Proceedings of the 7th Pacific Rim International Conference on

Modeling of Casting and Solidification Processes

Dalian, China, August 19-22, 2007

RECENT DEVELOPMENT OF MODELING OF

CASTING AND SOLIDIFICATION PROCESSES

Edited by JIN Jun-ze, YAO Shan,

HAO Hai, WANG Tong-min

Proceedings of Modeling ofCasting and Solidification Processes W, 2007

Edited by JINJun-ze,et al.

Table of Contents

Preface

Organization

Keynotes

Recent development and challenges of CAE in castingltsuo Ohnaka, Akira Sugiyama, Jindong Zhu and Toshihiko Murakami 3

Development of an advanced rheo-diecasting technique based on H-NCM

CP. Hong and J,M. Kim 9

The role of as-cast porosity, stress and strain on hot tearing in direct chill cast AA5182

S.L. Cockcroft, A.B. Phillion, J. Mitchell, DM. Maijer and P.D. Lee 17

Experimental investigation of drop formation by ink jet printingHsinHung Chou, MingHsiu Tsai, Chi Wei Chou, WengSing Hwang and Hao-Long Chen 25

Spray forming and advanced materials

Qingchun LI, Fuyang CAO, Jun SHEN, Jianfei SUN and Chengsong CUI 33

Trying to remember the early days of casting simulation in JapanNIYAMA Eisuke, UCHIDA Toshio and ANZAI Koichi 45

Multiphase Flow Simulation in Mold Filling Process with Level Set Method

JingHAO, Liliang Chen, Dunming Liao and Jianxin Zhou 51

Heat and Mass Flow Modeling for Casting and Solidification Processes

Amethod of inverse evaluation for interface heat transfer coefficient between

aluminium alloys and cooling water

Zhonglin HOU, Shan YAO,Jianan YE

, Guiyong WU and Junze JIN 65

Modelling of the solidification of immiscible alloysHaili Li and Jiuzhou Zhao 73

Study of accretion formation near gas bottom-blowing tuyere in steel making process

by using a low temperature wax model

Chiung Chieh Kuo, Yu Pin Huang, Weng Sing Hwang, Chien Chih Yen and Tian IWu 81

Modification and verification of accretion similarity conversion method for

pyrometallurgical gas bottom-blowing process

Yu Pin Huang, Kuo Chiung Chieh, Weng Sing Hwang, Jia Shyan Shiau and SMh Hsien Liu 89

V

Numerical simulation for low pressure die casting ofAl-alloy motor enclosure and

technology improvementGuofa Ml, Xiangyu LIU, Kuangfei WANG and Lei LI 97

Modeling of direct chill casting of superlight Mg-Li alloysShuyan Shi, Hai Hao, Xingguo Zhang, Peng Guo and Junze Jin 105

Analyses of the influencing factors of rotating impeller degassing process and water

simulation experimentGuofa Mi, Xiangyu Liu, Kuangfei Wang, Shouping Qi and Hongwei Wang 113

Fluid Flow Modeling for Casting and Solidification Processes

Numerical simulation of filling process in casting with lattice Boltzmann method

Jianglin Huang, Liliang Chen, Dimming Liao and Jianxin Zhou 123

Mold filling simulation by finite difference method with high order scheme in regularcartesian gridTomoki Sawada and Koichi Anzai 131

Direct simulation of fluid flow and shrinkage using particle methodHirata NAOYA and Anzai KOICHI 139

Mold filling simulation of semi-solid AZ9 ID Magnesium AlloyRuey-Jer Weng, Jer-Haur Kuo,Weng-Sing Hwang,Chee-Ang Loong and Cheng-Kuei Jen 145

New algorithm of molten metal flow and heat transfer during casting processesXun SUN, Yang GUAN, Hailan LI, Shiyan ZHANG, Junqing WANG and Bo YU 153

Simulation of mold filling and solidification on gravity casting ofAl-Si alloy (A357)

