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| Author(s): |
Felipe Bertelli
Total Authors: 1
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| Document type: | Doctoral Thesis |
| Press: | Campinas, SP. |
| Institution: | Universidade Estadual de Campinas (UNICAMP). Faculdade de Engenharia Mecânica |
| Defense date: | 2012-10-31 |
| Examining board members: |
Amauri Garcia;
Carlos de Moura Neto;
Cecília Amélia de Carvalho Zavaglia;
Claudio Alves de Siqueira Filho;
Maria Clara Filippini Ierardi
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| Advisor: | Noé Cheung; Amauri Garcia |
| Abstract | |
The analysis of the thermal behavior in a cylindrical metal/mold system during solidification is of both theoretical and industrial interest. The determination of the rate at which a metal solidifies and of temperature distribution is significant for optimization and control of casting processes. Numerical models are widely used in order to simulate the solidification process in a number of fields including casting, welding, crystal growing and laser processing. The numerical simulation of cylindrical castings can only produce reliable information if the thermal boundary conditions, such as the metal/mold heat transfer coefficient (h), and thermal parameters, such as growth and cooling rates, are known accurately. Despite the importance of h for cylindrical shaped castings, information available in the literature is meager. In the present study, a numerical model for the analysis of radial solidification of cylindrical shaped castings has been developed followed by an extensive experimental study encompassing horizontal and vertical cylindrical shaped castings involving radial heat transfer and including combination of situations of hollow and massive cylindrical castings inwardly and outwardly solidified. Alloys having quite different thermal properties and freezing ranges have been selected for the experimental study. The numerical model has been validated against experimental results of the kinetics of solidification of binary alloys from the adopted metallic systems (Al-Fe and Pb-Sb), as well as by comparison with theoretical predictions provided by an analytical model. An inverse heat conduction method has been used to derive time-varying heat transfer coefficients. It is shown that the h (t) profiles are given by an expression of the form h =a.t±m , where (-) refers to the inward solidification and (+) to the outward solidification against an inner mold. The analysis of the thermal resistance revealed that in some solidification systems, the resistance to heat transfer imposed by the solid layer formed during the solidification process prevailed from a certain moment of solidification. The high values of cooling rates and solidification rates imposed by heat extraction in radial cylindrical geometries induced, for Pb-Sb alloys, a dendritic solidification pattern even for low alloying contents. The evolution of dendritic spacings during the inward solidification followed a reversion, which is similar to that shown to occur for the rate of displacement of the liquidus isotherm from the casting surface to the center of the cylinder (AU) | |