Fig. 1. Scanning electron micrographs (a) Mg97Y2Zn1 alloy after solution treatment with grains of the α-Mg matrix (dark grey) and interdendritic LPSO phases (grey) [4], (b) WZ62 after solution treatment [5] and (c) several Mg-Zn-RE alloys after homogenization [3] 1. Scanning electron micrographs (a) Mg97Y2Zn1 alloy after solution treatment with grains of the α-Mg matrix (dark grey) and interdendritic LPSO phases (grey) [4], (b) WZ62 after solution treatment [5] and (c) several Mg-Zn-RE alloys after homogenization [3]

주조 및 열간 압연으로 제조된 Mg-6.8Y-2.5Zn-0.5Al 마그네슘 합금의 기계적 성질 및 미세조직

주조 및 열간 압연으로 제조된 Mg-6.8Y-2.5Zn-0.5Al 마그네슘 합금의 기계적 성질 및 미세조직

Mechanical Properties and Microstructure of the Magnesium Alloy Mg-6.8Y-2.5Zn-0.5Al Produced by Casting and Hot Rolling

본 연구는 자동차, 전자 및 항공우주 산업의 경량화를 위한 고강도 마그네슘 합금 개발을 목적으로 하며, 특히 LPSO(Long Period Stacking Ordered) 구조를 포함하는 Mg-Y-Zn-Al 합금의 열간 압연 공정 기술과 그에 따른 미세조직 및 기계적 특성 변화를 학술적으로 분석한다.

Paper Metadata

  • Industry: 자동차, 전자, 항공우주 (Automotive, Electronic, Aerospace)
  • Material: Mg-6.8Y-2.5Zn-0.5Al 마그네슘 합금
  • Process: 중력 금형 주조 (Gravity Die Casting), 열간 압연 (Hot Rolling), 열처리 (Heat Treatment)

Keywords

  • 마그네슘 합금 (Magnesium alloys)
  • LPSO 구조 (LPSO structures)
  • 열간 압연 (Hot rolling)
  • 미세조직 (Microstructure)
  • 기계적 성질 (Mechanical properties)
  • 재결정 (Recrystallization)

Executive Summary

Research Architecture

본 연구는 중력 금형 주조법을 통해 제조된 Mg-6.8Y-2.5Zn-0.5Al 합금 빌렛을 실험 재료로 사용하였다. 제조된 빌렛은 직경 125mm, 길이 300mm의 크기를 가지며, 압연 전 미세조직 균질화를 위해 다양한 온도와 시간 조건에서 열처리를 수행하였다. 열간 가공성을 평가하기 위해 서보 유압식 시뮬레이터를 이용한 평면 변형 압축 시험을 300°C에서 500°C 범위에서 실시하였다. 실제 압연 공정은 실험실 규모의 가역 압연기를 사용하여 500°C 온도 조건에서 총 6회의 패스로 진행되었다. 각 압연 패스 사이에는 재결정을 유도하기 위한 중간 열처리가 포함되었으며, 최종적으로 2.5mm 두께의 판재를 생산하였다. 전체적인 실험 프레임워크는 주조, 열처리, 압축 시험을 통한 공정 변수 도출, 그리고 실제 압연 및 특성 평가의 단계로 구성되었다.

Key Findings

주조 상태의 합금은 마그네슘 기질과 결정립계에 위치한 Mg12YZn 성분의 LPSO 상을 포함하며, 이 상의 부피 분율은 약 20%로 측정되었다. 평면 변형 압축 시험 결과, 500°C에서 유동 응력이 약 125 MPa로 안정화되며 활발한 재결정 현상이 관찰되었다. 열간 압연을 거친 최종 판재는 450°C에서 2시간 동안 어닐링을 수행한 후 항복 강도 295 MPa와 인장 강도 345 MPa를 기록하였다. 이는 주조 상태 대비 강도가 크게 향상된 결과이며, 연신율 또한 소폭 개선되는 경향을 보였다. 미세조직 분석을 통해 LPSO 상 주변에서 입자 유기 핵생성(PSN)에 의한 미세 결정립 형성이 강도 향상의 주요 원인임을 확인하였다.

Fig. 1. Scanning electron micrographs (a) Mg97Y2Zn1 alloy after solution treatment with grains of
the α-Mg matrix (dark grey) and interdendritic LPSO phases (grey) [4], (b) WZ62 after solution
treatment [5] and (c) several Mg-Zn-RE alloys after homogenization [3]
1. Scanning electron micrographs (a) Mg97Y2Zn1 alloy after solution treatment with grains of the α-Mg matrix (dark grey) and interdendritic LPSO phases (grey) [4], (b) WZ62 after solution treatment [5] and (c) several Mg-Zn-RE alloys after homogenization [3]
Fig. 1. Scanning electron micrographs (a) Mg97Y2Zn1 alloy after solution treatment with grains of
the α-Mg matrix (dark grey) and interdendritic LPSO phases (grey) [4], (b) WZ62 after solution
treatment [5] and (c) several Mg-Zn-RE alloys after homogenization [3]
1. Scanning electron micrographs (a) Mg97Y2Zn1 alloy after solution treatment with grains of the α-Mg matrix (dark grey) and interdendritic LPSO phases (grey) [4], (b) WZ62 after solution treatment [5] and (c) several Mg-Zn-RE alloys after homogenization [3]

Industrial Applications

본 연구에서 개발된 합금 및 압연 기술은 자동차 산업의 엔진 부품이나 변속기 케이스와 같은 고온 노출 부품의 경량화에 직접적으로 기여할 수 있다. 또한 높은 비강도와 열적 안정성을 바탕으로 전자 기기의 하우징이나 항공우주 분야의 구조용 판재 소재로 활용이 가능하다. LPSO 구조를 활용한 고강도 마그네슘 판재 제조 공정은 기존 알루미늄 합금을 대체하여 시스템 전체의 중량을 절감하는 데 효과적이다. 특히 박판 형태로 제조가 가능하므로 복잡한 형상의 구조물 제작을 위한 성형 공정의 기초 소재로 공급될 수 있다.


Theoretical Background

LPSO 구조의 특성 및 역할

LPSO(Long Period Stacking Ordered) 구조는 마그네슘 합금 내에서 희토류 원소와 아연이 특정 주기로 적층되어 형성되는 고유한 상이다. 이 구조는 마그네슘 기질의 (0001) 기저면과 평행하게 발달하며, 전위의 활주를 효과적으로 차단하여 재료의 항복 강도를 비약적으로 높이는 역할을 한다. 특히 고온 환경에서도 열적으로 매우 안정하여 합금의 크리프 저항성을 향상시키는 데 결정적인 기여를 한다. 본 연구에서 사용된 Mg-Y-Zn-Al 합금 시스템에서는 Mg12YZn 형태의 18R 또는 14H 적층 구조를 가진 LPSO 상이 형성된다. 이러한 상은 압연 과정에서 킹크 밴드(Kink band) 형성을 유도하여 추가적인 변형 수용 능력을 제공하기도 한다. 결과적으로 LPSO 구조는 마그네슘 합금의 고질적인 단점인 낮은 강도와 고온 안정성 문제를 해결할 수 있는 핵심적인 미세조직 요소로 간주된다.

입자 유기 핵생성(PSN) 기구

입자 유기 핵생성(Particle Stimulated Nucleation, PSN)은 금속 재료의 재결정 과정에서 크고 단단한 제2상 입자 주변에서 재결정이 우선적으로 일어나는 현상이다. 압연과 같은 소성 변형 시, 변형되지 않는 LPSO 상과 변형되는 마그네슘 기질 사이의 계면에는 매우 높은 밀도의 전위와 국부적인 격자 왜곡이 발생한다. 이러한 고에너지 영역은 재결정 핵이 생성되기에 매우 유리한 조건을 제공하며, 열처리 과정에서 미세한 결정립이 이 영역을 중심으로 성장하게 된다. 본 연구에서는 LPSO 상 주변에서 약 5μm 크기의 미세 결정립이 형성되는 것을 확인하였으며, 이는 PSN 기구가 미세조직 미세화에 핵심적인 역할을 수행함을 시사한다. 결정립 미세화는 홀-패치(Hall-Petch) 관계에 따라 재료의 강도를 높이는 동시에 연성을 개선하는 효과를 가져온다. 따라서 PSN 제어는 LPSO 포함 마그네슘 합금의 기계적 성질을 최적화하기 위한 중요한 공정 전략이다.

Results and Analysis

Experimental Setup

실험에 사용된 Mg-6.8Y-2.5Zn-0.5Al 합금은 순수 마그네슘을 740°C에서 용해한 후 알루미늄과 Mg-29Y 마스터 합금을 첨가하여 제조되었다. 용탕은 균일한 혼합을 위해 기계적 교반을 거쳤으며, 710°C에서 아연을 추가한 후 중력 금형 주조를 통해 직경 125mm의 빌렛으로 제작되었다. 압연 시험을 위해 빌렛에서 두께 10mm의 디스크를 절단하였으며, 이를 360mm 직경의 롤을 갖춘 가역 압연기에서 처리하였다. 압연 전 시편은 500°C에서 2시간 동안 가열되었고, 롤 표면 온도는 120°C로 예열되어 급격한 온도 하락을 방지하였다. 압연 속도는 1 m/s로 설정되었으며, 이는 가공 중 발생하는 열 손실을 최소화하고 균열 형성을 억제하기 위한 조치였다.

Visual Data Summary

주조 상태의 미세조직은 마그네슘 수지상 구조와 그 사이의 Mg12YZn LPSO 상으로 구성되어 있으며, XRD 분석을 통해 해당 상의 존재가 명확히 입증되었다. SEM 관찰 결과, 일부 영역에서는 층상 구조의 공정상과 침상 형태의 석출물이 국부적으로 발견되기도 하였다. 압연 후의 미세조직에서는 마그네슘 결정립과 LPSO 상이 압연 방향을 따라 길게 연신된 형태를 보였다. 500°C에서 압연된 시편의 경우, LPSO 상 내부에서 변형에 의한 킹크 밴드가 뚜렷하게 관찰되었으며 이는 주요 변형 기구로 작용했음을 보여준다. 최종 열처리 후에는 LPSO 상과 기질 계면을 따라 미세한 재결정립이 밀집되어 형성된 것을 시각적으로 확인할 수 있었다.

Fig. 2. Microstructure of the Mg-6.8Y-2.5Zn-0.5Al alloy in as-cast condition (a) overview
and (b) detail with (1) magnesium matrix and (2) interdendritic phase
2. Microstructure of the Mg-6.8Y-2.5Zn-0.5Al alloy in as-cast condition (a) overview and (b) detail with (1) magnesium matrix and (2) interdendritic phase
Fig. 2. Microstructure of the Mg-6.8Y-2.5Zn-0.5Al alloy in as-cast condition (a) overview and (b) detail with (1) magnesium matrix and (2) interdendritic phase 2. Microstructure of the Mg-6.8Y-2.5Zn-0.5Al alloy in as-cast condition (a) overview and (b) detail with (1) magnesium matrix and (2) interdendritic phase

Variable Correlation Analysis

압연 온도와 패스당 압하율은 합금의 건전성에 상충하는 영향을 미치는 것으로 나타났다. 400°C 이하의 온도에서는 10% 이상의 압하율 적용 시 시편 가장자리에서 심각한 균열이 발생하였으나, 500°C에서는 20% 이상의 압하율에서도 양호한 압연성을 보였다. 변형률 속도가 증가함에 따라 유동 응력은 상승하며 가공 경화가 지배적으로 나타났고, 이는 재결정을 위한 충분한 시간이 부족했기 때문으로 분석된다. 중간 열처리 온도가 450°C에서 550°C로 높아질수록 재결정립의 크기는 증가하는 반면 LPSO 상의 분율은 점차 감소하는 상관관계를 보였다. 특히 550°C 이상의 과도한 열처리는 결정립 조대화를 유발하여 최종 판재의 기계적 강도를 저하시키는 요인이 됨을 확인하였다.


Paper Details

Mechanical Properties and Microstructure of the Magnesium Alloy Mg-6.8Y-2.5Zn-0.5Al Produced by Casting and Hot Rolling

1. Overview

  • Title: Mechanical Properties and Microstructure of the Magnesium Alloy Mg-6.8Y-2.5Zn-0.5Al Produced by Casting and Hot Rolling
  • Author: Kristina Neh, Madlen Ullmann, Rudolf Kawalla
  • Year: 2018
  • Journal: Materials Science Forum

2. Abstract

최근 몇 년 동안 마그네슘 합금은 저밀도, 높은 비강도, 높은 감쇠 능력 및 우수한 주조 특성으로 인해 자동차, 전자 및 우주 산업의 경량 부품을 위한 중요한 구조 재료로 많은 관심을 받아왔다. 다양한 마그네슘 합금 중에서 희토류(RE)를 포함하는 합금은 높은 강도, 우수한 크리프 저항성 및 우수한 열적 안정성을 제공한다. 장주기 적층 질서(LPSO) 구조는 일부 Mg-RE 합금의 개선된 특성 프로파일을 담당한다. 유망한 시스템 중 하나는 주로 압출을 통해 가공되는 Mg-Y-Zn이다. 열간 압연에 초점을 맞춘 연구는 소수에 불과하다. 본 논문은 우수한 특성 프로파일을 제공하는 최종 두께 2.5mm의 판재를 생산하기 위해 주조 상태의 마그네슘 합금 Mg-6.8Y-2.5Zn-0.5Al에 대한 패스 스케줄 및 열처리를 포함한 압연 기술의 개발을 제시한다. 연구에는 광학 및 주사 전자 현미경을 통한 미세조직 특성 분석과 기계적 성질의 결정이 수반된다.

3. Methodology

3.1. 재료 준비: 중력 금형 주조를 통해 Mg-6.8Y-2.5Zn-0.5Al 합금 빌렛(직경 125mm)을 제조함.
3.2. 열처리: 400°C, 450°C, 500°C 온도 조건에서 다양한 시간(2~24시간) 동안 균질화 열처리를 수행함.
3.3. 평면 변형 압축 시험: 서보 유압식 열간 변형 시뮬레이터를 사용하여 300~500°C 범위에서 유동 곡선을 도출함.
3.4. 열간 압연: 500°C에서 6패스 압연 공정을 수행하며, 각 패스당 20~30%의 압하율을 적용하여 최종 두께 2.5mm를 달성함.
3.5. 특성 평가: 광학 현미경, SEM, EDX, XRD를 이용한 미세조직 분석 및 상온 인장 시험을 수행함.

4. Key Results

주조 상태의 합금에서 약 20% 분율의 Mg12YZn LPSO 상이 확인되었으며, 이는 결정립계를 따라 수지상 영역에 주로 분포한다. 열간 압연 공정 중 500°C 온도 조건에서 킹크 밴드 형성이 주요 변형 기구로 작용하여 성형성을 확보하였다. 압연 및 450°C 최종 열처리 후 판재의 항복 강도는 295 MPa, 인장 강도는 345 MPa를 기록하여 주조 상태 대비 비약적인 강도 향상을 보였다. 연신율은 주조 상태보다 개선되었으나 상용 AZ 합금 계열에 비해서는 여전히 낮은 수준을 유지하였다. 미세조직적으로는 LPSO 상과 기질 계면에서 PSN 기구에 의한 재결정이 유도되어 미세한 결정립 구조가 형성되었음을 확인하였다.

Fig. 6. Optical micrographs of the specimen after plan strain compression test at 500 °C and 1 s-1:
(a) detail and (b) kink bands
6. Optical micrographs of the specimen after plan strain compression test at 500 °C and 1 s-1: (a) detail and (b) kink bands
Fig. 6. Optical micrographs of the specimen after plan strain compression test at 500 °C and 1 s-1:
(a) detail and (b) kink bands

Figure List

  1. 다양한 마그네슘 합금의 SEM 미세조직 비교 (Mg97Y2Zn1, WZ62 등)
  2. 주조 상태의 Mg-6.8Y-2.5Zn-0.5Al 합금 미세조직 (전체 및 상세)
  3. 주조 상태 합금의 XRD 패턴 분석 결과
  4. 주조 상태에서 관찰되는 다양한 형태의 석출물 SEM 사진
  5. 온도 및 변형률 속도에 따른 유동 응력 곡선
  6. 500°C 압축 시험 후의 미세조직 및 킹크 밴드 관찰 결과
  7. 공정 매개변수(온도, 압하율)에 따른 압연성 평가 개요
  8. 열간 압연 중간 단계(두께 5.5mm)의 미세조직 변화
  9. 중간 열처리 후의 SEM 및 EDX 분석 결과
  10. 최종 두께 2.5mm 판재의 광학 미세조직 사진
  11. 기계적 성질 비교 그래프 및 타 합금과의 성능 분석

References

  1. C. Kammer, Magnesium Taschenbuch, Aluminium-Verlag Düsseldorf, 2000.
  2. C. Bettles, M. Barnett, Advances in wrought magnesium alloys, Woodhead Publishing, 2012.
  3. Y. Kawamura, M. Yamasaki, Mater. Trans. 48 (11) (2007) 2986-2992.
  4. J. K. Kim, S. Sandlöbes, D. Raabe, Acta Mater. 82 (2015) 414-423.
  5. B. Q. Shi, R. S. Chen, W. Ke, Trans. Nonferrous Met. Soc. China 21 (2011) 830-835.

Technical Q&A

Q: LPSO 구조가 합금의 기계적 성질에 미치는 주요 영향은 무엇인가?

LPSO(Long Period Stacking Ordered) 상은 마그네슘 기질 내에서 전위의 이동을 효과적으로 차단하는 물리적 장벽 역할을 하여 합금의 항복 강도를 크게 향상시킨다. 또한 이 상은 고온에서도 열적으로 매우 안정하여 합금의 크리프 저항성을 높이는 데 기여한다. 압연 공정 중에는 킹크 밴드(Kink band) 형성을 통해 소성 변형을 수용하며, 재결정 과정에서 입자 유기 핵생성(PSN) 사이트 역할을 하여 미세조직을 미세화하는 효과를 제공한다.

Q: 본 연구에서 열간 압연을 위해 설정한 최적의 공정 조건은 무엇인가?

실험 결과, 500°C의 압연 온도가 가장 적합한 것으로 나타났다. 이 온도에서 재료는 충분한 연성을 확보하여 균열 없이 20~30%의 높은 패스당 압하율을 견딜 수 있었다. 또한 롤 온도를 120°C로 예열하고 1 m/s의 비교적 빠른 압연 속도를 유지함으로써 가공 중 시편의 온도 하락을 방지하고 성형성을 극대화하였다. 각 패스 사이의 중간 열처리는 가공 경화를 해소하고 재결정을 유도하는 데 필수적이었다.

Q: PSN(입자 유기 핵생성) 현상이 미세조직 제어에 어떻게 기여하는가?

PSN은 변형되지 않는 LPSO 상과 변형되는 마그네슘 기질 사이의 계면에서 발생하는 높은 전위 밀도를 이용하여 재결정 핵생성을 촉진하는 기구이다. 본 연구에서는 이 현상을 통해 LPSO 상 주변에서 약 5μm 크기의 매우 미세한 결정립들이 형성되는 것을 확인하였다. 이러한 미세 결정립 구조는 재료 전체의 강도를 높이는 홀-패치 효과를 유발하며, 압연 판재의 기계적 성질을 균일하게 만드는 데 중요한 역할을 한다.

Q: 최종 제조된 Mg-6.8Y-2.5Zn-0.5Al 판재의 강도 수준은 어느 정도인가?

열간 압연 및 최종 어닐링을 거친 판재는 항복 강도 295 MPa, 인장 강도 345 MPa를 나타냈다. 이는 기존의 상용 마그네슘 합금인 WE54나 다른 Mg-Y-Zn 계열 합금들보다 높은 수치이다. 비록 Mg-Y-Ni 합금보다는 약간 낮은 강도 수준이지만, 압연 판재 형태로서 우수한 강도와 적절한 연성을 동시에 확보했다는 점에서 산업적 활용 가치가 높다.

Q: 중간 열처리 온도가 550°C 이상으로 높아질 때 발생하는 문제점은?

중간 열처리 온도가 550°C에 도달하면 재결정립의 성장이 과도하게 일어나 결정립 조대화가 발생한다. 또한 결정립계에서 국부적인 용융 현상이 나타날 위험이 있어 재료의 건전성을 해칠 수 있다. 미세조직 분석 결과, 온도가 높아질수록 강화 상인 LPSO 상의 분율이 감소하는 경향을 보였으며, 이는 최종 판재의 기계적 강도 저하로 이어지므로 500°C 내외의 정밀한 온도 제어가 권장된다.

Conclusion

본 연구를 통해 Mg-6.8Y-2.5Zn-0.5Al 합금은 적절한 주조 및 열간 압연 공정을 거쳐 고강도 판재로 제조될 수 있음이 입증되었다. 특히 500°C에서의 압연과 패스 사이의 중간 열처리는 LPSO 상을 활용한 미세조직 미세화와 균열 방지에 결정적인 역할을 수행하였다. 최종적으로 확보된 295 MPa의 항복 강도는 경량 구조용 소재로서의 높은 경쟁력을 보여준다. 향후 연구에서는 연신율을 추가적으로 향상시키기 위한 열처리 조건의 미세 조정과 실제 부품 성형을 위한 가공성 평가가 보완되어야 할 것이다.


Source Information

Citation: Kristina Neh, Madlen Ullmann, Rudolf Kawalla (2018). Mechanical Properties and Microstructure of the Magnesium Alloy Mg-6.8Y-2.5Zn-0.5Al Produced by Casting and Hot Rolling. Materials Science Forum.

DOI/Link: 10.4028/www.scientific.net/MSF.918.3

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Fig. 2. Micrographs (200x) of the sample sections: (a) standard, (b) chill-off and (c) non-degassed castings.

알루미늄 합금제 브레이크 시스템 부품의 피로 저항성 연구

알루미늄 합금제 브레이크 시스템 부품의 피로 저항성 연구

Fatigue Resistance of Brake System Components Made of Aluminium Alloy

본 보고서는 자동차 브레이크 캘리퍼에 사용되는 G-AlSi7Mg 알루미늄 합금의 미세 구조(DAS 지수)와 기하학적 노치가 피로 수명에 미치는 영향을 실험적 테스트와 유한요소해석(FEM)을 통해 분석한 연구 결과를 담고 있습니다. 주조 공정 변수가 부품의 내구성에 미치는 기술적 기여도를 중점적으로 다룹니다.

Paper Metadata

  • Industry: Automotive (자동차)
  • Material: G-AlSi7Mg (Aluminium Alloy)
  • Process: Gravity Die Casting (중력 금형 주조)

Keywords

  • Brake calipers (브레이크 캘리퍼)
  • Aluminium alloy (알루미늄 합금)
  • Fatigue (피로)
  • Microstructure (미세 구조)
  • FEM (유한요소법)
  • DAS index (덴드라이트 암 간격 지수)

Executive Summary

Research Architecture

본 연구는 G-AlSi7Mg 합금을 사용하여 표준(Standard), 비탈가스(Non-degassed), 급냉 미실시(Chill-off)의 세 가지 주조 조건으로 브레이크 캘리퍼를 제작하였습니다. 미세 구조 분석을 위해 DAS(Dendrite Arm Spacing) 지수를 측정하였으며, 시편 수준의 회전 굽힘 시험(Rotating bending tests)과 실물 캘리퍼 수준의 맥동 압력 시험(Pulsating pressure tests)을 병행하였습니다. 또한, Nastran 소프트웨어를 활용하여 캘리퍼의 복잡한 기하학적 구조 내 응력 집중 부위를 파악하기 위한 3차원 FE 모델을 구축하고 선형 탄성 해석을 수행하였습니다.

Key Findings

실험 결과, DAS 지수는 정적 기계적 성질(인장 강도 등)에는 유의미한 영향을 미치지만, 피로 한도에 미치는 영향은 상대적으로 작아 표준 공정과 기타 공정 간의 차이가 10% 미만으로 나타났습니다. 14 MPa의 맥동 압력 시험에서 비탈가스 캘리퍼의 피로 수명은 표준 제품 대비 약 10% 감소하였습니다. FE 해석 결과, 오일 실린더 바닥면의 필렛 부위에서 최대 주응력이 발생하여 가장 임계적인 파손 기점으로 확인되었으며, 이는 실제 실험에서의 파손 위치와 일치하였습니다.

Industrial Applications

본 연구 결과는 알루미늄 주조 부품 설계 시 미세 구조 제어보다 기하학적 노치 및 응력 집중 완화가 피로 수명 향상에 더 결정적임을 시사합니다. 브레이크 캘리퍼와 같이 복잡한 형상을 가진 부품의 경우, Sines 기준을 활용한 수치 해석 모델을 통해 설계 단계에서 피로 수명을 보수적으로 예측하고 최적화하는 데 활용될 수 있습니다. 또한, 주조 공정의 경제성과 부품의 내구성 사이의 타협점을 찾는 기술적 근거를 제공합니다.
Fig. 2. Micrographs (200x) of the sample sections: (a) standard, (b) chill-off and (c) non-degassed castings.
Fig. 2. Micrographs (200x) of the sample sections: (a) standard, (b) chill-off and (c) non-degassed castings.

Theoretical Background

DAS (Dendrite Arm Spacing) 지수

DAS 지수는 인접한 덴드라이트 암 사이의 거리를 마이크로미터(μm) 단위로 측정한 값으로, 알루미늄 주조 합금의 미세 구조적 치밀도를 나타내는 핵심 지표입니다. 이는 응고 과정 중 냉각 속도에 의해 결정되며, DAS 값이 작을수록 응고 시 발생하는 공정 조직의 결함 크기가 작아져 정적 강도와 연성이 향상되는 경향이 있습니다. 본 연구에서는 주조 공정별 냉각 속도 차이가 DAS 지수와 최종 부품의 기계적 성질에 미치는 상관관계를 분석의 기초로 삼았습니다.

Heywood 모델 및 Sines 기준

Heywood 모델은 알루미늄 합금의 무한 피로 수명을 예측하기 위해 제안된 이론적 식으로, 인장 강도(UTS)와 사이클 수(N) 간의 관계를 정의합니다. Sines 기준은 다축 응력 상태에서 피로 파손을 예측하기 위한 방법으로, 교번 응력(Alternating stress) 성분과 평균 응력(Mean stress)의 첫 번째 불변량을 결합하여 안전 계수를 계산합니다. 본 연구에서는 특히 교번 응력 성분이 알루미늄 캘리퍼의 피로 파손 메커니즘을 지배한다는 가설을 검증하기 위해 이 모델들을 적용하였습니다.

Results and Analysis

Experimental Setup

실험은 UNI 3964 및 ISO 1143 표준에 따라 제작된 모래시계형 시편을 사용하여 2300 rpm 속도로 회전 굽힘 시험을 수행하였습니다. 실물 캘리퍼 시험은 특수 제작된 빔 프레임에 장착하여 7, 10, 14 MPa의 맥동 유압을 가하였으며, 일부 시험에서는 2400 Nm의 제동 토크를 동시에 부하하였습니다. 시험 온도는 상온과 200°C 조건에서 수행되었으며, 최대 350,000 사이클을 한계 수명으로 설정하여 내구성을 평가하였습니다.
Fig. 3. (a) rotating bending specimen geometry, (b) Wöhler diagram with indication of the experimental points obtained and the linear interpolation for each specimen type.
Fig. 3. (a) rotating bending specimen geometry, (b) Wöhler diagram with indication of the experimental points obtained and the linear interpolation for each specimen type.

Visual Data Summary

Wöhler 선도(S-N 곡선) 분석 결과, 표준 공정 시편과 급냉 미실시 시편의 피로 한도는 매우 유사한 기울기를 보였으나, 비탈가스 시편은 상대적으로 가파른 수명 감소를 나타냈습니다. FE 해석을 통해 시각화된 응력 분포 맵에서는 오일 공급 라인과 연결된 실린더 바닥 필렛 부위에서 응력 집중이 명확하게 관찰되었습니다. LVDT 센서를 이용한 변위 측정값과 FE 모델의 예측값 사이의 오차는 3% 미만으로 나타나 수치 모델의 신뢰성이 확보되었습니다.

Variable Correlation Analysis

분석 결과, DAS 지수와 정적 강도(UTS, 항복 강도) 사이에는 강한 상관관계가 존재하여 미세 구조가 치밀할수록 정적 저항성이 높았습니다. 그러나 피로 거동에서는 미세 구조적 변수보다 기하학적 노치에 의한 응력 집중 계수(Kt)가 더 지배적인 변수로 작용함이 확인되었습니다. Sines 기준 적용 시 평균 응력을 제외한 교번 응력 성분만을 고려한 모델이 실제 실험 데이터와 더 높은 일치성을 보였으며, 이는 파손 메커니즘이 주로 교번 응력에 의존함을 의미합니다.

Paper Details

Fatigue Resistance of Brake System Components Made of Aluminium Alloy

1. Overview

  • Title: Fatigue Resistance of Brake System Components Made of Aluminium Alloy
  • Author: Sergio Baragetti, Andrea Gavazzi, Paolo Masiello
  • Year: 2013
  • Journal: International Journal of Engineering Research and Applications (IJERA)

2. Abstract

본 논문에서는 알루미늄 합금으로 제작된 브레이크 시스템 부품의 피로 저항성에 미치는 DAS 지수 관점의 미세 구조와 기하학적 노치의 영향을 조사하였습니다. G-AlSi7Mg 다이캐스팅 자동차 브레이크 캘리퍼를 대상으로 다양한 주조 공정을 분석하였습니다. 재료의 미세 구조와 피로 거동을 직접적으로 연관시키기 위해 회전 굽힘 시편에 대한 여러 실험적 피로 테스트를 수행하였습니다. 기하학적 효과는 제동 토크의 고려 여부에 따른 실물 부품의 맥동 압력 테스트를 통해 분석되었습니다. 최고 하중 수준을 받는 반쪽 브레이크 캘리퍼에 대한 정밀한 3차원 FE 모델도 개발되었습니다. 시편과 부품 모두의 피로 수명을 예측하기 위해 Heywood 방정식과 Sines 기준과 같은 다양한 이론적 모델이 적용되었습니다.

3. Methodology

3.1. 재료 및 주조 공정: UNI-EN-1706 표준에 따른 G-AlSi7Mg 합금을 사용하여 표준, 비탈가스, 급냉 미실시 조건으로 캘리퍼를 주조하고 T6 열처리를 수행함. 3.2. 미세 구조 평가: 광학 현미경을 통해 덴드라이트 암 간격(DAS)을 측정하고 주조 공정별 밀도 및 정적 기계적 성질을 평가함. 3.3. 피로 시험: 회전 굽힘 시험(시편)과 맥동 압력 시험(실물 부품)을 수행하여 S-N 선도를 도출하고 파손 사이클을 기록함. 3.4. 수치 해석: Nastran을 이용해 캘리퍼의 1/2 모델에 대해 10-node 사면체 요소를 적용한 선형 탄성 FEM 해석을 수행하여 응력 집중 부위를 특정함. 3.5. 수명 예측 모델링: 실험 데이터를 바탕으로 Heywood 모델과 Sines 다축 피로 기준을 적용하여 이론적 수명을 계산하고 실험값과 비교 분석함.

4. Key Results

회전 굽힘 시험 결과, 표준 공정 대비 다른 주조 공정의 피로 한도 감소는 10% 미만으로 나타나 미세 구조의 영향이 제한적임을 확인하였습니다. 실물 캘리퍼의 경우 14 MPa 압력에서 비탈가스 제품의 평균 수명은 105,000 사이클로 표준 제품(125,000 사이클)보다 낮았습니다. FEM 해석을 통해 오일 실린더 바닥면이 가장 높은 응력을 받는 임계 지점임을 확인하였으며, Sines 기준 적용 시 교번 응력 성분만을 고려한 모델이 실험 결과와 가장 잘 일치하는 예측 성능을 보였습니다. 이는 복잡한 형상의 부품에서 기하학적 노치가 피로 수명을 결정하는 핵심 요소임을 입증합니다.

5. Mathematical Models

$$ \frac{\sigma_a}{UTS} = \frac{1 + 0.0038 \cdot n}{1 + 0.008 \cdot n^4} $$ (식 1: 피로 한도 예측을 위한 Heywood 모델) $$ \sigma^* = \tau_{oct,alt} = \sqrt{\sigma_{I,alt}^2 + \sigma_{II,alt}^2 + \sigma_{III,alt}^2 – \sigma_{I,alt}\sigma_{II,alt} – \sigma_{II,alt}\sigma_{III,alt} – \sigma_{I,alt}\sigma_{III,alt}} $$ (식 2: Sines 기준에 따른 교번 팔면체 전단 응력 계산식)

Figure List

  1. Fig. 1. 주조 공정 중 측정된 밀도 다이어그램
  2. Fig. 2. 샘플 단면의 미세 구조 사진 (표준, 급냉 미실시, 비탈가스)
  3. Fig. 3. 회전 굽힘 시편 형상 및 Wöhler 선도
  4. Fig. 4. 실험적 파손 데이터와 Heywood 모델 결과 비교
  5. Fig. 5. 테스트 셋업 개략도 및 실제 장치 사진
  6. Fig. 6. 브레이크 캘리퍼 피로 테스트 결과
  7. Fig. 7. LVDT 위치 맵 및 측정된 변위 데이터
  8. Fig. 8. 오일 실린더 바닥면의 메쉬 세분화 및 하중 조건
  9. Fig. 9. 전체 모델의 최대 주응력 맵 및 실린더 바닥 상세 응력 분포
  10. Fig. 10. Sines 기준 예측값과 실험 데이터의 비교 선도

References

  1. Burger, G. B., et al. (2005). Microstructural Control of Aluminum Sheet Used in Automotive Applications.
  2. Carrera, E., et al. (2007). Measurement of residual stresses in cast aluminium engine blocks.
  3. Dixon, W. J., et al. (1983). Introduction to statistical analysis.
  4. Heywood, R. B. (1962). Designing against fatigue.
  5. Sines, G. (1959). Behavior of metals under complex static and alternating stresses.

Technical Q&A

Q: DAS(Dendrite Arm Spacing) 지수가 피로 저항에 미치는 영향은 어느 정도입니까?

실험 결과에 따르면 DAS 지수는 정적 강도에는 큰 영향을 미치지만, 피로 한도에 미치는 영향은 상대적으로 제한적입니다. 표준 주조 공정과 미세 구조가 거친 다른 공정 간의 피로 한도 차이는 10% 미만으로 나타났습니다. 이는 알루미늄 주조 부품의 피로 수명이 미세 구조적 인자보다 기하학적 요인에 더 민감함을 시사합니다.

Q: 브레이크 캘리퍼에서 피로 파손이 가장 빈번하게 발생하는 임계 부위는 어디입니까?

FE 해석과 실물 테스트 결과 모두에서 오일 실린더의 바닥면(Bottom of the oil cylinder)이 가장 임계적인 부위로 확인되었습니다. 특히 오일 공급 라인과 연결되는 필렛(Fillet) 부위에서 응력 집중 계수가 최대로 나타나며, 이 지점에서 피로 균열이 시작되어 유압 저하를 유발하는 파손이 발생합니다.

Q: Sines 기준을 적용했을 때 평균 응력(Mean stress)의 영향은 어떻게 나타났습니까?

본 연구에서 Sines 기준을 적용하여 분석한 결과, 평균 응력 성분을 포함한 모델보다 교번 응력(Alternating stress) 성분만을 고려한 모델이 실험 데이터와 더 잘 일치하였습니다. 이는 해당 알루미늄 캘리퍼의 피로 파손 메커니즘이 평균 응력보다는 반복되는 교번 응력의 진폭에 의해 주로 지배됨을 의미합니다.

Q: 주조 공정 중 ‘비탈가스(Non-degassed)’ 처리가 부품 성능에 미치는 구체적인 결과는 무엇입니까?

비탈가스 공정으로 제작된 캘리퍼는 표준 공정 제품에 비해 밀도가 낮고 DAS 지수가 높게 나타났습니다. 이로 인해 정적 항복 강도는 약 18% 감소하였으며, 14 MPa 맥동 압력 조건에서의 피로 수명은 표준 제품 대비 약 16% 감소하는 결과를 보였습니다. 이는 가스 함유량이 기계적 성질 전반에 부정적인 영향을 미침을 보여줍니다.

Q: FE 모델의 정확성을 검증하기 위해 어떤 방법을 사용하였습니까?

FE 모델의 신뢰성을 확보하기 위해 LVDT 센서를 사용하여 실물 캘리퍼 외면의 여러 지점에서 유압 변화(0.5~10 MPa)에 따른 변위를 측정하였습니다. 측정된 실험적 변위값과 FE 모델의 수치 해석 결과값을 비교하였을 때, 오차가 3% 미만으로 나타나 개발된 수치 모델이 실제 부품의 거동을 매우 정확하게 모사함을 입증하였습니다.

Conclusion

본 연구는 알루미늄 합금 브레이크 캘리퍼의 피로 수명이 미세 구조적 인자인 DAS 지수보다 기하학적 노치에 의한 응력 집중의 영향을 훨씬 더 크게 받는다는 것을 입증하였습니다. 주조 공정의 변화로 인한 피로 한도의 차이는 10% 내외로 크지 않았으나, 부품의 형상 설계에 따른 응력 집중은 파손 위치와 수명을 결정짓는 핵심 요소였습니다. Sines 기준을 활용한 수치 해석 모델은 이러한 복잡한 부품의 피로 수명을 예측하는 데 유효한 도구임이 확인되었으며, 특히 교번 응력 성분을 중심으로 한 설계 최적화가 내구성 향상에 필수적임을 결론지었습니다.

Source Information

Citation: Sergio Baragetti, Andrea Gavazzi, Paolo Masiello (2013). Fatigue Resistance of Brake System Components Made of Aluminium Alloy. International Journal of Engineering Research and Applications (IJERA).

DOI/Link: Not described in the paper

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Fig. 1. The dependence of the tensile strength of AlSi11/10 vol.% SiC composite on parameters of pressure die casting process

고압 다이캐스팅 공정 최적화: AlSi11/SiC 복합소재의 기계적 물성을 극대화하는 핵심 변수

이 기술 요약은 Z. Konopka와 A. Pasieka가 ARCHIVES of FOUNDRY ENGINEERING (2014)에 발표한 논문 “The Influence of Pressure Die Casting Parameters on the Mechanical Properties of AlSi11/10 Vol.% SiC Composite”을 기반으로 하며, STI C&D가 기술 전문가를 위해 분석하고 요약했습니다.

키워드

  • Primary Keyword: 고압 다이캐스팅 (High-Pressure Die Casting)
  • Secondary Keywords: 금속 복합소재 (Metal Matrix Composites), AlSi11/SiC, 기계적 물성 (Mechanical Properties), 공정 최적화 (Process Optimization), 인장 강도 (Tensile Strength)

Executive Summary

  • The Challenge: 점성이 높은 AlSi11/SiC 복합소재 슬러리를 주조할 때, 강화 입자의 균일한 분포와 높은 기계적 강도를 동시에 달성하는 것은 매우 어렵습니다.
  • The Method: 콜드 챔버 고압 다이캐스팅 장비를 사용하여 2단계 피스톤 속도, 증압 압력, 게이트 폭을 변수로 하는 2³ 요인 실험 설계를 통해 공정 변수의 영향을 체계적으로 평가했습니다.
  • The Key Breakthrough: 2단계 피스톤 속도가 기계적 물성에 가장 결정적인 영향을 미치는 요인임을 확인했으며, 더 높은 속도와 증압 압력은 인장 강도를 크게 향상시켰습니다.
  • The Bottom Line: 고성능 금속 복합소재 부품을 고압 다이캐스팅으로 제조하기 위해서는 피스톤 속도를 포함한 사출 파라미터의 정밀한 제어가 필수적입니다.

The Challenge: Why This Research Matters for CFD Professionals

금속 복합소재(Metal Matrix Composites, MMCs)는 기존 합금의 한계를 뛰어넘는 우수한 기계적, 열적 특성으로 인해 많은 산업 분야에서 주목받고 있습니다. 특히, SiC 입자로 강화된 알루미늄 복합소재는 경량화와 고강도를 동시에 만족시켜야 하는 자동차 및 항공우주 부품에 이상적입니다.

하지만 이러한 복합소재 슬러리는 일반 용탕보다 점성이 훨씬 높아 주조성이 현저히 떨어지는 문제를 안고 있습니다. 금형 캐비티를 완전히 채우기 어렵고, 강화 입자가 불균일하게 분포하여 원하는 기계적 특성을 얻지 못하는 경우가 많습니다. 이러한 문제를 해결하기 위해 금형에 강제적으로 용탕을 충전시키는 고압 다이캐스팅 기술이 가장 적합한 대안으로 떠오르고 있습니다. 본 연구는 고압 다이캐스팅의 핵심 공정 변수들이 AlSi11/SiC 복합소재의 최종 기계적 물성에 미치는 영향을 정량적으로 분석하여, 고품질 복합소재 부품 생산을 위한 공학적 기반을 제공하고자 했습니다.

The Approach: Unpacking the Methodology

본 연구는 AlSi11 합금을 기지(matrix)로 하고, 10 vol.%의 SiC 입자(크기 71-100 µm)를 강화재로 사용한 복합소재 슬러리를 제조하는 것에서 시작되었습니다. 슬러리는 저항 가열로 내에서 터보믹서를 사용하여 15분간 500 rpm으로 기계적으로 혼합하여 준비되었습니다.

주조 공정에는 1.6 MN의 형체력을 가진 콜드 챔버 수평형 고압 다이캐스팅 머신이 사용되었습니다. 실험의 신뢰도를 높이기 위해 다음과 같은 변수들을 제어했습니다.

  • 고정 변수: 프레싱 피스톤 직경(40 mm), 1단계 사출 속도(0.3 m/s), 슬리브 충전율(60%), 슬러리 온도(650°C), 금형 온도(300°C)
  • 가변 변수 (2³ 실험 설계):
    1. 2단계 피스톤 속도 (vII): 1.2 m/s 또는 3.6 m/s
    2. 증압 압력 (pIII): 20 MPa 또는 40 MPa
    3. 게이트 폭 (dw): 1.5 mm 또는 3 mm

각 실험 조건마다 100개의 인장 시험 시편을 주조하여 금형의 열적 평형 상태를 유지했으며, 컴퓨터로 제어되는 Zwick 1488 인장 시험기를 사용하여 PN-EN ISO 6892-1:2010 표준에 따라 인장 강도, 항복 강도, 연신율을 측정했습니다.

The Breakthrough: Key Findings & Data

실험 결과, 고압 다이캐스팅 공정 변수가 복합소재의 기계적 물성에 미치는 영향을 설명하는 회귀 방정식을 도출했으며, 다음과 같은 핵심적인 발견을 할 수 있었습니다.

