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At least 451 records · Page 25
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Numerical Simulation of Bulging Deformation for Wide-Thick Slab Under Uneven Cooling Conditions

In the present work, the bulging deformation of a wide-thick slab under uneven cooling conditions was studied using finite element method. The non-uniform solidification was first calculated using a 2D heat transfer model. The thermal material properties were derived based on a microsegregation model, and the water flux distribution was measured and applied to calculate the cooling boundary conditions. Based on the solidification results, a 3D bulging model was established. The 2D heat transfer model was verified by the measured shell thickness and the slab surface temperature, and the 3D bulging model was verified by the calculated maximum bulging deflections using formulas. The bulging deformation behavior of the wide-thick slab under uneven cooling condition was then determined, and the effect of uneven solidification, casting speed, and roll misalignment were investigated.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Numerical Simulation of Multiphase Magnetohydrodynamic Flow and Deformation of Electrolyte–Metal Interface in Aluminum Electrolysis Cells

A computational fluid dynamics based multiphase magnetohydrodynamic (MHD) flow model for simulating the melt flow and bath–metal interface deformation in realistic aluminum reduction cells is presented. The model accounts for the complex physics of the MHD problem in aluminum reduction cells by coupling two immiscible fluids, electromagnetic field, Lorentz force, flow turbulence, and complex cell geometry with large length scale. Especially, the deformation of bath–metal interface is tracked directly in the simulation, and the condition of constant anode–cathode distance (ACD) is maintained by moving anode bottom dynamically with the deforming bath–metal interface. The metal pad deformation and melt flow predicted by the current model are compared to the predictions using a simplified model where the bath–metal interface is assumed flat. The effects of the induced electric current due to fluid flow and the magnetic field due to the interior cell current on the metal pad deformation and melt flow are investigated. The presented model extends the conventional simplified box model by including detailed cell geometry such as the ledge profile and all channels (side, central, and cross-channels). The simulations show the model sensitivity to different side ledge profiles and the cross-channel width by comparing the predicted melt flow and metal pad heaving. In addition, the model dependencies upon the reduction cell operation conditions such as ACD, current distribution on cathode surface and open/closed channel top, are discussed.

42 ENGINEERING↗
DOE OSTI2018

A Numerical Simulation of Transport Phenomena During the Horizontal Single Belt Casting Process Using an Inclined Feeding System

Horizontal single belt casting (HSBC) has great potential to replace current conventional continuous casting (CCC) processes for sheet metal production, by directly casting 3 to 1 mm sheet for the automobile industry. In the present paper, two-dimensional mathematical models were developed to study transport phenomena, for the case of an inclined wall feeding system for a liquid aluminum wrought alloy (AA6111). Based on the commercial software ANSYS FLUENT 14.5 and user-defined functions, a two-layer turbulence model was used to examine the fluid flow emanating from a slot nozzle set above a water-cooled, high-speed, steel belt. The Volume of Fluid (VOF) method was used to predict the shape of the melt-air interface. A transformed coordinate system (x′, y′) was established in order to analyze the fluid flow on the inclined wall of the feeding system. The total pressure gauge gradient (∂p{sub total}/∂x) was used to describe the behavior of the melt film inside the slot nozzle of the head box. The modeling results show that during the melt film falling process, the total gauge pressure varies within the slot nozzle, which can decrease the stability of the falling film. The first impingement between the falling film and the inclined refractory wall of the feeding system gives rise to a local oscillation, and this influences the stability of the melt film moving downwards. At the rear meniscus position between the inclined wall and the moving belt, there is a clear vibration of the air-melt interface, together with a recirculation zone. The weak vibration of the air-melt interface could be induced by the periodic variation of the melt-air interface. Moreover, the formation of tiny air pockets is predicted. Finally, on the inclined wall of the feeding system, a suitable length of the transition area is needed to avoid over-acceleration of the melt film due to the force of gravity.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Numerical Simulation of Slag Eye Formation and Slag Entrapment in a Bottom-Blown Argon-Stirred Ladle

