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Numerical Simulation of Solidification of Work Roll in Centrifugal Casting

Process

Article  in  Journal of Materials Science and Technology -Shenyang- · February 2012

DOI: 10.1016/S1005-0302(12)60035-8

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 J. Mater. Sci. Technol., 2012, 28(2), 147–154.

Numerical Simulation of Solidification of Work Roll

in Centrifugal Casting Process

Nannan Song1) , Yikun Luan1) , Yunlong Bai1) , Z.A. Xu2) , Xiuhong Kang1)† and Dianzhong Li1)
1) Shenyang National Laboratory for Materials Science, Institute of Metal Research, Chinese Academy of Sciences,
Shenyang 110016, China
2) SIRRIS, the Collective Center for the Belgian Technological Industry, Technologiepark 915, 9052 Zwijnaarde, Belgium
[Manuscript received April 1, 2011, in revised form August 11, 2011]

A program on the solidification process of horizontal centrifugal casting coupled with eutectic carbides segregation has
been developed in this paper. Due to the geometrical features of work roll, a cylindrical coordinate system was used.
The temperature field of the outer layer at the end of filling process was imported as the initial temperature condition
for the solidification process. The model of eutectic carbides segregation caused by different densities between eutectic
MC and the molten steel was coupled in the program. The temperature field of the outer layer of work roll during
horizontal centrifugal casting process was investigated. Results show that the outer layer has a “sandwich shape” solid
fraction manner. Results also indicate that the segregation of eutectic MC is quite severe during centrifugal casting
process. It forms four zones of different content of carbides in radial direction. The simulated results of MC carbides
segregation phenomenon agree with the experimental observations.

KEY WORDS: Numerical simulation; Horizontal centrifugal casting; MC segregation;

Work roll

1. Introduction the design of the casting process. Computer simula-

tion, a powerful tool for the scientists and technolo-
Centrifugal casting is a widely used method for gists to visualize the casting process, is a key to obtain
producing eutectic carbides reinforced metal matrix the temperature field and solidification process[7] .
composites, tubes and some of work rolls[1–5] . Using In centrifugal casting process, the liquid metal so-
centrifugal casting to produce work roll is very compli- lidifies under centrifugal force. If the liquid contains
cated. Three different kinds of materials are needed some eutectic carbides, whose densities are different
to pour into the mould. Two of them are poured from the molten steel, the eutectic carbides will seg-
under horizontal centrifugal casting process, and the regate during solidification process under centrifugal
last one is filled under gravity. The process parame- force. In some techniques, this kind of segregation
ters are very difficult to be controlled, especially to is used during centrifugal casting as an advantage to
decide when to pour the intermediate layer and when produce certain products, such as produce particle re-
to start inner core filling. Fu and Liu[6] argued that inforced metal matrix composites[1,2] . For producing
it is better to pour the intermediate layer at the time work roll via horizontal centrifugal casting, the eutec-
when the temperature of 85% thickness of the outer tic carbides segregation phenomenon is unexpected,
layer is 10 ◦ C under the solidus, and then allow 15% which should be prevented from occurring.
of the outer layer to be re-melted. But to determine The aim of this paper is to investigate the solid-
the time interval between each step is very difficult. ification manner of work roll during horizontal cen-
Thereby, the temperature distribution and solid frac- trifugal casting process and to acquire a suitable fill-
tion of each layer are very important and crucial for ing time interval between pouring intermediate layer
and outer layer for the studied dimension of work roll.
† Corresponding author. Assoc. Prof., Ph.D.; E-mail address: Eutectic carbides segregation during solidification
[email protected] (X.H. Kang).
148 N.N. Song et al.: J. Mater. Sci. Technol., 2012, 28(2), 147–154.

Fig. 1 Schematic representation of the complete system of horizontal centrifugal casting of the outer layer

