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Journal articles on the topic 'Ingot'
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1
Zhao, Zhi Hao, Jian Zhong Cui, Jing Wang, and Gao Song Wang. "Homogenization Behaviors of Low Frequency Electromagnetic Casting and Direct Chill Casting 7050 Aluminum Alloy." Advanced Materials Research 97-101 (March 2010): 991–94. http://dx.doi.org/10.4028/www.scientific.net/amr.97-101.991.
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7050 aluminum alloy ingots were produced by low frequency electromagnetic casting (LFEC) and direct chill casting (DC) respectively. As-cast microstructures and homogenization behaviors of LFEC and DC ingots were investigated experimentally. The optical microscope and DSC analyses shown that the grain size of LFEC ingot was finer and the content of constituents and eutectic structure was less than that of DC ingot. Accordingly, the homogenization behaviors of the LFEC and DC ingots were significantly different. The remnant constituents of LFEC ingot were less in content and smaller in size than that of DC ingot after homogenization at 480°C for various lengths of time. Similar to the dissolving of constituents, the LFEC ingot exhibited faster diffusion kinetics of alloying elements from grain boundary to inner. The concentrations of Cu, Mg and Zn inside grain of LFEC ingot after homogenization for 12 h were 2.4%, 2.2% and 6.5% respectively, but the DC ingots had not reach the level even for 48 h.
2
Persson, Ewa Sjöqvist, Sofia Brorson, Alec Mitchell, and Pär G. Jönsson. "Impact of Solidification on Inclusion Morphology in ESR and PESR Remelted Martensitic Stainless Steel Ingots." Metals 11, no. 3 (March 2, 2021): 408. http://dx.doi.org/10.3390/met11030408.
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This study focuses on the impact of solidification on the inclusion morphologies in different sizes of production-scale electro-slag remelting (ESR) and electro-slag remelting under a protected pressure-controlled atmosphere, (PESR), ingots, in a common martensitic stainless steel grade. The investigation has been carried out to increase the knowledge of the solidification and change in inclusion morphologies during ESR and PESR remelting. In order to optimize process routes for different steel grades, it is important to define the advantages of different processes. A comparison is made between an electrode, ESR, and PESR ingots with different production-scale ingot sizes, from 400 mm square to 1050 mm in diameter. The electrode and two of the smallest ingots are from the same electrode charge. The samples are taken from both the electrode, ingots, and rolled/forged material. The solidification structure, dendrite arm spacing, chemical analyzes, and inclusion number on ingots and/or forged/rolled material are studied. The results show that the larger the ingot and the further towards the center of the ingot, the larger inclusions are found. As long as an ingot solidifies with a columnar dendritic structure (DS), the increase in inclusion number and size with ingot diameter is approximately linear. However, at the ingot size (1050 mm in diameter in this study) when the center of the ingot converts to solidification in the equiaxial mode (EQ), the increase in number and size of the inclusions is much higher. The transition between a dendritic and an equiaxial solidification in the center of the ingots in this steel grade takes place in the region between the ingot diameters of 800 and 1050 mm.
3
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.
4
Chen, Jian Mei, Yu Qiang Li, and Jia Qiang E. "Multi-Fields Coupled Simulation on Casting Process of Aluminum Alloy Based on Heat Conduction by Rotating Heat Pipe Bundle." Advanced Materials Research 621 (December 2012): 237–45. http://dx.doi.org/10.4028/www.scientific.net/amr.621.237.
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Based on the knowledge to defects and advantages of traditional ingot casting, a new approach for casting of aluminum alloy ingot, based on heat conduction by rotating heat pipes, is put forward in this paper. Different from the conventional casting method that cooling around ingot, the microstructure and properties of casting ingots can be significantly improved due to cooling of molten liquid from the central by rotating heat pipes proposed by this paper. Through simulation on the working process and the fields of flow and temperature, it can be speculatively seen that the ingot solidification is from inside to outside and that inner stress inside the ingot is compressive. The influences of speed of heat pipe bundle, casting speed and casting temperature on the temperature field in the ingot have been systematically studied. The ingots with different sizes can be prepared by changing size and structure layout of the heat pipes.
5
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.
6
Gamanyuk, Sergey B., Dmitriy V. Rutskiy, and Nikolay A. Zyuban. "An Investigation of Ingots Teemed under Different Thermal and Physical Solidification Conditions and the Analysis of Metal Quality of the Hollow Forgings Produced." Materials Science Forum 973 (November 2019): 36–40. http://dx.doi.org/10.4028/www.scientific.net/msf.973.36.
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Optical and electron microscopy are used in the paper to analyze the quality of the cast metal of a 1.53 ton ingot of steel 38ХН3МФАteemed with a cooling feeder head. In addition, the analysis of the metal of hollow forgings produced from ingots with “cooled” and thermally insulated feeders is performed. A metallographic study reveals that if the ingot top is cooled down, it results in an accelerated solidification throughout the entire mass of the ingot; in addition, the thermal centre shifts to the ingot central axial area.
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Tikal, Filip, Michal Duchek, and Jan Nacházel. "FEM Analyses of the Radiation in Heating Forging Furnace." Applied Mechanics and Materials 751 (April 2015): 235–38. http://dx.doi.org/10.4028/www.scientific.net/amm.751.235.
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The purpose of this study was to identify possible causes of longitudinal surface cracks found during early stages of ingot breakdown. However, these cracks need not necessarily form during forging or as a result of poor quality of the surface in metallurgical terms. Under certain conditions, they may occur even as the ingot is being heated in the furnace to the forging temperature. The cracks probably form within a few minutes after placing the ingot in the furnace as a result of the temperature gradient, which is most severe on the ingot surface. A numerical model was created to represent the case of three ingots in a furnace. Upon casting, the ingots are cooled down to no more than 600°C and then placed in a furnace at 1,100 - 1,200°C. Numerical simulations were used to analyse their internal stresses and temperatures.
8
Liu, Yu, Zhao Zhang, Guangqiang Li, Qiang Wang, and Baokuan Li. "Effect of Current on Segregation and Inclusions Characteristics of Dual Alloy Ingot Processed by Electroslag Remelting." High Temperature Materials and Processes 38, no. 2019 (February 25, 2019): 207–18. http://dx.doi.org/10.1515/htmp-2017-0144.
