Transport phenomena in metal processing operations

该高级研究计划旨在发现在液态金属和合金的加工和铸造过程中限制热量，质量和流体流动现象的基本问题，以及它们转化为金属板材产品。在液态钢的处理中，精炼金属目前从钢包转移到精炼炉中，用于在铸造之前重新分配到连续铸造机的模具中。建议更紧密地调节进入和通过转炉的钢内的氩气气泡的尺寸，以便使用它们来浮出尺寸范围为1-50微米的有害夹杂物。这些尺寸在工业操作中是不可能去除的。为了尝试这种复杂的程序，学生需要学习复杂的计算流体动力学，以预测金属和覆盖炉渣的流动，并使用先进的监测设备（温度，物种浓度和夹杂物传感器），以比较这些与来自全尺寸的等效实验结果，水模型蒸馏器，配备了最先进的控制系统，位于麦吉尔。类似地，当铸造钢和铝时，仍然常见的是铸造厚的金属板。在表面处理（去除氧化皮或表面加工）后，板坯从150 mm厚轧制到1 mm或更小！热轧米尔斯是资本密集型的，而且对环境不好。金属板材生产的未来是环保的近净成形铸造（NNSC）工艺（约2- 10 mm厚）。这些需要将熔融金属铸造到移动的冷却基底上，以便形成“完美”的凝固表面，没有瑕疵。为了实现这一具有挑战性的目标，麦吉尔大学的一个独特的试验规模水平单带连铸机（汇丰银行）现在可以与先进的，高度仪表化的模拟器一起使用。创新的基础工作提出，学习到底如何液体金属接触激冷表面，如何通过峰和谷（在微观尺度）的不完美的界面传递热量，并意味着修改接触的程度，这取决于合金系统和反应。使用最先进的仪器，这项研究的目的是发现方法来彻底改变目前的技术。

This advanced research program aims at discovering the fundamental issues limiting heat, mass, and fluid flow phenomena, during the processing and casting of liquid metals and alloys, and their transformation into sheet metal products. In the processing of liquid steel, refined metal is currently transferred from a ladle into a tundish for re-distribution into the moulds of continuous casting machines, prior to casting. It is proposed to regulate the sizes of argon bubbles within the steel passing into, and through, a tundish more closely, so as to use them to float out deleterious inclusions in the size range 1-50 microns. These sizes are impossible to remove in industrial operations. To attempt such sophisticated procedures, students need to learn complex computational fluid dynamics in order to predict the flows of metal and overlaying slags, and to use advanced monitoring equipment (sensors for temperature, species concentration, and inclusions), in order to compare these with equivalent experimental results from a full scale, water model tundish, fitted with a state of the art control system, located at McGill. Similarly, when casting steel and aluminum, it is still common to cast thick slabs of metal. Following surface conditioning (scale removal or surface machining), slabs are rolled down from 150 mm thick to a millimeter, or less! Hot rolling mills are capital intensive, and environmentally unsound. The future for metal sheet production is environmentally-green, near-net shape casting (NNSC) procedures (~2-10mm thick). These require casting molten metal onto a moving cooling substrate, so as to form a "perfect" solidified surface, free of blemishes. To accomplish this challenging goal, a unique pilot scale Horizontal Single Belt Caster (HSBC) at McGill is now available, together with an advanced, highly instrumented, simulator. Innovative fundamental work is proposed, learning exactly how the liquid metal contacts a chill surface, how the heat is transferred through an imperfect interface of peaks and valleys (at the micro-scale), and means to modify the degree of contact, depending on the alloy systems and reactions. Using state of the art instrumentation, this research aims at discovering ways to revolutionize current technologies.