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Casting Process Modeling and Validation
Computational simulations of gravity casting for metallic U-Pu-Zr nuclear fuel rods were performed with the free surface flow solver Flow3d. Two different casting apparatus designs were explored for studying the effects on the final cast rod profiles. Experimental data for the casting problem obtained from Idaho National Laboratory (INL) was validated with numerical simulations on one of the designs considered. The volume of the rods cast, length of the rods, and temperature profiles were predicted through the transient casting process and were found to match closely with experimental data. A sensitivity analysis with vent locations, pressure, mesh refinement, and effects of surface tension at the interface were explored. This work serves as a validation benchmark for the casting problem and provides guidelines when performing simulation exercises for modeling casting. This paper also provides the mathematical framework to enabling modeling of the casting process.
Flow of fresh concrete through reinforced elements: Experimental validation of the porous analogy numerical method
Numerical simulations of concrete castings are complex and time consuming. In order to decrease simulation time and to simplify simulation procedure, an innovative modelling approach, which treats reinforced sections in a formwork as porous media, was proposed. In the previous studies, this numerical model was proved suitable to simulate casting of model yield-stress fluids through reinforced elements. This article focuses on the experimental validation of the proposed model at the concrete scale. For this purpose, a large-scale laboratory casting of a highly reinforced beam is performed. The casting process is numerically simulated and the numerical results are compared to the experimental measurements.
Modeling of interdendritic porosity defects in an integrated computational materials engineering approach for metal casting
Modeling and simulation of multiphysical phenomena needs to be considered in the design and optimization of mechanical properties of cast components in order to accelerate the introduction of new cast alloys. The data on casting defects, including microstructure features, is crucial for evaluating the final performance-related properties of the component. Here in this paper, the required models for the prediction of interdendritic casting defects, such as microporosity and hot tears, are reviewed. The data on calculated solidification shrinkage is presented and its effects on microporosity levels discussed. Numerical simulation results for microporosity are presented for A356, 356 and 319 aluminum alloys using ProCAST TM software. The calculated pressure drop of the interdendritic liquid was observed to be quite significant and the regions of high-pressure drop can be used as an indicator of the severity of interdendritic microporosity defects.
Development and testing of coarse-grained models for ultrasonic simulations of cast austenitic stainless steel
Ultrasonic inspection of cast austenitic stainless steel (CASS) in the nuclear industry is particularly challenging because of sound field scatter and attenuation caused by the coarse-grained microstructure. Modeling and simulation are important tools in ultrasonic testing, as they can be used to help address key aspects of inspections, such as developing new probe designs, predicting inspection reliability, and testing phased-array focal laws. However, developing a useful and reliable CASS model is challenging due to the many grain interfaces and crystalline orientations that must be captured. We demonstrate a method of creating a realistic CASS model that is usable in CIVA, a commercially available modeling and simulation software platform. Using polished and chemically etched sections, we generate models of a coarse-grained equiaxed specimen and a columnar specimen. We also test an alternative method of generating a coarse-grained model using Voronoi regions. We qualitatively compare sound field scatter and quantitatively compare sound field attenuation and beam partitioning in simulated sound fields to those of laboratory-measured sound fields. Results show that the Voronoi models perform as well as or better than the models based on actual grain morphology. Here we also show that model-to-model randomness in Voronoi grain structure can impact the magnitude of a simulated echo response by a factor of two or more. Although CASS models are potentially a good depiction of reality for a given scenario, they should not be considered representative since CASS morphology can change significantly from specimen to specimen or within the same specimen.
Report on results of current and future metal casting
New modeling capabilities needed to simulate the casting of metallic fuels are added to Truchas code. In this report we summarize improvements we made in FY2015 in three areas; (1) Analysis of new casting experiments conducted with BCS and EFL designs, (2) the simulation of INL’s U-Zr casting experiments with Flow3D computer program, (3) the implementation of surface tension model into Truchas for unstructured mesh required to run U-Zr casting.
Report on results of current and future metal fuel casting
New modeling capabilities needed to simulate the casting of metallic fuels are added to Truchas code. In this report we summarize improvements we made in FY2015 in three areas; (1) Analysis of new casting experiments conducted with BCS and EFL designs, (2) the simulation of INL’s U-Zr casting experiments with Flow3D computer program, (3) the implementation of surface tension model into Truchas for unstructured mesh required to run U-Zr casting.