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AbstractThree dual alloy ingots were processed by electroslag remelting with 1500 A, 1800 A and 2100 A. The compositions and inclusions of ingots were analyzed by means of various analytical techniques. The results show that the segregation becomes severer with the increase of current. With the current increasing, the proportion of inclusions with large size, the T.[O] and sulfur content in the ingot increase, showing a worse cleanliness due to the severer electrode surface oxidation and shorter interaction time between slag pool and film of molten steel at the electrode tip. The single (Mn,Cr)S inclusion can precipitate in transition zone of each ingot and NiCrMoV zone of ingot with 1800 A and 2100 A due to higher sulfur content and the solute segregation during solidification. The ingot processed by ESR with 1500 A performed a balanced quality.
9
Zhang, Bin, and Craig Shaber. "Aluminum Ingot Thermal Stress Development Modeling of the Wagstaff® EpsilonTM Rolling Ingot DC Casting System during the Start-up Phase." Materials Science Forum 693 (July 2011): 196–207. http://dx.doi.org/10.4028/www.scientific.net/msf.693.196.
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Based on sequentially coupled CFD and FEM models, aluminum alloy rolling ingot thermal stress simulations have been conducted in order to understand start-up phase cold cracking phenomena and optimize tooling designs for 520×2120 mm rolling ingot casting on Wagstaff® Epsilon™ Ingot Tooling. In the CFD model, ingot surface temperature dependant and water flow rate dependant water boiling curves are applied. Thermal boundary conditions for the complex water intrusion phenomena under the ingot butt have been attempted. Temperature dependant elastic-plastic materials constitutive relationship has been employed in the transient thermal stress FEM model. Results of thermal stress development at ingot surface and inside the ingot are presented; Connection of cold cracking (ingot butt quarter and center cracks) with near surface stress development at the ingot butt is shown and the effect of water intrusion under the ingot butt on the butt stress development is also discussed. The predicted temperatures are validated against temperatures measured from cast-in thermocouples at strategic locations in field ingots in order to obtain realistic thermal boundary conditions. The predicted butt curl is also verified through field observation and measurement.
10
Kwapisiński, P., Z. Lipnicki, A. A. Ivanova, and W. Wołczyński. "Role of the Structural and Thermal Peclet Numbers in the Brass Continuous Casting." Archives of Foundry Engineering 17, no. 2 (June 27, 2017): 49–54. http://dx.doi.org/10.1515/afe-2017-0050.
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AbstractThe Structural Peclet Number has been estimated experimentally by analyzing the morphology of the continuously cast brass ingots. It allowed to adapt a proper development of the Ivantsov’s series in order to formulate the Growth Law for the columnar structure formation in the brass ingots solidified in stationary condition. Simultaneously, the Thermal Peclet Number together with the Biot, Stefan, and Fourier Numbers is used in the model describing the heat transfer connected with the so-called contact layer (air gap between an ingot and crystallizer). It lead to define the shape and position of the s/l interface in the brass ingot subjected to the vertical continuous displacement within the crystallizer (in gravity). Particularly, a comparison of the shape of the simulated s/l interface at the axis of the continuously cast brass ingot with the real shape revealed at the ingot axis is delivered. Structural zones in the continuously cast brass ingot are revealed: FC - fine columnar grains, C - columnar grains, E - equiaxed grains, SC - single crystal situated axially.
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Hu, Yuqi, Ripeng Jiang, Xiaoqian Li, Anqing Li, and Ziming Xie. "Effects of High-Intensity Ultrasound on the Microstructure and Mechanical Properties of 2195 Aluminum Ingots." Metals 11, no. 7 (June 30, 2021): 1050. http://dx.doi.org/10.3390/met11071050.
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The microstructural refinement of 2195 aluminum alloy ingots is particularly important for improving their industrial applications and mechanical properties. Combined with vacuum casting and inert gas protection, scalable high-strength ultrasonic melt processing (USMT) technology was used to manufacture 2195 aluminum alloy cylindrical ingots. Then, the influence of USMT on the main microstructural components (primary α-Al grains, secondary phase network, and precipitated particles) was studied. Our experiments show that the main microstructure of the ingot was improved after the introduction of ultrasound. Compared to the ingot formed without USMT, the size and morphology of the primary α-Al phase were optimized. The agglomeration of coarsening secondary phases can be alleviated, and the large layered secondary phase network becomes discontinuous throughout the ingot under USMT. At the same time, the mechanical properties of the solidified aluminum alloy ingots were also tested, and comparisons were made between samples formed with and without USMT. The results show that the stress concentration caused by the large area of coarse secondary phase in the ingot leads to the decrease of mechanical properties.
12
Puzikov, A. Ya, S. B. Gamanuk, N. A. Zyuban, D. V. Rutskiy, and K. A. Ivchenko. "THE INFLUENCE OF EXTERNAL FORCES ON THE CHARACTERISTICS OF HARDENING AND THE CHARACTER OF CONVECTIVE FLOWS DURING THE CURING OF INGOTS." IZVESTIA VOLGOGRAD STATE TECHNICAL UNIVERSITY, no. 7(254) (July 22, 2021): 56–62. http://dx.doi.org/10.35211/1990-5297-2021-7-254-56-62.
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The paper describes the influence of external influences on the features and nature of convective flows during the solidification of ingots. It is shown that topping up the profitable part of the ingot with hot portions of the melt changes the nature of the convective motion of the melt in the body of the model ingot. Laminar movement is observed before refilling, after turbulent. The change in the nature of the movement of the liquid in the body of the ingot contributes to an increase in the speed of the front of the solid phase, as evidenced by the results of calculating the rate of solidification throughout the solidification process of the model ingot. The analysis of the structural zones showed an increase in the zone of columnar crystals from 58.6% to 72.3% and the zone of the deposition cone, from 6.5% to 9.1% in refilled ingots compared to the classic ingot. There is also a decrease in the zone of differently oriented crystals from 26.8 to 13.7% and the crustal zone from 5.9% to 2.8%. The length of the axial zone increased from 36 to 54%, with a decrease in its diameter from 6.5 to 5.1%.
13
Hu, Yan, Hai Hao, and Xiao Teng Liu. "Temperature Field Analysis of Directional Solidification of Multi-Crystalline Silicon." Materials Science Forum 750 (March 2013): 96–99. http://dx.doi.org/10.4028/www.scientific.net/msf.750.96.
