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Predictive Capabilities of Multiphysics and Multiscale Models in Modeling Solidification of Steel Ingots and DC Casting of Aluminum

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Abstract

Prediction of solidification defects, such as macrosegregation and inhomogeneous microstructures, constitutes a key issue for industry. The development of models of casting processes needs to account for several imbricated length scales and different physical phenomena. For example, the kinetics of the growth of microstructures needs to be coupled with the multiphase flow at the process scale. We introduce such a state-of-the-art model and outline its principles. We present the most recent applications of the model to casting of a heavy steel ingot and to direct chill casting of a large Al alloy sheet ingot. Their ability to help in the understanding of complex phenomena, such as the competition between nucleation and growth of grains in the presence of convection of the liquid and of grain motion is shown, and its predictive capabilities are discussed. Key issues for future developments and research are addressed.

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Acknowledgements

The authors are grateful to the French State for support through the program “Investment in the future” operated by the National Research Agency (ANR) and referenced by ANR-11 LABX-0008-01 (LabEx DAMAS).

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Authors and Affiliations

  1. Institut Jean Lamour, CNRS—Université de Lorraine, 54011, Nancy Cedex, France

    Hervé Combeau & Miha Založnik

  2. MSMP, École Nationale Supérieure d’Arts et Métiers, Campus d’Aix-en-Provence, 13617, Aix-en-Provence, France

    Marie Bedel

Authors
  1. Hervé Combeau
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  2. Miha Založnik
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  3. Marie Bedel
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Correspondence to Hervé Combeau.

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Combeau, H., Založnik, M. & Bedel, M. Predictive Capabilities of Multiphysics and Multiscale Models in Modeling Solidification of Steel Ingots and DC Casting of Aluminum. JOM 68, 2198–2206 (2016). https://doi.org/10.1007/s11837-016-1993-z

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  • DOI: https://doi.org/10.1007/s11837-016-1993-z

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