Development of High-Performance Cast Crankshafts. Final Technical Report
The objective of this project was to develop technologies that would enable the production of cast crankshafts that can replace high performance forged steel crankshafts. To achieve this, the Ultimate Tensile Strength (UTS) of the new material needs to be 850 MPa with a desired minimum Yield Strength (YS; 0.2% offset) of 615 MPa and at least 10% elongation. Perhaps more challenging, the cast material needs to be able to achieve sufficient local fatigue properties to satisfy the durability requirements in today’s high performance gasoline and diesel engine applications. The project team focused on the development of cast steel alloys for application in crankshafts to take advantage of the higher stiffness over other potential material choices. The material and process developed should be able to produce high-performance crankshafts at no more than 110% of the cost of current production cast units, perhaps the most difficult objective to achieve. To minimize costs, the primary alloy design strategy was to design compositions that can achieve the required properties with minimal alloying and post-casting heat treatments. An Integrated Computational Materials Engineering (ICME) based approach was utilized, rather than relying only on traditional trial-and-error methods, which has been proven to accelerate alloy development time. Prototype melt chemistries designed using ICME were cast as test specimens and characterized iteratively to develop an alloy design within a stage-gate process. Standard characterization and material testing was done to validate the alloy performance against design targets and provide feedback to material design and manufacturing process models. Finally, the project called for Caterpillar and General Motors (GM) to develop optimized crankshaft designs using the final material and manufacturing processing path developed. A multi-disciplinary effort was to integrate finite element analyses by engine designers and geometry-specific casting simulations with existing materials models to optimize crankshaft cost and performance. Prototype crankshafts of the final design were to be produced and validated using laboratory bench testing and on-engine durability testing. ICME process simulation tools were used to investigate a broad range of processing concepts. These concepts included casting orientation, various mold and core materials, and various filling and feeding strategies. Each crankshaft was first simulated without gating and risers, which is termed natural solidification. The natural solidification results were used as a baseline for strategy development of each concept. Casting process simulations and ICME tools were proven to be reasonable predictors of real world results. Potential alloys were developed that could meet the project material property goals with appropriate normalization and temper treatments. For the alloys considered, post-normalization temper treatments proved to be necessary to achieve the desired yield strengths and elongations and appropriate heat treatments were designed using ICME tools. The experimental data of all the alloys were analyzed in combination with ICME tools to establish chemistry-process-structure relations. Several GM small gas engine (SGE) crankshafts were successfully cast in sand molds using two different sprue, runner, gate, riser, chill designs. These crankshafts were cast in two different steel alloys developed during the project, but casting finishing (e.g. riser removal) remains a cost challenge. A long list of future work was left unfinished when this project was unexpectedly terminated.
Numerical Simulation of V-shaped Segregation in Continuous Casting Blooms Based on a Microsegregation Model
This study establishes a volume-averaged model for transport phenomena to study V-shaped segregation in continuous casting blooms with different superheating and cooling rates by coupling fluid flow, macro-scale heat transfer, and solute transport. The results demonstrate that the modified Won–Thomas model considering back diffusion in the solid phase corresponds well with the measured carbon segregation. V-shaped segregation decreases with decreasing superheating and increases slightly with decreases in the cooling rate. The results of original position statistical distribution analysis correspond well with the simulation results. This phenomenon can be exploited to improve the quality of bloom.
A Review of Permanent Magnet Stirring During Metal Solidification
Rather than using conventional electromagnetic stirring (EMS) with three-phase alternating current, permanent magnet stirring (PMS), based on the use of sintered NdFeB material which has excellent magnetic characteristics, can be employed to generate a magnetic field for the stirring of liquid metal during solidification. Recent experience with steel casting indicates that PMS requires less than 20 pct of the total energy compared with EMS. Despite the excellent magnetic density properties and low power consumption, this relatively new technology has received comparatively little attention by the metal casting community. This paper reviews simulation modeling, experimental studies, and industrial trials of PMS conducted during recent years. With the development of magnetic simulation software, the magnetic field and associated flow patterns generated by PMS have been evaluated. Based on the results obtained from laboratory experiments, the effects of PMS on metal solidification structures and typical defects such as surface pinholes and center cavities are summarized. The significance of findings obtained from trials of PMS within the metals processing sector, including the continuous casting of steel, are discussed with the aim of providing an overview of the relevant parameters that are of importance for further development and industrial application of this innovative technology.