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A cost effective directional solidification (DS) technique is one of the main methods to produce multi-crystalline silicon (mc-Si) ingots for solar cells. A detailed understanding of the DS process is very important to control the formation and distribution of impurities, precipitates, thermal stress and dislocation defects in an ingot. All these factors have direct effects on the solar cells efficiency. The quality of crystal grown by DS is largely determined by the temperature field. In order to optimize the technique parameters and obtain high quality silicon ingots, the temperature fields with different heat transfer coefficients at different positions have been calculated during the silicon DS process. The influence of the heat transfer coefficients at the ingot top(ht), the ingot bottom (hb), and between ingot and crucible (hs) on the DS process of mc-Si have been analyzed. The calculation results may provide important theoretical basis for optimizing technological recipe in the productive practice.
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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.
15
Shi, Chen, Yongjun Wu, Daheng Mao, and Gaofeng Fan. "Effect of Ultrasonic Bending Vibration Introduced by the L-shaped Ultrasonic Rod on Solidification Structure and Segregation of Large 2A14 Ingots." Materials 13, no. 3 (February 10, 2020): 807. http://dx.doi.org/10.3390/ma13030807.
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In order to achieve long-term and stable ultrasonic treatment in the direct chill semi-continuous casting process, a new L-shaped ceramic ultrasonic wave guide rod is designed to introduce ultrasonic bending vibration into 2A14 aluminum alloy melt. The effect of ultrasonic bending vibration on the solidification structure and composition segregation of large 2A14 aluminum alloy ingots (φ 830 mm × 6000 mm) in the process of semi-continuous casting were studied by means of a direct reading spectrometer, scanning electron microscope, metallographic microscope, and hardness test. The ultrasonic ingot treated by bending vibration was compared with the ingot without ultrasonic treatment and the ingot treated by the traditional straight-rod titanium alloy wave guide rod. The results show that, during the solidification of 2A14 aluminum alloy, ultrasonic treatment can significantly refine the grain, break up the agglomerated secondary phase, and make its distribution uniform. The macro-segregation degree of solute including the negative segregation at the edge of the ingots and the positive segregation in the center can be reduced. Through comparative analysis, the macrostructure of the ingot, treated by the L-shaped ceramic ultrasonic wave guide rod, was found to be better than that of the ingot treated by the traditional straight-rod titanium alloy wave guide rod. In particular, the grain refinement effect at the edge of the ingot was the best, the secondary phase was smaller, more solute elements can be dissolved into the α-Al matrix, and the ability of the L-shaped ultrasonic wave guide rod to restrain segregation was stronger at the edge of the ingot.
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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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Lai, Hui Xian, Liu Qing Huang, Ming Fang, Cheng Hao Lu, Juan Chen, De Qin Yu, Jin Tang Li, et al. "Defects and Electrical Properties of Crystalline Silicon at Different Metallurgical Route." Applied Mechanics and Materials 420 (September 2013): 134–38. http://dx.doi.org/10.4028/www.scientific.net/amm.420.134.
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To investigate the effects of the metallurgical route on the defects in mc-Si, various metallurgical routes were conducted. Dislocation formation and the resistivity of the mc-Si were also studied. The results showed that high inhomogeneity in dislocation distribution within individual grains and paralleled tacking faults could be observed when the ingot was grown by using the feedstock prepared by adopting the sequence of slag treatment, acid leaching and vacuum refining. Different grains have various dislocation density, which was showed in ingot grown by utilizing the feedstock prepared by adopting the sequence of vacuum refining, slag treatment and acid leaching, tacking faults could also be seen, as well as some dislocation clusters. The resistivity of this two ingots was detected at various height by using the a 4-point probe silicon tester, it was expected that the resistivity of these two ingots has the same tendency of the change, and the value of the resistivity of the ingot obtained using the previous technology was relatively higher than that of the ingot obtained using the latter technology.
18
Huang, Xin Sheng, Kazutaka Suzuki, Akira Watazu, Ichinori Shigematsu, and Naobumi Saito. "Effects of Homogenization Treatment on Mechanical Properties of Hot-Rolled AZ31 Magnesium Alloy." Materials Science Forum 561-565 (October 2007): 255–58. http://dx.doi.org/10.4028/www.scientific.net/msf.561-565.255.
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The mechanical properties of the AZ31B alloy sheets processed by differential speed rolling (DSR) from the cast ingots homogenized at two different conditions were investigated. There still existed the uneven distribution of Al and Zn in the ingot homogenized at 673 K for 6 h, while it was homogeneous for the ingot homogenized at 723 K for 24 h. Compare with the sheet rolled from the ingot homogenized at 673 K for 6 h, the sheet rolled from the ingot homogenized at 723 K for 24 h exhibited a lower proof stress, a larger elongation, and a lager strain hardening exponent. The improvement in the ductility can be attributed to the elimination of the microsegregation of Al and Zn in the matrix.
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Luo, Da Wei. "Growth and Characterization of 420 kg Bulk Multicrystalline Silicon (mc-Si) Ingot Grown by Directional Solidification Process for Photovoltaic Application." Advanced Materials Research 873 (December 2013): 592–97. http://dx.doi.org/10.4028/www.scientific.net/amr.873.592.
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Cast mc-Si ingots are widely used in photovoltaic manufacturing. The utilization rate of industrial polycrystalline silicon ingot only about 70%, most of them are less than 70%, the main influence factors are casting process, raw and auxiliary materials as well as the crucible material. The growth process and the overall characteristics of 420 kg polycrystalline silicon ingot are analyzed and researched in detail. This paper focuses on the distribution characteristics and causes of the casting defect which are analyzed in detail and discussed, at the same time suggestions are given to improve the utilization rate of the ingot.
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Wu, Xiao Dong, Bin Liao, Chang Jian Yan, Li Huang, and Ling Fei Cao. "Grain Refinement in an Al-Zn-Mg-Cu Casting Ingot." Materials Science Forum 877 (November 2016): 104–8. http://dx.doi.org/10.4028/www.scientific.net/msf.877.104.
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The grain refinement in a high specific strength Al-Zn-Mg-Cu casting ingot was studied by add different amount of Al-Ti-C and Al-Ti-B master alloys during casting. The optical microscopy observation shows that the grain size of ingot is greatly reduced when adding Al-Ti-B as low as 0.01 wt%. Both the average size and the size difference among samples from various locations of ingots are smaller when the alloy casted with Al-Ti-B, which indicates that Al-Ti-B is effecient for the grain refinement in the Al-Zn-Mg-Cu casting ingot.
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Zhu, Qing Feng, Zhi Hao Zhao, Xiang Jie Wang, and Jian Zhong Cui. "Floating Grains in the HDC Casting 7075 Aluminum Alloy Ingot." Applied Mechanics and Materials 117-119 (October 2011): 1531–34. http://dx.doi.org/10.4028/www.scientific.net/amm.117-119.1531.
