Effects of Low Frequency Electromagnetic Field on the Solidification Structure of 6063 Aluminum Alloy during Hot-Top Casting

2011 ◽  
Vol 675-677 ◽  
pp. 857-860
Author(s):  
Xiang Jie Wang ◽  
Jian Zhong Cui ◽  
Qing Feng Zhu
Keyword(s):  
Electromagnetic Field ◽  
Aluminum Alloy ◽  
Low Frequency ◽  
Casting Process ◽  
Liquid Pool ◽  
Solidification Structure ◽  
Cooling Curves ◽  
Melt Temperature ◽  
Hot Top ◽  
6063 Aluminum Alloy

Low frequency electromagnetic (LFE) field was applied during the conventional hot-top casting process. Thermocouples were used to measure the cooling curves from the border to the center of the ingot during steady-state of casting process, cooling curves were obtained, and effects of low frequency electromagnetic field on the solidification, macrostructure during the conventional hot-top casting for 6063 aluminum alloy process were analyzed. The experimental results show that the forced convection caused by the low frequency electromagnetic (LFE) filed can make the melt temperature uniform, promote the evacuation of superheat, make the temperature in the liquid pool lower than the liquidus temperature of 6063 aluminum alloy, increase the number of floating nuclei, make the ingot with fine and homogeneous macrostructure, though there is no addition of any grain refiners.

A Numerical Simulation of the Electromagnetic Hot-Top Casting of 6063 Aluminum Alloy

2010 ◽  
Vol 148-149 ◽  
pp. 1680-1683
Author(s):  
Xiang Jie Wang ◽  
Jian Zhong Cui ◽  
Hai Tao Zhang
Keyword(s):  
Numerical Simulation ◽  
Mathematical Model ◽  
Electromagnetic Field ◽  
Low Frequency ◽  
Casting Process ◽  
Two Dimensional ◽  
Electromagnetic Process ◽  
Hot Top ◽  
6063 Aluminum Alloy ◽  
Good Agreement

On the basis of conventional hot-top casting and Casting, Refining and Electromagnetic process, a lower frequency electromagnetic field was applied during the hot-top casting process. A comprehensive two-dimensional (2-D) mathematical model based upon the ANSYS and FLUENT has been developed for the computation of the electromagnetic field, solidification, fluid flow and heat transport during conventional and low frequency electromagnetic hot-top casting processes. The results show that there is a good agreement between the experimental results and calculated results.

Effects of Low Frequency Electromagnetic Field on Hot Tear during Hot-Top Casting Process

2010 ◽  
Vol 97-101 ◽  
pp. 1012-1015
Author(s):  
Xiang Jie Wang ◽  
Jian Zhong Cui ◽  
Qing Feng Zhu ◽  
Zhi Hao Zhao
Keyword(s):  
Electromagnetic Field ◽  
Flow Direction ◽  
Low Frequency ◽  
Casting Process ◽  
Hot Top ◽  
Aluminium Casting

Hot tear is one of the main defects during the aluminium casting process, and it usually occurs during solidification. In this work, the low frequency electromagnetic field was applied to study the effects of low frequency electromagnetic field on hot tear during the conventional hot-top casting process. The results show that under the effect of the low frequency electromagnetic field, the structure of the ingot is refined, the flow direction is changed, and the depth of the sump becomes shallow. All these factors can decrease the hot tear susceptibility.

Effects of Low Frequency Electromagnetic Field on Cold-Shut Formation during Aluminium Alloy Hot-Top Casting

2011 ◽  
Vol 181-182 ◽  
pp. 130-133
Author(s):  
Xiang Jie Wang ◽  
Jian Zhong Cui ◽  
Yu Bo Zuo ◽  
Qing Feng Zhu
Keyword(s):  
Electromagnetic Field ◽  
Aluminum Alloy ◽  
Aluminium Alloy ◽  
Surface Quality ◽  
Low Frequency ◽  
Experimental Results ◽  
Cast Structure ◽  
Hot Top ◽  
Alloy Ingot ◽  
7050 Aluminum Alloy

On the basis of conventional hot-top casting, low frequency electromagnetic field was applied in the process of hot-top casting to produce 7050 aluminum alloy ingot, the influences of low frequency electromagnetic field on cold-shut have been studied. The experimental results show that under the effect of the low frequency electromagnetic filed, the depth of cold folding has been decreased, and the as-cast structure has been refined. The reasons for low frequency electromagnetic field improving the surface quality, refining the structure of the ingot were summarized.

