Numerical Modeling of Transient Two-Phase Flow and the Coalescence and Breakup of Bubbles in a Continuous Casting Mold

The multiphase flow and spatial distribution of bubbles inside a continuous casting (CC) mold is a popular research issue due to its direct impact on the quality of the CC slab. The behavior of bubbles in the mold, and how they coalesce and break apart, have an important influence on the flow pattern and entrapment of bubbles. However, due to the limitations of experiments and measurement methods, it is impossible to directly observe the multiphase flow and bubble distribution during the CC process. Thus, a three-dimensional mathematical model which combined the large eddy simulation (LES) turbulent model, VOF multiphase model, and discrete phase model (DPM) was developed to study the transient two-phase flow and spatial distribution of bubbles in a continuous casting mold. The interaction between the liquid and bubbles and the coalescence, bounce, and breakup of bubbles were considered. The measured meniscus speed and bubble diameter were in good agreement with the measured results. The meniscus speed increased first and then decreased from the nozzle to the narrow face, with a maximum value of 0.07 m/s, and appeared at 1/4 the width of the mold. The current mathematical model successfully predicted the transient asymmetric two-phase flow and completely reproduced the coalescence, bounce, and breakup of bubbles in the mold. The breakup mainly occurred near the bottom of the submerged entry nozzle (SEN) due to the strong turbulent motion of the molten steel after hitting the bottom of the SEN. The average bubble diameter was about 0.6 mm near the nozzle and gradually decreased to 0.05 mm from the nozzle to the narrow face. The larger bubbles floated up near the SEN due to the effect of their greater buoyancy, while the small bubbles were distributed discretely in the entire mold with the action of the molten steel jet. Overall, the bubbles were distributed in a fan shape. The largest concentration of bubbles was in the lower part of the SEN and the upper edge of the SEN outlet.     

Numerical and Experimental Study on the Direct Chill Casting of Large-Scale AA2219 Billets via Annular Coupled Electromagnetic Field

The internal coupled electromagnetic melt treatment (ICEMT) method is firstly proposed to produce high-quality and large-sized aluminum alloy billets. A three-dimensional model was established to describe the ICEMT process of direct chill casting (DC casting). The effect of ICEMT on the fluid flow patterns and temperature field in the DC casting of ϕ880 mm AA2219 billets is numerically analyzed. Moreover, the mechanisms of the ICEMT process on grain refinement and macrosegregation were discussed. The calculated results indicate that the electromagnetic field appears to be coupled circinate at the cross section of the melt, the fluid flow becomes unstable accompanied by the bias flow, and the temperature profiles are significantly more uniform. An experimental verification was conducted and the results prove that compared with traditional direct chill casting, the microstructures of the AA2219 large-scale billet under the ICEMT process are uniform and fine.     

Numerical Simulation and Experimental Investigation of the Preparation of Aluminium Alloy 2A50 Semi-Solid Billet by Electromagnetic Stirring

Electromagnetic stirring (EMS) has become one of the most important branches of the electromagnetic processing of materials. However, a deep understanding of the influence of the EMS on the thermo-fluid flow of the aluminium alloy melt, and consequently the refinement of the microstructure is still not available. This paper investigated the influence of the operating parameters of EMS on the magnetohydrodynamics, temperature field, flow field, and the vortex-shaped structure of the melt as well as the microstructure of the aluminium alloy 2A50 billet by numerical simulation and experiments. The operating parameters were categorised into three groups representing high, medium, and low levels of Lorentz forces generated by EMS. The numerical simulation matched well with the experimental result. It was found that a high level of EMS can improve the uniformity of the temperature and flow fields. The maximum speed was observed at the radius of around 25 mm under all EMS levels. Both the depth and diameter of the vortex-shaped structure generated increased with the enhancement in the EMS level. The average grain size of the edge sample of the billet was reduced by 48.3% while the average shape factor was increased by 51.0% under the medium-level EMS.     