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7075 aluminum alloy ingot with the diameters of 100 mm was produced by Horizontal Direct-Chill (HDC). The temperature in the melt was measured and the ingots were examined in detail with the aim to reveal the floating grains in the HDC ingot. Experimental results show that very large floating grains with coarse dendrite arm spacing (DAS) mainly concentrate in the half-moon area near bottom surface of the HDC casting ingot, under the function of gravity. The floating grains in the HDC casting process is much bigger than that founded in Vertical Direct-Chill (VDC) casting process.
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Kwapisiński, P., A. A. Ivanova, B. Kania, and W. Wołczyński. "Some Similarities / Differences between Steel Static and Virtual Brass Static Casting." Archives of Foundry Engineering 17, no. 1 (March 1, 2017): 109–14. http://dx.doi.org/10.1515/afe-2017-0020.
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Abstract An innovative method for determining the structural zones in the large static steel ingots has been described. It is based on the mathematical interpretation of some functions obtained due to simulation of temperature field and thermal gradient field for solidifying massive ingot. The method is associated with the extrema of an analyzed function and with its points of inflection. Particularly, the CET transformation is predicted as a time-consuming transition from the columnar- into equiaxed structure. The equations dealing with heat transfer balance for the continuous casting are presented and used for the simulation of temperature field in the solidifying virtual static brass ingot. The developed method for the prediction of structural zones formation is applied to determine these zones in the solidifying brass static ingot. Some differences / similarities between structure formation during solidification of the steel static ingot and virtual brass static ingot are studied. The developed method allows to predict the following structural zones: fine columnar grains zone, (FC), columnar grains zone, (C), equiaxed grains zone, (E). The FCCT-transformation and CET-transformation are forecast as sharp transitions of the analyzed structures. Similarities between steel static ingot morphology and that predicted for the virtual brass static ingot are described.
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Indeykin, I. A., R. V. Starykh, E. V. Salimzhanova, V. B. Fomichev, and L. V. Krupnov. "Effect of copper-nickel matte ingot cooling time on its floatation separation selectivity indicators." Izvestiya Vuzov. Tsvetnaya Metallurgiya (Universities' Proceedings Non-Ferrous Metallurgy), no. 1 (February 19, 2020): 4–12. http://dx.doi.org/10.17073/0021-3438-2020-1-4-12.
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A criterion used to evaluate the efficiency of converter matte foam separation into nickel and copper concentrates is a selectivity index based on the total recoveries of metals into target concentrates that in turn defines their cumulative impurities (secondary metals) content. In addition to various factors (meeting density and reagent flow charts, comminution parameters, etc.), the time of preceding cooling of ingots is also known to have a substantial effect on the process of converter matte separation at commercial scale. Laboratory studies on selective separation were made to evaluate the influence of converter matte crystallization conditions at constant comminution and floatation parameters. Commercial converter matte ingots produced at different cooling rates were ground and floated in the closed circuit under laboratory conditions according to the existing floatation flowsheet. The lab studies allowed to exclude the multifactor nature of the system and to examine the commercial converter separation process only from the viewpoint of converter matte melt cooling rate since the other factors were kept constant during the laboratory tests. The temperature field in the body of the converter matte ingot was measured during its cooling in the conditions of the current production – this is reflected in the chemical and phase composition of various ingot sections. The temperature of the ingot, due to its massiveness, varies considerably throughout the material volume. A small change in the ingot surface temperature can be accompanied by significant changes in the temperature in its body. The measurement results showed that the temperature gradient from the center to the periphery of the ingot exceeds400 °C. In this regard, reducing the time of converter matte cooling can lead to significant violations of the cooling mode in the central zones of the ingot. In accordance with the optical mineralogical analysis of samples, the longer was the ingot cooling time, the higher was its decrystallization implying the formation of coarse-particle structures of copper and nickel sulfides with sharp interface boundaries. The chemical analysis revealed that the highest possible selectivity index of converter matte copper and nickel separation with resulting copper and nickel sulfide concentrates, respectively, is reached after 72 h of cooling for converter matte ingots from the smelting shop of the Nadezhdinsky Metallurgical Plant.
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Wołczyński, W., A. A. Ivanova, P. Kwapisiński, and E. Olejnik. "Structural Transformations Versus Hard Particles Motion in the Brass Ingots." Archives of Metallurgy and Materials 62, no. 4 (December 1, 2017): 2461–67. http://dx.doi.org/10.1515/amm-2017-0362.
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AbstractA mathematical method for the forecast of the type of structure in the steel static ingot has been recently developed. Currently, the method has been applied to structural zones prediction in the brass ingots obtained by the continuous casting. Both the temperature field and thermal gradient field have been calculated in order to predict mathematically the existence of some structural zones in the solidifying brass ingot. Particularly, the velocity of theliquidusisotherm movement and thermal gradient behavior versus solidification time have been considered. The analysis of the mentioned velocity allows the conclusion that the brass ingots can evince: chilled columnar grains-, (CC), fine columnar grains-, (FC), columnar grains-, (C), equiaxed grains zone, (E), and even the single crystal, (SC), situated axially. The role of the mentioned morphologies is analyzed to decide whether the hard particles existing in the brass ingots can be swallowed or rejected by the solid / liquid (s/l) interface of a given type of the growing grains. It is suggested that the columnar grains push the hard particles to the end of a brass ingot during its continuous casting.
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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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Acosta, L. F. Romano, O. Zapata, I. Álvarez, R. Cerda, and L. Leduc Lezama. "Simulation of Heating Cycles for Large Steel Ingots." MRS Proceedings 1812 (2016): 23–28. http://dx.doi.org/10.1557/opl.2016.13.
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ABSTRACTA simulation model is presented, where temperature, phases and internal stresses can be predicted as a function of time during the heating of large steel ingots for forging. Heating cycle measurements and computer simulations are compared for an A105 steel grade 34-Ton tapered ingot. A study of the heat transfer inside a natural gas-fired furnace was carried out to make an estimation of internal stresses due to thermal expansion and phase transformation from α ferrite and pearlite to γ austenite during heating. The model was validated with a second test of an AISI 4330 steel grade 35.4-Ton ingot. The simulation model described can calculate internal stresses in any ingot in order to optimize its heating cycle without compromising ingot internal quality, reducing energy consumption and increasing productivity of the furnace.
