bluuebunny/crossref_metadata_2025_split huggingface dataset:
Modulating Meltpool Dynamics and Microstructure using Thermoelectric Magnetohydrodynamics in Additive Manufacturing
Authors: Kao A , Tonry C , Soar P , Krastins I , Fan X , Lee PD , Pericleous K 
Published: May 2023

Abstract
Meltpool modulation in Selective Laser Remelting Additive Manufacturing via an oscillating magnetic field generates Thermoelectric Magnetohydrodynamics (TEMHD) flow. Numerical predictions show that the resulting microstructure can be significantly altered. A multi-scale numerical model captures the meso-scale melt pool dynamics coupled to microscale solidification showing the microstructure evolution and solute redistribution. The results highlight the complex interaction of the various physical phenomena and also show the method’s potential to disrupt the epitaxial growth defect. The model predictions are supported by preliminary experimental results that demonstrate the dependency of the melt pool depth on magnetic field orientation. The results highlight how a time-dependent field has the potential to provide an independent control mechanism to tailor microstructures.
Uncertainty quantification for computational modelling of laser powder bed fusion
Authors: Wells S , Plotkowski A , Coleman J , Rolchigo M , Carson R , Krane M J M 
Published: May 2023

Abstract
Additive manufacturing (AM) may have many advantages over traditional casting and wrought methods, but our understanding of the various processes is still limited. Computational models are useful to study and isolate underlying physics and improve our understanding of the AM process-microstructure-property relations. However, these models necessarily rely on simplifications and parameters of uncertain value. These assumptions reduce the overall reliability of the predictive capabilities of these models, so it is important to estimate the uncertainty in model output. In doing so, we quantify the effect of model limitations and identify potential areas of improvement, a procedure made possible by uncertainty quantification (UQ). Here we highlight recent work which coupled and propagated statistical and systematic uncertainties from a melt pool transport model based in OpenFOAM, through a grain scale cellular automaton code. We demonstrate how a UQ framework can identify model parameters which most significantly impact the reliability of model predictions through both models and thus provide insight for future improvements in the models and suggest measurements to reduce output uncertainty.
Numerical modelling of macrosegregation in three-dimensional continuous casting of steel billets
Authors: Mramor K , Vertnik R , Šarler B 
Published: May 2023

Abstract
Macrosegregation presents a considerable defect in the continuous casting of billets and can critically affect the final properties of the product. The numerical modelling can help to predict and better understand the segregation and flow patterns inside the mould. The process is modelled with a physical model described by a set of conservation equations describing the t heat transfer, turbulence, fluid flow, solidification and segregation. A two-equation low-Re k-epsilon model and Abe-Kondoh-Nagano closures are used to close governing equations in this incompressible fluid flow example. The Boussinesq approximation is applied to account for the thermo-solutal buoyancy effects, and the Darcy approximation is applied for the description of the flow through the porous mushy zone. On a microscale, a lever rule solidification model is used to couple liquid fraction, temperature and concentration. The three-dimensional model is solved with the method based on local collocation with multiquadric radial basis functions on seven-nodded subdomains. The aim of this contribution is to explore the three-dimensional macrosegregation patterns of 0.51 wt% carbon steel in the solidified shell of the steel in the mould.
How electromagnetic stirring influences fluid flow in continuous casting of steel
Authors: Fainberg Jakob , Hepp Erik , Shvydkii Evgenii 
Published: May 2023