Modeling of Crucial Process Parameters for the Continuous Improvement of Special Steels at the Stomana Plant
In this study, a heat transfer model that takes under consideration the micro-segregation phenomena and has been extensively deployed for solidification studies concerning the plant casters is also applied to show the casting speed and superheat effects upon internal soundness. Τhe solidification path of C45R, 42CrMo4, S355 grades was simulated using Thermocalc{sup ®} and DICTRA software in order to examine the phases formed in crucial process temperature windows for the casting. Coupled Heat Transfer/Simple Micro-Segregation Model software has been deployed to simulate the effect of cooling rate on solidus temperature, and solid fraction during solidification. The solidus temperature results computed by the HT/SM and DICTRA were found to be in good agreement. However, the differences in the predicted solidification fractions may derive from the fact that DICTRA uses an average cooling rate whereas the heat transfer SM model takes into account also the local cooling rates in the solidification progress.
Physical vapor deposition simulator by graphical processor unit ray casting
This paper presents fast, accurate software for modeling physical vapor deposition systems over irregular surfaces. The model is implemented using graphics processing unit (GPU) ray casting. Applied models are viewed as a cross section of the area of interest. Given evaporation rate, time, and angular profiles in a vacuum system, an iterative time-step approach for calculating deposition profiles is calculated in the GPU architecture following a ballistic modeling approach. Thin-film technologies for the electronics industry will require evaporations on complex surfaces. Depending on the nature of the surface, a uniform thin film across the topology is wanted for various device parameters. The ray casting method is tested against various profiles. The code is freely distributed on GitHub (see https://github.com/adam-r-thomas/PVDS).
Pececillo
Pececillo is a proxy-app for the open source Truchas metal processing code (LA-CC-15-097). It implements many of the physics models used in Truchas: free-surface, incompressible Navier-Stokes fluid dynamics (e.g., water waves); heat transport, material phase change, view factor thermal radiation; species advection-diffusion; quasi-static, elastic/plastic solid mechanics with contact; electomagnetics (Maxwell's equations). The models are simplified versions that retain the fundamental computational complexity of the Truchas models while omitting many non-essential features and modeling capabilities. The purpose is to expose Truchas algorithms in a greatly simplified context where computer science problems related to parallel performance on advanced architectures can be more easily investigated. While Pececillo is capable of performing simulations representative of typical Truchas metal casting, welding, and additive manufacturing simulations, it lacks many of the modeling capabilites needed for real applications.
Pececillo
Pececillo is a proxy-app for the open source Truchas metal processing code (LA-CC-15-097). It implements many of the physics models used in Truchas: free-surface, incompressible Navier-Stokes fluid dynamics (e.g., water waves); heat transport, material phase change, view factor thermal radiation; species advection-diffusion; quasi-static, elastic/plastic solid mechanics with contact; electomagnetics (Maxwell's equations). The models are simplified versions that retain the fundamental computational complexity of the Truchas models while omitting many non-essential features and modeling capabilities. The purpose is to expose Truchas algorithms in a greatly simplified context where computer science problems related to parallel performance on advanced architectures can be more easily investigated. While Pececillo is capable of performing simulations representative of typical Truchas metal casting, welding, and additive manufacturing simulations, it lacks many of the modeling capabilites needed for real applications.
Simulation of Air Entrainment during Mold Filling: Comparison with Water Modeling Experiments
Oxide inclusions form during pouring of metal castings as a result of air entrainment. Recently, a model was developed by the authors to predict the volumetric air entrainment during pouring. It was found that the velocity, diameter, and turbulence intensity of the liquid stream affect the air entrainment rate during pouring. In this study, the developed air entrainment model is validated with water modeling experiments. In the water modeling studies, water was poured using a bottom pour ladle. The effects of nozzle opening, head height, nozzle diameter, and nozzle extension are simulated. The predictions compare favorably with the experimental measurements. Results indicate that low head height and short pouring time have a beneficial effect on reducing the air entrainment during pouring. In addition, a fully open nozzle and the use of a nozzle extension further reduce the amount of entrained air.
