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2 Archives of Foundry Engineering

2 2010

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Structure fields in the solidifying cast iron roll

Wołczyński W. S., Guzik E., Kania B., Wajda W.

Archives of Foundry Engineering

2010

Vol. 10, iss. 1 spec.

41--46

Some properties of the rolls depend on the ratio of columnar structure area to equiaxed structure area created during roll solidification. The C → E transition is fundamental phenomenon that can be apply to characterize massive cast iron rolls produced by the casting house. As the first step of simulation, a temperature field for solidifying cast iron roll was created. The convection in the liquid is not comprised since in the first approximation, the convection does not influence the studied occurrence of the C → E (columnar to equiaxed grains) transition in the roll. The obtained temperature field allows to study the dynamics of its behavior observed in the middle of the mould thickness. This midpoint of the mould thickness was treated as an operating point for the C → E transition. A full accumulation of the heat in the mould was postulated for the C → E transition. Thus, a plateau at the T(t) curve was observed at the midpoint. [...] A simulation was performed for the cast iron rolls solidifying as if in industrial condition. Since the incubation divides the roll into two zones: C and E; (the first with columnar structure and the second with fully equiaxed structure) some experiments dealing with solidification were made on semi-industrial scale.

Constrained/unconstrained solidification within the massive cast steel/iron ingots

Wołczyński W. S.

Archives of Foundry Engineering

2010

Vol. 10, iss. 2

195--202

Some properties of the ingot and especially of the steel forging ingots depend on the ratio of a columnar structure area to an equiaxed structure area created during solidification. The CE transition is fundamental phenomenon that can be applied to characterize massive cast steel ingots produced by the casting house. The mentioned ratio is created spontaneously due to the rate of heat transfer towards the ceramic mould and then to the environment. The ceramic mould operates as an isolator. So that the thickness of the mould together with a growing solid fraction control the heat transfer and finally the ratio of the columnar structure area to the equiaxed structure area. At first the increase of heat accumulation within the ceramic mould is observed. Next the stationary state for heat transfer is created and finally a gentle abatement of the mould temperature associated with the heat output to the environment is expected. The steep thermal gradients correspond to the increase of heat accumulation in the ceramic mould. The steep thermal gradients are required to promote the columnar structure formation. The full heat accumulation in the mould corresponds well with the CE transformation while the appearance of the moderate thermal gradients is referred to the gentle temperature abatement within the ceramic mould. The equiaxed structure is expected within this period of heat transfer behavior. The steep thermal gradients involve the activity of viscosity gradient in the liquid. As the result a sedimentary cones are formed at the bottom of the ingot. The CE transformation is associated with competition between columnar and equaixed structure formation. At the end of competition a fully equiaxed structure is formed. The viscosity gradient is replaced by the thermophoresis which is the driving force for the deposition of some equiaxed grain layers onto the surface of C+E zone. The convection together with the gravity allow the layers to be uniform along the whole height of the ingot. Some equiaxed grain layers are also deposited at the bottom of ingot onto the surface of sedimentary cones due to activity of the gravity. Additionally, some macro-segregation effects are observed in the ingot [...]