Effects of Low Frequency Electromagnetic Field on the Solidification Structure of Al-4.5%Cu Alloy during Level Casting Process

2011 ◽  
Vol 186 ◽  
pp. 176-179
Author(s):  
Xiang Jie Wang ◽  
Dan Dan Chen ◽  
Hui Xue Jiang ◽  
Gao Song Wang ◽  
Qing Feng Zhu ◽  
...  
Keyword(s):  
Electromagnetic Field ◽  
Low Frequency ◽  
Casting Process ◽  
Experimental Results ◽  
Solidification Structure ◽  
Melt Flow ◽  
Cu Alloy ◽  
Process Effects

On the basis of conventional level casting, low frequency electromagnetic field is applied during conventional level casting process. Effects of low frequency electromagnetic field on melt flow, macrostructure and microstructure have been studied. The experiment is performed on the Al-4.5% Cu alloy, and the experimental results show that with the application of the low frequency electromagnetic field, the macrostructure and microstructure are changed greatly. The reasons for the low frequency electromagnetic field changing the macrostructure and microstructure of the ingot were summarized.

Low-Frequency Electromagnetic Field Influencing Horizontal Direct Chill Casting of Aluminum Alloy Rods

2007 ◽  
Vol 546-549 ◽  
pp. 691-696
Author(s):  
Zhi Hao Zhao ◽  
Jian Zhong Cui ◽  
Qing Feng Zhu
Keyword(s):  
Electromagnetic Field ◽  
Aluminum Alloy ◽  
Low Frequency ◽  
Casting Process ◽  
Gravitational Effect ◽  
Direct Chill ◽  
Cooling Condition ◽  
Chill Casting ◽  
Alloy Ingot ◽  
Production Route

The horizontal direct chill (HDC) casting process is a well-established production route for an aluminum alloy ingot; however, the ingot may suffer from inhomogeneous microstructures and serious macrosegregation due to the unbalanced cooling condition and gravitational effect. In order to control the defect, a low frequency electromagnetic field has been applied in the HDC casting process and its influences on microstructures and macrosegregation have been studied. The results show that the low frequency electromagnetic field can improve macrostructures, reduce inhomogeneous microstructures and macrosegregation in HDC product; and two main parameters of the electromagnetic field—density and frequency influence the microstructures and solution distribution along the diameter of the ingot significantly. In the range of ampere-turns and frequency employed in the experiments, the optimum ampere-turns and frequency have been found to be 10000At, 30Hz.

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.

Experimental and Numerical Study of the Influence of a Low-Frequency Electromagnetic Field on the As-Cast Structure of Horizontal Direct Chill Casting Aluminum Alloy Slab

2009 ◽  
Vol 79-82 ◽  
pp. 1265-1268
Author(s):  
Zhi Hao Zhao ◽  
Jian Zhong Cui ◽  
Qing Feng Zhu ◽  
Gao Song Wang
Keyword(s):  
Electromagnetic Field ◽  
Aluminum Alloy ◽  
Temperature Field ◽  
Flow Pattern ◽  
Low Frequency ◽  
Direct Chill ◽  
Chill Casting ◽  
Cast Structure ◽  
Casting Aluminum Alloy ◽  
Casting Aluminum

The influences of low frequency electromagnetic field on the as-cast structure of horizontal direct chill casting aluminum alloy slab were experimental and numerical studied. The results of numerical analysis show that the interaction of the low-frequency electromagnetic field and the melt can generate an electromagnetically induced forced flow in the melt, which, in turn, changes flow pattern and temperature field in the mold. the as-cast structure of slab can be greatly improved by the changes of flow pattern and temperature field. The results of experimental analysis show that the grains of low frequency electromagnetic casting (LFEC) are fine, uniform, equiaxed, rosette-shaped; the surface of the slab of LFEC has no cold shut and less exudations. Moreover, the low-frequency electromagnetic field can improve the distribution of solute elements in the slab. The macrosegregation such as negative segregation and gravity segregation were reduced, which results in the homogenous distributions of the solute elements over the cross-section of the slab.

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