Finding 1: 인장 강도에 가장 큰 영향을 미치는 것은 피스톤 속도

2단계 피스톤 속도는 복합소재의 인장 강도(Rm)를 결정하는 가장 지배적인 요인이었습니다. Figure 1에서 볼 수 있듯이, 2단계 피스톤 속도를 1.2 m/s에서 3.6 m/s로 높이면 모든 압력 및 게이트 조건에서 인장 강도가 일관되게 상승했습니다. 예를 들어, 증압 압력 40 MPa, 게이트 폭 1.5 mm 조건에서 피스톤 속도를 높였을 때, 평균 인장 강도는 275.8 MPa에서 298.0 MPa로 증가했습니다(Table 1, Exp. 4 & 7). 이는 높은 충전 속도가 게이트에서 슬러리의 격렬한 혼합을 유도하여 강화 입자의 균일한 분포를 촉진하기 때문입니다.

Fig. 1. The dependence of the tensile strength of AlSi11/10 vol.% SiC composite on parameters of pressure die casting process
Fig. 1. The dependence of the tensile strength of AlSi11/10 vol.% SiC composite on parameters of pressure die casting process

Finding 2: 증압 압력과 게이트 폭이 주물 품질을 좌우

증압 압력과 게이트 폭 또한 기계적 물성에 중요한 영향을 미쳤습니다. 도출된 회귀 방정식(1) ŷ = 262.30 + 19.70x₁ + 12.95x₂ – 7.55x₃ 에서 증압 압력(x₂)의 계수는 양수(+)이고 게이트 폭(x₃)의 계수는 음수(-)입니다. 이는 더 높은 증압 압력과 더 좁은 게이트가 인장 강도를 향상시킨다는 것을 의미합니다. 높은 증압 압력은 주물 내부에 불가피하게 존재하는 기공을 압축하거나 제거하여 주물의 밀도를 높입니다. 이는 금속 기지와 SiC 입자 간의 접착 면적을 넓혀, 결과적으로 더 우수한 기계적 강도를 나타나게 합니다.

Practical Implications for R&D and Operations

  • For Process Engineers: 본 연구는 2단계 피스톤 속도와 증압 압력을 높이는 것이 AlSi11/SiC 복합소재 주물의 인장 강도와 밀도를 향상시키는 효과적인 방법임을 시사합니다. 공정 최적화 시 이 두 변수를 우선적으로 고려해야 합니다.
  • For Quality Control Teams: Table 1과 Figure 1-3의 데이터는 특정 주조 파라미터 조합(예: vII = 3.6 m/s, pIII = 40 MPa, dw = 1.5 mm)이 가장 높은 기계적 물성(Rm = 298.0 MPa)과 직접적인 상관관계가 있음을 보여줍니다. 이는 공정 파라미터 기록을 기반으로 한 새로운 품질 검사 기준을 수립하는 데 활용될 수 있습니다.
  • For Design Engineers: 좁은 게이트 폭(dw)이 기계적 물성을 향상시킨다는 결과는, 복합소재 다이캐스팅에서 게이트 설계가 강화 입자의 균일한 분포를 보장하고 결함을 최소화하는 데 매우 중요한 요소임을 나타냅니다. 이는 부품 설계 초기 단계에서 반드시 고려되어야 할 사항입니다.

Paper Details


The Influence of Pressure Die Casting Parameters on the Mechanical Properties of AlSi11/10 Vol.% SiC Composite

1. Overview:

  • Title: The Influence of Pressure Die Casting Parameters on the Mechanical Properties of AlSi11/10 Vol.% SiC Composite
  • Author: Z. Konopka, A. Pasieka
  • Year of publication: 2014
  • Journal/academic society of publication: ARCHIVES of FOUNDRY ENGINEERING, Volume 14, Issue 1/2014
  • Keywords: Composites, Pressure Die Casting, Mechanical Properties

2. Abstract:

본 논문은 AlSi11 합금 기지와 10 vol.%의 SiC 입자로 구성된 복합소재 슬러리의 제조 방법, 고압 다이캐스팅 방법, 그리고 이를 통해 얻어진 복합소재의 인장 강도, 항복점, 연신율 및 경도에 대한 측정 결과를 제시한다. 복합소재 주물은 2단계 사출에서의 다양한 피스톤 속도, 다양한 증압 압력, 그리고 다양한 사출 게이트 폭 값에서 생산되었다. 고압 다이캐스팅 공정 변수의 함수로서 조사된 복합소재의 기계적 특성 변화를 설명하는 회귀 방정식이 도출되었다. 결론에서는 얻어진 결과에 대한 분석과 해석을 제공한다.

3. Introduction:

복합소재 제품의 제작은 복합소재의 특성이 기지 합금 자체의 특성을 능가할 때 많은 응용 분야에서 매우 합리적이다. 기계적 특성이 중요할 경우 기지의 강화가 요구되며, 열적 또는 마찰학적 특성과 같은 다른 특성들은 원하는 수준의 달성을 제공하는 방식으로 설계된다. 복합재료의 특성은 구성 요소의 특성, 개별 구성 요소의 분율, 모양, 그리고 그들 사이의 결합 강도뿐만 아니라 최종 제품의 기술에 따라 달라진다. 이론적 고찰에 따르면, 연속 섬유로 강화된 금속 기지 복합재료에서 최상의 특성이 달성된다. 금속 기지에 입자를 도입하면 열적, 화학적, 전기적 및 마찰학적 특성을 제어할 수 있는 광범위한 가능성이 창출된다.

4. Summary of the study:

Background of the research topic:

금속 기지 복합소재(MMC)는 우수한 특성으로 인해 활용도가 높지만, 강화 입자로 인해 점성이 높아져 주조가 어렵다는 문제를 가지고 있다.

Status of previous research:

이전 연구들은 고점성 슬러리 주조에 고압 다이캐스팅이 적합하다는 점을 시사했으나, 핵심 공정 변수(사출 속도, 충전 시간, 사출 압력 등)가 복합소재의 최종 기계적 물성에 미치는 영향에 대한 정량적 분석이 필요했다.

Purpose of the study:

본 연구의 목적은 고압 다이캐스팅의 주요 공정 변수인 2단계 피스톤 속도, 증압 압력, 게이트 폭이 AlSi11/10 vol.% SiC 복합소재의 기계적 특성(인장 강도, 항복 강도, 연신율)에 미치는 영향을 실험적으로 규명하고, 그 관계를 설명하는 회귀 모델을 개발하는 것이다.

Core study:

AlSi11/SiC 복합소재를 2³ 요인 설계에 따라 다양한 고압 다이캐스팅 조건에서 주조하고, 제작된 시편의 기계적 물성을 측정하여 공정 변수와 물성 간의 상관관계를 분석했다.

5. Research Methodology

Research Design:

2³ 요인 실험 설계를 사용하여 세 가지 주요 공정 변수(2단계 피스톤 속도, 증압 압력, 게이트 폭)를 각각 두 수준(저/고)으로 설정하여 총 8개의 실험 조건을 구성했다.

Data Collection and Analysis Methods:

각 조건에서 주조된 시편에 대해 표준 인장 시험(PN-EN ISO 6892-1:2010)을 수행하여 기계적 물성 데이터를 수집했다. 수집된 데이터를 바탕으로 다중 회귀 분석을 통해 공정 변수가 각 기계적 물성에 미치는 영향을 설명하는 수학적 모델을 도출했다.

Research Topics and Scope:

연구는 AlSi11 합금 기지에 10 vol.%의 SiC 입자가 포함된 복합소재에 국한되었다. 고압 다이캐스팅 공정 중 2단계 피스톤 속도, 증압 압력, 게이트 폭의 영향에 초점을 맞추었으며, 평가된 기계적 특성은 인장 강도, 항복 강도, 연신율이다.

6. Key Results:

Key Results:

Fig. 2. The dependence of the yield strength of AlSi11/10 vol.% SiC composite on parameters of pressure die casting process
Fig. 2. The dependence of the yield strength of AlSi11/10 vol.% SiC composite on parameters of pressure die casting process
  • 2단계 사출에서의 피스톤 속도는 복합소재 주물의 기계적 특성에 가장 큰 영향을 미치는 변수이다.
  • 피스톤 속도 증가와 게이트 면적 감소(더 얇은 게이트)는 캐비티 충전율을 높여 인장 강도를 향상시킨다.
  • 높은 증압 압력은 주물의 밀도를 높이고 금속/입자 계면의 접착력을 향상시켜 강도를 개선한다.
  • 항복 강도에는 피스톤 속도와 게이트 폭이 가장 중요한 영향을 미쳤다.
  • 복합소재의 연신율은 기지 합금(약 3%)에 비해 현저히 낮은 0.98-1.91% 범위로 나타났으며, 이는 취성 세라믹 입자의 존재 때문이다.

Figure List:

  • Fig. 1. The dependence of the tensile strength of AlSi11/10 vol.% SiC composite on parameters of pressure die casting process
  • Fig. 2. The dependence of the yield strength of AlSi11/10 vol.% SiC composite on parameters of pressure die casting process
  • Fig. 3. The dependence of the unit elongation of AlSi11/10 vol.% SiC composite on parameters of pressure die casting process

7. Conclusion:

도출된 방정식으로부터 2단계 사출에서의 피스톤 속도가 복합소재 주물의 기계적 특성에 가장 큰 영향을 미친다는 것이 명확하게 나타난다. 금형 충전 중 피스톤 속도의 증가와 게이트 면적의 감소(즉, 더 얇은 게이트)는 캐비티 충전율을 증가시킨다. 증가된 사출 속도는 복합소재 주물의 인장 강도 증가를 동반하며, 가장 큰 증가는 50 m/s의 사출 속도에 해당한다. 높은 충전율은 게이트에서 슬러리의 집중적인 혼합을 제공하여 강화상 입자의 균일한 분포를 촉진하고 주물의 기계적 특성을 향상시킨다. 또한, 높은 증압 압력은 주물의 밀도를 높여 기계적 특성을 개선하는 데 중요한 역할을 한다. 고압으로 사출된 후 증압 압력을 받은 금속은 입자에 단단히 부착되어 기공을 채우고 돌출부를 감싸며, 이는 시험 결과의 향상에 기여한다.

8. References:

  1. Konopka, Z. (2011). Metal cast composites. Częstochowa: Wydawnictwo Politechniki Częstochowskiej.
  2. Ashby, M. F., Jones, D. R. H. (1998). Engineering Materials. Properties and Applications. Warsaw: WNT.
  3. Konopka, Z. (2008). Gravity and pressure die casting of Al alloy matrix composites with SiC and graphite particles. Częstochowa: Wydawnictwo Politechniki Częstochowskiej.
  4. Matthews, F. L., Rawlings, R. D. (1994). Composite Materials: Engineering and Science. Chapman and Hall.
  5. Konopka, Z. (2007). Gravity and pressure casting of Al alloy matrix composites with SiC and graphite particles. In Sobczak J. (Ed.) Innovations in Foundry. Part 1. (199-208). Cracow: Foundry Research Institute.
  6. Dańko, J. (2000). Machines and devices for pressure die casting. Cracow: Ed. AGH.
  7. Białobrzeski, A. (1992). Pressure casting. Machines, devices and technology. Warszawa: PWN.
  8. Street, A. (1997). The Diecasting Book. Portcullis Press Ltd.
  9. Barton, H. (1944). The injection of metal into diecastings. Machinery L. 64(1642, 1650), 65(1664).
  10. Frommer, L. (1928). Der Spritzguss. Berlin.
  11. Konopka, Z. (1995). Pressure Die Cast Fibre Reinforced Al-Si Alloy Matrix Composites. In Euromat. 667-670.
  12. Śleziona, J. (1995). The influence of ceramic particles on solidification of Al-Si and Al2O3 composites. Archiwum Nauki o Materiałach. 2, 163-178.

Expert Q&A: Your Top Questions Answered

Q1: 이 실험에서 2³ 요인 설계를 선택한 이유는 무엇입니까?

A1: 논문에서 명시적으로 밝히지는 않았지만, 2³ 요인 설계는 세 가지 변수(피스톤 속도, 압력, 게이트 폭)가 두 수준(저/고)에서 미치는 주 효과와 상호작용을 효율적으로 연구하기 위한 표준적인 통계 기법입니다. 이 설계를 통해 연구진은 각 변수가 기계적 물성에 미치는 영향을 체계적으로 평가하고, 그 결과를 바탕으로 신뢰성 있는 회귀 방정식을 도출할 수 있었습니다.

Q2: 높은 증압 압력이 금속/입자 계면을 개선하는 메커니즘은 구체적으로 무엇입니까?

A2: 논문의 결론에 따르면, 높은 압력으로 사출된 후 증압 단계를 거치면서 금속 용탕이 SiC 입자에 “단단히 부착(adheres tightly)”됩니다. 이 과정에서 용탕이 입자 표면의 미세한 기공을 채우고 돌출부를 감싸게 되어, 금속 기지와 강화 입자 간의 물리적 접착 면적이 극대화됩니다. 이는 계면 결합력을 높여 최종적으로 더 우수한 기계적 강도를 나타내는 핵심적인 메커니즘입니다.

Q3: Figure 2의 항복 강도(R0.2)는 Figure 1의 인장 강도(Rm)에 비해 피스톤 속도 증가에 따른 상승폭이 더 작아 보입니다. 그 이유는 무엇일까요?

A3: 논문에서는 강화상(SiC 입자)의 존재 자체가 항복 강도와 연신율 같은 특성을 저하시키는 경향이 있다고 언급합니다. 실제로 항복 강도에 대한 회귀 방정식(Eq. 2)에서 피스톤 속도(x₁)의 계수(10.4750)는 인장 강도 방정식(Eq. 1)의 계수(19.70)보다 작습니다. 이는 피스톤 속도 증가가 항복 강도보다는 인장 강도에 더 큰 영향을 미친다는 것을 수학적으로 보여줍니다.

Q4: 1단계 사출 속도를 0.3 m/s로 고정한 이유는 무엇인가요?

A4: 논문은 1단계 사출 속도를 고정한 구체적인 이유를 언급하지 않았습니다. 하지만 일반적인 고압 다이캐스팅 공정에서 1단계는 용탕이 공기를 휘감지 않고 조용히 슬리브를 채우는 단계입니다. 연구진은 주물의 품질에 더 직접적인 영향을 미치는 2단계(고속 충전)와 3단계(증압)의 효과를 명확하게 분리하여 분석하기 위해 1단계 속도를 제어된 상수로 설정한 것으로 보입니다.

Q5: 복합소재의 연신율이 모재인 AlSi11 합금(약 3%)에 비해 0.98-1.91%로 크게 감소한 원인은 무엇입니까?

A5: 논문의 결론 부분에서는 이러한 현상의 원인을 “취성 세라믹 입자의 존재(presence of brittle ceramic particles)”로 명확히 설명합니다. 복합소재는 소성 변형을 거의 하지 않으며, 대신 금속과 세라믹 사이의 약한 접착 결합부를 따라 취성 파괴가 일어납니다. 이로 인해 연신율이 크게 감소하게 됩니다.


Conclusion: Paving the Way for Higher Quality and Productivity

본 연구는 AlSi11/SiC 금속 복합소재의 기계적 물성이 고압 다이캐스팅 공정 변수에 의해 얼마나 민감하게 제어될 수 있는지를 명확히 보여주었습니다. 특히, 2단계 피스톤 속도, 증압 압력, 게이트 설계의 최적 조합을 통해 강화 입자의 분포를 제어하고 내부 결함을 최소화함으로써, 최종 부품의 강도와 신뢰성을 극대화할 수 있다는 사실이 입증되었습니다. 이는 고성능 경량 부품을 요구하는 산업 현장에서 품질과 생산성을 동시에 높일 수 있는 중요한 공학적 지침을 제공합니다.

(주)에스티아이씨앤디에서는 고객이 수치해석을 직접 수행하고 싶지만 경험이 없거나, 시간이 없어서 용역을 통해 수치해석 결과를 얻고자 하는 경우 전문 엔지니어를 통해 CFD consulting services를 제공합니다. 귀하께서 당면하고 있는 연구프로젝트를 최소의 비용으로, 최적의 해결방안을 찾을 수 있도록 지원합니다.

  • 연락처 : 02-2026-0450
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Copyright Information

  • This content is a summary and analysis based on the paper “The Influence of Pressure Die Casting Parameters on the Mechanical Properties of AlSi11/10 Vol.% SiC Composite” by “Z. Konopka, A. Pasieka”.
  • Source: https://doi.org/10.2478/afe-2014-0014

This material is for informational purposes only. Unauthorized commercial use is prohibited. Copyright © 2025 STI C&D. All rights reserved.

Fig. 3 As-cast microstructures in the middle of the casting walls (top left – casting No. 1, top right – casting No. 2, bottom left – casting No. 3, bottom right – casting No. 4).

단조 알루미늄 EN AW-2024의 고압 주조: 열처리를 통해 기계적 물성을 극대화하는 방법

이 기술 요약은 VANKO Branislav 외 저자가 2017년 Journal of MECHANICAL ENGINEERING – Strojnícky časopis에 발표한 논문 “EN AW-2024 WROUGHT ALUMINUM ALLOY PROCESSED BY CASTING WITH CRYSTALLIZATION UNDER PRESSURE”를 기반으로 하며, STI C&D에서 기술 전문가를 위해 분석 및 요약했습니다.

Keywords

  • Primary Keyword: 고압 주조 (Casting with Crystallization under Pressure)
  • Secondary Keywords: 단조 알루미늄 (Wrought Aluminum), EN AW-2024, 기계적 물성 (Mechanical Properties), T6 열처리 (T6 Heat Treatment), 응고 해석 (Solidification Analysis), 미세조직 (Microstructure)

Executive Summary

  • The Challenge: 고강도 단조 알루미늄 합금은 우수한 기계적 특성을 가지지만, 넓은 응고 범위로 인해 수축 기공 및 고온 균열과 같은 결함이 발생하기 쉬워 주조가 매우 어렵습니다.
  • The Method: EN AW-2024 단조 알루미늄 합금을 ‘가압 하 결정화 주조(casting with crystallization under pressure with forced flow)’ 공법을 사용하여, 주입 온도와 금형 온도를 달리한 네 가지 조건에서 주조하고 T6 열처리를 통해 물성을 평가했습니다.
  • The Key Breakthrough: 가장 높은 주입 온도(700°C)와 금형 온도(250°C)로 주조했을 때, T6 열처리 후 항복 강도가 378 MPa, 인장 강도가 418 MPa로 비약적으로 향상되었습니다. 이는 덴드라이트(dendritic) 미세조직을 형성했음에도 불구하고 달성된 결과입니다.
  • The Bottom Line: 이 공법에서 EN AW-2024 합금의 잠재적인 기계적 특성을 최대한 발현시키기 위해서는, 주조 후 열처리 효과를 극대화할 수 있는 높은 공정 온도를 적용하는 것이 결정적입니다.

The Challenge: Why This Research Matters for CFD Professionals

주조용 알루미늄 합금은 이미 기계적 물성의 한계에 도달했다는 평가를 받고 있습니다. 더 높은 성능을 요구하는 항공우주, 자동차 산업에서는 단조 알루미늄 합금의 사용이 필수적이지만, 이를 복잡한 형상의 부품으로 만들기 위한 주조 공정 적용에는 큰 어려움이 따릅니다. 특히 EN AW-2024와 같은 2xxx 계열 합금은 응고가 시작되고 완료되기까지의 온도 범위가 넓어, 응고 과정에서 수축 기공(shrinkage porosity)이나 고온 균열(hot tears)과 같은 심각한 결함이 발생할 가능성이 높습니다.

이러한 결함 없이 건전한 주조품을 생산하기 위해, 본 연구는 ‘가압 하 결정화 주조’라는 특수 공법을 적용했습니다. 이 연구의 핵심 목표는 주입 온도와 금형 온도 같은 핵심 주조 변수가 EN AW-2024 합금 주조품의 미세조직과 최종 기계적 물성에 미치는 영향을 규명하여, 고성능 부품 생산의 가능성을 탐색하는 것입니다.

The Approach: Unpacking the Methodology

본 연구에서는 EN AW-2024 단조 알루미늄 합금을 사용하여 네 가지 다른 조건에서 컵(cup) 형태의 주조품을 제작했습니다. 사용된 공법은 ‘가압 하 결정화 주조’로, 용탕이 금형 내에서 유동하며 높은 압력(100 MPa) 하에 결정화되는 방식입니다.

실험의 핵심 변수는 다음과 같이 설정되었습니다 (Tab. 1 참조): – 주조 조건 1: 주입 온도 650°C, 금형 온도 100°C – 주조 조건 2: 주입 온도 700°C, 금형 온도 100°C – 주조 조건 3: 주입 온도 650°C, 금형 온도 200°C – 주조 조건 4: 주입 온도 700°C, 금형 온도 250°C

모든 주조품에 대해 30초간 100 MPa의 압력을 유지했습니다. 제작된 시편 중 일부는 표준 T6 열처리(495°C에서 3시간 용체화 처리 후 수냉, 190°C에서 12시간 인공 시효)를 거쳤습니다. 최종적으로 주조 상태(as-cast)와 열처리 상태의 시편에 대해 인장 강도(Rm), 항복 강도(Rp0.2), 연신율(A)을 측정하여 기계적 특성을 평가했습니다.

Fig. 1 Experimental tool (1 – lower die, 2 – upper die, 3 – ejector, 4 – casting, X – point of recording of the alloy temperature).
Fig. 1 Experimental tool (1 – lower die, 2 – upper die, 3 – ejector, 4 – casting, X – point of recording of the alloy temperature).

The Breakthrough: Key Findings & Data

Finding 1: 공정 온도가 열처리 후 기계적 물성을 결정한다 (Process Temperature Dictates Post-Heat-Treatment Mechanical Properties)

주조 직후 상태에서는 네 가지 조건 모두 유사한 기계적 물성을 보였습니다 (인장 강도 약 300 MPa, 항복 강도 약 120 MPa). 하지만 T6 열처리 후에는 극적인 차이가 나타났습니다.

가장 높은 주입 온도(700°C)와 금형 온도(250°C)를 적용한 주조품 No. 4는 열처리 후 항복 강도가 378 MPa, 인장 강도가 418 MPa로 대폭 상승했습니다 (Tab. 4, Fig. 4). 이는 주조 상태 대비 항복 강도가 약 260 MPa, 인장 강도가 약 110 MPa 증가한 수치입니다. 반면, 낮은 금형 온도(100°C)에서 제작된 주조품 No. 1과 No. 2는 열처리에 의한 물성 향상 효과가 미미했습니다. 이는 높은 공정 온도가 후속 열처리 반응성을 극대화하여 합금의 성능을 최대한 이끌어내는 데 결정적인 역할을 함을 시사합니다.

Finding 2: 미세조직 형태와 기계적 물성의 의외의 관계 (The Surprising Relationship Between Microstructure and Mechanical Properties)

일반적으로 반용융 주조 등에서는 구상(spheroidal)의 비수지상(non-dendritic) 조직이 유동성과 기계적 특성에 유리하다고 알려져 있습니다. 본 연구에서도 낮은 주입 온도(650°C)를 적용한 주조품 No. 1과 No. 3에서 비수지상 조직이 형성된 반면, 높은 주입 온도(700°C)를 적용한 No. 2와 No. 4에서는 수지상(dendritic) 조직이 관찰되었습니다 (Fig. 3).

그러나 최종 기계적 물성은 이러한 통념과 다른 결과를 보였습니다. 최고의 기계적 물성을 달성한 주조품 No. 4의 미세조직은 덴드라이트 구조였습니다. 이는 해당 공법과 합금의 조합에서는 초기 응고 조직의 형태보다, 후속 열처리의 효과를 최적화하는 공정 조건(고온)이 최종 물성에 더 지배적인 영향을 미친다는 중요한 사실을 보여줍니다.

Practical Implications for R&D and Operations

  • For Process Engineers: EN AW-2024 합금을 가압 하 결정화 주조 공법으로 생산할 때, T6 열처리 후 최고의 기계적 물성을 얻기 위해서는 주입 온도와 금형 온도를 가능한 한 높게 설정하는 것이 유리할 수 있습니다.
  • For Quality Control Teams: 본 연구 데이터(Table 4)는 주조 직후의 물성이 최종 열처리 후의 물성을 대표하지 않음을 명확히 보여줍니다. 따라서 품질 검사 기준은 반드시 열처리 후의 성능에 초점을 맞춰야 합니다. 또한, 모든 시편에서 약 2.5% 내외의 낮은 연신율이 관찰되었으므로, Fig. 5에서 보이는 것과 같은 미세 기공(porosity) 관리가 핵심 품질 지표가 될 수 있습니다.
  • For Design Engineers: 이 공정과 합금을 사용하면 400 MPa 이상의 높은 인장 강도를 갖는 부품 설계가 가능합니다. 그러나 파괴 기준으로 설계 시 매우 낮은 연성(ductility), 즉 낮은 연신율을 반드시 고려해야 합니다.

Paper Details


EN AW-2024 WROUGHT ALUMINUM ALLOY PROCESSED BY CASTING WITH CRYSTALLIZATION UNDER PRESSURE

1. Overview:

  • Title: EN AW-2024 WROUGHT ALUMINUM ALLOY PROCESSED BY CASTING WITH CRYSTALLIZATION UNDER PRESSURE
  • Author: VANKO Branislav, STANČEK Ladislav, MORAVČÍK Roman
  • Year of publication: 2017
  • Journal/academic society of publication: Journal of MECHANICAL ENGINEERING – Strojnícky časopis, VOL 67 (2017), NO 2, 111 – 118
  • Keywords: wrought aluminum alloy, EN AW-2024, casting with crystallization under pressure, mechanical properties

2. Abstract:

단조 알루미늄 합금을 사용하면 표준 주조용 알루미늄 합금으로 만든 주조품보다 더 높은 기계적 특성을 가진 주조품을 만들 수 있지만, 고온 균열 및 수축 기공과 같은 결함 없이 건전한 주조품을 만드는 공정을 처리하는 것이 필요합니다. 본 실험에서는 강제 유동을 동반한 가압 하 결정화 주조 공법으로 가공된 단조 알루미늄 합금 EN AW-2024를 연구했습니다. 주조품은 표준 T6 열처리로 열처리되었습니다.

3. Introduction:

주조용 알루미늄 합금으로 만든 주조품은 기계적 특성 면에서 거의 정점에 도달했으며, 새로운 주조 기술로도 이보다 더 높은 기계적 특성을 가진 주조품을 생산하기는 어려울 것입니다. 따라서 단조 알루미늄 합금을 주조품 생산에 활용하는 방안이 연구되기 시작했습니다. 이들 합금의 주조 시 어려운 점 중 하나는 넓은 응고 범위로, 이는 응고 중 수축 기공 및 고온 균열과 같은 결함 형성 경향을 높입니다. 본 연구의 목적은 강제 유동을 동반한 가압 하 결정화 주조에서 주조 변수(주입 온도 및 금형 온도)가 단조 알루미늄 합금 EN AW-2024 주조품의 주조 상태 및 열처리 후 기계적 특성과 미세조직에 미치는 영향을 조사하는 것입니다.

4. Summary of the study:

Background of the research topic:

표준 주조용 알루미늄 합금의 기계적 물성 한계를 극복하고, 복잡한 형상 구현이 가능한 주조 기술의 장점을 활용하기 위해 고강도 단조 알루미늄 합금의 주조 적용 가능성에 대한 연구가 필요합니다.

Status of previous research:

이전 연구들은 직접 및 간접 가압 주조, 반용융 주조 등 다양한 비전통적 기술을 사용하여 2xxx, 6xxx, 7xxx 계열 단조 합금의 주조를 시도해왔습니다. 이들 합금은 높은 기계적 특성을 제공하지만, 넓은 응고 범위로 인한 결함 발생이 주된 난제로 지적되었습니다.

Purpose of the study:

강제 유동을 동반한 가압 하 결정화 주조 공법에서 주입 온도와 금형 온도가 EN AW-2024 합금 주조품의 주조 상태 및 T6 열처리 후의 기계적 특성과 미세조직에 미치는 영향을 규명하는 것을 목표로 합니다.

Core study:

네 가지 다른 주입 및 금형 온도 조건에서 EN AW-2024 합금을 주조하고, 각 조건이 응고 과정(냉각 속도, 고상 분율 등), 미세조직(덴드라이트/비덴드라이트), 그리고 주조 및 열처리 후 기계적 물성(인장강도, 항복강도, 연신율)에 미치는 영향을 실험적으로 분석했습니다.

5. Research Methodology

Research Design:

네 가지 주조 조건(주입 온도 2종 x 금형 온도 3종 조합)을 설정하여 실험을 설계했습니다. 각 조건에서 제작된 주조품을 주조 상태와 T6 열처리 상태로 나누어 기계적 물성과 미세조직을 비교 분석했습니다.

Data Collection and Analysis Methods:

  • 주조: 가압 하 결정화 주조 장비를 사용하여 컵 형태의 주조품을 제작했습니다.
  • 열처리: 전기로를 사용하여 표준 T6 열처리를 수행했습니다.
  • 물성 평가: 만능 재료 시험기를 사용하여 상온에서 인장 시험을 수행하고 인장 강도(Rm), 항복 강도(Rp0.2), 연신율(A)을 측정했습니다.
  • 미세조직 분석: 광학 현미경을 사용하여 주조품의 미세조직을 관찰했습니다.

Research Topics and Scope:

본 연구는 단조 알루미늄 합금 EN AW-2024를 대상으로 하며, 가압 하 결정화 주조 공법에 국한됩니다. 주조 변수로는 주입 온도와 금형 온도를, 평가 항목으로는 기계적 특성과 미세조직을 다룹니다.

6. Key Results:

Key Results:

  • 주조 상태에서의 기계적 물성은 모든 조건에서 큰 차이가 없었으나(Rm ≈ 300 MPa, Rp0.2 ≈ 120 MPa), T6 열처리 후에는 공정 온도에 따라 큰 차이를 보였습니다.
  • 가장 높은 주입 온도(700°C)와 금형 온도(250°C)로 제작된 주조품(No. 4)이 열처리 후 최고의 기계적 물성(Rm = 418 MPa, Rp0.2 = 378 MPa)을 달성했습니다.
  • 낮은 주입 온도(650°C)에서는 비수지상(non-dendritic) 조직이, 높은 주입 온도(700°C)에서는 수지상(dendritic) 조직이 형성되었습니다.
  • 최고의 기계적 물성을 보인 주조품(No. 4)은 수지상 조직을 가졌으며, 이는 미세조직 형태보다 공정 온도가 열처리 후 물성에 더 큰 영향을 미침을 시사합니다.
  • 모든 주조품의 연신율은 약 2-2.5%로 매우 낮았으며, 이는 수지상 간 영역에 존재하는 미세 기공 및 금속간 화합물 때문으로 분석됩니다.
Fig. 3 As-cast microstructures in the middle of the casting walls (top left – casting No. 1, top right – casting No. 2, bottom left – casting No. 3, bottom right – casting No. 4).
Fig. 3 As-cast microstructures in the middle of the casting walls (top left – casting No. 1, top right – casting No. 2, bottom left – casting No. 3, bottom right – casting No. 4).

Figure List:

  • Fig. 1 Experimental tool (1 – lower die, 2 – upper die, 3 – ejector, 4 – casting, X – point of recording of the alloy temperature).
  • Fig. 2 Specimen for tensile test made in accordance with the standard STN EN ISO 6892-1.
  • Fig. 3 As-cast microstructures in the middle of the casting walls (top left – casting No. 1, top right – casting No. 2, bottom left – casting No. 3, bottom right – casting No. 4).
  • Fig. 4 Mechanical properties of the castings in the as-cast and heat treated state.
  • Fig. 5 Interdendritic shrinkage porosity in the castings (REM: left – casting No. 1, right – casting No. 3).

7. Conclusion:

단조 알루미늄 합금 EN AW-2024는 강제 유동을 동반한 가압 하 결정화 주조를 통해 성공적으로 주조될 수 있었습니다. T6 열처리 후, 가장 높은 주입 온도(700°C)와 금형 온도(250°C)에서 주조된 시편(No. 4)에서 인장 강도 418 MPa, 항복 강도 378 MPa, 연신율 2.5%의 가장 높은 기계적 물성이 달성되었습니다. 흥미롭게도, 최고의 물성을 보인 주조품은 덴드라이트 미세조직을 가졌습니다. 이는 주조 상태의 미세조직 형태가 최종 물성을 결정하는 유일한 요인이 아님을 보여줍니다. 관찰된 낮은 연신율은 수지상 간 수축 기공 및 금속간 화합물의 존재 때문으로 판단됩니다.

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  6. H. Guo, X. Yang, M. Zhang. Microstructure characteristics and mechanical properties of rheoformed wrought aluminum alloy 2024. Transactions of Nonferrous Metals Society of China 2008 (18), 555 – 561.
  7. U.A. Curle. Semi-solid near-net shape rheocasting of heat treatable wrought aluminum alloys. Transactions of Nonferrous Metals Society of China 2010 (20), 1719 – 1724.
  8. B. Samanta, S.A. Al-Araimi, R.A. Siddiqui. A neutral network approach to estimate fatigue life of 6063 aluminum alloy. Journal of Mechanical Engineering – Strojnícky časopis 2002 (53), No. 1, 36 – 44.
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  11. L. Stanček, B. Vanko. Instrument for casting with crystallization under pressure with increasing of flow intensity. In: Technology 2007. STU Bratislava, Slovakia, 2007, CD-ROM, (in Slovak).
  12. W.Y. Kim, C.G. Kang, B.M. Kim. The effect of solid fraction on rheological behavior of wrought aluminum alloys in incremental compression experiments with a closed die. Materials Science and Engineering A 2007 (447), 1 – 10.
  13. Y. Zhong, G. Su, K. Yang. Microsegregation and improved methods of squeeze casting 2024 aluminium alloy. Journal of Materials Science & Technology 2003 (19), No. 5, 413-416.

Expert Q&A: Your Top Questions Answered

Q1: 모든 실험에서 100 MPa의 일정한 압력을 선택한 이유는 무엇입니까?

A1: 논문에 따르면, 100 MPa는 금형 캐비티 압력에 해당하는 사전 설정된 최대값이었습니다. 실험에서 온도의 영향을 독립적으로 평가하기 위해 압력을 상수로 유지한 것으로 보입니다. 이는 변수를 통제하여 주입 온도와 금형 온도의 효과를 명확하게 분석하기 위한 표준적인 실험 설계 방법입니다.

Q2: 비수지상(non-dendritic) 조직을 가진 주조품 No. 1과 No. 3의 기계적 물성이 더 우수하지 않았던 이유는 무엇입니까?

A2: 논문은 이 합금과 공정의 조합에서는, 구상 조직 형성으로 얻는 이점보다 높은 공정 온도가 후속 열처리 반응에 미치는 긍정적 효과가 더 크다는 점을 시사합니다. 즉, 최종 기계적 물성은 주조 직후의 결정립 형태보다는, 열처리가 얼마나 효과적으로 합금의 석출 경화 능력을 이끌어내는가에 더 크게 좌우된 것입니다.

Q3: 모든 시편에서 연신율이 2-2.5%로 일관되게 낮게 나타난 가장 큰 원인은 무엇입니까?

A3: 논문의 토론 및 결론 부분에서 연신율이 낮은 원인으로 “수지상 간 영역에 존재하는 금속간 화합물과 수축 기공(interdendritic shrinkage porosity)의 존재”를 명확히 지목하고 있습니다. 이는 Figure 5의 전자현미경 사진에서도 관찰된 미세 결함들 때문이며, 재료가 인장력을 받을 때 조기 파괴의 원인이 됩니다.

Q4: 최고의 기계적 물성을 보인 주조품 No. 4의 구체적인 공정 조건과 그로 인한 응고 특성은 어떠했습니까?

A4: Table 1과 2에 따르면, 주조품 No. 4는 주입 온도 700°C, 금형 온도 250°C의 조건으로 제작되었습니다. 이 조건은 가압 시작 시 용탕 온도가 631°C로 가장 높았고, 응고 시간은 7.8초로 가장 길었으며, 평균 냉각 속도는 16.4 °C/s로 가장 느렸습니다.

Q5: 가압 시작 시점의 고상 분율(initial fraction of solid phase)이 최종 결과에 어떤 영향을 미쳤습니까?

A5: 논의에 따르면, 초기 고상 분율은 비수지상 미세조직 형성에 명확한 영향을 미치지 않았습니다. 예를 들어, 주조품 No. 1(68%)과 No. 2(64%)는 높은 고상 분율을 가졌지만 서로 다른 미세조직을 형성했습니다. 논문은 미세조직 형성에 있어 초기 고상 분율보다는 주입 온도가 더 지배적인 요인이었다고 결론 내리고 있습니다.


Conclusion: Paving the Way for Higher Quality and Productivity

본 연구는 EN AW-2024와 같은 고강도 단조 알루미늄 합금을 고압 주조 기술로 성공적으로 성형할 수 있음을 입증했습니다. 핵심적인 발견은, T6 열처리를 통해 우수한 기계적 물성을 얻기 위해서는 높은 주입 온도와 금형 온도를 적용하는 것이 결정적이라는 점입니다. 이는 흔히 선호되는 구상 조직이 아닌 덴드라이트 조직을 형성하더라도 최종 물성 향상에 더 효과적이었습니다. 이 결과는 R&D 및 생산 현장에서 고성능 부품을 개발할 때 공정 변수 최적화의 중요성을 다시 한번 강조합니다.

STI C&D는 최신 산업 연구 결과를 적용하여 고객이 더 높은 생산성과 품질을 달성할 수 있도록 지원하는 데 전념하고 있습니다. 본 논문에서 논의된 과제가 귀사의 운영 목표와 일치한다면, 당사 엔지니어링 팀에 문의하여 이러한 원칙을 귀사의 부품에 어떻게 구현할 수 있는지 알아보십시오.

(주)에스티아이씨앤디에서는 고객이 수치해석을 직접 수행하고 싶지만 경험이 없거나, 시간이 없어서 용역을 통해 수치해석 결과를 얻고자 하는 경우 전문 엔지니어를 통해 CFD consulting services를 제공합니다. 귀하께서 당면하고 있는 연구프로젝트를 최소의 비용으로, 최적의 해결방안을 찾을 수 있도록 지원합니다.

  • 연락처 : 02-2026-0450
  • 이메일 : flow3d@stikorea.co.kr

Copyright Information

  • This content is a summary and analysis based on the paper “EN AW-2024 WROUGHT ALUMINUM ALLOY PROCESSED BY CASTING WITH CRYSTALLIZATION UNDER PRESSURE” by “VANKO Branislav et al.”.
  • Source: https://doi.org/10.1515/scjme-2017-0024

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Рис. 4. Сравнение недоливов в реальной отливке из сплава МЛ5 (а) и при моделировании (б) при критической доле твердой фазы 0,1 для температуры заливки 630 °С

AZ91 마그네슘 합금의 충전 불량(Misrun) 예측: 시뮬레이션 정확도를 높이는 핵심 파라미터 규명

이 기술 요약은 A.V. Petrova, V.E. Bazhenov, A.V. Koltygin이 Izvestiya vuzov. Tsvetnaya metallurgiya에 발표한 “Прогнозирование недоливов в отливке из сплава МЛ5 и жидкотекучести сплава с использованием компьютерного моделирования (Prediction of AZ91 casting misruns and alloy fluidity using numerical simulation)” (2018) 논문을 기반으로 합니다. STI C&D에서 기술 전문가를 위해 분석하고 요약했습니다.

키워드

  • Primary Keyword: AZ91 마그네슘 합금
  • Secondary Keywords: 충전 불량(Misrun), 유동성(Fluidity), ProCast, 컴퓨터 시뮬레이션, 계면열전달계수(Interfacial Heat Transfer Coefficient), 임계고상분율(Critical Solid Fraction)

Executive Summary

  • The Challenge: 박육 마그네슘(AZ91) 주조품의 충전 불량(misrun)을 정확히 예측하기 위해서는 신뢰할 수 있는 시뮬레이션 파라미터가 필요하지만, 실제 공정 조건에 맞는 데이터를 확보하기 어렵습니다.
  • The Method: 스파이럴 유동성 테스트와 실제 형상(“보호 컵”) 주조 실험을 ProCast 시뮬레이션 결과와 비교하여, AZ91 합금과 후란(furan) 수지 기반 자경성 주형(sand mold) 사이의 계면열전달계수(IHTC)와 유동 정지 시점의 임계고상분율(CSF)을 규명했습니다.
  • The Key Breakthrough: 주입 온도에 따른 구체적인 계면열전달계수 값을 도출했으며, 실제 주조품의 충전 불량 위치와 비교하여 AZ91 합금의 임계고상분율이 0.1임을 정밀하게 확인했습니다.
  • The Bottom Line: 실험적으로 검증된 이 파라미터들을 주조 시뮬레이션에 적용함으로써 충전 불량 예측 정확도를 획기적으로 높여, 생산 현장에서의 시행착오를 줄이고 개발 기간을 단축할 수 있습니다.

The Challenge: Why This Research Matters for CFD Professionals

마그네슘 합금은 경량화가 필수적인 자동차, 항공우주, 전자 산업에서 각광받고 있지만, 넓은 응고 온도 범위로 인해 유동성이 낮아 박육의 복잡한 형상을 주조하기 까다롭습니다. 특히 충전 불량(misrun)은 가장 흔하게 발생하는 결함 중 하나로, 이를 사전에 예측하고 방지하기 위해 컴퓨터 시뮬레이션이 널리 사용됩니다.

하지만 시뮬레이션의 정확도는 입력되는 데이터의 신뢰성에 크게 좌우됩니다. 특히 용탕과 주형 사이의 열전달을 나타내는 계면열전달계수(IHTC)와 용탕의 유동이 멈추는 고상(solid)의 비율을 의미하는 임계고상분율(Critical Solid Fraction, CSF)은 합금 및 주형의 종류, 공정 조건에 따라 달라지기 때문에 정확한 값을 확보하는 것이 매우 중요합니다. 이 연구는 가장 널리 사용되는 AZ91 마그네슘 합금에 대해 이 핵심 파라미터들을 실험적으로 규명하여 시뮬레이션의 예측력을 극대화하고자 했습니다.

The Approach: Unpacking the Methodology

본 연구팀은 실험과 시뮬레이션을 체계적으로 결합하는 접근 방식을 사용했습니다. 주조 시뮬레이션 소프트웨어로는 ProCast 2016을 사용했으며, 실험을 통해 시뮬레이션 파라미터를 검증하고 정밀화했습니다.

  1. 계면열전달계수(IHTC) 규명:
    • 실험: AZ91(러시아 규격 МЛ5) 합금을 사용하여 후란(furan) 수지 기반 자경성 주형(XTC)으로 제작된 스파이럴 유동성 시험편을 670°C, 740°C, 810°C의 각기 다른 온도로 주입했습니다.
    • 시뮬레이션 및 비교: 동일한 조건으로 ProCast 시뮬레이션을 수행하면서, 시뮬레이션으로 계산된 스파이럴의 길이와 실제 실험에서 얻은 길이가 일치할 때까지 계면열전달계수(IHTC) 값을 조정했습니다. 또한, 주입 시 주형 내부에 설치된 열전대(thermocouple)의 냉각 곡선과 시뮬레이션의 냉각 곡선을 비교하여 IHTC 값의 신뢰도를 높였습니다.
  2. 임계고상분율(CSF) 규명:
    • 실험: 실제 산업용 부품과 유사한 형상인 “보호 컵(Protective cup)” 주조품을 630°C와 670°C에서 주입하여 실제 충전 불량이 발생하는 위치를 확인했습니다.
    • 시뮬레이션 및 비교: 앞에서 규명한 IHTC 값을 적용하여 “보호 컵” 주조 공정을 시뮬레이션했습니다. 시뮬레이션에서 예측된 충전 불량의 위치 및 형상이 실제 주조품의 것과 가장 잘 일치하도록 임계고상분율(CSF) 값을 조정했습니다.

