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Multiphase Flow Simulation and Experimental Validation of Cooling Slope Rheoprocessing of A380 Alloy

Das, P (2023) Multiphase Flow Simulation and Experimental Validation of Cooling Slope Rheoprocessing of A380 Alloy. In: International Journal of Metalcasting .

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Official URL: https://doi.org/10.1007/s40962-023-01036-3


In this study, cooling slope slurry production technique of A380 alloy is studied with the help of a computational fluid dynamic-based numerical model, developed adopting the Eulerian two-phase flow approach. The transport processes involved during the melt flow along the slope are studied via solving the continuity equation as well as the conservation equations of momentum and energy. The phases considered in the present two-phase flow model are solidifying melt and air. Whereas non-equilibrium Schiel's model is used to track the solid content of the flowing melt during cooling slope slurry generation process, despite considering evolving primary Al grains as a separate phase. A temperature correction model is implemented here, and the solver temperature is updated depending upon the latent heat and liquid content of the melt, for a particular instance. Eight different numerical experiments are performed, consisting of different values of key process conditions, to establish the correlation between processing variables and slurry morphology. The key process variables considered here are as follows: melt pouring temperature into the slope, angle of inclination of the cooling slope, and slope wall temperature. The studied output characteristics of the generated slurry, predicted by the two-phase model, are as follows, velocity distribution, presence of fraction solid, and slurry temperature distribution. Further insights have been obtained on slurry morphology of chosen process conditions, at microscale, by employing an Eulerian three-phase flow model. The findings from the three-phase model include size and sphericity of primary Al grains, apart from macroscopic properties such as temperature, solid fraction, and viscosity.

Item Type: Journal Article
Publication: International Journal of Metalcasting
Publisher: Springer Science and Business Media Deutschland GmbH
Additional Information: The copyright for this article belongs to Springer Science and Business Media Deutschland GmbH.
Keywords: Computational fluid dynamics; Cooling; Morphology, A380 alloy; Cooling slopes; Eulerian; Eulerian multiphase model; Key process; Multiphase flow simulations; Multiphase modeling; Process condition; Semi-solids; Two phases flow, Two phase flow
Department/Centre: Division of Mechanical Sciences > Materials Engineering (formerly Metallurgy)
Date Deposited: 15 Jun 2023 08:49
Last Modified: 15 Jun 2023 08:49
URI: https://eprints.iisc.ac.in/id/eprint/81996

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