Guofa M, Hengtao ZHAO, Kuangfei WANG and Zhi-anXU 159

Flow field and temperature filed simulation of directional solidification of

polycrystalline silicon ingotsShuyan Shi, Hai Hao

, Xingguo Zhang, Shan Yao, Yuanyuan Li and Junze JIN 167

The comparison of filling process between the LFC and simple cavity foundry bynumerial simulation

Jianan YE, Shan YAO, Guiyong WU, Xiaolin ZHAO and Junze JIN 175

Numerical simulation of filling process of crankshaft made from nodular cast ironXiaolin ZHAO, Shan YAO, Jianan YE, Guiyong WU and Junze JIN 179

Multi objective optimization of plunger speed using criterion for cold shut in die castingSAKURAGI Takuya and NAKAYAMA Ichiyou 185

The study of the modification of iteration convergence criterion for mold fillingRi Li, YingcuiJu, Cuigu Wu, Hanlong Liu andXingchuan Xia ..193

Numerical modeling of electron beam melting and casting of Ti-6A1-4V alloy ingotJindong Zhu, Daan Maijer, Steven Cockcroft, Xuanhe Zhao, David Tripp and Stephen Fox 201

VI

Study of micro-droplet behavior for a piezoelectric inkjet printing device usinga double pulse voltage pattern

Hsuanchung Wu, Jhenghong Chen, Wengsing Hwang and Hueyjiuan Lin 211

Crystal Growth and Microstructure Modeling

Modeling of dendritic structure and microsegregation in solidification of Al-rich

quaternary alloysTing Dai, Mingfang Zhu, Shuanglin Chen, Weisheng Cao and Chun-Pyo Hong 223

Cellular automaton modeling of solidification microstructure ofAl-Si alloyHongwei ZHANG, Keiji NAKAJIMA, Qiang WANG, Tie LIU, Wei XING and Jicheng HE 233

Phase field simulation of polycrystalline solidification in binary alloys

Junjie Li, Jincheng Wang and Gencang Yang 241

Cellular automaton - lattice Boltzmann model for the simulation of dendritic growthwith melt convection

Dongke Sun, Mingfang Zhu,Dierk Raabe and Chun-Pyo Hong 249

Phase-field simulation of lamellar growths for a binary eutectic alloy

Xinzhong Li, Jingjie Guo, Yanqing Su, Shiping Wu andHengzhi Fu 259

A CA-FD model for directional solidification ofAl-7%Si alloy with DC current

Xiaohui FENG, Yuansheng YANG and Wenhui TONG 267

Phase selection ofAISI304 stainless steel during directional solidification

Junwei FU, Yuansheng YANG, Jianchao MA.Wenhui TONG and Jingjie GUO 275

Influence of crystal orientation on growth velocity of polycrystalline silicon for solar cells

Hirofumi Miyahara, Yusuke Nakamura, Ichihito Narita and Keisaku Ogi 281

3D multi-phase field simulation on binary eutectic isothermal solidification

Yujuan Yang, Jincheng Wang, Yuxiang Zhang, Yaochan Zhu and Gencang Yang 289

Numerical simulation of solidification structure formation of casting in multi-component

alloy using PF-CA method

Kenichi Ohsasa, Yukinobu Natsume and Kiyotaka Matsuura 295

A 2-dimension cellular automaton modelling ofGTAW solidification microstructure

Xiaohu Deng, Liwen Zhang, Jibin Pei and Delun Guo 303

Microstructure evolution of the shell in centrifugal castingY.S. JANG, M.H. LEE

,J.Y. MOON and CP. HONG

,.311

Simulation Method and Calculation Algorithm

Integrated database construction for casting processes

In-Sung Cho, Seung-Mok Yoo, Chae-Ho Lim and Jeong-Kil' Choi.^..u.....-v., 321

Calculation time reduction of solidification analysis by implicit-explicit FDM

VII

ONDA HiroshUOlKAWA Katsunari and ANZAI Koichi 329

Application of advanced smooth technology to post-processing of finite difference data

Shengyong PANG, Liliang CHEN, Ruixiang LIU, Jianxin ZHOU and Dimming LIAO 337

Uneven FDM mesh technology and its application on casting's mold filling simulation

