Controlling the thermo-metallurgical properties of the alloy during the ingot casting

The Solid software performs an indeep analysis of the solidification process. In this application case, the Solid software focuses on the ingot casting.

Controlling the thermo-metallurgical characteristics of steel ingot is a challenge as they determine the properties of the final workpiece.

One of the features of the Solid software is computing the sedimentation of equiaxed grains, to predict the thermo-metallurgical properties of the final ingot. Such simulations thus help in optimizing the final product .

Impact of process conditions on the alloys

This case is a 2D simulation of the solidification of a cylindrical 6.2 tonnes steel ingot. The cast steel is a ternary Fe-C-Si alloy, with 1.01wt.% carbon content.

This application is used to showcase the solidification models used in the SOLID software: the nucleation and growth of grains, the formation of the solidification structures, and their influence on segregation of the alloying element (carbon). In addition, the model takes into account the impact of filling and process conditions such as the hot top.

Changing parameters such as the filling rate or removing the exothermic properties of the hot top refractory affect the solidification and therefore the final macrosegregation. In this way, the Solid software shows the impact of process parameters on segregation and allows the user to easily test and compare different configurations.

Among the tested configurations:

• Removing the exothermic properties of the hot top leads to more intensity of positive segregation
• Reducing the filling rate by half has different effects, like increasing the grain density and reducing the size of negative segregation zone
• Comparisons of the different configurations a detailed in the following pages

Some results

As Solid is a 2D software using axi-symetry model, results are presented according to the simulation domain, used for the reference case.

The following results are then presented that way: Left part of the ingot: are presented the results about the solidification structure right part of the ingot: are presented the results about the segregation

Filling time influence

The Filling Time has a strong impact on the solidification process (on both solidification structures and segregation). Increasing the filling time, makes the columnar thicker. When doing the inverese (reducing the filling time), columnar thickness is reduced. This is typically the kind of relationship between process, time, temperature and micro-effects that the Solid software can describe.

Mould Temperature

The temperature of the mould during casting can influence the cooling of the ingot. This is assessed by comparing the reference simulation with one where the cast iron mould is preheated at 250°C (instead of 25°C for the reference). The results (opposite figure) show that with the preheated mould, the columnar thickness is slightly smaller, as the cooling rate for the columnar was lower. The overall segregation is similar, even if the positive segregation seems more intense at the top of the ingot.

More results

This application has been designed for showcasing the Solid software capabilities and main results. For some more details, you can contact us for downloading the full paper here

Solid: for a digital analysis of ingots casting process

Solid is today a real solution for developping and optimizing your projects. It offers a cost-effective solution for replacing the expansive trials. Solid is available as on premise license (different suited packages are proposed) and consulting services.

Visit our websites for more details about it at

https://www.scconsultants.com

Main targets of numerical simulation

Numerical simulation aims to get closer from the industrial process in order to bring much more accuracy in the results and in comfort in use.

Ludovic v7.0 : always closer to the twin screw extrusion process

Moving closer from the industrial process is a real motivation for our team, as our main target remains to answer the user's needs. As the twin screw process become more and more versatile, more and more technic and more and more focused on the performance : simulation has to do so.

The new developments of Ludovic V7.0

Lots of developments have been integrated into this newest version of THE software dedicated to corotating twin screw extruders. The Ludovic V7.0 roadmap is mainly driven by all of our users who share their needs or ideas for still improving the model. Thus, the different upgrades are tackling different issues : the user-friendly environment, the extruder design capability and the materials issues.

A refreshed interface

The Ludovic environment is a strength of the software. As it allows users to quickly design machines and screw profiles, the interface had to become more intuivite. For reaching this target, different improvements have been designed :

• Totally refreshed interface
• New Dashboard for more readability on the simulation key facts
• Simulation batch mode revisited : for designing a batch of simulations to be afterward computed

Going further into the process complexity

The user-friendly interface is not the only concern for a modeling software. It has to be complete enough for adressing all the possible issues and configurations handled by the industrials. That is the reason why the model of the software and the features have been pushed again further.

Among the most noticable new integrations :

• Integration of the new Turbine Mixing Elements (TME)
• Integration of Blister/Ring elements
• New Standard Database of simulations : integrating realistic configurations (compounds, masterbatches, agro...)
• Adding the Velocity results at the screw head

All the new integrated developments are listed on our eSupport site

Soon released

The last tests of this brand new version are now currently performed. Thus, the Ludovic V7.0 should be ready for May, 2020.

All the users being under active maintenance will received the link for downloading the Ludovic V7.0 version.

For any more details, feel free to contact us

Ludovic at the Leistritz Academy

During the Leistriz Pharma extrusion Academy, SC-Consultants presents the Ludovic software, with a special pharma version. The Leistritz Academy takes place in Nurnberg on March 30-31, 2017

Hot Melt Extrusion applications

SC-Consultants introduces new results in Ludovic for meeting the pharma industry specific requirements. With the Pharma Edition, the Ludovic software holds now dedicated results.

Join the Pharma Academy

See the program

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