JWBT1823-NastacCFD_Modeling.indd i 3 December 2015 1:44 PM FEBRUARY 14-18 DOWNTOWN NASHVILLE, TENNESSEE MUSIC CITY CENTER New proceedings volumes from the TMS2016 Annual Meeting: • 7th International Symposium on High-Temperature Metallurgical Processing • CFD Modeling and Simulation in Materials Processing 2016 • Characterization of Minerals, Metals, and Materials 2016 • Energy Technology 2016: Carbon Dioxide Management and Other Technologies • EPD Congress 2016 • Light Metals 2016 • Magnesium Technology 2016 • Rare Metal Technology 2016 • REWAS 2016 • Shape Casting: 6th International Symposium • TMS 2016 Supplemental Proceedings To purchase any of these publications, please visit www.wiley.com. TMS members should visit www.tms.org to learn how to get discounts on these or other books through Wiley. JWBT1823-NastacCFD_Modeling.indd ii 3 December 2015 1:44 PM Proceedings of a symposium sponsored by the Process Technology and Modeling Committee of the Extraction and Processing Division and the Solidification Committee of the Materials Processing and Manufacturing Division of The Minerals, Metals & Materials Society (TMS) held during FEBRUARY 14-18 DOWNTOWN NASHVILLE, TENNESSEE MUSIC CITY CENTER Edited by: Laurentiu Nastac, Lifeng Zhang, Brian G. Thomas, Miaoyong Zhu, Andreas Ludwig, Adrian S. Sabau, Koulis Pericleous, and Hervé Combeau JWBT1823-NastacCFD_Modeling.indd iii 3 December 2015 1:44 PM Copyright © 2016 by The Minerals, Metals & Materials Society. All rights reserved. Published by John Wiley & Sons, Inc., Hoboken, New Jersey. Published simultaneously in Canada. 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ISBN 978-1-119-22576-8 Printed in the United States of America. 10 9 8 7 6 5 4 3 2 1 JWBT1823-NastacCFD_Modeling.indd iv 3 December 2015 1:44 PM TaBle oF ConTenTS CFD Modeling and Simulation in Materials Processing 2016 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 v JWBT1823-NastacCFD_Modeling.indd v 3 December 2015 1:44 PM 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 vi JWBT1823-NastacCFD_Modeling.indd vi 3 December 2015 1:44 PM 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 vii JWBT1823-NastacCFD_Modeling.indd vii 3 December 2015 1:44 PM 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 viii JWBT1823-NastacCFD_Modeling.indd viii 3 December 2015 1:44 PM PREFACE This book contains the proceedings of the symposium, “CFD Modeling and Simulation in Materials Processing,” held at the TMS 2016 Annual Meeting & Exhibition in Nashville, Tennessee, February 14–18, 2016. This symposium dealt with computational uid dynamics (CFD) modeling and simulation of engineering processes. The papers published in this book were requested from researchers and engineers involved in the modeling of multiscale and multiphase phenomena in material processing systems. The symposium focused on the CFD modeling and simulation of the following processing areas: Iron and Steelmaking (Tundish, Casting, Converter, Blast Furnace), Smelting, Degassing, Ladle Processing, Mechanical Mixing, and Ingot Casting, Casting with External Field Interaction and Microstructure Evolution. The symposium also covered applications of CFD to engineering processes and demonstrated how CFD can help scientists and engineers to better understand the fundamentals of engineering processes. On behalf of all symposium organizers and participants, Prof. Laurentiu Nastac The University of Alabama Dept. of Metallurgical & Materials Engineering ix JWBT1823-NastacCFD_Modeling.indd ix 3 December 2015 1:44 PM EDITORS Laurentiu Nastac is currently an Associate Professor of Metallurgical and Materials Engineering at The University of Alabama, Metallurgical and Materials Engineering Department, Tuscaloosa, Alabama, a Key FEF Professor and the Director of the Solidi cation Laboratory and the UA-COE foundry. For his teaching and research interests please visit his website: http://lnastac.people.ua.edu/. Dr. Nastac received the Diploma Engineering degree in Metallurgy and Materials Science from the University “Politehnica” of Bucharest, Romania in 1985 and the M.S. and Ph.D. degrees in Metallurgical and Materials Engineering from The University of Alabama, Tuscaloosa in 1993 and 1995, respectively. He has held various engineering, research, and academic positions in Romania and the United States. At Caterpillar he conducted research in the area of macro transport and solidi cation-kinetics modeling and developed specialized casting simulation software. At Concurrent Technologies Corporation (CTC) he conducted research primarily in the area of advanced metalcasting and solidi cation processes with emphasis on the modeling and simulation of casting phenomena. In 1999, in recognition of his work on solidi cation of titanium-based alloys and superalloy remelt ingots, he received the prestigious Bunshah Best Paper Award from the American Vacuum Society, Vacuum Metallurgy Division. More recently, he received the NMC (Navy Metalworking Center) achievement award and 2 CTC awards. Dr. Nastac developed eight software tools; made more than 160 presentations; co-authored three patents, over 150 conference and journal articles and more than 70 scienti c reports in the materials science and manufacturing elds; and co-authored 10 books—one is a monograph titled Modeling and Simulation of Microstructure Evolution in Solidifying Alloys published by Springer in 2004. He is a key reader for Metallurgical and Materials Transactions, a member of the Editorial Board of the International Journal of Cast Metals Research, and a member of the TMS Solidi cation Committee; he has served on scienti c committees and as an organizer for international conferences dedicated to CFD modeling and simulation in materials processing area and for casting and solidi cation processes. xi JWBT1823-NastacCFD_Modeling.indd xi 3 December 2015 1:44 PM