Abstract
State-of-art simulation models provide quantitative insights into flow, solidification and stress formation for continuous casting processes. This includes the entire process, from the tundish and the flow into the mold to the solidifying strand, which is withdrawn through various cooling zones. Process simulation and optimization provides important information about quality and productivity to evaluate process alternatives. This is only be possible if all relevant process parameters can be taken into account. The use of electromagnetic stirring is a technology which plays a significant role in the majority of continuous casting processes worldwide and its effects cannot be neglected in simulation models. This paper will discuss the modeling of electromagnetic stirring (EMS) and its impact on steel slab continuous casting.
Two cases with and without EMS are presented. The theoretical background to calculate the Lorentz force are described. The EMS calculation described here works with traveling (linear) magnetic fields. The effect of the EMS on the flow behavior, solidification and macrosegregation is shown on an industrial-scale slab casting.
This information leads to a better understanding of the EMS process in industrial applications to avoid casting defects, improve the quality of the final product, and increase the efficiency of the casting process.
Non-metallic inclusion (NMI) deposition in a slide-gate submerged entry nozzle (SEN)
Authors: Shibly K U R M , Tullis S , Phillion A B 
Published: May 2023

Abstract
Clogging of the submerged entry nozzle (SEN) is a common and persistent issue in the continuous casting process for steel alloys. The dominant clogging mechanism has been attributed to the deposition and accumulation of non-metallic inclusions (NMI) in the steel melt. Prior studies of NMI deposition assume that every collision between an inclusion and the nozzle wall results in adhesion, which is unrealistic. In this study, a macroscopic transport model for fluid and NMI motion is combined with a microscale model for NMI adhesion and applied to a slide-gate nozzle. Eight NMI sticking probabilities (S) and three slide-gate linear opening positions are explored. Simulation results indicated that the more closed the slide-gate, the greater the total deposition of NMI. When the slide-gate was partially open, the particle area number density was highest above, within and just below the slide-gate. But when the slide-gate was fully opened the deposition was concentrated in the upper tundish nozzle. Deposition behaviour fell into two regimes based on S. When S ≤ 0.05, the particle deposition was low and increased rapidly with sticking probability. When S ≥ 0.05, the particle deposition was high but changed very little with sticking probability. Changes to sticking probability did not significantly affect the deposition locations or relative distribution of particles within the nozzle.
In situ observation of solidification in peritectic steels and evaluation of the strains induced in the solidifying shell
Authors: Yasuda H , Narumi T , Katsube R , Nanri Y 
Published: May 2023

Abstract
In the continuous casting of peritectic steels, unevenness and cracks of the solidifying shell are typical casting defects. This study focuses on the ferrite–austenite transformation and the influence of the transformation on the solidifying shell deformation. In situ observations revealed that the austenite hardly nucleated and, consequently, the undercooled ferrite massively transformed to the austenite in the solid state. Simultaneously, the austenite rapidly solidified in the remaining liquid. The volume changes due to the ferrite–austenite transformation and the solidification shrinkage were measured using time-resolved tomography. On the basis of the observations and measurements, a model that includes the ferrite–austenite transformation and the austenite solidification was proposed to evaluate the volumetric strains in the solidifying shell. There was a sharp peak in the volumetric strains derived from the model at hypo-peritectic compositions. This work demonstrates the need to include the ferrite–austenite transformation in the solid state and the rapid austenite solidification for understanding the solidifying shell deformation in peritectic steels.
Flow-enhanced remelting of settling/floating globular crystals during mixed columnar-equiaxed solidification
Authors: Wu M , Zhang Z , Zhang H , Ludwig A , Kharicha A 
Published: May 2023

Abstract
Previously, the authors have used a mixed columnar-equiaxed solidification model, successfully ‘reproduced’ the solidification benchmark experiments on the Sn-10wt.%Pb alloy under natural/forced convections (travelling magnetic stirring) as performed at SIMAP laboratory [Int. J. Heat Mass Transf. 85 (2015) 438-54]. The current contribution is to address the flow-effect on the remelting of settling/floating crystals during the mixed columnar-equiaxed solidification. The re-melting or growth is controlled by diffusion of solute in the liquid boundary layer. The diffusion length due to the flow-effect is modelled as a function of Schmidt and Reynolds numbers. The modelling results show that remelting rate of the floating/settling crystals, which originate from fragmentation and then brought to the superheated region by the forced flow, can be enhanced by the flow. In turn the released latent heat can reduce the temperature locally (even globally), hence to speed up the solidification of the columnar structure. Additionally, the solidification-migration-remelting of equiaxed grains present an important macrosegregation mechanism. By solidification of a crystal in the cold region it rejects solute, while by remelting of the crystal it dilutes the surrounding melt. These phenomena are found critical in many engineering castings with mixed columnar-equiaxed solidification.
A mathematical examination of the impact of mould transparency to infrared radiation on solidification during the investment casting process
Authors: Jones C A , Jarfors A E W , Rogers E , Vrethed P , Silva P , Jolly M R 
Published: May 2023