process was also studied. A suggestion was proposed ρ = [1 − Vk (t)]ρl + ρec · Vk (t) (5)
here to solve this problem.
C = [1 − Vk (t)]Cl + Cec · Vk (t) (6)
2. Description of the Models λ = [1 − Vk (t)]λl + λec · Vk (t) (7)
Eutectic carbides, whose densities are smaller than
2.1 Mathematical models
the molten steel, will move to the inside of the layer
owing to the centrifugal force. This will cause the
For horizontal centrifugal casting of work roll, it
volume fraction of the eutectic carbides in the molten
is very complex to simulate the temperature field in
steel to change at different places as can be seen from
Cartesian coordinates system. In this study, the tem-
the following equation.
perature distribution in the melt and mold will be
described by the energy equation under three dimen- Vk (1 + ∆t) = Vk (t) + ∆Vk+1 (t) − ∆Vk (t) (8)
sional cylindrical coordinates system.
µ ¶ µ ¶ where ∆Vk+1 (t) are the eutectic carbides which move
∂T 1 ∂ ∂T 1 ∂ ∂T
ρC = λ·r + 2 λ + into the k cell at t time and ∆Vk (t) are the eutectic
∂t r ∂r ∂r r ∂ϕ ∂ϕ
µ ¶ carbides which move out from the k cell at t time.
∂ ∂T .
λ +q (1) 2.2 Geometric model
∂z ∂z
Considering that the flow of heat is almost in the
The thickness of the outer layer of the roll simu-
radial direction, as well as the symmetrical section of
lated here is 53 mm. In the circumferential direction,
the roll[8] , the following explicit finite difference equa-
there is no heat transfer among each grid at the same
tion for an internal node (i, k) is obtained.
radial position. So the model is axisymmetric. Two-
n+1 n ∆t 1 0 (Ti+1 − Ti ) dimensional cylindrical coordinate model is used to
T(i,k) = T(i,k) + {[ (Ri+1 · λ1 −
ρC r[i] ∆r2 do the simulation. Fig. 1 is the schematic of the com-
plete system of horizontal centrifugal casting of the
(Ti − Ti−1 )
Ri0 · λ2 )] + outer layer. It can be seen from Fig. 1 that coating
∆r2 and protect slag are also considered in the model.
(Tk+1 − Tk ) (Tk − Tk−1 )
[λ3 − λ4 ]} (2)
∆k 2 ∆k 2 3. Boundary and Initial Conditions
Due to the employment of explicit finite difference
method to solve the heat transfer equation, the con- 3.1 Boundary conditions
vergence condition is very important. It is given in
the following formula[9] : Fig. 1 shows that the inner surface of the cast-
2 ing is covered by glass slag, which is used to protect
ρC(∆r)
∆t ≤ (3) the liquid metal from oxidation. Rotated mold will
2λ lead to turbulent movement of the ambient air. The
During centrifugal casting, the centrifugal force higher the rotation speed is, the more intense the tur-
is very strong. If eutectic carbides whose densities bulence is. That leads to non-ignorable convection ef-
are different from the molten steel exist in the liquid fect between the inner air and the inner surface. The
metal, segregation will occur. This kind of segrega- thickness of the protect slag, which contacts the in-
tion will have influence on the temperature field of the ner surface, is only about 2 mm. Because of the high
metal. The segregated models are given as below[1] : temperature, heat transfer between the liquid metal
d2 s ds and the slag is quick. This makes the slag also has
ρec V = V ω 2 s (ρec − ρL ) − 6πµr (4) radiation effect on the inner air. So, the boundary
dt2 dt
 N.N. Song et al.: J. Mater. Sci. Technol., 2012, 28(2), 147–154. 149

Fig. 2 Axial temperature field of the outer layer after different solidification time during centrifugal casting:
(a) 360 s after pouring, (b) 420 s after pouring

condition equation between protect slag and inner air of metallic carbides, which is considered to be VC
is shown as follows[10] : with density of 5700 kg/m3[12] and the density of the
∂T molten steel is 7200 kg/m3 , MC segregation in the
4 4
−λ · = h · (Twl − Tsur1 ) + ε · σ · (Tw1 − Tsur1 ) (9) steel under centrifugal force will occur. The initial
∂x
volume of MC eutectic carbides is set to be 5% ac-
The mold contacts the outer air, but sometimes cording to the alloy component. The thermal para-
contacts cooling water. The mold is usually preheated meters of the material are obtained from experiments.
to nearly 170 ◦ C. This makes it has radiation effect The liquidus of the high speed steel is 1320 ◦ C, and
on the outer air. Because of the high rotation speed the solidus is 1210 ◦ C[13] . Rotation speed of the mold,
of the mold, it also has convection effect on the outer preheated temperature of the mold and coating layer
air. The boundary condition can be seen from the thickness are considered in the simulation. Zircon
following equation: flour is used as coating material. Its thermal con-
∂T 4 4 ductivity is 8.37 W·m−1 ·K−1[9] . The other simulation
−λ · = h · (Tw2 − tsur2 ) + ε · σ · (Tw2 − Tsur2 ) (10)
∂x parameters can be seen in Table 1.
Under some casting conditions, where there is no The temperature field of the outer layer at the end
forced air around the mold, the free convection is of mould filling process in literature[14] is imported as
laminar. But the high speed rotating mold makes the initial temperature condition for the solidification
the ambient air turbulent during centrifugal casting. calculation of the outer layer.
So the convection heat transfer coefficient should not
be laminar any more. Here h is a function of the 4. Results and Discussion
rotation speed. It is calculated from the following
expression[11] : 4.1 Temperature field of the outer layer of work roll

λ During horizontal centrifugal casting of work roll,

h=Q [(0.5Re2 + Gr)P r]0.33 (11)
2r when the outer layer is poured into the mold, it con-
tacts the mold quickly and tightly. The inner sur-
3.2 Initial conditions face of the layer contacts the 2 mm thick protect
slag. Fig. 2 shows the axial temperature field of the
The material of the outer layer used is a type of outer layer after different solidification time. Fig. 2(a)
high speed steel containing high Mo and high V. Be- shows the temperature field at 360 s after pouring;
cause of the lower density of the preferentially formed Fig. 2(b) shows the temperature field at 420 s after
150 N.N. Song et al.: J. Mater. Sci. Technol., 2012, 28(2), 147–154.

