Журналы →  Chernye Metally →  2023 →  №10 →  Назад

To 75th anniversary of Sergey Zhulyev, founder of the scientific school of materials technology in Volgograd state technical university
Название Modeling the solidification process of a forging ingot when topping up the profitable part with a melt
DOI 10.17580/chm.2023.10.09
Автор S. B. Gamanyuk, D. V. Rutskii, N. A. Zyuban, M. V. Kirilichev
Информация об авторе

Volgograd State Technical University, Volgograd, Russia
S. B. Gamanyuk, Cand. Eng., Associate Prof., Dept. of Technology of Materials, e-mail: gamanuk@mail.ru
D. V. Rutskii, Cand. Eng., Associate Prof., Head of the Dept. of Technology of Materials, e-mail: drutskii@vstu.ru
N. A. Zyuban, Dr. Eng., Prof., Dept. of Technology of Materials, e-mail: tecmat49@vstu.ru
M. V. Kirilichev, Head of the Laboratory of the Dept. of Technology of Materials, e-mail: tecmat@vstu.ru


The paper presents the results of a laboratory study of refilling the profitable part of the ingot with melt, after a certain time interval after pouring the ingot body on the quantitative and qualitative characteristics of convective motion, the process of solidification and structure formation of the model ingot. The research was carried out by the method of physical (cold) modeling, for which a laboratory installation (mold-mold) was developed and manufactured, which allows visually studying the processes occurring during solidification and structure formation on a model of an ingot weighing 19.6 tons. Sodium sulfuric acid (crystalline hyposulfite) was used as a modeling solution. The correspondence of the processes occurring on the model and in real conditions of casting of industrial ingots was evaluated using similarity criteria obtained on the basis of dimension theory based on the analysis of physico-chemical processes occurring during casting and crystallization of the ingot. The casting of the melt into the mold-mold was carried out from above. The results of the research have established that model ingots, which are cast with refilling of the profitable part by melt after a specified time interval after pouring the ingot body, harden 1.4 times faster than the ingot cast according to classical technology. It was found that refilling the profitable part with melt contributed to a 1.3-fold increase in the volume fraction of the zone of columnar crystals, a 1.3-fold decrease in the volume fraction of the axial zone and a 2.2-fold decrease in the volume fraction of the zone of differently oriented crystals in model ingots. It is shown that for an ingot cast with refilling of profit by melt after 20 minutes, the length of the axial zone of the ingot is reduced by 1.8 times. The obtained results make it possible to develop a technology for differentiated casting of ingots when filling their profits with melt, which will allow regulating the processes of forming the metal structure and reducing the length of the axial zone.
The research was supported by the Russian Science Foundation grant No. 23-29-00973, https://rscf.ru/project/23-29-00973/.

Ключевые слова Physical simulation, pouring from above, crystallization mould, convective flows, topping up with melt, solidification, axial zone, a large forging ingot
Библиографический список

