Bernd Willers

Observation of dendritic growth and fragmentation in Ga–In alloys by X-ray radioscopy

Abstract Capabilities of the X-ray attenuation contrast radioscopy were utilised to provide a real time diagnostic technique for observations of dendritic growth and fragmentation during solidification of a Ga–30In (wt-%) alloy. The solidification process was visualised by means of a microfocus X-ray tube providing shadow radiographs at spatial resolutions of about 10 μm. Experiments have been carried out to solidify the Ga–In alloy unidirectionally either starting from the bottom or the top of the specimen. The first case is significantly affected by solutal convection, which governs a redistribution of solute concentration. A detachment of dendrite side arms, which is unambiguously caused by melt flow, was not observed. Dendritic fragmentation occurs during the solidification in the reverse top down direction. Variations of the applied cooling rate excited a transition from a columnar to an equiaxed dendritic growth (CET).

Use of time-modulated AC magnetic fields for melt flow control during unidirectional solidification

Abstract A new electromagnetic stirring approach using a combination of rotating (RMF) and travelling magnetic fields (TMF) is proposed, where both fields are applied subsequently in form of rectangular pulses. The strategy to utilise time-modulated RMF and TMF is aimed at overcoming the known deficiencies of conventional stirring, in particular flow-induced macrosegregation. This paper considers the directional solidification of Al–Si alloys from a water cooled copper chill. The results demonstrate that melt agitation using modulated magnetic field offers a considerable potential for a well aimed modification of casting properties by an effective control of the flow field, but, this goal requires a well considered optimisation of the magnetic field parameters.

The effect of pulsed electrical currents on the formation of macrosegregation in solidifying Al–Si hypoeutectic phases

Within this study, we conducted experimental investigations focusing on the formation of macrosegregation in Al-7wt-%Si alloys exposed to electric current pulses (ECP) during solidification. The distribution of eutectic phase was measured on various sections of the solidified samples. The results do not show the formation of reproducible segregation pattern. This finding can be attributed to the specific pattern and the turbulent character of the flow generated by the ECP treatment, the equiaxed growth of free-moving crystals and a non-symmetric distribution of the electromagnetic force due to an uneven wetting of the electrodes. An increasing input of energy by ECP intensifies the melt flow and increases the variations of phase distribution over a longitudinal section.

Liquid Metal Modelling of Flow Phenomena in the Continuous Casting Process of Steel

The quality of the produced steel in the continuous casting process is significantly governed by the melt flow in the mold. However, direct flow measurements in liquid metals are still rather scarce. In order to investigate these flow phenomena, three experimental facilities operating with low melting liquid metals were installed at Helmholtz-Zentrum Dresden-Rossendorf (HZDR). The melt flow in the models is measured by the Ultrasonic Doppler Velocimetry (UDV) or the Contactless Inductive How Tomography (CIFT), multi-phase flows can be visualized by X-ray imaging. The obtained measurement results are primarily used for validation of numerical models.

Numeric simulations of a liquid metal model of a bloom caster under the effect of rotary electromagnetic stirring

At the voestalpine Stahl Donawitz GmbH the continuous casting of round steel blooms is commonly supported by electromagnetically induced stirring of the liquid steel flow. A number of beneficial effects are attributed to electromagnetic stirring in the mould region (M-EMS), e.g. the enhanced transition from columnar to equiaxed solidification, the homogenization of the liquid steel flow or the reduction of surface and subsurface defects. Although the positive effects of M-EMS can be seen on the blooms (e.g. in etchings), the link between electromagnetic stirring of the steel melt and the quality of the solidified bloom is not sufficiently understood. Theoretical considerations are often limited to general cases and their results are therefore not directly applicable to real continuous casting geometries. On the other hand, plant measurements can only be performed to a limited extent due to the harsh conditions and other restrictions (e.g. safety regulations). In this work an alternative approach is used to investigate the steel flow in a round bloom caster under the influence of M-EMS. In a 1:3 scale Perspex model of a round bloom strand, measurements of the flow under the influence of a rotating magnetic field can be conducted. These measurements provide a validation benchmark for the numeric simulations. A numeric model of the before mentioned 1:3 scale model is implemented, encompassing the strand, the submerged entry nozzle as well as the M-EMS device. In the modelling approach, the bidirectional coupling between liquid steel flow and the electromagnetic field/forces has to be considered because otherwise the resulting tangential velocities will be overestimated. With the validated modelling approach, simulations of real casting machines can then be conducted, stirring parameter influences can be shown and conclusions for the real casting process can be drawn.

Flow Control during Solidification of AlSi-Alloys by Means of Tailored AC Magnetic Fields and the Impact on the Mechanical Properties

This paper presents an experimental study which in a first stage is focused on obtaining quantitative information about the isothermal flow field exposed to various magnetic field configurations. Melt stirring has been realized by utilizing a rotating magnetic field. In a second step directional solidification of AlSi7 alloys from a water-cooled copper chill was carried out to verifythe effect of a certain flow field on the solidification process and on the resulting mechanical properties. The solidified structure was reviewed in comparison to an unaffected solidified ingot. Measurements of the phase distribution, the grain size, the hardness and the tensile strength were realized. Our results demonstrate the potential of magnetic fields to control the grain size, the formation of segregation freckles and the mechanical properties. In particular, time–modulated rotating fields show their capability to homogenize both the grain size distribution and the corresponding mechanical properties.