Computerized simulation of shortened ingots with a controlled crystallization for manufacturing of high-quality forgings

The ingot with a cooled bottom crystallizer and a relative height approximately equal to 1.0 allows changing a front of the metal crystallization. The method of experimental and theoretical research studies has been proposed. The theoretical study has been performed using a finite element (FE) method. Verification of results of the FE modeling has been performed by means of experimental studies on aluminum and transparent models of the forging ingots. The investigations of macrostructures for ingot with controlled crystallization have been done. The results of the numerical simulation allow to establish that the temperature center of the crystallization is placed in the ingot's head. The basic part of the ingot is crystalized at equal thermal gradient. A fine-grained microstructure, which increases the density of the macrostructure, appears in the ingot's bottom. The investigation of the grain size along with the ingot's diameter at various levels has allowed to determine that the middle and bottom parts have a fine-grained macrostructure. The shortened ingot with direct crystallization and taper of 5% has obtained a homogeneous and dense macrostructure. Therefore, increasing the large forging ingots' quality is possible by using shortened ingots with inverse taper and controlled crystallization.