Microstructures and Macrosegregation of Al–Zn–Mg–Cu Alloy Billet Prepared by Uniform Direct Chill Casting

In this study, large-sized Al–Zn–Mg–Cu alloy billets were prepared by direct chill casting imposed with annular electromagnetic stirring and intercooling; a process named uniform direct chill casting. The effects of uniform direct chill casting on grain size and the alloying element distribution of the billets were investigated and compared with those of the normal direct chill casting method. The results show that the microstructures were refined and the homogeneity of the alloying elements distribution was greatly improved by imposing the annular electromagnetic stirring and intercooling. In uniform direct chill casting, explosive nucleation can be triggered, originating from the mold wall and dendrite fragments for grain refinement. The effects of electromagnetic stirring on macrosegregation are discussed with consideration of the centrifugal force that drives the movement of melt from the central part towards the upper-periphery part, which could suppress the macrosegregation of alloying elements. The refined grain can reduce the permeability of the melt in the mushy zone that can restrain macrosegregation.     

R-HPDC Process with Forced Convection Mixing Device for Automotive Part of A380 Aluminum Alloy

The continuing quest for cost-effective and complex shaped aluminum castings with fewer defects for applications in the automotive industries has aroused the interest in rheological high pressure die casting (R-HPDC). A new machine, forced convection mixing (FCM) device, based on the mechanical stirring and convection mixing theory for the preparation of semisolid slurry in convenience and functionality was proposed to produce the automotive shock absorber part by R-HPDC process. The effect of barrel temperature and rotational speed of the device on the grain size and morphology of semi-solid slurry were extensively studied. In addition, flow behavior and temperature field of the melt in the FCM process was investigated combining computational fluid dynamics simulation. The results indicate that the microstructure and pore defects at different locations of R-HPDC casting have been greatly improved. The vigorous fluid convection in FCM process has changed the temperature field and composition distribution of conventional solidification. Appropriately increasing the rotational speed can lead to a uniform temperature filed sooner. The lower barrel temperature leads to a larger uniform degree of supercooling of the melt that benefits the promotion of nucleation rate. Both of them contribute to the decrease of the grain size and the roundness of grain morphology.     

Productivity Enhancement by Prediction of Liquid Steel Breakout during Continuous Casting Process in Manufacturing of Steel Slabs in Steel Plant Using Artificial Neural Network with Backpropagation Algorithms

Breakout is one of the major accidents that often arise in the continuous casting shops of steel slabs in Bokaro Steel Plant, Jharkhand, India. Breakouts cause huge capital loss, reduced productivity, and create safety hazards. The existing system is not capable of predicting breakout accurately, as it considers only one process parameter, i.e., thermocouple temperature. The system also generates false alarms. Several other process parameters must also be considered to predict breakout accurately. This work has considered multiple process parameters (casting speed, mold level, thermocouple temperature, and taper/mold) and developed a breakout prediction system (BOPS) for continuous casting of steel slabs. The BOPS is modeled using an artificial neural network with a backpropagation algorithm, which further has been validated by using the Keras format and TensorFlow-based machine learning platforms. This work used the Adam optimizer and binary cross-entropy loss function to predict the liquid breakout in the caster and avoid operator intervention. The experimental results show that the developed model has 100% accuracy for generating an alarm during the actual breakout and thus, completely reduces the false alarm. Apart from the simulation-based validation findings, the investigators have also carried out the field application-based validation test results. This validation further unveiled that this breakout prediction method has a detection ratio of 100%, the frequency of false alarms is 0.113%, and a prediction accuracy ratio of 100%, which was found to be more effective than the existing system used in continuous casting of steel slab. Hence, this methodology enhanced the productivity and quality of the steel slabs and reduced substantial capital loss during the continuous casting of steel slabs. As a result, the presented hybrid algorithm of artificial neural network with backpropagation in breakout prediction does seem to be a more viable, efficient, and cost-effective method, which could also be utilized in the more advanced automated steel-manufacturing plants.     