Abstract
Investment casting is a highly dynamic process during which multiple competing physical phenomena are at work. Those seeking to understand and simulate such processes computationally are confronted with a considerable task, balancing accuracy with efficiency. Approximations and models based on well-understood and documented fundamental physics are powerful tools in a modeller’s arsenal. Driven by observed discrepancies between experimental thermocouple measurements and simulation predictions of casting temperatures, this work explores the additional alloy cooling mechanism of mould transparency to infrared radiation, targeting a new mathematical approximation applicable in such situations. Direct attenuation, scattering from coarse sand, sand distribution in the mould and material temperatures play a role in the extent of radiation transparency that must be considered. From this model, estimation of the additional cooling rate resulting from expected mould transparency can be determined and applied as a corrective measure to computation fluid dynamics (CFD) simulation results that do not capture this phenomenon.
Multiphase flow model of semi solid solidification of novel Al-15Mg2Si-Si composite
Authors: Das Prosenjit 
Published: May 2023

Abstract
In this work, a volume averaging technique based Eulerian multiphase flow CFD (Computational Fluid Dynamics) model is developed to simulate the semi-solid solidification of the cooling slope generated Al-15Mg2Si-4.5Si composite slurry. The four phases considered here are liquid (l), primary solid (Mg2Si), secondary solid (α-Al) and air (a). Whereas latent heat release during solidification is tackled via a temperature correction scheme. The effect of recalescence is also observed in the present solidification model. The simulation findings include shape and size of the α-Al and primary Mg2Si grains, solid fraction, temperature, melt viscosity etc. The developed multiphase flow model of cooling slope casting (semi solid solidification) is applied to a test case having melt pouring temperature (into the slope) of 650°C (923K). The simulation findings are then validated with the help of measurements of microstructural features observed in the experimental (optical) micrographs of the solidified samples.
Integrated property predictions during casting and heat treatment of Al-Si-Cu-Mg alloys by precipitation simulation
Authors: Mao Fengxin , Weidt Moritz , Roeser Frank , Thorborg Jesper , Barrales-Mora Luis 
Published: May 2023

Abstract
The production and manufacture of aluminium castings typically involves multiple heat treatment process steps. Simulation tools are very useful to help predict the evolution of mechanical properties, to improve process parameters and as a guideline for casting design. In this study, a kinetic model, based on Nucleation and Growth Theory (CNGT), was developed and implemented for modelling heat treatment in a casting process simulation tool. Starting from information generated from the simulation of solidification and cooling of the casting, simulation was carried out to predict further precipitation behaviour of multiple Cu or Mg-Si -containing phases during solution treatment, quenching, and artificial ageing processes in heat treatment of Al alloys. Model validation was carried out within the research cluster “Advance Metals and Processes” in Aachen, Germany. Heat treatments were performed on two different Al-Si-Cu-Mg alloys with different quench methods and at different ageing temperatures. Experimental investigations including atom probe, wavelength dispersive X-ray spectroscopy, and tensile tests were conducted to calibrate and validate the model. The simulations showed good agreement for the studied conditions and a promising modelling approach for integrated simulation of casting and heat treatment for industrial applications.
Development of a data assimilation system for the investigation of the dendrite solidification process by integrating in situ X-ray imaging and phase-field simulation
Authors: Yamamura A , Sakane S , Ohno M , Yasuda H , Takaki T 
Published: May 2023