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Tian, Ni, Qi Long Liu, Zi Yan Zhao, Gang Zhao, and Kun Liu. "Effects of Homogenization-Free on the Microstructures of an Al-Mg-Si-Cu Hot-Rolled Plate for Automotive Pannel." Materials Science Forum 941 (December 2018): 1529–34. http://dx.doi.org/10.4028/www.scientific.net/msf.941.1529.
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The microstructure of Al-1.01Mg-1.11Si-0.38Cu-0.69Mn aluminum alloy plate hot-rolled from homogenization and homogenization-free ingots were investigated by optical microscopy and scanning electron microscopy assisted with energy dispersive spectroscopy (SEM/EDS). The results showed that there are 3 main kinds of constituents such as Mg2Si, AlCuMgSi and AlFeMnSi in the as-cast Al-1.01Mg-1.11Si-0.38Cu-0.69Mn aluminum alloy ingot. After homogenization treated at 545°C for 24h, the black Mg2Si and the white bright AlCuMgSi particles in the ingot dissolved into matrix, but the grey AlFeMnSi phase partly dissolved, contracted into sphere and become coarse, many ultrafine dispersoids appear in the dendritic arms. The constituents in the plates hot-rolled from the homogenization and homogenization-free ingots are both distributed as broken chains along the rolling direction. However, compared with the particles configuration in the plate that hot-rolled from homogenization ingot, the particles in the plate that hot-rolled from the homogenization-free ingot are finer, more numerous and more homogenous, and with insufficient recrystallization when the plates are solution treated at 545°C for 2 h and then water quenched.
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shijie, Zhou, Liu hengquan, and Huang nan. "Effect of original grain size on microstructure and properties of extruded Mg-2Zn-0.2Mn biomedical alloy." Integrated Ferroelectrics 201, no. 1 (September 2, 2019): 231–40. http://dx.doi.org/10.1080/10584587.2017.1331418.
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Magnesium is a biocompatible and biodegradable metal, which has attracted much interest in biomedical engineering. Cast magnesium alloy shows the low strength and plasticity at ambient temperature. Microstructure, mechanical properties and degradation properties of the extrusion pressed magnesium alloy have been investigated for biomedical application in detail by optical microscopes, mechanical properties testing and corrosion testing. The magnesium alloy ingots were gained by different cooling rate. Then the ingots were extrude into bar at the same processing condition. The results show that the cooling rate of cast ingot is important factors that affect the properties of Mg alloy by dynamic recrystallisation extruding. The cooling rate of cast ingot has been successfully applied to control the microstructure, mechanical and degradation properties of the Mg alloy. Optical microscopy observation has indicated that the grain size of the dynamic recrystallisation extruding has been significantly decreased from fast cooling cast magnesium ingot, which has mainly contributed to the high tensile strength and good elongation. Fasting cooling rate of cast ingot and dynamic recrystallisation extruding has provided moderate corrosion resistance, which has opened a new window for materials design, especially for biomedical.
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Wang, Xiao Ming, Sheng Zhu, Zhi Hao Zhao, Qi Wei Wang, and Min Zhang. "Effect of Addition of Sc, Zr, Er on Microstructure of Al-Mg Ingot to Generate Welding Wire and Micro-Hardness of Surfacing Layer." Advanced Materials Research 940 (June 2014): 28–31. http://dx.doi.org/10.4028/www.scientific.net/amr.940.28.
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Al-Mg welding wires applied extensively in aluminum alloy welding field.5183 ingot and 5356 ingot added Sc, Zr and Er were fabricated by DC casting method and extruded into welding wire, furtherly. Surfacing layer on 7A52 aluminum alloy prepared by using automatic surfacing formation system. Optical microscopy (OM) and 1600-5122VD MICROMET 5104 micro-hardness tester utilized to observe microstructure of 5183 and 5356 ingots, to measure micro-hardness of surfacing layer fabricated by using 5183 and 5356 welding wire with Sc, Zr, Er addition, respectively. The results indicated that, owing to addition of rare earth element, re-crystallization of Al-Mg extruded ingot to generate welding wire was restrained markedly; Microstructure was refined obviously when Sc added; And average size of the grains was about 10μm. Micro-hardness of surfacing layer improved after addition of Sc, Zr, Er element in the ingots.
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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.
Full textAbstract:
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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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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Tkadlečková, M., P. Machovčák, K. Gryc, K. Michalek, L. Socha, and P. Klus. "Numerical Modelling of Macrosegregation in Heavy Steel Ingot / Modelowanie Numeryczne Procesu Makrosegregacji W Ciezkim Wlewku Stalowym." Archives of Metallurgy and Materials 58, no. 1 (March 1, 2013): 171–77. http://dx.doi.org/10.2478/v10172-012-0169-2.
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The paper presents new knowledge and experience from numerical modelling of macrosegregation in heavy steel ingot using ProCAST software. The main aim of numerical modelling realized under the conditions of the Department of Metallurgy and Foundry and Regional Materials Science and Technology Centre at VSB-TU Ostrava is the optimization of the production of heavy steel ingots produced in V´ITKOVICE HEAVY MACHINERY a.s. Input parameters of computation were determined by the real conditions of parallel experimental casting of a 90-ton steel ingot. The input data were also verified by thermal analysis and thermography measurement. The numerical results of macrosegregation were compared with the chemical analysis evaluated in a real ingot section. According to the comparison, attention will be focused next on determination of the effect of boundary conditions of filling and solidification of the ingot on the size of macrosegregation.
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LI, XIAOJIAN, HU ZHANG, and JIANGBO SHA. "EFFECT OF VACUUM INDUCTION MELTING TECHNOLOGY ON MECHANICAL PROPERTIES OF Nb-16Si-22Ti-2Al-2Hf-17Cr ALLOY." International Journal of Modern Physics B 24, no. 15n16 (June 30, 2010): 2940–45. http://dx.doi.org/10.1142/s0217979210065891.
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This paper dealt with the effect of different induction melting technologies on mechanical properties of Nb -16 Si -22 Ti -2 Al -2 Hf -17 Cr alloy. The cast ingots were fabricated first by arc-melting, and then remolten in the vacuum induction furnace. The results showed that the ingot with refining process of 1800°C/15min and 0.1 at% C addition had finer microstructure and higher room-temperature fracture toughness. In addition, the compressive strength of the ingot with refining technology of 1700°C/10min was 315MPa at 1250°C. However, the arc melting ingot had the lowest fracture toughness and high-temperature compressive strength.
