Modeling the Evolution of Casting Defect Closure in Ingots through Radial Shear Rolling Processing
Arbuz A. Panichkin A. Popov F. Kawalek A. Ozhmegov K. Lutchenko N.
January 2024Multidisciplinary Digital Publishing Institute (MDPI)
Metals
2024#14Issue 1
This paper investigates the behavior of transverse defects under significant total strain in conditions of complex vortex metal flow implemented through the radial shear rolling (RSR) method. The aim of this study is to assess the applicability of RSR processing for the in-depth transformation of small ingots of special steel into bars, particularly for the manufacturing of structural elements in specialized construction projects such as nuclear power plants. Although a substantial total strain is anticipated to enhance the steel structure and contribute to defect closure, the question of the development or closure of potential casting defects remains unclear. To address this issue, model tests were conducted to simulate the implementation of RSR processing. Defect behavior data under very complex vortex metal flow and high strain conditions were obtained for the first time and have scientific merit. A small steel ingot with a 32 mm diameter, containing a simulated artificial defect in the form of a transverse through-hole with a 5 mm diameter, was employed. During rolling, the workpiece diameter was progressively reduced by 2 mm with each subsequent pass, reaching a final diameter of 20 mm. Additionally, to provide a more detailed visualization of the defect evolution process, the same defect was modeled in an aluminum bar over six passes, and changes in defect volume and shape were analyzed after each pass. A highly detailed 3D visualization of the actual defect evolution was achieved based on cross-sections from experimental workpieces. These data corresponded to the total strain levels obtained by finite element method (FEM) simulation. Notably, a consistent similarity was observed between the test results for both metals, revealing a reduction in defect volume of up to 67.7%. The deformational welding of defects in the outer sections, encompassing one-third of the rod’s radius, occurred in the initial passes. However, defects in the axial zone of the rods remained unclosed, lengthening and gradually decreasing proportionally to the elongation of the rod, akin to conventional rolling. Consequently, the radial shear rolling (RSR) method is unsuitable for ingots with substantial discontinuities in the axial zone post-casting. Nevertheless, the method ensures the total welding of defects located in the outer zones of the ingots, even with minor applied deformations and a slight decrease in the diameter of the deformed ingot. Such data were obtained for the first time and should contribute to future investigations in this field.
casted structure , defect modeling , FEM simulation , ingot , radial shear rolling , stainless steel , transverse defect
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Core Facilities—Office the Provost, AEO Nazarbayev University, 53 Kabanbay Batyr Avenue, Astana, 010000, Kazakhstan
Institute of Metallurgy and Ore Benefication, JSC, Satbayev University, 29/133 Shevchenko St., Almaty, 050010, Kazakhstan
Department of Metallurgy, Faculty of Metallurgy and Mechanical Engineering, Karaganda Industrial University, 30 Republic Avenue, Temirtau, 101400, Kazakhstan
Department of Production Management, Faculty of Engineering Production and Materials Technology, Częstochowa University of Technology, ul. J.H. Dąbrowskiego 69, Częstochowa, 42-201, Poland
Core Facilities—Office the Provost
Institute of Metallurgy and Ore Benefication
Department of Metallurgy
Department of Production Management
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