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Simulation of Air Entrainment during Mold Filling: Comparison with Water Modeling Experiments

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Abstract

Oxide inclusions form during pouring of metal castings as a result of air entrainment. Recently, a model was developed by the authors to predict the volumetric air entrainment during pouring. It was found that the velocity, diameter, and turbulence intensity of the liquid stream affect the air entrainment rate during pouring. In this study, the developed air entrainment model is validated with water modeling experiments. In the water modeling studies, water was poured using a bottom pour ladle. The effects of nozzle opening, head height, nozzle diameter, and nozzle extension are simulated. The predictions compare favorably with the experimental measurements. Results indicate that low head height and short pouring time have a beneficial effect on reducing the air entrainment during pouring. In addition, a fully open nozzle and the use of a nozzle extension further reduce the amount of entrained air.

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Authors and Affiliations

  1. Department of Mechanical and Industrial Engineering, University of Iowa, Iowa City, IA, 52242, USA

    Seyyed Hojjat Majidi & Christoph Beckermann

  2. Department of Material Science and Engineering, University of Alabama at Birmingham, Birmingham, AL, 35294, USA

    John Griffin

Authors
  1. Seyyed Hojjat Majidi
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  2. John Griffin
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  3. Christoph Beckermann
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Correspondence to Christoph Beckermann.

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Manuscript submitted March 2, 2018.

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Majidi, S.H., Griffin, J. & Beckermann, C. Simulation of Air Entrainment during Mold Filling: Comparison with Water Modeling Experiments. Metall Mater Trans B 49, 2599–2610 (2018). https://doi.org/10.1007/s11663-018-1334-4

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  • DOI: https://doi.org/10.1007/s11663-018-1334-4

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