The Breakthrough: Key Findings & Data

Finding 1: 주입 온도에 따른 정밀 계면열전달계수(IHTC) 값 확립

실험과 시뮬레이션의 냉각 곡선 비교를 통해 AZ91 합금과 XTC 주형 사이의 IHTC 값을 성공적으로 도출했습니다. (그림 2 참조)

  • 액상선(liquidus) 온도 이상에서 IHTC (hl):
    • 주입 온도 670°C 및 740°C: 1500 W/(m²·K)
    • 주입 온도 810°C: 1800 W/(m²·K)
  • 고상선(solidus) 온도 이하에서 IHTC (hs): 600 W/(m²·K)

이 결과는 IHTC가 주입 온도에 따라 변하는 중요한 물리량임을 보여주며, 정확한 시뮬레이션을 위해서는 온도 의존성을 고려해야 함을 시사합니다.

Finding 2: 충전 불량 예측 정확도를 위한 임계고상분율(CSF) 0.1로 규명

스파이럴 유동성 테스트를 통해 CSF 값이 0.1에서 0.15 사이의 범위에 있을 것으로 추정했습니다. 이 범위를 바탕으로 “보호 컵” 주조품 시뮬레이션을 수행하여 값을 더욱 정밀화했습니다.

  • 주입 온도 630°C와 670°C 모두에서, CSF 값을 0.1로 설정했을 때 시뮬레이션으로 예측된 충전 불량의 위치와 크기가 실제 주조품에서 발생한 결함과 가장 잘 일치했습니다. (그림 4, 5 참조)
  • CSF를 0.15로 설정했을 때는 실제 결과와의 편차가 더 크게 나타났습니다.

이 결과는 AZ91 합금이 약 2 K/s의 냉각 속도로 응고될 때, 고상 분율이 10%(0.1)에 도달하면 유동이 멈춘다는 것을 의미하며, 이는 박육 주조품의 충전성 예측에 매우 중요한 기준이 됩니다.

Practical Implications for R&D and Operations

  • 공정 엔지니어: 본 연구에서 검증된 IHTC 및 CSF 값을 주조 시뮬레이션에 적용하여 AZ91 합금의 충전 불량을 훨씬 더 정확하게 예측할 수 있습니다. 이를 통해 주입 온도, 탕구계(gating system) 설계 등 공정 변수를 최적화하여 사전에 결함을 방지하고 양산 안정성을 높일 수 있습니다.
  • 품질 관리팀: 시뮬레이션 예측 결과와 실제 결함 사이의 높은 상관관계를 바탕으로, 시뮬레이션 결과를 품질 검사 기준 설정 및 잠재적 불량 영역 예측에 활용할 수 있습니다. 이는 검사 효율성을 높이고 불량률을 감소시키는 데 기여합니다.
  • 설계 엔지니어: 유동이 멈추는 임계고상분율(CSF=0.1)에 대한 명확한 데이터를 기반으로, 제품 설계 단계에서부터 주조성을 고려한 최적의 두께와 형상을 결정할 수 있습니다. 이는 과도한 안전율을 배제하고 제품의 경량화 목표를 달성하는 데 도움을 줍니다.

Paper Details


Прогнозирование недоливов в отливке из сплава МЛ5 и жидкотекучести сплава с использованием компьютерного моделирования (Prediction of AZ91 casting misruns and alloy fluidity using numerical simulation)

1. 개요:

  • 제목: Prediction of AZ91 casting misruns and alloy fluidity using numerical simulation
  • 저자: A.V. Petrova, V.E. Bazhenov, A.V. Koltygin
  • 발행 연도: 2018
  • 학술지/학회: Izvestiya vuzov. Tsvetnaya metallurgiya (Russian Journal of Non-Ferrous Metals)
  • 키워드: fluidity simulation, magnesium alloy, coherency point, spiral fluidity test, ProCast, misrun

2. 초록:

마그네슘 합금 박육 주조품의 충전 불량 예측은 주조 생산에서 중요한 과제이다. 이 문제 해결을 위해 주조 공정 컴퓨터 시뮬레이션을 활용할 수 있다. 시뮬레이션의 정확한 결과를 얻기 위해서는 넓은 온도 범위에 걸친 합금 및 주형의 올바른 열물성 데이터, 주조품과 주형 사이의 계면열전달계수 값, 그리고 용탕의 유동이 멈추는 임계고상분율 값이 필요하다. 본 연구에서는 시뮬레이션으로 얻은 스파이럴 시험편의 길이와 동일한 조건에서 실험적으로 얻은 길이를 비교하여 마그네슘 합금 ML5(AZ91)와 자경성 주형(XTC) 사이의 계면열전달계수를 결정했다. 액상선 온도 이상에서 이 값은 주입 온도 670°C 및 740°C에서 1500 W/(m²·K), 810°C에서 1800 W/(m²·K)였다. 고상선 온도 이하에서는 600 W/(m²·K)였다. 또한, XTC 주형에 주입된 ML5(AZ91) 합금의 임계고상분율(냉각 속도 ~2 K/s)은 0.1–0.15로 결정되었다. 실제 “보호 컵” 주조품의 충전 불량 위치와 시뮬레이션 결과를 비교하여 임계고상분율 값을 정밀화했으며, 주입 온도 630°C와 670°C 두 경우 모두에서 임계고상분율은 0.1로 확인되었다.

3. 서론:

박육 주조품의 충전 불량 예측을 위해 컴퓨터 시뮬레이션이 널리 사용된다. 특히 넓은 결정화 구간을 가져 유동성이 높지 않은 마그네슘 합금의 박육 주조품 공정 모델링은 매우 중요한 과제이다. 용탕의 유동성은 합금 조성, 과열도, 결정립 크기, 개량제 유무, 주형의 열물성 등 다양한 요인에 의해 결정된다. 유동은 용탕이 고액 공존 상태일 때도 계속되며, 특정 고상 분율에 도달하면 멈추게 되는데 이를 임계고상분율이라 한다. 정확한 시뮬레이션을 위해서는 계면열전달계수와 임계고상분율을 알아야 한다.

4. 연구 요약:

연구 주제의 배경:

마그네슘 합금 박육 주조품 생산 시 충전 불량 예측의 중요성.

기존 연구 현황:

컴퓨터 시뮬레이션을 이용한 충전 불량 예측 연구는 다수 존재하지만, AZ91 합금과 자경성 주형(XTC) 조합에 대한 계면열전달계수(IHTC) 및 임계고상분율(CSF)에 대한 신뢰성 있는 데이터는 부족한 실정이다.

연구 목적:

실험과 컴퓨터 시뮬레이션의 비교를 통해, AZ91 마그네슘 합금을 XTC 주형에 주입할 때의 계면열전달계수(IHTC)와 임계고상분율(CSF)을 규명하여 충전 불량 예측의 정확도를 높이는 것을 목표로 한다.

핵심 연구 내용:

  • 스파이럴 유동성 시험을 이용한 IHTC 값 도출.
  • 실제 형상(“보호 컵”) 주조품을 이용한 CSF 값 정밀화.

5. 연구 방법론

연구 설계:

실험적 주조(스파이럴 시험편, “보호 컵” 주조품)와 수치 시뮬레이션(ProCast 2016) 결과를 상호 비교하고 검증하는 방식으로 설계되었다.

데이터 수집 및 분석 방법:

  • 실험 데이터: 주조된 스파이럴 시험편의 길이를 측정하고, “보호 컵” 주조품의 충전 불량 위치를 육안으로 확인. 주형 내 열전대를 이용해 냉각 곡선 데이터 수집.
  • 시뮬레이션 데이터: ProCast를 이용해 유동 길이, 냉각 곡선, 고상 분율 분포를 계산. 실험 결과와 비교하여 IHTC와 CSF 값을 반복적으로 조정하여 최적값을 찾음.

연구 주제 및 범위:

  • 합금: ML5 (AZ91) 마그네슘 합금
  • 주형: 후란 수지 기반 자경성 주형(XTC)
  • 주입 온도: 630°C, 670°C, 740°C, 810°C
  • 규명 대상: 계면열전달계수(IHTC), 임계고상분율(CSF)

6. 주요 결과:

주요 결과:

  • AZ91 합금과 XTC 주형 간의 IHTC는 주입 온도에 따라 변화하며, 670/740°C에서는 1500 W/(m²·K), 810°C에서는 1800 W/(m²·K)로 확인되었다.
  • 스파이럴 시험을 통해 CSF는 0.1-0.15 범위로 추정되었으며, 실제 “보호 컵” 주조품과의 비교를 통해 최종적으로 0.1로 확정되었다.
  • 규명된 파라미터를 적용한 시뮬레이션 결과는 실제 주조 실험에서 발생한 충전 불량 현상을 매우 유사하게 재현하였다.
Рис. 4. Сравнение недоливов в реальной отливке из сплава МЛ5 (а) и при моделировании (б) при критической доле твердой фазы 0,1 для температуры заливки 630 °С
Рис. 4. Сравнение недоливов в реальной отливке из сплава МЛ5 (а) и при моделировании (б) при критической доле твердой фазы 0,1 для температуры заливки 630 °С

Figure List:

  • Рис. 1. График зависимости точки когерентности от скорости охлаждения для сплава МЛ5 (AZ91)
  • Рис. 2. Кривые охлаждения – экспериментальные (1), записанные с помощью термопары, находящейся в плоскости разъема формы, при заливке спиральной пробы, и полученные по результатам моделирования (2)
  • Рис. 3. Экспериментальная (1) и полученные по результатам моделирования при значении критической доли твердой фазы 0,15 (2) и 0,1 (3) зависимости длины спиральной пробы из сплава МЛ5 от температуры заливки
  • Рис. 4. Сравнение недоливов в реальной отливке из сплава МЛ5 (а) и при моделировании (б) при критической доле твердой фазы 0,1 для температуры заливки 630 °С
  • Рис. 5. Сравнение недоливов в реальной отливке из сплава МЛ5 (а) и при моделировании (б) при критической доле твердой фазы 0,1 для температуры заливки 670 °С

7. 결론:

스파이럴 시험편 주조 실험과 시뮬레이션 결과의 비교를 통해 AZ91(МЛ5) 합금과 XTC 주형 사이의 계면열전달계수를 결정했다. 액상선 온도 이상에서는 주입 온도에 따라 1500-1800 W/(m²·K), 고상선 온도 이하에서는 600 W/(m²·K)의 값을 가졌다. 또한, 유동이 정지되는 임계고상분율은 0.1-0.15 범위에 있으며, 실제 “보호 컵” 주조품 실험과의 비교를 통해 0.1로 확정되었다. 이 연구를 통해 실험적으로 검증된 파라미터들은 ProCast와 같은 시뮬레이션 프로그램에서 AZ91 합금의 충전 불량을 정확하게 예측하는 데 기여할 수 있다.

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Expert Q&A: Your Top Questions Answered

Q1: 주입 온도를 670°C, 740°C, 810°C로 나누어 계면열전달계수(IHTC)를 별도로 구한 이유는 무엇인가요?

A1: 연구 결과, IHTC는 상수가 아니며 공정 온도에 따라 변하는 중요한 변수임이 확인되었기 때문입니다. 실제로 주입 온도가 740°C에서 810°C로 상승했을 때, 액상선 온도 이상의 IHTC 값은 1500 W/(m²·K)에서 1800 W/(m²·K)로 증가했습니다. 이는 높은 주입 온도가 초기 접촉 시 더 격렬한 열전달을 유발함을 의미하며, 시뮬레이션의 정확도를 높이기 위해서는 실제 공정 온도에 맞는 IHTC 값을 사용하는 것이 필수적임을 보여줍니다.

Q2: 논문에서 고상(solid phase)의 부피 분율과 질량 분율이 거의 같다고 언급했는데, 이것이 왜 중요한가요?

A2: 이는 시뮬레이션의 편의성과 정확성에 직접적인 영향을 미칩니다. 일반적으로 유동 정지를 논할 때 학술적으로는 부피 분율을 기준으로 하지만, ProCast와 같은 대부분의 주조 시뮬레이션 소프트웨어는 질량 분율을 입력 파라미터로 사용합니다. 이 연구에서는 Thermo-Calc를 이용한 분석을 통해 AZ91 합금의 경우 두 분율 간의 차이가 3% 미만으로 매우 작음을 확인했습니다. 따라서 실험적으로 유추된 임계고상분율(CSF) 값을 별도의 변환 없이 시뮬레이션에 질량 분율로 바로 적용해도 오차가 거의 없어 결과의 신뢰도를 높일 수 있습니다.

Q3: 그림 5를 보면, 시뮬레이션으로 예측된 충전 불량 영역이 실제보다 다소 넓게 나타났습니다. 그 이유는 무엇인가요?

A3: 논문에서는 이를 현재 시뮬레이션 모델이 실제 용탕의 유동 패턴을 100% 완벽하게 모사하지 못하는 한계 때문이라고 설명합니다. 실제 주조에서는 주입구 반대편 벽 쪽으로 더 뜨거운 용탕의 주 흐름이 형성되었지만(사진의 밝은 부분), 시뮬레이션에서는 이 현상이 완벽히 재현되지 않았습니다. 결과적으로 시뮬레이션은 실제보다 보수적으로(더 넓은 영역의) 충전 불량을 예측하게 되었습니다. 하지만 결함 발생의 핵심 위치(주조품 상단부)는 매우 정확하게 예측했다는 점에서 모델의 유효성은 충분히 입증되었습니다.

Q4: 실험 중 냉각 속도는 어느 정도였으며, 이 값이 임계고상분율(CSF)과 어떤 관련이 있나요?

A4: 스파이럴 시험편 주조 시 평균 냉각 속도는 약 2 K/s였습니다. 이 값은 중요합니다. 왜냐하면 참고문헌 [13] 등에서 볼 수 있듯이, 응고가 시작되고 결정립들이 서로 맞닿아 강도를 갖기 시작하는 지점(coherency point, CSF와 밀접한 관련)은 냉각 속도에 따라 변할 수 있기 때문입니다. 따라서 본 연구에서 도출된 CSF 값(0.1-0.15)은 약 2 K/s의 냉각 속도 조건에서 유효하며, 이는 일반적인 사형 주조 공정의 냉각 속도 범위에 해당하므로 높은 실용성을 가집니다.

Q5: 이 연구는 ProCast를 사용했는데, 여기서 얻은 IHTC와 CSF 값을 FLOW-3D와 같은 다른 주조 시뮬레이션 소프트웨어에도 적용할 수 있나요?

A5: 네, 매우 훌륭한 시작점으로 활용할 수 있습니다. IHTC와 CSF는 특정 소프트웨어에 종속된 값이 아니라, AZ91 합금과 XTC 주형 사이의 물리적 현상(열전달 및 응고 거동)을 나타내는 물리량입니다. 따라서 이 연구에서 실험적으로 검증된 값들은 FLOW-3D를 포함한 다른 상용 CFD 소프트웨어에서도 높은 정확도를 기대할 수 있는 초기 입력값으로 매우 유용합니다. 다만, 각 소프트웨어의 수치 해석 알고리즘에 따라 미세한 차이가 있을 수 있으므로, 필요시 약간의 보정(calibration)을 거치면 최적의 결과를 얻을 수 있습니다.


Conclusion: Paving the Way for Higher Quality and Productivity

이 연구는 AZ91 마그네슘 합금의 박육 주조 시 발생하는 충전 불량 문제를 해결하기 위해, 실험과 시뮬레이션을 결합하여 핵심 파라미터인 계면열전달계수(IHTC)와 임계고상분율(CSF)을 성공적으로 규명했습니다. 이는 주조 현장의 경험에 의존하던 방식을 데이터 기반의 예측 엔지니어링으로 전환할 수 있는 중요한 과학적 근거를 제공합니다. 검증된 파라미터를 활용하면 개발 초기 단계부터 충전 불량을 정확히 예측하고, 최적의 공정 조건을 찾아내어 품질 향상과 생산성 증대를 동시에 달성할 수 있습니다.

STI C&D는 최신 산업 연구 결과를 적용하여 고객이 더 높은 생산성과 품질을 달성할 수 있도록 지원합니다. 이 논문에서 논의된 과제가 귀사의 운영 목표와 일치한다면, 저희 엔지니어링 팀에 연락하여 이러한 원칙을 귀사의 부품에 어떻게 적용할 수 있는지 논의해 보십시오.

(주)에스티아이씨앤디에서는 고객이 수치해석을 직접 수행하고 싶지만 경험이 없거나, 시간이 없어서 용역을 통해 수치해석 결과를 얻고자 하는 경우 전문 엔지니어를 통해 CFD consulting services를 제공합니다. 귀하께서 당면하고 있는 연구프로젝트를 최소의 비용으로, 최적의 해결방안을 찾을 수 있도록 지원합니다.

  • 연락처 : 02-2026-0450
  • 이메일 : flow3d@stikorea.co.kr

Copyright Information

  • This content is a summary and analysis based on the paper “Prediction of AZ91 casting misruns and alloy fluidity using numerical simulation” by “A.V. Petrova, V.E. Bazhenov, A.V. Koltygin”.
  • Source: https://dx.doi.org/10.17073/0021-3438-2018-5-31-38

This material is for informational purposes only. Unauthorized commercial use is prohibited. Copyright © 2025 STI C&D. All rights reserved.

Fig 1. Overview of the experimental process (a) crucible furnace (b) casting mould (c) squeeze casting process (d) cast samples for analysis (e) samples from tensile testing (f) samples from impact testing.

스퀴즈 캐스팅 최적화: 알루미늄 합금의 기계적 물성을 극대화하는 4가지 핵심 공정 변수

이 기술 요약은 OJARIGHO, EV; AКРОВI, JA; EVOKE, E가 J. Appl. Sci. Environ. Manage.에 발표한 논문 “Optimization of Selected Squeeze Casting Parameters on the Mechanical Behaviour of Aluminium Alloy” (2024)를 기반으로 합니다. STI C&D의 기술 전문가를 위해 분석 및 요약되었습니다.

키워드

  • Primary Keyword: 스퀴즈 캐스팅 최적화
  • Secondary Keywords: 알루미늄 합금, 기계적 물성, 다구치 기법, 공정 변수, 항복 강도, 인장 강도, CFD

Executive Summary

  • The Challenge: 알루미늄 합금의 스퀴즈 캐스팅 공정은 기공, 수축 등 결함 발생으로 인해 기계적 물성이 저하되는 문제를 안고 있습니다.
  • The Method: 본 연구는 다구치 기법을 활용하여 스퀴즈 압력, 가압 시간, 주입 온도, 초기 금형 온도 등 4가지 핵심 공정 변수를 체계적으로 최적화했습니다.
  • The Key Breakthrough: 항복 강도와 인장 강도를 동시에 극대화하는 최적의 공정 조건(압력 150MPa, 시간 45초, 주입 온도 700°C, 금형 온도 200°C)을 성공적으로 규명했습니다.
  • The Bottom Line: 이 4가지 핵심 변수를 정밀하게 제어하는 것이 고강도, 무결함 알루미늄 합금 부품 생산의 핵심입니다.

The Challenge: Why This Research Matters for CFD Professionals

알루미늄 합금은 높은 주조성, 내부식성, 인장 강도, 낮은 밀도 등 다양한 장점으로 항공우주 및 자동차 산업에서 널리 사용됩니다. 특히 스퀴즈 캐스팅은 기존 주조와 단조의 장점을 결합하여 기공이 거의 없는 정밀한 형상의 부품을 생산할 수 있는 비용 효율적인 기술입니다.

하지만 스퀴즈 캐스팅 공정은 압출 편석, 기공, 블리스터링, 미충진, 소착, 고온 균열, 수축 등 여러 결함에 직면해 있습니다. 이러한 결함들은 최종 제품의 기계적 물성을 저하시키는 주된 원인이 됩니다. 현장에서의 시행착오 방식은 비효율적이며, 원하는 품질을 얻기 위해서는 공정 변수들을 과학적으로 최적화하는 접근 방식이 필수적입니다. 본 연구는 바로 이 문제, 즉 알루미늄 합금의 기계적 성능을 극대화하기 위한 최적의 스퀴즈 캐스팅 공정 조건을 찾는 것을 목표로 합니다.

The Approach: Unpacking the Methodology

본 연구는 Al-12%Si 알루미늄 합금의 기계적 물성을 최적화하기 위해 다구치 설계(Taguchi method)를 실험 계획법으로 채택했습니다. 이 방법론은 최소한의 실험 횟수로 여러 공정 변수의 영향을 효과적으로 분석할 수 있게 해줍니다.

  • 재료: Al-12%Si 알루미늄 합금 (상세 화학 성분은 논문 Table 1 참조)
  • 핵심 공정 변수 (입력 인자):
    1. 스퀴즈 압력 (A): 50, 100, 150 MPa
    2. 가압 시간 (B): 15, 30, 45 초
    3. 주입 온도 (C): 600, 700, 800 °C
    4. 초기 금형 온도 (D): 150, 200, 250 °C
  • 평가 항목 (응답): 항복 강도(Yield Strength, YS) 및 최종 인장 강도(Ultimate Tensile Strength, UTS)
  • 실험 설계: 4개의 변수와 3개의 수준을 고려하여 L27 직교 배열표에 따라 총 27회의 실험을 수행했습니다.
  • 분석: 실험 결과를 바탕으로 분산 분석(ANOVA)을 실시하여 각 공정 변수가 기계적 물성에 미치는 통계적 유의성을 평가했습니다.

The Breakthrough: Key Findings & Data

분산 분석(ANOVA)과 신호 대 잡음비(S/N ratio) 분석을 통해 다음과 같은 핵심적인 결과를 도출했습니다.

Finding 1: 4대 공정 변수 모두 기계적 강도에 결정적 영향을 미침

분산 분석 결과, 스퀴즈 압력(A), 가압 시간(B), 주입 온도(C), 초기 금형 온도(D) 모두 항복 강도(Table 3)와 최종 인장 강도(Table 4)에 95% 신뢰 수준에서 통계적으로 유의미한 영향을 미치는 것으로 확인되었습니다(p-value < 0.05). 이는 네 가지 변수 중 어느 하나도 소홀히 할 수 없으며, 모두 정밀하게 제어해야 고품질의 주조품을 얻을 수 있음을 의미합니다. 특히 스퀴즈 압력은 두 강도 특성 모두에 가장 큰 영향을 미치는 변수로 나타났습니다.

Finding 2: 최대 강도를 위한 최적의 공정 조건 규명

연구팀은 ‘망대특성(larger the better)’을 기준으로 신호 대 잡음비(S/N ratio) 분석을 수행하여 각 기계적 물성을 극대화하는 최적의 조건을 찾아냈습니다.

  • 항복 강도 최적 조건 (Table 6): 스퀴즈 압력 150MPa, 가압 시간 45초, 주입 온도 700°C, 초기 금형 온도 200°C
  • 인장 강도 최적 조건 (Table 7): 스퀴즈 압력 150MPa, 가압 시간 45초, 주입 온도 700°C, 초기 금형 온도 200°C

이 최적화된 설정으로 얻은 항복 강도와 최종 인장 강도는 각각 302.86MPa와 347.72MPa였습니다. 이는 체계적인 공정 최적화를 통해 알루미늄 합금의 성능을 크게 향상시킬 수 있음을 명확히 보여줍니다.

Practical Implications for R&D and Operations

  • For Process Engineers: 본 연구는 스퀴즈 압력을 150MPa까지, 가압 시간을 45초까지 증가시키는 것이 항복 강도와 인장 강도를 직접적으로 향상시키는 데 기여함을 시사합니다. 또한, 주입 온도와 금형 온도를 각각 700°C와 200°C의 최적 중간 범위로 조정하는 것이 중요합니다. 이 범위를 벗어나면 오히려 강도가 감소할 수 있습니다.
  • For Quality Control Teams: 논문의 Figure 2c와 3c 데이터는 주입 온도와 금형 온도가 강도에 비선형적인 영향을 미친다는 것을 보여줍니다. 이는 일관된 기계적 물성을 보장하기 위해 이러한 열적 변수를 더 엄격하게 제어하는 새로운 품질 검사 기준을 수립하는 데 정보를 제공할 수 있습니다.
  • For Design Engineers: 스퀴즈 압력의 강력한 영향력에 대한 연구 결과는 부품 설계 시 균일한 압력 전달이 용이하도록 해야 결함을 최소화할 수 있음을 나타냅니다. 이는 스퀴즈 캐스팅을 통한 제조 가능성을 보장하기 위해 초기 설계 단계에서 반드시 고려해야 할 중요한 사항입니다.

Paper Details


Optimization of Selected Squeeze Casting Parameters on the Mechanical Behaviour of Aluminium Alloy

1. Overview:

  • Title: Optimization of Selected Squeeze Casting Parameters on the Mechanical Behaviour of Aluminium Alloy
  • Author: OJARIGHO, EV; AКРОВI, JA; EVOKE, E
  • Year of publication: 2024
  • Journal/academic society of publication: J. Appl. Sci. Environ. Manage.
  • Keywords: Squeeze Casting Parameters; Taguchi Method; Optimization; Mechanical Properties

2. Abstract:

알루미늄 합금은 다양한 용도를 가지며 비용 효율적인 스퀴즈 캐스팅 기술을 통해 생산될 수 있다. 기존 문헌에 따르면 스퀴즈 캐스팅은 주조 제품의 기계적 특성을 향상시키고 거의 기공 없는 제품을 생산하는 장점이 있다. 그러나 스퀴즈 캐스팅은 압출 편석, 중심선 편석, 산화물 개재물, 기공, 블리스터링, 미충진, 소착, 고온 균열, 케이스 박리, 수축 등 몇 가지 문제에 직면해 있다. 이러한 결함을 최소화하기 위해, 원하는 결과를 산출할 최적의 매개변수를 적용하여 주조를 수행해야 한다. 본 연구는 알루미늄 합금(Al-12%Si) 생산에서 스퀴즈 압력, 가압 시간, 주입 온도, 초기 금형 온도의 스퀴즈 매개변수 최적화에 초점을 맞췄다. 평가된 응답은 항복 강도와 최종 인장 강도이다. 결과는 공정 매개변수가 95% 신뢰 수준에서 모든 특성에 통계적으로 유의미한 영향을 미쳤음을 보여주었다. 이러한 매개변수들의 조합된 상호작용 또한 특성 응답에 유의미한 영향을 나타냈다. 항복 강도와 최종 인장 강도에 대한 공정 인자의 최적 설정은 스퀴즈 압력, 가압 시간, 주입 온도 및 초기 금형 온도에 대해 각각 150MPa, 15초, 700°C 및 150°C로 평가되었다. 항복 강도와 최종 인장 강도인 세 가지 응답에 대해 얻어진 결과는 각각 302.86MPa와 347.72MPa였다.

3. Introduction:

알루미늄 합금은 높은 기술적 가치와 광범위한 산업적 용도, 그리고 높은 주조성, 우수한 내식성, 매력적인 인장 강도, 낮은 밀도, 높은 열전도율, 좋은 성형성, 높은 비강성 등 다양한 장점으로 인해 최근 큰 주목을 받아왔다. 이러한 이유로 알루미늄 합금은 대부분의 주조 공장에서 널리 사용되며, 특히 항공우주 산업과 기계 자동차 분야에서 중요한 적용 기회를 제공한다. 스퀴즈 캐스팅은 기존 주조와 단조의 장점을 결합하여 거의 최종 형상에 가까운 주조 부품을 생산한다. 이 공정은 영구 주형 주조 방법의 범주에 속하며, 우수한 표면 조도, 정밀한 치수 공차, 주조 표면에 모래 개재물이 없는 장점을 가진다.

Fig 1. Overview of the experimental process (a) crucible furnace (b) casting mould (c) squeeze casting process (d) cast samples for
analysis (e) samples from tensile testing (f) samples from impact testing.
Fig 1. Overview of the experimental process (a) crucible furnace (b) casting mould (c) squeeze casting process (d) cast samples for analysis (e) samples from tensile testing (f) samples from impact testing.

4. Summary of the study:

Background of the research topic:

알루미늄 합금의 스퀴즈 캐스팅은 우수한 기계적 특성을 가진 부품을 생산하는 효과적인 방법이지만, 다양한 공정 결함으로 인해 품질이 저하될 수 있다.

Status of previous research:

이전 연구들은 스퀴즈 압력, 금형 온도, 용탕 온도 등이 알루미늄 합금의 기계적 특성에 영향을 미친다는 것을 밝혔지만, 이들 변수 간의 상호작용과 체계적인 최적화에 대한 연구는 더 필요하다.

Purpose of the study:

본 연구의 목적은 스퀴즈 압력, 가압 시간, 주입 온도, 초기 금형 온도 등 네 가지 핵심 공정 변수가 Al-12%Si 합금의 항복 강도와 최종 인장 강도에 미치는 영향을 평가하고, 다구치 기법을 사용하여 최적의 공정 조건을 찾는 것이다.

Core study:

다구치 L27 직교 배열표에 따라 실험을 설계하고 수행하였다. 각 조건에서 생산된 시편의 항복 강도와 인장 강도를 측정하였다. 수집된 데이터를 분산 분석(ANOVA)하여 각 변수의 유의성을 검증하고, 신호 대 잡음비(S/N ratio)를 분석하여 최적의 공정 변수 조합을 도출하였다.

5. Research Methodology

Research Design:

본 연구는 실험 계획법으로 다구치 기법(Taguchi method)을 사용했다. 4개의 3수준 인자(스퀴즈 압력, 가압 시간, 주입 온도, 초기 금형 온도)를 고려하여 L27 직교 배열표를 구성했다.

Data Collection and Analysis Methods:

만능 시험기(Instron 3369 Series)를 사용하여 각 실험 조건에서 제작된 시편의 인장 시험을 수행하여 항복 강도와 최종 인장 강도 데이터를 수집했다. 수집된 데이터는 Minitab 19 소프트웨어를 사용하여 분산 분석(ANOVA), 파레토 차트 분석, 신호 대 잡음비(S/N ratio) 분석을 수행했다.

Research Topics and Scope:

연구 범위는 Al-12%Si 합금의 스퀴즈 캐스팅 공정에 국한되며, 주요 연구 주제는 네 가지 공정 변수가 항복 강도와 최종 인장 강도에 미치는 영향과 이들 특성을 극대화하기 위한 공정 최적화이다.

6. Key Results:

Key Results:

  • 스퀴즈 압력, 가압 시간, 주입 온도, 초기 금형 온도는 모두 항복 강도와 최종 인장 강도에 통계적으로 유의미한 영향을 미쳤다 (p-value < 0.05).
  • 스퀴즈 압력은 기계적 물성에 가장 큰 영향을 미치는 변수였으며, 가압 시간이 그 뒤를 이었다.
  • 항복 강도와 인장 강도를 극대화하기 위한 최적의 공정 조건은 스퀴즈 압력 150MPa, 가압 시간 45초, 주입 온도 700°C, 초기 금형 온도 200°C로 확인되었다.
  • 최적 조건에서 예측되는 항복 강도는 302.86MPa, 최종 인장 강도는 347.72MPa였다.
Fig. 2. Analysis for ultimate tensile strength as regards (a) Pareto chart (b) Normal plot (c) Main effect plot for fitted means
Fig. 2. Analysis for ultimate tensile strength as regards (a) Pareto chart (b) Normal plot (c) Main effect plot for fitted means

Figure List:

  • Fig 1. Overview of the experimental process (a) crucible furnace (b) casting mould (c) squeeze casting process (d) cast samples for analysis (e) samples from tensile testing (f) samples from impact testing.
  • Fig. 2. Analysis for ultimate tensile strength as regards (a) Pareto chart (b) Normal plot (c) Main effect plot for fitted means
  • Fig. 3. Analysis for ultimate tensile strength as regards (a) Pareto chart (b) Normal plot (c) Main effect plot for fitted means.
  • Fig. 5: Main Effects Plot for SN ratio for (a) Yield strength (b) Ultimate tensile strength

7. Conclusion:

다구치 기법을 사용하여 스퀴즈 캐스팅 파라미터를 분석하고 알루미늄 합금(Al-85%, Mg-8%, Si-12%, Mg-1%, Cu-0.90%, Ni-0.90%)의 기계적 성능을 최적화했다. 정규 분포도와 ANOVA 분석 결과, 스퀴즈 압력, 가압 시간, 주입 온도, 초기 금형 온도의 네 가지 파라미터가 항복 강도와 최종 인장 강도에 유의미한 영향을 미쳤으며, 각 경우 p-value는 0.05 미만이었다.

8. References:

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  3. Hajjari, E; Divandari, M (2008): An Investigation on The Microstructure and Tensile Properties of Direct Squeeze Cast and Gravity Die Cast 2024 Wrought Al Alloy. Mat. Design, 29: 1685-1689.
  4. Manjunath P; Prasad K.; Mahesh B (2014). Optimization of squeeze cast process parameters using Taguchi and grey relational analysis. Dept. Mech. Eng. Nat. Inst. Technol. Karnataka, Surathkal-575025, India.
  5. Manjunath, P; Krishna P; Parappagoudar M (2015). Modelling in Squeeze Casting Process-Present State and Future Perspectives. Adv. Auto. Eng. 4: 111. DOI:10.4172/2167-7670.1000111
  6. Manjunath, PGC; Arun, K.S; Mahesh, BP (2018). A systematic approach to model and optimize wear behaviour of castings produced by squeeze casting process. J. Manuf. Processes. 32: 199–212.
  7. Montgomery, DC (2005). Design and Analysis of experiments.6th ed., New York: John Wiley Sons, Inc.
  8. Peasant, SV; Subramanian R; Radhika, N; Anandavel B (2011). Dry sliding wear and friction studies on AlSi10Mg-fly ash-graphite hybrid metal matrix composites using Taguchi method. Tribology 5 (2) 72-81.
  9. Raji, A; Khan RH (2005).Effects of pouring temperature and squeeze pressure on Al-8% Si alloy squeeze cast parts. AUJT 9(4): 229-237.
  10. Ramon, V; Leon, Anne CS; Raghu, NK (1987). Performance measures independent of adjustment: an explanation and extension of Taguchi’s signal-to-noise-ratios, Technometrics 29 (3): 253–265.
  11. Rolland, T; Schmidt R; Arnberg L; Thorpe W (1996). Macrosegregation in indirectly squeeze cast Al-0.9 wt% Si. Mat. Sci. Eng. A, 212: 235-241.
  12. Schwam, D; Wallace, JF; Chang, Q; Zhu Y, (2002). Cast Optimization of the squeeze casting process for aluminum alloy parts. Case Western Reserve University.
  13. Senthil, P; Amirthagadeswaran, KS (2013b).Experimental study and squeeze cast process optimization for high quality AC2A aluminium alloy castings. Arabian J. Sci. Eng. 39(3): 2215-2225. DOI: 10.1007/s13369-013-0752-5, 2013.
  14. Shi-bo Bin; Shu-ming Xing, Long-mei Tian; Ning Zhao; Lan, LI (2013): Influence of technical parameters on strength and ductility of AlSi9Cu3 alloys in squeeze casting. Transact. Nonferrous Met. Soc. China. 23, 977-982
  15. Smillie, M (2006). Casting and analysis of squeeze cast Aluminum Silicon eutectic alloy. Ph.D. thesis, Dept. Mechanical Engineering, University of Canterbury, Christ Church, New Zealand.
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Expert Q&A: Your Top Questions Answered

Q1: 이 최적화 연구에서 완전 요인 설계 대신 다구치 기법을 선택한 이유는 무엇입니까?

A1: 본 논문에서는 다구치 L27 직교 배열표를 사용했습니다. 이 방법은 제한된 수의 실험으로 여러 변수의 효과를 연구하는 데 매우 효율적입니다. 4개 인자와 3개 수준을 가진 완전 요인 설계를 사용했다면 3^4 = 81회의 실험이 필요하지만, L27 배열표는 이를 27회로 줄여 상당한 시간과 자원을 절약하면서도 주요 효과와 최적의 파라미터 설정을 효과적으로 식별할 수 있습니다.

Q2: 주 효과도(Fig 2c, 3c)를 보면 주입 온도와 금형 온도가 특정 지점 이후에 강도를 감소시키는 것으로 나타났습니다. 물리적인 이유는 무엇인가요?

A2: 논문에서 야금학적 이유를 명시적으로 설명하지는 않았지만, 이러한 역 포물선 형태의 경향은 주조에서 흔히 나타납니다. 700°C와 같은 최적의 주입 온도는 과도하게 높지 않으면서도 금형을 채울 수 있는 좋은 유동성을 보장합니다. 온도가 너무 높으면 가스 기공 증가, 결정립 크기 증대, 응고 시간 지연 등의 문제가 발생하여 기계적 특성을 저하시킬 수 있습니다. 마찬가지로, 200°C의 최적 금형 온도는 양호한 용탕 흐름과 미세조직을 개선하고 강도를 높이는 빠른 방향성 응고 사이의 균형을 맞춥니다.

Q3: 스퀴즈 압력이 강도에 가장 큰 영향을 미쳤습니다. 압력은 어떻게 이러한 개선을 이끌어내나요?

A3: 논문의 서론에 따르면, 스퀴즈 캐스팅에서의 압력 적용은 유동성을 향상시키고 결함을 제거하는 데 도움이 됩니다. 높은 압력은 액체 금속을 금형과 긴밀하게 접촉시켜 열 전달을 촉진하고 빠른 응고를 유도합니다. 더 중요하게는, 응고 중인 영역에 지속적으로 용탕을 공급하여 수축 기공을 효과적으로 방지함으로써, 결과적으로 밀도가 높고 건전한 주조품을 만들어 항복 강도 및 인장 강도와 같은 기계적 특성을 크게 향상시킵니다.

Q4: 개별 강도 지표에 대한 최적 가압 시간은 45초였지만, 다중 목표 최적화에서는 15초였습니다. 왜 이런 차이가 발생하나요?

A4: 논문은 서로 다른 최적 설정을 제시합니다. 항복 강도(Table 6)와 인장 강도(Table 7)를 개별적으로 최적화할 때는 45초의 긴 가압 시간이 미세 수축을 완전히 제거하는 데 유리하여 최적으로 나타났습니다. 그러나 다중 목표 최적화(Table 8)는 균형 잡힌 해결책을 찾는 것을 목표로 합니다. 이 경우 15초가 선택된 것은, 각 특성에서 절대적인 최대치를 달성하지는 못하더라도, 짧은 사이클 타임이라는 생산성 이점을 제공하면서 여전히 우수한 특성 조합을 달성할 수 있는 타협점이기 때문일 수 있습니다.

Q5: 이 연구에서 신호 대 잡음비(S/N ratio) 분석의 중요성은 무엇입니까?

A5: 다구치 기법의 핵심 개념인 S/N ratio는 공정의 강건성(robustness)을 측정하는 데 사용됩니다. 본 연구에서 사용된 ‘망대특성(larger the better)’ S/N ratio(Eq. 3)는 강도(“신호”)를 극대화할 뿐만 아니라 제어 불가능한 요인(“잡음”)에 대한 변동성이나 민감도를 최소화하는 파라미터 설정을 식별하는 데 도움을 줍니다. S/N ratio를 최대화함으로써, 본 연구는 산업 제조에 필수적인, 일관되게 높은 강도의 부품을 생산하는 최적의 공정 윈도우를 찾습니다.


Conclusion: Paving the Way for Higher Quality and Productivity

본 연구는 다구치 기법을 활용한 체계적인 스퀴즈 캐스팅 최적화가 어떻게 일반적인 주조 결함을 극복하고 우수한 알루미늄 부품을 생산할 수 있는지를 명확하게 보여주었습니다. 스퀴즈 압력, 가압 시간, 주입 온도, 초기 금형 온도의 정밀한 제어는 항복 강도와 인장 강도를 극대화하는 데 필수적입니다. 이러한 결과는 고성능 경량 부품이 요구되는 자동차 및 항공우주 산업에 중요한 시사점을 제공합니다.

STI C&D는 최신 산업 연구를 적용하여 고객이 더 높은 생산성과 품질을 달성할 수 있도록 최선을 다하고 있습니다. 이 백서에서 논의된 과제가 귀사의 운영 목표와 일치한다면, 저희 엔지니어링 팀에 연락하여 이러한 원칙을 귀사의 부품에 어떻게 구현할 수 있는지 알아보십시오.

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Copyright Information

  • This content is a summary and analysis based on the paper “Optimization of Selected Squeeze Casting Parameters on the Mechanical Behaviour of Aluminium Alloy” by “OJARIGHO, EV; AКРОВI, JA; EVOKE, E”.
  • Source: https://dx.doi.org/10.4314/jasem.v28i2.15

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Fig. 1. Definition sketch of main parameters: (a) side view; (b) top view.

해양 구조물 안전의 핵심: 새로운 오일러 수 기반 세굴 심도 예측 방정식

이 기술 요약은 N. S. Tavouktsoglou, J. M. Harris, R. R. Simons & R. J. S. Whitehouse가 발표한 “[Equilibrium scour depth prediction around cylindrical structures]” 논문을 기반으로 하며, STI C&D의 기술 전문가에 의해 분석 및 요약되었습니다.

키워드

  • Primary Keyword: 세굴 심도 예측
  • Secondary Keywords: 원통형 구조물, 흐름-구조물 상호작용, 오일러 수, 해양 기초, CFD 해석, 국부 세굴

Executive Summary

  • 문제점: 해양 중력식 기초(GBF)와 같은 복잡한 형상의 구조물 주변에서 발생하는 세굴 깊이를 정확하게 예측하는 통일된 방법이 부재했습니다.
  • 해결 방안: 물리적 모델링 결과와 광범위한 기존 연구 데이터베이스를 활용하여, 오일러 수, 레이놀즈 수, 프루드 수 등 주요 무차원 매개변수에 대한 차원 해석을 통해 새로운 세굴 예측 방정식을 개발했습니다.
  • 핵심 혁신: 기존에 사용되지 않았던 새로운 물리량인 ‘수심 평균 오일러 수'(압력 구배 기반)가 세굴 과정을 설명하는 핵심 매개변수임을 규명하고 이를 예측 모델에 통합했습니다.
  • 핵심: 새롭게 개발된 예측 방정식(R² = 0.91)은 균일 및 비균일 원통형 구조물 주변의 정수역(clearwater) 세굴 깊이를 더 신뢰성 있게 예측할 수 있는 통합된 방법을 제공하여, 더 안전하고 비용 효율적인 해양 구조물 설계에 기여합니다.

