Formation Mechanism and Control Methods of Macrosegregation in Ingots

Macrosegregation refers to large-scale, composition inhomogeneities formed during alloy solidification, typically manifesting as positive or negative segregation bands, A-type segregation, V-type segregation, and centerline segregation. Unlike mi-crosegregation, macrosegregation cannot be eliminated by subsequent heat treatment or plastic deformation and therefore has a direct and irreversible influence on the me-chanical properties, service reliability, and safety of large-scale components. In large steel ingots and aluminum alloy ingots, macrosegregation is often accompanied by shrinkage cavities and porosity, further deteriorating internal quality and increasing the risk of premature failure.

Sample Chapter(s)
Preface (131 KB)

Components of the Book:

Preface

Nomenclature

Chapter 1 Introduction

1.1 Topic Selection Basis and Significance
1.2 Research Progress on Macrosegregation in Ingot Casting
1.3 Research Progress on Shrinkage Cavities and Porosity
1.4 Research on the Control of Ingot Defects
References

Chapter 2 Numerical Methods for Macrosegregation Prediction

2.1 Research Methods in Fluid Mechanics
2.2 Computational Fluid Dynamics
2.3 Fundamentals of Computational Fluid Dynamics
2.4 Euler-Euler Multiphase Flow Theory
2.5 Volume Average Theory
2.6 Principles of CFD Operation
References

Chapter 3 Macrosegregation Study of Large Ingots Based on the Dendritic Solidification Model

3.1 Introduction
3.2 Model Introduction
3.3 Model Validation
3.4 Geometric Model
3.5 Simulation Results
3.6 Result Discussion
3.7 Summary
References

Chapter 4 Prediction of Macrosegregation in Castings of Different Sizes by Three-Phase Dendrite Model

4.1 Introduction
4.2 Model Introduction
4.3 Geometric Model
4.4 Simulation Results
4.5 Result Discussion
4.6 Summary
References

Chapter 5 Prediction of Macrosegregation, Shrinkage Cavities and Porosity in Large Ingots by Four-Phase Dendrite Model

5.1 Introduction 5.2 Model Introduction 5.3 Geometric Model 5.4 Simulation Results 5.5 Result Discussion 5.6 Summary References

Chapter 6 Principles and Research Methods of Layered Casting Technology

6.1 Introduction
6.2 Principle of Layered Casting Process
6.3 Research Methods
References

Chapter 7 Experimental Study on the Layered Casting Process of Al-4.5 Wt% Cu

7.1 Introduction
7.2 Experimental Process
7.3 Experimental Results and Analysis
7.4 Summary
References

Chapter 8 Macrosegregation Simulation of Layered Casting Al-4.5 Wt% Cu Ingots

8.1 Introduction
8.2 Traditional Casting Process Model
8.3 Layered Casting Process Model
8.4 Summary
References

Chapter 9 Simulation Study on Macrosegregation of 55-Ton Large Steel Ingots in Layered Casting

9.1 Introduction
9.2 Geometric Model
9.3 Macrosegregation Distribution of 55-Ton Large Steel Ingots Prepared by Traditional Casting Process
9.4 The Solidification Process of the Layered Casting Technology for 55 Tons of Steel Ingots
9.5 Comparison of Macrosegregation in Ingots Prepared by Layered Casting Process and Traditional Casting Process
9.6 The Influence of Parameters of Layered Casting Process on Macrosegregation
9.7 Summary
References

Chapter 10 Application of Innovative Layered Casting Method in 55-Ton Large Steel Ingots

10.1 Introduction
10.2 Simulation of the Gradient Cooling Layered Casting Process for a 55-Ton Large Steel Ingot
10.3 New Process of Low-Level Pouring Gradient Cooling Layered Casting
10.4 Summary
References

Chapter 11 The Influence of Stepwise Gradient Cooling Method on Macrosegregation

11.1 Introduction
11.2 Geometric Model
11.3 Simulation Results and Discussion
11.4 Summary
References

Readership: Students, academics, teachers, and other people attending or interested in macrosegregation in ingots.

1		Preface Fengli Ren, Honghao Ge PDF (131 KB)

9		Nomenclature Fengli Ren, Honghao Ge PDF (263 KB)

1		Chapter 1 Introduction Fengli Ren, Honghao Ge PDF (2351 KB)

41		Chapter 2 Numerical Methods for Macrosegregation Prediction Fengli Ren, Honghao Ge PDF (647 KB)

73		Chapter 3 Macrosegregation Study of Large Ingots Based on the Dendritic Solidification Model Fengli Ren, Honghao Ge PDF (2182 KB)

111		Chapter 4 Prediction of Macrosegregation in Castings of Different Sizes by Three-Phase Dendrite Model Fengli Ren, Honghao Ge PDF (2339 KB)

145		Chapter 5 Prediction of Macrosegregation, Shrinkage Cavities and Porosity in Large Ingots by Four-Phase Dendrite Model Fengli Ren, Honghao Ge PDF (2153 KB)

177		Chapter 6 Principles and Research Methods of Layered Casting Technology Fengli Ren, Honghao Ge PDF (676 KB)

191		Chapter 7 Experimental Study on the Layered Casting Process of Al-4.5 Wt% Cu Fengli Ren, Honghao Ge PDF (1576 KB)

213		Chapter 8 Macrosegregation Simulation of Layered Casting Al-4.5 Wt% Cu Ingots Fengli Ren, Honghao Ge PDF (4576 KB)

261		Chapter 9 Simulation Study on Macrosegregation of 55-Ton Large Steel Ingots in Layered Casting Fengli Ren, Honghao Ge PDF (2715 KB)

291		Chapter 10 Application of Innovative Layered Casting Method in 55-Ton Large Steel Ingots Fengli Ren, Honghao Ge PDF (7538 KB)

317		Chapter 11 The Influence of Stepwise Gradient Cooling Method on Macrosegregation Fengli Ren, Honghao Ge PDF (1778 KB)

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