Skip to main content
Log in

Spray casting of steel strip: Process analysis

  • Published:
Metallurgical Transactions A Aims and scope Submit manuscript

Abstract

Near-net shape manufacturing (NNSM) of thin steel sections by spray casting eliminates casting as a separate step with attendant improved microstructures and properties and significant energy savings. The process involves atomization of a stream of liquid metal and deposition of droplets in the generated spray on a moving substrate at mass flow rates of 0.25 to 2.5 kg/s. In this paper, NNSM of steel strip by the Osprey spray casting process is investigated by combining numerical simulation and experiments. Critical input parameters for the computation are quantified utilizing existing state-of-the-art mathematical models and specific experiments. Numerical computation of the consolidation of the spray at the substrate during manufacture of thin sections is conducted using bothcontinuum anddiscrete event (“splat solidification”) approaches to predict: (1) variation of strip thickness in the transverse dimension and (2) isotherms and cooling rates across the strip thickness. Predicted geometries of the strip simulated by the continuum model are in good agreement with measurements. Predicted isotherms in narrow strip by the continuum approach are in reasonable agreement with thermocouple measurements for intermediate thicknesses (2 to 5 mm), and the observed microstructure is consistent with predicted cooling rates. The discrete event model predicts significantly higher cooling rates than the continuum model in the basal portion of the strip. This is consistent with the observed grain size in thin strip (<l-mm thick) and in the basal portion of thick strip. Beyond a threshold thickness, however, the discrete event model confirms the formation and persistence of a partially liquid layer at the growing surface of the deposit with an attendant decrease in the cooling rate. The influence of critical parameters on “splat solidification” is analyzed and assessed.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. W.A. Tony:Iron and Steelmaker, 1987, vol. 14 (12), pp. 11–13.

    Google Scholar 

  2. P.C. Mathur: M.S. Thesis, Drexel University, Philadelphia, PA, 1986.

    Google Scholar 

  3. P.C. Mathur, D. Apelian, and A. Lawley:Acta Metall., 1989, vol. 37 (1), pp. 429–43.

    CAS  Google Scholar 

  4. P.C. Mathur: Ph.D. Thesis, Drexel University, Philadelphia, PA, 1988.

    Google Scholar 

  5. A.R.E. Singer and R.W. Evans:Met. Technol., 1983, vol. 10, pp. 61–68.

    CAS  Google Scholar 

  6. E. Gutierrez-Miravete, E.J. Lavernia, G.M. Trapaga, J. Szekely, and N.J. Grant:Metall. Trans. A, 1989, vol. 20A (1), pp. 71–85.

    CAS  Google Scholar 

  7. H. Jones:Rapid Solidification of Metals and Alloys, The Institution of Metallurgists, London, 1982, p. 43.

    Google Scholar 

  8. E. Gutierrez-Miravete, G.M. Trapaga, and J. Szekely:Casting of Near Net Shape Products, Y. Sahai, J.E. Battles, R.S. Carbonara, and C.E. Mobley, eds., TMS, Warrendale, PA, 1988, pp. 133–51.

    Google Scholar 

  9. A.G. Gillen, P.C. Mathur, D. Apelian, and A. Lawley:Prog. Powder Metall., E.A. Carlson and G. Gaines, eds., Metal Powder Industries Federation, Princeton, NJ, 1986, vol. 42, pp. 753–73.

    Google Scholar 

  10. P.C. Mathur and D. Apelian: in Book Series on Powder Metallurgy, I. Jenkins and J.V. Wood, eds., Institute of Metals, London, vol. 3, in press.

  11. P.C. Mathur, S. Annavarapu, D. Apelian, and A. Lawley:J. Miner. Met. Mater. Soc., 1989, vol. 41 (10), pp. 23–28.

    CAS  Google Scholar 

  12. B.P. Bewlay and B. Cantor: inRapidly Solidified Materials, P.W. Lee and R.S. Carbonara, eds., ASM, Metals Park, OH, 1986, p. 97. 13. P.S. Grant, S. Rogers, B. Cantor, and L. Katgerman: Presented at the TMS Annual Meeting, Anaheim, CA, Feb. 18–22, 1990.

