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OBJECTIVES

Intelligent Inclusion Modeling for Steel Foundries. Ryan W. McChesney , Dr. Kent Peaslee , Dr. Lifeng Zhang Department of Materials Science and Engineering Missouri University of Science and Technology . INCLUSION DISTRIBUTION IN THE MOLD . OBJECTIVES. APPROACH

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OBJECTIVES

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  1. Intelligent Inclusion Modeling for Steel Foundries Ryan W. McChesney, Dr. Kent Peaslee , Dr. Lifeng Zhang Department of Materials Science and Engineering Missouri University of Science and Technology INCLUSION DISTRIBUTION IN THE MOLD OBJECTIVES • APPROACH • Consider the refractories being used as well as the deoxidation methods being practiced and the slag being formed • Consider changes in the stream characteristics such as the free surface and other factors affecting oxygen entrapment • The model will be developed by using FACTSAGE thermodynamic software to determine the types and nature of slag/refractory and refractory/steel reactions that occur • The casting process and the fluid dynamics which determine the agglomeration and distribution of the inclusions in the casting will be modeled using MAGMA and FLUENT • The laboratory testing to validate the model will be conducted in the Missouri S&T foundry laboratory • The laboratory test samples will be characterized using the ASPEX particle identification and characterization analyzer (PICA 1020) • Identify the sources of inclusions • Determine what effects the size, morphology, composition • and distribution • Develop a model to predict defects present in steel castings • prior to process implementation • BACKGROUND • Various inclusions that form in steel castings represent a costly problem for steel foundries • The inclusions act as stress risers within the casting and adversely affect the mechanical properties • Inclusions act as sites for crack initiation and nucleation • Sources of Inclusions and factors affecting their growth • - Refractories and their related reaction products • -Pouring stream characteristics • -Deoxidation methods used • -Reoxidation • -Fluid Flow in Mold • -Slag layer on the ladle • MODEL INPUT • The model will use input that consist of • -Refractory type • -Deoxidation methods used • -Pouring stream characteristics • -Mold geometry and mold material • -Steel composition INCLUSION CONTENT AND THE POURING STREAM (1) • MODEL OUTPUT • The model will use output that consist of • -Unfavorable refractory reactions • -Oxygen entrapment • -Final inclusion volume in casting • -Average size and composition of inclusions • Acknowledgements • Intelligent Systems Center • (1) “Modeling of Reoxidation Inclusion Formation During Filling of Steel Castings” • Kent D. Carlson and ChristophBeckermann , MS&T 2005 • (1)“Modellingof reoxidation inclusion formation • in steel sand casting” • A. J. Melendez, K. D. Carlson and C. Beckermann* • , Journal of cast metals research 2010

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