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Foundry production
ArticleName Calculation of ingot sizes using three-dimensional numerical simulation
ArticleAuthor O. Jaouen, J. Demurger, D. Poirier, M. Stoltz

Transvalor S.A. (Mougins, France):

O. Jaouen, Product Manager Thercast, e-mail:

Ascometal Creas (Hagondange, France):
J. Demurger

D. Poirier

M. Stoltz


Ascometal, through the use of Thercast software, has developed a technology for producing a new 10-ton ingot based on the characteristics of the currently produced 6.2-ton ingot. The solidifi cation time was estimated by calculations and then verified using measurements. Among other parameters of the new size ingot, special attention was paid to controlling the distribution of porosity, as a result of which criteria for its localization were proposed. Good agreement was observed between the areas of the ingot predicted by modeling of the zone with porosity and their real location. This made it possible to control the number and sizes of such foci of porosity. In addition, segregation studies were undertaken. If for the ingot weighing 6.2 tons an excellent agreement was observed between the modeling forecast of segregation and the results of its measurements, then in the similar research option for the 10 ton ingot noticeable differences were noted. Regarding the qualitative analysis, the predicted and calculated indicators are completely consistent with each other, but quantitatively the range of negative segregation in the bottom of the 10-ton ingot is not consistent with the measured segregation values. This is due to the fact that when calculating using the software model, the factor of deposition of solid particles was not taken into account. At present, additional studies are being carried out in order to eliminate this drawback and take into account the nucleation, growth, and movement of solid particles in the liquid phase of the alloy. The main goal is the possible use of modeling as an additional means to reduce macroliquation in ingots.

keywords Forged parts, ingots, segregation, axial porosity, air gap, thermal model, mechanical model, segregation model

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