A transient mathematical model is developed for simulating the bubble-steel-slag-top gas four-phase flow in a bottom-blown argon-stirred ladle with a 70-ton capacity. The Lagrangian discrete phase model (DPM) is used for describing the moving behavior of bubbles in the steel and slag. To observe the formation process of slag eye, the volume of fluid (VOF) model is used to track the interfaces between three incompressible phases: metal/slag, metal/gas, and slag/gas. The complex multiphase turbulent flow induced by bubble-liquid interactions is solved by a large eddy simulation (LES) model. Slag eye area and slag droplet dispersion are investigated under different gas flow rates. The results show that the movement of bubbles, formation and collapse of slag eye, volatility of steel/slag interface and behavior of slag entrapment can be properly predicted in the current model. When the gas flow rate is 300 L/min, the circulation driven by the bubble plume will stir the entire ladle adequately and form a slag eye of the right size. At the same time, it will not cause strong erosion to the ladle wall, and the fluctuation of the interface is of adequate intensity, which will be helpful for improving the desulfurization efficiency; the slag entrapment behavior can also be decreased. Interestingly, with the motion of liquid steel circulation, the collision and coalescence of dispersed slag droplets occur during the floating process in the vicinity of the wall.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Numerical Simulation of V-shaped Segregation in Continuous Casting Blooms Based on a Microsegregation Model

This study establishes a volume-averaged model for transport phenomena to study V-shaped segregation in continuous casting blooms with different superheating and cooling rates by coupling fluid flow, macro-scale heat transfer, and solute transport. The results demonstrate that the modified Won–Thomas model considering back diffusion in the solid phase corresponds well with the measured carbon segregation. V-shaped segregation decreases with decreasing superheating and increases slightly with decreases in the cooling rate. The results of original position statistical distribution analysis correspond well with the simulation results. This phenomenon can be exploited to improve the quality of bloom.

42 ENGINEERING↗
DOE OSTI2018

Numerical Simulation of Recirculating Flow and Physical Model of Slag–Metal Behavior in an RH Reactor: Application to Desulfurization

Computational fluid dynamics (CFD) techniques and a 1:7.5 physical model of an RH degasser have been used to evaluate the flow of gas and metal inside an RH reactor for vacuum degassing of liquid steel. The effect of gas injection on the gas spatial distribution, steel circulation rate and flow field inside the ladle, snorkels and vacuum chamber have been assessed. N-pentane oil was employed to evaluate the average residence time as well as the slag droplet size distribution. The predicted radial gas distribution and liquid circulation rate have been validated against experimental data from a physical model. The results with incorporation of the virtual mass force coefficient of 0.25 and the turbulence dispersion force showed better predictions of gas distribution in the up-snorkel as well as circulation rate. Full-scale simulations were performed, and the predicted circulation rate was significantly affected by the argon bubble expansion. Data from these simulations were used to analyze the degree of desulfurization performed by the addition of desulfurizing agents inside the vacuum chamber. A model of the kinetics of desulfurization based on the results from the physical model and CFD simulation and on slag dispersion inside liquid steel yields degrees of desulfurization similar to the industrial trials reported in the literature.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Numerical Simulation of Gas and Liquid Two-Phase Flow in the RH Process

A mathematical model has been established to simulate the gas–liquid two-phase flow in the RH process. The effects of interphase forces and the bubble-induced turbulence on the fluid flow and motion of gas bubbles were investigated. The interphase forces include the drag force, the virtual mass force, the lift force, and the pressure gradient force, respectively. The prediction results of the liquid velocity and the recirculation rate were compared with the experimental data measured with a Particle Image Velocimetry technique. The results indicated that the drag force and the virtual mass force dominated the gas plume shape in the up-leg snorkel, and significantly influenced the liquid velocity and the distribution of the gas phase. The lift force mainly affected the spreading of gas bubbles in the radial direction of the snorkel. However, the pressure gradient force could be neglected because it had no effect on the liquid velocity and the gas volume fraction. The increase of the bubble-induced turbulence decreased the liquid velocity, and by adjusting the lift force, it widened the shape of the individual gas plumes. To accurately simulate the gas–liquid flow behavior in the RH degasser, these appropriate parameters, such as the drag coefficient, the virtual mass coefficient, the lift coefficient, and the bubble-induced turbulence coefficient, were determined by comparing the predicted results and the measured data.

