Journal articles: 'Ingot molds'

1

Stets, P. D., N. G. Goch, V. S. Voroshilin, V. N. Golovkin, and G. G. Kondratova. "Thermally balanced ingot molds." Metallurgist 35, no. 3 (March 1991): 51. http://dx.doi.org/10.1007/bf00759898.

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2

Selivanov, Yu N., N. G. Lipovaya, A. I. Gunina, L. I. Eliseev, and B. A. Afanas'ev. "New protective coating for ingot molds." Metallurgist 35, no. 3 (March 1991): 50. http://dx.doi.org/10.1007/bf00759897.

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3

Zinchenko, V. G., M. O. Peshkov, and V. E. Roshchin. "Increasing the quality of forged ingots via thermal shielding of ingot molds." Russian Metallurgy (Metally) 2012, no. 6 (June 2012): 531–34. http://dx.doi.org/10.1134/s0036029512060249.

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4

Kiselev, V. I., V. A. Denisov, V. G. Korogodskii, A. V. Shnaider, and Yu D. Isupov. "Advantages of using lignosulfonates to lubricate ingot molds." Metallurgist 33, no. 12 (December 1989): 238. http://dx.doi.org/10.1007/bf00750274.

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5

Smolyakov, A. S., S. I. Shakhov, and B. A. Sivak. "Improvement of the tube mold to ensure uniform primary cooling of the ingot." Ferrous Metallurgy. Bulletin of Scientific , Technical and Economic Information 77, no. 3 (March 28, 2021): 288–94. http://dx.doi.org/10.32339/0135-5910-2021-3-288-294.

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For centering the cooling jackets of CCM tube molds relative to the tube, bolts twisted into the jacket are used. The adjustment is made manually, as a result the annular gap between the sleeve and the jacket can have a significant deviation from the specified values. The gap function is to cool the structure by passing water. Taking into account that almost all the modern CCMs for casting long, bloom and round billets are equipped with tube molds, creating a mold design in which the gap between the tube and the cooling jacket is formed with a high degree of accuracy, ensuring uniform heat removal from the walls of the tube is an urgent task. This is necessary to ensure a uniform thickness of the shell of the solidifying billet. The conditions were considered for the formation of a uniform shell of a solidifying ingot in a mold and the production of a billet that meets the requirements for its surface and geometric dimensions, the absence of internal and external cracks of thermal origin. It was shown that the violation of the alignment of the cooling jacket and the tube surfaces results in violation of the uniformity of the cooling water flow. The difference in the volume of water flowing in various parts of the gap between the tube and the jacket can reach 40%. When casting billets with diameters of 600 and 550 mm, the difference in heat flows due to misalignment in existing molds can be 30–40% and 25–35% respectively, and with a cross section of 300×400 mm – 13–23%. In order to eliminate these shortcomings, a new design of the tube mold was developed in VNIIMETMASH (Moscow), in which the gap between the sleeve and the cooling jacket is formed with high accuracy, ensuring uniform heat removal from the walls of the tube and obtaining a uniform thickness of the shell of the solidifying ingot. This will ensure that the casted billet meets the requirements for its quality parameters and geometric dimensions. The diagram of the designed mold for the bloom CCM, which produces billets with a cross section of 340×380 mm is presented.

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Belevitin, Vladimir, Yevgen Smyrnov, and Vitalii Skliar. "Forecasting Increase of Quality of Large-Sized Forgings Used for Stamping, Piercing, and Rolling of High-Duty Products." Materials Science Forum 989 (May 2020): 660–64. http://dx.doi.org/10.4028/www.scientific.net/msf.989.660.

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When utilizing current combined systems of manufacturing large-sized shaft forgings, there is a tendency towards using an integrated approach, which consists in optimizing the shape of forged ingots and methods of their forging, intensifying shear strains in the axial zone of the ingots during their plastic deformation, and eliminating asymmetry of external forces at various points along the cross section of the ingot being deformed. This paper presents the results of the comparative analysis of quality of shaft forgings when forging ingots with a three-beam symmetric and asymmetric cross-section, as well as with the traditional octahedral cross-section, are used for the manufacture of shaft forgings. It has been shown that the use of forging ingots with a three-beam symmetrical and asymmetrical cross section provided an increase of KCU by an average of 4.3% and 13.1%, and of density by 17.5% and 21.0%, respectively, in the absence and presence of inert gas (argon) blowdown of the melt in the casting ladle before casting it into ingot molds. Their use also contributes to an increase in the number of forgings, suitable for ultrasonic testing, according to the C/c class with a permissible equivalent discontinuity diameter of ≤ 3 mm.

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7

Panychev, S. I., and G. Sh Kiriya. "Production of a protective oxide coating on ingot molds." Metallurgist 34, no. 9 (September 1990): 188. http://dx.doi.org/10.1007/bf00748253.

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8

Tyurin, V. A., Yu V. Lukanin, and A. V. Morozov. "Ingot molds for obtaining long cylindrical ingots and features of the macrostructure of the metal." Metallurgist 56, no. 9-10 (January 2013): 742–47. http://dx.doi.org/10.1007/s11015-013-9645-9.

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9

Bubnov, S. Yu. "Mechanization of the tilting of ingot molds with calcium carbide." Metallurgist 31, no. 6 (June 1987): 171–72. http://dx.doi.org/10.1007/bf00733003.

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10

Sakhnov, B. I., and B. F. Stroganov. "Casting of steel into ingot molds as a “submerged” jet." Metallurgist 55, no. 9-10 (January 2012): 659–63. http://dx.doi.org/10.1007/s11015-012-9483-1.

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11

Timofeev, Viktor N. "Induction Heating of the Filling Conveyor Molds." Journal of Siberian Federal University. Engineering & Technologies 14, no. 5 (August 2001): 583–89. http://dx.doi.org/10.17516/1999-494x-0335.

