CFD Modeling and Simulation in Materials Processing 2016

This collection explores computational fluid dynamics (CFD) modeling and simulation of engineering processes, with contributions from researchers and engineers involved in the modeling of multiscale and multiphase phenomena in material processing systems.

The papers cover the following processes: Iron and Steelmaking (Tundish, Casting, Converter, Blast Furnace); Microstructure Evolution; Casting with External Field Interaction; and Smelting, Degassing, Ladle Processing, Mechanical Mixing, and Ingot Casting.

The collection also covers applications of CFD to engineering processes, and demonstrates how CFD can help scientists and engineers to better understand the fundamentals of engineering processes.

Preface ix

Editors xi

Iron and Steelmaking (Tundish, Casting, Converter, Blast Furnace)

On the Importance of Modeling 3D Shrinkage Cavities for the Prediction of Macrosegregation in Steel Ingots 3
A. Ludwig, M. Wu, and A. Kharicha

Computational Fluid Dynamics Simulations of a Laboratory Flash Reactor Relevant to a Novel Ironmaking Process 11
Deqiu Fan, Yousef Mohassab, and H.Y. Sohn

Fluid Flow and Inclusion Motion in a Five-Strand Continuous Casting Tundish 19
Abulikemu Yasen and Dongteng Pan

Liquid Steel Flow and Interactions with Nonmetallic Phases in the Continuous Casting Tundish Using CFD & Physical Modeling 27
Christopher Eastman Jr., Peter Glaws, and Dongbu Cao

Simulation of Fluid Flow and Heat Transfer in Plasma Arc Region of AC Electric Arc Furnace 35
Qipeng Dong and Jiongming Zhang

Simulation of Heat Transfer in Slab Continuous Casting Mold and New Formation Mechanism of Shell Hot Spots 43
Zhaozhen Cai and Miaoyong Zhu

Computational Investigation of Splashing Behaviors in Steelmaking Converter 51
Qiang Li, Mingming Li, Mingxia Feng, and Zongshu Zou

Simulation of Air Entrainment in High Pressure Die Casting Applications 59
Juergen Jakumeit, Herfried Behnken, Frank Schmidt, Julian Gänz, Bastian Thorwald, and Michael Mathes

Numerical Simulation of the Multiphase Flow in the Single-Tundish System 67

Shupei Liu, Bo Wang, Zhiliang Yang, Shuai Feng, Kongfang Feng, Jinyin Xie, and Jieyu Zhang
CFD Analysis of Blast Furnace Operating Condition Impacts on Operational Efficiency 75
Tyamo Okosun, Armin K. Silaen, Guangwu Tang, Bin Wu, and Chenn Q. Zhou

Microstructure Evolution

Validation of a Model for the Columnar to Equiaxed Transition with Melt Convection 85
Mahdi Torabi Rad and Christoph Beckermann

Modeling the Multicomponent Columar-to-Equiaxed Transition of Alloy 625 93
Kyle Fezi and Matthew J.M. Krane

Performance Optimization and Evaluation of a 3D CA-FVM Model for Dendritic Growth of Fe-C Alloy 101
Weiling Wang, Sen Luo, and Miaoyong Zhu

Multiscale Modeling of the Solidification Structure Evolution of Continuously Cast Steel Blooms and Slabs 109
Laurentiu Nastac, Mikko Kärkkäinen, Pilvi Hietanen, and Seppo Louhenkilpi

Numerical Simulation of Dendritic Growth of Fe-C Binary Alloy with Natural Convection 117
Sen Luo, Weiling Wang, and Miaoyong Zhu

Localized Strengthening of Al-Based Casting Alloys by Automatized Optimization of Laser Heat Treatment 125
A. Ludwig and T. Holzmann

Casting with External Field Interaction

A High-Order Acoustic Cavitation Model for the Treatment of a Moving Liquid Metal Volume 135
G S Bruno Lebon, Iakovos Tzanakis, Koulis Pericleous, and Dmitry Eskin

