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Metals
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Computational Simulation and Numerical Modeling of Metal Refining and Casting...
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Computational Simulation and Numerical Modeling of Metal Refining and Casting Process

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Computation and Simulation on Metals".

Deadline for manuscript submissions: closed (31 March 2023) | Viewed by 5482

Special Issue Editor

Dr. Jae Hong Shin

E-Mail Website
Guest Editor
Korea Institute of Industrial Technology, Incheon 21655, Republic of Korea
Interests: steelmaking; secondary refining; inclusion; pyrometallurgy; recovery of valuable metal; computational thermodynamics; computational simulation of metallurgical process
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

During the refining and casting process of metals, it occurred that complex and varied physical and chemical phenomena such as fluid flow, electromagnetic, heat transfer, mass transfer, and thermodynamic reactions.

To understand these physicochemical phenomena of metal refining and casting processes, it is very important that the prediction of physicochemical phenomena during the refining and casting process using computational simulation and numerical modeling.

In addition, to reduce the expensive experimental trials used to evaluate the impact of different optimization strategies, advanced process modeling is needed. Modeling and simulations serve us as an invaluable source of information for conducting process analysis and as an alternative to expensive, dangerous, and time-consuming experimental trials.

Mathematical modeling and computational simulation of metal refining and casting processes have been a very active field of research over the past 30 years, as illustrated by hundreds of publications per year. The purpose of this Special Issue is to provide an updated review and the latest research trends in numerical modeling and computational simulation of metal refining and casting processes that have advanced over the past 30 years.

Papers dealing with simulation and modeling topics in all fields related to metal refining/casting processes (vacuum metallurgy, remelting, degassing, inclusion control, solidification control, defect control, etc.) are recommended. We particularly welcome contributions issued from a collaboration between academic and industrial researchers.

Dr. Jae Hong Shin
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • simulation
  • numerical modeling
  • refining process
  • casting process
  • pyrometallurgy
  • ferrous metal
  • non-ferrous metal
  • metallurgical process

Published Papers (4 papers)