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In the smelting and foundry production of aluminum ingots, filling conveyors are widely used. Aluminum ingots of a certain shape and weight are obtained by crystallizing liquid aluminum (melt) in the molds of the filling conveyor. As the mills move along the conveyor, the melt gradually hardens in them. In high-performance conveyors, the mills move through the water to increase the cooling rate of the melt. Therefore, after the mill is freed from the hardened ingot, water enters it. In order to avoid temperature shock and possible release of liquid metal, the molds must be dried and heated before pouring. At present, gas burners are used in aluminum plants for this purpose [1]. The purpose of this work is to study the possibility of induction heating of the filling conveyor molds. The calculation is carried out using Fourier series in complex form and approximate boundary conditions on the surface of ferromagnetic molds. The approximate boundary conditions avoid the need to calculate the electromagnetic field in a nonlinear ferromagnetic medium. In the heated object, the energy of the induced alternating electric field is irreversibly converted into thermal energy. This dissipation of thermal energy, which leads to the heating of the object, is determined by the presence of conduction currents (eddy currents). Induction heating is widely used in metallurgy for melting, heating and mixing of electrically conductive bodies. The method is based on the absorption of electromagnetic energy by bodies of an alternating magnetic field created by an inductor. The heated product is located in the immediate vicinity of the inductor. There are many publications on analytical and numerical, analysis of physical processes in the inductor-heated billet system. In this paper, an analytical calculation of electromagnetic processes in the system of inductor – ferromagnetic molds of the filling conveyor is carried out. The analytical solution is obtained by using the approximate boundary condition of L. R. Neumann on the surface of nonlinear ferromagnetic molds

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12

Kim, H. J., and Y. G. Kweon. "The application of thermal sprayed coatings for pig iron ingot molds." Journal of Thermal Spray Technology 5, no. 4 (December 1996): 463–68. http://dx.doi.org/10.1007/bf02645277.

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13

Smirnov, A. N., V. L. Pilyushenko, Yu V. Pettik, and V. Z. Bolotinskii. "Increasing the life of cast-iron ingot molds by vibrational treatment." Metallurgist 33, no. 8 (August 1989): 151. http://dx.doi.org/10.1007/bf00750200.

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14

Smirnov, A. N. "Low-frequency vibrational treatment to increase the service life of ingot molds." Metallurgist 41, no. 3-4 (March 1997): 134–35. http://dx.doi.org/10.1007/bf02767885.

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15

Ren, Li Na, Chun Liu, Zhi Yuan Rui, and Ming Yan Kou. "Research of Thermoanalysis of Horizontal Casting Machine Supporting Parts Based on Finite Element." Advanced Materials Research 875-877 (February 2014): 2113–17. http://dx.doi.org/10.4028/www.scientific.net/amr.875-877.2113.

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Horizontal casting machine is one of the key equipments of the continuous casting production line for aluminum ingot, the stable running of transporting chain has direct effects on the surface roughness of the finished aluminum ingots and the technical data of the machine. The casting machine supports are the main carriers of molds,the drive chain and other components,which have long-term work in hot and humid environment and easily leads to the running stationarity of transporting chain reduced. So in order to improve the operation stability of the transporting chains of the casting machine and the surface roughness of the finished aluminum ingots, the sequential coupling analysis methods of thermal structural coupled analysis module of the finite element software ANYSYS is used to analysis of thermal deformation and temperature field simulation for the casting machine supports, and determine the size and distribution pattern of the thermal deformation and thermal stress of the casting machine bearing parts,the simulation results provide a theoretical basis for new product design and development work in the selection ,structure and layout optimization.

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16

Markov, Yu I., E. N. Gadzhi, A. I. Fedorov, I. P. Chernyavskii, A. Yu Fadeev, and T. V. Markova. "Lubricating slabbing ingot molds with lignosulfonates with the use of a centering device." Metallurgist 30, no. 2 (February 1986): 58–59. http://dx.doi.org/10.1007/bf01140964.

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17

Vozhdaev, V. P., A. G. Timoshin, Yu N. Selivanov, A. V. Gorin, V. G. Loginov, and Yu I. Karamyshev. "Teeming steel into ingot molds with hot tops lined with heat-insulating inserts." Metallurgist 29, no. 10 (October 1985): 308–9. http://dx.doi.org/10.1007/bf00737568.

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18

Kiselev, V. N., and M. N. Sorokina. "System for monitoring and analyzing the durability of ingot molds for casting steel." Metallurgist 44, no. 2 (February 2000): 68–70. http://dx.doi.org/10.1007/bf02463533.

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19

Jeong, M. J., Chang Hwan Seo, Yeong Hwan Song, K. J. Kang, and Bo Young Hur. "Effect of Different Upper Side Types of Plaster Molds on the Pore Formation of Al Foams via Upward Foaming Method." Materials Science Forum 569 (January 2008): 269–72. http://dx.doi.org/10.4028/www.scientific.net/msf.569.269.

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Fabrication of Aluminum foam with near net shape has been investigated by powder metallurgy method and conventional pouring method. PM method is good for fabrication of near net shape foam, but it needs high cost compared with pouring method. More cost-effective methods are needed to make near net shape al foam to be applied various field. Therefore, novel method for fabrication Al foam was researched in this paper. In order to prepare near shape Al foams with homogeneous pore structures, the so-called upward foaming method was designed and applied. By using this method, two kinds of molds were designed, one is stainless mold used for melting and foaming Al and another is the plaster mold with near net shape. The fabrication procedures of near net shape Al foam are as following: (1) a quantity of Al ingot was melted in the stainless mold; (2) Ca particles was added in the Al melt to increase its viscosity; (3) TiH2 was introduced in the thickened Al melt to make melt being foamed; (4) the plaster mold was put on the stainless steel one to make enlarging Al melt foam fill with the plaster one; (4) the plaster mold was removed and was cooled. In this study, in order to get near net Al foam with relative good pore structures, the plaster molds were designed with three different upside styles and their effects on the pore structures (pore size, porosity and cell wall thickness) of Al foams were investigated. The results showed that the Al foam had the relative good pore structures when the plaster mold with a void was applied.

