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Ludwig, Andreas

Publications and source records attributed to Ludwig, Andreas.

5 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

A Comprehensive Analysis of Macrosegregation Formation During Twin-Roll Casting

A two-phase Eulerian–Eulerian volume-averaged model is used to predict the formation of macrosegregation during the twin-roll casting of inoculated Al-4 wt pct Cu alloys. For low solid fractions, the equiaxed crystals are modeled according to the submerged object approach. However, above a given transition limit, they are assumed to behave like a viscoplastic material. This means that the solid phase behaves as a coherent structure that can influence the motion of the liquid. Such approach allows one to take into account the flow dynamics arising from the occurrence of both solidification and hot rolling simultaneously, which usually occurs in twin-roll casting. Therefore, it is possible to explain the origin of the macrosegregation patterns obtained in the simulations based on the relative motion between the phases. Compression-induced expulsion of segregated melt is observed as a result of the deformation of the solidifying shells. Such occurrence leads to a negative macrosegregation region in the outer part of the as-cast strip. Then, because the solute-enriched melt is squeezed out toward adjacent regions, two positively segregated bands can be found near the center of the domain. Furthermore, it is shown how solidification-induced feeding weakens the absolute value of the negative and positive segregation bands.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Scale-Adaptive Simulation of Transient Two-Phase Flow in Continuous-Casting Mold

Scale-adaptive simulation (SAS) of the transient gas–liquid two-phase flow in a laboratory-scale continuous-casting mold is presented. The main objective is to investigate the applicability of the scale-adaptive unsteady Reynolds-averaged Navier–Stokes turbulent model (URANS SAS) for predicting the transient multiscale turbulent structures in a two-phase flow. Good quantitative agreements with the experimental data and the large eddy simulation (LES) results are obtained both for the time-averaged velocity field and for the transient turbulent characteristics. The introduction of the von Karman length-scale into the turbulence-scale equation allows the SAS model to dynamically adjust to the resolved turbulent structures. The LES-like pulsating behavior of the air gas and the large-scale liquid eddy magnitudes in the unsteady regions of flow field are captured by the SAS model. The classical − 5/3 law of power spectrum density (PSD) of the axial velocity is kept properly for the single-phase turbulent flow. For two-phase flow, the decay of PSD is too steep at the high-frequency region; the predicted PSD obtained with SAS is damped stronger than that estimated by LES. The SAS model offers an attractive alternative to the existing LES approach or to the other hybrid RANS/LES models for strongly unsteady flows.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Heat Transfer Coefficient at Cast-Mold Interface During Centrifugal Casting: Calculation of Air Gap

During centrifugal casting, the thermal resistance at the cast-mold interface represents a main blockage mechanism for heat transfer. In addition to the refractory coating, an air gap begins to form due to the shrinkage of the casting and the mold expansion, under the continuous influence of strong centrifugal forces. Here, the heat transfer coefficient at the cast-mold interface h has been determined from calculations of the air gap thickness d{sub a} based on a plane stress model taking into account thermoelastic stresses, centrifugal forces, plastic deformations, and a temperature-dependent Young’s modulus. The numerical approach proposed here is rather novel and tries to offer an alternative to the empirical formulas usually used in numerical simulations for a description of a time-dependent heat transfer coefficient h. Several numerical tests were performed for different coating thicknesses d{sub C}, rotation rates Ω, and temperatures of solidus T{sub sol}. Results demonstrated that the scenario at the interface is unique for each set of parameters, hindering the possibility of employing empirical formulas without a preceding experiment being performed. Initial values of h are simply equivalent to the ratio of the coating thermal conductivity and its thickness (~ 1000 Wm{sup −2} K{sup −1}). Later, when the air gap is formed, h drops exponentially to values at least one order of magnitude smaller (~ 100 Wm{sup −2} K{sup −1}).

36 MATERIALS SCIENCE↗
NASA NTRS2012

Microstructure Formations in the Two-Phase Region of the Binary Peritectic Organic System TRIS-NPG

In order to prepare for an onboard experiment on the International Space Station (ISS), systematic directional solidification experiments with transparent hypoperitectic alloys were carried out at different solidification rates around the critical velocity for morphological stability of both solid phases. The investigations were done in the peritectic region of the binary transparent organic TRIS-NPG system where the formation of layered structures is expected to occur. The transparent appearance of the liquid and solid phase enables real time observations of the dynamic of pattern formation during solidification. The investigations show that frequently occurring nucleation events govern the peritectic solidification morphology which occurs at the limit of morphological stability. As a consequence, banded structures lead to coupled growth even if the lateral growth is much faster compared to the growth in pulling direction.

Mogeritsch, Johann↗