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Materials Processing FFUUNNDDAAMMEENNTTAALLSS2023 EDITED BY Samuel Wagstaff Alexandra Anderson Adrian S. Sabau The Minerals, Metals & Materials Series · · Samuel Wagstaff Alexandra Anderson Adrian S. Sabau Editors Materials Processing Fundamentals 2023 Editors SamuelWagstaff AlexandraAnderson OculatusConsulting GopherResource Marietta,GA,USA Tampa,FL,USA AdrianS.Sabau OakRidgeNationalLaboratory OakRidge,TN,USA ISSN 2367-1181 ISSN 2367-1696 (electronic) TheMinerals,Metals&MaterialsSeries ISBN 978-3-031-22656-4 ISBN 978-3-031-22657-1 (eBook) https://doi.org/10.1007/978-3-031-22657-1 ©TheMinerals,Metals&MaterialsSociety2023 Thisworkissubjecttocopyright.AllrightsaresolelyandexclusivelylicensedbythePublisher,whether thewholeorpartofthematerialisconcerned,specificallytherightsoftranslation,reprinting,reuse ofillustrations,recitation,broadcasting,reproductiononmicrofilmsorinanyotherphysicalway,and transmissionorinformationstorageandretrieval,electronicadaptation,computersoftware,orbysimilar ordissimilarmethodologynowknownorhereafterdeveloped. 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CoverIllustration:Left:FromChapter“TowardMeso-scaleModellingofSlagFoamingPhenomenain Pyrometallurgy”,QuinnG.Reynoldsetal.,Figure5:Dispersed-phasemarkerphasesandvelocitiesforug =0.02m/scase.https://doi.org/10.1007/978-3-031-22657-1_10.Right:FromChapter“EffectofWearing ImpellersonMultiphaseFlowandDesulfurizationDuringKRMechanicalStirringProcess”,WeiChen etal.,Figure3:Effectofthenumberofemployedheatsoftheimpelleronthedistributionofflowpattern, ainitialstate,bafteremployed120heats,cafteremployed220heats.https://doi.org/10.1007/978-3- 031-22657-1_2.Bottom:FromChapter“SimulationofFerroalloyCastinginCopperMoulds”,HaifeiAn etal.,Figure8:Temperaturefieldofthemouldat50sbeforedemoulding.https://doi.org/10.1007/978- 3-031-22657-1_18. ThisSpringerimprintispublishedbytheregisteredcompanySpringerNatureSwitzerlandAG Theregisteredcompanyaddressis:Gewerbestrasse11,6330Cham,Switzerland Preface ThesymposiumMaterialsProcessingFundamentalsishostedattheAnnualMeeting ofTheMinerals,Metals&MaterialsSociety(TMS)astheflagshipsymposiumofthe ProcessTechnologyandModelingCommittee.Itisauniqueopportunityforinter- disciplinarypresentationsanddiscussionsabout,amongothers,processing,sensing, modeling,multi-physics,computationalfluiddynamics,andthermodynamics. Thematerialscoveredincludeferrousandnon-ferrouselements,andtheprocesses range from mining unit operations to jointing and surface finishing of materials. Acknowledging that modern processes involve multi-physics, the symposium and its proceedings allow the reader to learn the methods and outcome of other fields’ modelingpractices,oftenenablingthedevelopmentofpracticalsolutionstocommon problems.Modelingofbasicthermodynamicandphysicalpropertiesplaysakeyrole, along with computational fluid dynamics and multi-phase transport and interface modeling. Contributions to the proceedings include applications such as steel processing, modeling of steel and non-ferrous alloys treatments for properties control, multi- physics, and computational fluid dynamics modeling for molten metal processes andpropertiesmeasurement.Extractive,recovery,andrecyclingprocessmodeling isalsopresented,completingabroadviewofthefieldandpracticesofmodelingin materialsprocessing. The engagement of TMS and committee members to chair sessions and review manuscriptsmakesthissymposiumanditsproceedingspossible.Theeditorandco- editorsacknowledgetheinvaluablesupportandcontributionofthesevolunteersas wellasTMSstaffmembers,inparticular,PatriciaWarren,TrudiDunlap,andMatt Baker. SamuelWagstaff AlexandraAnderson AdrianS.Sabau v Contents PartI ProcessOptimization ModelingofMacro-scaleReactionEffectsinaSecondaryLead ReverberatoryFurnace ............................................ 