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Research

15 pages, 3892 KiB  
Article
A Computational Fluid Dynamics Study on Physical Refining of Steel Melts by Filtration
by Shahin Akbarnejad, Dong-Yuan Sheng and Pär Göran Jönsson
Metals 2023, 13(6), 1022; https://doi.org/10.3390/met13061022 - 26 May 2023
Viewed by 1012
Abstract
In this paper, a previous experimental investigation on physical refining of steel melts by filtration was numerically studied. To be specific, the filtration of non-metallic alumina inclusions, in the size range of 1–100 µm, was stimulated from steel melt using a square-celled monolithic [...] Read more.
In this paper, a previous experimental investigation on physical refining of steel melts by filtration was numerically studied. To be specific, the filtration of non-metallic alumina inclusions, in the size range of 1–100 µm, was stimulated from steel melt using a square-celled monolithic alumina filter. Computational fluid dynamics (CFD) studies, including simulations of both fluid flow and particle tracing using the one-way coupling method, were conducted. The CFD predicted results for particles in the size range of ≤5 µm were compared to the published experimental data. The modeled filtration setup could capture 100% of the particles larger than 50 µm. The percentage of the filtered particles decreased from 98% to 0% in the particle size range from 50 µm to 1 µm. Full article
(This article belongs to the Special Issue Computational Simulation and Numerical Modeling of Metal Refining and Casting Process)
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16 pages, 6007 KiB  
Article
Effect of Wide-Spectrum Pulsed Magnetic Field on Solidification Structure of Pure Al at Constant Flow Velocity
by Yawei Sun, Bohuai Yao, Zhen Zhao and Yongyong Gong
Metals 2023, 13(5), 860; https://doi.org/10.3390/met13050860 - 28 Apr 2023
Viewed by 786
Abstract
The electromagnetic force generated by a pulsed magnetic field within a metal melt leads to changes in the internal temperature and flow fields of the molten metal, thus improving the solidification of the metal structure. Using the combination of a solidification test, experimental [...] Read more.
The electromagnetic force generated by a pulsed magnetic field within a metal melt leads to changes in the internal temperature and flow fields of the molten metal, thus improving the solidification of the metal structure. Using the combination of a solidification test, experimental simulation and theoretical analysis, this study simulated the distribution of both electromagnetic force and the flow field in a metal melt under wide-spectrum pulse conditions, and studied the influence of a wide-spectrum pulsed magnetic field on the solidification structure of pure aluminium with a constant flow velocity. The results of this study show that the structural refinement of the solidification of pure aluminium can be different, in spite of equal flow velocity. Furthermore, this study shows that an applied time-averaged electromagnetic force causes crystal nuclei to pass through the solid–liquid interface boundary layer and promotes the growth of crystal grains. These grains flowed with the melt flow field to achieve both refinement and homogenization of the solidified structure. Full article
(This article belongs to the Special Issue Computational Simulation and Numerical Modeling of Metal Refining and Casting Process)
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22 pages, 23824 KiB  
Article
Thermodynamic Calculations of Direct Reduction Smelting Technology of Copper Oxide Ores Based on Smelting Slag from the Yubeidi Site, Yunnan Province
by Shuoyang Li, Xiaocen Li, Rong Zhu and Yanxiang Li
Metals 2023, 13(4), 707; https://doi.org/10.3390/met13040707 - 04 Apr 2023
Viewed by 1696
Abstract
The current research on metallurgical remains from scientific excavations in northeast Yunnan from the Bronze Age period is insufficient. In order to study the smelting technology of the Bronze Age in north-eastern Yunnan, samples of slag and mineral excavated from the Yubei Di [...] Read more.
The current research on metallurgical remains from scientific excavations in northeast Yunnan from the Bronze Age period is insufficient. In order to study the smelting technology of the Bronze Age in north-eastern Yunnan, samples of slag and mineral excavated from the Yubei Di site in Dongchuan were examined. Based on the outcome of the characterization analysis, a simulation was executed utilizing the software Factsage 7.1 in order to generate a phase diagram that accurately portrays the melting procedure. This simulation aimed to produce the most credible representation of the phase transition by employing computational methods. Characterisation methods included Metallographic Microscopy, Scanning Electron Microscopy Energy Dispersive Spectromicropy (SEM-EDS), X-ray diffraction (XRD), and Radiocarbon Date (14C dating). The results showed that there was much copper ore left in the slag of the site. Most of these copper ores were in the form of copper ferrite or cuprous oxide. The copper ore was copper oxide ore, and metal copper particles appeared in a small amount of the slag. Most of the slags unearthed from the site of the Yubeidi site were products of sulfur-containing oxide reduction and smelting into copper. Based on the outcomes of the simulations, it was established that the slag excavated from the Yubeidi site was mainly from the reduction and smelting process of sulphur-containing copper oxide minerals into copper, without consciously adding fluxes, not having mastered the slag-making techniques for different types of copper ores, and with primitive techniques. The carbon 14 dating results show that the age of the slag was during the Spring and Autumn Period and the Warring States Period. Full article
(This article belongs to the Special Issue Computational Simulation and Numerical Modeling of Metal Refining and Casting Process)
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13 pages, 3871 KiB  
Article
Experimental Investigation and Numerical Simulation of the Fluidity of A356 Aluminum Alloy
by Hyeon-Sik Bang, Hyeok-In Kwon, Sung-Bean Chung, Dae-Up Kim and Min-Su Kim
Metals 2022, 12(11), 1986; https://doi.org/10.3390/met12111986 - 20 Nov 2022
Cited by 2 | Viewed by 1541
Abstract
The fluidity of A356 aluminum alloy was experimentally determined at the melt temperatures and vacuum degrees by a series of suction fluidity tests. In order to achieve different cooling rates during the test, quartz tubes, as well as stainless steel tubes, were employed [...] Read more.
The fluidity of A356 aluminum alloy was experimentally determined at the melt temperatures and vacuum degrees by a series of suction fluidity tests. In order to achieve different cooling rates during the test, quartz tubes, as well as stainless steel tubes, were employed as the fluidity channels. As the melt temperature increased from 650 to 730 °C, fluidity lengths either linearly increased from 26 to 36 cm or parabolically increased from 13 to 29 cm when quartz tubes or stainless steel tubes were employed, respectively. As the vacuum degree of the fluidity test increased from 0.005 to 0.03 MPa, fluidity increased from 25 to 43 cm in quartz tubes while the smaller increase in fluidity from 20 to 31 cm was observed in stainless steel tubes. Shorter fluidity lengths in stainless steel tubes than those in quartz tubes under the same fluidity measurement condition were due to faster solidification speed confirmed by microstructural analysis. In order to predict the fluidity of the A356 alloy obtained from the suction fluidity tests, a mathematical model was developed based on heat and mass transfer equations coupled with thermodynamic calculations by ChemApp software. The simulation results show good agreement with the fluidity length obtained in the present study. From a series of model calculations, the effects of casting parameters on the fluidity of the A356 melt were discussed. Full article
(This article belongs to the Special Issue Computational Simulation and Numerical Modeling of Metal Refining and Casting Process)
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