1. Skoblo S. Ya., Kazachkov E. A. Ingots for large forgings. Moscow : Metallurgiya. 1973. 247 p.
2. Smirnov A. N., Makurov S. L., Safonov V. M., Tsuprun A. Yu. Large ingot. Donetsk: Veber, 2009. 279 p.
3. Zhulyev S. I., Zyuban N. A., Rutskyi D. V. Steel ingots: quality problems and new technologies : monograph. Volgograd : VolgGTU, 2016. 176 p.
4. Chen Zh., Senk D., Firsbach F. Experimental investigations on solidification of 500-kg steel ingots with laboratory trials. Metallurgical and Materials Transactions B. 2018. Vol. 49B. pp. 2514–2532. DOI: 10.1007/s11663-018-1325-5
5. Kang-Xin Chen, Hou-Fa Shen. Numerical simulation of macrosegregation caused by thermal–solutal convection and solidifcation shrinkage using ALE model. Acta Metallurgica Sinica (English Letters). 2019. Vol. 32. pp. 1396–1406. DOI: 10.1007/s40195-019-00897-0
6. Ghods M., Lauer M., Grugel R. N., Tewari S. N., Poirie D. R. Macrosegregation due to convection in Al-19Cu alloy directionally solidified through an abrupt expansion in cross-section: A comparison with Al–7Si. Journal of Materials Engineering and Performance. 2017. Vol. 26. pp. 4876–4889. DOI: 10.1007/s11665-017-2925-y
7. Ebisu Y. Numerical studies on the effects of axial magnetic fields and cooling intensities on the macrosegregation of directionally solidified Ni-based alloys: Elimination of thermal convection and stabilization of interdendritic liquid flow. Metallurgical and Materials Transactions B. 2022. Vol. 53. pp. 2779–2799.
8. Tashiro Koichi, Watanabe Shiro, Kitagawa Ikujiro, Tamura Itaru. Influence of mould design on the solidification and soundness of heavy forging ingots. Transactions of the Iron and Steel Institute of Japan. 1983. Vol. 23, Iss. 4. pp. 312–321. DOI: 10.2355/isijinternational1966.23.312
9. Gamanyuk S. B. Study of a large forging steel ingot of modified geometry in order to improve the quality of forging`s metal: Dissertation … of Candidate of Engineering Sciences. Volgograd, 2012. 162 p.
10. Romashkin A. N., Malginov A. N., Tolstykh D. S., Ivanov I. A., Dub V. S. Influence of ingot geometry on the volume of axial porosity in it. Kompyuternye issledovaniya i modelirovanie. 2015. Vol. 7. No. 1. pp. 107–112. DOI: 10.20537/2076-7633-2015-7-1-107-112
11. Jiaqi Wang, Paixian Fu, Hongwei Liu, Dianzhong Li, Yiyi Li. Shrinkage porosity criteria and optimized design of a 100-ton 30Cr2Ni4MoV forging ingot. Materials & Design. 2012. Vol. 35. pp. 446–456. DOI: 10.1016/j.matdes.2011.09.056
12. Zhang C.-J., Bao Y.-P., Wang M. Influence of casting parameters on shrinkage porosity of a 19 ton steel ingot. Metallurgia Italiana. 2016. Vol. 108, Iss. 1. pp. 37–44.
13. Zhang Chaojie, BaoYanping, Wang Min, Guo Baoqi. Influence of casting parameters on the shrinkage porosity of a 40-ton steel ingot by numerical simulation. Proceedings of the 6th International Congress on the Science and Technology of Steelmaking. 2015. pp. 543–546.
14. Yu Z., Zhang H., Wang X., Wu X. Study on heat transfer characteristics during solidification of 18-ton steel ingot with large ratio of height to diameter. Metallurgia Italiana. 2020. Vol. 112, Iss. 5. pp. 37–47.
15. Zhang C., Loucif A., Jahazi M., Morin J.-B. FE modelling and prediction of macrosegregation patterns in large size steel ingots: Influence of filling rate. Metals. 2022. Vol. 12, Iss. 1. 29. DOI: 10.3390/met12010029
16. Zhang C., Loucif A., Jahazi M., Tremblay R., Lapierre L.-P. On the effect of filling rate on positive macrosegregation patterns in large size cast steel ingots. Applied Sciences (Switzerland). 2018. Vol. 8, Iss. 10. 1878. DOI: 10.3390/app8101878
17. Marx K., Rödi S., Schramhauser S., Seemann M. Optimization of the filling and solidification of large ingots. Metallurgia Italiana. 2014. Vol. 106. Iss. 11-12. pp. 11–19.
18. Computer modeling system for foundry processes LVMFlow/NovaFlow&SolidCV. Available at: http://lvmflow.ru/ (accessed: 30.08.2023).
19. Computer modeling system for foundry processes PoligonSoft. Available at: https://poligonsoft.ru/ (accessed: 30.08.2023).
20. Ludwig A., Stefan-Kharicha M., Kharicha A., Wu M. Massive formation of equiaxed crystals by avalanches of mushy zone segments. Metallurgical and materials transaction A. 2017. Vol. 48A. pp. 2927–2930.
21. Stefan-Kharicha M., Kharicha A., Mogeritsch J., Wu M., Ludwig A. Review of ammonium chloridewater solution properties. Journal of chemical and engineering. 2018. Vol. 63. pp. 3170–3183.
22. Gamanyuk S. B., Zyuban N. A., Rutskyi D. V., Palatkin S. V. Device for studying the process of crystallization of ingots in a mold. Patent RF, No. 169365. Applied: 24.05.2016. Published: 15.03.2017. Bulletin No. 8.
23. Efimov V. A., Eldarkhanov A. S. Modern technologies for casting and crystallization of alloys. Moscow : Mashinostroenie. 1998. 359 p.
24. Gorunov A. I., Naumenko V. V., Rutskyi D. V. Influence of topping up the profitable part on the processes of solidification and structure forming for the ingot of 38KhN3MFA steel. Izvestiya Volgogradskogo gosudarstvennogo tekhnicheskogo universiteta. Seriya "Problemy materialovedeniya, svarkin i prochnosti v mashinostroenii". Iss. 2: Interuniversity collection of scientific articles. 2008. No. 10. pp. 157–159.
25. Eldarkhanov A. S., Efimov V. A., Nuradinov A. S. Processes of casting formation and their modeling. Moscow : Mashinostroenie. 2001. 208 p.

Language of full-text русский
Полный текст статьи Получить