Frontiers in Solidification: An MPMD Symposium Honoring Jonathan A. Dantzig: Casting Processes
Sponsored by: TMS Materials Processing and Manufacturing Division, TMS Functional Materials Division, TMS Light Metals Division, TMS Structural Materials Division, TMS: Aluminum Committee, TMS: Chemistry and Physics of Materials Committee, TMS: Process Technology and Modeling Committee, TMS: Solidification Committee
Program Organizers: Andre Phillion, McMaster University; Michel Rappaz, Ecole Polytechnique Fédérale De Lausanne; Melis Serefoglu, Marmara University; Damien Tourret, IMDEA Materials Institute
Wednesday 2:00 PM
March 22, 2023
Room: 28E
Location: SDCC
Session Chair: Andre Phillion, McMaster University; Michel Rappaz, EPFL; Melis Serefoglu, Marmara University; Damien Tourret, IMDEA Materials
2:00 PM Invited
Scaling Analysis In Solidification Process Modeling: Matthew Krane1; 1Purdue University
Scaling analysis applied to transport phenomena conservation equations is a useful tool for finding functional relationships among physical mechanisms and to estimate the order-of-magnitude of the terms in those equations. Because these terms represent different phenomena, scaling provides a physically sound rationale for neglecting certain terms to make simplifying assumptions. Here I review the basic methodology and show examples from the solidification processing literature, including analyses of heat transfer, liquid flow in melt pools and mushy zones, and segregation. These and many other results demonstrate that the proper use of this approximate technique can produce fundamental insights into the behavior of casting processes and improve intuition for evaluating results of more detailed analyses.
2:30 PM Invited
Computational Models of Microstructure and Thermal Distortion during Initial Solidification of Steel: Brian Thomas1; Ghavam Azizi1; Mohsen Asle Zaeem1; 1Colorado School of Mines
The initial stages of solidification are of vital importance to the surface quality of cast metal products. In this work, computational models of initial solidification are applied to investigate solidification microstructure and thermal distortion during initial solidification of steel during continuous casting. A phase field model of columnar dendrite growth is applied to investigate the effect of steel grade during initial solidification of low-carbon steel with manganese and silicon. A finite-element model including non-linear temperature-, phase-, and carbon-content-dependent elastic-viscoplastic constitutive equations is applied to study the effect of steel grade and interfacial heat flux on thermal distortion of a solidifying steel droplet. These fundamental models are validated with measurements and provide new insights into the phenomena which govern initial solidification. Of particular interest is the quantitative prediction of deeper depressions in ultra-low carbon and peritectic steels, which lead to cracks and other surface defects in the commercial process.
3:00 PM
Mutual Translations between Fundamental Knowledge and Industrial Practice in the Field of Al Alloys Solidification and Casting: Philippe Jarry1; 1Constellium C-TEC
Starting from a functional analysis of the DC Casting of Al alloys, the various kinds of feedbacks from downstream specifications to the operation and design of the casting process will be listed. Illustrations will be given of how engineering problems can kindle fundamental understanding and how research work at the forefront of scientific knowledge can be translated back into engineering development. Emphasis will be especially put on phase and morphology selection during solidification of Al alloys; on input from atomistic modelling for guiding alloy design; and at the other end of length scales on how fundamental knowledge can be organised to rationalise and guide DC Casting start-up recipe devising.
3:20 PM Break
3:40 PM
Design of Light Wind Turbine Parts by Simulation Based Machine Learning: Youness Bami1; Can Huang1; Emir Subasic1; Felix Weber2; Jannik Zimmermann2; Vitali Züch2; Juergen Jakumeit1; 1Access E.V.; 2RWTH Aachen
The steady increase in the size and power of modern wind turbines has led to the need to reduce the weight of their castings. Shape optimization leads to thinner parts that are lighter and solidify faster. Faster solidification often leads to better local material properties, which in turn enable further size reductions. By integrating casting simulation with property prediction into shape optimization, this link between size and properties can be used to design lighter parts.To achieve this goal, multiphase casting simulation is combined with a microscopic diffusion-driven growth model for eutectic grains in nodular cast iron to calculate microstructure parameters and estimate local material properties of wind turbine components. Based on many precomputed simulation data, a hybrid machine learning approach is trained to predict grain structure parameters and mechanical properties. First promising results of this simulation-based machine learning (SMiLe) approach are reported and compared with simulation and experimental results.
4:00 PM
Near-congruent Cu-Mn Bronze Produced with Ferro-manganese: Kevin Trumble1; 1Purdue University
Copper-manganese alloys based on the congruent minimum at 34.6 wt% Mn have high castability due to the vanishingly narrow freezing range, resulting in cellular (non-dendritic) solidification under conventional casting. Alloys with the near-congruent Cu:Mn ratio were produced using blends of electrolytic Mn (99.9%) and standard ferro-manganese (78% Mn, balance Fe, C), bringing in additional Fe and C. Microstructure analysis revealed a potent effect of grain nucleation due to the high-melting Fe, and mixtures of carbon-containing phases, depending on the oxidizing conditions in air melting. Microstructure development is analyzed in terms of the available ternary and quaternary phase relations.
4:20 PM
Microstructure and Crystallographic Texture in Twin-roll Casting of AA1050: Simulation and Industrial Validation: Jonathan Dantzig1; Onur Meydanoglu2; Arash Kazazi3; Hatice Mollaoglu Altuner2; Cemil Isiksacan2; Melis Serefoglu4; 1University of Illinois; 2Assan Aluminum; 3Koc University; 4Marmara University
Twin-roll casting is a process in which liquid metal is introduced into a narrow gap between rotating rolls, where it first solidifies and is then deformed to produce thin sheet. The complex microstructural features resulting from the combined solidification and deformation have a profound effect on the properties of the final product.We present a computational model of the TRC process that accurately predicts the final microstructure and crystallographic texture through the cast strip, in addition to measurable process outcomes, such as roll separating force and forward slip. We demonstrate the validation of the model by a series of industrial trials, where AA1050 aluminum alloy was cast under a variety of processing conditions. The model allows us to examine the interplay of solidification, shear, and compression through the sheet thickness as they produce the final microstructure and crystallographic texture.
4:40 PM Invited
Frontiers in Solidification - 2023: Jonathan Dantzig1; 1University of Illinois at Urbana-Champaign
The frontiers of solidification span the length and time scale spectrum, from those associated with the attachment of individual atoms at the solid-fluid interface; through the formation of microstructure; all the way up to the macroscopic scale of industrial castings. Our understanding of the important phenomena at each scale has advanced through the combination of experimentation, modeling and reduction to practice in industrial settings. This talk will focus on the state-of-the art in several of these areas, and discuss some of the outstanding issues and challenges that lie ahead.