Liquid Metal Processing & Casting Conference (LMPC 2022): Other Processing
Program Organizers: Matthew Krane, Purdue University; Mark Ward, University of Birmingham; Abdellah Kharicha, Montauniversitšt

Wednesday 1:20 PM
September 21, 2022
Room: Grand Ballroom
Location: Bellevue Hotel

Session Chair: Matthew Krane, Purdue University


1:20 PM Introductory Comments

1:25 PM  
Development of an Acoustic Levitation Based Contactless Metrological Apparatus: Applications to Surface Tension and Viscosity Measurements of Low Melting Temperature Ga Droplets: Herve Strozyk1; Thibault Quatravaux1; Pierre Chapelle1; Jonathan Martens1; Julien Jourdan1; 1Institut Jean Lamour
    Aerospace engine efficiency is directly linked to the hot source temperature. Due to the very high temperature and mechanical stresses, turbine blades and discs have to be manufactured using alloys with exceptional high temperature properties. Nickel-based superalloys combine these properties. Conventional manufacturing processes are expensive, so manufacturers are promoting digital design methods. But numerical models rely on accurate thermophysical databases to be effectively representative of real processes. Due to the high chemical reactivity of nickel-based superalloys, viscosity and surface tension measurements are difficult. We have developed a non-contact laser-powered melting furnace, based on the acoustic levitation phenomenon, to perform these measurements on samples in liquid form. In order to develop this complex device, we have already carried out some measurements on low melting point Sn-Pb alloys. This first phase of development has allowed us to identify improvements to be made in order to levitate high melting point reactive alloys.

1:50 PM  
Segment Casting- a Semi-continuous Casting Technology for High-end Semi-finished Products Enters the Market: Stefano Baf1; Oleksii Novokshonov1; Harald Holzgruber1; Alexander Scheriau1; Klaus von Eynatten2; Michael Kubin1; 1INTECO melting and casting technologies GmbH; 2Eycon-steel plant technology
    The concept of the segment casting technology was developed by INTECO to provide a novel casting technology for special steels to reduce production costs at improved quality levels and combing this with moderate investment costs, highest production flexibility and improved operational working conditions. The process of Segment Casting combines proven technologies of ingot casting and continuous casting and features synergies from Electro-Slag-Remelting as well as Powder Metallurgy. Segment Casting comprises a vertical semi-continuous casting process capable of producing ingots of up to a diameter of approx. 1500mm or even more. The ingot length of max. ~15m is cut off-line to accurate ingot weights requested by the final customer for maximised yield throughout the production route. This paper describes the Segment Casting process including innovative technological key features, and provides an overview on possible applications. Furthermore, first operational results of large section sizes up to 1.200mm diameter are discussed and presented.

2:15 PM  
Comparison of the Degassing Efficiency for Different Injector Types: Moritz Eickhoff1; Tim Haas1; Herbert Pfeifer1; 1RWTH Aachen University
     There are many different metallurgical processes, like ladle and converter in the steelmaking as well as many processes in non-ferrous metallurgy, where gas is injected into a vessel. Typically, inert gases are used for homogenization and refining, but there are also oxidizing and reducing gas species used in some of the processes. In all cases small bubbles well distributed in the vessel are preferred to maximize the gas-metal-interface. In this work different injector systems like open lance, 3-hole-nozzle, Laval-nozzle and impeller are compared concerning their degassing efficiency. Therefore, a cylindrical water model is filled with water. While degassing with pure nitrogen the oxygen concentration of the water is measured continuously.The measurements show huge differences concerning the degassing rate as well as the residual oxygen content in the water for the different injectors.

2:40 PM  Student
Discrete Liquid Flow in a Random Packed Bed with Implications to Iron Making Blast Furnace: Venkat Arunchaitanya Gadi1; Govind S Gupta1; 1Indian Institute of Science
    The molten iron below the cohesive zone of the blast furnace flows as droplets and rivulets in the coke matrix. So, It is essential to understand the physics of discrete liquid flow inside randomly packed particles. The present study models the discrete flow of liquid inside a randomly packed bed by considering liquid as droplets and rivulets. A randomly packed bed is created using the Discrete Element Method, and void centroids and void volumes are calculated. After this, the liquid is allowed to flow at the desired flow rate through the voids of the bed. The breakage of liquid into droplets and rivulets is estimated by balancing the forces of surface tension with the other forces acting on the liquid. Finally, the liquid distribution at the bottom of the bed is analysed.

3:05 PM  
Simulation of the Arc Dynamics During the VAR Process: Abdellah Kharicha1; 1Montauniversitšt
    Based on a three-dimensional Plasma magnetohydrodynamic model, the arc dynamics under different applied axial magnetic fields(AMFs) magnitude is analyzed. In the model both the plasma dynamics and the collective motion of cathode spots are simulated. The influences of the azimuthal self-magnetic field and different poloidal distributed AMFs on the vacuum arc characteristics are studied. The comparison with VAR experimental results shows good agreements. Periodic asymmetric and rotating behaviors of the arc are predicted. When a magnetic field is applied, the spots gather and rotates coherently.