Materials Processing Fundamentals: Molten Metal Processing and Modeling
Sponsored by: TMS Extraction and Processing Division, TMS Materials Processing and Manufacturing Division, TMS: Process Technology and Modeling Committee
Program Organizers: Jonghyun Lee, Iowa State University; Samuel Wagstaff, Oculatus Consulting; Alexandra Anderson, Gopher Resource; Fiseha Tesfaye, Metso Metals Oy, Åbo Akademi University; Guillaume Lambotte, Boston Metal; Antoine Allanore, Massachusetts Institute of Technology

Tuesday 8:30 AM
March 16, 2021
Room: RM 42
Location: TMS2021 Virtual

Session Chair: Jonghyun Lee, Iowa State University


8:30 AM  
Contactless Inductive Flow Tomography for Control of Liquid Metal Flow with Electromagnetic Actuators: Ivan Glavinic1; Matthias Ratajczak1; Frank Stefani1; Sven Eckert1; Thomas Wondrak1; 1Helmholtz-Zentrum Dresden-Rossendorf
    To achieve an optimal flow pattern in the mould of a continuous caster, it is desirable to use a tailored control of the flow using electromagnetic actuators (e.g. electromagnetic brakes or stirrers) based on the current flow condition in the mould. However, the rough environment provides a challenge. Contactless Inductive Flow Tomography (CIFT) is a technique that can provide information about the flow structure by visualizing the full velocity field in the mould. In order to reconstruct the flow, the perturbation of an applied magnetic field by the flow is measured. It is obvious that every change of the strength of the magnetic field of an electromagnetic brake influences the measured values. In this paper we cover the challenges of measuring the flow induced magnetic field in the range of nT in the presence of varying magnetic field of the electromagnetic actuators in the range of 100 mT.

8:50 AM  
X-ray and Neutron Radiographic Experiments on Particle-laden Molten Metal Flows: Tobias Lappan1; Mārtiņš Sarma1; Sascha Heitkam2; David Mannes3; Pavel Trtik3; Natalia Shevchenko1; Kerstin Eckert2; Sven Eckert1; 1Helmholtz-Zentrum Dresden-Rossendorf; 2Technische Universität Dresden; 3Paul Scherrer Institut
    In metallurgical processing, non-metallic inclusions in metallic materials are one highly relevant challenge. Bubble injection into molten metals boosts the inclusion control and removal, thus enhancing metal homogenisation and purification. Although this principle of bubble flotation has been used for a long time, the effects of bubble-inclusion interactions in molten metals are not yet well researched. Imaging measurements of multiphase metal flows are challenging for two main reasons: the metals’ high melting temperatures, and their opaqueness for visible light. This work focuses on X-ray and neutron radiographic experiments employing low-melting gallium alloys laden with small model particles. Both, bubbles and particles, are visualised simultaneously with high spatial and temporal resolution to analyse their motions by tracking algorithms. We demonstrate the capability of time-resolved X-ray and neutron radiography to image flows in particle-laden optically opaque fluids, thus contributing to pave the way for systematic investigations of particle and bubble flows in molten metals.

9:10 AM  
Computational Fluid Dynamics Modeling of Damped Oscillations of Molten Metal Droplets: Ali Rabeh1; Makrand Khanwale1; Baskar Ganapathysubramian1; Michael SanSoucie2; Jonghyun Lee1; 1Iowa State University; 2NASA MSFC
    Interfacial tension between molten slags and steel is being measured by the extended oscillating droplet method using the Electrostatic Levitation Furnace aboard the international space station. The oscillation and damping behavior of a levitated core-shell compound droplet is captured using a photo sensor. The obtained damping curves are analyzed to extract two oscillation frequencies by which the interfacial tension is to be calculated. A numerical model has been developed to predict the damping of the compound droplet. The developed model is being utilized to design space experiments and interpret the results downloaded from the international space station. This presentation introduces our recent efforts on the development and improvement of the numerical model to support the upcoming space experiments.

9:30 AM  
Numerical Simulation of the Influence of Particle Physical Properties on Flow Field during the Aeration Leaching Process: Mingzhao Zheng1; Qiuyue Zhao1; Zimu Zhang1; Lei Zhou1; Ting-an Zhang1; 1Northeastern University
    The aeration leaching process is a three-phase reaction of gas, liquid and solid. The solid phase is black opaque particles. It is difficult to observe the flow field and the distribution of each phase. The water model experiment does not involve chemical reactions, and the physical properties of the solid particles remain unchanged. The effect of particle changes on the flow field cannot be explored. This study is based on computational fluid dynamics (CFD) software, using the Euler-Euler three-fluid model. A 60L stirred reactor was simulated, and the solid-liquid ratio in the tank was 1:4, ventilation rate Q=1~2.5m³/h, speed 400~500rpm. This study simulated the particle changes in the real reaction process, and analyzed the phase distribution and flow field.