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20

Xu, Zhang Yin, and Yin Ju Jiang. "Study on the Thermal Fatigue Resistance of Ductile Iron." Advanced Materials Research 512-515 (May 2012): 2093–96. http://dx.doi.org/10.4028/www.scientific.net/amr.512-515.2093.

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Simulated service condition of aluminum ingot casting molds, samples of ductile iron was tested in a temperature Cycle from750°C and water-cooled to 25°C till a crack appeared in the sample. its thermal fatigue resistance of samples based various microstructure included as—casting, annealing or alloying ferritic matrix structure, or alloying pearlitic structure and the upper or low the bainitic structure had been researched. The study shows that the thermal fatigue resistance of the annealing ferritic nodular cast iron was superior to the others.

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21

Lee, Jye-Long, and Shen-Chih Lee. "Thermal fracture endurance of cast irons with application study of pig iron ingot molds." Metallurgical and Materials Transactions A 26, no. 6 (June 1995): 1431–40. http://dx.doi.org/10.1007/bf02647593.

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22

Popandopulo, I. K., O. V. Nosochenko, S. V. Leporskii, V. G. Panasenko, S. A. Solov'ev, and N. T. Vistorovskii. "Bottom-pouring of steel into LP-20 ingot molds in an oxygen-converter shop." Metallurgist 29, no. 8-9 (September 1985): 260–62. http://dx.doi.org/10.1007/bf00737824.

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23

Kiselev, V. N., and E. A. Bodyagin. "Use of Concentrate Prepared from Discarded Open-Hearth Slag to Make Alloyed Iron for Ingot Molds." Metallurgist 48, no. 1/2 (January 2004): 11–12. http://dx.doi.org/10.1023/b:mell.0000027857.11821.8b.

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24

Kalashnikova, O. A., and V. V. Dremov. "Influence of Forced Convection on the Solidification of Metal in Cast-Iron and Ceramic Ingot Molds." Journal of Engineering Physics and Thermophysics 89, no. 5 (September 2016): 1161–67. http://dx.doi.org/10.1007/s10891-016-1479-4.

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25

Shefer, A. K., Yu G. Sagalaev, G. G. Mikhailova, V. S. Radya, and G. A. Vyshgorod'ko. "Effect of the composition of the blast-furnace charge on the life of large slabbing ingot molds." Metallurgist 29, no. 6 (June 1985): 199–201. http://dx.doi.org/10.1007/bf00737602.

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26

Nicholson, Paul T., Caroline M. Jackson, and Katharine M. Trott. "The Ulu Burun Glass Ingots, Cylindrical Vessels and Egyptian Glass." Journal of Egyptian Archaeology 83, no. 1 (December 1997): 143–53. http://dx.doi.org/10.1177/030751339708300108.

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This paper examines a possible Egyptian origin for the glass ingots discovered in the Ulu Burun shipwreck off the Turkish coast and seeks to relate them to cylindrical vessels believed to be ingot moulds from Tell el-Amarna. A preliminary distinction between types of Ulu Burun ingot is also suggested and a comparison made between the ingot moulds from Amarna and those from Qantir.

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27

Alam, M. K., S. L. Semiatin, and Z. Ali. "Thermal Stress Development During Vacuum Arc Remelting and Permanent Mold Casting of Ingots." Journal of Manufacturing Science and Engineering 120, no. 4 (November 1, 1998): 755–63. http://dx.doi.org/10.1115/1.2830216.

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The development of thermal stresses in ingots during the vacuum arc remelting (VAR) as well as specialized permanent mold casting (PMC) process was modeled via numerical solution of the two-dimensional, nonsteady-state heat conduction and stress equilibrium equations. The numerical analysis was carried out in conjunction with experimental studies of the mechanical properties and microstructure of a cracked VAR titanium aluminide ingot. Numerical solutions were obtained for different values of ingot diameter, crucible-ingot interface heat transfer coefficients, and lengths of the melted-and-resolidified ingot. For both VAR and PMC, model predictions revealed that the maximum tensile thermal stresses are developed at the bottom of the ingot; the magnitude of such stresses increases with ingot diameter and the magnitude of the interface heat transfer coefficients. The microstructural analysis of a cracked ingot indicated that the thermal cracking occurred in the temperature range where the alloy has very little ductility. The predicted development of large tensile stresses correlates well with observations of thermal cracking during VAR of near-gamma titanium aluminide alloy ingots. By contrast, the predicted thermal stresses developed during PMC are lower, thus suggesting an attractive alternative to VAR to obtain sound, crack-free ingots.

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28

Jiang, Zhou Hua, and Xin Geng. "Research on the Surface Quality of ESR Large Slab Ingots." Advanced Materials Research 146-147 (October 2010): 670–73. http://dx.doi.org/10.4028/www.scientific.net/amr.146-147.670.

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A special bifilar 40t electroslag remelting(ESR) furnace for slab products has been fabricated to produce heavy plates for special application. The ESR slabs with the maximum thickness of the world in size of 980 mm thickness, 2000 mm wideness and 2800 mm length have been produced successfully. However, the ingots surface quality is a serious problemn in ESR process for large slab ingots, for ingot and mold with a relatively mobile, larger ingot contraction and thicker slag skin. Using CaF2-CaO-Al2O3-SiO2-MgO slag, suited remelting rate, lower filling ration, smooth movement of mold and adjusting taper of the mold and are necessary for improving surface quality of the ESR large slab ingots.

