Numerical simulation of solidification structure during electroslag remelting casting of ZG06Cr13Ni4Mo ingot based on CAFE and moving boundary method

Abstract

A comprehensive mathematical model of the solidification structure during the process of electroslag remelting casting (ESRC) of low carbon martensite stainless steel ZG06Cr13Ni4Mo has been established. The change of metal pool profile and grain growth and the microstructure evolution process from the beginning to the steady stage of the ESRC process were investigated by using the moving boundary method and the coupled technology CAFE method (cellular automaton – finite element method). The transition from equiaxed grains at the lateral wall of the mould to columnar grains has been revealed. In addition, casting of this steel has been carried out and the microstructure of the ingot obtained after grinding and acid leaching. According to the comparison of the metal pool profile, morphology and growth direction of the dendrite and the secondary dendrite arm spacing (SDAS) between the experimental results and the simulation results, the validity of the model has been demonstrated, which can provide a favourable theoretical foundation to optimise the process parameters for the control of solidification structure of ESRC of low carbon martensite stainless steel ZG06Cr13Ni4Mo.

Get full access to this article

View all access options for this article.

References

Sun

Liu

C. M.

: ‘Status and tendency of development for cast low carbon martensitic stainless steel', Foundry, 2007, 56, (1), 1–5.

Jiang

Z. H.

: ‘Physical chemistry and transport phenomena of electroslag metallurgy’; 2000, Shenyang, Northeastern University Press.

Feng

Liu

F. B.

H. B.

Jiang

Z. H.

Dong

Y. W.

Chen

Song

Z. W.

Geng

: ‘Research on mechanical properties of ZG06Cr13Ni4Mo low carbon martensitic stainless steel manufactured by electroslag casting process', J. Mater. Metall., 2013, 12, (1), 45–49.

Z. B.

: ‘Development of electroslag metallurgy and remelting casting in China’, Foundry, 2004, 53, (11), 855–8\61.

Yao

H. P.

Zhang

H. M.

: ‘Simulation on the microstructure of electroslag remelting ingot’, Foundry Technol., 2008, 29, (12), 1670–1673.

Nastac

Stefanescu

D. M.

: ‘Macrotransport-solidification kinetics modeling of equiaxed dendritic growth: Part I. Model development and discussion’, Metall. Mater. Trans. A, 1996, 27, (12), 4061–4074.

Nastac

Stefanescu

D. M.

: ‘Macrotransport-solidification kinetics modeling of equiaxed dendritic growth: Part II. Computation problems and validation on INCONEL 718 superalloy castings', Metall. Mater. Trans. A, 1996, 27, (12), 4075–4083.

Rappaz

Gandin

C. A.

: ‘Probabilistic modelling of microstructure formation in solidification processes', Acta Metall. Mater., 1993, 41, (2), 345–360.

Kurz

Giovanola

Trivedi

: ‘Theory of microstructural development during rapid solidification’, Acta Mater., 1986, 34, (5), 823–830.

10.

Wang

J. L.

Wang

F. M.

C. R.

Zhang

J. M.

: ‘Simulation of 3D-microstructure in free-cutting steel 9SMn28 under water cooling condition with convection and porosity', ISIJ Int., 2010, 50, (2), 222–230.

11.

Rappaz

Thevoz

: ‘Solute diffusion model for equiaxed dendritic growth', Acta Metall. Mater., 1987, 35, (7), 1487–1497.

12.

Zhu

M. F.

Hong

C. P.

: ‘A modified cellular automaton model for the simulation of dendritic growth in solidification of alloys',ISIJ Int., 2001, 41, (5), 436–445.

13.

Luo

Zhu

M. Y.

Louhrnkilpi

: ‘Numerical simulation of solidification structure of high carbon steel in continuous casting using cellular automaton method', ISIJ Int., 2012, 52, (5), 823–830.

14.

B. K.

Wang

Chen

M. Q.

: ‘A coupled cellular automaton finite element mathematical model for the multiscale phenomena of electroslag remelting H13 die steel ingot', JOM, 2014, 66, (7), 1153–1165.

15.

Dilthey

Pavlik

Reichel

: ‘Numerical simulation of dendritic solidification with modified cellular automata', in ‘Mathematical modelling of weld phenomena 3’, (ed. H. Cerjak and H. K. D. H. Bhadeshia), Chap. 2, 85–105; 1997, London, UK, The Institute of Materials, The University of Cambridge.

16.

Miettinen

: ‘Thermodynamic-kinetic simulation of constrained dendrite growth in steels', Metall. Mater. Trans. B, 2000, 31, (2), 365–379.

17.

Ishida

Natsume

Ohsasa

: ‘Numerical simulation of solidification structure formation in high Mn steel casting using cellular automaton method', ISIJ Int., 2008, 48, (12), 1728–1733.

18.

Cornelissen

M. C. M.

: ‘Mathematical-model for solidification of multicomponent alloys', Ironmak. Steelmak., 1986, 13, (4), 204–212.

19.

Kubícek

Peprˇica

: ‘Diffusion in molten metals and melts: application to diffusion in molten iron', Int. Met. Rev., 1983, 28, (1), 131–157.

20.

Meng

Thomas

B. G.

: ‘Heat-transfer and solidification model of continuous slab casting: CON1D', Metall. Mater. Trans. B, 2003, 34, (5), 685–705.

21.

Zhang

Y. J.

Kou

H. C.

P. F.

Zhong

J. S.

Zhou

: ‘Simulation on solidification structure and shrinkage porosity(hole) in TC4 ingot during vacuum arc remelting process', Spec. Cast. Nonferrous Alloys, 2012, 32, (5), 418–421.

22.

Okane

Umeda

: ‘Eutectic growth of unidirectionally solidified Fe–Cr–Ni alloy', ISIJ Int., 1998, 38, (5), 454–460.

23.

Q. F.

: ‘Research on internal qualities and mechanical properties of low carbon martensitic stainless steel by ESRC'; 2012, Boston, MA, Northeastern University.

24.

McLean

: ‘Directly solidified materials for high temperature service', 26; 1983, London, The Metals Society.