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Smyrnov, Yevgen, Vitalii Skliar, and Doston Parpiev. "Evaluating Plasticity of Alloy AD31 on Ingot Height." Solid State Phenomena 316 (April 2021): 461–67. http://dx.doi.org/10.4028/www.scientific.net/ssp.316.461.
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The authors present the results of evaluating the distribution of plastic properties on the height of a log ingot with the diameter of 145 mm, obtained by means of semi-continuous casting, from the aluminum alloy AD31. The authors study semi-continuous alloys of three manufacturers. One part of ingots was obtained with the use of only primary aluminum, secondary raw materials and secondary raw materials with the addition of primary aluminum. With the purpose of stabilizing the process of presswork the authors define the values of yield stress in the ingot lower and upper parts and study its microstructure. The research was conducted for the ingots without thermal treatment after accelerated homogenization. It is shown that the ingots, produced with the use of primary aluminum only, have less scattered plastic properties in terms of the height. That is why, for the case of press-working the items with thin components, it is reasonable to use the ingots from primary aluminum.
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Liu, Min, and Qing Xian Ma. "Modeling and Numerical Simulation Research on Hollow Steel Ingot Forging Process of Heavy Cylinder Forging." Advanced Materials Research 712-715 (June 2013): 627–32. http://dx.doi.org/10.4028/www.scientific.net/amr.712-715.627.
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Aiming at the disadvantages of low utilization ratio of steel ingot, uneven microstructure properties and long production period in the solid steel ingot forging process of heavy cylinder forgings such as reactor pressure vessel, a new shortened process using hollow steel ingot was proposed. By means of modeling of lead sample and DEFORM-3D numerical simulation, the deformation law and grain refinement behavior for 162 ton hollow steel ingot upsetting at different reduction ratios, pressing speeds and friction factors were investigated, and the formation rule of inner-wall defects in upsetting of hollow steel ingots with different shape factors was further analyzed. Simulation results show that the severest deformation occurs in the shear zone of meridian plane in the upsetting process of hollow steel ingot, and the average grain size in the shear zone is the smallest. As pressing speed increases, the forming load gradually increases and the deformation uniformity gets worse, while the average grain size decreases. An increase in friction factor can increase the peak value of effective strain, but it significantly reduces the deformation uniformity, increases the forming load and goes against grain refinement. Moreover, the four kinds of defects on the inner wall of steel ingot can be eliminated effectively by referring to the plotted defect control curve for hollow steel ingot during high temperature upsetting.
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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.
Full textAbstract:
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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Zuo, Yu Bo, Qing Feng Zhu, Lei Li, Guang Ming Xu, and Jian Zhong Cui. "Effect of Electromagnetic Field on the Macrosegregation Behaviour of Al-Cu Alloy Ingot Prepared with Direct-Chill Casting Process." Materials Science Forum 877 (November 2016): 84–89. http://dx.doi.org/10.4028/www.scientific.net/msf.877.84.
Full textAbstract:
A low frequency electromagnetic field was introduced into the direct chill (DC) casting process and the ingots of Al-Cu alloy were prepared to study the macrosegregation behaviour of the ingots under the influence of the electromagnetic field. The experimental results showed that there is an obvious positive segregation near to the surface and a negative segregation in the centre area of the ingot. Cu shows the highest segregation tendency among the main elements of Cu, Mg and Mn. Grain refiner element Ti shows a segregation trend opposite to that of Cu. With the application of electromagnetic field, the negative centreline segregation in the centre area of the ingot was evidently reduced although it didn’t show significant effect on the segregation near to the ingot surface. A significant grain refinement was also achieved with the application of electromagnetic field. The mechanism of the reduction of macrosegregation with electromagnetic field was also analyzed in the present work.
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Zheng, Hong-guang, Li-jiang Yao, and Heng Xu. "Effect of Two Kinds of Refiners on the Solidification Structure and Property of Invar Alloy." High Temperature Materials and Processes 32, no. 4 (August 16, 2013): 375–81. http://dx.doi.org/10.1515/htmp-2012-0153.
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AbstractThe solidification structure of two 500 g cylindrical ingots of Fe-36Ni invar alloy, which were melted in a carbon tube furnace and cast adding Ce and Zr-Ti refiners respectively, were investigated. The results showed that the grain size became smaller. With the increase of refiner content, the ratio of equiaxed grains of ingot increased and the equiaxed grain size decreased. As for the 100 kg flat ingot, which was melted in a vacuum induction furnace and cast with Ce and Zr-Ti refiners respectively, the situation was different slightly. When adding Ce the dendritic grain diameter of the flat ingot became finer and the equiaxed grain ratio remained low; however, the mechanical property deteriorated. While adding Zr-Ti complex refiners, the solidification structure of the alloy was improved dramatically. Therefore, the mechanical properties at room temperature of as-cast flat ingots were improved. Furthermore, its high temperature ductility range expanded and the expansion coefficient of its hot-rolling plate remained almost the same.
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Narivskyi, A. V., A. N. Smirnov, N. I. Tarasevich, and S. Ye Kondratyuk. "Chemical and physical heterogeneities and gases in large steel ingot." Metaloznavstvo ta obrobka metalìv 96, no. 4 (December 1, 2020): 3–9. http://dx.doi.org/10.15407/mom2020.04.003.
Full textAbstract:
For creation of the high-tech equipment that is used in energy, heavy engineering, chemistry and transport, the unique large-sized steel products are required. In the manufacture of such products, large forging ingots in the mass to 600 tons are used. However, an increase in the mass of the ingots leads to the formation of chemical and physical heterogeneity, enlargement and unfavorable distribution of non-metallic inclusions, of the development of segregation defects in them, which reduce the strength and exploitation characteristics of the metal. In this connection, the quality forgings and finished parts are not always meet the producing demands and the loss of metal, in the form of technological waste and rejects are reaching significant values. It is known that eccentric zonal segregation, especially it’s the most dangerous variety - cords, significantly reduce the quality and properties of products from large steel ingots. In connection with the continuous expansion of the production of large ingots, the problem of creating optimal technologies for their formation, which reduce or exclude the possibility of the formation of chemical heterogeneity and cords in steel during crystallization, it is currently important and relevant. In this paper it are presented the results of studies of the structure, gas distribution, physical and chemical heterogeneities in the cross section and height of an ingot in the mass of 140 tons, which was casted in vacuum from steel 25KHN3MFA. It is shown that depending on the temperature and time conditions of ingot hardening, among which the crystallization interval (due to the chemical composition of steels), cooling intensity in different volumes in height and cross section of ingot, temperature gradient before the crystallization front, solubility of alloying elements and gas content in the melt, etc. Based on this, when developing technology for large ingots to ensure their quality, optimal structure and properties should take into account not only their dimensions, but also the combination of these thermokinetic parameters on the crystallization process, dendritic structure formation, manifestations of liquation in different ingot volumes. Keywords: ingot, segregation strip and inclusions, dendrites, structure, oxygen, oxides, sulfides.