Abstract
The dendrite solidification process has been observed and simulated using state-of-the-art techniques, such as time-resolved X-ray tomography (4D-CT) and high-performance phase-field (PF) simulations. 4D-CT has enabled the direct observation of the 3D dendrite growth in opaque alloys. However, the spatiotemporal resolution is not sufficient for investigating fast phenomena because a 3D solidification structure is obtained using hundreds of transmission images during the 180° rotation of a sample. High-performance PF simulations have enabled the simulation of multiple 3D dendrite growth phenomena. However, the material properties required in PF solutions of alloys are often unavailable. Therefore, integrating in situ X-ray observations with PF simulations using data assimilation is a promising approach for simultaneously solving these issues. In this study, we developed a data assimilation system with an ensemble Kalman filter, in which the solid fraction along the thickness of a sample was used as observation data to enable data assimilation using X-ray transmission images. The performance of the developed data assimilation system was evaluated via twin experiments for columnar dendrite growth during the directional solidification of a binary alloy in a thin film. The results showed that data assimilation using the solid fraction as observation data estimated the material properties and solidification morphologies with reasonable accuracy.
Modelling of major phases formation during solidification of Ferro-Silicon-Magnesium
Authors: Gouttebroze S , Marthinsen A , Kroka B , Götz A , Ott E 
Published: May 2023

Abstract
Ductile cast iron, also known as nodular cast iron, is a graphite-rich cast iron with high impact and fatigue resistance, due to its nodular graphite inclusions. Ductile cast iron is produced by incorporating additives (often FeSi alloys) to the iron base metal at different production steps to obtain the desired graphite shape. A crucial step is the addition of Magnesium to promote the spheroidization of the graphite. The most common method is by adding crushed and sized Ferro-Silicon-Magnesium (FSM). The alloy composition, microstructure, and sizing are assumed to affect the key parameters of this reaction, namely, reactivity, recovery, and slag formation. Therefore, the study of the solidification of FSM is important to understand and predict its performance at the foundries. The present work aims at understanding and predicting numerically the formation of the major phases during the solidification process. Two approaches have been used: thermodynamic calculations through Thermo-Calc solver and phase field modelling using MICRESS. The models have been calibrated by comparison with advanced statistical characterization of the microstructure. The results indicate a competitive growth of the major phases and transformation of phases in solid state that can be emulated by the model.
Numerical study on the formation of spurious grains and freckles during the directional solidification of superalloys
Authors: Zhang H , Wu M , Liu X , Ma D , Song M , Ludwig A , Kharicha A 
Published: May 2023

Abstract
Freckles, a significant issue encountered during the directional solidification of superalloys, are recognised by a trail of equiaxed grains parallel to the direction of gravity accompanied by local eutectic enrichment. In the current study, a mixed-columnar-equiaxed multiphase volume-average solidification model was employed to study the formation of freckles in superalloy casting. Fragments produced via flow-driven and capillary-driven fragmentation mechanisms are considered as the source of spurious grains. The transport and the growth/remelting of the fragments are considered. According to the simulation results, some segregation channels develop at the corners of the casting. Flow-driven fragments are produced in/around the segregation channels, whereas capillary-driven fragments are produced at a certain depth of the mushy zone across the entire section of the casting. The fragmentation rate caused by the flow-driven mechanism is several orders of magnitude larger than that caused by the capillary-driven mechanism, i.e. the flow-driven fragmentation mechanism is dominant for the currently investigated sample. After the solidification process, four freckles formed at the casting corners on the shadowed side, whereas it was freckle-free on the bright side.
Phase field simulation of segregation and precipitates formation during steel solidification
Authors: Santillana B , Paruchuri V , Prahl U 
Published: May 2023