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29

Valeev, Dmitry, Dmitry Zinoveev, Alex Kondratiev, Dmitry Lubyanoi, and Denis Pankratov. "Reductive Smelting of Neutralized Red Mud for Iron Recovery and Produced Pig Iron for Heat-Resistant Castings." Metals 10, no. 1 (December 23, 2019): 32. http://dx.doi.org/10.3390/met10010032.

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The chemical and mineral composition of the red mud from the Ural Aluminum Plant were studied by XRF, XRD, and Mössbauer spectroscopy. Experiments on reductive smelting of red mud were carried out in a range of temperatures (1650–1750 °C) to recover iron from the aluminum production waste with maximum efficiency. It was found that it is possible to obtain pig iron with a high content of titanium, phosphorus, and vanadium, and low sulfur content. The efficiency of iron recovery at 1750 °C was found to be around 98%. Thermodynamic calculations were carried out to assist in finding the optimal conditions for the process (e.g., carbon content, furnace temperature, slag liquidus temperature). It was also found that the pig iron phase obtained at 1650 to 1700 °C is not separated from the slag phase into ingot compared with the sample obtained at 1750 °C. Pig iron obtained at 1750 °C can be used to produce molds for the steel-casting equipment.

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30

Liu, Rui Qing, An Yun Li, Li Jun Peng, and Guang Bin Qiu. "Microstructure and Properties of As-Cast Cu-20Ni-5Sn Alloy." Applied Mechanics and Materials 341-342 (July 2013): 18–22. http://dx.doi.org/10.4028/www.scientific.net/amm.341-342.18.

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Cu-20Ni-5Sn alloy has not only high content of Ni melted point 1453°C, but also low melting point elements of Sn melted at 231.9°C, therefore, the grain structure of alloy as-cast is in perfect dendrite that lends to form segregation and inverse segregation of Sn, so that the hot rolling (cogging) processing is restricted. The influence of casting methods, cooling rate and heat treatment on the microstructures and properties of as-cast Cu-20Ni-5Sn alloy were investigated. The results show that, compared to the ingot casted in iron mold and graphite mold, the microstructure of Cu-20Ni-5Sn ingot prepared by horizontal continuous casting is the finest and the Sn segregation level is in lowest. The microstructure of the ingot casted in graphite mold is in the most perfected dendritic and with the highest segregation of Sn, the microstructure of ingot in iron molding is in the middle. The ingots must be homogenized before cold-processing. Homogenization treatment can eliminate Sn segregation and dissolve the non-equilibrium phase of ingots.

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31

Duan, Zhen Hu, Xuan Du, Hou Fa Shen, and Bai Cheng Liu. "Experimental and Numerical Study of Macrosegregation in a 160 Steel Ingot." Materials Science Forum 850 (March 2016): 299–306. http://dx.doi.org/10.4028/www.scientific.net/msf.850.299.

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Large steel ingots are the important material for the equipment manufacturing industry. It is still difficult to predict and control the macrosegregation in ingot. In this paper, the cooling curves at the surface of ingot and temperature variation of the mold were measured. The carbon distribution was measured through the local region dissection of ingot. Then, based on the definite the heat transfer coefficient at the interface of mold/ingot, a two-phase model with consideration of the motion of equiaxed grains is applied for the prediction of macrosegregation in 160-t steel ingot formed during the solidification. The results indicate that the heat transfer coefficient at the interface of mold/ingot decreases sharply after starting solidification and then varies slowly. Negative segregation at the bottom of ingot forms due to the interaction of solidification interface and equiaxed grains deposition during solidification. The positive segregation appears in the riser with thanks to the solidification shrinkage and the floating enriched solute. Finally, the results of the predicted and the measured are in good agreement.

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32

Haga, Toshio, Takumu Sugishita, Hiroshi Fse, Hisaki Watari, and Shinichi Nishida. "Gravity Casting and Hot Forging of Al-Mg Alloy and Al-Mg Alloy with Fe Added." Materials Science Forum 1042 (August 10, 2021): 69–75. http://dx.doi.org/10.4028/www.scientific.net/msf.1042.69.

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Al-4.7%Mg alloy with 0, 0.2, 0.4, 0.6 and 0.8% Fe added was cast using a copper mold and an insulator mold. The cooling rates of ingots cast using the copper mold and the insulator mold were 30.6 °C/s and 0.5 °C/s, respectively. The tensile stress and elongation of the ingots cast by the copper mold were superior to those cast by the insulator mold. The addition of Fe did not lead to tensile stress, but the elongation became smaller as the Fe content increased. The elongation of the ingot cast using the copper mold became much smaller on addition of only 0.2% Fe. The tensile stress and elongation were improved by hot forging with 50% reduction. The elongation of the ingots with Fe added was significantly improved by the hot forging. The degree of improvement of the tensile stress and elongation for the ingots cast using the insulator mold was remarkable.

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33

Moravec, Ján, Peter Kopas, Lenka Jakubovičová, and Bohuš Leitner. "Experimental casting of forging ingots from model material." MATEC Web of Conferences 157 (2018): 05017. http://dx.doi.org/10.1051/matecconf/201815705017.

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The paper describes the process of casting ingots from the model material into a special mold made for these tests. The material was chosen stearin, which proved to be suitable for this type of laboratory test. During the solidification process of the ingot model under laboratory conditions, it was observed how gradually the layer formed on the contour of the casting. Gradual cooling of the ingot resulted in a decrease in the volume of the liquid phase in his body. The fog is readily observable by the naked eye and this is manifested by the formation of a gap between the ingot mold wall and the ingot body. A silicone oil has been used as a separating melt separating layer and the wall of the ingot that has reliably fulfilled this task. Casting was done in two ways, with a standing and lagging mold. The process of filling the cavity itself was to create conditions for the linear flow of the melt. Observation of the ingot after its solidification confirmed the fact that the filling of the cavity proceeded under such conditions in terms of the melt flow rate.