Influence of Gating System Parameters of Die-Cast Molds on Properties of Al-Si Castings

The resulting quality of castings indicates the correlation of the design of the mold inlet system and the setting of technological parameters of casting. In this study, the influence of design solutions of the inlet system in a pressure mold on the properties of Al-Si castings was analyzed by computer modelling and subsequently verified experimentally. In the process of computer simulation, the design solutions of the inlet system, the mode of filling the mold depending on the formation of the casting and the homogeneity of the casting represented by the formation of shrinkages were assessed. In the experimental part, homogeneity was monitored by X-ray analysis by evaluating the integrity of the casting and the presence of pores. Mechanical properties such as permanent deformation and surface hardness of castings were determined experimentally, depending on the height of the inlet notch. The height of the inlet notch has been shown to be a key factor, significantly influencing the properties of the die-cast parts and influencing the speed and filling mode of the mold cavity. At the same time, a significant correlation between porosity and mechanical properties of castings is demonstrated. With the increasing share of porosity, the values of permanent deformation of castings increased. It is shown that the surface hardness of castings does not depend on the integrity of the castings but on the degree of subcooling of the melt in contact with the mold and the formation of a fine-grained structure in the peripheral zones of the casting.     

An optically scanned EMS reporting form and analysis system for statewide use: development and five years' experience.

Analysis of emergency medical services (EMS) systems data is crucial to planning, education, research, and quality assurance programs. Currently, comparative analysis of EMS data between regions or states is virtually impossible due to wide variations in data collection and analysis methods. To devise a practical and uniform EMS reporting system, we referenced the minimum data set (MDS) established by the federal government in 1974 and surveyed 22 states known to be using uniform reporting systems. In developing our final data set, elements were added based on inclusion in the MDS, national survey results, a review of current EMS literature, and consensus of local EMS providers. This set of 48 elements then was incorporated into a reporting form using narrative and optically scanned formats, allowing automated data collection for computer analysis. After a pilot study, the system was improved to allow high-speed ink reading and large volume data storage and analysis using a microcomputer. This system has subsequently been adopted by seven states. The combined data base exceeds 250,000 cases. Error screening algorithms ensure data integrity and are also used for quality assurance. Customized output reports can be generated within minutes and have assisted in EMS quality assurance, planning, and research. We believe that the successful performance of this system supports the use of the suggested data elements as well as optical scanning and microcomputer analysis of EMS data.     

Numerical Analysis of Physical Characteristics and Heat Transfer Decoupling Behavior in Bypass Coupling Variable Polarity Plasma Arc

A novel bypass coupling variable polarity plasma arc was proposed to achieve the accurate adjusting of heat and mass transfer in the welding and additive manufacturing of aluminum alloy. However, the physical characteristics and decoupled transfer behavior remain unclear, restricting its application and development. A three-dimensional model of the bypass coupling variable polarity plasma arc was built based on Kirchhoff’s law, the main arc and the bypass arc are coupled by an electromagnetic field. The model of current attachment on the tungsten electrode surface is included for simulating different heating processes of the EP and EN phases in the coupling arc. The distribution of temperature field, flow field, and current density of the bypass coupling variable polarity plasma arc was studied by the three-dimensional numerical model. The heat input on the base metal under different current conditions is quantified. To verify the model, the arc voltages are compared and the results in simulation and experiment agree with each other well. The results show that the radius of the bypass coupling arc with or without bypass current action on the base metal is different, and the flow vector of the bypass coupling arc plasma with bypass current is larger than the arc without bypass current. By comparing the heat transfer on the electrodes’ boundary under different current conditions, it is found that increasing the bypass current results in the rise in heat input on the base metal. Therefore, it is concluded that using bypass current is unable to completely decouple the wire melting and the heat input of the base metal. The decoupled degree of heat transfer is one of the important factors for accurate control in the manufacturing process with this coupling arc.     

