Advanced Solidification Processing and Casting Technologies

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Casting, Forming and Heat Treatment".

Deadline for manuscript submissions: closed (31 March 2023) | Viewed by 7583

Special Issue Editor


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Guest Editor
IMDEA Materials Institute, C/ Eric Kandel, 2 Tecnogetafe 28906, Getafe, Madrid, Spain
Interests: solidification and casting process optimization and development; high-throughput methods; gas atomization of metallic powders; additive manufacturing

Special Issue Information

Dear Colleagues,

Advanced solidification processing and casting technologies have been initiated to respond to the challenges imposed by the need to optimize existing processes, making them more sustainable and less expensive, via new processes for smart and high-performance materials and components, as well as by the development towards integrated materials design. High-performance metallic components can be manufactured via innovative near net shape solidification processing, involving little solid-state post-processing, which is energy-intensive, time consuming, and inevitably high cost. Although significant advances in this field have already been achieved, there are still a lot of unanswered questions as well as challenges to be met.

This Special Issue on Advanced Solidification Processing and Casting Technologies is intended to highlight the latest developments in the field by compiling a comprehensive collection of papers on various aspects of processing and technology innovation. The scope spans a wide range of processes (e.g., traditional and advanced casting, joining, liquid metal engineering) and research approaches (e.g., theoretical, experimental, computational). Topics of interest include, but are not restricted to, the following:

  • Traditional casting processes (sand casting, low- and high-pressure die casting, lost foam, investment casting, ingot casting, continuous/semi-continuous casting, remelting processes (ESR, VAR), welding and soldering, etc.);
  • Advanced casting processes (centrifugal casting, squeeze casting, suction casting, thixo- and rheo-casting, reactive infiltration, rapid solidification, directional solidification, high-throughput methods, etc.);
  • Modeling (new physics-based and data-based models linking materials processing, microstructure, defects, and properties; microstructure evolution, e.g., dendritic growth, globular-to-dendritic transition, columnar-to-equiaxed transition, scale bridging, etc.);
  • In situ processing and monitoring (efficient use of resulting data, machine learning, artificial intelligence, etc.);
  • Innovative materials and novel alloy design.

Dr. Srdjan Milenkovic
Guest Editor

Manuscript Submission Information

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Keywords

  • solidification
  • casting
  • modeling
  • processing–microstructure–properties relationship
  • microstructure evolution
  • in situ processing and monitoring

Published Papers (5 papers)