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34

Killick, David. "Tracing Ingombe Ilede's trade connections." Antiquity 91, no. 358 (August 2017): 1087–88. http://dx.doi.org/10.15184/aqy.2017.100.

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McIntosh and Fagan (above) write that “For 45 years, Ingombe Ilede has been viewed as a key nexus linking the Copperbelt and Great Zimbabwe”. Some regional specialists have not believed this since the publication of Swan's (2007) important review of the sizes and shapes of prehistoric copper ingots found in modern Zimbabwe. Swan noted that both of the ingot moulds found at Great Zimbabwe (which have a clear stylistic connection to the Copperbelt) are of the earlier HIH style (ninth to fourteenth centuries AD; de Maret 1995; Nikis & Livingstone Smith in press). But neither the later HXR-style copper ingots (fourteenth to seventeenth centuries)—some of which were excavated at Ingombe Ilede—nor the moulds to make them have been found on a Zimbabwe tradition site. The distribution of HXR ingots within the modern nation of Zimbabwe is almost exclusively in the north, within the former territory of the Mutapa state (Swan 2007: fig. 2). The clear implication is that the HXR ingot style—and thus the elite burials at Ingombe Ilede—post-date the breakup of the state ruled from Great Zimbabwe, which gave birth to the Mutapa (northern) and Torwa (southern) states. The new radiocarbon dates by McIntosh and Fagan provide welcome confirmation of this inference.

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35

Syryamkin, R. S., Yu A. Gorbunov, S. B. Sidelnikov, and A. Yu Otmahova. "STUDY INTO THE INFLUENCE OF THE GRAIN STRUCTURE REFINEMENT DEGREE OF ALLOY 6063 INGOTS ON THEIR PLASTICITY, EXTRUSION PARAMETERS AND PROPERTIES OF EXTRUDED PROFILES." Izvestiya Vuzov Tsvetnaya Metallurgiya (Proceedings of Higher Schools Nonferrous Metallurgy, no. 6 (December 14, 2018): 51–57. http://dx.doi.org/10.17073/0021-3438-2018-6-51-57.

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The analysis of scientific and technical literature and practical data made it possible to found that changes in casting parameters for ingots using different mold designs allows varying the degree of ingot grain structure refinement in a sufficiently wide range, which should be reflected in the conditions of aluminum alloy profile extrusion as well as physical and mechanical properties of these profiles. Therefore, the purpose of the research was to assess the influence of the degree of grain structure refinement for Alloy 6063 ingots on extrusion deformation and speed parameters and mechanical properties of profiles produced. The study used several batches of Alloy 6063 ingots 178 mm in diameter cast under industrial conditions, as well as profiles obtained by direct extrusion on a 18 MN horizontal hydraulic press subjected to quenching and aging. The grain size in homogenized ingots was estimated by light microscopy using the Olimpus optical microscope, and mechanical properties tests were carried out using the Inspect 20 kN-1 universal test machine. It was found that the initial grain size in the ingot structure exerts a significant influence both on ingot plasticity during extrusion, and on the final structure and mechanical properties of profile products made of aluminum alloys. Having analyzed the results obtained, we can conclude that the increase in strength characteristics of products extruded from ingots with a more refined structure is due to the fact that fine grains are retained in the structure of metal after its deformation, and cast metal plasticity increases with the degree of grain structure refinement in the ingot. This leads to the higher efficiency of profile product hardening and metal outflow rate during extrusion.

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36

Michalik, Rafał, A. Tomaszewska, and H. Woźnica. "Influence of Casting Conditions and Alloy Additions on the Zn22Al2Cu Structure." Defect and Diffusion Forum 326-328 (April 2012): 547–54. http://dx.doi.org/10.4028/www.scientific.net/ddf.326-328.547.

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Zn-Al-Cu alloys are characterized by a number of beneficial properties that include good castability, good tribological properties and low energy input for forming the product. When compared to bronze, Zn-Al-Cu alloys have a lower density. Properties of Zn-Al-Cu can be improved by the partial or total replacement of copper with silicon and rare earth element additions. In the literature there are few studies on the effect of casting conditions and modifying the chemical composition through the introduction of alloy micro-additives on the alloy structure. The aim of this study was to determine the effect of casting conditions and silicon and rare earth element additions on the structure of Zn-22% Al-2%Cu alloy. The subjects examined were the unmodified alloy, the alloy with 1.5% Si and the alloy with 1.5% Si and rare earth elements (mich metal). Samples were cast in sand and graphite molds. The liquidus temperature for each of these examined samples was determined. Structure examinations were carried out in samples taken from the top, center and bottom of the ingot. In order to determine the microstructure of the examined structures metallographic examinations using an optical microscope and a scanning electron microscope with energy dispersive spectroscopy (EDS) capabilities, an X-ray microscope, was performed. Quantitive analysis on specific, characteristic microzones was performed based on the EDS X-ray spectroanalysis results.

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Sorek, A., and Z. Kudliński. "The Influence of the Near-Meniscus Zone in Continuous Casting Mold on the Surface Quality of the Continuous Casting Ingots." Archives of Metallurgy and Materials 57, no. 1 (March 1, 2012): 371–77. http://dx.doi.org/10.2478/v10172-012-0036-1.

