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Control the process to control the Product
Based on a 30-year experience, SC-Consultants is your partner in manufacturing processes
optimization by providing numerical engineering applied solutions
SC-Consultants
2
The SC-Consultants company
30 years of experience in consulting actions and software solutions provider for manufacturing processes :
Foundry, Casting, Heating & Cooling, SolidificationAeronautic / Automotive / Nuclear / Hydraulic
ExtrusionAgro & Pet Food / Plasturgy
Mixingadvanced materials, Pharma
3
The SC-Consultants company
A French company
Based in Saint Etienne (France) and a subsidiary in Montreal (Canada)
Specialized in the industrial processes optimization
Software edition
Services and consulting
10 employees
Worldwide experience and implementationR&D facilitiesTechnical partnershipsCommercial partnerships
Headquarters
offices
representatives
customers
SC-Consultants network
5
1
The SC-Consultants company
StrategicInitiatives
Services
Software
Strategic InitiativesScientific community
For project development
For collaborative R&D
ServicesDissemination of R&D outcomes
Consultancy
Technical assistance on process simulation
Training
Software solution providerProcess specific software EditionApplication specific software Development
6
R&D participation
Partnerships with specialized laboratories
CEMEF From Mines ParisTech
Material behaviour, numerical developments
INRA
National Research Center on Agro Food
Material characterization
Institut Jean Lamour
From Ecole des Mines de Nancy
Metalworking industries
Techno partners
Aimplas, Fraunhofer, Univ Bonn, Univ Cleveland, Univ Lowell, ...
The SC-Consultants R&D background
Control the process to control the Product
Based on a 2D model, the Solid software is dedicated to casting/ingots casting simulation
Solid® software
8
Introduction
ApplicationsFor simplified geometries (2D)Continuous castingIngots castingFixed mesh (no distorsions)
9
Collaborative model
Scientific background Research development performed in close collaboration of Pr Herve Combeau from IJL – Nancy Lorraine University
List of publication available
Continuous development since 1993Industrial consortium (national and private funds)
Software Research industrialization performed by SCCSolid Users's Club
10
Overview
Simulation software for solidification
Features
Benefits
For all Casting issues
2D Model
For any applications Fast
computationsIndeep analysis
Process Control Knowledge capitalization
Easy set upFast computation Fast ROI
Screening functioning window
11
Solid focus
Solid : simulation of metallic alloys solidification
Liquid Solid
Phase change
12
State diagram
Eutectic + α
α
L + α
L
Temperature decrease
At the equilibrium state
13
The solid state – Typical structure
Composed by a set of "grains"
Structure example
Columnars
Equiaxes
Dendritic Equiaxes
Solidification local time, shrinkage, porosity, grains morphology
Industrial scale segregations (macro, meso and micro)
Macroscopic view thermo solute convection
Thermal convection Solute convection
Case of a lighter solute as the environment liquid
Case of heavier solute as the environment liquid
15
Microscopic – Simplified model for solidification
Simplified growth : Perfect diffusion
No diffusion
Xs Xl
Xs
Xl
solid liquid
x
k = Xs / Xl
Xs Xl
solid liquid
Xs*
Xs*
Xl
x
k = Xs / Xl
Xs
X l=X 0
f l+(1−f l )k
X l=X 0⋅f lk−1
16
The different phenomena in solidification
Thermal
CFD
Segregation+
Growth
Process parameters and alloys
Thermo-Solute convection+
Solid motion
Grains growth+
Microsegregation
17
Solid - 4 levels of modelingThermal
Solidification front , Temperature
Thermal + Fluid Mechanics + segregations (weak coupling) – No solid motion
Solidification front, Temperature
Velocity, pressure
Local compositions
Thermal + Fluid Mechanics + segregations (strong coupling) – No solid motion
Solidification front, Temperature, velocity, pressure
Local composition
Thermal + Fluid Mechanics + segregations (strong coupling) + solid motion + ECT (in option)
Solidification front, temperature, velocity, pressure
Local composition
Structures
18
Computations
2D resolution
Finite volume
Fluid mechanics : simplex method
Growth : from simple to sophisticated scheme (dendritic, ….)