Jianxin ZHOU, Liliang CHEN, Dunming LIAO and Ruixiang LIU 345

Development of integrated simulation portal for casting processes on the net

Sang-Hyun CHO, Jeong-Tae KIMand Jeong-Kil CHOI 353

The construction of the casting expert system based on the database by utilizingsimulation and modeler

C.H. Lim, IS. Cho, S.M. Yoo and J.K. Choi 361

Study on cut-cell method for casting process simulation

Young-Sim CHOI, Jun-Ho HONG, Ho-Young HWANG and Jeong-Kil CHOI 371

Micro- and Macro-segregation

Using a multiphase approach to study the mechanisms which cause macrosegregationsMenghuai Wit, Laszlo Konozsy, Autumn Fjeld and Andreas Ludwig 379

Analysis of macrosegregation formation under the application of various types of

magnetic fields

X.D. Wang, A. Ciobanas, Y. Fautrelle, G. Zimmermann and A. Weiss 389

Effect of parameters on microsegregation patterns of Ni-Cu binary alloyChangsheng ZHU, Li FENG, Zhiping WANG andRongzhen XIAO 397

Stress and Deformation Modeling

Estimation and reduction of deformation defects in steel castings by a CAE system

Shinya Kanou, Kenji Ogawa, Akihiro Sato, Itsuo Ohnaka, Akira Sugiyama and Fumiaki Kinoshita 407

Simulation of thermal stresses and hot crack in the heavy ingot mould duringsolidification process

Lugui Chen, Ping Ma, Xiuhong Kang, Lijun Xia, Dianzhong Li and Yiyi Li 413

Research on the thermal simulation compression of spheroidal cast iron

Kai Qi, Zhixin Wang, Fudong Bai, Tingju Li and Meiqing Sun 423

Three-dimensional FEM numerical simulation of the die spinningZhi Yang, Wenlong Zhou, Liming Liu and YiXu 429

Continuous Casting/Direct Chill Casting

Simulation of continuous casting slab in induction heating processHao LIU, Liliang Chen, Jianxin Zhou and Dunming Liao 439

Crystallization of mold flux for continuous easting of steel by heat treatment

vni

Hidenori Mizuno, Hisao Esaka, Kei Shinozuka and Manabu Tamura 447

Mathematical modeling of the horizontal DC casting process for T-ingot productionM. Lane, M. DiCiano, DM. Maijer, S.L. Cockcroft and A. Larouche 455

Modeling wire rod of continuous castingHungju Chang, Weihien Jang, Dechang Tsai, Weng-sing Hwang, Longsun Chao and Yangming Lit 465

Coupled numerical simulation of flow field and temperature field for inner-outer coupled

cooling slab continuous castingXiaochao CUI, Yanjuan JIN, Zhu ZHANG andJunting ZHANG 473

Numerical simulation of mold filling and solidification process for beam blank

continuous casting

Yanjuan JIN, Xiaochao CUI, Puyu ZHANG and Zhu ZHANG 481

Investigation on mould heat transfer in continuous casting of round billet

Liangliang Guo,Man Yao, Xudong Wang and Hebi Yin 489

Mathematical and PIV physical simulation for melt flow in continuous casting of

aluminum alloy slab

Xu Xuan, Xingguo Zhang, Huanyue Zhang, Canfeng Fang and Hai Hao 499

Electromagnetic Coupling

Effect of multi-electromagnetic fields on the quality of continuous casting hollow billet

Qi ZHANG, Tongmin WANG, Tingju LI andJunze JIN 509

Numerical simulation of thermal and flow fields in induction skull melting process

GuanxiaXUE, Tongmin WANG, Yanqing SU, Too SONG, Qi ZHANG,Jingjie GUO, Tingju LI and

Junze JIN 517

Research of computing method of the magnetic field distribution in the soft-contact mold

Xianshu ZHENG, Fangyi QU, Yongdong ZHOU and Junze JIN 525

Computer simulation of electromagnetic field and shape of liquid column in round ingotelectromagnetic castingFeng Qi, Tingju Li, Junze Jin and Yihai Sun 533

