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The increasing importance of resource availability and closed-loop material cycles are driving materials research to reduce alloying content in conventional materials or even substitute them with more sustainable alternatives. Intermetallic iron aluminide alloys (FeAl) present a potential alternative. Many alloy concepts for improved high-temperature properties or ductility have already been successfully implemented in casting technologies on a laboratory scale. However, successful testing of FeAl alloys on an industrial scale was still pending at the beginning of the project.
Therefore, the aim of the project was to develop simulation based casting concepts for industrial casting processes using the base alloy Fe-26Al-4Mo-0.5Ti-1B and to narrow down process limits by means of hot cracking tests. Findings were transferred into practice-oriented guidelines for casting of iron aluminides, which is accessible to future applicants in SMEs. The focus was placed on centrifugal casting combined with investment casting or die casting. In addition to numerous design and casting process parameters, heat treatments and alloying additions (Al, Mo, B) were varied to determine the influence of alloying elements on castability, microstructure and mechanical properties. Data from microstructure analyses (microscopic imaging, determination of grain sizes as well as phase compositions and volume fractions, fractography), mechanical tests (hardness measurements, compression tests, ambient and high-temperature tensile tests, creep tests) as well as measurements of thermophysical properties could be generated on the base alloy. Correlations of materials data with process variables allowed conclusions to be drawn on strengthening mechanisms and ductility of the alloy and how they can be controlled in terms of processing and component design. Successful casting of highly complex components with thin wall thicknesses and optimised alloy compositions points out prospects for new fields of application.
The increasing importance of resource availability and closed-loop material cycles are driving materials research to reduce alloying content in conventional materials or even substitute them with more sustainable alternatives. Intermetallic iron aluminide alloys (FeAl) present a potential alternative. Many alloy concepts for improved high-temperature properties or ductility have already been successfully implemented in casting technologies on a laboratory scale. However, successful testing of FeAl alloys on an industrial scale was still pending at the beginning of the project.
Therefore, the aim of the project was to develop simulation-based casting concepts for industrial casting processes using the base alloy Fe-26Al-4Mo-0.5Ti-1B and to narrow down process limits by means of hot cracking tests. Findings were transferred into practice-oriented guidelines for casting of iron aluminides, which is accessible to future applicants in SMEs. The focus was placed on centrifugal casting combined with investment casting or die casting. In addition to numerous design and casting process parameters, heat treatments and alloying additions (Al, Mo, B) were varied to determine the influence of alloying elements on castability, microstructure and mechanical properties. Data from microstructure analyses (microscopic imaging, determination of grain sizes as well as phase compositions and volume fractions, fractography), mechanical tests (hardness measurements, compression tests, ambient and high-temperature tensile tests, creep tests) as well as measurements of thermophysical properties could be generated on the base alloy. Correlations of materials data with process variables allowed conclusions to be drawn on strengthening mechanisms and ductility of the alloy and how they can be controlled in terms of processing and component design. Successful casting of highly complex components with thin wall thicknesses and optimised alloy compositions points out prospects for new fields of application.
In the last decades, numerical simulations of fresh concrete flow have gained importance in concrete industry. They showed a potential to become a tool for prediction of concrete casting and to help engineers to avoid expensive mistakes on site. A promising field for application of numerical modelling is casting of Self-Compacting Concrete (SCC), since the main area of application of SCC are complex and highly-reinforced building elements. Simulations of fresh concrete flow involve complex mathematical models and time-consuming computations. In case of casting simulations, the simulation time is additionally significantly increased because each reinforcement bar occurring in succession has to be considered one by one. This is particularly problematic in case of SCC casting, since this type of concrete is typically used for heavily-reinforced structural members. With the aim to decrease simulation time and to come closer to a practical simulation tool, we proposed an innovative modelling approach that models a zone with arrays of the reinforcement bars as a porous medium (PM). By defining characteristic parameters of the PM, its influence on the flow can be defined. This approach simplifies the geometry to be modelled and significantly decreases the computational time. The present contribution provides a brief description the proposed numerical model and of the conducted validation studies. The applicability of the model on fresh concrete is verified through the comparison between experimental measurements and numerical simulations.
Numerical simulations of concrete castings are complex and time consuming. In order to decrease simulation time and to simplify simulation procedure, an innovative modelling approach, which treats reinforced sections in a formwork as porous media, was proposed. In the previous studies, this numerical model was proved suitable to simulate casting of model yield-stress fluids through reinforced elements. This article focuses on the experimental validation of the proposed model at the concrete scale. For this purpose, a large-scale laboratory casting of a highly reinforced beam is performed. The casting process is numerically simulated and the numerical results are compared to the experimental measurements.
First, we define in this paper two benchmark flows readily usable by anyone calibrating a numerical tool for concrete flow prediction. Such benchmark flows shall allow anyone to check the validity of their computational tools no matter the numerical methods and parameters they choose. Second, we compare numerical predictions of the concrete sample final shape for these two benchmark flows obtained by various research teams around the world using various numerical techniques. Our results show that all numerical techniques compared here give very similar results suggesting that numerical simulations of concrete filling ability when neglecting any potential components segregation have reached a technology readiness level bringing them closer to industrial practice.