The effect of steel composition on solidification behavior and ingot mold design

In this study, the effect of ingot mould design on ingot solidification behaviour was simulated using the finite element method and compared with experimental casting results. In addition, the effect of different steel grades on ingot mold design has been tried to be examined. As input to the MAGMASoft simulation program, which uses the finite element method, similar parameters used in production tried to be defined. A total of four different ingot mould geometries with round and square sections with 2 different taper angles were simulated. Two of these moulds were selected and prepared, and the casting of different steel grades into these moulds was carried out in a laboratory-type vacuum induction furnace (VIM) with a capacity of 100 kg. In the simulation results, the values that could predict the internal structure errors that might form during the solidification of the steel were examined. While the porosity and microporosity were determined as percentages, they tried to quantify with the Niyama and Hot Spot FS Time values. These values were the parameters depending on the temperature gradient and cooling rate of the solidification behaviour. Simulation studies had shown that when moving from round mould geometry to square mould geometry and increasing the taper angle of the mould, the amount of porosity and microporosity decreases. Furthermore, a solidification structure with less probability of error was formed. The examinations made on two different ingot sections that were cast showed that the simulation results and the physical results matched. It has been observed that the porosity rate is higher in high alloy steel grades.