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The Influence of the Near-Meniscus Zone in Continuous Casting Mold on the Surface Quality of the Continuous Casting IngotsThe physical, chemical and mechanical phenomena which take place in the near-meniscus zone of continuous casting mold are the significant factors influencing the quality of CC ingot and especially the quality of its surface. Such phenomena consist of the following processes: lubrication of the ingot surface by the liquid slag-forming phase of mold powder, creation of meniscus, formation of the specific kind of galvanic cell and connected with this cell ions migration of liquid mold powder. Application of the mold powders is the commonly used lubrication method of the surface of CC ingots in mold (in near-meniscus zone). According to the ionic structure theory of the liquid metallurgical slags the following thesis can be formulated: the liquid slag-forming phase of mold powder is the ionic liquid. The ionic liquid occurs between two metals: the copper wall of mold and the steel surface of ingot can create a specific kind of galvanic cell in the upper part of mold (the near-meniscus zone of mold). The paper presents results of industrial research of low-carbon steel continuous casting. The electromotive force of galvanic cell situated in the upper (near-meniscus) part of CC mold was measured. Moreover, the influence of applied powders with different alkalinity on the character of oscillatory marks forming on the ingot surface was considered. The galvanic cell, which is created in the upper part of mold in the near-meniscus zone, can cause the essential change of the chemical composition of electrolyte (liquid phase of mold powder) in the near-electrodes zones. So in the process the condition of lubrication and character of obtained oscillatory mark can also be changed.

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Ohsasa, Kenichi, Kiyotaka Matsuura, Kazuya Kurokawa, and Seiichi Watanabe. "Numerical Simulation of Solidified Structure Formation of Al-Si Alloy Casting Using Cellular Automaton Method." Materials Science Forum 575-578 (April 2008): 154–63. http://dx.doi.org/10.4028/www.scientific.net/msf.575-578.154.

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For the purpose of the prediction of casting structures, heterogeneous nucleation rate in the undercooled melt of solififying Al-Si alloys were evaluated by comparing experimentally observed macrostructures of solidified ingots with numerically simulated ones. Molten alloys were unidirectionally solidified in an adiabatic mold from a steel chill block located at the bottom of the mold. In the experiment, columnar to equiaxed transition (CET) was observed. A numerical simulation for grain structure formation of the sample ingots was carried out using a cellular automaton (CA) method, and heterogeneous nucleation rate in the solidifying alloys were evaluated by producing the similar structures to experimental ones. An attempt was made to predict the grain structure of conventionally cast ingots using the evaluated heterogeneous nucleation rate. However, the simulation could not predict the structure of ingot with low superheat due to crystal multiplication near the mold wall. The crystal multiplication mechanism, so-called "Big Bang mechanism", was introduced into the simulation and the simulation could predict the grain macrostructure composed of columnar and equiaxed crystals that were similar to experimentally observed one.

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Brocato, Carmelo Maria. "Technological Jump in Aluminium Ingot Production." Materials Science Forum 630 (October 2009): 243–50. http://dx.doi.org/10.4028/www.scientific.net/msf.630.243.

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Abstract Usual production of modern cast houses includes semi products and re-melt products. Billets, slabs and rod belong to the family of semi products, while T-bars, sows and ingots are incorporated in the category of re-melt products. Re-melt forms have been developed to be easily transported and easily processed in locations even far away from the cast house where these have been produced. Unlike sow and T-bars, ingots need to be stacked in bundles and securely strapped to allow safe and easier handling and transportation. Yet, the ingots can be processed one-by-one by small users or can be loaded into the melting furnace bundle-by-bundle. The shape and weight of pure aluminium ingots of the old prior art were determined with two aims: maximization of the production rate and minimization of the production costs: for many years heavy ingots have been produced by pouring molten aluminium into a chain of open top moulds. The traditional complex shape of the ingots was intended to facilitate de-moulding operations and bundle piling. For the above reasons, the most common ingot weight worldwide has ranged, until now, from 22.5 to 23.5kg. Now a new technology launched by Continuus-Properzi offers bigger hourly production rates and handy, safe and sound ingots of 30 pounds (13.6kg) as well as more compact and stable bundles. These advantages are paralleled by low maintenance costs and a very high yield near to 90%. With similar investment and production costs the new technology can give a 30% yearly production increase and winning ingot characteristics.

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Piątkowski, Jaroslaw, and Tomasz Matuła. "Effect of Cooling Rate and Modification on the Structure of Cast AlSi17 Alloy." Solid State Phenomena 212 (December 2013): 221–24. http://dx.doi.org/10.4028/www.scientific.net/ssp.212.221.

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In the paper an effect of alloy modification, the mold material and the heat dissipation on the structure of hypereutectic silumin AlSi17 are presented. The investigated alloy was cast into: a ceramic (ATD), graphite and copper molds. In order to verify the conditions of heat dissipation through the mold, were used an additional cooling agents, such as water and liquid nitrogen. From the obtained ingots were prepared samples, which were stereological analyzed in the Metilo program.

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Kadhim, Mohamed Ali, Hussain Al Ali Jalal Ghuloom, Garry Martin, and Michael Jacobs. "Aluminium Bahrain - Benefits at ALBA from Use of Improved Graphite Rings for Production of Extrusion Ingots." Materials Science Forum 630 (October 2009): 251–57. http://dx.doi.org/10.4028/www.scientific.net/msf.630.251.

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Surface quality and metallurgical characteristics of extrusion ingot have a significant impact on the extrudability of the billet. Both the type of casting mould and mould maintenance significantly influences billet surface quality. ALBA, like the majority of extrusion ingot producers, uses moulds with graphite technology, where a mix of oil and gas is injected through a graphite ring into the mould to improve billet surface quality. ALBA has a policy of continual improvement in the areas of safety, product quality and productivity to enhance customer satisfaction. During 2008, an extensive campaign was conducted in ALBA’s casthouse to select the optimum type of casting rings for Airslip™ moulds supplied by Wagstaff Inc. The graphite casting rings evaluated must be suitable for the casting conditions and environment within the casthouse at ALBA. This paper details the methodology and the criteria set for the selection of the optimum graphite casting ring type as well as the results achieved. The results of the work showed a preference for L type casting rings, which enhance the quality of the extrusion ingots and extend the service life of the graphite ring.