Study on the form position of the air gap between mould and ingot in electromagneticcontinuous castingFeng Qi , Tingju Li and Junze Jin 541

Temperature simulation of electromagnetic continuous casting ofAZ61 magnesium billets

Yue Qiu, Xingguo Zhang, Hai Hao, Peng Guo and Canfeng Fang 545

Effect on the movement behavior of non-metallic particles under electromagnetic field

Zhongtao Zhang, Qingtao Quo,Jim ZHANG and Tingju LI,

553

Two-phase flow simulation on hollow billet solidification under rotating and traveling

magnetic fields

IX

Tongmin Wang, Qi Zhang, Tingju Li and Junze Jin 559

Casting Defects and Their Prediction

Hot tearing of aluminum alloys: influence of intermetallic compounds crystallizationat later stage of solidification

NAGAUM Hiromi and UMEDA Takateru 569

Modeling of centerline defects and it's application on soft reduction of continuous casting

Tingli WANG, Shan YAO,Hai HAO, Zhonglin HOU and Junze JIN 577

Prediction and reduction of inclusion defects in steel castings by a CAE system

Shinya Kanou, Kenji Ogawa, Itsuo Ohnaka, Akira Sugiyama and Fumiaki Kinoshita...585

Numerical simulation methods to predict the gas porosity defects

Jun-Ho HONG, Young-Sim CHOI, Ho-Young HWANG andJeong-Kil CHOI 591

Advanced Solidification and Materials Processing

In-situ observation of solidification of Sn-Ag alloysHisao Esaka, Mizuho Sakuta, Kei Shinozuka and Manabu Tamura 601

Control of solidified structures and intergranular precipitations in Al-Li binary alloys byhigh magnetic fields

Tie Liu, Qiang Wang, Ke Wang, Yi Yuan, Hongwei Zhang,Keiji Nakajima andJicheng He 607

An efficient tabulation technique for multi-scale solidification modeling of

multi-component alloysQ. Du, D.G. Eskin and L.Katgerman 613

Effects of diameters and chiralities on the optical properties of single-walled carbon

nanotubes by first principlesYu Zhang, Bin Wen, Jijun Zhao, Mingshan Zhao, Xingguo Zhang and Tingju Li 621

Manufacturing of silicon ingot by metallurgic castingJian ZHANG, Xiaodong MA, Zhongtao ZHANG and Tingju LI 629

Assessing controllability of low pressure die casting using process simulation

Xinmei SHI, Daan M. MAIJER and Guy DUMONT 635

Numerical study on rheocasting A356 alloy using cooling slope methodXiaoli Zhang, Tongmin Wang, Tingju Li, Haitao Teng.Bin Wen, Shuisheng Xie and

Junze Jin 643

Pattern-less rapid casting and rapid process evaluation

Changke YE, Shan YAO, Jianan YE, Guiyong WU and Junze JIN 649

Development of new semi-solid method and practical application to bearing bracketsJ.G. Sim, J.Y. Moon, J.M. Kim and CP. Hong 657

X

Industrial Applications of Modeling and Simulation

Computer modelling of deformation and annealing processes and their industrial

applicationsHualongLi, PARK Jong-Tae, PARK Sooho and SZPUNAR Jerzy 665

Experience of industrial application of commercial software for casting processes

simulation

V.P. Monastyrskiy and I.L.Koynov 671

Numerical simulation and technology optimization for producing large-sized castingsJunqing WANG, Xun SUN, Yang GUAN, Penghua WANG, Hailan LI, Bo YU, Limei BAI and

Xinzhi SUN 679

Prediction of room temperature mechanical properties in aluminium castingsZhanli GUO, Nigel SAUNDERS, Peter MODOWNIK and Jean-Philippe SCHILLE 687

Application of mathematical models to development of new open mould conveyor

ingot casting technologyJ. Grandfield, T. Nguyen, P. Rohan, V. Nguyen, M. Prakash and P. Cleary ..701

XI