Effect of Nozzle Port Angle on Transient Flow and Surface Slag Behavior During Continuous Steel-Slab Casting
Undesirable flow variations can cause severe instabilities at the interface between liquid mold flux and molten steel across the mold top-region during continuous steel casting, resulting in surface defects in the final products. A three-dimensional Large Eddy Simulation (LES) model using the volume of fluid method for the slag and molten steel phases is validated with plant measurements, and applied to gain new insights into the effects of nozzle port angle on transient flow, top slag/steel interface movement, and slag behavior during continuous slab casting under nominally steady conditions. Upward-angled ports produce a single-roll flow pattern with lower surface velocity, due to rapid momentum dissipation of the spreading jet. However, strong jet wobbling from the port leads to greater interface variations. Severe level drops allow easy entrapment of liquid flux by the solidifying steel shell at the meniscus. Sudden level rises may also be detrimental, leading to overflow of the solidified meniscus region. Downward-angled ports produce a classic double-roll pattern with less jet turbulence and a more stable interface everywhere except near the narrow faces. Finally, the flow patterns, surface velocity, and level predicted from the validated LES model are compared with steady-state standard k-ε model predictions.
Manufacturing of Al-Ce/Metal-Matrix-Composites (MMC) for Harsh Environments
An integrated modeling/simulation and experimental approach will be used to design and synthesize Al-Ce/MMC for use in key technologies where improved energy efficiency and performance is harsh environments is required. Modeling and simulation work including thermodynamic modeling, DFT calculations, and continuum modeling of casting processes and mechanical behavior, will be combined with lab-scale synthesis to identify potential matrix and reinforcing phase compositions for large-scale synthesis. The experimental synthesis work will rely on lab-scale casting and gas atomization to identify the optimal matrix compositions for pilot/commercial-scale synthesis is Al-Ce/MMC. Selected Al-Ce/MMC will be synthesized by commercial scale melt processing, powder metallurgy and thermomechanical processing. The corrosion resistance, mechanical properties as a function of temperature, and thermal conductivity of the composites will be characterized to validate target properties are met or exceeded. This work will focus on two selected applications; however, the design framework will have broad applicability for composites for numerous harsh service condition applications. We will have synthesized Al-Ce/MMC that exhibit better performance in harsh environments than currently used materials.
Strong lensing analysis of the galaxy cluster MACS J1319.9+7003 and the discovery of a shell galaxy
We present a strong-lensing (SL) analysis of the galaxy cluster MACS J1319.9+7003 (z = 0.33, also known as Abell 1722), as part of our ongoing effort to analyze massive clusters with archival Hubble Space Telescope (HST) imaging. We spectroscopically measured with Keck/Multi-Object Spectrometer For Infra-Red Exploration (MOSFIRE) two galaxies multiply imaged by the cluster. Our analysis reveals a modest lens, with an effective Einstein radius of θ{sub e}(z=2)=12±1{sup ′′}, enclosing 2.1±0.3×10{sup 13} M{sub ⊙}. We briefly discuss the SL properties of the cluster, using two different modeling techniques (see the text for details), and make the mass models publicly available (ftp://wise-ftp.tau.ac.il/pub/adiz/MACS1319/). Independently, we identified a noteworthy, young shell galaxy (SG) system forming around two likely interacting cluster members, 20″ north of the brightest cluster galaxy. SGs are rare in galaxy clusters, and indeed, a simple estimate reveals that they are only expected in roughly one in several dozen, to several hundred, massive galaxy clusters (the estimate can easily change by an order of magnitude within a reasonable range of characteristic values relevant for the calculation). Taking advantage of our lens model best-fit, mass-to-light scaling relation for cluster members, we infer that the total mass of the SG system is ∼1.3×10{sup 11} M{sub ⊙}, with a host-to-companion mass ratio of about 10:1. Despite being rare in high density environments, the SG constitutes an example to how stars of cluster galaxies are efficiently redistributed to the intra-cluster medium. Dedicated numerical simulations for the observed shell configuration, perhaps aided by the mass model, might cast interesting light on the interaction history and properties of the two galaxies. An archival HST search in galaxy cluster images can reveal more such systems.