Electron Beam Melting and Refining of Metals: Computational Modeling and Optimization

Computational modeling offers an opportunity for a better understanding and investigation of thermal transfer mechanisms. It can be used for the optimization of the electron beam melting process and for obtaining new materials with improved characteristics that have many applications in the power industry, medicine, instrument engineering, electronics, etc. A time-dependent 3D axis-symmetrical heat model for simulation of thermal transfer in metal ingots solidified in a water-cooled crucible at electron beam melting and refining (EBMR) is developed. The model predicts the change in the temperature field in the casting ingot during the interaction of the beam with the material. A modified Pismen-Rekford numerical scheme to discretize the analytical model is developed. These equation systems, describing the thermal processes and main characteristics of the developed numerical method, are presented. In order to optimize the technological regimes, different criteria for better refinement and obtaining dendrite crystal structures are proposed. Analytical problems of mathematical optimization are formulated, discretized and heuristically solved by cluster methods. Using important for the practice simulation results, suggestions can be made for EBMR technology optimization. The proposed tool is important and useful for studying, control, optimization of EBMR process parameters and improving of the quality of the newly produced materials.     

Graphite Compactness Degree and Nodularity of High-Si Ductile Iron Produced via Permanent Mold versus Sand Mold Casting

In recent years, high-Si ductile cast irons (3–6% Si) have begun to be used more and more in the automotive and maritime industries, but also in wind energy technology and mechanical engineering. Si-alloyed ferrite has high strength, hardness and oxidation and corrosion resistance, but it has low ductility, toughness and thermal conductivity, with graphite as an important influencing factor. In this study, 4.5% Si uninoculated ductile iron solidified in thin wall castings (up to 15 mm section size) via a permanent (metal) mold versus a sand mold, was evaluated. Solidification in a metal mold led to small size, higher graphite particles (less dependent on the section size). The graphite particles’ real perimeter was 3–5% higher than the convex perimeter, while the values of these parameters were 41–43% higher in the sand mold. Increasing the casting section size led to an increased graphite perimeter, with it being much higher for sand mold. The graphite particles’ shape factors, involving the maximum and minimum size, were at a lower level for metal mold solidification, while by involving the difference between P_r and P_c, is higher for the metal mold. The shape factor, including the graphite area and maximum size, had higher values in the metal mold, sustaining a higher compactness degree of graphite particles and a higher nodularity regarding metal mold solidification (75.5% versus 67.4%). The higher was due to the graphite compactness degree level (shape factor increasing from 0.50 up to 0.80), while the lower was due to the graphite nodularity for both the metal mold (39.1% versus 88.5%) and the sand mold (32.3% versus 83.1%). The difference between the metal mold and sand mold as the average graphite nodularity increased favored the metal mold.     

Role of the physician in the prehospital setting

Despite the initial successes achieved in early emergency medical services (EMS) systems, many prehospital care services have developed without the intense involvement of physicians whose interest fueled the first experimental medical programs of prehospital care. Among a myriad of variables affecting EMS is the important element of intense, authoritative physician involvement in education, field supervision, and research. Recognizing this problem, many states now have legislated that EMS systems be closely supervised by medical directors. Political and financial constraints often have diluted medical influence and authority, and intense, direct field supervision is the exception rather than the rule. successful EMS systems can demonstrate their influence on morbidity and mortality through appropriate data collection and quality assurance programs. Such programs appear to have in common the element of direct involvement of competent physicians in initial training, field supervision, and policy decisions. Until recently, full-time compensated physician involvement in EMS has been regarded as unnecessary or impractical. Certainly in large urban centers such full-time involvement is mandatory. While in smaller municipalities full-time commitments may be unnecessary, partial compensation for time dedicated to EMS pursuits should be part of the EMS budget. It has been the experience of major urban EMS systems that field participation by physicians has lent irrefutable credibility to the authority of medical directors. Beyond the obvious benefits of quality assurance and supervision, the in-field EMS physician provides the impetus and leadership for EMS research conducted at the street level. Because EMS is the practice of medicine through physician surrogates in a prehospital setting, it sets the stage and tone for subsequent patient care and outcome.(ABSTRACT TRUNCATED AT 250 WORDS)     

Numerical Simulation and Experimental Validation of Squeeze Casting of AlSi9Mg Aluminum Alloy Component with a Large Size

