Yikun Luan

Inclusion flotation-driven channel segregation in solidifying steels.

Channel segregation, which is featured by the strip-like shape with compositional variation in cast materials due to density contrast-induced flow during solidification, frequently causes the severe destruction of homogeneity and some fatal damage. An investigation of its mechanism sheds light on the understanding and control of the channel segregation formation in solidifying metals, such as steels. Until now, it still remains controversial what composes the density contrasts and, to what extent, how it affects channel segregation. Here we discover a new force of inclusion flotation that drives the occurrence of channel segregation. It originates from oxide-based inclusions (Al2O3/MnS) and their sufficient volume fraction-driven flotation becomes stronger than the traditionally recognized inter-dendritic thermosolutal buoyancy, inducing the destabilization of the mushy zone and dominating the formation of channels. This study uncovers the mystery of oxygen in steels, extends the classical macro-segregation theory and highlights a significant technological breakthrough to control macrosegregation.

Modelling of horizontal centrifugal casting of work roll

A numerical model to simulate horizontal centrifugal roll castings is presented in this paper. In order to simulate the flow fluid and solidification of horizontal centrifugal roll casting correctly, the model uses a body fitted mesh technique to represent the geometry. This new method maps a plate layer mesh to a circular mesh. The smooth body fitted mesh method gives more accurate calculation results for cylindrical geometries. A velocity depending on the angular velocity and inner radius of the mould is set up as a velocity boundary condition. The fluid flow coupled with heat transfer and solidification in a rapidly rotating roll is simulated. A gravity free falling method is applied as a pouring condition. A moveable pouring system is also used in the simulations. High speed steel is used to produce the work roll. Two different gating positions and a moveable gating system are simulated in this paper. Results show that the position of pouring system has a significant influence on the temperature distribution. The temperature distribution at a fixed central pouring system is more favourable than the distribution from a side pouring system. A moving gating system method is a better way to obtain a uniform temperature field in centrifugal casting and offers an alternative for existing techniques.

Chemical Compositions, Microstructure and Mechanical Properties of Roll Core used Ductile Iron in Centrifugal Casting Composite Rolls

The industrial manufacture processes of three kinds of roll core used ductile irons have been investigated via systematical experiments. Effects of the ratio of C/Si, pig iron, nodularizer and alloying method on the microstructure and mechanical properties of the heavy section ductile iron have been analyzed. It has been found that when treated with RE-Mg plus Sb, high quality nodular castings can be produced even if much anti spheroidizing alloy elements are included in the pig iron. The alloy element Sb played an important role in the control of graphite morphology.