Advances in the Science and Engineering of Casting Solidification: An MPMD Symposium Honoring Doru Michael Stefanescu

The book contains the proceedings of the honorary symposium “Advances in the Science and Engineering of Casting Solidification” (TMS2015, Orlando, Florida, March 15-19, 2015) held in honor of Professor Doru Michael Stefanescu, Emeritus Professor, Ohio State University and the University of Alabama, USA. The book encompasses the following four areas: (1) Solidification processing: theoretical and experimental investigations of solidification processes including castings solidification, directional solidification of alloys, electromagnetic stirring, ultrasonic cavitation, mechanical vibration, active cooling and heating, powder bed-electron beam melting additive manufacturing, etc. for processing of metals, polymers and composite materials; (2) Microstructure Evolution: theoretical and experimental studies related to microstructure evolution of materials including prediction of solidification-related defects and particle pushing/engulfment aspects; (3) Novel Casting and Molding Processes: modeling and experimental aspects including high pressure die casting, permanent casting, centrifugal casting, low pressure casting, 3D silica sand mold printing, etc.; and (4) Cast Iron: all aspects related to cast iron characterization, computational and analytical modeling, and processing.

Table of Contents:
Preface xi About the Honoree xiii About the Editors xv Solidification Processing I Science of Casting and Solidification: ASM Handbook Contributions - Honoring Professor Dora Michael Stefanescu 3 A. Lupulescu, S. Henry, K. Marken, and S. Lampman On the Solidification of Metal Alloys during Microgravity Conditions 9 H. Fredriksson Formation of the Tin Rich Layer and Inverse-Segregation in Phosphor Bronzes during Continuous Casting 15 S. Saleem, M. Vynnycky, and H. Fredriksson A Model of Cavitation for the Treatment of a Moving Liquid Metal Volume 23 G. Lebon, K. Pericleous, I. Tzanakis, and D. Eskin Ultrasonic Processing of 6061-Based Nanocomposites for High Performance Applications 31 S. Jia, P. Allison, T. Rushing, and L. Nastac Numerical Modeling of the Dispersion of Ceramic Nanoparticles during Ultrasonic Processing of A356-based Nanocomposites 37 D. Zhang and L. Nastac Optical Floating-Zone Crystal Growth of Heusler Ni-Mn-Sn Alloy 49 J. Yu, J. Ren, H. Li, and H. Zheng Solidification Processing II Modeling of Macrosegregation during Solidification of Steel Ingot Casting 57 W. Tu, H. Shen, and B. Liu Scaling Analysis of Alloy Solidification and Fluid Flow in a Rectangular Cavity 65 A. Plotkowski, K. Fezi, and M. Krane Structure and Casting Defects of Aluminum Billets Produced by Direct-Chill Casting 73 D. Eskin The Fluid Flow and Solidification Phenomenon in Billet Continuous Casting Process with Mold and Final Electromagnetic Stirrings 81 D. Jiang and M. Zhu Columnar-to-Equiaxed Transition in Zn-27wt.%Al Alloys: A Comparation Between Vertical and Horizontal Directional Solidifications 93 A. Ares and C. Schvezov Microstructure Investigation of Aluminum Die-Cast Parts with Different Gating Conditions Tested in Fatigue 101 R. Ruxanda and R. Obara Solidification Processing III A Coupled Thermo-Mechanical Simulation on Squeeze Casting Solidification Process of Three-Dimensional Geometrically Complex Components 113 J. Tang, Z. Han, F. Wang, J. Sun, and S. Xu Double Oxide Film Defects in Al Castings and the Effect of Different Element Additions 121 Q. Chen, A. Caden, and W. Griffiths The Design of New Submerged Entry Nozzles for Beam-Blank Continuous Casting 129 M Zhu, M. Xu, and S. Luo Effects of Ce on the Thermal Stability of the Ω Phase in a Cast Aluminum Metal Matrix Composite 137 F. Melotti, A. Dustan, T. Hirst, and W. Griffiths Solidification Processing IV Non-Metallic Ti Oxides and MnS/FeS2 Complex Precipitation in Ti-Killed Steel 147 J. Chen, D. Zhao, H. Li, and S. Zheng Prediction of Surface Porosity Defects in High Pressure Die Casting 155 M. Saeedipour, S. Schneiderbauer, S. Pirker, and S. Bozorgi Engineered Cooling Process for High Strength Ductile Iron Castings 165 S. Lekakh, A. Mikhailov, and J. Kramer Numerical Simulation of Solidification Structure for YQ450NQR1 Steel Bloom in