3 NicholasJ.Walla, EmilyA.Higley, ArminK.Silaen, AlexandraAnderson,JosephGrogan,andChennQ.Zhou Effect of Wearing Impellers on Multiphase Flow and Desulfurization During KR Mechanical Stirring Process ........................................................... 15 WeiChen,YanyuZhao,andLifengZhang PostProcessingApproachtoModelMicrosilicaFormation ............ 25 KurianJ.Vachaparambil,KristianEtienneEinarsrud,HalvorDalaker, andStefanAndersson ThermodynamicsandKineticsofCokeBreezeCombustionUnder DifferentOxygenContentintheSinteringProcess .................... 35 DongqingWang,WenPan,ZhixingZhao,andYapengZhang PartII ContinuousCasting Inverse Calculation of Time-Spatial Varying Mold Heat Flux DuringContinuousCastingfromFastResponseThermocouples ....... 47 HaihuiZhang,HuiqiangShen,andPengchengXiao Quality Prediction of Hot Rolled Products and Optimization ofContinuousCastingProcessParametersBasedonBigData Mining ........................................................... 65 ZibingHou,ZhiqiangPeng,QianLiu,andGuanghuaWen StudyontheUniformityofSurfaceTemperatureofContinuous CastingSlabBasedonSolidificationandHeatTransferSimulations .... 75 YadongWangandLifengZhang vii viii Contents HowtoPreventPorosityDefectsinSteelCastingComponent .......... 83 IzudinDugic FluctuantSolidificationBehaviorintheCenterlineofContinuous CastingBilletsBasedonNumericalSimulation ....................... 97 DongweiGuo,ZihangZeng,KunhuiGuo,andZibingHou PartIII SlagandLadleTreatment Toward Meso-scale Modelling of Slag Foaming Phenomena inPyrometallurgy ................................................. 113 QuinnG.ReynoldsandOliverF.Oxtoby SimulationontheSlagDesulfurizationDuringtheLFRefining inaGas-BlowingLadle ............................................ 125 JujinWang,YuexinZhang,BinyuLyu,andLifengZhang AModifiedThermodynamicSoftwaretoControltheComposition ofInclusionsDuringCalciumTreatmentProcess ..................... 135 WeijianWangandLifengZhang PartIV NewProcessesandInsights ReductantFormationEnthalpyinDCFerrochromeSmelting: MerelyAcademicorFundamentaltoOperation? ..................... 145 H.J.Oterdoom,M.A.Reuter,andJ.H.Zietsman MeasuringandProcessingofElectricalParametersinaSubmerged ArcFurnace ...................................................... 161 HákonValurHaraldsson, HalldórTraustason, YonatanA.Tesfahunegn,MereteTangstad,andGurúnSævarsdóttir VolatilizationBehaviorofArsenicfromaHematiteOreDuring Non-isothermalHeatinginArgonAtmosphere:AnOverview .......... 171 E.K.ChiwandikaandS.-M.Jung ComprehensiveRecoveryofElementalSulfurandSulfideMinerals fromPressureAcidLeachingResidueofZincSulfideConcentrate withanIntegratedFlocculationFlotation-HotFiltrationProcess ....... 185 GuiqingLiu, BangshengZhang, ZhonglinDong, FanZhang, FangWang,TaoJiang,andBinXu PartV AdditiveManufacturingandMaterialsFirstPrinciples Automatic Process Mapping for Ti64 Single Tracks in Laser PowderBedFusion ................................................ 199 TobyWilkinson,MassimilianoCasata,andDanielBarba Contents ix PartVI PosterSession SimulationofFerroalloyCastinginCopperMoulds .................. 213 HaifeiAn, WeijianTian, HaoChen, ShaojunChu, LihongLi, andHaoBai EffectsofTemperatureandDensityonTransitionSlabLength DuringSteelGradeTransition ...................................... 