Table 1 Thermomechanical properties of the high speed steel and simulation parameters
Parameter Value and dimension Parameter Value and dimension
Latent heat 1.05×106 J·kg−1 Pouring temperature 1450 ◦ C
Thermal conductivity 22.9 W·m−1 ·K−1 Mold preheated temperature 170 ◦ C
Solid density of the steel 7.589×103 kg·m−3 Thickness of the coating 2 mm
Liquid density of the steel 7.0×103 kg·m−3 Thickness of the protect slag 2 mm
Inner casting radius 187 mm Rotation speed of the mold 680 r/min
Outer casting radius 240 mm

of 4 mm away from the mold wall, cool quicker than

the other places both for the shoulder and the middle
part in the axial direction. They solidify nearly in
1 min. That is because these places contact the mold,
which has a very low temperature. The places with a
distance of 23 mm away from the inner surface, which
are in the middle part of the outer layer in radial di-
rection, solidify nearly in 7–8 min after pouring the
outer layer. The places with a distance of 8 mm away
from the inner surface, solidify nearly in 6–7 min after
pouring the outer layer. So it can be concluded that
to let the outer layer have a good re-melt condition
in the future, it is better to fill the intermediate layer
6–7 min after pouring the outer layer. At the same
radial position of the outer layer, the shoulder places
always have the lowest temperature.

4.2 Solid fraction of the outer layer of work roll

Fig. 3 Relation between temperature and solidification
time in different positions of the outer layer:
In order to know the solidification manner clearly,
(a) the schematic positions of the monitored it is better to use solid fraction field to do the illus-
points, (b) the temperature of the monitored tration. Fig. 4 shows the solid fraction of the outer
points layer of work roll at different solidification time under
centrifugal casting. Fig. 4(a) shows solid fraction at
pouring. Both of them indicate that the surface con- 360 s after pouring; Fig. 4(b) shows solid fraction at
tacting the mold has lower temperature than the in- 420 s after pouring. From Fig. 4 it can be seen that
ner surface contacting the protect slag. This means the solidification type of work roll under centrifugal
that the slag not only protects the liquid from oxida- casting is “sandwich shape”. This solidified manner
tion but also prevents the temperature from dropping means that when pouring the intermediate layer into
sharply. From Fig. 2 it can also be seen that the tem- the mold after 8 mm thickness of the inner surface of
perature of the shoulder is the lowest, which will cause the outer layer solidified, the middle part of the outer
defects in the future. layer in radial direction still has higher temperature
The temperature fields of six different positions in than the inner surface. If pouring speed of the inter-
the outer layer are monitored. Fig. 3 shows the re- mediate layer is higher than the critical velocity or
lation between temperature and solidification time of pouring time is earlier than the critical time interval,
different positions of the outer layer under the same it will cause defects and re-melt much more metals in
initial conditions. Line 1 and line 2 stand for the po- the outer layer. But if being controlled better, this so-
sitions with a distance of 8 mm away from the inner lidified manner of the outer layer can just satisfy the
surface: line 1 is in the middle part of the roll (posi- sequence solidification after pouring the intermediate
tion 1); line 2 is at the shoulder of the roll (position layer. From Fig. 4, it can also be seen that the shoul-
2). Line 3 and line 4 stand for the positions with a der place is totally solidified at 360 s after pouring.
distance of 23 mm away from the inner surface: line This place will be re-melted hardly.
3 is in the middle part of the roll (position 3), line
4 is at the shoulder of the roll (position 4). Line 5 4.3 Simulation results of MC eutectic carbides segre-
and line 6 stand for the positions with a distance of gation of the outer layer of work roll
49 mm away from the inner surface: line 5 is in the
middle part of the roll (position 5), line 6 is at the Rotation speed plays an important role in the
shoulder of the roll (position 6). From Fig. 3, it can filling process of centrifugal casting. For solidifica-
be seen that the places with a distance of 49 mm away tion process, the rotation speed affects interface heat
from the inner surface, which means with a distance transfer coefficient between liquid and the mold. Cen-
 N.N. Song et al.: J. Mater. Sci. Technol., 2012, 28(2), 147–154. 151