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Wołczyński, W., Z. Lipnicki, A. W. Bydałek, and A. A. Ivanova. "Structural Zones in Large Static Ingot. Forecasts for Continuously Cast Brass Ingot." Archives of Foundry Engineering 16, no. 3 (September 1, 2016): 141–46. http://dx.doi.org/10.1515/afe-2016-0067.

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Abstract Some metallographic studies performed on the basis of the massive forging steel static ingot, on its cross-section, allowed to reveal the following morphological zones: a/ columnar grains (treated as the austenite single crystals), b/ columnar into equiaxed grains transformation, c/ equiaxed grains at the ingot axis. These zones are reproduced theoretically by the numerical simulation. The simulation was based on the calculation of both temperature field in the solidifying large steel ingot and thermal gradient field obtained for the same boundary conditions. The detailed analysis of the velocity of the liquidus isotherm movement shows that the zone of columnar grains begins to disappear at the first point of inflection and the equiaxed grains are formed exclusively at the second point of inflection of the analyzed curve. In the case of the continuously cast brass ingots three different morphologies are revealed: a/ columnar structure, b/ columnar and equiaxed structure with the CET, and c/ columnar structure with the single crystal formation at the ingot axis. Some forecasts of the temperature field are proposed for these three revealed morphologies. An analysis / forecast of the behavior of the operating point in the mold is delivered for the continuously cast ingot. A characteristic delay between some points of breakage of the temperature profile recorded at the operating point and analogous phenomena in the solidifying alloy is postulated.

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Wang, Gao Song, Zhi Hao Zhao, and Jian Zhong Cui. "The Magnetic Field Interference in Dual-Ingot Low Frequency Electromagnetic Continuous Casting." Advanced Materials Research 821-822 (September 2013): 868–72. http://dx.doi.org/10.4028/www.scientific.net/amr.821-822.868.

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The magnetic field interference was studied by numerical simulation and experimental examination during dual-ingot low-frequency electromagnetic casting process. By using ANSYS software package to mesh and compute, the magnetic field distribution of semi-continuous casting mold region was simulated. The calculated results were verified with the experimental ones and the effects of current direction, shield, silicon sheet and the coil distance on the distribution of magnetic field and ingot were observed. The result indicated that: regardless of current direction, the magnetic field interference among coils appears and the magnetic flux density weakens in the neighbor part of coils. When the current direction of adjacent coils is opposite, the magnetic intensity in ingots is stronger than that of in the same direction. As the distance between coils increases, the magnetic field reduction generated by interference decreases. The magnetic field interference can be alleviated by setting silicon steel sheets or shield.

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Ribeiro, Tiago Ramos, Moysés Leite de Lima, Marcelo Aquino Martorano, and João Batista Ferreira Neto. "Silicon refining by a metallurgical processing route." Rem: Revista Escola de Minas 66, no. 4 (December 2013): 479–84. http://dx.doi.org/10.1590/s0370-44672013000400012.

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Directional solidification experiments were carried out in a Bridgman furnace to remove carbon and metallic impurities from silicon. For carbon removal, solidification was achieved by extracting the mold from the hot into the cold zone of the furnace, while for the removal of metallic impurities, solidification occurred by cooling the furnace with a motionless mold. In the experiments of carbon removal, a mold extraction rate of 5 µm/s results in an ingot with columnar grain structure aligned in the ingot axial direction and a macrosegregation of carbon and SiC particles to the ingot top regions. However, at a mold extraction rate of 80 µm/s, the grain structure consisted of columnar grains aligned in the radial direction and SiC particles were observed throughout the ingot, showing lower macrosegregation with a carbon concentration still larger at the ingot top. In the metallic impurities removal experiment, an ingot with a columnar grain structure aligned in the ingot axial direction was obtained and the concentration profiles showed significant metallic impurities macrosegregation to the ingot top.

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Zhao, Ya Nan. "Influence of Mould Slenderness Ratio on the Solidification of Heavy Ingots by Numerical Simulation." Key Engineering Materials 871 (January 2021): 27–31. http://dx.doi.org/10.4028/www.scientific.net/kem.871.27.

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The quality of heavy ingot normally depends on the processing factor and ingot mould type. Based on the ingot mould type only, the quality and solidification process of a 96-ton ingot moulds with different slenderness-ratios have been studied numerically using the software package ProCAST. The results show that the position of shrinkage porosity moves up and the macroporosity in the ingot center increases prominently as slenderness-ratio increasing, meanwhile, the inclusion-floating time through the middle and bottom part of ingot decreases, and A-segregation alleviates as well. The correlation between the quality and slenderness-ratio of the ingot is not a liner relationship, when the slenderness ratio is 1.4, the ingot has better quality.

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Ye, Tie, Zhi Wen Lu, and Chun Hua Ma. "Effects of the Processing on Mechanical Properties of High-Strength Structural Steel HG785D." Key Engineering Materials 727 (January 2017): 76–81. http://dx.doi.org/10.4028/www.scientific.net/kem.727.76.

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The steel ingots of high-strength structural steel HG785D were produced by using a special water-cooled copper ingot mold. It analyzed the reason of the slab to achieve rapid solidification and shrinkage reducing with the simulation by using AnyCasting software. The difference properties between 100mm and 240mm steel plate with the same components were studied. The results show that properties are better with the increasing of the compression ratio, the times of TMCP and the reduction. The properties of 240mm steel plate with different composition were studied under the same heat treatment condition. Niobium, vanadium and titanium are in favor of the mechanical properties, but have little effect on the plasticity of structural steel. It should increase the harden ability of the alloy elements to improve mechanical properties of the steel HG785D.