    Google Scholar 

  13. M.C. Flemings:Solidification Processing, McGraw-Hill, New York, NY, 1974.

    Google Scholar 

  14. J. Madjeski:Int. J. Heat Mass Transfer, 1976, vol. 19, pp. 1009–13.

    Article  Google Scholar 

  15. E.R. Garrity: Ph.D. Thesis, Drexel University, Philadelphia, PA, 1989.

    Google Scholar 

  16. R.M. German:Powder Metallurgy Science, Metal Powder Industries Federation, Princeton, NJ, 1984, pp. 32–33.

    Google Scholar 

  17. P. Mathur, Y.C. Wei, and D. Apelian: inModeling of Control of Welding and Casting Processes IV, A.F. Giamei and G.J. Abbaschian, eds., TMS, Warrendale, PA, 1988, p. 275.

    Google Scholar 

  18. H.S. Carslaw and J.C. Jaeger:Conduction of Heat in Solids, Oxford University Press, Oxford, United Kingdom, 1973, pp. 75–76.

    Google Scholar 

  19. H. Martin: inAdvances in Heat Transfer, J.P. Harnett and T.F. Irvine, eds., Academic Press, New York, NY, 1977, vol. 13.

    Google Scholar 

  20. A. Lawley and D. Apelian: Drexel University Tech. Rep. No. 2, NSF Grant No. MSM-8519047, 1988.

  21. S. Annavarapu: M.S. Thesis, Drexel University, Philadelphia, PA, 1987.

    Google Scholar 

  22. S. Annavarapu, A. Lawley, and D. Apelian:Metall. Trans. A, 1988, vol. 19A (12), pp. 3077–86.

    CAS  Google Scholar 

  23. A. Suzuki, T. Suzuki, Y. Nagaoka, and Y. Iwata:J. Jpn. Inst. Met., 1968, vol. 32, p. 1301.

    CAS  Google Scholar 

  24. N.J. Grant: inCasting of Near Net Shape Products, Y. Sahai, J. Battles, R.S. Carbonara, and C.E. Mobley, eds., TMS, Warrendale, PA, 1988, p. 203.

    Google Scholar 

  25. A.R.E. Singer:J. Inst. Met., 1972, vol. 100, pp. 185–90.

    CAS  Google Scholar 

  26. A.G. Leatham, W. Reichelt, and O.H. Metelmann: inNear Net Shape Manufacturing Process, P.W. Lee and B.L. Ferguson, eds., ASM INTERNATIONAL, Metals Park, OH, 1988, p. 259.

    Google Scholar 

  27. K. Wunnenberg, R. Flender, W. Fix, and R. Schneider:Proc. Int. Cont. Casting Conf, Brussels, Belgium, May 17, 1988, pp. 728–41.

  28. G. Hartmann, P.N. Hansen, and P.R. Sahm: inModeling and Control of Casting and Welding Processes IV, A.F. Giamei and G.J. Abbaschian, eds., TMS, Warrendale, PA, 1988, pp. 915–21.

    Google Scholar 

  29. Thermophysical Properties of Matter, TPRC Data Series, Purdue University, Plenum Press, New York, NY, 1977.

  30. R.D. Pehlke, A. Jeyarajan, and H. Wada:Summary of Thermal Properties for Casting Alloys and Mold Materials, National Science Foundation, Washington, DC, NSF/MEA-82028, 1982.

    Google Scholar 

Download references

Author information

Authors and Affiliations

Authors

Additional information

DIRAN APELIAN, formerly Howmet Professor of Materials Engineering at Drexel University

Rights and permissions

Reprints and permissions

About this article

Cite this article

Annavarapu, S., Apelian, D. & Lawley, A. Spray casting of steel strip: Process analysis. Metall Trans A 21, 3237–3256 (1990). https://doi.org/10.1007/BF02647318

Download citation

  • Received:

  • Issue Date:

  • DOI: https://doi.org/10.1007/BF02647318

Keywords

Navigation