The squeeze casting process for an AlSi9Mg aluminum alloy flywheel housing component was numerically simulated using the ProCAST software, and orthogonal simulation tests were designed according to the L16 (4) ⁵ orthogonal test table to investigate the alloy melt flow rule under four factors and four levels each of the pouring temperature, mold temperature, pressure holding time and specific pressure, as well as the distributions of the temperature fields, stress fields and defects. The results showed that the flywheel housing castings in all 16 test groups were fully filled, and the thinner regions solidified more quickly than the thicker regions. Hot spots were predicted at the mounting ports and the convex platform, which could be relieved by adding a local loading device. Due to the different constraints on the cylinder surface and the lower end surface, the solidification was inconsistent, the equivalent stress at the corner junction was larger, and the castings with longer pressure holding time and lower mold temperature had larger average equivalent stress. Shrinkage cavities were mainly predicted at mounting ports, the cylindrical convex platform, the peripheral overflow groove and the corner junctions, and there was also a small defect region at the edge of the upper end face in some test groups.     

A New Approach to Electromagnetic Blood Flow Determination by Means of Catheter in an External Magnetic Field

Maximal reduction in transverse catheter dimension has been achieved for the purpose of creating an intravascular electromagnetic flow sensor capable of percutaneous introduction into the vascular system. The electrodes are mounted on a flexible frame which collapses as it passes through a small branch blood vessel and expands to span the diameter of the main vascular trunk when entering it. Unlike the catheter flow sensors developed previously, which are velometers, i.e., sensors of fluid velocity, the present one is capable of measuring the volume rate of flow in branch blood vessels as well as in the major sections of the vascular tree. The magnetic field is provided by a large air core electromagnet placed externally to the animal or patient. A special circuit utilizing two electrodes and three leads permits reduction of the unwanted quadrature signal to zero. A standard sine wave electromagnetic flow meter channel designed for use with conventional electromagnetic flow transducers is adequate for flow measurements as well as for power supply to the large magnet. Illustrations of the performance of the apparatus in vitro and in vivo are presented.     

A Finite Element Analysis for Improvement of Shaping Process of Complex-Shaped Large-Size Silicon Carbide Mirrors

In the gel-casting process, the proper selection of technological parameters is crucial for the final quality of a green body. In this work, the finite element method is used to investigate the mold characteristics in the gel-casting process, and the typical flow behaviors under different conditions are presented. Based on the distribution characteristics of temperature, pressure and flow field of gel polymer, the simulated results provide some possible reasons for the generation mechanisms of defects. Then, a series of simulations were performed to investigate the effect of process parameters on the molding quality of green gel-cast bodies. The results show that the decreasing loading speed can effectively reduce the number of defects and improve the molding quality. In addition, this paper presents a new technique by applying the exhaust hole to decrease the number of defects and, hence, improve structural integrity. The influence of the loading speed on the mold characteristics is well understood for the gating system with an exhaust hole, which suggests to us appropriate parameters for optimizing the molding design. This work provides a theoretical basis to explicate the generating mechanism of defects involved in the gel-casting process and acquires an optimized technique to produce a silicon carbide green body.     

Analysis and Design of Lattice Structures for Rapid-Investment Casting

This paper aims to design lattice structures for rapid-investment casting (RIC), and the goal of the design methodology is to minimize casting defects that are related to the lattice topology. RIC can take full advantage of the unprecedented design freedom provided by AM. Since design for RIC has multiple objectives, we limit our study to lattice structures that already have good printability, i.e., self-supported and open-celled, and improve their castability. To find the relationship between topological features and casting performance, various lattice topologies underwent mold flow simulation, finite element analysis, casting experiments, and grain structure analysis. From the results, the features established to affect casting performance in descending order of importance are relative strut size, joint number, joint valence, and strut angle distribution. The features deemed to have the most significant effect on tensile and shear mechanical performance are strut angle distribution, joint number, and joint valence. The practical application of these findings is the ability to optimize the lattice topology with the end goal of manufacturing complex lattice structures using RIC. These lattice structures can be used to create lightweight components with optimized functionality for various applications such as aerospace and medical.     