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Research

20 pages, 6765 KiB  
Article
Digital-Twin-Based Coordinated Optimal Control for Steel Continuous Casting Process
by Jian Yang, Zhenping Ji, Wenhong Liu and Zhi Xie
Metals 2023, 13(4), 816; https://doi.org/10.3390/met13040816 - 21 Apr 2023
Cited by 1 | Viewed by 1357
Abstract
A digital-twin-model-based optimal control system is presented for the steel continuous casting process. The system is designed for the coordinated optimization and dynamic control of secondary cooling and final electromagnetic stirring (FEMS), and involves three related parts. Firstly, a three dimensional real-time heat [...] Read more.
A digital-twin-model-based optimal control system is presented for the steel continuous casting process. The system is designed for the coordinated optimization and dynamic control of secondary cooling and final electromagnetic stirring (FEMS), and involves three related parts. Firstly, a three dimensional real-time heat transfer model is established as the digital twin of the heat transfer process of continuous casting; for high accuracy, it is calibrated offline and calibrated online using measurements of the surface temperatures and shell thicknesses (only offline). Secondly, according to metallurgical rules, cooling and stirring are optimized coordinatively, based on the established digital-twin model and chaos particle swarm optimization algorithm. Thirdly, cooling and stirring are further dynamically controlled for quality stability. Finally, the system is applied in a bloom caster with model errors ≤ ±10 °C and control errors ≤ ±4 °C, which reduces the macro-segregation over grade 1.5 from 11% to 3.3%. Full article
(This article belongs to the Special Issue Advanced Solidification Processing and Casting Technologies)
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10 pages, 3976 KiB  
Article
Effect of Solidification Variables on the Tensile Property of 2.8 wt% C–26 wt% Cr White Iron
by Deuk-Won Jang, Jong-Ho Shin, In-Soo Kim, In-Yong Jung, Chang-Yong Jo and Je-Hyun Lee
Metals 2022, 12(9), 1416; https://doi.org/10.3390/met12091416 - 27 Aug 2022
Cited by 2 | Viewed by 964
Abstract
The present study aimed to investigate the increasing solidification rate during directional solidification developed from in situ composites of M7C3/austenite eutectic, to in situ composites with a small portion of dendrites, and to partial in situ composites with equiaxed [...] Read more.
The present study aimed to investigate the increasing solidification rate during directional solidification developed from in situ composites of M7C3/austenite eutectic, to in situ composites with a small portion of dendrites, and to partial in situ composites with equiaxed structures. M7C3 fibre aligned along the solidified direction in the in situ composites; however, its orientation and shape became irregular among the dendrites. In situ composite structure has higher tensile strength than partial in situ composite or equiaxed material. Crack initiation in the fibre occurred because the fibre could not accommodate the deformation of the matrix under tensile stress. The tensile fracture was caused by both crack initiations in the M7C3 fibre or at the randomly oriented particles, and the crack propagation to matrix. Full article
(This article belongs to the Special Issue Advanced Solidification Processing and Casting Technologies)
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13 pages, 5286 KiB  
Article
Microstructure Formation of Cast and Directionally Solidified Mo-Ti-B Alloys
by Vadym Petrusha, Georg Hasemann, Rachid Stefan Touzani, Volodymyr Bolbut, Iurii Bogomol and Manja Krüger
Metals 2022, 12(6), 916; https://doi.org/10.3390/met12060916 - 26 May 2022
Viewed by 1646
Abstract
In the present work the solidification of various Mo-Ti-B alloys was studied. The alloy compositions were chosen in the direct vicinity of a U-type invariant reaction in relation to the published Mo-rich corner of the Mo-Ti-B liquidus projection. The aim of this study [...] Read more.
In the present work the solidification of various Mo-Ti-B alloys was studied. The alloy compositions were chosen in the direct vicinity of a U-type invariant reaction in relation to the published Mo-rich corner of the Mo-Ti-B liquidus projection. The aim of this study was to understand the solidification path of as-cast Mo-Ti-B alloys and to derive specific knowledge on their peritectic microstructure evolution. In addition to experiments in an arc-melter, zone melting was used to allow slow cooling of a selected alloy composition. Using the achieved experimental data of the alloys investigated, DFT-calculations were carried out to study the influence of Ti on phase formation and stability, their lattice parameters, and mechanical properties. Full article
(This article belongs to the Special Issue Advanced Solidification Processing and Casting Technologies)
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24 pages, 17012 KiB  
Article
Effects of Primarily Solidified Dendrite and Thermal Treatments on the M23C6 Precipitation Behavior of High-Chromium White Iron
by Young-Gy Song, Jun-Seok Oh, Baig-Gyu Choi, Chang-Yong Jo and Je-Hyun Lee
Metals 2021, 11(11), 1690; https://doi.org/10.3390/met11111690 - 23 Oct 2021
Cited by 4 | Viewed by 1308
Abstract
The precipitation behavior of M23C6 carbide during thermal treatment of high-Cr white iron with various fractions of primarily solidified dendrite was studied and reviewed. M23C6 precipitation in the primarily solidified dendrite occurred preferentially during conventional heat treatment, [...] Read more.
The precipitation behavior of M23C6 carbide during thermal treatment of high-Cr white iron with various fractions of primarily solidified dendrite was studied and reviewed. M23C6 precipitation in the primarily solidified dendrite occurred preferentially during conventional heat treatment, whereas it occurred scarcely in the eutectic austenite. The reaction between M7C3 and austenite caused the dissolution of M7C3 into austenite, followed by precipitation of M23C6 along the periphery of eutectic M7C3. Relatively low-temperature thermal treatment (modified heat treatment) led to precipitation of M23C6 particles in the eutectic austenite, which is presumed to be caused by solubility difference depending on temperature. Full article
(This article belongs to the Special Issue Advanced Solidification Processing and Casting Technologies)
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19 pages, 18552 KiB  
Article
Effect of Dendrite Fraction on the M23C6 Precipitation Behavior and the Mechanical Properties of High Cr White Irons
by Jun-Seok Oh, Young-Gy Song, Baig-Gyu Choi, Chalothorn Bhamornsut, Rujeeporn Nakkuntod, Chang-Yong Jo and Je-Hyun Lee
Metals 2021, 11(10), 1576; https://doi.org/10.3390/met11101576 - 03 Oct 2021
Cited by 4 | Viewed by 1288
Abstract
High Cr white irons with various fractions of primary dendrite have been prepared through the modification of their chemical composition. Increasing C and Cr contents decreased the primary dendrite fraction. Eutectic solidification occurred with the phase fraction ratio of austenite: M7C [...] Read more.
High Cr white irons with various fractions of primary dendrite have been prepared through the modification of their chemical composition. Increasing C and Cr contents decreased the primary dendrite fraction. Eutectic solidification occurred with the phase fraction ratio of austenite: M7C3 = 2.76:1. The measured primary dendrite fractions were similar to the calculated results. ThermoCalc calculation successfully predicted fractions of M7C3, austenite, and M23C6. Conventional heat treatment at high temperature caused a destabilization of austenite, releasing it’s solute elements to form M23C6 carbide. Precipitation of M23C6 during destabilization preferentially occurred within primary (austenite) dendrite, however, the precipitation scarcely occurred within austenite in eutectic phase. Thus, M23C6 precipitation by destabilization was relatively easy in alloys with a high fraction of primary dendrite. Full article
(This article belongs to the Special Issue Advanced Solidification Processing and Casting Technologies)
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