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Rutskii, D. V., N. A. Zyuban, and S. B. Gamanyuk. "Effect of Semisolid Metal Casting of Large Forging Ingots on Quality of Large-Sized Forgings Produced." Solid State Phenomena 265 (September 2017): 962–68. http://dx.doi.org/10.4028/www.scientific.net/ssp.265.962.
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The paper reports the findings on the effect of various casting methods on the quality and development of primary dendritic structure in large-sized forging ingots of steel 38ХН3МФА. One ingot was teemed as per a conventional teeming method while the other was teemed with an inoculated metal stream. It was established that the dendritic parameter value in the inoculated ingot is much smaller than that in the conventional ingot. Consequently, the solidification process occurs at a higher rate in the inoculated ingot compared with that in the conventional ingot, and this assumption is supported by a more homogeneous dendritic structure. It is demonstrated that disperse inoculants positively affect the structure, physical and chemical homogeneity as well as the mechanical properties of cast metal. This finding is clearly supported by the examination of the forgings made of the conventionally teemed ingot and the one teemed with an inoculated stream. When inoculants were introduced in the metal stream, total chemical heterogeneity increased on the average by 1.2-2 times. It is established that the best results for the inoculation casting method are achieved when 2.4-2.6% inoculants are introduced in the stream. Such quantity of inoculants forms at a distance of 5 meters between the guiding pipe and the hot top.
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Li, Wan Ming, Zhou Hua Jiang, and Hua Bing Li. "Simulation and Calculation to Segregation of High Nitrogen Steels Solidification Process Based on PROCAST Software." Advanced Materials Research 217-218 (March 2011): 1185–90. http://dx.doi.org/10.4028/www.scientific.net/amr.217-218.1185.
Full textAbstract:
Segregation and liberation occur easily in high nitrogen stainless steels, which can result in the formation of pores and the discarding of the steels. So it is very important to investigate the segregation and liberation theory during the solidification process of high nitrogen stainless steels. In the manuscript, the pouring and solidification progress of high nitrogen steels ingots were simulated through Pro Engineer and PROCAST software. The dynamic variation of temperature field and pressure field were obtained. With the results of PROCAST, the macrosegregation of 20kg weight ingot and 1.7 tons weight ingot were predicted using mathematical model of zone segregation. The predicted results show that 20kg weight ingot has no obvious macrosegregation and 1.7 tons weight ingot has obvious macrosegregation, which is consistent with measuring results. It shows that the accuracy of simulation and calculation to segregation of high nitrogen steels solidification process based on PROCAST software is high.
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Wang, En Gang, En Jiang, Guo Feng Zhan, An Yuan Deng, and Ji Cheng He. "Solidification Structure of Incoloy800 Superalloy with Electromagnetic Field." Materials Science Forum 706-709 (January 2012): 2480–83. http://dx.doi.org/10.4028/www.scientific.net/msf.706-709.2480.
Full textAbstract:
The evolution of solidification structure in Incoloy800 with and without electromagnetic stirring (EMS) are studied to investigate its influence on the morphology of solidifying crystals and element segregation. The samples examination and EDX analysis show that some broken dendrite in the subsurface of the ingot were brought into the internal part of the ingot, it is proves the shear mechanism of EMS to dendrite or column crystal in the initial solidifying period, and the equiaxed grain region is formed in the internal part of ingots owing to the stirring effect of EMS. Both of them are helpful to reduce the element segregation in Incoly800 ingots.
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Ai, Xin Gang, Sheng Li Li, Dong Wei Zhang, Nan Lv, and Jun Tao. "Simulation and Productive Practice of 60 Tons Huge Rectangular Ingot by Wind Cooling." Advanced Materials Research 233-235 (May 2011): 2714–17. http://dx.doi.org/10.4028/www.scientific.net/amr.233-235.2714.
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Huge rectangular ingots becomes crying needs in the condition of lots of heavy plate mills more than 5m have been in operation. In this paper, a special method of wind cooling outside mould has been presented and applied to produce 60t rectangular ingot. Mathematical simulation results tell us that by wind cooling, the solidification time of the 60t ingot can be shortened by 67 minutes, internal soundness can be ensured. The wind cooling process can obviously improve microstructure and preventing skull patch by increasing the thickness of solidified shell. A 60 tons huge rectangular ingot is successfully produced by wind cooling, the surface quality of is very well and the internal soundness should be improved further.
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Williamson, Rodney L., and Joseph J. Beaman. "Modern Control Theory Applied to Remelting of Superalloys." Materials Science Forum 706-709 (January 2012): 2484–89. http://dx.doi.org/10.4028/www.scientific.net/msf.706-709.2484.
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Over the past several years we have worked to develop tools to improve the quality of superalloy ingots produced by vacuum arc remelting (VAR) and electroslag remelting (ESR). Part of this work has focused on developing model-based process controllers that employ predictive, dynamic, low-order electrode melting and ingot solidification models to estimate important process variables. These estimated variables (some of which are not subject to measurement) are used for feedback and to evaluate the health of the processes. Modern controllers are capable of detecting and flagging various process upsets and sensor failures, and can take remedial action under some circumstances. Model-based variable estimates are continuously compared with measurements when available, and the residuals are used to correct the next generation of estimates. This technology has led to improved VAR and ESR melt rate controllers and is currently being used to develop a VAR ingot solidification controller. A first generation ingot pool depth controller has been tested on a laboratory VAR furnace and the results are very encouraging. In this test, a 152 mm diameter Alloy 718 electrode was remelted into a 216 mm diameter ingot, but the technology is easily scaled to industrial sizes. Successful development of this technology could allow for melting at higher powers without the formation of channel segregates (freckles) by stabilizing the ingot solidification zone. It may also allow for the production of larger diameter VAR superalloy ingots than is possible to produce with the current generation of VAR controllers for the same reason.
