Dynamic modelling and validation of the metal/flux interface in continuous casting

This paper concerns the development and validation (using an oil/water system) of a finite volume computer model of the continuous casting process for steel flat products. The emphasis is on hydrodynamic aspects and in particular the dynamic behaviour of the metal/slag interface due to the momentum imparted by the submerged entry nozzle (SEN) jets that bring the metal into the mould. Instability and wave action encourage the entrainment of inclusions into the melt affecting product quality. To track the interface between oil and water a new implicit algorithm was developed, called the Counter Diffusion Method. To prevent numerical damping of low frequency waves, a time-filtered version of the k- model was incorporated in the model. The physics of the interface dynamics are affected by density stratification and surface interfacial tension, with additional source terms introduced in the turbulence model to account for the former effect. Gas bubbles were modelled using a Lagrangian tracking method. The model was validated against experimental measurements obtained in a water model apparatus at Arcelor Research. Silicon oil was used to represent the lighter layer whilst air was pumped through the SEN to represent the argon

Numerical modelling of silicon melt purification in induction directional solidification system

Solar grade silicon production is an energy intensive and harmful to the environment process. Yet 40% of this valuable product material is lost into sawdust (kerf loss) during wafering. The kerf waste from Fixed Abrasive Sawing of PV silicon wafers is pelletized and then remelted in an induction furnace. The furnace has a square cross-section quartz crucible, surrounded by graphite susceptors and heated by an induction coil that enables directional solidification of the new ingot. Top and bottom 'pancake' coils provide additional temperature control. Once melted, silicon becomes electrically conductive and subject to stirring by induction. To recycle the silicon, particulate impurities (due to the sawing, condensed silicon oxides or carbides) need to be removed. Flow control and the electromagnetic Leenov-Kolin force are used to expel particulates, through a novel dual frequency induction scheme. Three-dimensional, multi-physics numerical modelling captures the electromagnetic, fluid-flow and heat-transfer effects in this process. The presented results show it is possible to retain the impurity particles on the sides of the solidified ingot where they can be sliced off and removed

The integration of structural mechanics into microstructure solidification modelling

In situ structural mechanics are an often neglected area when modelling alloy microstructure during solidification, despite the existence of practical examples and studies which seem to indicate that the interaction between thermal or mechanical stresses and microstructure can have a significant impact on its evolution and hence the final properties at a macroscopic level. A bespoke structural mechanics solver using the finite volume method has been developed to solve the linear elasticity equations, with design choices being made to facilitate the coupling of this solver to run in situ with an existing solidification model. The accuracy of the structural mechanics solver is verified against an analytic solution and initial results from a fully coupled system are presented which demonstrate in a fundamental example that the interaction between structural mechanics and a solidifying dendrite can lead to a significant change in growth behaviour

Acoustic resonance for contactless ultrasonic cavitation in alloy melts

Contactless ultrasound is a novel, easily implemented, technique for the Ultrasonic Treatment (UST) of liquid metals. Instead of using a vibrating sonotrode probe inside the melt, which leads to contamination, we consider a high AC frequency electromagnetic coil placed close to the metal free surface. The coil induces a rapidly changing Lorentz force, which in turn excites sound waves. To reach the necessary pressure amplitude for cavitation with the minimum electrical energy use, it was found necessary to achieve acoustic resonance in the liquid volume, by finely tuning the coil AC supply frequency. The appearance of cavitation was then detected experimentally with an externally placed ultrasonic microphone and confirmed by the reduction in grain size of the solidified metal. To predict the appearance of various resonant modes numerically, the exact dimensions of the melt volume, the holding crucible, surrounding structures and their sound properties are required. As cavitation progresses the speed of sound in the melt changes, which in practice means resonance becomes intermittent. Given the complexity of the situation, two competing numerical models are used to compute the soundfield. A high order time-domain method focusing on a particular forcing frequency and a Helmholtz frequency domain method scanning the full frequency range of the power supply. A good agreement is achieved between the two methods and experiments which means the optimal setup for the process can be predicted with some accuracy

Progress in the development of a contactless ultrasonic processing route for alloy grain refinement