A Constant-Field Interrupted Resonance System for Percutaneous Electromagnetic Measurement of Blood Flow

A combination of deformable flow probes of negligible lateral dimensions with an electronic circuit capable of providing a prolonged plateau of dB/dt = 0 and of sampling the flow signal at the end of this interval permits electromagnetic measurement of blood flow with a reliable zero base line secured by switching off the magnet. An extracorporeal magnet provides the magnetic field. The flow transducer is introduced into the vascular system percutaneously through a standard angiographic catheter by conventional technique. The idea of the current generator can be described as "principle of interrupted resonance." The current wave form can be described as a sequence of disconnected bisected sine waves joined at the apices by horizontal current plateaus where di/dt is strictly zero.     

Mesoscopic Fluid-Particle Flow and Vortex Structural Transmission in a Submerged Entry Nozzle of Continuous Caster

Understanding the essence of the flow oscillations within a submerged-entry nozzle (SEN) is essential to control flow patterns in the continuous casting mold and consequently increase the superficial quality of steel products. A numerical study of the mesoscopic fluid-particle flow in a bifurcated pool-type SEN under steady operating conditions is conducted using the lattice Boltzmann method (LBM) coupled with the large eddy simulation (LES) model. The accuracy of the model has been verified by comparing vortex structures and simulated velocities with published experimental values. The LBM modeling is also verified by comparing the “stair-step” jet patterns observed in the experiment. The geometrical parameters and operational conditions of physical experiments are reproduced in the simulations. By comparing the time-averaged velocities of Reynolds-averaged Navier–Stokes equations (RANS) with LBM models, transient mesoscopic fluid-particles and related vortex structures can be better reproduced within the SEN. The visualization of internal flow within the SEN is illustrated through the mass-less Discrete Phase Model (DPM) model. The trajectories show that the LBM–LES–DPM coupled model is good at predicting the transient vortical flow within the SEN. A large vortex is found inside the exit port and continuously changes in shape and size therein. The monitoring points and lines within the SEN are selected to illustrate the velocity variations and effective viscosity, which can reflect the oscillating characteristics even under stable operating conditions without changes at the exit from the SEN. Furthermore, the formation, development, diffusion, and dissipation of the vortex structures from the exit port of the SEN are also investigated using the Q criteria. The comparison of the power spectrum with high-frequency components along the exit port indicates that the flow oscillations must originate from within the SEN and are intensified in the exit port. The mesoscopic LBM model can replicate the fluid-particle flow and vortex structure transmission as well as their turbulence effects inside the SEN in detail.     

Computer modeling of emergency medical system performance

Emergency medical services (EMS) system managers face difficult problems when determining the need for system expansion and unit deployment. Information relevant to the decision is often limited and frequently not in a usable format. This lack of usable information often results in decisions that create less-than-optimal EMS systems. A constant search for greater efficiency prompted the development of a computer simulation model to analyze the current EMS system operated by the Tucson Fire Department and to provide statistical information on the effects of potential vehicle base locations on system performance. The simulation model generates data that reflect a variety of parameters necessary in base location analysis. Included in the performance statistics for each unit and for the entire system are indicators of unit use rates, minimum and maximum response times, and proportion of calls reached within the critical response time of eight minutes or less. The model has been carefully validated and used in unit redeployment and unit activation in Tucson, Arizona.     

Importance of the great vessels in the genesis of the electrocardiogram

The electrocardiogram is the graphic representation against time of the difference in potential between points of the body caused by the current field of the heart. To examine the origin of this current field, a method of transforming body surface electrocardiographic data to the epicardial surface has been developed. The computed epicardial current density distributions in 219 patients with acute inferior myocardial infarction showed that, in 89% of patients, the current flow out of the heart during the ST segment came from two regions, not only from the infarction region but also from a region over the great vessels. This findings suggests that current flows from the ischemic region, through the low-resistance pathway provided by the intracavity blood, out the great vessels, and back to the epicardium. A similar pathway has been hypothesized when ischemia caused endocardial ST elevation, such as during a stress test or with unstable angina. To test this hypothesis, a group of patients with ST depression on the 12-lead electrocardiogram, not associated with ST elevation, was examined with body surface mapping. Ninety-four percent of patients had epicardial current density distributions that showed a region of current flow out of the heart and over the great vessels that was consistent with this hypothesis. This could explain the poor localization of coronary artery disease by electrocardiographic techniques when there is ST depression on the body surface.