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Numerical Study on the Solid–Liquid Interface Evolution of Large-Scale Titanium Alloy Ingots During High Energy Consumption Electron Beam Cold Hearth Melting

  • Heat Transfer Utilization in Pyrometallurgy
  • Published:
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Abstract

In the present paper, a three-dimensional thermal-fluid multi-physical model has been established to investigate the effect of energy consumption operations on the evolutionary tendency of the solid–liquid interface for large-scale Ti-6 wt.%Al-4 wt.%V (TC4) round (Φ260 mm and Φ620 mm)/slab (1050 mm × 220 mm) ingots produced by electron beam cold hearth melting. The results qualitatively revealed the evolutionary tendency of the solid–liquid interface in different casting conditions, indicating that the solid–liquid interface with a gentle casting speed at a low pouring temperature will generate symmetric solid–liquid interfaces which were slightly affected by the modification of the pouring temperature. With an increasing energy input resulting from the rising casting speed, the deformation of the solid–liquid interface near the inlet was increased. As a result, the risk of breaking out and the formation of a non-uniform microstructure in the Φ620-mm round ingots and slab ingots was greatly increased.

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Abbreviations

\( A_{\text{mush}} \) :

Mushy zone constant

\( \beta \) :

Liquid fraction

\( c_{p} \) :

Specific heat (J/kg K)

\( g \) :

Acceleration due to gravity (m/s2)

\( H \) :

Enthalpy (J/kg)

\( h \) :

Sensible enthalpy (J/kg)

\( h_{\text{ref}} \) :

Reference enthalpy (J/kg)

\( \Delta H_{f} \) :

Pure solvent melting heat (J/kg)

\( k \) :

Thermal conductivity (K/m K)

L :

Characteristic length (m)

P :

Pressure (Pa)

\( \rho \) :

Density (kg/m3)

\( \overline{\overline{\tau }} \) :

Stress tensor (N/m2)

\( T_{\text{ref}} \) :

Reference temperature (K)

\( T \) :

Temperature (K)

t :

Time (s)

\( \vec{v} \) :

Cell velocity (m/s)

\( \vec{v}_{\text{p}} \) :

Pull velocity (m/s)

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Acknowledgements

This work was supported by China Postdoctoral Science Foundation No. 2018M633421, National Natural Science Foundation of China (Grant No. 51764052) and Innovative Research Team (in Science and Technology) in University of Yunnan Province.

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Authors and Affiliations

  1. Key Laboratory of Green-Chemistry Materials in University of Yunnan Province, Yunnan Minzu University, Kunming, 650500, China

    Lei Gao & Guo Chen

  2. R&D Center, Yunnan Titanium Industry Co., Ltd., Chuxiong, 675000, China

    Haiguang Huang

  3. Kunming University of Science and Technology, Kunming, 650093, China

    Lei Gao, Yehua Jiang, Guo Chen & Rong Zhou

  4. Process Metallurgy Research Labs, University of Toronto, Toronto, ON, M5S 3E4, Canada

    Kinnor Chattopadhyay

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  1. Lei Gao
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  2. Haiguang Huang
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  3. Yehua Jiang
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  4. Guo Chen
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  5. Kinnor Chattopadhyay
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  6. Rong Zhou
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Correspondence to Yehua Jiang or Guo Chen.

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Gao, L., Huang, H., Jiang, Y. et al. Numerical Study on the Solid–Liquid Interface Evolution of Large-Scale Titanium Alloy Ingots During High Energy Consumption Electron Beam Cold Hearth Melting. JOM 72, 1953–1960 (2020). https://doi.org/10.1007/s11837-020-04089-5

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  • DOI: https://doi.org/10.1007/s11837-020-04089-5

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