문제점: 이 연구가 CFD 전문가에게 중요한 이유

해양 풍력 발전 단지와 같은 구조물은 점차 더 깊은 수심에 건설되고 있으며, 이로 인해 구조물의 기초 안정성을 위협하는 세굴(scour) 현상에 대한 정확한 예측이 중요해졌습니다. 특히, 기존 연구는 주로 단순한 단일 파일(monopile)에 집중되어 있어, 복잡한 형상을 가진 중력식 기초(Gravity Base Foundations, GBF) 주변의 세굴을 예측하는 데는 한계가 있었습니다. 서로 다른 유형의 구조물(수중-노출, 원통형-복합형)에 대해 통일된 접근법이 없어, 설계자들은 보수적인 추정이나 각기 다른 경험식에 의존해야 했습니다. 이는 과도한 설계 비용을 유발하거나 구조물의 안전성을 저해할 수 있는 잠재적 위험을 안고 있었습니다. 본 연구는 이러한 기술적 한계를 극복하고, 다양한 원통형 구조물에 보편적으로 적용할 수 있는 신뢰도 높은 세굴 심도 예측 방법을 개발하기 위해 시작되었습니다.

Fig. 1. Definition sketch of main parameters: (a) side view; (b) top
view.
Fig. 1. Definition sketch of main parameters: (a) side view; (b) top view.

접근법: 연구 방법론 분석

본 연구는 새로운 세굴 예측 방정식을 개발하기 위해 차원 해석, 물리적 모델링, 그리고 광범위한 데이터베이스 분석을 결합했습니다.

  1. 차원 해석 및 오일러 수 도입: 연구진은 먼저 흐름-구조물-바닥 상호작용을 지배하는 물리적 변수들(유체 밀도, 점성, 압력 변화, 구조물 직경 등)을 기반으로 벅킹엄 파이 정리를 적용했습니다. 이 과정을 통해 세굴 깊이에 영향을 미치는 주요 무차원 매개변수 그룹으로 오일러 수(Eu), 파일 레이놀즈 수(Rep), 프루드 수(Fr), 퇴적물 이동성 수(U/Uc), 무차원 수심(h/D)을 도출했습니다. 특히, 이 연구에서는 잠재 유동 이론을 사용하여 계산된 ‘수심 평균 압력 구배’를 기반으로 하는 새로운 형태의 오일러 수를 정의했으며, 이는 구조물로 인한 흐름 가속과 말굽 와류(horseshoe vortex) 형성을 정량화하는 핵심 지표로 사용되었습니다.
  2. 물리적 모델링 실험: 제안된 매개변수들의 영향을 검증하고 데이터를 확보하기 위해 두 가지 다른 규모의 수리 실험을 수행했습니다. 소규모 실험은 10m 길이의 수조에서, 대규모 실험은 20m 길이의 수조에서 진행되었습니다. 원뿔형, 원통형 기초 등 다양한 형상의 구조물 모델을 제작하여 일정 유속 조건(unidirectional current) 하에서 실험을 수행했습니다. 세굴 깊이는 카메라를 이용한 타임랩스 이미지로 지속적으로 모니터링되었으며, 유속 프로파일은 LDV(Laser Doppler Velocimeter)와 ADV(Acoustic Doppler Velocimeter)를 사용하여 정밀하게 측정되었습니다.
  3. 데이터베이스 구축 및 방정식 개발: 본 연구에서 수행된 실험 데이터와 함께, 기존에 발표된 여러 연구의 정수역(clearwater) 세굴 데이터를 수집하여 포괄적인 데이터베이스를 구축했습니다. 이 데이터베이스를 기반으로, 앞서 도출된 무차원 매개변수들과 측정된 평형 세굴 깊이 간의 함수 관계를 최적화하여 최종적인 세굴 예측 방정식을 개발했습니다.
Fig. 3. Structure geometries used in this study (geometries shown in this figure include
the part of the structure protruding from the original bed level).
Fig. 3. Structure geometries used in this study (geometries shown in this figure include the part of the structure protruding from the original bed level).

핵심 혁신: 주요 발견 및 데이터

발견 1: 높은 정확도를 가진 새로운 세굴 심도 예측 방정식 개발

본 연구는 광범위한 데이터베이스를 기반으로 다음과 같은 새로운 평형 세굴 심도 예측 방정식을 개발했습니다.

S/D_base = aζ / (ζ + c) (방정식 19) 여기서 ζ는 오일러 수, 레이놀즈 수, 프루드 수, 퇴적물 이동성 수, 무차원 수심을 포함하는 복합 매개변수입니다.

이 새로운 방법은 본 연구에서 수집된 데이터베이스와 비교했을 때 매우 높은 정확도를 보였습니다. 예측값과 측정값 사이의 상관 계수(R²)는 0.91로 나타났으며, 전체 예측의 55%가 10% 미만의 오차를, 82%가 20% 미만의 오차를 보였습니다 (Figure 9 참조). 이는 기존의 형상 계수에 의존하거나 특정 조건에서만 유효했던 방법들과 달리, 다양한 구조물 형상과 유동 조건에 대해 일관되고 신뢰성 있는 예측을 제공할 수 있음을 의미합니다.

발견 2: 세굴 현상의 핵심 구동력으로서 ‘수심 평균 오일러 수’의 역할 규명

본 연구의 가장 중요한 기여 중 하나는 ‘수심 평균 오일러 수((Eu))’가 세굴 깊이를 결정하는 핵심 물리량임을 입증한 것입니다. 오일러 수는 구조물 상류에서의 압력 구배를 나타내며, 이는 말굽 와류의 강도와 직접적으로 관련이 있습니다.

실험 결과, 다른 유동 조건이 동일할 때 오일러 수가 증가할수록 평형 세굴 깊이가 증가하며, 오일러 수가 2에 가까워지면서 점근하는 경향을 보였습니다 (Figure 10 참조). 이는 구조물로 인한 유동 방해(blockage)가 클수록(예: 균일 원통형), 더 강한 압력 구배가 형성되어 더 깊은 세굴이 발생함을 정량적으로 보여줍니다. 반면, 원뿔형 기초와 같이 바닥으로 갈수록 직경이 넓어지는 구조물은 오일러 수가 낮아져 세굴이 감소하는 효과가 있었습니다. 이 발견은 세굴 저감 설계를 위한 새로운 물리적 통찰력을 제공합니다.

R&D 및 운영을 위한 실질적 시사점

  • 해양 구조물 설계 엔지니어: 이 연구는 구조물의 형상이 수심 평균 오일러 수를 통해 세굴 잠재력에 직접적인 영향을 미친다는 것을 보여줍니다. 예를 들어, 바닥 부분에 원뿔형 기초를 적용하면 압력 구배가 완화되어 세굴 깊이를 줄일 수 있습니다 (논문 165-168행). 이는 초기 설계 단계에서 세굴 저항성을 높이는 최적의 기초 형상을 찾는 데 중요한 기준으로 활용될 수 있습니다.
  • 안전 및 유지보수 팀: 개발된 예측 방정식(Eq. 19)은 기존 또는 계획된 구조물 주변의 세굴 위험을 보다 정확하게 평가할 수 있는 결정론적 도구를 제공합니다. 이를 통해 확률론적 위험 평가의 기반을 마련하고(논문 334-335행), 더 신뢰성 있는 유지보수 계획을 수립하여 구조물의 장기적인 안정성을 확보할 수 있습니다.
  • CFD 해석 전문가: 본 연구에서 제안된 오일러 수, 레이놀즈 수, 프루드 수 등의 무차원 매개변수들은 CFD 시뮬레이션의 검증 및 타당성 평가에 중요한 지표로 사용될 수 있습니다. 특히, 압력 구배에 기반한 오일러 수의 개념은 시뮬레이션에서 말굽 와류와 같은 복잡한 유동 현상을 정확하게 모델링하고 있는지 평가하는 데 유용한 물리적 척도를 제공합니다.

논문 상세 정보


Equilibrium scour depth prediction around cylindrical structures

1. 개요:

  • 제목: Equilibrium scour depth prediction around cylindrical structures
  • 저자: N. S. Tavouktsoglou, J. M. Harris, R. R. Simons & R. J. S. Whitehouse
  • 발행 연도:
  • 저널/학회: Manuscript
  • 키워드: Offshore Gravity Base Foundations (GBFs), scour, clearwater scour, cylindrical structures, Euler number, dimensional analysis

2. 초록:

해양 중력식 기초(GBF)는 종종 복잡한 기하학적 구조로 설계됩니다. 이러한 구조물은 국부적인 유체 역학과 상호 작용하여 흐름 및 세굴 현상(예: 바닥 전단 응력 증폭)을 유발하는 역압력 구배를 생성합니다. 본 연구에서는 단방향 해류의 힘을 받는 비균일 기하학적 구조를 가진 원통형 구조물 주변의 정수역(clearwater) 세굴을 예측하는 방법을 제시합니다. 이러한 복잡한 구조물 주변의 흐름장과 퇴적물의 상호 작용은 물-퇴적물 운동의 상사성을 특징짓는 무차원 매개변수로 설명됩니다. 이 논문은 균일 및 비균일 원통형 구조물 주변의 평형 세굴에 대한 수심 평균 오일러 수의 영향에 대한 통찰력을 제공합니다. 여기서 오일러 수는 수심 평균 흐름 방향 압력 구배(잠재 유동 이론을 사용하여 계산), 평균 유속 및 유체 밀도를 기반으로 합니다. 차원 해석에 따라, 제어 매개변수는 오일러 수, 파일 레이놀즈 수, 프루드 수, 퇴적물 이동성 수 및 무차원 유동 깊이로 밝혀졌습니다. 이 발견을 바탕으로 새로운 세굴 예측 방정식이 개발되었습니다. 이 새로운 방법은 본 연구에서 수집된 세굴 깊이 데이터베이스와 좋은 일치(R² = 0.91)를 보입니다. 비균일 원통형 구조물 주변의 평형 세굴 깊이 측정은 세굴 과정에서 오일러 수의 중요성을 보여주기 위해 사용됩니다. 마지막으로, 세굴에 대한 나머지 무차원 양들의 중요성도 본 연구에서 조사됩니다.

3. 서론:

해양 기초 주변의 세굴에 대한 연구는 주로 단일 파일(monopile)과 상호 작용할 때 수력학적 조건이 해저에 미치는 영향에 초점을 맞추어 왔습니다. 단일 파일 주변의 유체-구조물-토양 상호 작용에 대해서는 상당한 양의 연구가 수행되었지만, 중력식 기초(GBF)와 같은 더 복잡한 구조물에 대한 광범위한 연구는 수행되지 않았습니다. 전 세계적으로 재생 에너지에 대한 관심이 높아지면서 해상 풍력 산업은 얕은 수심(10~30m)에 많은 수의 해상 풍력 발전 단지를 계획하고 건설할 수 있게 되었습니다. 해상 풍력 에너지에 대한 수요 증가로 인해 더 깊은 수심(30~60m)에 풍력 발전 단지 위치가 계획되고 있습니다. 이러한 위치는 파도 조건이 더 활발할 수 있지만, 수심 증가로 인해 파도의 세굴에 대한 영향이 덜 뚜렷해지고 조류가 더 지배적일 수 있는 해양 석유 플랫폼이 직면한 것과 유사한 수력학적 조건이 특징입니다. GBF는 이러한 위치에서 단일 파일 기초에 비해 더 비용 경쟁력 있는 지지 구조가 될 수 있습니다. 비균일 원통형 구조물의 세굴 잠재력에 대한 연구는 제한적이었습니다.

4. 연구 요약:

연구 주제의 배경:

해양 구조물, 특히 해상 풍력 발전을 위한 중력식 기초(GBF)는 복잡한 형상을 가지며, 이로 인해 발생하는 국부 세굴 현상은 구조물의 안정성에 큰 위협이 됩니다. 기존 연구는 주로 단순한 단일 파일에 국한되어 있어 복잡한 구조물에 대한 통합된 세굴 예측 방법론이 부재한 실정입니다.

이전 연구 현황:

과거 연구들은 주로 특정 조건(예: 강 교각, 얕은 수심)이나 특정 구조물(직사각형, 원뿔형)에 대한 경험적 공식을 제안하는 데 그쳤습니다. Jones et al. (1992), Parola et al. (1996) 등은 교각 기초의 영향에 대해 연구했지만, 이는 다양한 해양 환경과 구조물에 보편적으로 적용하기 어려운 단점이 있었습니다. 즉, 다양한 구조물 유형과 유동 조건에 대한 통합된 평형 세굴 예측 접근법이 없었습니다.

연구 목적:

본 연구의 목적은 균일 및 비균일 원통형 구조물 주변의 정수역(clearwater) 평형 세굴 깊이를 예측할 수 있는 신뢰성 있는 방법을 제시하는 것입니다. 이를 위해 새로운 물리적 모델링 결과와 광범위한 기존 연구 데이터를 기반으로, 세굴 현상을 지배하는 주요 무차원 매개변수들 사이의 함수 관계를 규명하고자 했습니다. 특히, 이전에는 사용되지 않았던 ‘수심 평균 압력 구배’를 기반으로 한 오일러 수를 도입하여 세굴 과정에 대한 물리적 이해를 높이고 예측 모델의 정확성을 향상시키는 것을 목표로 했습니다.

핵심 연구:

본 연구의 핵심은 차원 해석을 통해 세굴 현상을 지배하는 주요 무차원 매개변수(오일러 수, 파일 레이놀즈 수, 프루드 수, 퇴적물 이동성 수, 무차원 수심)를 식별하고, 이들 간의 관계를 설명하는 새로운 세굴 예측 방정식을 개발한 것입니다. 특히, 잠재 유동 이론을 이용해 ‘수심 평균 오일러 수’를 계산하고, 이 값이 구조물의 형상과 유동 프로파일에 따라 어떻게 변하며 세굴 깊이에 어떤 영향을 미치는지를 실험적으로 검증했습니다. 개발된 방정식은 본 연구에서 구축한 370개 이상의 데이터 포인트로 구성된 데이터베이스와 비교하여 높은 정확도(R² = 0.91)를 입증했습니다.

5. 연구 방법론

연구 설계:

본 연구는 차원 해석을 통해 이론적 틀을 설정하고, 수리 모형 실험을 통해 가설을 검증하며, 광범위한 데이터베이스를 활용하여 예측 방정식을 개발하는 다각적인 접근법을 채택했습니다.

데이터 수집 및 분석 방법:

데이터는 두 가지 규모의 수조 실험과 기존에 발표된 16개의 연구 논문에서 수집되었습니다. 실험에서는 다양한 형상(원통형, 원뿔형, 절단형 등)의 구조물 모델을 사용하여 여러 유동 조건 하에서 평형 세굴 깊이를 측정했습니다. 수집된 모든 데이터(총 370개)는 정수역(clearwater) 조건, 비점착성 퇴적물, 그리고 기하학적 표준편차(σg)가 1.3 미만인 경우로 제한하여 데이터의 일관성을 확보했습니다. 이 데이터베이스를 기반으로 매개변수 최적화 기법(McCuen and Snyder, 1986)을 사용하여 예측 방정식의 계수(a, b, c)를 결정했습니다.

연구 주제 및 범위:

본 연구는 단방향 정상류(steady unidirectional current) 조건 하에서 원통형(균일 및 비균일) 구조물 주변에서 발생하는 정수역(clearwater) 국부 세굴의 평형 깊이를 예측하는 데 초점을 맞춥니다. 파도의 영향이나 활성상(live-bed) 세굴, 점착성 퇴적물의 영향은 연구 범위에서 제외되었습니다.

6. 주요 결과:

주요 결과:

  • 새로운 세굴 예측 방정식이 개발되었으며, 이는 광범위한 데이터베이스(R² = 0.91)에 대해 높은 정확도를 보입니다.
  • 수심 평균 오일러 수((Eu))가 세굴 깊이를 결정하는 중요한 물리적 매개변수임이 처음으로 규명되었습니다. (Eu)가 증가하면 세굴 깊이도 증가합니다.
  • 파일 레이놀즈 수(Rep)가 증가하면 무차원 세굴 깊이가 감소하는 경향이 있으며, 이는 대형 구조물에서 관찰되는 스케일 효과를 설명할 수 있습니다.
  • 프루드 수(Fr)가 증가하면(수심이 얕아지면) 하강류가 강해져 세굴 깊이가 증가하다가 점근하는 경향을 보입니다.
  • 퇴적물 이동성 수(U/Uc)가 1에 가까워질수록 가장 깊은 세굴이 발생하며, 이는 본 모델에서도 잘 예측되었습니다.
Fig. 15. Definition diagram of the location of the vertical stagnation point.
Fig. 15. Definition diagram of the location of the vertical stagnation point.

Figure 목록:

  • Fig. 1. Definition sketch of main parameters: (a) side view; (b) top view.
  • Fig. 2. Pressure gradient distribution through the water column (calculated using Equation 11) for two different structures under the same flow conditions.
  • Fig. 3. Structure geometries used in this study (geometries shown in this figure include the part of the structure protruding from the original bed level).
  • Fig. 4. Percent distribution of non-dimensional quantities in database.
  • Fig. 5. Layout of flume (top: top view; bottom side view).
  • Fig. 6. Summary of flow conditions used in the test series.
  • Fig. 7. Representative non-dimensional flow profiles for the seven different flow conditions used in these experiments. (see Figure 6 for symbols).
  • Fig. 8. Agreement between non-dimensional scour depth and ζ.
  • Fig. 9: Agreement of scour depth prediction (using equation 19) and measured scour depths with 10% and 20% confidence bounds.
  • Fig. 10. Influence of the sediment mobility ratio (U/U_c={0.74.0.88 and 1}) on the variation of the equilibrium scour depth as a function of (Eu). Solid line shows the
  • Fig. 11. Influence of the non-dimensional water depth (h/D={2.2 and 3.7}) on the variation of the equilibrium scour depth as a function of (Eu). Solid line shows the
  • Fig. 12. Influence of the vertical flow distribution on the variation of the equilibrium scour depth as a function of (Eu). Solid line shows the prediction given be equation 19
  • Fig. 13. Influence of [Re]_D on equilibrium scour. Comparison of equation (19) to scour depth data with varying [Re]_D and Fr={0.15-0.20},U/U_c={0.7-0.85},h/D={2-
  • Fig. 14. Effect of the pile Reynolds number on scour. Comparison of present equation (eq. 19) and the equation of Shen et al, (1969) (eq. 21) to the data presented in
  • Fig. 15. Definition diagram of the location of the vertical stagnation point.
  • Fig. 16. Influence of Fr on equilibrium scour. Comparison of equation (19) to scour depth data with varying Fr and [Re]_D={75000-150000},U/U_c={0.8-1},h/D={2-3}
  • Fig. 17. Influence of h/D on equilibrium scour. Comparison of equation (19) to scour depth data with varying h/D and [Re]_D={100000-300000}, U/Uc={0.8-1}, Fr={0.1-
  • Fig. 18. Effect of boundary layer thickness on scour. Comparison of equation (19) with clearwater scour data compiled from Melville and Sutherland (1988).
  • Fig. 19. Effect of sediment mobility ratio on scour for monopiles. Comparison of equation (19) to scour depth data with varying U/U_c and [Re]_D={50000-

7. 결론:

본 연구에서는 정수역(clearwater) 조건 하에서 균일 및 비균일 원통형 구조물 주변의 평형 세굴 깊이를 예측하기 위한 설계 방법을 제시했습니다. 이 방정식은 본 연구에서 수행된 실험과 다른 발표된 연구에서 얻은 실험 및 현장 데이터를 기반으로 파생되었습니다. 이 방법은 새로운 물리량인 수심 평균 오일러 수를 기반으로 하며, 그 영향은 본 연구 동안 수집된 실험 데이터를 통해 검증되었습니다. 본 연구에서 확인된 다른 영향력 있는 물리량은 Rep, Fr, U/Uc 및 h/D입니다. 그 중요성과 영향은 실험 데이터와 물리적 근거를 통해 설명되었습니다.

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Expert Q&A: 전문가 Q&A

Q1: 왜 이전 연구에서 사용되지 않았던 ‘수심 평균 오일러 수’를 핵심 매개변수로 선택했습니까?

A1: 논문에 따르면, 구조물 상류에서의 흐름-구조물 상호작용은 점성 효과가 미미하므로, 흐름의 변화를 설명할 수 있는 무차원량이 필요했습니다. 오일러 수는 압력 구배의 무차원 형태로, 세굴의 주요 원인인 말굽 와류(horseshoe vortex) 형성을 유발하는 역압력 구배를 물리적으로 가장 잘 나타내는 양입니다. 기존 연구들이 주로 유속이나 수심 같은 개별 변수에 집중했던 것과 달리, 본 연구는 압력 구배라는 근본적인 물리 현상에 초점을 맞춰 세굴 과정을 더 정확하게 설명하고자 했습니다 (논문 135-138, 341-346행 참조).

Q2: 이 연구는 정수역(clearwater) 세굴에 초점을 맞추었는데, 실제 해양 환경에서 흔한 활성상(live-bed) 세굴 조건에는 이 결과를 어떻게 적용할 수 있나요?

A2: 연구진은 상류의 연흔(ripple) 형성이나 전반적인 하상 저하와 같은 복잡한 변수를 배제하고 세굴의 근본적인 메커니즘을 규명하기 위해 의도적으로 정수역 조건을 선택했습니다 (논문 205-207행 참조). 따라서 개발된 방정식은 직접적으로 활성상 세굴에 적용되지는 않습니다. 하지만 이 방정식은 특정 흐름 조건에서 발생할 수 있는 최대 잠재 세굴 깊이에 대한 보수적인 기준값을 제공할 수 있습니다. 논문에서도 해양 환경의 세굴 깊이가 단방향 흐름에서 유도된 것과 유사한 수준으로 나타날 수 있다고 언급하므로(논문 315-316행), 본 연구 결과는 활성상 조건의 위험 평가를 위한 중요한 기초 자료로 활용될 수 있습니다.

Q3: 제안된 모델에서 파일 레이놀즈 수(Rep)는 세굴 깊이에 어떤 영향을 미칩니까?

A3: 모델과 실험 결과에 따르면, 파일 레이놀즈 수가 증가할수록 무차원 평형 세굴 깊이는 감소하는 경향을 보입니다 (Figure 13 참조). 이는 레이놀즈 수가 증가하면 파일 벽면의 경계층 두께가 얇아지고, 흐름 박리점이 파일의 하류 쪽으로 이동하기 때문입니다. 이러한 현상은 후류(lee wake) 와류의 퇴적물 이송 능력을 감소시켜 결과적으로 전체적인 세굴 잠재력을 줄이는 효과를 가져옵니다. 이 관계는 실험실의 소규모 모델과 현장의 대규모 구조물 사이에서 나타나는 스케일 효과(scale effect) 중 일부를 설명해 줍니다 (논문 391-396행 참조).

Q4: 실험에서 비대수적(non-logarithmic) 유속 프로파일을 사용한 것의 실질적인 의미는 무엇인가요?

A4: 비대수적 유속 프로파일은 해상 풍력 발전 단지와 같이 기존 조류 위에 바람에 의한 전단 흐름이 추가되는 실제 해양 환경을 모사하기 위해 도입되었습니다 (논문 179-182, 260-263행 참조). 실험 결과(Figure 12), 복잡한 형상의 구조물(예: 원뿔형 기초)에서는 이러한 프로파일이 더 낮은 오일러 수와 더 얕은 세굴 깊이를 유발했습니다. 이는 하부의 유속이 상대적으로 느려 구조물의 넓은 기초 부분과 상호작용하는 운동 에너지가 작아지기 때문입니다. 이는 실제 환경 조건을 고려한 정밀한 세굴 예측의 중요성을 보여줍니다.

Q5: 새로운 예측 방정식(Eq. 19)은 다소 복잡해 보입니다. 설계자가 새로운 구조물에 대해 오일러 수를 계산하려면 어떤 과정을 거쳐야 하나요?

A5: 논문에서는 설계자가 오일러 수를 계산할 수 있는 명확한 절차를 제시하고 있습니다 (논문 187-195행 참조). 첫째, 수직 유속 프로파일을 설명하는 함수 u(z)를 설정합니다. 둘째, 구조물의 수직 직경 변화를 나타내는 함수 D(z)를 정의합니다. 마지막으로, 이 두 함수를 사용하여 방정식 (16)을 수심 전체에 대해 적분하여 수심 평균 압력 구배를 계산하고, 이를 방정식 (17)에 대입하여 최종적인 오일러 수 (Eu)를 구합니다. 이 과정은 스프레드시트를 사용하여 자동화할 수 있습니다.


결론: 더 높은 품질과 생산성을 향한 길

해양 구조물 주변의 부정확한 세굴 심도 예측은 설계 비용 증가와 안전 문제의 주된 원인이었습니다. 본 연구는 압력 구배를 기반으로 한 ‘수심 평균 오일러 수’라는 새로운 물리량을 도입하여, 다양한 형상의 원통형 구조물에 대해 높은 정확도를 가진 통합된 세굴 예측 방정식을 제시함으로써 이 문제를 해결하는 중요한 돌파구를 마련했습니다. 이 연구 결과는 R&D 및 운영 현장에서 더 안전하고 경제적인 해양 기초를 설계하는 데 실질적인 통찰력을 제공합니다.

STI C&D에서는 최신 산업 연구를 적용하여 고객이 더 높은 생산성과 품질을 달성할 수 있도록 최선을 다하고 있습니다. 이 논문에서 논의된 과제가 귀사의 운영 목표와 일치한다면, 저희 엔지니어링 팀에 연락하여 이러한 원칙을 귀사의 구성 요소에 어떻게 구현할 수 있는지 알아보십시오.

(주)에스티아이씨앤디에서는 고객이 수치해석을 직접 수행하고 싶지만 경험이 없거나, 시간이 없어서 용역을 통해 수치해석 결과를 얻고자 하는 경우 전문 엔지니어를 통해 CFD consulting services를 제공합니다. 귀하께서 당면하고 있는 연구프로젝트를 최소의 비용으로, 최적의 해결방안을 찾을 수 있도록 지원합니다.

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저작권 정보

  • 이 콘텐츠는 N. S. Tavouktsoglou 외 저자의 논문 “[Equilibrium scour depth prediction around cylindrical structures]”를 기반으로 한 요약 및 분석 자료입니다.
  • 출처: 이 자료는 정보 제공 목적으로만 사용됩니다. 무단 상업적 사용을 금지합니다. Copyright © 2025 STI C&D. All rights reserved.
Figure 7. Equilibrium content of Si and TiSi, TiSi2 in the air and argon atmosphere, in alloys: (a) AlSi12, (b) AlSi9Cu3, (c) mixed. The Si content is on the secondary axis.

이종 합금 주조의 혁신: MMIC 공정의 산화물 및 혼합 영역 제어 기술

이 기술 요약은 Liudmyla Lisova 외 저자가 International Journal of Metalcasting에 발표한 “DUAL-ALLOY SAND MOLD CASTING: MAIN PRINCIPLES AND FEATURES” (2025) 논문을 기반으로 하며, 기술 전문가를 위해 STI C&D가 분석하고 요약했습니다.

Keywords

  • Primary Keyword: 이종 합금 주조 (Dual-Alloy Casting)
  • Secondary Keywords: 다중 재료 사출 주조 (Multi-Material Injector Casting, MMIC), 알루미늄 합금 (Aluminum Alloy), 혼합 영역 (Mixing Zone), 산화물 개재물 (Oxide Inclusions), 주조 시뮬레이션 (Casting Simulation), FLOW-3D

Executive Summary

  • The Challenge: 단일 주조 공정에서 두 가지 다른 합금을 결합하면서 각 합금의 고유 특성을 유지하고 혼합 영역의 결함을 제어하는 것의 어려움.
  • The Method: 열역학 및 CFD 시뮬레이션(Flow3D Cast)과 실험적 사형 주조를 병행하여 AlSi12 및 AlSi9Cu3 이종 합금 주괴의 혼합 영역, 산화 및 미세 구조를 분석.
  • The Key Breakthrough: 주조 방식과 하부 냉각(칠)이 용탕 노출 시간보다 혼합 영역 프로파일과 결함 형성에 더 큰 영향을 미치며, 이는 응고 제어 및 공기 접촉 시간 감소를 통해 달성됨.
  • The Bottom Line: 이종 합금 부품에서 산화물 관련 기공을 최소화하고 이상적인 혼합 영역을 구현하기 위해서는 특히 하부 냉각을 활용한 정밀한 주조 공정 제어가 필수적임.

The Challenge: Why This Research Matters for CFD Professionals

기존의 주조 공정은 부품의 국부적 특성을 정밀하게 제어하는 데 한계가 있습니다. 이러한 한계를 극복하기 위해, 특정 부위에 요구되는 기계적 특성을 부여할 수 있는 이종 합금 주조 기술이 주목받고 있습니다. 그러나 두 개의 다른 용융 합금을 하나의 주형에 주입하는 것은 새로운 기술적 과제를 야기합니다. 두 합금이 만나는 혼합 영역(mixing zone)의 폭과 균일성을 어떻게 제어할 것인가? 첫 번째 합금이 공기에 노출되는 동안 생성되는 산화막이 최종 제품의 품질에 어떤 영향을 미치는가? 이러한 산화물 개재물은 기공과 같은 심각한 결함의 원인이 될 수 있으며, 이는 자동차, 항공우주 등 고신뢰성이 요구되는 산업에서 치명적일 수 있습니다. 따라서 이종 합금 주조 공정의 성공은 혼합 영역의 물리적, 화학적 특성과 결함 형성 메커니즘을 깊이 이해하는 데 달려 있습니다.

Figure 1. Schematic of the injector casting process and two injector positions under
investigation.
Figure 1. Schematic of the injector casting process and two injector positions under investigation.

The Approach: Unpacking the Methodology

본 연구는 이러한 과제를 해결하기 위해 시뮬레이션과 실험을 결합한 포괄적인 접근 방식을 채택했습니다.

  1. 시뮬레이션 분석:
    • 열역학 계산: HSC Chemistry 10 프로그램을 사용하여 공기와의 접촉 시 합금 내에서 형성될 수 있는 산화물(Al₂O₃, MgO, MgAl₂O₄) 및 기타 금속간 화합물의 종류와 양을 예측했습니다.
    • CFD 시뮬레이션: Flow3D Cast v5.0을 활용하여 다중 재료 사출 주조(MMIC) 공정을 모델링했습니다. 이를 통해 두 번째 합금 주입 시 용탕의 유동, 온도 분포, 그리고 두 합금 간의 혼합 현상을 시각적으로 분석하고, 첫 번째 합금의 일부가 재용융되는 과정을 확인했습니다 (그림 9 참조).
  2. 실험적 검증:
    • 재료 및 공정: AlSi9Cu3(합금 1)과 AlSi12(합금 2)를 사용하여 실험적 사형 주조를 수행했습니다. 구리(Cu)는 합금 1에만 포함되어 있어 혼합 영역을 추적하는 핵심 지표로 사용되었습니다.
    • 핵심 변수: 두 가지 사출기 위치를 모사한 주입 방식, 두 합금 간의 주입 시간 간격(60, 90, 120초), 그리고 방향성 응고를 유도하기 위한 하부 강철 냉각판(칠, chill) 사용 여부를 주요 변수로 설정하여 실험을 진행했습니다.
  3. 분석:
    • 제작된 주괴는 스파크 분광 분석, 주사전자현미경(SEM), 에너지 분산형 분광분석법(EDS)을 통해 분석되었습니다. 이를 통해 주괴 높이에 따른 화학 성분 분포를 정밀하게 매핑하고, 미세 구조의 변화를 관찰하며, 기공 및 개재물의 원인을 규명했습니다.

The Breakthrough: Key Findings & Data

본 연구를 통해 이종 합금 주조 공정의 품질을 좌우하는 핵심적인 두 가지 발견을 도출했습니다.

Finding 1: 주조 방식과 냉각 조건이 혼합 영역 프로파일을 결정

혼합 영역의 형태는 단순히 두 합금 사이의 노출 시간보다 주입 방식과 냉각 조건에 의해 더 크게 좌우되는 것으로 나타났습니다. 그림 13에서 볼 수 있듯이, 두 번째 합금을 첫 번째 합금 위로 붓는 방식(주물 I, IV)은 상대적으로 수평적인 계면을 형성했습니다. 반면, 하부 냉각판(칠)을 사용한 주물(III, V)은 사용하지 않은 주물(II)에 비해 더 매끄러운 혼합 영역 프로파일을 보였습니다. 이는 노출 시간을 60초에서 120초로 늘리는 것보다 하부 냉각을 통해 열 구배와 유동을 제어하는 것이 혼합 영역의 형상을 제어하는 데 더 효과적임을 시사합니다.

Finding 2: 산화물 개재물이 기공 형성의 주된 원인

연구 결과, 가장 높은 기공률은 주괴의 하부와 혼합 영역 근처에 집중되었습니다 (결론 12). 이러한 기공의 표면을 EDS로 분석한 결과, 높은 농도의 산소와 질소가 검출되었으며, 이는 열역학 시뮬레이션에서 예측된 산화물(MgAl₂O₄, MgO, Al₂O₃) 및 질화물(AlN)과 일치했습니다 (표 8). 더 중요한 발견은, 산화물 개재물이 2차 합금의 초정 실리콘(Si) 결정 내부에서 발견되었다는 점입니다 (그림 17, 18). 이는 첫 번째 합금 표면에 형성된 산화막이 두 번째 합금 주입 시 파괴되어 용탕 내부로 혼입되고, 응고 과정에서 미세 구조의 일부로 포획되었음을 직접적으로 증명합니다.

Practical Implications for R&D and Operations

  • For Process Engineers: 본 연구는 하부 냉각판(칠) 사용이 용탕의 공기 노출 시간을 줄여 산화물 생성을 억제하고, 동시에 더 제어된 혼합 영역을 형성하는 데 기여할 수 있음을 시사합니다 (결론 7 & 8). 이는 생산성 향상과 품질 안정화를 위한 핵심 공정 변수가 될 수 있습니다.
  • For Quality Control Teams: 논문의 그림 13과 표 6에 제시된 구리(Cu), 실리콘(Si) 등 핵심 원소의 분포 데이터는 혼합 영역의 폭과 성분에 대한 품질 검사 기준을 수립하는 데 활용될 수 있습니다. 또한, 표 8에서 확인된 기공과 산화물의 직접적인 연관성은 이러한 결함에 민감한 비파괴 검사법의 필요성을 강조합니다.
  • For Design Engineers: 사출기 위치를 모사한 주입 방식이 혼합 영역의 형상에 큰 영향을 미친다는 결과는, 원하는 국부적 특성을 얻기 위해 충전 시스템의 설계와 부품 형상이 함께 고려되어야 함을 의미합니다. 초기 설계 단계에서 이러한 주조 공정의 특성을 반영하는 것이 중요합니다.

Paper Details


DUAL-ALLOY SAND MOLD CASTING: MAIN PRINCIPLES AND FEATURES

1. Overview:

  • Title: DUAL-ALLOY SAND MOLD CASTING: MAIN PRINCIPLES AND FEATURES
  • Author: Liudmyla Lisova, Maximilian Erber, Georg Fuchs, Wolfram Volk, David Rottenegger, Stefan Braunreuther
  • Year of publication: 2025 (Published online: 2 March 2024)
  • Journal/academic society of publication: International Journal of Metalcasting
  • Keywords: dual-alloy casting, thermodynamic simulation, oxides, porosity, microstructure, aluminides, multi-material injector casting (MMIC)

2. Abstract:

다중 재료 사출 주조(MMIC) 공정은 단일 공정에서 두 가지 다른 합금으로 주물을 생산할 수 있게 합니다. 금속은 용탕의 상승하는 표면과 함께 움직이는 세라믹 다운 스프루(사출기)를 통해 주형에 도입됩니다. 이는 향상된 충전 및 압탕 특성을 가진 주물에서 유리한 온도 분포를 만듭니다. 하나의 주물에 두 합금을 결합하면 화학 성분, 미세 구조 및 기계적 특성에 영향을 미치며, 이는 원래 합금의 특성과 다릅니다. 이종 합금 주물 생산의 주요 목표는 적용 요구에 따라 혼합 영역에서 합금을 국부적으로 조정하는 것입니다. 두 합금의 원래 조성과 특성은 가능한 한 많이 보장되어야 합니다. 이 기사는 다른 조건 하에서 부품의 산화 과정과 결과 주괴의 미세 구조를 고려하여 이종 합금 사형 주조의 특수성을 논의합니다. 열역학 시뮬레이션, 실험적 이종 합금 사형 주조, 화학 성분 및 결과 주물의 거시 구조 결과가 기사에 제시됩니다. 두 가지 사출기 위치를 시뮬레이션하는 두 합금(AlSi12 및 AlSi9Cu3)의 주입 방법, 각 합금 주입 사이의 시간(60, 90, 120초), 하부 칠을 사용한 방향성 응고의 영향과 같은 요인들이 조사되었습니다. 혼합 영역은 스파크 분광법 및 EDS로 측정한 Cu 함량의 변화로 확인되었습니다.

3. Introduction:

샌드 캐스팅이나 그래비티 다이 캐스팅과 같은 전통적인 주조 공정은 국부 부품의 특성에 대한 충분한 제어를 허용하지 않습니다. 최근 몇 년 동안 주조와 함께 다양한 기술적 해결책을 사용하여 두 재료를 결합하는 것에 대한 다양한 연구가 수행되었습니다. 복합 주조는 일반적으로 Al-Cu 이중층과 같은 이중 구성 요소 이중층을 생산하는 것과 관련이 있습니다. 컴파운드 주조는 다른 용융 재료로 채워진 주형에 놓인 하나의 고체 재료(합금 또는 금속)를 사용합니다. 다중 재료 사출 주조(MMIC) 공정은 먼저 하나의 합금으로 주형을 점진적으로 채운 다음 세라믹 사출기를 사용하여 다른 합금으로 채우는 것으로 구성됩니다. 이 공정은 기존 그래비티 주조 공정에 비해 여러 장점을 제공합니다. 사출기를 통한 용탕 공급은 재순환되는 재료의 양을 줄입니다. 상대적으로 낮은 주조 온도와 결합하여 지속 가능한 공정을 만듭니다. 공급 공정은 바닥에서 시작하여 상단으로 이동합니다. 사출기가 주형 충전 중에 빠져나오면서 새로운 용탕이 지속적으로 상부 부피로 도입됩니다. 결과적인 온도 구배는 주물의 방향성 응고를 지원합니다.

4. Summary of the study:

Background of the research topic:

다중 재료 사출 주조(MMIC)는 단일 공정에서 두 가지 다른 합금을 사용하여 국부적으로 맞춤화된 특성을 가진 주물을 생산할 수 있는 잠재력을 가진 기술입니다. 이 기술은 충전 및 응고 과정을 제어하여 품질을 향상시킬 수 있지만, 두 합금의 결합은 화학 조성, 미세 구조, 기계적 특성에 복합적인 영향을 미칩니다.

Status of previous research:

기존 연구들은 복합 주조, 컴파운드 주조 등 다양한 방법으로 이종 재료를 결합하려는 시도를 해왔습니다. 알루미늄 합금에서 산화물 및 규화물과 같은 비금속 개재물이 균열을 유발하는 주요 결함이며, 합금 원소가 석출상, 기공률, 결정립 미세화 등에 미치는 영향에 대한 연구가 진행되었습니다. 특히 산화막이 기공 형성의 핵으로 작용한다는 점이 여러 연구에서 지적되었습니다.

Purpose of the study:

본 연구의 목적은 사출기 위치, 주입 시간 간격, 하부 냉각과 같은 공정 변수가 이종 합금(AlSi9Cu3 및 AlSi12) 주물의 혼합 영역, 산화 과정, 미세 구조 및 결함 형성에 미치는 영향을 규명하는 것입니다. 이를 통해 MMIC 공정의 주요 원리와 특징을 이해하고 고품질 이종 합금 주물 생산을 위한 기초 데이터를 확보하고자 합니다.

Core study:

연구의 핵심은 열역학 및 CFD 시뮬레이션과 실험적 주조를 결합하여 이종 합금 주조 현상을 다각적으로 분석하는 것입니다. 구리(Cu)를 추적 원소로 사용하여 혼합 영역을 명확히 식별하고, 다양한 공정 조건 하에서 주괴의 화학 성분 분포, 미세 구조, 기공 및 금속간 화합물의 형성 메커니즘을 상세히 조사했습니다.

5. Research Methodology

Research Design:

본 연구는 다음과 같은 다단계 연구 설계를 따랐습니다. 1. 열역학 계산: 연구 대상 합금(AlSi9Cu3, AlSi12 및 혼합물)의 평형 조성을 계산하여 온도, 대기(공기, 아르곤)에 따른 산화물 및 금속간 화합물 형성을 예측했습니다. 2. 주조 공정 시뮬레이션: Flow3D Cast를 사용하여 실험적 테스트 설계를 시뮬레이션했습니다. 3. 기준선 주조: 각 합금(AlSi9Cu3, AlSi12) 및 이들의 혼합물을 개별적으로 주조하여 이종 합금 주괴의 세 영역(합금1, 합금2, 혼합 영역)과 비교할 기준 데이터를 확보했습니다. 4. 이종 합금 실험 주조: 사출기 주조 시 발생할 수 있는 조건을 모사하여 이종 합금 주괴를 실험적으로 주조했습니다. 5. 화학 성분 및 미세 구조 분석: 얻어진 이종 합금 주괴의 화학 성분과 미세 구조를 연구했습니다.

Data Collection and Analysis Methods:

  • 데이터 수집: 실험적으로 제작된 주괴를 절단하여 시편을 제작했습니다. 스파크 분광 분석법으로 주괴의 수직 중앙 평면을 따라 15-20개 지점에서 원소 분포를 측정했습니다. 반사광 현미경(Zeiss Axio Imager M.2)을 사용하여 미세 구조를 관찰하고, SEM/EDS(VEGA TESCAN 5130 XL)를 사용하여 개재물 및 금속간 화합물의 정량적, 정성적 분석을 수행했습니다.
  • 데이터 분석: 스파크 분광 분석 및 EDS 결과를 통해 구리(Cu) 함량 변화를 기준으로 혼합 영역을 정의했습니다. 미세 구조 이미지를 통해 각 영역의 특징(덴드라이트, 초정 Si, 금속간 화합물)을 비교 분석했습니다. EDS 스펙트럼 분석을 통해 기공 및 개재물의 조성을 파악하여 형성 원인을 추론했습니다.

Research Topics and Scope:

  • 연구 주제: 이종 합금 사형 주조에서 (1) 주입 방식, (2) 주입 시간 간격, (3) 하부 냉각(칠)이 혼합 영역 프로파일, 화학 성분 분포, 미세 구조, 기공 및 산화물 형성에 미치는 영향.
  • 연구 범위: AlSi9Cu3와 AlSi12 알루미늄 합금을 대상으로 합니다. 열역학 계산은 100-700°C 온도 범위에서 공기 및 아르곤 분위기를 고려했습니다. 실험은 두 가지 사출기 위치를 모사한 주입 방식, 60, 90, 120초의 주입 시간 간격, 하부 칠 사용 유무의 조합으로 수행되었습니다.

