The numerical simulation of element segregation control during the electron beam cold hearth melting process of large-sized Ti-6wt%Al-4wt%V titanium alloy slab
Large-scale Ti-6wt%Al-4wt%V alloy ingots exhibit aluminum evaporation tendency and macrosegregation phenomena during the electron beam cold hearth melting (EBCHM) process. To address these challenges, this study innovatively proposes using the design of a multi-overflow-port melting pool strengtheni...
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| Format: | Article |
| Language: | English |
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Elsevier
2025-05-01
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| Series: | Journal of Materials Research and Technology |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2238785425012529 |
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| author | Yuchen Xin Yang Liu Lei Gao Haoyu Fang Zheng Chai Jianzong Shao Shenghui Guo Li Yang Dong Lu Xiangming Li |
| author_facet | Yuchen Xin Yang Liu Lei Gao Haoyu Fang Zheng Chai Jianzong Shao Shenghui Guo Li Yang Dong Lu Xiangming Li |
| author_sort | Yuchen Xin |
| collection | DOAJ |
| description | Large-scale Ti-6wt%Al-4wt%V alloy ingots exhibit aluminum evaporation tendency and macrosegregation phenomena during the electron beam cold hearth melting (EBCHM) process. To address these challenges, this study innovatively proposes using the design of a multi-overflow-port melting pool strengthening method, implemented on opposite sides, drawing inspiration from pyrometallurgical copper refining techniques. A numerical model was developed to investigate the method's effectiveness in suppressing the longitudinal development of the melting pool and enhancing melt homogenization. Experiments conducted using an electron beam button furnace validated the model, demonstrating good agreement in terms of melting pool morphology and aluminum distribution. The numerical simulation results indicate that the multiple overflow ports design effectively suppresses the longitudinal development of the impact cavity and improves element uniformity. Specifically, at a casting speed of 20 mm/min and a temperature of 2273 K, the design reduces the thermal impact cavity depth by 146.19 mm and the maximum aluminum concentration difference by 0.616 wt% compared to the single overflow port design. This study provides a technical and theoretical foundation for homogenization control in the casting of large-sized Ti-6wt%Al-4wt%V ingots. |
| format | Article |
| id | doaj-art-fab48ca6802e4e2f83416ddf54ce63dc |
| institution | DOAJ |
| issn | 2238-7854 |
| language | English |
| publishDate | 2025-05-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Journal of Materials Research and Technology |
| spelling | doaj-art-fab48ca6802e4e2f83416ddf54ce63dc2025-08-20T03:08:14ZengElsevierJournal of Materials Research and Technology2238-78542025-05-01368671868710.1016/j.jmrt.2025.05.098The numerical simulation of element segregation control during the electron beam cold hearth melting process of large-sized Ti-6wt%Al-4wt%V titanium alloy slabYuchen Xin0Yang Liu1Lei Gao2Haoyu Fang3Zheng Chai4Jianzong Shao5Shenghui Guo6Li Yang7Dong Lu8Xiangming Li9Faculty of Metallurgy and Energy Engineering, Kunming University of Science and Technology, Kunming, 650093, ChinaFaculty of Metallurgy and Energy Engineering, Kunming University of Science and Technology, Kunming, 650093, ChinaFaculty of Metallurgy and Energy Engineering, Kunming University of Science and Technology, Kunming, 650093, China; International Joint Research Center for Advanced Manufacturing Technology of Super Hard Materials, Kunming, 650093, China; Corresponding author. Faculty of Metallurgy and Energy Engineering, Kunming University of Science and Technology, Kunming, 650093, China.Faculty of Metallurgy and Energy Engineering, Kunming University of Science and Technology, Kunming, 650093, ChinaFaculty of Metallurgy and Energy Engineering, Kunming University of Science and Technology, Kunming, 650093, ChinaFaculty of Metallurgy and Energy Engineering, Kunming University of Science and Technology, Kunming, 650093, China; International Joint Research