Numerical Modeling of Low Frequency Electromagnetic Casting of 7XXX Aluminum Alloys

2007 ◽  
Vol 546-549 ◽  
pp. 707-712
Author(s):  
Hai Tao Zhang ◽  
Hiromi Nagaum ◽  
Yu Bo Zuo ◽  
Jian Zhong Cui
Keyword(s):  
Electromagnetic Field ◽  
Temperature Field ◽  
Fluid Flow ◽  
Low Frequency ◽  
Solidification Process ◽  
Casting Process ◽  
Mathematic Model ◽  
Electromagnetic Casting ◽  
Finite Element Package ◽  
Flow Heat

Low frequency electromagnetic casting is a new developed technology that appears in the recent years. In this paper, a comprehensive mathematical model has been developed to describe the interaction of the multiple physics fields during LFEC (low frequency electromagnetic casting) process. The model is based on a combination of the commercial finite element package ANSYS and the commercial finite volume package FLUENT, with the former for calculation of the electromagnetic field and the latter for calculation of the magnetic driven fluid flow, heat transfer and solidification. Moreover, the model has been verified against the temperature measurements obtained from one 7XXX aluminum alloy billet of 200mm in diameter, during the LFEC casting processes, respectively. There was a good agreement between the calculated results and the measured results. Further, the effects of electromagnetic frequency on fluid flow, temperature field and solidification during LFEC process have investigated numerically by using the mathematic model. The choosing criterion of the electromagnetic frequency during LFEC process has been used in order to obtain the best structure of the billets by analyzing the effects of fluid flow and temperature field on the solidification process in the presence of electromagnetic field.

Coupled Modeling of Electromagnetic Field, Fluid Flow, Heat Transfer and Solidification during Conventional DC Casting and Low Frequency Electromagnetic Casting of 7XXX Aluminum Alloys

2006 ◽  
Vol 15-17 ◽  
pp. 18-23 ◽  
Author(s):  
Hai Tao Zhang ◽  
Hiromi Nagaum ◽  
Yu Bo Zuo ◽  
Jian Zhong Cui
Keyword(s):  
Heat Transfer ◽  
Electromagnetic Field ◽  
Fluid Flow ◽  
Low Frequency ◽  
Casting Process ◽  
Coupled Modeling ◽  
Electromagnetic Casting ◽  
Flow Heat ◽  
Dc Casting ◽  
Heat Transfer And Solidification

A comprehensive mathematical model has been developed to describe the interaction of the multiple physics fields during the conventional DC casting and LFEC (low frequency electromagnetic casting) process. The model is based on a combination of the commercial finite element package ANSYS and the commercial finite volume package FLUENT, with the former for the calculation of the electromagnetic field and the latter for the calculation of the magnetic driven fluid flow, heat transfer and solidification. Moreover, the model has been verified against the temperature measurements obtained from two 7XXX aluminum alloy billets of 200mm diameter, cast during the conventional DC casting and the LFEC casting processes. In addition, a measurement of the sump shape of the billets were carried out by using addition melting metal of Al-30%Cu alloy into the billets during casting process. There was a good agreement between the calculated results and the measured results. Further, comparison of the calculated results during the LFEC process with that during the conventional DC casting process indicated that velocity patterns, temperature profiles and the sump depth are strongly modified by the application of a low frequency electromagnetic field during the DC casting.

Numerical simulation on sprue distributions during cladding casting process

2016 ◽  
Vol 26 (8) ◽  
pp. 2340-2354 ◽  
Author(s):  
Xing Han ◽  
Haitao Zhang ◽  
Bo Shao ◽  
Dongtao Wang ◽  
Longgang Cheng ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Temperature Field ◽  
Casting Process ◽  
Mathematic Model ◽  
Melt Flow ◽  
Content Type ◽  
Metallurgical Bonding ◽  
Flow Heat ◽  
Simulation Results ◽  
Interface Bonding Strength

Purpose The purpose of this paper is to investigate the influence of sprue distributions on the flow field and temperature field of the cladding casting process and verify the simulation results by experiments. Design/methodology/approach A steady-state mathematic model for the coupling of fluid flow, heat transfer and solidification to describe the process of cladding casting was present. The effect of sprue distributions on melt flow and temperature field was discussed. Based on the numerical simulation results, the cladding billet was prepared successfully. Moreover, the model has been verified against by temperature measurements during the cladding casting process. Findings There is a good agreement between the measured and calculated results. The homogeneity of melt flow determines the formability of cladding billets and circular temperature difference affects the bonding of the two alloys. The AA4045/AA3003 cladding billet with no defects in size of f140/f110 mm was fabricated successfully. The alloy elements diffused across the interface and formed diffusion layer with a thickness of 15 µm. The interface bonding strength is higher than the tensile strength of AA3003, indicating the metallurgical bonding between two alloys. Research limitations/implications The casting parameters are limited to the aluminum alloy cladding billet in size of f140/f110 mm in this paper. Originality/value There are few reports of cladding billet, which are used to prepare condense pipes of automotive engines. The effect of distribution schemes on the cladding casting process is rarely studied.

Effect of Casting Temperature on the Microstructure of Al-Zn-Mg-Cu Aluminium Alloy Billets Prepared by LFEC Process

2013 ◽  
Vol 634-638 ◽  
pp. 1690-1693
Author(s):  
Yu Bo Zuo ◽  
Lei Li ◽  
Qing Feng Zhu ◽  
Jian Zhong Cui
Keyword(s):  
Aluminum Alloy ◽  
Temperature Field ◽  
Aluminium Alloy ◽  
Large Range ◽  
Low Frequency ◽  
Casting Process ◽  
Casting Temperature ◽  
Grain Refining ◽  
Cu Alloy ◽  
Electromagnetic Casting

In order to understand the effect of casting temperature on the low frequency electromagnetic casting process, 200mm billets of an Al-Zn-Mg-Cu alloy were produced, the microstructure was analyzed and the temperature field was measured during the casting process. The experimental results showed that low frequency electromagnetic casting process has an evident grain refining effect on aluminum alloy and casting temperature is not a sensitive parameter for this process, which can tolerate a large range of casting temperature. In the range of 710 to 750 °C, casting temperature does not show significant effect on the microstructure.

Effects of the Low Frequency Electromagnetic Field on the Centerline Macrosegregation of 7075 Aluminum Ingots

2011 ◽  
Vol 295-297 ◽  
pp. 1705-1708
Author(s):  
Dan Dan Chen ◽  
Hai Tao Zhang ◽  
Xiang Jie Wang ◽  
Jian Zhong Cui
Keyword(s):  
Electromagnetic Field ◽  
Steady State ◽  
Mushy Zone ◽  
Transition Region ◽  
Low Frequency ◽  
Casting Process ◽  
Direct Chill ◽  
Mushy Region ◽  
Chill Casting ◽  
Temperature Contour

The effects of the low frequency electromagnetic field on the macrosegregation of the 7075 aluminum ingots were investigated. The 7075 aluminum ingots with the diameter of 200 mm were prepared by the conventional direct chill casting and the low frequency electromagnetic field casting (LFEC) processes, respectively. The temperature during casting at steady state was measured, and the mushy region was observed from the temperature contour. The concentrations of the alloying elements were measured by the spectrograph. It was found that the transition region was broadened, but the mushy zone became narrower with presence of the low frequency electromagnetic field. The centerline macrosegregation of the ingots was alleviated by the low frequency electromagnetic casting process.

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