Simulation of the metal alloy casting into its mould
Example of CFD modeling application for metallurgy
The ladle is an important part of most ingot production processes in metallurgy. It connects the crucible, in which the alloy is melted and heated to the right temperature, to the mould, in which it will solidify. In addition to regulating flow, it can also be used to remove unwanted inclusions through various processes, including flotation. In an environment where experimental measurements can sometimes be difficult (high temperatures, etc.), simulating the behaviour of the liquid alloy using CFD modeling can help to understand the flow and optimise designs and process parameters.
Assessment of inclusion flotation and solidification risk in a casting tundish
Context and issues
- CFD modelling in metallurgy and alloy casting;
- Need to understand flow structures and nature;
- Need to assess particle retention capacity and control the risk of solidification;
- Objective of optimising design and process values;
- Multiphysics modelling and multi-model coupling;
- Key physical concepts: free surface flow, conjugate heat transfer, liquid-particle-gas three-phase flow, solidification.
Project contributions
- Development and validation of customised models (new solver, new libraries);
- Development of complex simulations with reasonable calculation times;
- Creation of meshes and simulations. Detailed analysis of the alloy’s behaviour with regard to the various issues to be addressed, and study of the impact of different parameters;
- Contribution to design optimisation.
Technical environment
- Linux, personal computing cluster;
- HPC cluster in partnership (EPYC processors);
- Programming in C/C++, analysis scripts in Python;
- Meshing and CFD in a customised OpenFOAM environment, with specific solver and libraries.