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Hermansyah, Adid A., Kosasih Kosasih, and Hafid Hafid. "Penelitian Proses Pembuatan Konsentrat dan Ingot Tembaga dari Batuan Mineral Cu sebagai Substitusi Impor." Jurnal Riset Teknologi Industri 9, no. 1 (August 31, 2016): 20–29. http://dx.doi.org/10.26578/jrti.v9i1.1700.
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Research on the manufacturing process of concentrates and ingots of copper from Cu mineralized rocks as import substitution has been done. The aim is to produce import substitute products from raw materials from copper alloys in domestic. The research method was taken, consist of: (1) the manufacturing concentrates process, namely Cu smoothing stone (crusher), soaking in sulfuric acid (H2SO4) and dilution with Zn powder, (2) ingot-making process, that is burned on non-ferrous furnace (melting process) and liquid non-ferrous metals in print according to the desired size. Based on the results of the experimentaltrial the composition of concentrates and ingots of copper is dominated by Cu-Pb (98.7% -1.05%), the hardness of copper ingots is 62.28 Hv (hardness exceeds the standards of pure copper: Hv 20-40). The results of SEM and EDS showed the presence of a layer of copper matrix is quite tight and together, where the elements of Pb slip the matrix Cu. We hope that the products manufacturing process technology of copper alloys can be produced by SMEs mining in Indonesia to developing the added value of local mineral alloy.ABSTRAKPenelitian proses pembuatan konsentrat dan ingot tembaga dari batuan mineral Cu sebagai substitusi impor dengan tujuan untuk menghasilkan produk substitusi impor dari bahan baku paduan tembaga yang berasal dari dalam negeri. Metode penelitian yang dilakukan adalah: (1) proses pembuatan konsentrat, yaitu; penghalusan batu Cu (crusher), perendaman dengan asam sulfat (H2SO4) dan pelarutan dengan serbuk Zn, (2) proses pembuatan ingot, yaitu; dibakar pada tungku non ferro (proses peleburan) dan cairan logam non ferro di cetak sesuai ukuran yang dikehendaki. Berdasarkan hasil percobaan diketahui bahwa komposisi konsentrat maupun ingot tembaga didominasi oleh Cu-Pb (98,7%-1,05%), kekerasan yang dimiliki ingot tembaga adalah 62,28Hv (melebihi kekerasan pada standar tembaga murni: 20-40 Hv). Hasil pengujian SEM dan EDS menunjukkan adanya lapisan matrix tembaga yang cukup rapat dan menyatu, dimana unsur Pb menyelip pada matrix Cu. Diharapkan teknologi proses pembuatan produk dari paduan tembaga dapat diproduksi oleh Industri Kecil dan Menengah (IKM) penambangan di Indonesia untuk meningkatkan nilai tambah mineral paduan lokal. Kata kunci : konsentrat, ingot tembaga, tungku non ferro.
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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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Xu, Wen Yong, Zhou Li, Hua Yuan, Yue Wang, Na Liu, and Guo Qing Zhang. "Influence of Master Alloy on the Cleanliness of Spray Formed Superalloy." Materials Science Forum 788 (April 2014): 421–25. http://dx.doi.org/10.4028/www.scientific.net/msf.788.421.
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Three kinds of master alloys, including scrap material, vacuum induction melting (VIM) ingot and electro slag remelting (ESR) ingot, were spray formed into different billets. The influence of master alloy on the cleanliness of spray formed superalloy was investigated by means of electron beam (EB) button melting and Scanning Electron Microscopy (SEM), on the basis of optimized process of spray forming and EB button melting. The results show that the inclusions in spray formed preform are mainly composed of alumina and magnesia, stem from master alloy and some refractory materials in the process of remelting. The cleaner the master alloy, the lower level of inclusion contents of the billet. Among three kinds of master alloys, the ESR ingot exhibit the cleanest melt surface in the process of re-melting and contains much smaller inclusions in EB button. The cleanliness of spray formed billet is better than ingot stack for deposition. Superclean sprayforming billet with smaller size inclusions (<100μm) can be attained by the ESR ingots.
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Zhao, Ya Nan, and Shi Guang Ba. "Influence of Riser Necking Ratio and Taper on the Solidification of Heavy Ingots by Numerical Simulation." Key Engineering Materials 871 (January 2021): 59–64. http://dx.doi.org/10.4028/www.scientific.net/kem.871.59.
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The effect of riser necking ratio and taper on solidification process of 96T steel ingot have been studied numerically using the software package ProCAST. The results show that the solidification time decrease with the increase of riser necking ratio, and the position of shrinkage porosity moves up and the secondary porosity presents a tendency of increase, and the inclusions on the shoulder of body ingot decreases. The riser taper has little effect on the solidification process of heavy ingots.
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Wang, Fuyue, Xiangjie Wang, and Jianzhong Cui. "Effect of Low-Frequency Electromagnetic Casting on Micro-Structure and Macro-Segregation of 5A90 Alloy Ingots." Materials 13, no. 12 (June 15, 2020): 2720. http://dx.doi.org/10.3390/ma13122720.
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The effect of low-frequency electromagnetic fields on the micro-structure and macro-segregation of 5A90 alloy ingots during the semi-continuous casting process were quantitatively investigated. The ingots of a 5A90 alloy with a diameter 170 mm were produced by the conventional direct chill casting (DCC) process and low-frequency electromagnetic casting (LFEC) with 10 Hz/100 A. The results showed that LFEC can substantially refine the micro-structure and shorten the width of the columnar grain area of an ingot. The refinement effect came with the relieving of grain boundary segregation and an improvement in the macro-segregation of the ingot. Compared with the traditional DCC process, the tensile properties of the aged alloy prepared by the LFEC process were improved due to the effects of the increase in solid solubility and the strengthening of the grain refinement, so that the stability of the tensile properties was also improved. Meanwhile, the rate of yield increased by 2.3% with a decrease in the peeling thickness of the ingot.
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Ao, Guang Wu, Ming Gang Shen, and Zhen Shan Zhang. "Numerical Simulation of Unidirectional Solidification on Ingot of Heavy Plate Based on MARC." Advanced Materials Research 291-294 (July 2011): 359–62. http://dx.doi.org/10.4028/www.scientific.net/amr.291-294.359.
Full textAbstract:
Unidirectional solidification technology is a producing process of cast large-sized ingots industry and control the single orientation microstructure of solidification. Combined with the conditions of production, casting the 23t ingot of unidirectional solidification for experiment, we made numerical simulation of the 23t unidirectional solidification ingot with MARC; these are consistent with the result of experiment, and testified the simulation is feasible, offered gist for the design of the mould and casting, and took on reference to the product field.