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Zhang, Hui Shu, Dong Ping Zhan, Bi Tao Deng, Li Jun Wang, and Zhou Hua Jiang. "Numerical Simulation of Air Gap Formation in Water-Cooled Mold Casting." Advanced Materials Research 881-883 (January 2014): 1790–94. http://dx.doi.org/10.4028/www.scientific.net/amr.881-883.1790.

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While using water cooled mold to produce steel ingot, an air gap is generated between the ingot and the mold, which has an important influence on the ingot quality. The air gap formation law and its influence on the solidification process were calculated by used FE software Procast. It is shown that, air gap occurs in a few minutes after the solidification begins. In 75-100s later the gap reaches 0.2-0.5 mm and starts to influent the heat transport significantly, the rate of the temperature decrease becomes slower. When the solidification is finished, there is a lager gap on the two narrow surfaces than it on the other wide surfaces; and the gap on the two narrow surfaces is different. The air gap on the narrow surface close to the sprue has a width of 12-20 mm; on the other narrow surface away from the sprue has a width of 4-13 mm. The biggest gap on the two wide surfaces has a size about 6.5mm. For the air gap is formatted between the ingot shell and the ingot mold, the solidification time is 50% longer than that of without air gap.

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Tan, Zhe, Mikael Ersson, and Pär G. Jönsson. "Effect of TurboSwirl on Inclusions during Ingot Casting of Steels." Mathematical Problems in Engineering 2015 (2015): 1–10. http://dx.doi.org/10.1155/2015/805734.

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The use of TurboSwirl to obtain an improved steel cleanliness during filling of an ingot was numerically studied by VOF and DPM models. It was found that a radius-reduced TurboSwirl or a proper tapered mold entrance nozzle with an adequate developed region for steel flow can reduce the risk of mold flux entrapment in a mold. The ingot casting process can create highly turbulent conditions inside the mold during the initial stages of casting. Since the TurboSwirl generates much calmer filling conditions it can promote separation of large nonmetallic inclusions. The TurboSwirl also collects large inclusions (200 μm) towards the axis of rotation, which should promote agglomeration. In addition, the residence time for inclusions of small sizes can be prolonged, increasing chance of agglomeration, which indirectly promotes their separation from steel. Moreover, the average turbulent dissipation rate in an ingot casting swirl setup is about 40 % higher than that in a no swirl setup. This further facilitates the agglomeration of inclusions before they enter the mold. The removal of nonmetallic inclusions is thus enhanced because of an increasing inclusion collision rate due to both Stokes collisions and turbulent collisions, while maintaining a calm flow inside the mold.

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Hugo, Mathilde, Alain Jardy, Bernard Dussoubs, Jessica Escaffre, and Henri Poisson. "Mathematical Modeling of the Mold Current and Its Influence on Slag and Ingot Behavior during ESR." Journal for Manufacturing Science and Production 15, no. 1 (March 31, 2015): 79–88. http://dx.doi.org/10.1515/jmsp-2014-0052.

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AbstractElectroSlag Remelting (ESR) is widely used to produce high added value alloys for critical applications (aerospace industry, nuclear plants, etc.). In collaboration with Aubert & Duval, Institut Jean Lamour has been developing for several years a numerical transient model of an ESR heat. In the previous version of the model, the crucible was assumed to be perfectly electrically insulated from the electrode-slag-ingot system. However, this assumption must be challenged: the solidified slag skin at the slag/mold and ingot/mold interfaces may actually allow a fraction of the melting current to reach the crucible. In this paper, an evolution of the model is presented that enabled us to take into account the possibility of mold current. The simulation results were compared with actual experimental data. Sensitivity studies showed the influence of slag properties and operating parameters on the final quality of the ingot. Results highlighted that even a weakly conductive solidified slag skin at the inner surface of the model can be responsible for a non-negligible amount of current circulating between the slag and crucible, which modifies the fluid flow, heat transfer and solidification of both the slag phase and the metallic ingot.

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Karimi-Sibaki, E., A. Kharicha, M. Wu, A. Ludwig, and J. Bohacek. "A Parametric Study of the Vacuum Arc Remelting (VAR) Process: Effects of Arc Radius, Side-Arcing, and Gas Cooling." Metallurgical and Materials Transactions B 51, no. 1 (October 29, 2019): 222–35. http://dx.doi.org/10.1007/s11663-019-01719-5.

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Abstract Main modeling challenges for vacuum arc remelting (VAR) are briefly highlighted concerning various involving phenomena during the process such as formation and movement of cathode spots on the surface of electrode, the vacuum plasma, side-arcing, the thermal radiation in the vacuum region, magnetohydrodynamics (MHD) in the molten pool, melting of the electrode, and solidification of the ingot. A numerical model is proposed to investigate the influence of several decisive parameters such as arc mode (diffusive or constricted), amount of side-arcing, and gas cooling of shrinkage gap at mold–ingot interface on the solidification behavior of a Titanium-based (Ti-6Al-4V) VAR ingot. The electromagnetic and thermal fields are solved in the entire system including the electrode, vacuum plasma, ingot, and mold. The flow field in the molten pool and the solidification pool profile are computed. The depth of molten pool decreases as the radius of arc increases. With the decreasing amount of side-arcing, the depth of the molten pool increases. Furthermore, gas cooling fairly improves the internal quality of ingot (shallow pool depth) without affecting hydrodynamics in the molten pool. Modeling results are validated against an experiment.

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Journal articles on the topic 'Ingot molds'

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