Fig. 4 Solid fraction of the outer layer of work roll after different solidification time: (a) 360 s after pouring,
(b) 420 s after pouring

trifugal force also causes eutectic carbides to segregate casting mold. This leads the MC free zone to be the
in liquid. Different rotation speeds will cause differ- second zone from the outer surface.
ent eutectic carbides segregation degrees of high speed
steel. Here, MC segregation is coupled with tempera- 4.4 Experimental results of MC segregation
ture drop. Fig. 5 shows the simulation results of MC
segregation phenomenon during solidification process. To verify the model, experimental research has
The initial volume fraction of MC is set to be 5% ac- been carried out. The same dimension work rolls as
cording to the elements content of the steel used here the simulated one were produced. Fig. 6 shows the
as can be seen in Fig. 5(a). It can be seen in Fig. 5(b) roll produced in the factory for the experiment.
that after 75 s solidification, the MC moved into the Fig. 7 shows that MC segregation under rotation
inner surface of the outer layer because of the lower speed of 680 r/min. Because of the lower density of
density[6] . From Fig. 5(c) it can be seen that there are MC, it runs into the inner position of the outer layer.
four typical MC zones in the radial direction from in- Owing to the segregation of the alloy elements, struc-
ner surface to the outer surface: a zone with maximal ture segregation can also be observed. This can be
concentration, a transient zone, where the concentra- seen from Fig. 7(b). It is investigated that MC are V-
tion increases from the initial to maximal, MC free rich carbides containing mostly V with small amounts
zone and a zone with the initial concentration. The of Mo, Cr, and Fe[15] . Fig. 8 shows the segregation of
inner zone with maximal concentration, is caused by V element of the outer layer in radial direction mea-
the lower density of the segregation carbides. If car- sured by electron probe microanalysis (EPMA). It can
bides densities are higher than the molten steel, this be seen from Fig. 8 that the amount of V element in
zone will be in the outer surface. In the developed the inner surface of the layer is bigger than that in
program, when the solid fraction of the grid is bigger the outer surface of the layer. To solve this problem,
than the critical fraction, the volume of MC in that Nb element was recommended to be added into the
grid is not able to be changed. The “sandwich shape” alloy. Nb element encourages forming (NbV)C car-
solid manner causes the transient zone to be formed. bides, which has similar density with molten steel and
For the thin layer close to the mold surface, segrega- this will decrease the tendency of carbides segregation
tion is not obvious owing to the shock cooling of the caused by centrifugal force[16] .
152 N.N. Song et al.: J. Mater. Sci. Technol., 2012, 28(2), 147–154.

Fig. 5 Simulation results of MC carbides segregation phenomenon: (a) the initial volume of 5% MC carbides,
(b) the volume of MC carbides after 75 s, (c) the magnified figure of the circled place in (b)

Fig. 6 Roll produced in the factory for the experiment: (a) the rough casting after rough machining, (b) the outer
layer and intermediate layer cut from the casting
 N.N. Song et al.: J. Mater. Sci. Technol., 2012, 28(2), 147–154. 153

Fig. 7 MC segregation of the outer layer of work roll: (a) the position of MC segregation in the three layers of
work roll unit (mm), (b) macrostructure of MC segregation in the outer layer

Acknowledgements
The authors thank the financial support from
CAS/SAFEA International Partnership Program for Cre-
ative Research Teams. And also thank Enquan Huo, se-
nior engineer in Tangshan XianLong Metallurgical Roll
Co., Ltd for experimental production instruction.

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Nomenclature

c, cl , cec Specific heat (J·kg−1 ·K−1 )

Gr Grashof number
h Convection heat transfer coefficient (W·m−2 ·K−1 )
Pr Prandtl number
Q Parameter of the casting unit
q̇ Internal heat generation (J·kg−1 )
Ri0 , Ri+1
0
The distance of the back and front of the grid from the (0, 0) (m)
r[i] The radius of the casting at i grid (m)
ri , r0 The inner and outer radius of the outer layer (m)
Re Reynolds number
r, z, φ The radial, axial and circle directions of work roll
s The position of the segregation element (m)
T, Twl , Tw2 , Rsur1 , Tsur2 Ttemperature (K)
t Time (s)
V Volume of the segregate eutectic carbides (m3 )
Vk Volume fraction of the eutectic carbides in k grid
ρ, ρl , ρec Density (kg·m−3 )
λ, λl , λec , λ1 , λ2 , λ3 , λ4 Thermal conductivity of casting (W·m−1 ·K−1 )
ε The emissivity
µ Viscosity (Pa·s)
σ Stefan-Boltzmann’s constant (5.67×10−8 W·m−2 ·K−4 )

where l and ec subscripts indicate the liquid and eutectic carbides, separately. ω1, ω2, sur1 and sur2 subscripts
indicate inner surface of the slag, outer surface of the mold, inner air of the roll and the outside mold air,
separately. The 1, 2, 3 and 4 subscripts stand for the four directions of one grid.

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