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Numerical modelling of acoustic streaming during the ultrasonic melt treatment of direct-chill (DC) casting

Numerical modelling of acoustic streaming during the ultrasonic melt treatment of direct-chill (DC) casting

Lebon, Gerard S. B., Salloum-Abou-Jaoude, Georges, Eskin, Dmitry, Tzanakis, Iakovos, Pericleous, Koulis ORCID: 0000-0002-7426-9999 and Jarry, Philippe (2019) Numerical modelling of acoustic streaming during the ultrasonic melt treatment of direct-chill (DC) casting. Ultrasonics Sonochemistry, 54. pp. 171-182. ISSN 1350-4177 (doi:https://doi.org/10.1016/j.ultsonch.2019.02.002)

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Abstract

Acoustic streaming and its attendant effects in the sump of a direct-chill (DC) casting process are successfully predicted under ultrasonic treatment for the first time. The proposed numerical model couples acoustic cavitation, fluid flow, heat and species transfer, and solidification to predict the flow pattern, acoustic pressure, and temperature fields in the sump. The model is numerically stable with time steps of the order of 0.01 s and therefore computationally attractive for optimization studies necessitating simulation times of the order of a minute. The sump profile is altered by acoustic streaming, with the slurry region depressed along the centreline of the billet by a strong central jet. The temperature gradient in the transition zone is increased, potentially interfering with grain refinement. The cooling rate in the sump is also altered, thereby modifying the dendrite arm spacing of the as-cast billet. The relative position of the sonotrode affects the sump profile, with the sump depth decreased by around 5 mm when the sonotrode is moved above the graphite ring level by 100 mm. The acoustic streaming jet penetrates into the slurry zone and, as a result, the growth direction of dendritic grains in the off-centre position is altered.

Item Type: Article
Additional Information: © 2019 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY license (http://creativecommons.org/licenses/BY/4.0/)
Uncontrolled Keywords: acoustic cavitation; liquid aluminium; direct-chill casting; numerical modelling; ultrasonic melt processing; non-linear acoustics
Subjects: Q Science > QA Mathematics
Faculty / Department / Research Group: Faculty of Architecture, Computing & Humanities
Faculty of Architecture, Computing & Humanities > Centre for Numerical Modelling & Process Analysis (CNMPA)
Faculty of Architecture, Computing & Humanities > Centre for Numerical Modelling & Process Analysis (CNMPA) > Computational Science & Engineering Group (CSEG)
Faculty of Architecture, Computing & Humanities > Department of Mathematical Sciences
Last Modified: 25 Apr 2019 12:57
Selected for GREAT 2016: None
Selected for GREAT 2017: None
Selected for GREAT 2018: None
Selected for GREAT 2019: None
URI: http://gala.gre.ac.uk/id/eprint/22922

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