Center for Advanced Manufacturing Technology of Super Hard Materials, Kunming, 650093, ChinaFaculty of Metallurgy and Energy Engineering, Kunming University of Science and Technology, Kunming, 650093, China; International Joint Research Center for Advanced Manufacturing Technology of Super Hard Materials, Kunming, 650093, China; Corresponding author. International Joint Research Center for Advanced Manufacturing Technology of Super Hard Materials, Kunming, 650093, China.Faculty of Metallurgy and Energy Engineering, Kunming University of Science and Technology, Kunming, 650093, China; International Joint Research Center for Advanced Manufacturing Technology of Super Hard Materials, Kunming, 650093, ChinaChina Nonferrous Metals Innovation Institute (Tianjin) Co., Ltd., No.86, Ziguang Road Automotive Industrial Area, Xiqing District, Tianjin, 300393, ChinaFaculty of Materials Science and Engineering, Kunming University of Science and Technology, Kunming, 650093, China; Corresponding author.Large-scale Ti-6wt%Al-4wt%V alloy ingots exhibit aluminum evaporation tendency and macrosegregation phenomena during the electron beam cold hearth melting (EBCHM) process. To address these challenges, this study innovatively proposes using the design of a multi-overflow-port melting pool strengthening method, implemented on opposite sides, drawing inspiration from pyrometallurgical copper refining techniques. A numerical model was developed to investigate the method's effectiveness in suppressing the longitudinal development of the melting pool and enhancing melt homogenization. Experiments conducted using an electron beam button furnace validated the model, demonstrating good agreement in terms of melting pool morphology and aluminum distribution. The numerical simulation results indicate that the multiple overflow ports design effectively suppresses the longitudinal development of the impact cavity and improves element uniformity. Specifically, at a casting speed of 20 mm/min and a temperature of 2273 K, the design reduces the thermal impact cavity depth by 146.19 mm and the maximum aluminum concentration difference by 0.616 wt% compared to the single overflow port design. This study provides a technical and theoretical foundation for homogenization control in the casting of large-sized Ti-6wt%Al-4wt%V ingots.http://www.sciencedirect.com/science/article/pii/S2238785425012529Ti-6wt%Al-4wt%VElectron beam cold hearth melting (EBCHM)Casting moldElement segregation |
| spellingShingle | Yuchen Xin Yang Liu Lei Gao Haoyu Fang Zheng Chai Jianzong Shao Shenghui Guo Li Yang Dong Lu Xiangming Li The numerical simulation of element segregation control during the electron beam cold hearth melting process of large-sized Ti-6wt%Al-4wt%V titanium alloy slab Journal of Materials Research and Technology Ti-6wt%Al-4wt%V Electron beam cold hearth melting (EBCHM) Casting mold Element segregation |
| title | The numerical simulation of element segregation control during the electron beam cold hearth melting process of large-sized Ti-6wt%Al-4wt%V titanium alloy slab |
| title_full | The numerical simulation of element segregation control during the electron beam cold hearth melting process of large-sized Ti-6wt%Al-4wt%V titanium alloy slab |
| title_fullStr | The numerical simulation of element segregation control during the electron beam cold hearth melting process of large-sized Ti-6wt%Al-4wt%V titanium alloy slab |
| title_full_unstemmed | The numerical simulation of element segregation control during the electron beam cold hearth melting process of large-sized Ti-6wt%Al-4wt%V titanium alloy slab |
| title_short | The numerical simulation of element segregation control during the electron beam cold hearth melting process of large-sized Ti-6wt%Al-4wt%V titanium alloy slab |
| title_sort | numerical simulation of element segregation control during the electron beam cold hearth melting process of large sized ti 6wt al 4wt v titanium alloy slab |
| topic | Ti-6wt%Al-4wt%V Electron beam cold hearth melting (EBCHM) Casting mold Element segregation |
| url | http://www.sciencedirect.com/science/article/pii/S2238785425012529 |
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