A high frequency tuned electromagnetic (EM) induction coil can be used to induce ultrasonic pressure waves leading to gas cavitation in alloy melts. This is a useful ‘contactless’ approach compared to the usual immersed sonotrode technique. One then expects the same benefits obtained in the traditional ultrasonic treatment (UST) of melts, such as degassing, microstructure refinement and dispersion of particles. However, such an approach avoids melt contamination due to probe erosion prevalent in immersed sonotrodes and it has the potential to be used on higher temperature and reactive alloys. Induction stirring due to the Lorentz force produced by the coil is an added benefit, allowing for the treatment of large melt volumes, a current limitation of UST systems. At ultrasonic frequencies (> 20 kHz), due to the ‘skin effect’ electromagnetic forces vibrate just a thin volume by the surface of the metal facing the induction source. These vibrations are transmitted as acoustic pressure waves into the bulk and to achieve sufficient fluctuation amplitudes for cavitation, acoustic resonance is sought by carefully adjusting the generator frequency. This is akin to the tuning of a musical instrument, where the geometry and sound properties of the metal, crucible and surrounding structure play an important part. In terms of modelling, this is a multi-physics system, since fluid flow with heat transfer and phase change are coupled to electromagnetic and acoustic fields. The various models used and their coupling are explained in this paper, together with the various complications arising by the physics of cavitation. Experimental validation is obtained on a prototype rig featuring a conical induction coil inserted into the melting crucible containing the various alloys being examined. When resonance is reached, measurements demonstrate strong stirring, evidence of cavitation and finally grain refinement

Calibration and performance tests of the Very-Front-End electronics for the CMS electromagnetic calorimeter

The Very-Front-End electronics processing signals from photodetectors of the CMS electromagnetic calorimeter have been put through an extensive test programme to guarantee functionality and reliability. The final characteristics of the VFE boards designed for the calorimeter barrel and endcaps are presented. The results, which have been also verified during test beam at CERN, confirm the high quality of the boards production and show that the CMS detector specifications are reached

Finite volume solutions for electromagnetic induction processing

A new method is presented for numerically solving the equations of electromagnetic induction in conducting materials using native, primary variables and not a magnetic vector potential. Solving for the components of the electric field allows the meshed domain to cover only the processed material rather than extend further out in space. Together with the finite volume discretisation this makes possible the seamless coupling of the electromagnetic solver within a multi-physics simulation framework. After validation for cases with known results, a 3-dimensional industrial application example of induction heating shows the suitability of the method for practical engineering calculation

Performance of a Tungsten-Cerium Fluoride Sampling Calorimeter in High-Energy Electron Beam Tests

A prototype for a sampling calorimeter made out of cerium fluoride crystals interleaved with tungsten plates, and read out by wavelength-shifting fibres, has been exposed to beams of electrons with energies between 20 and 150 GeV, produced by the CERN Super Proton Synchrotron accelerator complex. The performance of the prototype is presented and compared to that of a Geant4 simulation of the apparatus. Particular emphasis is given to the response uniformity across the channel front face, and to the prototype's energy resolution.Comment: 6 pages, 6 figures, Submitted to NIM

Multiphysics Modelling of Ultrasonic Melt Treatment in the Hot-Top and Launder during Direct-Chill Casting: Path to Indirect Microstructure Simulation

Copyright: © 2021 by the authors. This study concerns the numerical simulation of two competing ultrasonic treatment (UST) strategies for microstructure refinement in the direct-chill (DC) casting of aluminium alloys. In the first, more conventional, case, the sonotrode vibrating at 17.3 kHz is immersed in the hop-top to treat the sump melt pool, in the second case, the sonotrode is inserted between baffles in the launder. It is known that microstructure refinement depends on the intensity of acoustic cavitation and the residence time of the treated fluid in the cavitation zone. The geometry, acoustic field intensity, induced flow velocities, and local temperature are factors which affect this treatment. The mathematical model developed in this work couples flow velocity, acoustics modified by cavitation, heat transfer, and solidification at the macroscale, with Lagrangian refiner particles, used to determine: (a) their residence time in the active zones, and (b) their eventual distribution in the sump as a function of the velocity field. This is the first attempt at using particle models as an efficient, though indirect, alternative to microstructure simulation, and the results indicate that UST in the launder, assisted with baffle separators, yields a more uniform distribution of refining particles, avoiding the strong acoustic streaming jet that, otherwise, accompanies hot-top treatment, and may lead to the strong segregation of refining particles. Experiments conducted in parallel to the numerical studies in this work appeared to support the results obtained in the simulation.EPSRC (UK), under the UltraMelt 2 project, grant numbers EP/R011001/1, EP/R011044/1, and EP/R011095/1

Calibration and performance of the photon sensor response of FACT -- The First G-APD Cherenkov telescope

The First G-APD Cherenkov Telescope (FACT) is the first in-operation test of the performance of silicon photo detectors in Cherenkov Astronomy. For more than two years it is operated on La Palma, Canary Islands (Spain), for the purpose of long-term monitoring of astrophysical sources. For this, the performance of the photo detectors is crucial and therefore has been studied in great detail. Special care has been taken for their temperature and voltage dependence implementing a correction method to keep their properties stable. Several measurements have been carried out to monitor the performance. The measurements and their results are shown, demonstrating the stability of the gain below the percent level. The resulting stability of the whole system is discussed, nicely demonstrating that silicon photo detectors are perfectly suited for the usage in Cherenkov telescopes, especially for long-term monitoring purpose