CFD Investigation of Rotational Sloshing Waves in a Top-Submerged-Lance Metal Bath

Computational fluid dynamics (CFD) is applied to investigate rotational sloshing waves in a top-submerged-lance (TSL) cylindrical metal bath. The study is an extension of a recent work of the authors, where the top injection of Ar into a metallic bath was examined in a quasi-2D flat setup, allowing the numerical model to be extensively validated against experimental data based on x-ray radiography. The new analysis of top gas injection in a cylindrical vessel reveals the appearance of rotational sloshing in the bath, which is maintained by a condition of synchronism between the gas bubbles and the free surface of the bath. A numerical quantification is achieved with specific post-processing of the simulation results, showing the effect of control parameters such as the lance immersion depth and the gas flow rate. This fundamental research study demonstrates the capability of CFD modeling to predict bath dynamics known from literature and practice, the understanding of which is essential for the design of TSL furnaces.

Modification of Aluminium-Silicon Near-Eutectic Alloy with Use of Electrolysis of Sodium Salt

The present work discusses results of preliminary tests concerning the technology of continuous dosage of sodium to a metallic bath from the aspect of modification of EN AC-44200 alloy, through the use of a multiple compound (salt) of sodium. The technology consists in continuous electrolysis of sodium salts occurring directly in a crucible with liquid alloy. As a measure of the degree of alloy modification over the course of testing, the ultimate tensile strength (UTS or Rm) and analysis of microstructure are taken, which confirm the obtained effects of the modification on the investigated alloy. Assurance of stable parameters during the process of continuous modification with sodium, taking into consideration the fact of complex physical-chemical phenomena, requires additional tests aimed at their optimization and determination of a possibility of implementation of such technology in metallurgical processes.

Effect of the Metallic Aging on the Microstructure and Mechanical Properties of Titanium Alloy

ABSTRACTDifferent aging heat treatments were performed in a Titanium alloy using as aging media metallic baths in comparison to typical furnace aging. As a first step, a Duplex Aging (DA) consisted of solubilization followed by quenching to room temperature after aging heat treatment in different metallic baths (Zn, Sn and Bi). A second procedure was Alternative Aging (AA) which consisted of solubilization and direct aging inside three different aforementioned baths. Microstructural aging variations begins at half hour until 30 h at 550°C inside metallic bath of Zn, Sn or Bi. Both kinds of aging promoted a microstructural variation and so on microhardness values. Microstructural analysis by Optical Microscopy showed a structural refinement after AA treatment. The highest hardness value of 375 HVN was achieved in Alternative Aging with Zn bath, which was found to be dependent on laminar α phase refining. Moreover, after AA treatment for 0.5, 1, 2, 3, 4, 10 and 30 h at 550°C in the metallic bath of Zn and Sn, the results indicated similar hardness values in different times, resulting in the fastest kinetic for Sn metallic bath at 2 h compared to that 4 h in Zn metallic bath. The observed increase in micro-hardness is not very attractive, it is recommended to use large aging times in order to stabilize final spacing of microstructural features in AA treatment.

Theoretical and Practical Aspects Regarding Al-SiC Particles Composites Obtaining by Casting

The paper presents the principal aspects regarding the obtaining of the mixture aluminium - silicon carbide particles. It is discussed about the wetting conditions and the critical acceleration necessary for the incorporation of particles into the melt. The high values obtained for this parameter involve applying some methods to improve the wettability: the covering of the complementary material with a thin layer of Ni, the alloying of the aluminium melt, the overheating of the metallic bath and the heat treatment of the silicon carbide particles. Also, the mechanical stirring conditions necessary to realize the mixture are presented. The settling process of the silicon carbide particles in the melt as a function of particles size, shape and volumetric concentration is also analysed. The presence of complementary material leads to the growth of the mixture viscosity. Therefore, the liquid alloy was investigated like a continuous medium in connection with the apparent viscosity. The main aspects regarding the solidification of metallic composites processed by casting method based upon theoretical concepts, general knowledge about casting of composites and experimental data are discussed. Finally, the specific defects caused by an insufficiently controlled solidification process and prevention measures are shown.

Bainite Formation at Low Temperatures in High C-Si Steel and its Mechanical Behavior

A significant amout of stabilized austenite can be obtained in high carbon steel containing high amounts of manganese and silicon (1.5-2 %). At relatively low temperatures the bainite plates formed are extremely thin, making the material very strong. In this study, the influence of the thermal cycle of austempering on the mechanical behavior of a spring steel 0.56C-1.43Si-0.58Mn-0.47Cr (wt. %), with TRIP effect was investigated. The thermal cycle consisted of heating three groups of hot-rolled wire steel at austenite field of 900°C for 300 s, and quickly transferring those to a metallic bath maintained at 200, 220 or 270°C, respectively, for different heat treatment times. The samples were then tested in tension and their microstructures were examined by scanning and transmission electron microscopy. The samples treated at 220°C showed higher elongation, yield strength and tensile strength than those maintained at 200 or 270°C. The high level of strength and ductility is due to a mixture of martensite and very fine bainitic ferrite with interlath film of retained austenite. The temperature has shown a strong influence on bainite formation kinetics. The fracture behavior of the steel was also evaluated using SEM fractography.

Float Foil Growth of Si-Foils for Solar Cell Applications

A new Float Foil Growth (FFG) technique has been demonstrated for growing thin Si foils from molten metal solvent, such as molten indium (In) or tin (Sn), at temperatures below 1,000°C. Si source is first dissolved to saturation (or close to saturation) in a molten metallic bath (or solvent) at a temperature T2 (T2 ≤ 1,000°C), and the molten bath is then cooled to T1, where T2 » T1. Due to lower solubility of Si at T1 than at T2, Si separates (or is driven) out of solution and, due to its much lower density than that of the molten metallic bath, it floats to the top of the melt to form a floating thin Si-foil. The thickness of the Si foil is determined primarily by T2, the dissolution temperature (i.e., Si solubility at T2), and the depth of the molten bath. This paper reports preliminary results demonstrating the utility of the FFG technique for growing Si-foils. Si foils with thickness range of 50-200μm were obtained from molten In baths. The Si foils were multicrystalline with crystalline (or grain) size of several millimeters, having a strong <111> preferred orientation. The Si-foils were very pure; with In (solvent) content as low as 14ppb. Other metallic impurities were below 0.1ppm, oxygen content was as low as 1.8ppm, and carbon content was below the detection level (50ppb). It is expected that large FFG thin Si-foils, when produced on large scale, will offer significant Si material cost and energy savings (> 80%), compared with conventional sliced Si wafers, with similar photovoltaic conversion efficiency.