Continuous Casting Process 173 K. Dou, L. Wang, J. Qing, X Zhang, B. Wang, B. Liu, and Q. Liu Microstructure Evolution I Modeling of Microstructure Evolution during Alloy Solidification 183 M Zhu, S. Pan, and D. Sun A Lattice Boltzmann Model for Dendritic Growth under Natural Convection 191 M Hashemi, M. Eshraghi, and S. Felicelli Modeling of Dendritic Structure and Microsegregation in Solidification of Al-Rich Quaternary Alloys 199 T. Dai, M. Zhu, S. Chen, and W. Cao Microstructure Evolution II In Situ Study on the Evolution of Dendrite Morphology Affected by Electric Field in Sn-Bi Alloy 209 F. Yang, F. Cao, R. Li, H. Kang, Y. Fu, T. Xiao, and T. Wang Heterogeneous Strip Originated from Inclusions: Characterization and Physical Mechanism 215 X Ma and D. Li An Investigation of Dendritic Segregation in Directionally Solidified CMSX-4 Superalloy 223 G. Matache, D. Stefanescu, C. Puscasu, andE. Alexandrescu Modeling of Casting Defects in an Integrated Computational Materials Engineering Approach 231 A. Sab au X-ray Observations Showing the Effect of Fluid Flow on Dendritic Solidification in Ga-In Alloys 241 N. Shevchenko, O. Roshchupkina, and S. Eckert Cast Iron I Defect Formation Mechanisms in Lamellar Cast Iron Related to the Casting Geometry 251 A. Diôszegi, P. Svidrô, L. Elmquist, and I. Dugic Characterization of Directionally Solidified Gray Iron 261 E. Rivera, T. Christiansen, A. Genau, and A. Catalina Age-Strengthening of Cast Iron and Its Effects on Machinability: Review of the Literature 269 V. Richards Examination of Austenite Solidification and Spheroidal Graphite Growth in Ni-Fe-C Alloys 277 J. Qing, V. Richards, and D. Van Aken Production of Selected Key Ductile Iron Castings Used in Large-Scale Windmills 287 Y Pan, H. Lin, C. Lin, and R. Chang An Overview of Isothermal Coarsening in Hypoeutectic Lamellar Cast Iron 295 J. Hernando and A. Diôszegi Cast Iron II Experimental Studies of Gray Cast Iron Solidification with Linear Variable Differential Transformer 305 A. Tadesse and H. Fredriksson Undercooling, Cooling Curves and Nodule Count for Hypo- Hyper- and Eutectic Thin-Walled Ductile Iron Castings 313 W. Kapturkiewicz and A. Burbelko Graphite Growth Morphologies in High Al Cast Iron 323 H. Muhmond and H. Fredriksson Thermophysical Properties of Thin Walled Compacted Graphite Iron Castings 331 M Gôrny, J. Lelito, and M. Kawalec Understanding Cast Iron Materials and Components: A Never Ending Story 339 I. Svensson and J. Olofsson Understanding Superfine Graphite Iron Solidification through Interrupted Solidification Experiments 347 G. Alonso, D. Stefanescu, P. Larrahaga, E. De la Fuente, E. Aguado, and R. Suarez Novel Casting and Molding Processes Counter Gravity Casting 357 J. Campbell A Numerical Model for Predicting the Gas Evolution in Silica Sand (Furan Binder) Mold Castings 363 L. Nastac, S. Jia, M. Nastac, and R. Wood Solidification Processing V Evaluation of the Casting/Chill Interface Thermal Behaviour during A319 Alloy Sand Casting Process 373 F. Mehr, S. Cockcroft, C. Reilly, and D. Maijer Dependence of Hardness on Microstructure of a Directionally Solidified Sn-40wt.%Bi-0.7wt.%Cu Alloy 381 B. Silva and J. Spinelli Contributions on Optimizing Approximations in the Study of Melting and Solidification Processes that Occur in Processing by Electro-Erosion 391 F. Potra, T. Potra, and V. Soporan Investigation of Thin-Walled IN718 Castings by Counter-Gravity Investment Casting 399 A. Dong, N. Yan, J. Zhang, J. Wang, B. Sun, H. Gao, and D. Shu Thermal Test of Nodular Cast Iron Cooling Stave 407 J. Zheng, H. Zuo, J. Zhang, and F. Li Author Index 413 Subject Index 415

About the Author :
Laurentiu Nastac, The University of Alabama Baicheng Liu, Tsinghua University Hasse Fredriksson, KTH - Royal Institute of Technology Jacques Lacaze, Université de Toulouse Chun-Pyo Hong, Yonsei University Adrian Catalina, Caterpillar Inc. Andreas Buhrig-Polaczek, RWTH Aachen University Daan M. Maijer, The University of British Columbia Charles Andrew Monroe, University of Alabama at Birmingham Adrian S. Sabau, Oak Ridge National Laboratory Roxana Ruxanda, Emerson Climate Technologies Alan A. Luo, The Ohio State University Subhayu Sen, Geocent Attila Diószegi, Jönköping University, School of Engineering