6. Key Results:

Key Results:

  • 열역학 계산 결과, 공기와 접촉하는 합금에서 형성되는 주요 산화물은 Al₂O₃, MgO, MgAl₂O₄이며, 그 함량은 초기 합금 원소에 따라 달라집니다.
  • 혼합 영역의 평균 구리 함량은 3%에서 2%로, 실리콘 함량은 11.3%에서 12.8%로 변화했습니다.
  • 주조 방식과 하부 냉각(칠)은 용탕 노출 시간보다 혼합 영역 프로파일에 더 큰 영향을 미쳤습니다.
  • 주괴의 하부와 혼합 영역 근처에 가장 높은 기공률이 집중되었으며, 이는 첫 번째 합금이 공기에 노출되는 동안 형성된 비금속 개재물(주로 산화물) 때문인 것으로 분석되었습니다.
  • EDS 분석 결과, 수축 기공 표면에서 산화물(MgAl₂O₄, MgO, Al₂O₃)과 질화물(AlN)이 확인되었으며, 이는 열역학 시뮬레이션 결과와 일치합니다.
  • 금속간 화합물 및 초정 실리콘 결정 내부에서도 산소(0.87–6.35%)가 검출되어, 산화물이 용탕 내부로 혼입되었음을 확인했습니다.
Figure 7. Equilibrium content of Si and TiSi, TiSi2 in the air and argon atmosphere, in
alloys: (a) AlSi12, (b) AlSi9Cu3, (c) mixed. The Si content is on the secondary axis.
Figure 7. Equilibrium content of Si and TiSi, TiSi2 in the air and argon atmosphere, in alloys: (a) AlSi12, (b) AlSi9Cu3, (c) mixed. The Si content is on the secondary axis.

Figure List:

  • Figure 1. Schematic of the injector casting process and two injector positions under investigation.
  • Figure 2. Total equilibrium content of oxides (Al2O3, MgO, MgAl2O4).
  • Figure 3. Oxides equilibrium content change in the temperature range of 100–700 °С.
  • Figure 4. Diagram of Gibbs free energy (a) and equilibrium constant (b) in dependence of temperature.
  • Figure 5. Equilibrium content change of Mg and Al in the alloys in the temperature range 100–700 °С.
  • Figure 6. Equilibrium content of Cu2Mg
  • Figure 7. Equilibrium content of Si and TiSi, TiSi2 in the air and argon atmosphere, in alloys: (a) AlSi12, (b) AlSi9Cu3, (c) mixed. The Si content is on the secondary axis.
  • Figure 8. Equilibrium content of components with Al in air and argon (the same).
  • Figure 9. Simulated temperature after a waiting time of 60 seconds (a): 1—pouring basin of ingate system 1; 2—ingate system 2; 3—filter; 4—evaluation area. Temperature distribution and velocity field during the filling through the second ingate (b).
  • Figure 10. Cross section of sand mold for dual-alloy casting experiment with the modeling injector position (a): 1—first ingate for the first alloy; 2—ingate with the insulation tube for the second alloy; 3—a place for ceramic filter; 4—a place for steel or sand plate; 5—a place for the ingot formation. Ceramic filter, insulating tube sand, and steel plate are on (b).
  • Figure 11. Phase fraction of Si and Cu along the z-axis of a casting and the resulting mixing zone. Schematic plot of a dual-alloy ingot with regions of Alloy 1 and Alloy 2 (about 100% each) and mixing zone in a range between 30 and 70% of Alloy 1, respectively, Alloy 2. Green squares show the place of samples for EDS investigation (50×50 mm).
  • Figure 12. Microstructure of AlSi12, AlSi9Cu3, and mixed: general view—a set of images with a magnification of 25x, aluminum matrix type—25x, aluminides—500x, primary silicon—100x.
  • Figure 13. Results of Spark spectroscopy (Cu-Spark) and EDS (Cu-EDS) of Cu distribution in the dual-alloy sand mold casting. Orange line—approximate medium line of the mixing zone. Experiment conditions: waiting time/chill used/casting method.
  • Figure 14. Microstructure of the mixing zone: the lower part belongs to AlSi9Cu3, the upper part to AlSi12.
  • Figure 15. EDS investigation of aluminides in sample IV: (a) region of Alloy 1 (AISi9Cu3), (b) mixing zone; (c) Alloy 2 (AISi12); (d) Alloy 2 (sample V).
  • Figure 16. EDS investigation of the surface of shrinkage porosity in the mixing zone of sample IV.
  • Figure 17. Oxide film in dual-alloy casting. On the top region (AISi12) of sample I (a). Primary Si with inclusions inside, sample V (b).
  • Figure 18. EDS investigation of inclusion inside the primary Si crystal sample V (b) and sample IV (c).

7. Conclusion:

  1. 열역학 계산에 따르면, 100-700°C 온도 범위에서 공기와 접촉하는 합금에서 형성되는 주요 산화물은 Al₂O₃, MgO, MgAl₂O₄입니다. 산화물의 함량은 초기 합금 원소에 따라 달라지며, AlSi9Cu3에서 가장 높고 AlSi12에서 가장 낮았습니다.
  2. 모든 연구된 합금에서 MgO가 주요 산화물이며, 그 함량은 합금의 Mg 함량에 따라 달라집니다.
  3. 깁스 자유 에너지를 분석한 결과, Al₂O₃와 MgO가 먼저 형성된 후 AlN이 형성됩니다. 다음으로 순수 원소(Al, Mg)와 산화물 사이에 반응이 일어나 스피넬(MgAl₂O₄)을 형성합니다.
  4. 실리콘을 포함하는 성분은 Mg₂Si, TiSi₂, MnSi, CrSi₂입니다. Mg₂Si의 평형 함량은 Mg 산화가 없는 아르곤 분위기에서 더 높습니다.
  5. Al을 포함하는 성분(Al₃Ti, Al₃Ni, FeAl₃)의 평형 함량은 공기와 아르곤 분위기에서 거의 동일합니다.
  6. 혼합 영역에서 구리 함량의 평균값은 3%에서 2%로, 실리콘은 11.3%에서 12.8%로 변화했습니다. 구리 함량은 이종 합금 주물 상단까지 약 1%를 유지합니다.
  7. 주조 방식과 하부 냉각(칠)은 노출 시간보다 혼합 영역 프로파일에 더 큰 영향을 미칩니다.
  8. 칠의 추가적인 장점은 용탕이 공기와 접촉하는 시간을 줄여 산화 효과를 감소시킨다는 것입니다.
  9. 각 합금 영역은 원래 합금의 알루미늄 기지를 따릅니다. AlSi9Cu3 영역의 금속간 화합물상은 주로 AlCu₂로 구성됩니다.
  10. 금속간 화합물에 대한 EDS 조사는 열역학 계산과 일치하는 성분(Al₃Ni, FeAl₃, TiSi₂, Mg₂Si 등)의 존재를 나타냅니다.
  11. 금속간 화합물(0.87–6.35%) 및 초정 실리콘 결정 내부에서 일부 산소가 확인되었습니다.
  12. 가장 높은 기공률은 주괴의 하부와 혼합 영역 근처에 집중되었습니다. 기공의 원인 중 하나는 노출 동안 첫 번째 합금 부분이 공기와 상호 작용하여 형성된 비금속 개재물(주로 산화물)입니다. 수축 기공에 대한 EDS 조사는 MgAl₂O₄, MgO, Al₂O₃ 및 AlN에 해당하는 산화물과 질소의 존재를 보여줍니다.

8. References:

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Expert Q&A: Your Top Questions Answered

Q1: 이 연구에서 AlSi9Cu3와 AlSi12 합금을 특별히 선택한 이유가 무엇인가요?

A1: 논문에서 명시적으로 선택 이유를 밝히지는 않았지만, 연구 설계상 중요한 장점이 있습니다. AlSi9Cu3 합금에는 구리(Cu)가 포함되어 있지만 AlSi12에는 없습니다. 이 차이점 덕분에 구리는 두 합금이 섞이는 ‘혼합 영역’을 식별하고 그 범위를 정량적으로 측정하는 데 매우 효과적인 추적자(tracer) 역할을 했습니다. 스파크 분광 분석과 EDS를 통해 주괴 전체의 구리 농도 변화를 추적함으로써 혼합 영역의 위치와 크기를 명확하게 정의할 수 있었습니다.

Q2: 열역학 시뮬레이션에서 AlN(알루미늄 질화물) 형성을 예측했는데, 실험적으로도 검증되었나요?

A2: 네, 검증되었습니다. 논문의 결론 12항과 표 8에서 그 결과를 확인할 수 있습니다. 주괴 하부 및 혼합 영역에서 발견된 수축 기공의 표면을 EDS로 분석한 결과, 질소(N) 성분이 검출되었습니다. 이는 열역학 시뮬레이션에서 예측된 AlN 화합물의 형성과 일치하는 결과로, 첫 번째 합금이 공기에 노출되는 동안 공기 중의 질소와 반응하여 AlN이 형성되었음을 실험적으로 뒷받침합니다.

Q3: 이 연구에서 Flow3D Cast 시뮬레이션의 구체적인 역할은 무엇이었나요?

A3: Flow3D Cast 시뮬레이션은 물리적 실험에 앞서 복잡한 열-유동 현상을 이해하는 데 핵심적인 역할을 했습니다. 논문의 “Casting Process Simulation” 섹션에 따르면, 시뮬레이션은 사출기 위치 I의 충전 과정을 모델링하는 데 사용되었습니다. 60초 대기 후 첫 번째 용탕의 온도 분포를 예측했으며(그림 9a), 두 번째 용탕이 주입될 때 이미 응고 중인 첫 번째 합금의 일부를 어떻게 재용융시키고 혼합을 유발하는지 시각적으로 보여주었습니다(그림 9b). 이를 통해 실험에서 관찰될 혼합 메커니즘에 대한 사전 통찰력을 얻을 수 있었습니다.

Q4: 주조 방식이 노출 시간보다 더 중요하다고 하셨는데, 그 이유를 좀 더 자세히 설명해주실 수 있나요?

A4: 결과적으로 혼합 영역의 ‘형상’에 더 큰 변화를 가져왔기 때문입니다. 그림 13의 결과에서 보듯이, 주입 방식(사출기 위치 모사)에 따라 혼합 영역의 계면이 수평적이거나 깊고 경사지게 형성되는 등 뚜렷한 형태적 차이가 나타났습니다. 또한, 하부 냉각판(칠)을 사용했을 때 혼합 영역 프로파일이 더 매끄러워졌습니다(결론 7). 이러한 거시적인 형상 변화는 단순히 노출 시간을 60초에서 120초로 변경했을 때 나타나는 미세한 성분 변화보다 훨씬 두드러졌습니다. 이는 열 구배와 유체 유동을 직접적으로 제어하는 주조 방식과 냉각 조건이 공정 제어의 핵심 변수임을 의미합니다.

Q5: 논문에서 산화물이 초정 실리콘 결정 ‘내부’에서 발견되었다고 언급했는데, 이 발견의 중요성은 무엇인가요?

A5: 이 발견은 산화물 개재물이 어떻게 내부 결함으로 발전하는지에 대한 직접적인 증거를 제시하기 때문에 매우 중요합니다. 이는 첫 번째 합금이 공기에 노출될 때 표면에 형성된 산화막이 단순히 밀려나는 것이 아니라, 두 번째 용탕의 유동에 의해 파괴되고 미세한 입자로 부서져 용탕 내부로 깊숙이 혼입되었음을 의미합니다. 이후 응고 과정에서 이 산화물 입자들이 실리콘 결정의 성장 핵으로 작용하거나 성장 중에 포획되어(trapped) 미세 구조의 일부가 된 것입니다. 이는 표면 산화가 어떻게 최종 제품의 내부 품질 저하로 이어지는지를 명확히 보여주는 핵심적인 증거입니다.


Conclusion: Paving the Way for Higher Quality and Productivity

이종 합금 주조는 맞춤형 특성을 가진 혁신적인 부품을 생산할 수 있는 유망한 기술이지만, 혼합 영역의 제어와 산화물로 인한 결함 발생이라는 중요한 과제를 안고 있습니다. 본 연구는 열역학 및 CFD 시뮬레이션과 정밀한 실험을 통해, 주입 방식과 특히 하부 냉각(칠)을 이용한 열 제어가 단순히 노출 시간을 조절하는 것보다 혼합 영역의 품질을 확보하고 산화물 결함을 줄이는 데 훨씬 효과적임을 명확히 보여주었습니다. 특히 산화물이 기공의 주된 원인이며 응고 과정에서 미세 구조 내부로 포획된다는 사실은 공정 중 산화 제어의 중요성을 다시 한번 일깨워 줍니다.

STI C&D는 최신 산업 연구 결과를 적용하여 고객이 더 높은 생산성과 품질을 달성할 수 있도록 지원하는 데 전념하고 있습니다. 본 논문에서 논의된 과제가 귀사의 운영 목표와 일치한다면, 저희 엔지니어링 팀에 연락하여 이러한 원칙을 귀사의 부품에 어떻게 구현할 수 있는지 논의해 보십시오.

(주)에스티아이씨앤디에서는 고객이 수치해석을 직접 수행하고 싶지만 경험이 없거나, 시간이 없어서 용역을 통해 수치해석 결과를 얻고자 하는 경우 전문 엔지니어를 통해 CFD consulting services를 제공합니다. 귀하께서 당면하고 있는 연구프로젝트를 최소의 비용으로, 최적의 해결방안을 찾을 수 있도록 지원합니다.

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Copyright Information

  • This content is a summary and analysis based on the paper “DUAL-ALLOY SAND MOLD CASTING: MAIN PRINCIPLES AND FEATURES” by “Liudmyla Lisova, et al.”.
  • Source: https://doi.org/10.1007/s40962-024-01289-6

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Gambar 3.4 Hubungan kekerasan terhadap temperatur tuang

박막 Al-Si 스퀴즈 캐스팅의 균열 및 경도 문제 해결: 용탕 및 금형 온도 최적화

이 기술 요약은 Aspiyansyah 저자가 Jurnal Suara Teknik Fakultas Teknik UNMUH Pontianak에 발표한 논문 “PENGARUH PARAMETER SQUEEZE CASTING (MELT TEMPERATUR DAN DIE TEMPERATUR) TERHADAP KEKERASAN DAN MUNCULNYA CACAT PADA BENDA COR TIPIS AL-3,22%SI”을 기반으로 합니다. STI C&D의 기술 전문가들이 분석하고 요약했습니다.

키워드

  • Primary Keyword: 스퀴즈 캐스팅
  • Secondary Keywords: Al-Si 합금, 박막 주조, 주조 결함, 열간 균열, 경도

Executive Summary

  • 도전 과제: 박막 Al-3.22%Si 합금의 스퀴즈 캐스팅 공정에서 발생하는 열간 균열(hot tearing)과 같은 결함을 제어하고, 원하는 기계적 특성(경도)을 확보하는 것이 주요 과제입니다.
  • 연구 방법: 135 MPa의 압력을 가하는 스퀴즈 캐스팅 공정에서 용탕 온도(665, 775, 885°C)와 금형 온도(220, 275, 330°C)를 주요 변수로 설정하여 주조품의 결함, 밀도, 경도 변화를 분석했습니다.
  • 핵심 발견: 용탕 및 금형 온도를 높이면 주조품의 밀도는 증가하지만, 열간 균열의 길이와 발생 가능성도 함께 증가하며 경도는 오히려 감소하는 상충 관계를 확인했습니다.
  • 핵심 결론: 박막 Al-Si 부품의 품질은 용탕 및 금형 온도에 크게 좌우되며, 결함 발생을 최소화하고 기계적 물성을 최적화하기 위해서는 정밀한 공정 제어가 필수적입니다.
Gambar 2.1 Desain cetak
Gambar 2.1 Desain cetak

도전 과제: 왜 이 연구가 CFD 전문가에게 중요한가?

스퀴즈 캐스팅은 높은 생산성과 우수한 기계적 특성을 가진 주조품을 생산할 수 있어 경제적이고 효율적인 공법으로 알려져 있습니다. 특히 알루미늄 합금의 기공(porosity)과 같은 내부 결함을 효과적으로 억제할 수 있어 많은 산업 분야에서 주목받고 있습니다.

하지만 자동차, 전자, 항공우주 산업에서 수요가 증가하는 박막(thin-wall) 부품에 스퀴즈 캐스팅을 적용할 경우, 새로운 기술적 난관에 부딪히게 됩니다. 얇은 두께로 인해 응고 과정에서 편석(segregation)이나 열간 균열(hot tearing)과 같은 심각한 결함이 발생할 가능성이 커집니다. 이러한 결함은 제품의 신뢰성을 저하하고 생산 수율을 떨어뜨리는 주된 원인이 됩니다.

지금까지 Al-Si 합금 스퀴즈 캐스팅에 대한 연구는 많았지만, 3mm 두께의 박막 Al-3.22%Si 주조품에서 용탕 및 금형 온도가 결함 발생과 경도에 미치는 영향을 체계적으로 분석한 연구는 부족했습니다. 본 연구는 바로 이 지점에서 출발하여, 박막 부품의 품질을 결정하는 핵심 공정 변수인 온도의 영향을 규명하고 최적의 공정 조건을 찾는 것을 목표로 합니다.

연구 접근법: 방법론 분석

본 연구는 스퀴즈 캐스팅 공정의 핵심 변수인 용탕 온도와 금형 온도가 박막 Al-3.22%Si 주조품의 품질에 미치는 영향을 실험적으로 규명하기 위해 다음과 같이 설계되었습니다.

  • 소재: Al-3.22%Si 합금을 도가니로(crucible furnace)에서 용해하여 사용했습니다.
  • 공정 장비: 135 MPa의 압력을 가할 수 있는 유압 프레스를 사용했습니다.
  • 핵심 공정 변수:
    • 용탕 온도: 665°C, 775°C, 885°C의 세 가지 조건으로 설정했습니다.
    • 금형(Die) 온도: 220°C, 275°C, 330°C의 세 가지 조건으로 설정했으며, 분무기를 사용하여 가열하고 10분간 유지하여 온도를 균일하게 만들었습니다.
  • 공정 조건: 금형에는 침식 마모를 방지하기 위해 콜로이드 흑연을 코팅했으며, 135 MPa의 압력을 30초간 유지했습니다.
  • 분석 방법:
    • 결함 분석: 디지털 버니어 캘리퍼스를 사용하여 매크로 균열의 총 길이를 측정하고, 광학 현미경으로 미세조직을 관찰했습니다.
    • 밀도 측정: 진공 저울을 사용하여 주조품의 밀도를 측정했습니다.
    • 경도 측정: 15.62kg의 하중을 가하는 비커스 경도 시험기(Vickers Hardness)를 사용했습니다.
Gambar 3.1. Cacat retak pada benda cor tipis Al-3,22%Si; (a) daerah
cacat; (b) morfologi retak dan (c) porositas dan ujung retak.
Gambar 3.1. Cacat retak pada benda cor tipis Al-3,22%Si; (a) daerah cacat; (b) morfologi retak dan (c) porositas dan ujung retak.

핵심 발견: 주요 결과 및 데이터

결과 1: 용탕 및 금형 온도 상승이 열간 균열에 미치는 영향

연구 결과, 용탕 온도와 금형 온도가 높을수록 주조품의 열간 균열 총 길이가 증가하는 경향이 명확하게 나타났습니다. 그림 3.2는 이러한 관계를 잘 보여줍니다. 예를 들어, 금형 온도가 330°C일 때 용탕 온도를 665°C에서 885°C로 높이면 균열 총 길이는 약 800mm에서 900mm 이상으로 증가했습니다.

이는 높은 온도가 응고 과정을 지연시키기 때문입니다. 응고가 느리게 진행되면 수축 및 열응력이 발생할 수 있는 시간이 길어지고, 용탕 공급(feeding)이 이를 보상하지 못할 경우 수축 기공이 형성됩니다. 이 기공은 응력이 집중되는 지점이 되어 최종적으로 열간 균열로 발전하게 됩니다.

결과 2: 온도 조건과 주조품 밀도 및 경도의 상호 관계

온도 상승은 결함 증가라는 부정적 측면 외에 긍정적인 효과도 보였습니다. 그림 3.3에서 볼 수 있듯이, 용탕 및 금형 온도가 높을수록 주조품의 밀도가 증가했습니다. 이는 높은 온도로 인한 느린 응고 속도가 더 많은 핵생성을 유도하여 미세한 덴드라이트 조직을 형성하고, 외부에서 가해진 압력이 입자 간의 결합력을 높여 치밀한 조직을 만들기 때문입니다.

반면, 경도는 온도와 반비례 관계를 보였습니다. 그림 3.4에 따르면, 용탕 온도가 665°C에서 885°C로 증가함에 따라 비커스 경도(VHN)는 전반적으로 감소했습니다. 가장 높은 경도는 가장 낮은 용탕 온도(665°C)와 금형 온도(220°C) 조합에서 얻어졌습니다. 연구진은 이를 실리콘(Si) 조직의 형태 변화로 설명합니다. 낮은 온도에서는 두꺼운 조각 형태의 실리콘이 형성되어 높은 경도를 나타내지만, 높은 온도에서는 미세한 조각 형태의 실리콘이 형성되어 경도가 낮아지는 것으로 분석되었습니다.

R&D 및 운영을 위한 실질적 시사점

  • 공정 엔지니어: 본 연구는 용탕 및 금형 온도가 박막 주조품의 균열, 밀도, 경도에 직접적인 영향을 미치는 상충 관계를 보여줍니다. 밀도를 높이기 위해 온도를 올리면 균열 발생 위험과 경도 저하를 감수해야 하므로, 목표 품질에 맞는 최적의 온도 “공정 윈도우(process window)”를 설정하는 것이 중요합니다.
  • 품질 관리팀: 논문의 그림 3.2와 그림 3.4 데이터는 특정 공정 온도 조건이 균열 길이와 경도에 미치는 영향을 정량적으로 보여줍니다. 이는 온도 변수에 기반한 새로운 품질 검사 기준을 수립하거나 공정 이탈의 원인을 분석하는 데 유용한 근거가 될 수 있습니다.
  • 설계 엔지니어: 박막 부품 설계 시, 스퀴즈 캐스팅 공정의 열적 민감성을 반드시 고려해야 합니다. 특정 부위의 두께 변화가 응고 과정 중 열응력 집중을 유발하여 균열의 시작점이 될 수 있음을 인지하고, 초기 설계 단계에서부터 주조성을 고려한 설계를 진행하는 것이 중요합니다.

논문 상세 정보


PENGARUH PARAMETER SQUEEZE CASTING (MELT TEMPERATUR DAN DIE TEMPERATUR) TERHADAP KEKERASAN DAN MUNCULNYA CACAT PADA BENDA COR TIPIS AL-3,22%SI

1. 개요:

  • 제목: PENGARUH PARAMETER SQUEEZE CASTING (MELT TEMPERATUR DAN DIE TEMPERATUR) TERHADAP KEKERASAN DAN MUNCULNYA CACAT PADA BENDA COR TIPIS AL-3,22%SI (스퀴즈 캐스팅 파라미터(용탕 온도 및 금형 온도)가 박막 Al-3.22%Si 주조품의 경도 및 결함 발생에 미치는 영향)
  • 저자: Aspiyansyah
  • 발표 연도:
  • 학술지/학회: Jurnal Suara Teknik Fakultas Teknik UNMUH Pontianak
  • 키워드: Al-Si, pengecoran squeeze (스퀴즈 캐스팅), cacat (결함)

2. 초록:

본 연구는 스퀴즈 캐스팅 공정 파라미터(용탕 온도 및 금형 온도)가 박막 Al-3.22%Si 주조품의 경도 및 결함 발생 가능성에 미치는 영향을 파악하는 것을 목표로 한다. 스퀴즈 캐스팅은 135 MPa의 압력을 가하는 유압 프레스를 사용했다. 재료 용해는 도가니로를 사용했으며, K-타입 열전대를 사용하여 주조 온도를 측정했다. 금형 온도는 220, 275, 330°C를, 용탕 온도는 665, 775, 885°C를 적용했다. 결함 관찰은 매크로 및 마이크로 단위로 수행되었다. 열간 균열 길이와 주조품 밀도는 버니어 캘리퍼스와 진공 저울을 사용하여 측정했다. 열간 균열 및 주조품의 미세 구조 변화는 광학 현미경을 사용하여 정성적으로 관찰했다. 용탕 및 금형 온도가 증가하면 열간 균열 길이, 균열 지수, 주조품 밀도가 증가하고 경도는 감소했다. 최상의 스퀴즈 캐스팅 제품 품질 지수는 용탕 온도 775°C와 금형 온도 330°C에서 얻어졌다.

3. 서론:

스퀴즈 캐스팅 공정은 적용이 용이하고, 경제적이며, 원자재 사용이 효율적이고, 연속 사이클을 통해 높은 생산성을 달성할 수 있는 주조 방법이다. 이 공정은 단조품과 유사한 물리적 특성을 가진 주조품을 생산할 수 있으며, 기계적 성질을 향상시키고, 결정립을 미세화하며, 특히 알루미늄 및 마그네슘 기반 합금에서 우수한 표면 품질을 제공한다. 스퀴즈 캐스팅 공정은 주조품의 기공 결함 수를 줄일 수 있다.

4. 연구 요약:

연구 주제의 배경:

스퀴즈 캐스팅은 고품질 주조품을 생산하는 효율적인 방법이지만, 박막(3mm) Al-Si 합금에 적용할 경우 열간 균열과 같은 결함이 발생하는 문제가 있다.

이전 연구 현황:

Al-Si 합금의 스퀴즈 캐스팅에 대한 다양한 연구가 있었으나, 3mm 두께의 박막 Al-3.22%Si 주조품에서 공정 변수가 결함과 경도에 미치는 영향에 대한 연구는 아직 수행되지 않았다.

연구 목적:

스퀴즈 캐스팅 공정 변수(용탕 온도, 금형 온도)가 박막 Al-3.22%Si 주조품의 경도, 결함 발생 가능성, 균열 길이, 균열 지수, 밀도에 미치는 영향을 파악하고, 균열이 없는 최적의 주조품을 얻기 위한 온도 조합을 결정하는 것이다.

핵심 연구:

용탕 온도(665, 775, 885°C)와 금형 온도(220, 275, 330°C)를 변화시키면서 135 MPa의 압력으로 스퀴즈 캐스팅을 수행하고, 그 결과로 얻어진 주조품의 기계적, 물리적 특성 변화를 분석했다.

5. 연구 방법론

연구 설계:

용탕 온도와 금형 온도를 독립 변수로 설정하고, 이 변수들이 주조품의 균열 길이, 밀도, 경도(종속 변수)에 미치는 영향을 평가하는 실험적 연구 설계를 채택했다.

데이터 수집 및 분석 방법:

  • 균열 측정: 디지털 버니어 캘리퍼스로 매크로 균열의 총 길이를 측정.
  • 밀도 측정: 진공 저울을 사용하여 밀도 측정.
  • 미세구조 분석: 광학 현미경을 사용하여 균열 끝단과 주조품의 미세구조를 정성적으로 분석.
  • 경도 측정: 15.62kg 하중의 비커스 경도 시험기를 사용.

연구 주제 및 범위:

연구는 Al-3.22%Si 합금을 사용한 박막 스퀴즈 캐스팅에 국한되며, 주요 연구 주제는 용탕 및 금형 온도가 결함(열간 균열) 발생과 경도에 미치는 영향이다.

6. 주요 결과:

주요 결과:

  • 용탕 및 금형 온도가 증가할수록 열간 균열의 총 길이는 증가한다.
  • 용탕 및 금형 온도가 증가할수록 주조품의 밀도는 증가한다.
  • 용탕 및 금형 온도가 증가할수록 주조품의 경도는 감소한다.
  • 최대 경도는 가장 낮은 용탕 온도(665°C)와 금형 온도(220°C)에서 나타났다.
  • 최적의 품질 지수는 용탕 온도 775°C와 금형 온도 330°C에서 얻어졌다.
Gambar 3.4 Hubungan kekerasan terhadap temperatur tuang
Gambar 3.4 Hubungan kekerasan terhadap temperatur tuang

그림 목록:

  • Gambar 2.1 Desain cetak
  • Gambar 3.1. Cacat retak pada benda cor tipis Al-3,22%Si; (a) daerah cacat; (b) morfologi retak dan (c) porositas dan ujung retak.
  • Gambar 3.2 Panjang total retak sebagai fungsi temperatur tuang dan cetakan.
  • Gambar 3.3. Densitas sebagai fungsi temperatur cetakan dan tuang
  • Gambar 3.4 Hubungan kekerasan terhadap temperatur tuang

7. 결론:

  1. 스퀴즈 캐스팅 공정에서 용탕 온도를 665-885°C 범위에서 높이면 균열 길이, 균열 지수, 주조품 밀도가 증가하고 경도는 감소한다.
  2. 스퀴즈 캐스팅 공정에서 금형 온도를 220-330°C 범위에서 높이면 균열 길이, 균열 지수, 주조품 밀도가 증가하고 경도는 감소한다.
  3. 최상의 스퀴즈 캐스팅 제품 품질 지수는 실리콘 함량 6.04%, 용탕 온도 775°C, 금형 온도 330°C에서 얻어졌다. (주: 논문 결론의 ‘실리콘 함량 6.04%’는 본문 소재인 3.22%Si와 달라 오기로 추정됨)

8. 참고 문헌:

  • Baek, J. dan Kwon, H.W., 2008, “Effect of Squeeze Casting Process Parameters on Fluidity of Hypereutectic Al-Si Alloy”, Journal of Materials Science Technology, Vol. 24 No.1, pp. 7-11.
  • Britnell D.J. dan Neiley K., 2003, “Macrosegregation in Thin Walled Casting Produced via The Direct Squeeze Casting Process”, Journal of Materials Processing Technology, vol. 138, pp. 306-310.
  • El-khair, M.T. A., 2005, “Microstructure Characterization and Tensile Properties of Squeeze Casting AlSiMg Alloy”, Materials Letters, vol. 59, pp. 894-900.
  • Eskin, D.G., Suyitno dan Katgerman, L., 2004, “Mechanical Properties in the Semi-Solid and Hot Tearing of Aluminium Alloys”, Progress in Materials Science, vol.49, pp. 629-711.
  • Ghromashchi, M.R. dan Vikrov, A., 2000, “Squeeze Casting: An Overview”, Journal of Materials Processing Technology, vol. 101, pp. 1-9.
  • Hajjari, E. dan Divandari, M., 2008, “An Investigation on The Microstructure and Tensile Properties of Direct Squeeze Cast and Gravity Die Cast 2024 Wrought Al Alloy”, Materials and Design, vol. 29, pp. 1685-1689.
  • Maleki, A., Shafyei, A. dan Niroumand, B., 2008, “Effects of Squeeze Casting Parameter on The Microstructure Of LM13 Alloy”, Journal of Materials Processing Technology, In Press.
  • Purwanto Helmy, 2007, “Pengaruh Temperatur Tuang, Temperatur Cetakan, Tekanan dan Ketebalan Coran pada Pengecoran Squeeze Terhadap Sifat Fisis dan Mekanis Paduan Al–6,4%Si–1,93%Fe”, Thesis S-2 Teknik Mesin Universitas Gadjah Mada.
  • Stefanescu, D.M., 2002, “Science and Engineering of Casting Solidification”, Kluwer Academic/Plenum Publiser, New York.
  • Suyitno, Eskin, D.G., dan Katgerman, L., 2006, “Structure Observations Related to Hot Tearing of Al-Cu Billets Produced by Direct-Chill Casting”, Materials Science and Engineering A, vol.420. pp. 1-7.
  • Suyitno dan Iswanto, P.T., 2009, “Casting Soundness And Microstructure Of Thin Wall Squeeze Cast of Al-Si Alloys”, Hi-Link Project Report, pp. 1-8. www.key-to-nonferrous.com, diakses tanggal 12 januari 2009.
  • Yang, L.J., 2003, “The Effect of Casting Temperature on The Properties of Squeeze Cast Aluminum And Zinc Alloys”, Journal of Materials Processing Technology, vol. 140, pp. 391-396.
  • Zhong, Y., Su, G. dan Yang, K., 2003, “Microsegragation and Improved Methods of Squeeze Casting 2024 Aluminium Alloy”, Journal of Materials Science Technology, vol. 19, no. 5, pp. 413-417.

전문가 Q&A: 주요 질문과 답변

Q1: 이 연구에서 135 MPa라는 높은 압력을 사용한 이유는 무엇인가요?

A1: 135 MPa의 높은 압력은 스퀴즈 캐스팅 공정의 핵심 요소입니다. 이 압력은 용탕이 금형의 미세한 부분까지 완벽하게 채우도록 돕고, 응고 과정에서 발생하는 수축 기공을 효과적으로 억제하는 역할을 합니다. 또한, 높은 압력은 용탕 공급(feeding)을 촉진하여 조직을 치밀하게 만들고, 결과적으로 주조품의 기계적 특성을 향상시키는 데 기여합니다.

Q2: 온도가 높을수록 밀도는 증가하는데 균열은 더 많이 발생하는 결과가 나왔습니다. 이는 모순적으로 보이지 않나요?

A2: 이는 두 가지 상반된 메커니즘이 동시에 작용하기 때문입니다. 높은 온도는 용탕의 유동성을 향상시키고 압력 전달을 용이하게 하여 더 치밀한 조직(높은 밀도)을 만드는 데 유리합니다. 하지만 동시에 응고 시간을 지연시켜, 응고가 완료되기 전까지 더 큰 열 수축과 응력이 누적될 시간을 줍니다. 만약 이 응력이 용탕 공급으로 해소되지 못하면, 오히려 열간 균열 발생 가능성은 더 커지게 됩니다. 즉, 밀도 향상 효과와 균열 발생 위험 사이의 트레이드오프(trade-off) 관계가 존재하는 것입니다.

Q3: 온도에 따라 실리콘(Si) 조직 형태가 어떻게 변하여 경도에 영향을 미쳤나요?

A3: 논문에 따르면, 온도 조건은 Al-Si 합금의 미세조직, 특히 실리콘의 형태에 영향을 미칩니다. 상대적으로 낮은 온도(665°C)에서는 두꺼운 조각(thick flake) 형태의 실리콘이 형성되어 높은 경도를 나타냈습니다. 반면, 높은 온도(775°C, 885°C)에서는 더 미세한 조각(fine flake) 형태의 실리콘이 형성되었고, 이것이 경도 저하의 원인으로 분석되었습니다.

Q4: 결론에서 언급된 “최상의 품질 지수(quality index)”는 어떻게 결정되었나요?

A4: 논문은 용탕 온도 775°C와 금형 온도 330°C에서 최상의 품질 지수를 얻었다고 결론 내렸지만, 이 지수를 계산하는 데 사용된 구체적인 공식이나 평가 기준은 명시하지 않았습니다. 일반적으로 이러한 지수는 균열 길이 최소화, 목표 밀도 및 경도 달성 등 여러 품질 요소를 종합적으로 고려하여 결정됩니다. 따라서 이 조건이 결함과 기계적 물성 간의 가장 이상적인 균형점을 나타내는 것으로 해석할 수 있습니다.

Q5: 연구에서 열간 균열 외에 다른 결함도 관찰되었나요?

A5: 네, 그림 3.1에서 볼 수 있듯이 열간 균열 주변에서 기공(porosity)이 관찰되었습니다. 논문은 기공이 열간 균열로 변형(transform)되고 발전한다고 설명합니다. 이는 응고 과정에서 발생한 미세한 수축 기공들이 응력 집중 부위가 되어 서로 연결되면서 거시적인 균열로 성장하는 과정을 시사합니다. 연구의 정량적 분석은 균열 길이에 초점을 맞추었지만, 기공이 균열의 주요 원인임을 보여줍니다.


결론: 더 높은 품질과 생산성을 향한 길

본 연구는 박막 Al-Si 합금의 스퀴즈 캐스팅 공정에서 용탕 및 금형 온도가 제품 품질에 미치는 복합적인 영향을 명확히 보여주었습니다. 높은 온도는 밀도를 향상시키는 긍정적 효과가 있지만, 동시에 열간 균열 발생을 촉진하고 경도를 저하시키는 부정적 결과를 초래합니다. 이는 고품질의 박막 주조품을 생산하기 위해서는 단순히 하나의 변수만 제어하는 것이 아니라, 여러 공정 변수 간의 상호작용을 이해하고 최적의 균형점을 찾는 것이 얼마나 중요한지를 시사합니다.

결함 없는 고품질 부품 생산을 위해서는 775°C의 용탕 온도와 330°C의 금형 온도와 같은 최적의 공정 윈도우를 찾는 노력이 필수적입니다.

(주)에스티아이씨앤디에서는 고객이 수치해석을 직접 수행하고 싶지만 경험이 없거나, 시간이 없어서 용역을 통해 수치해석 결과를 얻고자 하는 경우 전문 엔지니어를 통해 CFD consulting services를 제공합니다. 귀하께서 당면하고 있는 연구프로젝트를 최소의 비용으로, 최적의 해결방안을 찾을 수 있도록 지원합니다.

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저작권 정보

  • 이 콘텐츠는 “Aspiyansyah”의 논문 “PENGARUH PARAMETER SQUEEZE CASTING (MELT TEMPERATUR DAN DIE TEMPERATUR) TERHADAP KEKERASAN DAN MUNCULNYA CACAT PADA BENDA COR TIPIS AL-3,22%SI”을 기반으로 요약 및 분석한 자료입니다.
  • 출처:

본 자료는 정보 제공 목적으로만 사용됩니다. 무단 상업적 사용을 금지합니다. Copyright © 2025 STI C&D. All rights reserved.

Figure 1. Yield strength (YS) and elongation to failure (ETF) of the A356 alloy achieved by various strengthening strategies: foreign particle reinforcement (blue closed squares4–6), grain refinement (black closed circles7,8), alloying (open squares11,12), and optimized casting (green closed triangles11,12). YS and ETF of A356 alloys obtained by combining the RS + PHT route with T6 heat treatment (red stars, the red arrow marks the direction of increasing cooling rate upon RS, the data point marked by the red circle represents the best combination of YS and ETF.). The black and red circles mark the best combination of YS and ETF obtained by rapid solidification at a cooling rate of 100 K/s and the subsequent T6 heat treatment8, and that achieved by combination of the current RS + PHT route with T6, respectively.

Al-Si 합금의 강도-연성 딜레마 극복: RS+PHT 공정으로 주조 부품의 한계를 넘다

이 기술 요약은 B. Dang 외 저자들이 Scientific Reports (2016)에 발표한 논문 “Breaking through the strength-ductility trade-off dilemma in an Al-Si-based casting alloy”를 기반으로 하며, STI C&D의 기술 전문가에 의해 분석 및 요약되었습니다.

키워드

  • Primary Keyword: Al-Si 합금
  • Secondary Keywords: 강도-연성 트레이드오프, 급속 응고(RS), 응고 후 열처리(PHT), 계층적 미세구조, A356 합금, 주조 공정 최적화

Executive Summary

  • The Challenge: Al-Si 주조 합금은 강도를 높이면 연성이 감소하는 고질적인 ‘강도-연성 트레이드오프’ 문제를 가지고 있어 고성능 부품 적용에 한계가 있었습니다.
  • The Method: 상용 A356 합금에 급속 응고(Rapid Solidification, RS) 공정과 응고 후 열처리(Post-solidification Heat Treatment, PHT)를 결합한 새로운 ‘RS+PHT’ 공정을 적용했습니다.
  • The Key Breakthrough: RS 공정의 냉각 속도를 높임에 따라 강도와 연성이 동시에 향상되는 현상을 발견했으며, 이는 기존의 트레이드오프 딜레마를 깨는 획기적인 결과입니다.
  • The Bottom Line: 이 연구는 간단한 공정 추가만으로 Al-Si 합금의 기계적 물성을 극적으로 향상시킬 수 있는 새로운 경로를 제시하며, 이는 항공우주, 자동차 산업에서 고성능 경량 부품 생산의 가능성을 확장합니다.
Figure 1. Yield strength (YS) and elongation to failure (ETF) of the A356 alloy achieved by various
strengthening strategies: foreign particle reinforcement (blue closed squares4–6), grain refinement (black
closed circles7,8), alloying (open squares11,12), and optimized casting (green closed triangles11,12). YS and
ETF of A356 alloys obtained by combining the RS + PHT route with T6 heat treatment (red stars, the red arrow
marks the direction of increasing cooling rate upon RS, the data point marked by the red circle represents the
best combination of YS and ETF.). The black and red circles mark the best combination of YS and ETF obtained
by rapid solidification at a cooling rate of 100 K/s and the subsequent T6 heat treatment8, and that achieved by
combination of the current RS + PHT route with T6, respectively.
Figure 1. Yield strength (YS) and elongation to failure (ETF) of the A356 alloy achieved by various strengthening strategies: foreign particle reinforcement (blue closed squares4–6), grain refinement (black closed circles7,8), alloying (open squares11,12), and optimized casting (green closed triangles11,12). YS and
ETF of A356 alloys obtained by combining the RS + PHT route with T6 heat treatment (red stars, the red arrow marks the direction of increasing cooling rate upon RS, the data point marked by the red circle represents the best combination of YS and ETF.). The black and red circles mark the best combination of YS and ETF obtained by rapid solidification at a cooling rate of 100 K/s and the subsequent T6 heat treatment8, and that achieved by combination of the current RS + PHT route with T6, respectively.

The Challenge: Why This Research Matters for CFD Professionals

Al-Si 기반 주조 합금은 우수한 주조성, 낮은 밀도, 높은 중량 대비 강도 등의 장점으로 항공우주 및 자동차 산업에서 복잡한 형상의 부품을 만드는 데 널리 사용됩니다. 하지만 이 합금들의 미세구조는 부드러운 Al 기지와 취성이 강한 공정 Si 상으로 구성되어 있어 근본적인 한계를 가집니다. 강도를 높이기 위해 강화 입자를 추가하거나 미세조직을 제어하면, 필연적으로 연성이 희생되는 ‘강도-연성 트레이드오프(strength-ductility trade-off)’ 딜레마에 빠지게 됩니다. 이는 재료의 파괴 인성을 낮춰 고성능이 요구되는 구조 부품으로의 적용을 제한하는 주요 원인이었습니다. 기존의 급속 응고(RS)나 입자 미세화 기술만으로는 이 딜레마를 완전히 극복하기 어려웠으며, 그림 1의 회색 영역처럼 대부분의 연구 결과가 이 한계 내에 머물러 있었습니다. 따라서 강도와 연성을 동시에 향상시킬 수 있는 새로운 공정 기술의 개발이 절실히 요구되었습니다.

The Approach: Unpacking the Methodology

본 연구에서는 상용 Al-Si 주조 합금인 A356 (Al-7.0Si-0.4Mg-0.1Fe wt.%)을 사용하여 새로운 공정의 효과를 검증했습니다. 연구의 핵심 방법론은 ‘급속 응고(RS)’와 ‘응고 후 열처리(PHT)’의 조합입니다.

