treatment of a
Moving Liquid Metal Volume ..............................................................................135
G S Bruno Lebon, Iakovos Tzanakis, Koulis Pericleous, and Dmitry Eskin
Progress on Numerical Modeling of the Dispersion of Ceramic
Nanoparticles during Ultrasonic Processing and Solidification of
Al-Based Nanocomposites ...................................................................................143
Daojie Zhang and Laurentiu Nastac
Effects of Velocity-Based Packing Criteria on Models of Alloy
Solidification with Free Floating Solid ................................................................151
A. Plotkowski and Matthew J.M. Krane
Large Eddy Simulations on the Effects on Double-Ruler Electromagnetic
Braking and Nozzle Submergence Depth on Molten Steel Flow in a
Commercial Continuous Casting Mold ...............................................................159
Kai Jin, Surya P. Vanka, Brian G. Thomas, and Xiaoming Ruan
Smelting, Degassing, ladle Processing, Mechanical Mixing,
and Ingot Casting
CFD Modeling of a Ladle with Top Stirring Lance .............................................169
Haibo Ma, Xia Chen, Hoyong Hwang, Megan Pratt, Russel J. Mulligan,
Bin Wu, Guangwu Tang, and Chenn Q. Zhou
Numerical Simulation on Multiphase Flow in the Two Side-Blown
Oxygen-Enriched Copper Smelting Furnace .......................................................179
Liu Guanting, Liu Yan, Li Xiaolong, and Zhang Ting-an
3D CFD Modeling of the LMF System ...............................................................187
Laurentiu Nastac, Daojie Zhang, Qing Cao, April Pitts, and Robert Williams
Application of CFD to Multi-Phase Mixing in the Metals and
Mining Industries .................................................................................................195
Duane Baker and Adam Blackmore
vii
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Numerical Study and Experimental Validation of Multiple Pouring
Process in a 438-t Steel Ingot ...............................................................................203
Zhenhu Duan, Houfa Shen, Jinwu Kang, and Baicheng Liu
3D CFD Multicomponent Model for Cold Spray Additive Manufacturing of
Titanium Particles ................................................................................................213
Muhammad Faizan-Ur-Rab, Saden H. Zahiri, S.H. Masood, M. Jahedi,
and R. Nagarajah
Numerical Simulation of Effect of Different Electrodes on Magnetic
Force and Flow Field of Pure Aluminum Melt ....................................................221
Qixin Wang, Xiang Wang, Zhishuai Xu, Ning Pei, Yongyong Gong, and Qijie Zhai
Poster Session
Gas-Solid Flow and Injected Gas Distribution in OBF Analyzed
by DEM-CFD .......................................................................................................229
Zeshang Dong, Jingsong Wang, Jinzhou Liu, Xuefeng She, Qingguo Xue, and Lin Lin
Improving Current Efficiency Through Optimizing Electrolyte Flow in
Zinc Electrowinning Cell .....................................................................................239
Hongdan Wang, Wentang Xia, Wenqiang Yang, and Bingzhi Ren
Influence of Heavy Reduction (HR) on the Internal Quality of the
Bearing Steel GCr15 Bloom ................................................................................247
Cheng Ji, Chen-hui Wu, and Miao-yong Zhu
Numerical Study of Flow Behavior and Optimization of Nozzle Ports in
Continuous Casting Slab Mold ............................................................................255
Shuai Feng, LingXiang Hong, Bo Wang, Shupei Liu, Zhiliang Yang,
Kongfang Feng, Liang Bai, and Jieyu Zhang
The Effect of Pulse Width on the Characteristic of Discharge and
Flow for Pure Aluminum .....................................................................................263
Xiang Wang, Zhishuai Xu, Qixin Wang, Qijie Zhai, Ning Pei, and
Yongyong Gong
Author Index ........................................................................................................271
Subject Index .......................................................................................................275
viii
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PREFACE
This book contains the proceedings of the symposium, “CFD Modeling and
Simulation in Materials Processing,” held at the TMS 2016 Annual Meeting &
Exhibition in Nashville, Tennessee, February 14–18, 2016.
This symposium dealt with computational uid dynamics (CFD) modeling and
simulation of engineering processes. The papers published in this book were
requested from researchers and engineers involved in the modeling of multiscale
and multiphase phenomena in material processing systems.
The symposium focused on the CFD modeling and simulation of the following
processing areas: Iron and Steelmaking (Tundish, Casting, Converter, Blast Furnace),
Smelting, Degassing, Ladle Processing, Mechanical Mixing, and Ingot Casting,
Casting with External Field Interaction and Microstructure Evolution.
The symposium also covered applications of CFD to engineering processes and
demonstrated how CFD can help scientists and engineers to better understand the
fundamentals of engineering processes.
On behalf of all symposium organizers and participants,
Prof. Laurentiu Nastac
The University of Alabama
Dept. of Metallurgical & Materials Engineering
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EDITORS
Laurentiu Nastac is currently an Associate Professor of
Metallurgical and Materials Engineering at The University
of Alabama, Metallurgical and Materials Engineering
Department, Tuscaloosa, Alabama, a Key FEF Professor
and the Director of the Solidi cation Laboratory and the
UA-COE foundry. For his teaching and research interests
please visit his website: http://lnastac.people.ua.edu/. Dr.
Nastac received the Diploma Engineering degree in
Metallurgy and Materials Science from the University
“Politehnica” of Bucharest, Romania in 1985 and the M.S.
and Ph.D. degrees in Metallurgical and Materials
Engineering from The University of Alabama, Tuscaloosa in 1993 and 1995,
respectively. He has held various engineering, research, and academic positions in
Romania and the United States. At Caterpillar he conducted research in the area of
macro transport and solidi cation-kinetics modeling and developed specialized
casting simulation software. At Concurrent Technologies Corporation (CTC) he
conducted research primarily in the area of advanced metalcasting and solidi cation
processes with emphasis on the modeling and simulation of casting phenomena. In
1999, in recognition of his work on solidi cation of titanium-based alloys and
superalloy remelt ingots, he received the prestigious Bunshah Best Paper Award
from the American Vacuum Society, Vacuum Metallurgy Division. More recently, he
received the NMC (Navy Metalworking Center) achievement award and 2 CTC
awards. Dr. Nastac developed eight software tools; made more than 160 presentations;
co-authored three patents, over 150 conference and journal articles and more than 70
scienti c reports in the materials science and manufacturing elds; and co-authored
10 books—one is a monograph titled Modeling and Simulation of Microstructure
Evolution in Solidifying Alloys published by Springer in 2004. He is a key reader for
Metallurgical and Materials Transactions, a member of the Editorial Board of the
International Journal of Cast Metals Research, and a member of the TMS
Solidi cation Committee; he has served on scienti c committees and as an organizer
for international conferences dedicated to CFD modeling and simulation in materials
processing area and for casting and solidi cation processes.
xi
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