In Practice - 1
ConfigurationGeometry definitionSetting of the appropriate materials and BC (RDB)Setting of the mesh (FV)
Data file construction by modulesFiles (non homogeneous initialisation, filling, ...)Computation options, model selectionThermo-physical and metallurgical properties of the alloy Thermo-physical properties of the molding elementsQuantification of boundary conditions
Computation setting upAccording to the model level : tens of minutes to ….
Results analysisIsovalues maps, curves, … with Paraview software
In Practice - 2 Configuration and data file: an integrated framework on windows system
Solver : on demand on windows or Linux system /Paraview for post-process
Configuration : geometry, materials and BC
Configuration : mesh definition
Zoom
23
Control file construction: integrated
24
Control file construction: integrated
Visualization of solidification path
25
Taking into account filling: a simplified approach
Ref : 3t3 ingot – Aubert & Duval
Initialization with an empty mold At the end of the filling
Taking into account filling: a simplified approach with a list of available results
Localization of secondary shrinkage and map of C segregations
Ref : 3t3 ingot – Aubert & Duval
Localization of primary shrinkage and Niyama criterium
27
Taking into account filling: a global analysis Zoom on the filling stage
0.00 0.02 0.04 0.06 0.08 0.10 0.12 0.140
20
40
60
80
100
Evolution of volumes
%vol_remp%vol_s
Time(h)
Volu
me
(%)
Ref : 3t3 ingot – Aubert & Duval
0.00 0.02 0.04 0.06 0.08 0.10 0.12 0.14
-2.50E+05
-2.00E+05
-1.50E+05
-1.00E+05
-5.00E+04
0.00E+00
Evolution of thermal flux
Filling
time (h)
flux
(W
/m2.
°C)
28
Initialization with heterogeneous data: continuous simulation with unmoulding option
Instantaneous unmoulding
12 12.2 12.4 12.6 12.8 13 13.2 13.4 13.6 13.8 14
-3.00E+03
-2.50E+03
-2.00E+03
-1.50E+03
-1.00E+03
-5.00E+02
0.00E+00
Evolution of thermal flux (alloy)
SolidificationAfter unmolding
time (h)
flux
(W
/m2)
End of moulding stage (13h)
Thermal simulation(30mn)
Ref : 3t3 ingot – Aubert & Duval
2929
Applications ofSolid® software
30
Simulation application: Prediction in a 65 ton steel ingot (ArcelorMittal Industeel, France)
Macrosegregation prediction in a 65 ton steel ingot – Combeau et all – ICRF, 201230
Development of macrosegregation and macrostructure
Solid-liquid interaction Sedimentation and packing
Grain growth Morphology development
Nucleation and fragmentation => CET
Flow through the columnar zone
++
--C
t
rv
l T
31
Industrial conditions - 65 ton ingot (ArcelorMittal Industeel, Le Creusot)
C 0.22%
S 0.007%
P 0.008%
Si 0.18%
Mn 0.25%
Ni 1.14%
Cr 1.6%
Mo 0.19%
Thermosensors measurementsin the mold
Sulfur print Macrostructure & macrosegregation
Exotermic powder
Cast iron molds
Cast iron plate
Hot top
32
Simulation conditions in Solid - 65 ton ingot
0 2 4 6 8 10 12 14 160
100
200
300
400
500
600
700Temperature evolution over time
T14 ExpT14 SimT22 ExpT22 Sim
time(h)
tem
pera
ture
( °
C)
22
14
h a =
(7.5
+4×
5.67
×10
-8 ε
T3 )
W/m
2/K
ε =
0.9
, T
ext =
20
°C
Boundary conditions validated according to measurements in the mold
Exothermic powder
perf
ect c
onta
ct
Comparison between 2 levels of modeling : fixed solid and grain motion
33
Global analysis: temperature evolution
Start 4h 8h30
34
Global analysis: local solidification time, liq fraction evolution after 8h30
35