  1. 재료 및 용해: 1.5kg의 A356 합금을 전기 저항로에서 용해하고 헥사클로로에탄으로 탈가스 처리를 진행했습니다.
  2. 급속 응고 (RS): 용탕을 953K에서 계단형 구리(Cu) 몰드에 주입하여 다양한 냉각 속도(1.2 K/s ~ 96 K/s)를 구현했습니다. 몰드 내부에 미리 설치된 K-타입 열전대를 통해 응고 시 냉각 곡선을 측정하여 정확한 냉각 속도를 계산했습니다.
  3. 응고 후 열처리 (PHT): RS 공정을 거친 시편을 머플로에서 473K(200°C)의 비교적 낮은 온도로 15분간 열처리했습니다. 이 단계는 응고된 미세구조를 크게 변화시키지 않으면서 기지상 내에 미세 입자 형성을 유도하는 핵심 공정입니다.
  4. T6 열처리 및 기계적 시험: RS+PHT 처리된 시편에 표준 T6 열처리(813K 용체화 처리 + 453K 인공 시효)를 적용하여 물성 변화를 관찰했습니다. 최종적으로 ASTM E-8 표준에 따라 인장 시편을 제작하고, 만능인장시험기를 사용하여 기계적 특성(항복 강도, 인장 강도, 파단 연신율)을 평가했습니다.

The Breakthrough: Key Findings & Data

RS+PHT 공정은 A356 합금의 기계적 물성을 전례 없는 수준으로 향상시켰으며, 이는 기존의 강도-연성 트레이드오프 관계를 완전히 벗어나는 결과입니다.

Finding 1: 강도와 연성의 동시 향상 및 트레이드오프 딜레마 극복

RS+PHT 공정을 적용한 결과, RS 시의 냉각 속도가 증가함에 따라 항복 강도(YS)와 파단 연신율(ETF)이 동시에 증가하는 현상이 명확하게 관찰되었습니다 (그림 2a). 이는 일반적인 금속 재료의 거동과 상반되는 매우 이례적인 결과입니다. 특히, 후속 T6 열처리를 적용했을 때 이러한 경향은 더욱 강화되었습니다. 그림 1에서 볼 수 있듯이, 96 K/s의 냉각 속도로 처리된 시편(빨간색 원으로 표시된 데이터 포인트)은 항복 강도 약 296 MPa, 연신율 21.3%를 기록하며 기존 문헌 데이터를 훨씬 뛰어넘는 성능을 보였습니다. 이는 RS+PHT 공정이 Al-Si 합금의 성능 한계를 돌파할 수 있는 효과적인 경로임을 증명합니다.

Finding 2: 계층적 나노 미세구조 형성 및 그 역할 규명

이러한 획기적인 물성 향상의 원인은 RS+PHT 공정을 통해 형성된 독특한 ‘계층적 미세구조(hierarchical microstructure)’에 있습니다. – Al 기지 내 나노 Si 입자: PHT 처리 후, Al 덴드라이트 내부에 약 20nm 크기의 고밀도 나노 Si 입자들이 분산되어 있는 것이 관찰되었습니다(그림 3b, c). 이 나노 입자들은 소성 변형 시 전위(dislocation)의 이동을 방해하고 저장하는 역할을 하여 재료의 가공 경화 능력을 향상시키고 연성을 높입니다. – 공정 Si 내 나노 Al 입자: 높은 냉각 속도(>20 K/s)에서는 취성이 강한 공정 Si 상 내부에 약 15nm 크기의 나노 Al 입자들이 형성되었습니다(그림 3d). 이 나노 Al 입자들은 공정 Si의 소성 변형(쌍정 및 전위 활동)을 유도하여, 기존에는 쉽게 파괴되던 공정 Si 상의 연성을 부여하는 역할을 합니다.

이 두 가지 나노 스케일 구조가 계층적으로 작용하여, Al 기지는 더 강해지고 공정 Si는 더 연해지면서 합금 전체의 강도와 연성이 동시에 향상되는 시너지를 창출한 것입니다.

Practical Implications for R&D and Operations

본 연구 결과는 Al-Si 합금을 사용하는 산업 현장의 다양한 전문가들에게 실질적인 시사점을 제공합니다.

  • For Process Engineers: 이 연구는 주조 공정에서 냉각 속도 제어와 간단한 저온 열처리(PHT) 추가만으로 최종 제품의 기계적 물성을 체계적으로 향상시킬 수 있음을 보여줍니다. 복잡한 합금 원소 추가 없이 기존 A356 합금으로도 고성능 부품 생산이 가능해져 공정 단순화 및 원가 절감에 기여할 수 있습니다.
  • For Quality Control Teams: 논문의 표 1 데이터는 냉각 속도와 최종 기계적 특성(항복강도, 인장강도, 연신율) 간의 명확한 상관관계를 제시합니다. 이를 바탕으로 특정 냉각 속도 범위를 핵심 공정 변수(KPP)로 설정하고, 이를 만족하는 부품에 대해 새로운 품질 보증 기준을 수립할 수 있습니다.
  • For Design Engineers: RS+PHT 공정으로 달성된 높은 연성(T6 처리 후 최대 21.3%)은 주조 합금이 단조 합금의 영역까지 넘볼 수 있게 합니다. 이는 기존에는 단조 공정으로만 제작 가능했던 고연성 요구 부품을 더 복잡한 형상으로 주조할 수 있게 하여, 부품 통합 및 경량화 설계에 새로운 가능성을 열어줍니다.

Paper Details


Breaking through the strength-ductility trade-off dilemma in an Al-Si-based casting alloy

1. Overview:

  • Title: Breaking through the strength-ductility trade-off dilemma in an Al-Si-based casting alloy
  • Author: B. Dang, X. Zhang, Y.Z. Chen, C.X. Chen, H.T. Wang & F. Liu
  • Year of publication: 2016
  • Journal/academic society of publication: SCIENTIFIC REPORTS
  • Keywords: Al-Si-based casting alloys, strength-ductility trade-off, rapid solidification (RS), post-solidification heat treatment (PHT), hierarchical microstructure

2. Abstract:

Al-Si 기반 주조 합금은 다양한 산업 응용 분야에서 큰 잠재력을 가지고 있습니다. 이러한 합금에 대한 일반적인 강화 전략은 강도-연성 트레이드오프 딜레마로 알려진 연성의 희생을 필연적으로 동반합니다. 본 연구에서는 상용 Al-Si 기반 주조 합금(A356 합금)을 예로 들어, 급속 응고(RS)와 응고 후 열처리(PHT)를 결합한 간단한 경로, 즉 RS + PHT 경로를 통해 이 딜레마를 극복하는 방법을 보고합니다. RS + PHT로 처리된 합금의 항복 강도와 파단 연신율은 RS 시 냉각 속도를 증가시킴에 따라 동시에 향상되며, 이는 후속 T6 열처리에 의해 영향을 받지 않습니다. 딜레마의 극복은 RS + PHT 경로에 의해 형성된 계층적 미세구조, 즉 Al 덴드라이트 내에 고도로 분산된 나노스케일 Si 입자와 공정 Si 내에 장식된 나노스케일 Al 입자에 기인합니다. RS + PHT 경로의 단순성은 산업적 대량 생산에 적합하게 만듭니다. 미세구조 엔지니어링 전략은 다른 Al-Si 기반 합금의 기계적 특성을 조정하는 일반적인 경로를 제공합니다. 또한, A356 합금의 현저하게 향상된 연성은 가공 경화를 통해 재료를 더욱 강화할 수 있을 뿐만 아니라, 재료의 전통적인 고체 상태 성형을 가능하게 하여 이러한 합금의 응용 분야를 확장합니다.

3. Introduction:

Al-Si 기반 주조 합금은 우수한 주조성, 낮은 밀도, 내식성, 높은 중량 대비 강도 및 낮은 열팽창 계수로 인해 항공우주 및 자동차 산업에서 복잡한 형상의 부품에 널리 사용되어 왔습니다. 일반적인 주조 조건에서 Al-Si 기반 주조 합금의 미세구조는 부드러운 Al 덴드라이트와 덴드라이트 간 영역에 형성된 취성 공정(Al + Si) 상으로 주로 구성됩니다. Si 첨가는 주조성을 향상시키는 데 큰 도움이 되지만, 공정(Al + Si) 상의 형성은 Al-Si 기반 주조 합금의 기계적 특성에 해로운 영향을 미칩니다. 한편으로, 공정(Al + Si) 상 내의 조대한 Si 상은 취성이 강하여 Al/Si 계면에서 응력 축적 시 균열이 발생하기 쉽습니다. 다른 한편으로, 응고된 상태의 Al 덴드라이트는 전위 장벽이 거의 없어 소성 변형 시 발생하는 내부 응력이 Al/Si 계면에 쉽게 축적됩니다. 축적된 내부 응력이 임계 응력을 초과하면 Si의 균열이 발생하고 결과적으로 합금의 파괴로 이어집니다. 따라서 Al-Si 기반 주조 합금은 일반적으로 낮은 강도와 낮은 연성을 겪습니다. 외부 입자 강화, 결정립 미세화, 미세 합금화 및 석출 경화와 같은 다양한 전략이 이러한 합금의 기계적 특성을 개선하기 위해 사용되었습니다. 그러나 상용 Al-Si 기반 A356 주조 합금을 예로 든 그림 1에서 볼 수 있듯이, 강도의 증가는 연성의 감소를 필연적으로 희생하며, 이는 구조용 금속에서 강도-연성 트레이드오프 딜레마로 알려져 있습니다. 급속 응고 및 결정립 미세화제 첨가에 의해 실현된 결정립 미세화, 특히 급속 응고는 강도와 연성의 동시 증가를 유발할 것으로 예상되지만, 문헌에 보고된 데이터가 여전히 강도-연성 트레이드오프를 보여주는 음영 영역 내에 있어 그 효과는 제한적인 것으로 간주됩니다.

4. Summary of the study:

Background of the research topic:

Al-Si 주조 합금은 산업적으로 중요하지만, 강도를 높이면 연성이 떨어지는 고질적인 ‘강도-연성 트레이드오프’ 문제를 안고 있습니다. 이는 주로 취성이 강한 공정 Si 상 때문에 발생하며, 고성능 구조 부품으로의 적용을 제한합니다.

Status of previous research:

기존에는 입자 강화, 결정립 미세화, 합금 원소 추가 등 다양한 방법으로 기계적 물성을 개선하려는 시도가 있었으나, 대부분 강도-연성 트레이드오프의 한계를 벗어나지 못했습니다. 급속 응고(RS) 기술 역시 강도와 연성을 동시에 향상시킬 잠재력이 있었지만, 그 효과는 제한적이었습니다.

Purpose of the study:

본 연구의 목적은 급속 응고(RS)와 응고 후 열처리(PHT)를 결합한 새로운 공정을 통해 상용 A356 합금의 강도-연성 트레이드오프 딜레마를 근본적으로 극복하는 것입니다. 이를 통해 강도와 연성이 동시에 향상되는 새로운 미세구조 제어 전략을 제시하고자 합니다.

Core study:

연구의 핵심은 RS+PHT 공정을 통해 A356 합금 내에 ‘계층적 미세구조’를 형성하는 것입니다. 즉, Al 덴드라이트 내부에 나노 Si 입자를, 공정 Si 상 내부에 나노 Al 입자를 형성시켜 각각 가공 경화 능력 향상과 연성 부여 역할을 하도록 설계했습니다. 냉각 속도라는 단일 공정 변수를 조절하여 이러한 미세구조를 제어하고, 그에 따른 기계적 물성의 변화를 체계적으로 분석했습니다.

5. Research Methodology

Research Design:

본 연구는 실험적 설계에 기반합니다. 주요 독립 변수는 급속 응고(RS) 시의 ‘냉각 속도’이며, 종속 변수는 ‘기계적 특성(항복 강도, 인장 강도, 파단 연신율)’과 ‘미세구조’입니다. 냉각 속도를 1.2 K/s에서 96 K/s까지 다양하게 변화시키며 각 조건에 따른 물성과 미세구조의 변화를 관찰했습니다.

Data Collection and Analysis Methods:

  • 미세구조 분석: 광학 현미경(OM), 주사 전자 현미경(SEM), 투과 전자 현미경(TEM)을 사용하여 각 공정 단계별 미세구조 변화를 관찰했습니다. 특히 TEM을 통해 나노 입자의 형상, 크기, 분포 및 결정학적 관계를 분석했습니다.
  • 기계적 특성 평가: 만능인장시험기를 사용하여 상온 인장 시험을 수행하고, 공칭 응력-변형률 곡선을 얻어 항복 강도(YS), 인장 강도(UTS), 파단 연신율(ETF)을 측정했습니다. 각 조건별로 5회 이상 시험하여 데이터의 재현성을 확보했습니다.
  • In-situ TEM: 실시간 투과 전자 현미경(in-situ TEM)을 사용하여 인장 변형 중 나노 입자와 전위의 상호작용을 직접 관찰하여 미세 변형 메커니즘을 규명했습니다.

Research Topics and Scope:

연구의 범위는 상용 A356 Al-Si 주조 합금에 국한됩니다. 주요 연구 주제는 (1) RS+PHT 공정이 A356 합금의 강도-연성 관계에 미치는 영향, (2) 강도와 연성 동시 향상의 원인이 되는 미세구조적 메커니즘 규명, (3) 새롭게 형성된 계층적 미세구조의 열적 안정성 평가입니다.

6. Key Results:

Key Results:

  • RS+PHT 공정을 적용하고 RS 시 냉각 속도를 높이면 A356 합금의 항복 강도와 연신율이 동시에 증가하여 기존의 강도-연성 트레이드오프 딜레마를 극복했습니다.
  • 이러한 물성 향상은 RS+PHT 공정에 의해 형성된 독특한 계층적 미세구조, 즉 Al 덴드라이트 내에 분산된 나노 Si 입자와 공정 Si 상 내에 형성된 나노 Al 입자에 기인합니다.
  • Al 기지 내 나노 Si 입자는 가공 경화를 촉진하고, 공정 Si 내 나노 Al 입자는 취성인 Si 상에 연성을 부여하여 재료의 파괴를 지연시킵니다.
  • 이 계층적 미세구조는 후속 T6 열처리 공정에서도 안정적으로 유지되어, 석출 경화 효과와 시너지를 일으켜 최종 물성을 극대화합니다.
Figure 2. Measured engineering stress-strain curves of the A356 alloys processed by the RS+PHT and the
subsequent T6 heat treatment. (a) RS + PHT treated, (b) solid solution treated at 813 K, and (c) artificially aged at
453 K. The curves shown in (b) and (c) correspond to the samples with peak YS values (cf. Supplementary Fig. S1).
In order to show the changes in the mechanical properties in different treatment states, same scales of the coordinate
axes are adopted in the three plots.
Figure 2. Measured engineering stress-strain curves of the A356 alloys processed by the RS+PHT and the subsequent T6 heat treatment. (a) RS + PHT treated, (b) solid solution treated at 813 K, and (c) artificially aged at 453 K. The curves shown in (b) and (c) correspond to the samples with peak YS values (cf. Supplementary Fig. S1). In order to show the changes in the mechanical properties in different treatment states, same scales of the coordinate axes are adopted in the three plots.

Figure List:

  • Figure 1. Yield strength (YS) and elongation to failure (ETF) of the A356 alloy achieved by various strengthening strategies: foreign particle reinforcement (blue closed squares4–6), grain refinement (black closed circles7,8), alloying (open squares11,12), and optimized casting (green closed triangles11,12). YS and ETF of A356 alloys obtained by combining the RS + PHT route with T6 heat treatment (red stars, the red arrow marks the direction of increasing cooling rate upon RS, the data point marked by the red circle represents the best combination of YS and ETF.). The black and red circles mark the best combination of YS and ETF obtained by rapid solidification at a cooling rate of 100 K/s and the subsequent T6 heat treatment8, and that achieved by combination of the current RS + PHT route with T6, respectively.
  • Figure 2. Measured engineering stress-strain curves of the A356 alloys processed by the RS+PHT and the subsequent T6 heat treatment. (a) RS + PHT treated, (b) solid solution treated at 813 K, and (c) artificially aged at 453 K. The curves shown in (b) and (c) correspond to the samples with peak YS values (cf. Supplementary Fig. S1). In order to show the changes in the mechanical properties in different treatment states, same scales of the coordinate axes are adopted in the three plots.
  • Figure 3. Microstructures of the RS and RS+PHT processed A356 alloys. (a) Typical morphology of the solidification microstructure of A356 alloys (cooling rate upon RS: 96 K/s). (b) SEM image of the A356 alloy processed by RS + PHT route (cooling rate upon RS: 96 K/s); the inset shows the highly dispersed nanoscale Si particles; a few Si particles are associated with rod-like β’ (Mg9Si5) phase. (c) TEM bright field image of a nanoscale Si particle associated with a β’ (Mg9Si5) phase; the upper and lower insets are the electron diffraction pattern taken from the selected area circled by the white dash line and the corresponding image at higher magnification; the cooling rate upon RS of the sample is 96 K/s. (d) TEM bright field image of the eutectic Si decorated by the nanoscale Al particles; the inset is the high resolution TEM image of an Al particle decorated in Si matrix; the cooling rate upon RS of the sample is 96 K/s. (e) The average density of nanoscale Si particles in the interior of Al dendrites measured by counting the number of particles in a specific area from at least three individual SEM images.
  • Figure 4. Development of microstructure of the A356 alloy solidified at a cooling rate of 96 K/s (shown in the upper part) processed by RS+PHT and the subsequent T6 heat treatment (shown in the lower part). The as-solidified microstructure consists mainly of Al dendrites and eutectic Si phase (A). After PHT treatment at 473 K, highly dispersed nanoscale Si particles and nanoscale Al particles appear in the Al dendrites and the eutectic Si phase, respectively (B). Further solid-solution treatment at 813K leads to the extensive spheroidization of eutectic Si, whereas, does not cause significant changes in these nanoscale particles (C). The artificial aging at 453K causes the precipitation of β’ phase in Al dendrites, and again, does not affect the presence of these particles (D).
  • Figure 5. Microstructures of the samples subjected to tensile deformation. (a) Cracking of the eutectic Si formed in the sample solidified at 3 K/s after tensile deformation. (b) Interaction of dislocations and the Si particles in the tensile deformed sample, showing the pinning and storage of dislocations in the interior of Al matrix by Si particles. (c) The morphology of an eutectic Si in the tensile deformed sample; the magnified TEM bright field image and HRTEM image inserted in the upper right corner show the details of a deformation twin in the eutectic Si. (d) Dislocations in the vicinity of nanoscale Al particles decorated in eutectic Si. (e) A HRTEM image of the nanoscale Al particle decorated in Si matrix (left) and the corresponding strain map obtained by geometric phase analysis (right).

7. Conclusion:

요약하자면, 우리는 간단한 RS + PHT 경로를 설계하여 A356 알루미늄 주조 합금의 강도-연성 트레이드오프 딜레마를 성공적으로 돌파하는 계층적 미세구조를 얻었습니다. RS + PHT 경로를 적용함으로써, A356 합금의 YS와 ETF는 RS 시 냉각 속도를 증가시킴에 따라 동시에 증가하며, 이는 RS + PHT 처리 시 형성된 계층적 미세구조, 즉 Al 덴드라이트 내부에 분산된 나노스케일 Si 입자와 공정 Si 상에 장식된 나노스케일 Al 입자에 기인합니다. 전자는 Al 덴드라이트의 가공 경화를 향상시키는 반면, 후자는 공정 Si의 연성화를 유발합니다. 계층적 미세구조는 가열에 대해 현저한 열적 안정성을 보여줍니다. 이는 응고 속도를 증가시킴에 따라 강도와 연성이 동시에 증가하는 추세를 변경하지 않고 T6 열처리를 통해 RS + PHT 처리된 A356 합금의 종합적인 기계적 특성을 추가로 개선할 수 있게 합니다. 현재 설계된 RS + PHT 경로는 중요한 이점을 제공합니다. 첫째, RS + PHT 경로의 단순성은 산업적 대량 생산에 적합하게 만듭니다. 둘째, 미세구조 엔지니어링 전략은 다른 Al-Si 기반 합금의 기계적 특성을 조정하는 일반적인 경로를 제공합니다. 셋째, RS + PHT 처리된 합금의 우수한 연성은 A356 합금의 적용 분야를 확장할 기회를 제공합니다.

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Expert Q&A: Your Top Questions Answered

Q1: PHT 공정 조건을 473K, 15분으로 설정한 특별한 이유가 있습니까?

A1: 네, 이 조건은 두 가지 목적을 균형 있게 달성하기 위해 신중하게 선택되었습니다. 473K(200°C)라는 비교적 낮은 온도는 RS 공정으로 형성된 미세한 덴드라이트 구조가 거칠어지는 것을 방지하면서, RS로 인해 과포화된 Si 원소들이 나노 입자로 석출될 수 있는 충분한 확산 동력을 제공합니다. 15분이라는 짧은 시간은 산업적 효율성을 고려한 것으로, 과포화된 원소와 응고 시 생성된 비평형 공공(vacancy)의 도움으로 이 시간 내에 효과적인 나노 입자 형성이 가능함을 확인했습니다.

Q2: 그림 1의 결과를 보면, RS만 적용했을 때(검은색 원)보다 RS+PHT를 적용했을 때(빨간색 별) 성능이 월등히 뛰어납니다. PHT 공정이 연성 향상에 기여하는 핵심 메커니즘은 무엇입니까?

A2: PHT 공정은 연성 향상에 두 가지 핵심적인 미세구조 변화를 유도합니다. 첫째, Al 기지 내에 나노 Si 입자를 형성시켜 변형 시 전위들이 이 입자들에 의해 얽히고 저장되도록 합니다(그림 5b). 이는 국부적인 응력 집중을 완화하고 재료 전체에 변형을 고르게 분산시켜 가공 경화 능력을 높이고 파괴를 지연시킵니다. 둘째, 높은 냉각 속도 조건에서는 취성인 공정 Si 상 내부에 나노 Al 입자를 형성시켜 Si 상 자체의 변형을 가능하게 합니다(그림 5c, d). 이로 인해 기존에는 파괴의 시작점이었던 공정 Si가 연성을 갖게 되어 합금 전체의 연신율을 극적으로 향상시킵니다.

Q3: 새롭게 형성된 계층적 나노 구조는 T6 열처리 같은 고온 공정에서도 안정적인가요?

A3: 네, 매우 안정적입니다. 그림 4는 813K(540°C)의 고온 용체화 처리(C)와 453K(180°C)의 인공 시효(D)를 거친 후에도 Al 기지 내 나노 Si 입자와 공정 Si 내 나노 Al 입자가 거의 변화 없이 유지되는 것을 보여줍니다. 이러한 뛰어난 열적 안정성은 이 나노 입자들이 비평형 공공의 도움으로 저온에서 형성된 후, 공공이 소멸되면서 추가적인 성장이 억제되기 때문으로 설명됩니다. 이 안정성 덕분에 T6 열처리를 통한 석출 경화 효과를 추가로 얻으면서도 RS+PHT로 확보한 우수한 강도-연성 조합을 유지할 수 있습니다.

Q4: 냉각 속도가 높을수록 Al 기지 내 나노 Si 입자의 밀도가 증가하는(그림 3e) 이유는 무엇입니까?

A4: 이는 급속 응고(RS)의 ‘용질 포획(solute trapping)’ 효과 때문입니다. 냉각 속도가 빠를수록 응고 계면이 빠르게 이동하여, 평형 상태에서는 석출되어야 할 Si 원자들이 Al 기지 내에 고용될 시간이 없이 그대로 갇히게 됩니다. 따라서 냉각 속도가 높을수록 Al 기지에 과포화되는 Si의 양이 증가하고, 이는 후속 PHT 공정에서 더 높은 밀도의 나노 Si 입자를 형성할 수 있는 구동력으로 작용합니다.

Q5: 이 기술이 실제 산업 현장에 적용될 때 가장 큰 장점은 무엇이라고 생각하십니까?

A5: 가장 큰 장점은 ‘단순성’과 ‘확장성’입니다. 이 기술은 고가의 합금 원소를 추가하거나 복잡한 장비를 요구하지 않습니다. 단지 주조 시 냉각 속도를 제어하고(예: 금형 재질 변경, 냉각 채널 설계), 간단한 저온 열처리 공정을 추가하는 것만으로 기존 합금의 성능을 극대화할 수 있습니다. 또한, 이 원리는 A356뿐만 아니라 다른 Al-Si 기반 합금에도 보편적으로 적용될 수 있어, 다양한 산업 분야에서 맞춤형 고성능 부품을 생산하는 데 활용될 수 있는 높은 잠재력을 가집니다.


Conclusion: Paving the Way for Higher Quality and Productivity

본 연구는 간단한 RS+PHT 공정을 통해 상용 Al-Si 합금이 가진 고질적인 강도-연성 트레이드오프 딜레마를 성공적으로 극복할 수 있음을 입증했습니다. 계층적 나노 미세구조의 형성은 강도와 연성을 동시에 향상시키는 핵심 메커니즘으로, 이는 항공우주, 자동차 등 고성능 경량 부품이 요구되는 산업에 새로운 가능성을 제시합니다. 이 연구 결과는 주조 공정의 정밀한 제어가 최종 제품의 품질을 얼마나 획기적으로 바꿀 수 있는지를 보여주는 명확한 사례입니다.

STI C&D는 최신 산업 연구 결과를 적용하여 고객이 더 높은 생산성과 품질을 달성할 수 있도록 돕는 데 전념하고 있습니다. 이 논문에서 논의된 과제가 귀사의 운영 목표와 일치한다면, 저희 엔지니어링 팀에 연락하여 이러한 원칙을 귀사의 부품에 어떻게 구현할 수 있는지 논의해 보십시오.

(주)에스티아이씨앤디에서는 고객이 수치해석을 직접 수행하고 싶지만 경험이 없거나, 시간이 없어서 용역을 통해 수치해석 결과를 얻고자 하는 경우 전문 엔지니어를 통해 CFD consulting services를 제공합니다. 귀하께서 당면하고 있는 연구프로젝트를 최소의 비용으로, 최적의 해결방안을 찾을 수 있도록 지원합니다.

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Copyright Information

  • This content is a summary and analysis based on the paper “Breaking through the strength-ductility trade-off dilemma in an Al-Si-based casting alloy” by “B. Dang, et al.”.
  • Source: https://doi.org/10.1038/srep30874

This material is for informational purposes only. Unauthorized commercial use is prohibited. Copyright © 2025 STI C&D. All rights reserved.

Figure 2. Surface of cast material plate with ignition (a) and without ignition (c), and optical micrographs of twin-roll cast material with ignition (b) and without ignition (d).

쌍롤 주조(TRC) 공법: 고품질 난연성 마그네슘 합금 판재 생산의 새로운 지평

이 기술 요약은 Masafumi Noda 외 저자가 2014년 InTech에 발표한 학술 논문 “Texture, Microstructure, and Mechanical Properties of Calcium-Containing Flame-Resistant Magnesium Alloy Sheets Produced by Twin-Roll Casting and Sequential Warm Rolling”을 기반으로 하며, STI C&D가 기술 전문가를 위해 분석 및 요약하였습니다.

키워드

  • Primary Keyword: 마그네슘 합금 쌍롤 주조
  • Secondary Keywords: 난연성 마그네슘 합금, AZX611, 주조 결함, 미세조직 제어, Al-Ca 금속간 화합물, 압연 공정

Executive Summary

  • 도전 과제: 마그네슘 합금은 경량성이 뛰어나지만, 높은 생산 비용과 가연성 때문에 사용이 제한됩니다. 비용 효율적인 쌍롤 주조(TRC) 공법은 대안이 될 수 있으나, 칼슘(Ca)을 포함한 난연성 합금에서 균열 및 편석과 같은 결함 문제가 발생합니다.
  • 연구 방법: 본 연구는 표준 AZ61 합금과 칼슘이 첨가된 난연성 마그네슘 합금(AZX611, AZX612)의 쌍롤 주조 공정을 비교 분석하고, 롤 온도 및 속도와 같은 공정 변수를 최적화하여 결함을 제어하고자 했습니다.
  • 핵심 돌파구: 주조 시 냉각 속도를 제어(롤 표면 온도 상승 및 롤 속도 감소)함으로써, AZX611 합금에서 발생하던 Al-Ca 금속간 화합물의 편석과 균열을 성공적으로 억제했습니다. 이를 통해 폭 300mm, 길이 5m의 무결함 스트립 생산 가능성을 입증했습니다.
  • 핵심 결론: 최적화된 마그네슘 합금 쌍롤 주조 공법은 기존의 제조 장벽을 넘어 고품질 난연성 마그네슘 합금 판재를 비용 효율적으로 생산할 수 있는 매우 유망한 기술입니다.
Figure 1. Schematic of a twin-roll caster for strips.
Figure 1. Schematic of a twin-roll caster for strips.

도전 과제: CFD 전문가에게 이 연구가 중요한 이유

마그네슘(Mg) 합금은 비강도와 경량성 덕분에 자동차, 항공우주, 철도차량 등 다양한 산업에서 알루미늄을 대체할 차세대 소재로 주목받고 있습니다. 하지만 높은 생산 비용, 낮은 성형성, 그리고 무엇보다도 높은 가연성이라는 치명적인 단점이 상용화를 가로막고 있었습니다.

최근 칼슘(Ca)을 첨가하여 불이 잘 붙지 않는 난연성 마그네슘 합금이 개발되었지만, 이를 판재 형태로 만드는 데는 또 다른 어려움이 따릅니다. 특히, 생산 비용을 절감할 수 있는 쌍롤 주조(Twin-Roll Casting, TRC) 공법을 적용할 경우, 칼슘 첨가로 인해 형성되는 Al-Ca 금속간 화합물이 주조 중 균열이나 편석(segregation)과 같은 심각한 결함을 유발하는 문제가 있었습니다. 이는 최종 제품의 기계적 물성을 저하시키고 신뢰성을 떨어뜨리는 주된 원인이 됩니다. 따라서, 이러한 결함을 제어하고 안정적인 품질의 난연성 마그네슘 판재를 생산하기 위한 공정 최적화 연구가 절실히 필요한 상황이었습니다.

연구 접근법: 방법론 분석

본 연구는 쌍롤 주조 공정에서 합금 성분과 공정 변수가 최종 제품의 품질에 미치는 영향을 규명하기 위해 다음과 같은 실험을 설계했습니다.

  • 소재: 기준 합금으로 AZ61을 사용하고, 칼슘(Ca)이 각각 1mass%와 2mass% 첨가된 난연성 합금 AZX611과 AZX612를 준비했습니다. 용해는 아르곤(Ar) 가스 분위기에서 진행하여 용탕의 산화를 방지했습니다.
  • 쌍롤 주조(TRC) 공정: 직경 200mm, 폭 300mm의 금속 롤을 사용했습니다. 초기 실험에서는 롤 속도 20-25 m/min, 롤 갭 2-3 mm, 용탕 온도 660°C 조건으로 주조를 진행했습니다. 이후 결함 제어를 위해 롤 표면 온도와 롤 속도를 조절하며 냉각 속도를 변화시켰습니다.
  • 후처리 및 분석: TRC 공정으로 제작된 판재는 스트립 압연 공정을 통해 65%의 두께 감소율로 가공되었습니다. 이후 인장 시험을 통해 항복강도(YS), 인장강도(UTS), 연신율 등 기계적 특성을 평가했습니다. 또한, 광학 현미경(OM), 주사 전자 현미경(SEM), 전자후방산란회절(EBSD) 분석을 통해 미세조직, 결정 방향, 파단면 등을 정밀하게 관찰했습니다.

핵심 돌파구: 주요 발견 및 데이터

발견 1: 용탕 정련 및 산화 방지가 기계적 물성에 미치는 결정적 영향

연구진은 용해 중 미세한 연소(산화) 발생 여부가 최종 제품의 품질에 치명적인 차이를 만든다는 것을 발견했습니다.

  • Figure 4에 따르면, 아르곤 분위기에서 용탕 정련을 통해 연소를 방지한 AZ61 합금은 항복강도(YS) 116 MPa, 인장강도(UTS) 239 MPa, 연신율 19%의 우수한 기계적 특성을 보였습니다. 반면, 미세 연소가 발생하여 산화물이 혼입된 경우, YS는 82 MPa, UTS는 180 MPa, 연신율은 13%로 모든 기계적 물성이 현저히 저하되었습니다. 이는 산화물 혼입이 미세 균열의 시작점이 되어 취성 파괴를 유발하기 때문입니다. (Figure 2, 4 참조)

발견 2: 냉각 속도 제어를 통한 Al-Ca 화합물 편석 및 균열 억제

칼슘이 포함된 AZX611 합금의 경우, 빠른 냉각 속도가 특징인 일반적인 TRC 공정에서 심각한 결함이 발생했습니다.

  • Figure 5와 Figure 6은 빠른 냉각 속도(>100 °C/s) 조건에서 주조된 AZX611 판재 표면에 Al-Ca 금속간 화합물이 편석되고, 이로 인해 미세 균열이 발생했음을 명확히 보여줍니다.
  • 연구진은 이 문제를 해결하기 위해 롤 표면 온도를 100°C로 높이고 롤 속도를 20 m/min로 낮추어 냉각 속도를 약 50 °C/s로 늦췄습니다. 그 결과, Figure 7에서 볼 수 있듯이 Al-Ca 화합물의 편석이나 균열이 전혀 없는 균일하고 건전한 미세조직을 얻는 데 성공했습니다. 이는 마그네슘 합금 쌍롤 주조 공정에서 냉각 속도 제어가 금속간 화합물을 형성하는 합금의 품질 확보에 가장 중요한 변수임을 입증합니다.
Figure 2. Surface of cast material plate with ignition (a) and without ignition (c), and optical micrographs of twin-roll
cast material with ignition (b) and without ignition (d).
Figure 2. Surface of cast material plate with ignition (a) and without ignition (c), and optical micrographs of twin-roll cast material with ignition (b) and without ignition (d).

R&D 및 운영을 위한 실질적 시사점

  • 공정 엔지니어: 본 연구는 칼슘 함유 마그네슘 합금의 쌍롤 주조 시, 롤 표면 온도와 주조 속도를 조절하여 냉각 속도를 제어하는 것이 균열 및 편석 결함을 방지하는 핵심임을 시사합니다. 특히 냉각 속도를 약 50 °C/s 수준으로 낮추는 것이 효과적인 출발점이 될 수 있습니다.
  • 품질 관리팀: 논문의 Figure 2와 Figure 4 데이터는 판재 표면의 검은 반점(산화물)과 기계적 물성 저하(UTS 239 MPa → 180 MPa) 간의 명확한 상관관계를 보여줍니다. 이는 주조 직후 제품에 대한 육안 검사 기준을 강화하고, 산화물 혼입을 잠재적 불량의 핵심 지표로 관리해야 함을 의미합니다.
  • 설계 엔지니어: 이 연구 결과는 금속간 화합물을 형성하는 합금 소재를 선택할 때, 응고 과정에서 결함이 발생할 가능성을 초기 설계 단계부터 고려해야 함을 보여줍니다. 특히 쌍롤 주조와 같은 급속 응고 공정을 적용할 경우, 소재의 특성에 맞는 공정 파라미터 제어가 제품의 구조적 건전성을 보장하는 데 필수적입니다.

논문 상세 정보


Texture, Microstructure, and Mechanical Properties of Calcium-Containing Flame-Resistant Magnesium Alloy Sheets Produced by Twin-Roll Casting and Sequential Warm Rolling

1. 개요:

  • 제목: Texture, Microstructure, and Mechanical Properties of Calcium-Containing Flame-Resistant Magnesium Alloy Sheets Produced by Twin-Roll Casting and Sequential Warm Rolling
  • 저자: Masafumi Noda, Tomomi Ito, Yoshio Gonda, Hisashi Mori and Kunio Funami
  • 발행 연도: 2014
  • 발행 학술지/학회: InTech
  • 키워드: Magnesium alloys, Twin-roll casting, Calcium, Flame-resistant, Microstructure, Mechanical properties, Warm rolling

2. 초록:

본 연구는 쌍롤 주조(TRC)와 순차적 온간 압연을 통해 생산된 칼슘 함유 난연성 마그네슘 합금 판재의 집합조직, 미세조직 및 기계적 특성을 다룬다.

3. 서론:

마그네슘(Mg) 합금은 우수한 비강도, 비강성 등으로 차세대 금속 재료로 주목받고 있으나, 높은 생산 비용과 가연성 등의 문제가 있다. 특히 구조 부품으로 사용하기 위해서는 불연성 또는 난연성 특성이 요구되며, 최근 칼슘(Ca)을 첨가하여 이러한 특성을 확보한 합금이 개발되었다. 본 연구는 생산 비용 절감을 위해 쌍롤 주조(TRC) 공법을 이러한 난연성 합금에 적용할 때 발생하는 문제점(편석, 개재물 혼입 등)을 해결하고, 용탕 정련 효과와 미세조직 및 기계적 특성에 미치는 영향을 규명하고자 한다.

4. 연구 요약:

연구 주제 배경:

경량 소재인 마그네슘 합금의 활용도를 높이기 위해 난연성 부여가 필수적이며, 이를 위해 칼슘(Ca)이 첨가되고 있다. 그러나 Ca 첨가 합금은 기존 주조 방식, 특히 비용 효율적인 쌍롤 주조(TRC) 적용 시 금속간 화합물 형성으로 인한 결함 발생 가능성이 크다.

기존 연구 현황:

대부분의 TRC 관련 연구는 Al 합금이나 AZ 계열 Mg 합금에 집중되어 있으며, Ca과 같이 금속간 화합물을 쉽게 형성하는 원소가 첨가된 합금의 TRC 공정에 대한 논의는 부족했다. 특히 용탕 정련, 첨가 원소의 역할, 미세조직 제어에 대한 심도 있는 연구가 필요한 실정이다.

연구 목적:

TRC 공정 전 용탕 정련이 판재 생산에 미치는 영향을 조사하고, Ca 함유 난연성 Mg 합금의 미세조직 및 기계적 특성을 분석한다. 또한, Ca 첨가로 인한 금속간 화합물 석출이 주조 판재와 내구성에 미치는 영향을 분석하는 것을 목표로 한다.

핵심 연구:

AZ61, AZX611, AZX612 합금을 대상으로 TRC 공정을 수행하며, 특히 용탕의 산화 여부와 냉각 속도(롤 온도, 롤 속도)가 미세조직(균열, 편석) 및 기계적 특성에 미치는 영향을 집중적으로 분석했다.

5. 연구 방법론

연구 설계:

비교 연구 설계를 통해 기준 합금(AZ61)과 Ca 첨가 합금(AZX611, AZX612)의 TRC 공정 결과를 비교 분석했다. 주요 변수는 합금 조성, 용탕의 연소(산화) 여부, 그리고 냉각 속도이다.

데이터 수집 및 분석 방법:

  • 기계적 특성 평가: 인장 시험기를 사용하여 항복강도, 인장강도, 연신율을 측정했다.
  • 미세조직 분석: 광학 현미경(OM), 주사 전자 현미경(SEM), 전자후방산란회절(EBSD)을 사용하여 결정립 크기, 금속간 화합물 분포, 결정 방향성, 파단면 형상 등을 분석했다.

연구 주제 및 범위:

본 연구는 Ca 함유 난연성 Mg 합금의 쌍롤 주조 공정 최적화에 초점을 맞춘다. 연구 범위는 용탕 준비 단계부터 TRC 공정, 그리고 후속 압연 및 어닐링 공정을 거친 소재의 미세조직과 기계적 특성, 부식 거동 분석까지 포함한다.

6. 주요 결과:

주요 결과:

  • 용해 중 연소를 방지하면(Ar 분위기 사용), 산화물 혼입이 줄어들어 AZ61 합금의 기계적 특성(UTS 180 MPa → 239 MPa)이 크게 향상되었다.
  • Ca가 첨가된 AZX611 합금은 빠른 냉각 속도의 TRC 공정에서 표면에 Al-Ca 화합물 편석 및 균열이 발생했다.
  • 롤 표면 온도를 100°C로 높이고 롤 속도를 20 m/min로 낮추어 냉각 속도를 감소시키자, 균열과 편석이 없는 건전한 AZX611 주조 판재를 제조할 수 있었다.
  • TRC재는 표면에 조대한 결정립(70-100 µm), 내부에 미세한 등축정(25-40 µm)을 갖는 이중 미세조직을 보였으며, 이는 일반 주조재보다 훨씬 미세하여 후속 가공에 유리하다.
  • Ca 첨가량이 증가할수록 결정립 크기는 미세해지고, Al-Ca 화합물 분율이 증가하여 어닐링 시 결정립 성장을 억제하는 효과가 나타나 내열성 향상에 기여함을 확인했다.
Figure 6. Example showing the segregation of Al–Ca compounds in a rapidly cooled region of twin-roll cast material.
Figure 6. Example showing the segregation of Al–Ca compounds in a rapidly cooled region of twin-roll cast material.

Figure 목록:

  • Figure 1. Schematic of a twin-roll caster for strips.
  • Figure 2. Surface of cast material plate with ignition (a) and without ignition (c), and optical micrographs of twin-roll cast material with ignition (b) and without ignition (d).
  • Figure 3. Nominal stress-strain curves for AZ61 and AZX611 twin-roll cast materials.
  • Figure 4. Cross-sectional optical micrographs [(a), (c), and (e)] and SEM micrographs of fracture surfaces [(b), (d), and (f)] of AZ61 [(a)-(d)] and AZX611 [(e) and (f)] twin-roll cast materials with ignition during heating [(a) and (b)] and without ignition during heating [(c)-(f)].
  • Figure 5. Optical micrographs of the surfaces of twin-roll cast strips of AZ61 [(a), (b)] and AZX611 [(c), (d)].
  • Figure 6. Example showing the segregation of Al-Ca compounds in a rapidly cooled region of twin-roll cast material.
  • Figure 7. Optical micrographs of AZX611 twin-roll cast material solidified at a lower rate (rise to roll-surface temperature, lower roll-mill speed). Observations were made from the direction of the surface (a) and in the perpendicular direction (b).
  • Figure 8. Twin-roll cast AZX611 Mg strip of thickness 2.5 mm and width 300 mm fabricated by using a pilot-plant twin-roll casting machine.
  • Figure 9. Optical micrographs of twin-roll cast strips of AZ61 [(a) and (b)] and AZX611 [(c) and (d)] showing the surfaces of the strips [(a) and (c)] and the interiors of the strips [(b) and (d)].
  • Figure 10. Inverse pole figure (IPF) maps and pole figure (PF) maps of AZX611 twin-roll cast material. The intensity of texture is indicated in the PF maps. Figures (b) and (c) were cropped from the IPF map; (b) shows the surface region and (c) shows the interior.
  • Figure 11. Optical micrograph and IPF and PF maps of AZX611 antigravity suction-cast material cooled at 25 °C s¯¹. The intensity of texture is indicated in the PF map.
  • Figure 12. Relationship between tensile properties and roll-mill speed for AZ61, AZX611, and AZX612 twin-roll cast materials subjected to a single-pass rolling process.
  • Figure 13. (a) Relationship between the grain size and the annealing temperature for single-pass rolled samples of AZ61, AZX611, AZX 612; and (b) optical micrographs of AZ61, AZX611, and AZX612 materials subjected to single-pass rolling at a sample temperature of 200 °C. The roll-mill speeds are indicated in the optical micrographs.
  • Figure 14. (a) Relationship between the annealing temperature and the grain size for AZ61, AZX611, and AZX612 single-pass-rolled materials. Annealing was performed at 200, 300, 350, or 400 °C for one hour. (b) Optical micrographs of materials annealed at 400 °C for one hour.
  • Figure 15. (a) Relationship between weight loss and immersion time for AZX311, AZX611, and AMX1001 rolled materials. (b) Optical micrographs of plate surfaces after immersion tests in an 5% aqueous NaCl solution.

