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Removal of Bifilms from Al Melts by Stirring in Unbaffled and Baffled Crucibles

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Abstract

The free surface of aluminum melt, during stirring under different rotation speeds in unbaffled and baffled crucibles, was simulated numerically using a RANS turbulence model coupled with a particle-tracking method. The effect of mechanical stirring of Al melts containing 0.3, 0.7, and 4.5 wt pct Mg in unbaffled and baffled crucibles on the rate of elimination of bifilms from the melt was also investigated using a reduced pressure test. The results showed that the stirring increased the rate of removal of bifilms from the melt due to an increase in the rate of formation of cracks on the bifilms. Using baffles in the crucible accelerated the rate of removal of bifilms by changing the pattern of movement of bifilms in the melt. The critical stirring speeds, above which the oxide layer on the Al melt could submerge into the bulk liquid, were determined by the simulation. It was confirmed by the experimental results to be about 158 and 420 RPM for the unbaffled and baffled crucibles, respectively.

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Abbreviations

D :

Rotor diameter (m)

d p :

Particle diameter (m)

F D :

Drag force (N)

F g :

Gravitational force vector (N)

Fr:

Froude number (—)

Fr*:

Modified Froude number (—)

FrCr :

Critical Froude number (—)

g :

Gravity acceleration (m s−2)

I :

Identity matrix (—)

k :

Turbulent kinetic energy (m2 s−2)

m p :

Particle mass (kg)

N :

Stirring speed (s−1)

N Cr :

Critical stirring speed (s−1)

P :

Pressure (Pa)

P k :

Turbulent energy production (kg m−1 s−3)

r :

Radial distance (m)

t :

Time (s)

u :

Fluid velocity (m s−1)

v :

Velocity of particle (m s−1)

V ss :

Free surface velocity (m s−1)

We:

Weber number (—)

ε :

Turbulent dissipation rate (m2 s−3)

μ :

Dynamic viscosity (Pa s)

μ T :

Turbulent dynamic viscosity (Pa s)

ρ :

Fluid density (kg m−3)

ρ P :

Particle density (kg m−3)

σ :

Surface tension (N m−1)

τ P :

Response time of particle velocity (s)

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Authors and Affiliations

  1. Department of Metallurgy and Materials Science, School of Engineering, Shahid Bahonar University of Kerman, JomhooriEslami Blvd, Kerman, Iran

    Hamed Bagherpour-Torghabeh, Ramin Raiszadeh & Hamid Doostmohammadi

Authors
  1. Hamed Bagherpour-Torghabeh
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  2. Ramin Raiszadeh
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  3. Hamid Doostmohammadi
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Correspondence to Ramin Raiszadeh.

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Manuscript submitted February 27, 2018.

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Bagherpour-Torghabeh, H., Raiszadeh, R. & Doostmohammadi, H. Removal of Bifilms from Al Melts by Stirring in Unbaffled and Baffled Crucibles. Metall Mater Trans B 49, 3456–3469 (2018). https://doi.org/10.1007/s11663-018-1414-5

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