Materials Processing Fundamentals 2023

246 Pages·2023·7.317 MB·English

by  Samuel Wagstaff, Alexandra Anderson, Adrian S. Sabau

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
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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.