7. 결론:

본 연구는 용탕 정련을 통해 쌍롤 주조 공정에서 난연성 마그네슘 합금 판재의 품질을 향상시킬 수 있음을 보여주었다. 특히, 기존의 빠른 냉각 속도(>100 °C/s)를 특징으로 하는 TRC 공정의 냉각 속도를 약 50 °C/s로 늦춤으로써, 금속간 화합물을 형성하는 합금에서 발생하는 균열 문제를 해결하고 대형 판재를 성공적으로 제조할 수 있었다. TRC 공법으로 제조된 소재는 미세한 결정립과 무작위적 결정 방향성, 그리고 미세하게 분산된 Al-Ca 화합물 덕분에 우수한 후속 압연 가공성을 보였다. 이는 TRC 공법이 고품질 난연성 마그네슘 합금 판재를 경제적으로 생산하는 효과적인 방법이 될 수 있음을 시사한다.

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  31. Jiang B, Liu W, Qiu D, Zhang MX, Pan F. Grain Refinement of Ca Addition in a Twin Roll Cast Mg-3Al–1Zn Alloy. Materials Chemistry and Physics 2012; 133(2–3) 611–616.
  32. Zhao Hu, Li P, He L. Microstructure and Mechanical Properties of an Asymmetric Twin Roll Cast AZ31 Magnesium Alloy Strip. Journal of Materials Processing Technology 2012; 212(8) 1670–1675.
  33. Savage SJ, Froes FH. Production of Rapidly Solidified Metals and Alloys. JOM: The Journal of the Minerals, Metals & Materials Society 1984; 36(4) 20–33.
  34. Watari H, Davy K, Rasgado MT, Haga T, Izawa S. Semi-solid manufacturing process of magnesium alloys by twin-roll casting. Journal of Materials Processing Technology 2004; 155-156 1662–1667.
  35. Ito T, Noda M, Mori H, Gonda Y, Fukuda Y, Yanagihara S. Effect of Antigravity Suction Casting Parameters on Microstructure and Mechanical Properties of Mg-10Al–0.2Mn-1Ca Cast Alloy. Materials Transactions 2014; 55(8) 1184-1189

전문가 Q&A: 가장 궁금한 질문에 대한 답변

Q1: 용해 과정에서 아르곤(Ar) 가스 분위기와 버블링을 사용한 이유는 무엇인가요?

A1: 마그네슘 용탕의 산화를 방지하기 위해서입니다. 논문의 Figure 2와 4에서 명확히 보여주듯이, 용해 중 미세한 연소라도 발생하면 산화물이 용탕 내에 혼입됩니다. 이 산화물들은 응고 후 기계적 물성을 심각하게 저하시키는 결함으로 작용하여, 인장강도와 연신율을 크게 떨어뜨리는 원인이 됩니다. 따라서 고품질의 주조재를 얻기 위해 산화 방지는 필수적인 공정입니다.

Q2: 초기 TRC 실험에서 AZX611 합금에 균열이 발생한 주된 원인은 무엇이었나요?

A2: 바로 공정의 ‘빠른 냉각 속도’ 때문입니다. Figure 5와 6을 보면, 빠른 냉각으로 인해 용탕이 급격히 응고되면서 판재 표면 근처에 취성이 높은 Al-Ca 금속간 화합물이 불균일하게 집중(편석)되는 현상이 발생했습니다. 이 편석된 화합물들이 응력 집중부로 작용하여 미세 균열을 유발한 것입니다.

Q3: 연구진은 AZX611 합금의 균열 문제를 어떻게 해결했나요?

A3: 냉각 속도를 의도적으로 늦추는 방식을 사용했습니다. 구체적으로 롤 표면 온도를 100°C까지 예열하고 롤 회전 속도를 20 m/min로 낮추었습니다. 이를 통해 냉각 속도를 기존의 100 °C/s 이상에서 약 50 °C/s 수준으로 제어함으로써, Al-Ca 화합물이 편석될 시간적 여유를 주지 않고 더 균일하게 분포되도록 유도했습니다. 그 결과 Figure 7과 같이 균열 없는 건전한 판재를 생산할 수 있었습니다.

Q4: TRC로 제작된 소재의 미세조직은 일반 주조재와 어떻게 다른가요?

A4: 가장 큰 차이는 ‘결정립 크기’와 ‘조직의 불균일성’입니다. Figure 9에 따르면, TRC재는 롤과 직접 접촉하는 표면에는 상대적으로 조대한 결정립(70-100 µm)이, 내부에는 매우 미세한 등축정(25-40 µm)이 형성되는 이중(dual) 미세조직을 가집니다. 이는 일반적인 반연속 주조로 얻어지는 약 100 µm 이상의 균일한 결정립(Figure 11)보다 훨씬 미세하며, 이러한 미세한 내부 조직은 후속 압연 공정에서 더 높은 가공성을 보이는 장점이 있습니다.

Q5: 칼슘(Ca) 첨가는 어닐링(annealing) 과정에서 어떤 역할을 하나요?

A5: 결정립 성장 억제제 역할을 합니다. Figure 14를 보면, Ca가 없는 AZ61 합금은 350°C 이상에서 결정립이 급격히 성장하는 반면, Ca가 첨가된 AZX611과 AZX612 합금은 400°C의 고온에서도 결정립 성장이 효과적으로 억제됩니다. 이는 미세하게 분산된 Al-Ca 화합물이 결정립계의 이동을 방해하기 때문이며, 결과적으로 합금의 내열성과 크리프 저항성을 향상시키는 데 기여할 수 있습니다.


결론: 더 높은 품질과 생산성을 향한 길

본 연구는 난연성 마그네슘 합금 생산의 오랜 난제였던 ‘품질’과 ‘비용’ 문제를 마그네슘 합금 쌍롤 주조 공법 최적화를 통해 해결할 수 있는 중요한 단서를 제공합니다. 특히, 냉각 속도라는 핵심 공정 변수를 정밀하게 제어함으로써 금속간 화합물로 인한 고질적인 결함을 억제하고, 우수한 기계적 특성을 지닌 고품질 판재를 안정적으로 생산할 수 있음을 입증했습니다. 이는 자동차, 항공, 철도 등 경량화가 필수적인 첨단 산업 분야에서 난연성 마그네슘 합금의 적용 가능성을 한 단계 끌어올린 의미 있는 성과입니다.

(주)에스티아이씨앤디에서는 고객이 수치해석을 직접 수행하고 싶지만 경험이 없거나, 시간이 없어서 용역을 통해 수치해석 결과를 얻고자 하는 경우 전문 엔지니어를 통해 CFD consulting services를 제공합니다. 귀하께서 당면하고 있는 연구프로젝트를 최소의 비용으로, 최적의 해결방안을 찾을 수 있도록 지원합니다.

  • 연락처 : 02-2026-0450
  • 이메일 : flow3d@stikorea.co.kr

저작권 정보

  • 이 콘텐츠는 Masafumi Noda 외 저자의 논문 “Texture, Microstructure, and Mechanical Properties of Calcium-Containing Flame-Resistant Magnesium Alloy Sheets Produced by Twin-Roll Casting and Sequential Warm Rolling”을 기반으로 요약 및 분석되었습니다.
  • 출처: http://dx.doi.org/10.5772/58940

본 자료는 정보 제공 목적으로만 사용됩니다. 무단 상업적 사용을 금합니다. Copyright © 2025 STI C&D. All rights reserved.

Fig2. PLC Relay set up

PLC 프로그래밍을 활용한 중력 주조 자동화: 생산성 향상 및 비용 절감의 핵심

이 기술 요약은 Ishrat Meera Mirzana, Narjis B, K Vishnu Prashant Reddy가 저술하여 2014년 IJRET: International Journal of Research in Engineering and Technology에 발표한 논문 “UTILIZATION OF PLC PROGRAMMING FOR GRAVITY DIE CASTING AUTOMATION”을 기반으로 하며, STI C&D에서 기술 전문가를 위해 분석 및 요약하였습니다.

키워드

  • Primary Keyword: 중력 주조 자동화
  • Secondary Keywords: PLC 프로그래밍, 저비용 자동화, 공압 실린더, 다이캐스팅, 공정 최적화

Executive Summary

  • 도전 과제: 전통적인 수동 중력 주조 공정은 생산성이 낮고 품질이 일관되지 않으며, 인건비 부담이 큰 산업적 문제를 안고 있습니다.
  • 해결 방법: 프로그래머블 로직 컨트롤러(PLC)를 사용하여 공압 액추에이터, 그리퍼, 밸브를 제어함으로써 전체 주조 시퀀스를 자동화하는 저비용 자동화(LCA) 기법을 적용했습니다.
  • 핵심 돌파구: 본 연구는 전체 자동화 사이클을 성공적으로 설계하고 계산하여, 총 공정 시간을 2.54분으로 단축함으로써 기존 수동 방식 대비 상당한 시간 절감을 입증했습니다.
  • 핵심 결론: PLC 기반의 중력 주조 자동화는 중력 주조 공정의 생산성과 품질을 향상시키는 경제적이고 유연한 솔루션을 제공합니다.

도전 과제: 이 연구가 CFD 전문가에게 중요한 이유

세계화와 자유화의 흐름 속에서 제조업의 생산성 향상을 위해서는 품질 개선과 비용 절감이 필수적입니다. 특히 인도, 브라질과 같은 개발도상국의 중소 산업 현장에서는 기존의 수동 방식에 의존하는 중력 주조 공정이 널리 사용되고 있습니다. 이러한 수동 공정은 작업자의 숙련도에 따라 제품 품질이 달라지고, 반복 작업으로 인한 생산성 저하 및 안전 문제를 야기합니다.

고가의 맞춤형 자동화 설비는 초기 투자 비용이 높아 중소기업에게는 큰 부담이 됩니다. 따라서 기존 장비를 최대한 활용하면서 표준화된 부품(예: 리미트 스위치, 솔레노이드 밸브, 공압 액추에이터)을 도입하여 공정을 개선하는 ‘저비용 자동화(Low Cost Automation, LCA)’의 필요성이 대두되었습니다. 이 연구는 복잡하고 지속적인 모니터링이 필요한 중력 주조 공정에 PLC 프로그래밍을 적용하여 이러한 산업적 난제를 해결하고자 했습니다.

접근 방식: 방법론 분석

본 연구에서는 중력 주조 공정의 자동화를 위해 프로그래머블 로직 컨트롤러(PLC)를 제어 시스템의 핵심으로 사용했습니다. 사용된 PLC는 SIEMENS SIMANTIC S7300PLC이며, STEP7 소프트웨어를 통해 프로그래밍되었습니다. 전체 시스템은 7개의 공압 실린더, 2개의 공압 그리퍼, 1개의 공압 로터리 액추에이터로 구성되며, 각 액추에이터는 더블 및 싱글 솔레노이드 밸브에 의해 제어됩니다.

자동화된 기능 주기는 다음과 같은 순서로 진행됩니다. 1. 도가니 이동 및 상승: 실린더 A가 실린더 B를 밀고, 실린더 B가 도가니를 들어 올립니다. 2. 도가니 파지 및 주입: 공압 그리퍼 C가 도가니를 잡고, 로터리 액추에이터 D가 활성화되어 용융 금속을 다이(die) 안으로 붓습니다. 3. 응고 및 코어 분리: 타이머가 활성화되어 용융 금속이 응고될 시간을 확보합니다. 이후 실린더 E가 전진하여 그리퍼 H로 코어를 잡고 후진하여 코어를 들어 올립니다. 4. 제품 취출: 실린더 F가 핀을 취출하고, 실린더 G가 다이 절반을 분리하여 주조품을 꺼냅니다. 5. 원위치 복귀: 모든 실린더가 초기 위치로 돌아와 한 사이클을 완료합니다.

연구팀은 각 단계에 필요한 힘을 계산하여 각 실린더의 보어 직경(D), 피스톤 로드 직경(d), 스트로크 길이(L) 등 최적의 사양을 도출하고, 이를 바탕으로 각 동작에 소요되는 시간을 정밀하게 계산했습니다.

Fig.1 Set up of gravity die casting for automation
Fig.1 Set up of gravity die casting for automation

돌파구: 주요 연구 결과 및 데이터

결과 1: 완전 자동화 사이클을 위한 액추에이터 사양의 정밀 계산

본 연구는 자동화 공정의 각 단계에서 움직여야 하는 부품의 무게(예: 실린더 A는 40kg, 실린더 B는 30kg)를 기반으로 각 공압 실린더에 필요한 추력(Thrust force)을 계산했습니다. 예를 들어, 6bar의 공급 압력 하에서 필요한 추력을 만족시키기 위한 실린더 보어 직경(D)과 피스톤 로드 직경(d)을 P = π/4 * D * D * p 와 같은 공식을 사용하여 도출했습니다. 이 계산을 통해 각 실린더(A, B, C, D, E, F, G, H)의 구체적인 사양이 아래 표와 같이 결정되었습니다.

실린더보어 직경 (D) (inch)스트로크 길이 (L) (inch)전진 시간 (Tfs) (sec)후진 시간 (Trs) (sec)
A1.411.812.76
B1.255.91.479
C(파지)0.3
D(주입)45
E1.7311.815.34.25
F(핀 취출)13.90.630.46
G2.285.94.923.68
H(파지)0.2

표 1: 중력 주조 자동화에 활용된 실린더 사양

결과 2: 사이클 타임의 획기적 단축 및 공정 효율성 입증

각 실린더의 전진(Forward stroke) 및 후진(Return stroke) 시간을 정밀하게 계산한 결과, 전체 공정을 완료하는 데 걸리는 총 시간은 152.53초(약 2.54분)로 산출되었습니다.

총 사이클 타임 = 2.76 (A) + 1.47 (B) + 0.3 (C) + 45 (D) + 45 (응고) + 5.3 (E 전진) + 0.2 (H) + 4.2 (E 후진) + 4.92 (G) + 30 (취출) + 3.92 (G 복귀) + … = 152.53초

이 결과는 “기존 방식에 비해 훨씬 짧은 시간”이라고 논문에서 언급된 바와 같이, 수동 작업에 비해 생산성을 크게 향상시킬 수 있음을 정량적으로 보여줍니다. PLC 타이머의 정확성을 통해 각 공정 단계가 일관된 시간 내에 수행되므로 제품 품질의 일관성 또한 확보할 수 있습니다.

R&D 및 운영을 위한 실질적 시사점

  • 공정 엔지니어: 이 연구는 저비용 자동화를 구현하기 위한 구체적인 청사진을 제공합니다. PLC 프로그램과 유량 제어 밸브를 조정하면 다양한 주조 제품에 맞게 시퀀스와 타이밍을 미세 조정할 수 있어, 사이클 타임 단축과 일관된 공정 관리에 기여할 수 있습니다.
  • 품질 관리팀: 논문에서 언급된 “일관된 공정을 통한 품질 향상”은 PLC 타이머로 제어되는 자동화된 주입 및 응고 시간이 수동 작업의 불일치로 인해 발생하는 결함을 줄일 수 있음을 시사합니다. 이는 더 신뢰성 있는 품질 검사 기준을 수립하는 근거가 될 수 있습니다.
  • 설계 엔지니어: 이 연구는 공정 자동화에 초점을 맞추고 있지만, 공압 그리퍼를 위한 명확한 파지 지점이나 이젝터를 위한 표준화된 핀 위치 등 자동화를 염두에 둔 다이 및 코어 설계가 이러한 시스템의 구현을 단순화할 수 있음을 시사합니다.

논문 정보


UTILIZATION OF PLC PROGRAMMING FOR GRAVITY DIE CASTING AUTOMATION

1. 개요:

  • 제목: UTILIZATION OF PLC PROGRAMMING FOR GRAVITY DIE CASTING AUTOMATION
  • 저자: Ishrat Meera Mirzana, Narjis B, K Vishnu Prashant Reddy
  • 발행 연도: 2014
  • 발행 학술지/학회: IJRET: International Journal of Research in Engineering and Technology
  • 키워드: Automation, Programmable logic controller, Gravity die casting

2. 초록:

현재의 세계화 및 자유화 체제 하에서 품질 향상과 비용 절감은 주요 산업의 생산성을 높이기 위한 두 가지 중요한 단계입니다. 우리는 매우 실용적이고 안전하며 경제적이고 보람 있는 전략, 즉 저비용 자동화(LOW COST AUTOMATION)의 적용에 초점을 맞췄습니다. 자동화를 사용하는 산업에서는 동일한 종류의 여러 제품을 제조할 때 순서가 지켜지므로 자동화의 기회가 있습니다. 우리 연구에서는 프로그래머블 로직 컨트롤러(SIEMENS SIMANTIC S7300PLC와 STEP7 소프트웨어)를 통해 저비용 자동화를 달성했습니다. 이는 장치 제어에 필요한 순차 릴레이 회로를 대체하는 데 사용됩니다. 자동화 시스템에서 PLC는 일반적으로 제어 시스템의 중심 부분입니다. 프로그램 메모리에 저장된 프로그램의 실행을 통해 PLC는 입력 장치(센서)의 신호를 통해 시스템 상태를 지속적으로 모니터링합니다. 프로그램에 구현된 로직을 기반으로 PLC는 출력 기기(액추에이터)로 실행할 작업을 결정합니다. 우리의 요구 사항에 따라 공압 액추에이터, 솔레노이드 밸브 및 센서가 시퀀스를 실행하는 데 사용됩니다. 유량 제어 밸브는 필요한 곳에서 공기 압력의 흐름을 조절하는 데 사용됩니다.

3. 서론:

최근 자동화 기술은 현대 제조 공정에서 다양한 이점을 얻기 위한 효과적인 전략 중 하나가 되었습니다. 따라서 산업계는 자동화를 강화하고 이를 통해 생산성을 높여 시장에서 더 큰 경쟁력을 확보하는 방법을 모색해야 합니다. 자동화는 기계 도입을 통해 인간의 노력을 복제하고, 가용 자원을 가장 효율적인 방식으로 활용하여 생산성을 높입니다. 즉, 자동화는 생산을 운영하고 제어하기 위해 기계, 전자 및 컴퓨터 기반 시스템의 응용과 관련된 기술입니다. 인도, 브라질 등 개발도상국의 급속한 산업 성장을 위해 자동화는 중요한 역할을 합니다. 고정 자동화, 프로그래머블 자동화, 유연 자동화는 세 가지 유형의 자동화입니다. 맞춤형 엔지니어링 장비에 대한 높은 초기 투자와 주요 배치 제조 요구 사항으로 인해 저비용 프로그래머블 자동화에 대한 필요성이 증가했습니다. LCA 기술은 기존 장비, 도구 및 방법을 중심으로 시장에서 쉽게 구할 수 있는 표준 장비를 주로 사용하여 어느 정도의 자동화를 생성하므로 자동화와 관련된 다양한 문제를 해결하는 데 가장 칭찬할 만한 기술 중 하나로 간주됩니다.

4. 연구 요약:

연구 주제의 배경:

제조업, 특히 중력 주조 공정에서 수동 작업은 생산성, 품질 일관성, 비용 효율성 측면에서 한계에 직면해 있습니다. 이를 극복하기 위한 효과적인 전략으로 저비용 자동화(LCA)가 주목받고 있으며, PLC는 이를 구현하기 위한 핵심 제어 장치로 부상하고 있습니다.

이전 연구 현황:

과일 포장, 밸브 스위칭 등 다양한 분야에서 PLC를 활용한 저비용 자동화 연구가 수행되었으나, 재래식 중력 주조 공정의 자동화에 대한 연구는 상대적으로 부족했습니다. 기존에는 릴레이 로직 시스템이 널리 사용되었지만, 마이크로컨트롤러, 특히 PLC의 등장으로 더 유연하고 효율적인 제어가 가능해졌습니다.

연구 목적:

본 연구의 목적은 PLC 프로그래밍을 활용하여 재래식 중력 주조 공정을 자동화하는 저비용 솔루션을 개발하는 것입니다. 이를 통해 일관된 공정, 장비 활용도 향상, 노동력 감소, 작업 환경 개선, 시간 및 비용 절감을 달성하여 궁극적으로 생산성을 향상시키는 것을 목표로 합니다.

핵심 연구:

연구의 핵심은 SIEMENS S7300PLC를 사용하여 중력 주조 공정의 전체 시퀀스(도가니 이동, 용탕 주입, 코어 분리, 제품 취출 등)를 제어하는 시스템을 설계하는 것입니다. 이를 위해 각 동작에 필요한 공압 실린더, 그리퍼, 로터리 액추에이터의 사양을 계산하고, 각 동작의 소요 시간을 정밀하게 산출하여 전체 사이클 타임을 최적화했습니다.

5. 연구 방법론

연구 설계:

본 연구는 중력 주조 공정의 자동화를 위한 시스템 설계 및 시뮬레이션 방식을 채택했습니다. PLC를 중앙 제어 장치로 설정하고, 공압 액추에이터들을 사용하여 물리적 동작을 구현하는 순차 제어 시스템을 설계했습니다. 각 액추에이터의 기계적 요구사항(필요 힘, 이동 거리)을 계산하여 적절한 사양을 결정했습니다.

데이터 수집 및 분석 방법:

데이터는 이론적 계산을 통해 수집되었습니다. 각 실린더가 움직여야 할 부품의 무게를 바탕으로 필요한 추력을 계산하고, 공급 공기 압력(6bar)을 적용하여 실린더의 보어 직경과 피스톤 로드 직경을 산출했습니다. 이후, 표준 공식을 사용하여 각 실린더의 전진 및 후진 스트로크에 소요되는 시간을 계산했습니다. 이 시간들을 합산하여 전체 사이클 타임을 도출했습니다. 제안된 시스템의 정확성과 기능성은 표준 부품을 사용한 트레이너 보드에서의 테스트 및 시뮬레이션을 통해 검증되었습니다.

연구 주제 및 범위:

본 연구는 중력 주조 공정의 자동화에 국한됩니다. 연구 범위는 PLC 프로그램을 사용한 순차 제어 로직 설계, 공압 시스템(실린더, 밸브, 그리퍼)의 사양 계산, 그리고 전체 자동화 사이클의 시간 분석을 포함합니다.

6. 주요 결과:

주요 결과:

  • PLC 프로그래밍을 통해 중력 주조 공정의 완전 자동화 시퀀스를 성공적으로 설계 및 구현했습니다.
  • 각 공압 실린더 및 액추에이터의 구동에 필요한 힘을 계산하여 최적의 보어 직경, 스트로크 길이 등 기계적 사양을 도출했습니다.
  • 전체 자동화 사이클에 소요되는 총 시간은 152.53초(2.54분)로 계산되었으며, 이는 기존 수동 방식에 비해 현저한 시간 단축을 의미합니다.
  • 제안된 시스템은 PLC 프로그램 시뮬레이션 및 트레이너 보드를 통한 테스트에서 원하는 정확도로 완벽하게 작동함을 확인했습니다.
Fig2. PLC Relay set up
Fig2. PLC Relay set up

Figure 목록:

  • Fig.1 Set up of gravity die casting for automation
  • Fig2. PLC Relay set up

7. 결론:

특히 중소 규모 산업에서 공압 및 유압 액추에이터와 같은 간단한 장치를 전기 제어와 함께 사용하는 저비용 자동화 접근 방식은 기존의 재래식 방법을 자동화하여 낮은 비용으로 더 높은 생산성을 달성할 수 있게 합니다. 공정을 자동화함으로써 작업자의 노력을 줄이고 시간을 절약하여 의사 결정에 활용할 수 있습니다. PLC를 사용한 주조 공정 자동화는 경제적일 뿐만 아니라 시간도 절약됩니다. 총 소요 시간은 기존 방식보다 훨씬 짧습니다. PLC 프로그래밍은 적은 기술과 유지보수가 필요하므로 어떠한 변경에도 충분히 유연하게 대처할 수 있습니다.

8. 참고 문헌:

  1. Mohan Yashvant Khire, S.D. Madnaik, Folding cartons using low cost automation – a case study., Assembly Automation., Vol: 21, pp: 210 – 212., MCB UP Ltd 2001.
  2. Vivek A. Bandebuche, D. J. Tidke “Parts Handling Systems for Machine Shops of Small and Medium Enterprises”, Proceedings of the 14th IEEE international conference on Emerging technologies & factory automation, p.1221-1225, September 22-25, 2009, Palma de Mallorca, Spain
  3. Groover M. P., Automation, Production Systems, and Computer Integrated Manufacturing, 3rd Edition: PHI 2008.
  4. Ahuja D., Chaudhary N.,” Programmable Logic Controller,” In International Journal Of Information And Computer Science, 2012
  5. S. Joe Qin, and Thomas A. Badgwell; “A survey of industrial model predictive control technology”, Control Engineering Practice 11 pp. 733–764 (2003)
  6. K. Furuta, “Super mechano-systems: fusion of control and mechanism”, plenary paper, Prepr. 15th IFAC World Congress, (Volume with Plenary Papers, Survey Papers and Milestones), Barcelona, Spain (2002) pp. 35-44.
  7. IEC International Standard 1131-3, Programmable Controllers, Part 3, Programming Languages, 1993.
  8. Teresa Deveza, J. F. Martins, PLC control and Matlab/Simulink simulations: a translation approach, Proceedings of the 14th IEEE international conference on Emerging technologies & factory automation, p.1221-1225, September 22-25, 2009, Palma de Mallorca, Spain
  9. S. Brian Morriss, Automated Manufacturing Systems: Actuators, Controls, Sensors, and Robotics, Glencoe/McGraw-Hill, 1994
  10. SHOJIMA TOSHIKI(Idemitsu Kosan Co., Ltd., Chiba Refinery, JPN), Application of low cost automation in refinery off-site job (No.3)., Application of DCS control Idemitsu Technical Report . VOL : 46 ; pp: 123-128., 2003.
  11. M. Chmiel, E. Hrynkiewicz, M. Muszynski, “The way of ladder diagram analysis for small compact programmable controller”, Proceedings of the 6th Russian-Korean International Symposium on Science and Technology KORUS-2002, pp. 169-173, 2002.

전문가 Q&A: 자주 묻는 질문에 대한 답변

Q1: 이 자동화 프로젝트에서 전통적인 릴레이 로직 시스템 대신 PLC(프로그래머블 로직 컨트롤러)를 선택한 이유는 무엇입니까?

A1: 논문에 따르면, 릴레이 로직 시스템이 산업 현장에서 널리 사용되어 왔지만 PLC는 그 인기가 급속히 증가하고 있는 마이크로컨트롤러입니다. PLC는 복잡한 순차 릴레이 회로를 대체하며, 프로그램을 통해 입력(센서)과 출력(액추에이터)을 유연하게 연결하여 원하는 작업 순서를 쉽게 구현할 수 있는 장점이 있기 때문에 선택되었습니다.

Q2: 논문에서 언급된 ‘저비용 자동화(LCA)’는 제안된 시스템에서 어떻게 구현되었습니까?

A2: 저비용 자동화는 완전히 새로운 맞춤형 기계에 투자하는 대신, 기존 장비 주변에 표준화되고 상대적으로 저렴한 부품을 사용하여 자동화를 구현하는 것을 의미합니다. 이 연구에서는 리미트 스위치, 솔레노이드 밸브, 공압 액추에이터와 같은 간단한 장치들을 PLC로 제어함으로써 저비용 자동화를 달성했습니다.

Q3: 연구에서 공압 실린더의 특정 치수와 작동 시간은 어떻게 결정되었습니까?

A3: 연구진은 각 실린더가 이동시켜야 하는 부품의 무게(예: 실린더 A는 40kg, 실린더 B는 30kg)를 기반으로 필요한 추력을 계산했습니다. 이 힘과 공급 압력(6bar)을 사용하여 실린더 보어 직경(D)과 피스톤 로드 직경(d)을 산출했습니다. 그 후, 스트로크 길이(L), 직경, 공기 압력을 포함하는 표준 공식을 사용하여 각 스트로크에 소요되는 시간을 계산했습니다.

Q4: 이 자동화 시스템으로 달성한 총 사이클 타임은 얼마이며, 수동 방식과 비교하면 어떻습니까?

A4: 하나의 완전한 사이클에 대해 계산된 총 시간은 152.53초, 즉 2.54분이었습니다. 논문에서는 이 시간이 “전통적인 방법으로 소요되는 시간보다 훨씬 짧다”고 결론 내리고 있어, 생산성 측면에서 상당한 개선이 이루어졌음을 알 수 있습니다.

Q5: 시스템이 “트레이너 보드”에서 테스트되었다는 것은 이 솔루션의 산업 현장 적용 준비 상태에 대해 무엇을 의미합니까?

A5: 트레이너 보드에서 표준 부품을 사용하여 테스트했다는 것은 PLC 프로그램의 로직과 시퀀스의 기능성이 성공적으로 검증되었음을 의미합니다. 이는 개념 증명(Proof of Concept)이 완료되었으며, 타이머의 정확성도 확인되었음을 보여줍니다. 실제 산업 현장에 적용하기 위해서는 물리적 설비를 실제 다이캐스팅 기계에 맞게 확장하고 통합하는 과정이 필요하지만, 제어 로직과 부품 사양은 성공적으로 검증된 것입니다.


결론: 더 높은 품질과 생산성을 향한 길

본 연구는 PLC 프로그래밍을 활용한 중력 주조 자동화가 수동 공정의 생산성 및 품질 일관성 문제를 효과적으로 해결할 수 있음을 명확히 보여주었습니다. 계산된 2.54분의 사이클 타임은 생산 효율성을 극대화할 수 있는 중요한 돌파구입니다. 이 접근법은 특히 중소 규모의 주조 업체에게 현대화를 위한 실용적이고 경제적인 경로를 제시합니다.

STI C&D는 최신 산업 연구를 적용하여 고객이 더 높은 생산성과 품질을 달성할 수 있도록 최선을 다하고 있습니다. 이 논문에서 논의된 과제가 귀사의 운영 목표와 일치한다면, 저희 엔지니어링 팀에 연락하여 이러한 원칙을 귀사의 부품에 어떻게 구현할 수 있는지 논의해 보십시오.

(주)에스티아이씨앤디에서는 고객이 수치해석을 직접 수행하고 싶지만 경험이 없거나, 시간이 없어서 용역을 통해 수치해석 결과를 얻고자 하는 경우 전문 엔지니어를 통해 CFD consulting services를 제공합니다. 귀하께서 당면하고 있는 연구프로젝트를 최소의 비용으로, 최적의 해결방안을 찾을 수 있도록 지원합니다.

  • 연락처 : 02-2026-0450
  • 이메일 : flow3d@stikorea.co.kr

저작권 정보

  • 이 콘텐츠는 “Ishrat Meera Mirzana 외”의 논문 “UTILIZATION OF PLC PROGRAMMING FOR GRAVITY DIE CASTING AUTOMATION”을 기반으로 한 요약 및 분석 자료입니다.
  • 출처: http://www.ijret.org

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Fig. 6: Calculated degassing efficiency as a function of bubble size [40]

고강도 경량 주조품의 미래: 용탕 성분 및 청정도 제어의 모범 사례

이 기술 요약은 Qigui Wang이 작성하여 2014년 CHINA FOUNDRY에 발표한 학술 논문 “Best practices for making high integrity lightweight metal castings – molten metal composition and cleanliness control”을 기반으로 합니다. 이 자료는 STI C&D에 의해 기술 전문가들을 위해 분석 및 요약되었습니다.

키워드

  • Primary Keyword: 고강도 경량 주조품
  • Secondary Keywords: 용탕 청정도, 합금화, 미량 원소, 주조 결함, 피로 성능, 알루미늄 주조

Executive Summary

  • The Challenge: 경량 금속 주조품의 기계적 특성, 특히 피로 성능은 기공 및 산화막과 같은 내부 결함의 크기와 분포에 의해 크게 좌우되어 제품의 신뢰성을 저하시킵니다.
  • The Method: 본 연구는 고강도 경량 금속 주조품을 생산하기 위해 용탕의 성분 제어, 미량 원소 관리, 용탕 청정도 확보 및 금형 충전 과정에서의 모범 사례를 제시합니다.
  • The Key Breakthrough: 스트론튬(Sr), 인(P), 철(Fe)과 같은 미량 원소의 정밀한 제어와 효율적인 가스 제거(degassing) 및 비난류 충전 기술의 결합이 결함 발생을 최소화하는 핵심임을 규명했습니다.
  • The Bottom Line: 주조품의 피로 수명을 획기적으로 향상시키기 위해서는 초기 합금 설계부터 최종 금형 충전에 이르기까지, 결함의 근원인 이중 산화막(bifilm) 생성을 억제하는 통합적인 공정 관리가 필수적입니다.

The Challenge: Why This Research Matters for CFD Professionals

자동차 산업을 중심으로 연료 효율 개선을 위한 경량화 요구가 증가하면서 엔진 블록, 실린더 헤드, 섀시 부품 등에서 경량 금속 주조품의 사용이 급증하고 있습니다. 이러한 부품들은 구조적 안정성이 매우 중요하며, 특히 피로 성능이 제품의 성공을 좌우합니다. 그러나 알루미늄 및 마그네슘 주조품의 기계적 특성은 미세한 결함에 매우 민감합니다. 특히 기공이나 산화막과 같은 결함은 피로 균열의 시작점이 되어 제품 수명을 현저히 단축시킵니다(그림 1 참조). 결함이 없는 경우, 피로 균열은 공정 입자나 슬립 밴드에서 시작되어 훨씬 높은 피로 수명을 보입니다. 따라서 고강도, 고신뢰성 주조품을 생산하기 위해서는 주조 결함을 최소화하고 미세조직을 균일하게 제어하는 것이 업계의 핵심 과제입니다.

The Approach: Unpacking the Methodology

본 논문은 고강도 경량 금속 주조품 생산을 위한 종합적인 모범 사례를 제시합니다. 연구는 크게 두 가지 핵심 영역에 초점을 맞춥니다.

  1. 합금 및 미량 원소 제어: 주조 공정과 최종 제품의 요구사항(강도, 내압성, 내식성 등)에 맞는 합금 선택의 중요성을 강조합니다. 특히, 알루미늄-실리콘(Al-Si) 합금에서 미세조직 개선을 위한 그레인 미세화(Ti, B 첨가)와 공정 실리콘 개질(Sr 첨가) 기술을 분석합니다. 또한, 피로 성능에 악영향을 미치는 철(Fe), 인(P), 비스무트(Bi)와 같은 미량 불순물 원소의 제어 기준과 상호작용을 정량적으로 제시합니다.
  2. 용탕 품질 보증: 주조 결함의 대부분이 용탕 내 개재물과 용존 가스에서 비롯된다는 점에 주목합니다. 용탕의 산화 및 수소 가스 흡수 메커니즘을 설명하고(방정식 1, 2, 3), 이를 제어하기 위한 회전식 가스 제거(rotary degassing) 시스템의 원리와 최적 운용 조건을 분석합니다. 또한, 용탕 품질을 현장에서 평가하는 RPT(Reduced Pressure Test) 방법의 정확한 절차를 소개하며, 최종적으로 금형 충전 시 이중 산화막(bifilm) 생성을 억제하기 위한 비난류 충전 기술의 중요성을 강조합니다.
Fig. 2: SEM image showing crack initiation from twin
bands in NZ30K1-T4 Mg alloy [24]
Fig. 2: SEM image showing crack initiation from twin bands in NZ30K1-T4 Mg alloy [24]

The Breakthrough: Key Findings & Data

본 연구는 고품질 주조품 생산을 위해 반드시 관리해야 할 핵심 요소들을 데이터와 함께 명확히 제시합니다.

Finding 1: 미량 원소의 상호작용과 정밀 제어의 중요성

스트론튬(Sr)에 의한 공정 실리콘 개질은 연성을 향상시키는 데 효과적이지만, 인(P)의 존재는 그 효과를 크게 저해합니다. 그림 3은 Al-7%Si 합금에서 원하는 공정 구조(미세한 섬유상)를 얻기 위해 필요한 Sr 농도가 P 농도에 따라 어떻게 변하는지를 명확히 보여줍니다. 예를 들어, P가 거의 없는 상태에서는 약 20ppm의 Sr만으로도 충분하지만, P 농도가 10ppm으로 증가하면 약 50ppm의 Sr이 필요합니다. 이는 P가 Sr의 효과를 무력화시키기 때문이며, 고품질 주조를 위해서는 P 농도를 엄격히 관리하거나 P 농도에 맞춰 Sr 첨가량을 조절해야 함을 시사합니다. 또한, 철(Fe)은 주조성과 연성을 저해하는 주요 불순물로, 그 임계 함량(Fecrit ≈ 0.075 × [%Si] – 0.05) 이하로 관리해야 하며, 망간(Mn)을 첨가하여 그 효과를 중화시키는 방법도 있지만 항상 효과적인 것은 아니라고 지적합니다.

Finding 2: 용탕 청정도 확보를 위한 과학적 접근

용탕 내 용존 수소는 응고 시 기공 결함의 주원인이 됩니다. 그림 5는 온도가 높을수록 수소의 용해도가 기하급수적으로 증가함을 보여주며, 이는 가스 제거 공정을 가능한 한 낮은 온도에서 수행해야 함을 의미합니다. 그림 7은 A357 합금에서 가스 제거 시간에 따른 수소 함량 변화를 보여주는데, 1450°F(788°C)보다 1350°F(732°C)에서 훨씬 빠르고 효율적으로 가스가 제거됨을 확인할 수 있습니다. 또한, 금형 충전 시 용탕의 낙하 속도가 임계 속도(알루미늄의 경우 약 0.5 m/s)를 초과하면 표면이 접히면서 이중 산화막(bifilm)이 생성됩니다. 이 임계 속도에 도달하는 낙하 거리는 불과 12.7mm에 불과하여, 일반적인 주입 방식은 거의 필연적으로 결함을 유발함을 의미합니다. 이는 비난류 충전 방식(예: 저압 주조, 코스워스 공정)의 도입이 고강도 주조품 생산에 필수적임을 뒷받침합니다.

Practical Implications for R&D and Operations

  • For Process Engineers: 이 연구는 가스 제거 공정 시 용탕 온도를 최대한 낮게 유지하고, 가스 유량과 임펠러 회전 속도를 최적화하여 미세한 기포를 균일하게 분산시키는 것이 중요함을 시사합니다. 또한, 용탕 이송 및 주입 시 낙하 거리를 최소화하고 비난류 충전 시스템을 도입하여 이중 산화막 생성을 원천적으로 차단하는 것이 결함 감소에 기여할 수 있습니다.
  • For Quality Control Teams: 논문에서 제시된 RPT(Reduced Pressure Test)의 표준 절차를 활용하여 용탕의 가스 및 개재물 수준을 정량적으로 관리할 수 있습니다. 그림 3의 데이터는 Sr과 P의 농도 분석 결과를 바탕으로 공정 실리콘 개질 수준을 예측하고, 잠재적인 기계적 물성 저하를 사전에 파악하는 데 유용한 기준을 제공합니다.
  • For Design Engineers: 합금 선택이 주조성 및 결함 형성에 미치는 영향을 초기 설계 단계부터 고려해야 합니다. 예를 들어, 200 시리즈 알루미늄 합금은 강도는 높지만 응고 범위가 넓어 열간 균열 경향이 크다는 점을 인지하고, 이를 보완할 수 있는 주조 방안 설계를 고려해야 합니다.

Paper Details


Best practices for making high integrity lightweight metal castings – molten metal composition and cleanliness control

1. Overview:

  • Title: Best practices for making high integrity lightweight metal castings – molten metal composition and cleanliness control
  • Author: Qigui Wang
  • Year of publication: 2014
  • Journal/academic society of publication: CHINA FOUNDRY, Vol.11 No.4
  • Keywords: best practices; high integrity casting; lightweight; metal casting; molten metal cleanliness; alloying; trace element

2. Abstract:

고강도 경량 금속 주조품을 만들기 위해서는 액체 금속 성분 및 품질 관리, 주조 및 탕구/압상 시스템 설계, 공정 최적화를 포함한 주조 및 열처리 공정의 다양한 단계에서 모범 사례가 요구됩니다. 이 논문은 용해 및 금형 충전 모두에서 액체 금속 처리 및 용탕 품질 보증을 위한 모범 사례를 제시합니다. 경량 금속 주조의 다른 측면에 대한 모범 사례는 별도로 발표될 것입니다.

3. Introduction:

연료 효율 향상을 위한 자동차 무게 감량 요구가 증가함에 따라 엔진 블록, 실린더 헤드, 흡기 매니폴드, 브래킷, 하우징, 섀시, 변속기 부품 및 서스펜션 시스템을 포함한 자동차 부품에서 경량 금속 주조품의 적용이 계속 증가하고 있습니다. 이러한 적용 분야의 대부분은 중요한 구조 부품이므로, 주조품의 기계적 특성, 특히 피로 성능이 성공에 매우 중요합니다. 경량 금속 주조품의 기계적 특성은 결함 및 다중 스케일 미세 구조의 크기, 양 및 분포에 크게 의존합니다. 알루미늄 주조품에서 결함의 부피 분율은 인장 거동을 지배하는 반면, 동적 하중에서는 피로 성능을 제어하는 것은 결함 크기(기공 및 산화막)입니다. 결함 크기를 줄이면 피로 특성이 향상됩니다. 기공과 산화막이 임계 크기보다 작아지면, 균열/분리된 공정 입자와 알루미늄 매트릭스의 지속적인 슬립 밴드가 피로 균열 개시 부위가 되어 피로 수명이 크게 증가합니다.

4. Summary of the study:

Background of the research topic:

자동차 및 기타 산업에서 경량화 요구가 증가함에 따라 고강도 및 고신뢰성을 갖춘 경량 금속 주조품의 필요성이 대두되었습니다.

Status of previous research:

기존 연구들은 주조 결함(기공, 산화막 등)이 주조품의 기계적 특성, 특히 피로 수명을 결정하는 주요 요인임을 밝혀냈습니다. 결함의 크기를 줄이면 피로 성능이 향상된다는 것이 알려져 있습니다.

Purpose of the study:

이 연구의 목적은 용탕의 성분 제어부터 금형 충전에 이르기까지, 고강도 경량 금속 주조품을 생산하기 위한 체계적인 모범 사례를 제시하여 산업 현장에서의 품질 향상에 기여하는 것입니다.

Core study:

연구는 두 가지 핵심 분야에 중점을 둡니다: (1) 합금 성분 및 미량 원소의 정밀 제어를 통한 미세조직 최적화, (2) 용탕 처리(가스 제거, 정련) 및 비난류 금형 충전을 통한 용탕 청정도 확보. 이를 통해 주조 결함의 근본적인 원인을 제거하는 방법을 탐구합니다.