42 ENGINEERING↗
DOE OSTI2019

Numerical Simulation of Residual Stress for Laser Welding of Ti-6Al-4V Alloy Considering Solid-State Phase Transformation

In the present work, a thermal-metallurgical-mechanical model which considered the influence of phase transformation was used to predict the residual stress field of Ti-6Al-4V after laser welding. In this model, the Johnson–Mehl–Avrami equation was used to predict diffusional solid-state phase transformations: α phase to β phase during heating and β phase to α phase during cooling. The Koistinen–Marburger equation was used to predict diffusionless solid-state phase transformation of β phase to martensite during cooling. The properties of material were obtained using a mixing rule based on the phase fraction and the property of each pure phase. By applying this model, the effect of solid-state phase transformations of Ti-6Al-4V alloy on temperature field and stress field during laser welding was considered in the simulation. In addition, experiments were carried out for comparison, which significantly verified the accuracy of the applied model.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Remedial Amendment Delivery near the Water Table Using Shear Thinning Fluids: Experiments and Numerical Simulations

The use of shear thinning fluids (STFs) containing xanthan is a potential enhancement for emplacing a solute amendment near the water table and within the capillary fringe. Most research to date related to STF behavior has involved saturated and confined conditions. A series of flow cell experiments were conducted to investigate STF emplacement in variable saturated homogeneous and layered heterogeneous systems. Besides flow visualization using dyes, amendment concentrations and pressure data were obtained at several locations. The experiments showed that injection of STFs considerably improved the subsurface distribution near the water table by mitigating preferential flow through higher permeability zones compared to no-polymer injections. The phosphate amendment migrated with the xanthan SFT without retardation. Despite the high viscosity of the STF, no excessive mounding or preferential flow were observed in the unsaturated zone. The STOMP simulator was able to predict the experimentally observed fluid displacement and amendment concentrations reasonably well. Cross flow between layers could be interpreted as the main mechanism to transport STFs into lower permeability layers based on the observed pressure gradient and concentration data in layers of differing hydraulic conductivity.

Environmental Molecular Sciences Laboratory↗
DOE OSTI2015

Numerical simulation of phase transition problems with explicit interface tracking

Phase change is ubiquitous in nature and industrial processes. Started from the Stefan problem, it is a topic with a long history in applied mathematics and sciences and continues to generate outstanding mathematical problems. For instance, the explicit tracking of the Gibbs dividing surface between phases is still a grand challenge. Our work has been motivated by such challenge and here we report on progress made in solving the governing equations of continuum transport in the presence of a moving interface by the front tracking method. The most pressing issue is the accounting of topological changes suffered by the interface between phases wherein break up and/or merge takes place. The underlying physics of topological changes require the incorporation of space-time subscales not at reach at the moment. Therefore we use heuristic geometrical arguments to reconnect phases in space. This heuristic approach provides new insight in various applications and it is extensible to include subscale physics and chemistry in the future. We demonstrate the method on applications such as simulating freezing, melting, dissolution, and precipitation. The later examples also include the coupling of the phase transition solution with the Navier-Stokes equations for the effect of flow convection.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2016

Determination of mineral dissolution regimes using flow-through time-resolved analysis (FT-TRA) and numerical simulation

Flow-through time resolved analysis (FT-TRA) involves subjecting small mineral samples (< 10 mg) inserted in a miniature flow-through cell (50 μL) to controlled flows of eluent analyzed on-line by ICP-MS. In this study, FT-TRA is used to empirically determine the dissolution regimes for the two well-studied minerals forsterite and calcite, representing minerals with relatively slow and fast dissolution kinetics. A proportional increase in steady-state effluent [Mg, Si] concentrations with increasing flow-through cell eluent residence times confirms a dominantly surface-controlled dissolution regime for a powdered forsterite sample at pH 2.3, implying that transport limitations are negligible. In contrast, the relationship between flow rates and dissolution rates for single grain calcite samples at pH 2.3-4 reveals that transport limitations affect the rate of calcite dissolution. In order to provide a quantitative and process-based assessment of the effect of diffusive transport limitations, simulations of the calcite experiments were performed with a high resolution, pore-scale model that considers the geometry of the calcite grain and the FT-TRA flow-through reactor. The pore-scale model reproduces the observed effluent [Ca] concentrations for all experimental conditions using a single set of surface kinetic parameters, by accounting for the formation of a diffusive boundary layer (DBL) that varies in thickness as a function of flow rates. These results demonstrate that combining FT-TRA with pore-scale modeling makes it possible to obtain unprecedented insights not achievable by either method separately, including quantification of DBL thicknesses and the determination of transport controls as a function of pH, flow velocity and residence times.

58 GEOSCIENCES↗