CD Laboratory for Multi-Phase Modelling of Metallurgical Processes

The aim of the research is to develop computer simulations that accurately describe various metal production processes and contribute to their optimisation.

In many metal extraction and production processes (metallurgy), the movements of solid and gaseous components of a melt play an important role. These movements have a significant influence on the quality of the finished product. As part of the research work, selected metallurgical processes are analysed in more detail and described mathematically.

The selected processes include macrosegregation in a number of different manufacturing processes. This is the unwanted segregation of a melt that occurs due to various physical processes. This is investigated in the casting of stainless steel and in the continuous casting of phosphor bronze. However, the avoidance of macrosegregation through mechanical action on the strands (soft reduction) is also included in the research.

Other processes that are analysed and numerically described are the movements of non-metallic foreign particles and gas bubbles during the continuous casting of steel. The development of microstructures (generally a mixture of components that interact mechanically) is also analysed.

In addition, the so-called refeeding is analysed, a process in which a melt is filled in order to prevent volume loss during solidification - and thus cavities in the metal block. In particular, electro-slag remelting is analysed, in which replenishment takes place by means of an inductively heated melt residue (slag).

In addition, local events that lead to the re-melting of an already solidified material are analysed and simulated. In particular, the turbulence in gas-melt flows during the production of so-called composite large cast components is analysed.

The data obtained and simulations developed help to understand the physical processes taking place and to optimise key processes.