227 SichengSong,YanhuiSun,YaoguangLi,andChaoZhuo MathematicalSimulationStudyontheEffectofNozzleSideHole StructureParametersontheBehaviorofMoltenSteelinStainless SteelMold ........................................................ 241 Si-kunPeng,Ming-meiZhu,Kun-chiJiang,andCheng-hongLi AuthorIndex ...................................................... 251 SubjectIndex ..................................................... 253 About the Editors Samuel Wagstaff is currently a partner at Oculatus Consulting, specializing in aluminum processing and product development. He holds degrees in Mechanical Engineering from Cornell University (B.S.) and Mate- rials Science from MIT (M.S., Sc.D.). Previously as the Lead Scientist at Novelis, he led new product and process development for the entire R&D ecosystem acrossthreecontinents.Currently,Dr.Wagstafffocuses on increasing profitability and productivities of non- ferrous products by process improvement and funda- mentalresearch.Hehashelpedtodesignover1million tons of recycle capacity in the aluminum sector and is theauthorofover35patents.Samiscurrentlyserving astheprincipalinvestigatorona$1MReMADEgrant to develop technology to improve the recyclability of organicladenaluminumscrap. AlexandraAndersonPh.D.,PMP,isanR&Dmanager at Gopher Resource, LLC, an environmental solutions company specializing in lead battery recycling. Her work focuses on driving furnace productivity and effi- ciencyinitiativesthroughcomputationalfluiddynamic (CFD) modeling and implementing novel equipment designs.Currently,sheisalsotheprincipalinvestigator for a DOE HPC4Manufacturing partnership between Gopher Resource and Oak Ridge National Lab inves- tigating high-fidelity multi-phase furnace modeling. AlexandraobtainedherB.S.inMechanicalEngineering from Gonzaga University and her M.S. and Ph.D. in Metallurgical and Materials Engineering from the xi xii AbouttheEditors Colorado School of Mines. Her dissertation investi- gated fluid flow and thermal profiles within secondary lead reverberatory furnaces using CFD techniques. AlexandraisactiveinTheMinerals,Metals&Materials Society (TMS), where she serves as the vice-chair of theProcessTechnologyandModelingCommittee;she wasalsotherecipientofthe2021TMSExtractionand Processing Division (EPD) Young Leader Award. Her scholarlyactivitiesincludeninepeer-reviewedpublica- tions, co-editorships of seven special topics for JOM, as well as several podium presentations at national conferences. Adrian S. Sabau received an Engineer Diploma in MechanicalandMaterialsProcessingfromtheUniver- sityofCraiova,Romania,andaPh.D.degreeinMechan- icalEngineeringfromSouthernMethodistUniversityin 1996. In 1999, Dr. Sabau joined Oak Ridge National Laboratory as a Research Staff Member of Mate- rials Science and Technology, where he worked as a SeniorResearchStaffMemberfrom2008.Since2018, Dr. Sabau has been a Computational Materials Scien- tistintheComputationalSciences&EngineeringDivi- sion. Dr. Sabau seeks to advance the materials processing, metal casting, photonic processing, and materials for energy applications through the develop- mentofcomputationalfluiddynamicsandexperimental methodologies for the property measurement, process analysis, and materials behavior in response to condi- tions experienced in service. Dr. Sabau is an ASME fellow,andASMfellow,andtherecipientofthreeR&D 100awardsinprocesssciences.Hewasgranted7patents andhaspublished169technicalpapers.