Multiphysics Modelling of Ultrasonic Melt Treatment in the Hot-Top and Launder during Direct-Chill Casting: Path to Indirect Microstructure Simulation

This study concerns the numerical simulation of two competing ultrasonic treatment (UST) strategies for microstructure refinement in the direct-chill (DC) casting of aluminium alloys. In the first, more conventional, case, the sonotrode vibrating at 17.3 kHz is immersed in the hop-top to treat the sump melt pool, in the second case, the sonotrode is inserted between baffles in the launder. It is known that microstructure refinement depends on the intensity of acoustic cavitation and the residence time of the treated fluid in the cavitation zone. The geometry, acoustic field intensity, induced flow velocities, and local temperature are factors which affect this treatment. The mathematical model developed in this work couples flow velocity, acoustics modified by cavitation, heat transfer, and solidification at the macroscale, with Lagrangian refiner particles, used to determine: (a) their residence time in the active zones, and (b) their eventual distribution in the sump as a function of the velocity field. This is the first attempt at using particle models as an efficient, though indirect, alternative to microstructure simulation, and the results indicate that UST in the launder, assisted with baffle separators, yields a more uniform distribution of refining particles, avoiding the strong acoustic streaming jet that, otherwise, accompanies hot-top treatment, and may lead to the strong segregation of refining particles. Experiments conducted in parallel to the numerical studies in this work appeared to support the results obtained in the simulation.

Effect of ultrasonic melt treatment on the microstructure and tensile properties of Al-25% Si alloy assisted by phosphorus addition

The effects of ultrasonic melt treatment (UST) on the microstructure and tensile properties of Al-25% Si alloys with and without phosphorus addition were investigated. The average size of the primary Si firstly decreased and then increased with the rise of the ultrasonic intensity. The minimum value is about 25.4 and 32.8 μm when the ultrasonic intensity is 900 W with phosphorus addition and 1 200 W without phosphorus addition. The average number of primary Si per unit area firstly increased and then decreased in both alloys with increasing of ultrasonic intensity. Both tensile strength and elongation were improved mainly due to the refinement of microstructure by UST. Finally, the mechanism of UST on the primary Si is discussed.