Progress on Numerical Modeling of the Dispersion of Ceramic Nanoparticles during Ultrasonic Processing and Solidification of Al-Based Nanocomposites 143
Daojie Zhang and Laurentiu Nastac

Effects of Velocity-Based Packing Criteria on Models of Alloy Solidification with Free Floating Solid 151
A. Plotkowski and Matthew J.M. Krane

Large Eddy Simulations on the Effects on Double-Ruler Electromagnetic Braking and Nozzle Submergence Depth on Molten Steel Flow in a Commercial Continuous Casting Mold 159
Kai Jin, Surya P. Vanka, Brian G. Thomas, and Xiaoming Ruan

Smelting, Degassing, Ladle Processing, Mechanical Mixing, and Ingot Casting

CFD Modeling of a Ladle with Top Stirring Lance 169
Haibo Ma, Xia Chen, Hoyong Hwang, Megan Pratt, Russel J. Mulligan, Bin Wu, Guangwu Tang, and Chenn Q. Zhou

Numerical Simulation on Multiphase Flow in the Two Side-Blown Oxygen-Enriched Copper Smelting Furnace 179
Liu Guanting, Liu Yan, Li Xiaolong, and Zhang Ting-an

3D CFD Modeling of the LMF System 187
Laurentiu Nastac, Daojie Zhang, Qing Cao, April Pitts, and Robert Williams

Application of CFD to Multi-Phase Mixing in the Metals and Mining Industries 195
Duane Baker and Adam Blackmore

Numerical Study and Experimental Validation of Multiple Pouring Process in a 438-t Steel Ingot 203
Zhenhu Duan, Houfa Shen, Jinwu Kang, and Baicheng Liu

3D CFD Multicomponent Model for Cold Spray Additive Manufacturing of Titanium Particles 213
Muhammad Faizan-Ur-Rab, Saden H. Zahiri, S.H. Masood, M. Jahedi, and R. Nagarajah

Numerical Simulation of Effect of Different Electrodes on Magnetic Force and Flow Field of Pure Aluminum Melt 221
Qixin Wang, Xiang Wang, Zhishuai Xu, Ning Pei, Yongyong Gong, and Qijie Zhai

Poster Session

Gas-Solid Flow and Injected Gas Distribution in OBF Analyzed by DEM-CFD 229
Zeshang Dong, Jingsong Wang, Jinzhou Liu, Xuefeng She, Qingguo Xue, and Lin Lin

Improving Current Efficiency Through Optimizing Electrolyte Flow in Zinc Electrowinning Cell 239
Hongdan Wang, Wentang Xia, Wenqiang Yang, and Bingzhi Ren

Influence of Heavy Reduction (HR) on the Internal Quality of the Bearing Steel GCr15 Bloom 247
Cheng Ji, Chen-hui Wu, and Miao-yong Zhu

Numerical Study of Flow Behavior and Optimization of Nozzle Ports in Continuous Casting Slab Mold 255
Shuai Feng, LingXiang Hong, Bo Wang, Shupei Liu, Zhiliang Yang, Kongfang Feng, Liang Bai, and Jieyu Zhang

The Effect of Pulse Width on the Characteristic of Discharge and Flow for Pure Aluminum 263
Xiang Wang, Zhishuai Xu, Qixin Wang, Qijie Zhai, Ning Pei, and Yongyong Gong

Author Index 271

Subject Index 275

Lifeng Zhang, University of Science & Technology, Beijing, China.

Brian G. Thomas, University of Illinois at Urbana-Champaign, IL, USA.

Miaoyong Zhu, Northeastern University, China.

Andreas Ludwig, Montanuniversität Leoben, Austria.

Adrian S. Sabau, Oak Ridge National Laboratory, USA.

Koulis Pericleous, University of Greenwich, London, UK.

Hervé Combeau, Ecole des Mines de Nancy, France.