Macrosegregations predictions - 65 ton ingot
ΔC/C0
Fixed solid Moving grains Centerline segregation
36
Macrosegregations predictions - 65 ton ingot (ArcelorMittal Industeel, Le Creusot)
ΔC/C0
Fixed solid Moving grains Centerline segregation
37
Macrosegregations predictions - 65 ton ingot (ArcelorMittal Industeel, Le Creusot)
ΔC/C0
Fixed solid Moving grains Centerline segregation
38
Understanding the macrosegregations creation - 65 ton ingot – Fixed solid
1h 30min 3h 45min 8h 10min 20h
ΔC/C0
39
Understanding the macrosegregations creation - 65 ton ingot – Fixed solid
1h 30min 3h 45min 8h 10min 20h
ΔC/C0
40
Understanding the macrosegregations creation - 65 ton ingot – Fixed solid
1h 30min 3h 45min 8h 10min 20h
ΔC/C0
++
––
++
41
Understanding the macrosegregations creation - 65 ton ingot – Moving grains
1h 15min 2h 40min 3h 45min 20h
T [ºC] ΔC/C0
Grain density
Grain density [m-3]
ΔC/C0
42
Understanding the macrosegregations creation - 65 ton ingot – Moving grains
1h 15min 2h 40min 3h 45min 20h
T [ºC] ΔC/C0
Grain density
Grain density [m-3]
ΔC/C0
43
Understanding the macrosegregations creation - 65 ton ingot – Moving grains
1h 15min 2h 40min 3h 45min 20h
T [ºC] ΔC/C0
Grain density
Grain density [m-3]
ΔC/C0
++
––
44
Understanding the macrosegregations creation - 65 ton ingot – Moving grains
1h 15min 2h 40min 3h 45min 20h
T [ºC] ΔC/C0
ΔC/C0ΔC/C0
45
Comparison with experimental results - 65 t ingot
46
Comparison with experimental results - 65 t ingot
47
Comparison with experimental results - 65 t ingot
48
Origin of equiaxed grains origin ? ECT modeling with Solid
Each structure has its own solid phase, extra- and intra-dendritic liquid phases.
Equiaxed grains are blocked when they enter in a REV with columnar struct. already present
Columnar
Equiaxed
Modelling of Columnar-to-equiaxed and equiaxed-to-columnar transitions in ingots using a multIphase model, Leriche et all, MCWASP 2015
49
Application to a 6t2 steel (Asco Industries)Element C Si Cr Mn Ni S P Mo
wt % 1.01 0.23 1.34 0.33 0.11 0.021 0.015 0.03
2,7
m
~ 0,65 m
Co
lum
nar
zo
ne
Eq
uia
xed
z
on
e
Structures distribution
Mixed structures (branched grains) Dendritic morphology
Globular morphology
Cast iron mold
PhD T. Mazet 1995
50
6t2 ingot – Pre process with Solid
Adiabatic
Con
vect
ive
+ R
a dia
tive
h eat
tran
sfer
t
Symetry
mold
ingot
refractory
Adiabatic
51
6t2 steel ingot – Evolution of Carb and Temp
52
6t2 steel ingot – ECT position
SimulationExperiment
Hei
gh
t (m
) Simulation
53
Continuous casting application -
Inoculants moving integration
Grains size computation
Thermo-solutal convection
Ingot
Ingot mold
Mold
Water streaming
Solid
54
Semi continuous casting Al-Cu
Thermo-metallurgical stationary conditions set up
Temperature distribution Cu segregration Structure distribution
Application Constellium
55
Summary: Solid ?
Solid is a simulation software dedicated to casting ingot
Solid offersMulti components alloysMaterial molding differentiationFilling (simplified approach)
Solid predicts Global process resultsCasting defaultsSegregation and structure correlated to final properties
56
Sciences Computers Consultants(Headquarters)
10 rue du plateau des GlièresF-42000 Saint Etienne+33 (0)4 77 49 75 80
Sciences Computers Consultants Inc.(Sales office North America)1455 rue Drummond, Suite B
Montréal H3G 1W3+1 514 687 4708
Http://www.scconsultants.comHttp://www.mixingsimulation.technology