Abstract
Multi-phase field modelling using MICRESS® has been used to perform simulations of the nucleation and evolution microstructure in a 2D domain as function of fundamental thermo-physical parameters, time, cooling rate and chemical composition during solidification. In order to have a better understanding of primary precipitates evolution during solidification in a case hardening steel and the precipites chosen were niobium-carbides (NbC) and manganese sulphides (MnS), simulations were done including the nucleation and growth of precipitates and coupled through thermodynamic databases. The results show a good comparison with the experimental microstructure measured with SEM-EDX measurements. The simulated time dependent segregation profiles of Nb and Mn in the interdendritic regions, and the precipitates composition, have a good similarity with the measurements. Even when the size and morphology of the NbC and MnS particles has a difference in the both simulated and experimental situations, this can be explained by the low resolution used in the simulation. This publication shows the modelling results and the comparison with the experimental measurements.
Tracking the evolution of hot tears in aluminium alloys using high-speed X-ray imaging
Authors: Han Insung , Feng Shikang , Lui Andrew , Wilde Fabian , Grant Patrick S , Liotti Enzo 
Published: May 2023

Abstract
Hot tears are detrimental defects forming during the final stage of solidification when the remaining liquid loses the capacity to compensate for liquid to solid volume shrinkage. Although a mature semi-quantitative description of hot tearing has been developed, little is known about the dynamic evolution of hot tears as experimental studies have been conducted mostly post-solidification or in semi-static in-situ conditions. Here, we present a methodology to investigate the evolution of hot tears with high spatial and temporal resolution using synchrotron-based X-ray radiography. We develop a novel hot tear detection and tracking algorithm for quantification of hot tear density, area fraction and merging from the analysis of radiographic sequences of the solidification of thin metal samples. The methodology is demonstrated for an Al-5wt%Cu alloy and examples of the results and new insights that can be achieved are described.
Revealing and simulating the effect of hidden damage on local and full-field deformation behaviour of cast aluminium
Authors: Olofsson Jakob , Bogdanoff Toni , Tiryakioğlu Murat 
Published: May 2023

Abstract
Pores have been the main focus of quality assurance in castings. Latest research has shown that in aluminium castings pores can form only if there is existing entrainment damage, i.e., pores are merely the visible parts of the entrainment damage, and usually invisible damage is much more extensive. However, its effect on deformation behaviour has not been previously established or observed in-situ. This work applies 2D Digital Image Correlation (DIC) to an in-situ full-field stress-strain analysis of tensile samples with a non-conventional heterogeneous stress distribution. The observations reveal that the effect of hidden damage extends far beyond its impact on fracture behaviour and is responsible for initiating local strain concentrations during deformation. By extracting local stress-strain data, FE simulations have been performed to mimic the effect of local hidden damage on the heterogeneous stress-strain field. SEM and FIB-SEM analysis has been applied to investigate the cause for the strain concentrations. The combined results show that hidden damage in the form of oxide films is not only responsible for premature fracture, but also affects the deformation behaviour of tensile samples by introducing dispersed strain concentrations.
Integrated fatigue life predictions of aluminium castings using simulated local microstructure and defects
Authors: Olofsson Jakob 
Published: May 2023

AbstractIn this work, an integrated simulation approach previously developed for static FE analyses is extended to microstructure- and defect-based fatigue life assessments of castings. The approach,the closed chain of simulations for cast components, combines casting process simulation with microstructure modelling and local material characterisation to generate heterogeneous material data for FE analysis and fatigue life assessment. The method is demonstrated on a High-Pressure Die Cast aluminium component. Areas with a high risk of defects are identified based on the simulated solidification conditions, and heterogeneous material data for the fatigue life analysis is generated. Fatigue testing has been performed with different levels of porosities to quantify the effect of defects on the element-specific Wöhler curves. Pore characteristics are assessed using 2D X-ray, fracture surface analysis and Kitagawa diagram. The results highlight the importance of taking the risk of defect formation into consideration when designing industrial aluminium castings subjected to fatigue loads.