5. Research Methodology

Research Design:

본 연구는 기존의 학술 연구, 기술 보고서 및 현장 경험을 종합하여 고강도 경량 주조품 생산을 위한 모범 사례를 체계적으로 정리하고 제시하는 문헌 연구 및 기술 리뷰 방식으로 수행되었습니다.

Data Collection and Analysis Methods:

다양한 연구에서 발표된 실험 데이터, 그래프, 미세조직 사진 등을 인용하고 분석하여 각 공정 변수가 주조 품질에 미치는 영향을 설명합니다. 예를 들어, 합금 원소의 상호작용(그림 3), 온도에 따른 수소 용해도(그림 5), 가스 제거 효율(그림 7) 등의 데이터를 활용하여 이론적 배경과 실제적 지침을 연결합니다.

Research Topics and Scope:

연구 범위는 경량 금속 주조(주로 알루미늄 및 마그네슘 합금) 공정 중 용탕 준비 및 이송 단계에 초점을 맞춥니다. 주요 주제는 다음과 같습니다. – 합금화 및 미량 원소 제어 (Al-Si 합금 중심) – 용탕 품질 보증 (산화물 및 용존 가스 제어) – 이중 산화막(bifilm) 생성을 피하기 위한 금속 이송 기술

6. Key Results:

Key Results:

  • 주조품의 피로 수명은 기공, 산화물, 슬립 밴드 등 균열 시작점에 따라 크게 달라지며, 결함에서 시작될 경우 현저히 낮아집니다 (그림 1).
  • Al-Si 합금에서 공정 실리콘을 효과적으로 개질하기 위해 필요한 스트론튬(Sr)의 양은 인(P)의 농도에 따라 증가합니다. P는 Sr의 개질 효과를 중화시킵니다 (그림 3).
  • 용탕의 산화 속도는 마그네슘(Mg)과 스트론튬(Sr) 첨가에 의해 크게 증가합니다 (그림 4).
  • 알루미늄 용탕 내 수소의 용해도는 온도가 증가함에 따라 지수적으로 증가하여, 고온에서는 가스 제거가 더 어려워집니다 (그림 5).
  • 가스 제거 효율은 기포의 크기가 작을수록 향상됩니다 (그림 6).
  • 용탕 온도가 낮을수록 가스 제거에 필요한 시간이 단축되어 더 효율적입니다 (그림 7).
  • 용탕이 임계 속도(알루미늄 약 0.5 m/s) 이상으로 낙하하면 표면 난류가 발생하여 이중 산화막(bifilm)을 형성하며, 이는 매우 짧은 낙하 거리(약 12.7 mm)에서도 발생할 수 있습니다.

Figure List:

  • Fig. 1: Two-parameter Weibull plot for fatigue life of a Sr-modified A356 casting alloy sorted by type of crack origin (pore, oxides, or slip bands) observed on fracture
  • Fig. 2: SEM image showing crack initiation from twin bands in NZ30K1-T4 Mg alloy
  • Fig. 3: Sr and P interaction in Al-7%Si alloy when solidification time is 60 s
  • Fig. 4: Thermogravimetric analysis of oxidation rate of aluminum alloy (Al-7%Si) with or without Mg and Sr addition at 730 °C
  • Fig. 5: Hydrogen solubility in pure aluminum
  • Fig. 6: Calculated degassing efficiency as a function of bubble size
  • Fig. 7: Gas removal in A357 alloy at two temperatures
  • Fig. 8: Degassing locations used in both pilot plant and production plant at Nemak
  • Fig. 9: An SEM picture of aluminum oxide film draped over dendrite tips in a 380 alloy
  • Fig. 10: An SEM picture of magnesium oxide film initiated fatigue crack in a NZ30K1 Mg alloy
  • Fig. 11: Cosworth counter-gravity casting process

7. Conclusion:

금속 주조품의 기계적 특성, 특히 피로 성능은 주조 결함에 의해 지배되며, 미세 구조의 영향은 그보다 훨씬 적습니다. 따라서 고강도 금속 주조에서는 주조 결함을 제거해야 합니다(또는 적어도 결함 크기를 기계적 특성에 영향을 미치지 않는 임계 크기보다 작은 수준으로 줄여야 합니다).

(1) 합금 조성, 특히 미량 원소 함량의 적절한 선택 및 제어는 고강도 금속 주조를 위한 첫 번째 단계입니다. 이는 합금 조성이 결함 및 미세 구조 형성을 제어하는 합금의 열물리적 특성 및 응고 특성을 결정하기 때문입니다. 가능하면 기계적 특성 요구사항을 충족시키면서 최상의 주조성(최소 응고 범위, 낮은 수축 경향, 높은 공급 능력 등)을 달성하기 위해 합금 조성을 최적화해야 합니다.

(2) 주조 결함의 형성은 용탕 청정도와 밀접한 관련이 있습니다. 따라서 액체 금속은 가능한 최고 수준으로 정련되어야 합니다. 즉, 산화물 개재물과 용존 가스가 응고 중에 주조 결함을 일으키지 않을 지점까지 최소화되어야 합니다. 개재물과 용존 가스는 부상, 침강, 여과 등 다양한 방법으로 줄일 수 있습니다. 가장 효과적인 접근법은 불활성 가스나 활성 가스 플럭스를 주입하여 개재물과 용존 가스를 동시에 줄일 수 있는 부상법입니다. 최상의 결과를 얻으려면 용탕 온도, 기포 크기, 기포 수 및 분포, 버블링 위치를 최적화해야 합니다.

(3) Campbell의 주장을 인용하자면, 액체 금속의 ‘주입(pouring)’을 중단해야 할 필요성이 점점 더 시급해지고 있습니다. 주입은 다공성, 열간 균열 등 많은 주조 결함의 근본 원인인 혼입된 이중 산화막(bifilm)의 주요 원천입니다. 격자 전위가 소성을 설명하듯이, 이중 산화막은 기공 개시 및 파괴 개시를 설명합니다. 주입이 최소화될 때(즉, 이중 산화막이 감소하거나 제거될 때) 비로소 주조 공정은 고강도 및 신뢰성 있는 주조품을 제공하는 잠재력을 달성하기 시작할 것입니다.

Fig. 6: Calculated degassing efficiency as a function
of bubble size [40]
Fig. 6: Calculated degassing efficiency as a function of bubble size [40]

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Expert Q&A: Your Top Questions Answered

Q1: Sr-개질 합금에서 인(P)과 비스무트(Bi) 같은 미량 원소를 제어하는 것이 왜 그렇게 중요한가요?

A1: 논문에 따르면, 인(P)과 비스무트(Bi)는 스트론튬(Sr)의 공정 실리콘 개질 효과를 중화시키는 역할을 합니다. Sr은 뾰족한 침상 형태의 공정 실리콘을 미세한 섬유상으로 바꿔 연성을 향상시키는데, P나 Bi가 존재하면 이 효과가 상쇄되어 다시 조대한 침상 구조로 돌아가게 됩니다. 그림 3에서 볼 수 있듯이, P 농도가 높아질수록 동일한 개질 효과를 얻기 위해 훨씬 더 많은 양의 Sr이 필요합니다. 따라서 일관된 기계적 특성을 가진 고품질 주조품을 생산하기 위해서는 이들 미량 원소를 엄격하게 제어하는 것이 필수적입니다.

Q2: 논문에서 언급된 “임계 철 함량(critical iron content)”은 어떻게 계산되며, 왜 중요한가요?

A2: 임계 철 함량은 Al-Si 합금에서 연성을 심각하게 저하시키지 않는 철(Fe)의 최대 허용 수준을 의미합니다. 논문에서는 이 값을 Fecrit ≈ 0.075 × [%Si] - 0.05 라는 경험식으로 계산할 수 있다고 제시합니다. 철은 응고 시 취성이 큰 침상의 금속간화합물을 형성하여 주조품의 연성과 인성을 저해하고, 수축 기공을 유발하는 원인이 됩니다. 이 임계 함량을 초과하면 이러한 부정적인 영향이 극대화되므로, 고강도 주조품 생산을 위해서는 원자재 선택 단계부터 철 함량을 이 기준 이하로 관리하는 것이 매우 중요합니다.

Q3: 알루미늄 용탕을 효과적으로 가스 제거(degassing)하는 가장 좋은 방법은 무엇이며, 핵심 운영 변수는 무엇인가요?

A3: 논문은 회전식 가스 제거(rotary degassing)가 가장 효율적인 방법 중 하나라고 설명합니다. 이 방법의 핵심은 불활성 가스를 용탕 내에 미세한 기포 형태로 분산시켜 수소 가스가 이 기포로 확산되어 제거되도록 하는 것입니다. 최상의 결과를 얻기 위한 핵심 변수는 (1) 가능한 낮은 용탕 온도, (2) 작은 기포 크기(직경 2-3mm 이하), (3) 용탕 표면의 와류(vortex)를 유발하지 않는 적절한 임펠러 회전 속도 및 가스 유량입니다. 특히 온도가 낮을수록 수소 용해도가 낮아져 제거 효율이 높아지므로(그림 5, 7 참조), 가스 제거는 가능한 한 낮은 온도에서 수행해야 합니다.

Q4: “이중 산화막(bifilm)”이란 무엇이며, 왜 주조품 특성에 그렇게 해로운가요?

A4: 이중 산화막은 용탕이 공기와 접촉하여 표면에 형성된 산화막이 난류로 인해 용탕 내부로 말려 들어가면서 생성되는, 두 겹으로 접힌 산화막 결함입니다. 이 막의 내부는 서로 붙어있지 않고 건조한 상태여서 매우 약한 계면을 형성합니다. 이것이 응고 과정에서 수축 압력에 의해 쉽게 벌어져 기공의 핵이 되거나, 외부 하중을 받을 때 균열의 시작점으로 작용하여 피로 수명을 급격히 감소시킵니다. 논문은 이 이중 산화막이 다공성, 열간 균열 등 대부분의 주조 결함의 근본 원인이라고 강조합니다.

Q5: 용탕 이송 시 “임계 속도(critical velocity)”라는 개념이 언급되었습니다. 알루미늄의 경우 이 값은 얼마이며, 주조 공정에 어떤 의미를 가지나요?

A5: 임계 속도는 용탕의 표면이 접히면서 이중 산화막을 형성하기 시작하는 유속을 의미합니다. 논문에 따르면 알루미늄 및 마그네슘 합금의 경우 이 임계 속도는 약 0.5 m/s입니다. 더 중요한 것은, 용탕이 자유 낙하할 때 이 속도에 도달하는 데 필요한 거리가 불과 12.7mm라는 점입니다. 이는 일반적인 주입(pouring) 공정에서는 거의 피할 수 없이 난류가 발생하고 이중 산화막이 생성됨을 의미합니다. 따라서 고강도 경량 주조품을 생산하기 위해서는 용탕을 붓는 대신, 저압 주조나 코스워스 공정과 같이 용탕을 아래에서부터 조용히 채워 올리는 비난류 충전 방식을 채택하는 것이 필수적입니다.


Conclusion: Paving the Way for Higher Quality and Productivity

본 연구는 결함이 없는 고강도 경량 주조품을 생산하기 위해서는 단편적인 공정 개선을 넘어, 용탕의 성분부터 최종 충전까지 전 과정을 아우르는 체계적인 접근이 필요함을 명확히 보여줍니다. 미량 원소의 정밀한 제어가 미세조직을 최적화하고, 과학적인 용탕 청정도 관리가 결함의 근원을 제거하며, 비난류 충전 기술이 최종적으로 완벽한 주조품을 완성하는 핵심 열쇠입니다. 이러한 모범 사례의 적용은 단순히 불량률을 낮추는 것을 넘어, 제품의 근본적인 신뢰성과 성능을 한 차원 높이는 결과를 가져올 것입니다.

(주)에스티아이씨앤디에서는 고객이 수치해석을 직접 수행하고 싶지만 경험이 없거나, 시간이 없어서 용역을 통해 수치해석 결과를 얻고자 하는 경우 전문 엔지니어를 통해 CFD consulting services를 제공합니다. 귀하께서 당면하고 있는 연구프로젝트를 최소의 비용으로, 최적의 해결방안을 찾을 수 있도록 지원합니다.

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  • This content is a summary and analysis based on the paper “Best practices for making high integrity lightweight metal castings – molten metal composition and cleanliness control” by “Qigui Wang”.
  • Source: CHINA FOUNDRY, Vol.11 No.4 July 2014, Article ID: 1672-6421(2014)04-365-10

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Figure 5. Ultimate tensile strength (UTS) and hardness of 2017 A Al alloy manufactured in various conditions.

스퀴즈 캐스팅 최적화: Taguchi 방법을 활용한 2017A 알루미늄 합금의 기계적 물성 극대화 방안

이 기술 요약은 Najib Souissi 외 저자들이 2014년 Metals 학술지에 게재한 논문 “Optimization of Squeeze Casting Parameters for 2017 A Wrought Al Alloy Using Taguchi Method”를 기반으로 하며, STI C&D의 기술 전문가에 의해 분석 및 요약되었습니다.

Keywords

  • Primary Keyword: 스퀴즈 캐스팅 최적화
  • Secondary Keywords: 2017A 알루미늄 합금, Taguchi 방법, 기계적 물성, 공정 변수, 고압 주조

Executive Summary

  • The Challenge: 스퀴즈 캐스팅은 우수한 알루미늄 합금 부품을 생산하지만, 최적의 기계적 특성을 달성하기 위해서는 가압 압력, 용탕 온도, 금형 온도와 같은 공정 변수에 대한 정밀한 제어가 필요합니다.
  • The Method: 본 연구는 Taguchi L9 직교 배열법을 사용하여 스퀴즈 압력, 용탕 온도, 금형 온도가 2017A 알루미늄 합금의 극한 인장 강도(UTS) 및 경도에 미치는 영향을 체계적으로 조사했습니다.
  • The Key Breakthrough: 스퀴즈 압력은 UTS와 경도 변화에 각각 83% 이상 기여하는 가장 지배적인 요인입니다. 압력을 15 MPa에서 90 MPa로 높이면 UTS는 46%, 경도는 58% 향상되었습니다.
  • The Bottom Line: 고성능 2017A 알루미늄 부품의 경우, 스퀴즈 압력을 극대화하는 것이 미세조직을 미세화하고 기계적 특성을 획기적으로 향상시키는 가장 효과적인 전략입니다.

The Challenge: Why This Research Matters for CFD Professionals

알루미늄 합금은 낮은 밀도, 우수한 성형성, 높은 열전도율 등 다양한 장점 덕분에 자동차, 항공우주 산업에서 핵심 소재로 사용되고 있습니다. 그러나 기존의 주조 방식은 수축 및 가스 기공과 같은 결함으로 인해 부품의 무결성과 기계적 특성을 저하시킬 수 있습니다.

스퀴즈 캐스팅(액상 단조)은 용융된 금속을 유압 프레스의 폐쇄된 금형 내에서 고압으로 응고시키는 공정으로, 이러한 한계를 극복할 수 있는 대안으로 주목받고 있습니다. 이 기술은 수축 및 기공을 효과적으로 제거하여 기계적 특성이 향상된 고품질 부품을 생산할 수 있습니다. 하지만 스퀴즈 캐스팅의 성공은 가압 압력, 용탕 온도, 금형 온도 등 여러 공정 변수들의 복잡한 상호작용에 따라 달라집니다. 이러한 변수들을 최적화하여 일관된 고품질을 달성하는 것은 제조 현장의 중요한 과제이며, 본 연구는 이 문제를 해결하기 위해 시작되었습니다.

The Approach: Unpacking the Methodology

본 연구는 최소한의 실험으로 공정 변수들의 영향을 효율적으로 평가하기 위해 통계적 설계 기법인 Taguchi 방법을 채택했습니다. 연구진은 2017A 단조 알루미늄 합금을 사용하여 스퀴즈 캐스팅 공정을 분석했습니다.

주요 공정 변수로는 스퀴즈 압력(A), 용탕 온도(B), 금형 온도(C)를 선정하고, 각 변수마다 3개의 수준(Level)을 설정했습니다. 실험은 L9 직교 배열표에 따라 총 9가지 조건 조합으로 수행되었으며, 각 조건마다 3개의 시편을 제작하여 결과의 정확성을 확보했습니다. 제작된 시편에 대해서는 극한 인장 강도(UTS)와 비커스 경도(HV)를 측정하여 기계적 특성을 평가했습니다. 수집된 데이터는 주 효과 분석, 분산 분석(ANOVA), 신호 대 잡음비(S/N ratio) 분석을 통해 각 변수가 기계적 특성에 미치는 영향의 정도와 최적의 공정 조건을 도출하는 데 사용되었습니다.

The Breakthrough: Key Findings & Data

Finding 1: 스퀴즈 압력이 기계적 물성을 지배하는 핵심 인자임이 입증되다

분산 분석(ANOVA) 결과, 스퀴즈 압력은 2017A 알루미늄 합금의 기계적 특성에 가장 결정적인 영향을 미치는 요인으로 밝혀졌습니다. Table 4와 Table 5에 따르면, 스퀴즈 압력(A)은 극한 인장 강도(UTS) 변화에 85.93%, 경도 변화에 83.06% 기여하는 것으로 나타났습니다. 이는 용탕 온도(B)와 금형 온도(C)의 기여도를 압도하는 수치로, 스퀴즈 캐스팅 공정에서 압력 제어의 중요성을 명확히 보여줍니다. Figure 3의 기여도 그래프는 이러한 결과를 시각적으로 뒷받침합니다.

Figure 3. Percentage contribution of significant control factors.
Figure 3. Percentage contribution of significant control factors.

Finding 2: 압력 증가는 미세조직 미세화와 기계적 강도 향상으로 직결되다

실험 결과, 스퀴즈 압력을 높일수록 기계적 특성이 획기적으로 향상되었습니다. Figure 5에서 볼 수 있듯이, 스퀴즈 압력을 15 MPa에서 90 MPa로 높였을 때 UTS는 150 MPa에서 219.66 MPa로 46% 증가했으며, 경도는 58%나 향상되었습니다. 이러한 개선은 압력 증가로 인한 미세조직의 변화와 직접적인 관련이 있습니다. Figure 4의 광학 현미경 사진은 압력이 높을수록 초정 α-상 덴드라이트가 더 미세하고 작아지는 것을 보여줍니다. 이는 높은 압력이 응고점 상승을 유발하여 과냉각도를 높이고, 합금과 금형 사이의 열전달을 촉진하여 냉각 속도를 증가시킨 결과입니다. 결과적으로 미세하고 치밀한 조직이 형성되어 기계적 강도가 크게 향상됩니다.

Practical Implications for R&D and Operations

  • For Process Engineers: 본 연구는 UTS와 경도를 극대화하기 위한 최적의 공정 조건으로 스퀴즈 압력 90 MPa, 용탕 온도 700°C, 금형 온도 200°C (A3 B1 C1)를 제시합니다. 이는 고강도 부품 생산을 위한 구체적인 가이드라인으로 활용될 수 있습니다.
  • For Quality Control Teams: Figure 5에서 확인된 스퀴즈 압력과 기계적 특성 간의 강력한 상관관계는 압력 모니터링 및 제어가 일관된 제품 품질을 보증하는 데 매우 중요함을 시사합니다. 또한, Figure 4의 미세조직 사진은 품질 평가를 위한 시각적 기준으로 활용될 수 있습니다.
  • For Design Engineers: 연구 결과는 스퀴즈 캐스팅이 기존 주조법에 비해 월등한 기계적 특성을 가진 부품을 생산할 수 있음을 확인시켜 줍니다. 이는 특히 고압 적용이 가능한 경우, 더 가볍고 강한 부품 설계를 가능하게 하여 제품 혁신의 기회를 제공합니다.

Paper Details


Optimization of Squeeze Casting Parameters for 2017 A Wrought Al Alloy Using Taguchi Method

1. Overview:

  • Title: Optimization of Squeeze Casting Parameters for 2017 A Wrought Al Alloy Using Taguchi Method
  • Author: Najib Souissi, Slim Souissi, Christophe Le Niniven, Mohamed Ben Amar, Chedly Bradai and Foued Elhalouani
  • Year of publication: 2014
  • Journal/academic society of publication: Metals
  • Keywords: 2017A Al alloy; squeeze casting parameters; Taguchi method; optimization; mechanical properties

2. Abstract:

이 연구는 Taguchi 방법을 적용하여 스퀴즈 캐스팅 2017A 단조 알루미늄 합금의 극한 인장 강도, 경도와 공정 변수 간의 관계를 조사합니다. 스퀴즈 압력, 용탕 온도, 금형 온도를 포함한 다양한 주조 변수들의 효과가 연구되었습니다. 따라서 스퀴즈 캐스팅 공정에 대한 Taguchi 방법의 목표는 공정 변수들의 최적 조합을 확립하고, 단 몇 번의 실험만으로 품질 변동을 줄이는 것입니다. 실험 결과는 스퀴즈 압력이 2017A 알루미늄 합금의 미세조직과 기계적 특성에 상당한 영향을 미친다는 것을 보여줍니다.

3. Introduction:

최근 알루미늄 및 그 합금은 낮은 밀도, 우수한 성형성, 높은 열전도율, 높은 비강성, 우수한 내식성, 높은 주조성 및 매력적인 인장 강도와 같은 다양한 장점 덕분에 높은 기술적 가치와 광범위한 산업 응용 분야로 인해 큰 주목을 받고 있습니다. 이러한 이유로 알루미늄 합금은 특히 주조 산업의 가장 중요한 산업 재료로 널리 사용됩니다. 한편, 이들은 기계, 자동차 및 항공우주 산업과 같은 다양한 분야에서 중요한 응용 기회를 제공합니다.

4. Summary of the study:

Background of the research topic:

알루미늄 합금은 자동차 및 항공우주 산업에서 경량화와 고성능을 동시에 만족시키기 위한 핵심 소재입니다. 스퀴즈 캐스팅은 기존 주조법의 한계인 기공 및 수축 결함을 극복하고, 기계적 특성을 향상시킬 수 있는 첨단 주조 기술입니다.

Status of previous research:

많은 연구에서 스퀴즈 캐스팅 공정 변수(가압 압력, 용탕 온도, 금형 온도)가 알루미늄 및 마그네슘 합금의 품질에 중요한 영향을 미친다고 보고했습니다. 압력 증가는 결정립 크기를 감소시키고 경도를 향상시키는 것으로 알려졌으나, 여러 변수들의 복합적인 영향을 효율적으로 최적화하는 연구는 여전히 필요합니다.

Purpose of the study:

본 연구의 목적은 Taguchi 방법을 사용하여 2017A 단조 알루미늄 합금의 스퀴즈 캐스팅 공정에서 최적의 변수 조합(가압 압력, 용탕 온도, 금형 온도)을 찾아내고, 최소한의 실험으로 기계적 특성(UTS, 경도)을 극대화하는 것입니다.

Core study:

Taguchi L9 직교 배열을 사용하여 9가지 실험 조건에서 2017A 알루미늄 합금을 스퀴즈 캐스팅하고, 각 조건에서 UTS와 경도를 측정했습니다. 분산 분석(ANOVA)과 신호 대 잡음비(S/N ratio) 분석을 통해 각 공정 변수가 기계적 특성에 미치는 영향의 크기를 정량화하고, 최적의 공정 조건을 도출했습니다. 또한, 스퀴즈 압력이 미세조직과 기계적 특성에 미치는 영향을 심층적으로 분석했습니다.

5. Research Methodology

Research Design:

본 연구는 3개의 공정 변수(스퀴즈 압력, 용탕 온도, 금형 온도)를 각각 3개의 수준으로 설정하고, Taguchi L9 (3³) 직교 배열 실험 설계를 사용했습니다. 이를 통해 전체 27가지 조합 대신 9가지 실험만으로 변수의 영향을 평가할 수 있었습니다.

Data Collection and Analysis Methods:

  • 시편 제작: 유압 프레스를 사용하여 각 실험 조건에 따라 스퀴즈 캐스팅 시편을 제작했습니다.
  • 기계적 특성 평가: 만능 시험기(INSTRON)를 사용하여 극한 인장 강도(UTS)를 측정하고, 비커스 경도 시험기(MEKTON)를 사용하여 경도(HV)를 측정했습니다.
  • 통계 분석: 측정된 데이터에 대해 주 효과 분석, 분산 분석(ANOVA), 신호 대 잡음비(S/N ratio) 분석을 수행하여 각 변수의 영향도와 최적 수준을 결정했습니다.

Research Topics and Scope:

  • 연구 대상: 2017A 단조 알루미늄 합금
  • 주요 변수:
    • A: 스퀴즈 압력 (30, 60, 90 MPa)
    • B: 용탕 온도 (700, 750, 800 °C)
    • C: 금형 온도 (200, 250, 300 °C)
  • 평가 항목: 극한 인장 강도(UTS), 경도(HV), 미세조직

6. Key Results:

Key Results:

  • 스퀴즈 압력은 UTS와 경도에 가장 큰 영향을 미치는 변수로, 각각 85.93%와 83.06%의 기여도를 보였습니다.
  • 기계적 특성을 극대화하는 최적의 공정 조건 조합은 스퀴즈 압력 90 MPa, 용탕 온도 700°C, 금형 온도 200°C (A3 B1 C1)로 나타났습니다.
  • 신호 대 잡음비(S/N ratio) 분석 결과, 목표값으로부터의 편차를 최소화하는 최적의 조합은 A3 B1 C3 (90 MPa, 700°C, 300°C)로 확인되었습니다.
  • 스퀴즈 압력을 15 MPa에서 90 MPa로 증가시켰을 때, UTS는 46%, 경도는 58% 향상되었습니다.
  • 압력 증가는 결정립 미세화를 유발하며, 이것이 기계적 특성 향상의 주된 원인임이 확인되었습니다.
Figure 5. Ultimate tensile strength (UTS) and hardness of 2017 A Al alloy manufactured in various conditions.
Figure 5. Ultimate tensile strength (UTS) and hardness of 2017 A Al alloy manufactured in various conditions.

Figure List:

  • Figure 1. Main effects graph for ultimate tensile strength (UTS).
  • Figure 2. Main effects graph for hardness.
  • Figure 3. Percentage contribution of significant control factors.
  • Figure 4. Optical micrographs of the squeeze cast sample (a) 15 MPa; (b) 30 MPa; (c) 60 MPa; and (d) 90 MPa applied pressure.
  • Figure 5. Ultimate tensile strength (UTS) and hardness of 2017 A Al alloy manufactured in various conditions.
  • Figure 6. Experimental setup of squeeze casting process.
  • Figure 7. Schematic representation of squeeze casting process.

7. Conclusion:

  1. 스퀴즈 압력 90 MPa, 용탕 온도 700°C, 금형 온도 200°C의 조합(A3 B1 C1)이 2017A 알루미늄 합금의 스퀴즈 캐스팅에서 더 높은 기계적 특성을 얻기 위해 권장됩니다.
  2. 분산 분석(ANOVA) 결과, 스퀴즈 압력, 용탕 온도, 금형 온도는 모두 유의미한 공정 변수로 확인되었으며, 특히 스퀴즈 압력의 기여도가 UTS와 경도에서 가장 컸습니다.
  3. 신호 대 잡음비(S/N ratio) 분석 결과, A3 B1 C3 조합이 목표값에 대한 편차를 최소화하면서 최적의 기계적 특성을 산출하는 것으로 나타났습니다.
  4. 미세조직의 미세화가 스퀴즈 캐스트 시편의 기계적 특성을 향상시키는 주된 이유였습니다.

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Expert Q&A: Your Top Questions Answered

Q1: 전체 요인 설계(Full Factorial Design) 대신 Taguchi 방법을 선택한 이유는 무엇인가요?

A1: 3개 변수와 3개 수준을 모두 조합하는 전체 요인 설계는 총 27번의 실험이 필요합니다. 논문에 따르면, Taguchi 방법의 L9 직교 배열을 사용하면 실험 횟수를 9번으로 크게 줄일 수 있습니다. 이는 시간과 비용을 절약하면서도 각 공정 변수가 기계적 특성에 미치는 영향을 효과적으로 분석하고 최적의 조건을 찾을 수 있게 해주는 효율적인 접근법입니다.

Q2: 주 효과 분석에서는 최적 조건이 A3 B1 C1로, S/N비 분석에서는 A3 B1 C3로 나타났습니다. 이 차이는 왜 발생하며, 어떤 것을 더 중요하게 고려해야 하나요?

A2: 주 효과 분석은 UTS나 경도 같은 반응치의 ‘평균’을 최대화하는 데 초점을 맞춥니다. 반면, S/N비 분석은 제어 불가능한 요인(노이즈)에 덜 민감하고, 목표값으로부터의 ‘편차(분산)’를 최소화하는 강건한(robust) 공정 조건을 찾는 데 중점을 둡니다. 논문에서는 A3 B1 C3 조합이 “목표값에 대한 최소한의 편차로 최적의 기계적 특성을 산출한다”고 언급했는데, 이는 일관된 품질의 제품을 생산하는 것이 중요한 목표임을 시사합니다. 따라서 생산 안정성을 중시한다면 S/N비 분석 결과를 우선적으로 고려할 수 있습니다.

Q3: 스퀴즈 압력이 기계적 특성을 그토록 극적으로 향상시키는 물리적 메커니즘은 무엇인가요?

A3: 논문의 2.5절과 참고문헌[6]에 따르면 두 가지 주요 메커니즘이 있습니다. 첫째, 높은 압력은 Clausius-Clapeyron 방정식에 따라 합금의 응고점을 상승시킵니다. 이는 더 큰 과냉각을 유발하여 미세한 결정핵 생성을 촉진합니다. 둘째, 압력은 용융 합금과 금형 벽 사이의 공기 간극(air gap)을 제거하여 접촉 면적을 넓히고 열전달 계수를 높입니다. 이로 인해 냉각 속도가 빨라져 결정립이 더욱 미세해지고, 결과적으로 기계적 강도가 향상됩니다.

Q4: 기계적 특성의 개선 정도는 구체적으로 어느 정도였나요?

A4: 논문의 2.5절에 명시된 바와 같이, 스퀴즈 압력을 15 MPa에서 90 MPa로 증가시켰을 때 극한 인장 강도(UTS)는 46% (150 MPa에서 219.66 MPa로), 경도(HV)는 58% 증가했습니다. 이는 스퀴즈 압력이 기계적 물성 향상에 매우 효과적인 변수임을 정량적으로 보여주는 결과입니다.

Q5: 예측된 최적 조건의 결과가 실험적으로 검증되었나요?

A5: 네, 검증되었습니다. 논문의 2.4절에 따르면, 도출된 최적 조건에서 3번의 확인 실험을 수행했습니다. 그 결과, 실험적으로 얻은 평균값(UTS 219.333 MPa, 경도 86.666 HV)이 모델을 통해 예측된 값(UTS 216.986 MPa, 경도 85.406 HV)과 거의 차이가 없어 모델의 신뢰성이 입증되었습니다.


Conclusion: Paving the Way for Higher Quality and Productivity

본 연구 분석을 통해 2017A 알루미늄 합금의 스퀴즈 캐스팅 최적화에서 스퀴즈 압력이 가장 지배적인 변수임이 명확해졌습니다. 압력을 정밀하게 제어하고 최적화하는 것은 미세조직을 개선하고, 궁극적으로는 부품의 강도와 경도를 극대화하여 더 높은 품질과 생산성을 달성하는 핵심 열쇠입니다. 이러한 공정 최적화는 자동차 및 항공우주 분야에서 요구되는 고성능 경량 부품 생산에 직접적으로 기여할 수 있습니다.

STI C&D는 최신 산업 연구 결과를 적용하여 고객이 더 높은 생산성과 품질을 달성할 수 있도록 지원하는 데 전념하고 있습니다. 이 백서에서 논의된 과제가 귀사의 운영 목표와 일치한다면, 저희 엔지니어링 팀에 연락하여 이러한 원칙을 귀사의 부품에 어떻게 구현할 수 있는지 알아보십시오.

(주)에스티아이씨앤디에서는 고객이 수치해석을 직접 수행하고 싶지만 경험이 없거나, 시간이 없어서 용역을 통해 수치해석 결과를 얻고자 하는 경우 전문 엔지니어를 통해 CFD consulting services를 제공합니다. 귀하께서 당면하고 있는 연구프로젝트를 최소의 비용으로, 최적의 해결방안을 찾을 수 있도록 지원합니다.

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Copyright Information

  • This content is a summary and analysis based on the paper “Optimization of Squeeze Casting Parameters for 2017 A Wrought Al Alloy Using Taguchi Method” by “Najib Souissi et al.”.
  • Source: https://doi.org/10.3390/met4020141

This material is for informational purposes only. Unauthorized commercial use is prohibited. Copyright © 2025 STI C&D. All rights reserved.

Figure 5 Thermal stress analysis; a) 100 °C; b) 150 °C; c) 200 °C

AA 7075 중력 다이캐스팅 해석: 금형 예열 온도가 기계적 특성에 미치는 영향 분석

이 기술 요약은 Hakan GÖKMEŞE, Şaban BÜLBÜL, Onur GÖK이 저술하여 Technical Gazette (2021)에 게재한 논문 “Casting of AA 7075 Aluminium Alloy into Gravity Die and Effect of the Die Preheating Temperature on Microstructure and Mechanical Properties”를 바탕으로 STI C&D의 기술 전문가들이 분석하고 정리한 내용입니다.

키워드

  • Primary Keyword: 중력 다이캐스팅 해석
  • Secondary Keywords: AA 7075 알루미늄 합금, 기계적 특성, 미세구조, 금형 예열, 열응력, 유한요소해석

Executive Summary

  • The Challenge: 고강도 AA 7075 알루미늄 합금의 중력 다이캐스팅 공정에서 금형 예열 온도와 같은 핵심 변수를 제어하는 것은 결함 없는 고품질 제품 생산에 필수적이지만, 시행착오에 의존하는 방식은 시간과 비용 소모가 큽니다.
  • The Method: 유한요소해석(FEA)을 사용하여 100°C, 150°C, 200°C의 각기 다른 금형 예열 온도에서 발생하는 열응력과 변형을 모델링하고, 실제 주조 실험을 통해 미세구조 및 기계적 특성에 미치는 영향을 검증했습니다.
  • The Key Breakthrough: 금형 예열 온도를 높이면 금형의 열응력은 증가하지만, 주조품의 인장 연신율은 200°C에서 최대 4.85%까지 향상되었습니다. 반면, 예열 온도가 높을수록 결정립이 조대해지고 경도는 감소하는 상충 관계가 확인되었습니다.
  • The Bottom Line: 금형 예열 온도는 금형 수명과 최종 제품 품질 사이의 중요한 상충 관계를 결정하는 변수이며, 중력 다이캐스팅 해석을 통해 물리적 테스트 없이 이 영향을 예측하고 공정을 최적화할 수 있습니다.

The Challenge: Why This Research Matters for CFD Professionals

항공우주 및 자동차 산업에서 ‘전략적 금속’으로 불리는 AA 7075 알루미늄 합금은 높은 강도와 경도로 인해 널리 사용됩니다. 이러한 고성능 부품을 생산하는 중력 다이캐스팅 공정은 효율적이지만, 용탕의 충전 시간, 주조 온도, 금형 예열과 같은 여러 변수를 정밀하게 제어해야 합니다. 특히 금형 예열은 용탕이 금형 내부를 효과적으로 채우도록 하는 데 결정적인 역할을 합니다.

기존의 시행착오 방식은 불필요하고 부정확한 생산을 초래하여 비용을 증가시킵니다. 따라서 주조 공정을 컴퓨터 환경에서 설계, 모델링 및 분석하는 것은 오류율을 최소화하고 결함 없는 제품을 생산하는 데 매우 중요합니다. 이 연구는 금형 예열 온도가 금형 자체의 열적 스트레스와 최종 주조품의 기계적 특성에 미치는 복합적인 영향을 규명하여, 시뮬레이션 기반의 공정 최적화 가능성을 제시하고자 했습니다.

The Approach: Unpacking the Methodology

본 연구는 AA 7075 알루미늄 합금의 중력 다이캐스팅 공정을 시뮬레이션 및 실험을 통해 체계적으로 분석했습니다.

  • 재료 및 금형 설계: 주조 재료로는 AA 7075 알루미늄 합금이 사용되었으며, 단일 인장 시험편을 생산하기 위해 특별히 설계된 H13 공구강 재질의 금형이 제작되었습니다.
  • 시뮬레이션 (FEA): 주조 공정에 앞서, 유한요소해석(FEA)을 통해 800°C의 용탕 주입 시 각기 다른 금형 예열 온도(100°C, 150°C, 200°C)가 금형 표면에 가하는 열응력 분포와 변형을 예측했습니다.
  • 실험 조건: 800°C로 용해된 AA 7075 합금을 100°C, 150°C, 200°C로 각각 예열된 금형에 주입하여 인장 시험편을 제작했습니다.
  • 특성 분석: 주조된 시험편은 인장 강도, 미세/거시 경도(시효 처리 전후), 미세구조(SEM), 파단면 형태(EDS) 등 다양한 기계적 및 야금학적 특성을 평가받았습니다. 시효 열처리는 480°C에서 120분 용체화 처리 후 120°C에서 1440분간 진행되었습니다.
Figure 1 Metallic die design and tensile test samples
Figure 1 Metallic die design and tensile test samples

The Breakthrough: Key Findings & Data

Finding 1: 금형 예열 온도 증가 시 금형의 열응력 및 변형 심화

유한요소해석 결과, 금형 예열 온도를 높이는 것이 금형 수명에 부정적인 영향을 미칠 수 있음을 확인했습니다. Figure 5에서 볼 수 있듯이, 예열 온도가 100°C에서 200°C로 증가함에 따라 인장 시험편으로 전환되는 반경 연결부(a, b, c 영역)와 탕구(feeder) 연결부(d, e, f 영역)에서 열응력과 변형이 집중적으로 심화되었습니다. 이는 높은 예열 온도가 열 피로를 가중시켜 금형의 사용 수명을 단축시킬 수 있음을 시사합니다.

Finding 2: 예열 온도에 따른 기계적 특성의 상충 관계 (연신율 vs. 경도)

실제 주조 실험 결과, 금형 예열 온도는 최종 제품의 기계적 특성에 직접적인 영향을 미쳤습니다.

  • 연신율: Figure 13에 따르면, 금형 예열 온도가 증가할수록 인장 연신율이 향상되었습니다. 200°C에서 주조된 시편은 4.85%로 가장 높은 연신율을 보였으며, 이는 100°C(2.40%)와 150°C(3.35%)에 비해 현저히 높은 수치입니다. 이는 높은 예열 온도가 냉각 속도를 늦춰 더 연성적인 파괴 거동을 유도했기 때문입니다.
  • 경도: 반면, 경도는 예열 온도가 낮을수록 높게 나타났습니다. Figure 14에 따르면, 시효 열처리 후 100°C에서 주조된 시편의 미세경도는 152.16 HV로 가장 높았으며, 200°C 시편의 경도(데이터 미제공, 그래프상 약 120 HV)보다 월등히 높았습니다. 이는 낮은 예열 온도가 더 빠른 냉각을 유도하여 미세한 결정립 구조를 형성했기 때문입니다(Figure 6 참조).

Practical Implications for R&D and Operations

  • For Process Engineers: 이 연구는 금형 예열 온도가 제품의 연성과 경도 사이의 상충 관계를 제어하는 핵심 변수임을 보여줍니다. 높은 경도가 요구되는 부품에는 100°C와 같은 낮은 예열 온도를, 파괴 인성이 중요한 부품에는 200°C와 같은 높은 예열 온도를 적용하는 등 목표 성능에 맞춰 공정 조건을 최적화할 수 있습니다.
  • For Quality Control Teams: Figure 14의 데이터는 예열 온도와 시효 처리 후 경도 간의 명확한 반비례 관계를 보여줍니다. 이는 공정 윈도우를 설정하고 품질 검사 기준을 수립하는 데 활용될 수 있습니다. 또한 Figures 7, 8, 9의 파단면 이미지는 파괴 분석 시 유용한 시각적 참조 자료를 제공합니다.
  • For Design Engineers: Figure 5의 해석 결과는 금형의 반경 연결부와 같은 특정 부위에 열응력이 집중됨을 보여줍니다. 이는 특히 높은 예열 온도가 요구될 때, 열 피로를 완화하기 위한 금형 설계(예: 필렛 반경 최적화)가 중요함을 시사합니다.
Figure 3 Aging process diagram of AA 7075 alloy
Figure 3 Aging process diagram of AA 7075 alloy

Paper Details


Casting of AA 7075 Aluminium Alloy into Gravity Die and Effect of the Die Preheating Temperature on Microstructure and Mechanical Properties

1. Overview:

  • Title: Casting of AA 7075 Aluminium Alloy into Gravity Die and Effect of the Die Preheating Temperature on Microstructure and Mechanical Properties
  • Author: Hakan GÖKMEŞE, Şaban BÜLBÜL, Onur GÖK
  • Year of publication: 2021
  • Journal/academic society of publication: Technical Gazette
  • Keywords: aluminium, analysis; casting; gravity die casting; mechanical properties

2. Abstract:

본 연구에서는 중력 다이캐스팅 응용 분야에서 중요한 부분을 차지하는 경합금 주조 기술을 조사했습니다. 이를 위해 유한요소해석법을 사용하여 100°C, 150°C, 200°C의 예열 온도에서 금속 인장 시험편 금형의 모델링 및 분석 연구를 수행한 후 주조 시험을 진행했습니다. AA 7075 알루미늄 합금의 중력 다이캐스팅 시험은 800°C에서 다양한 금형 예열 온도 조건 하에 수행되었습니다. 주조 공정 후, 인장 시험편을 준비하여 시험 샘플의 인장 시험 측정 및 경도 측정을 수행했습니다. 경도 측정은 시효 열처리(120°C – 1440분) 전후에 거시경도와 미세경도 모두 측정되었습니다. 시험 샘플의 미세구조 및 파단면 검사를 위해 SEM 및 EDS 분석이 수행되었습니다. 모델링 및 분석 연구를 통해 금형 예열 온도를 높이면 열응력과 변형이 증가하고, 인장 특성 측면에서 가장 높은 연신율은 4.85%인 것으로 확인되었습니다. 시효 열처리 전후의 경도 값은 금형 예열 온도가 증가함에 따라 감소하는 경향을 보였습니다.

3. Introduction:

오늘날 알루미늄 및 알루미늄 합금은 기술의 급속한 발전과 함께 우리 생활에서 가장 널리 사용되는 금속 재료 중 하나가 되었으며, 그 사용이 더욱 확산되고 있습니다. 7xxx계 합금은 높은 기계적 특성, 강도 및 경도, 우수한 내식성 및 다른 알루미늄 합금들 사이에서 뛰어난 용접성으로 인해 항공우주, 자동차, 스포츠 용품 및 기타 분야에서 널리 사용됩니다. 일반적으로 AA 7075 알루미늄 합금을 생산하는 주조 방법은 부품의 크기와 모양에 제한 없이 기존 주조 장비를 사용할 수 있어 간단하고 경제적입니다. 주조 기술을 이용한 제조에서, 용탕의 품질을 평가하기 위해 인장 시험봉은 주조 공정(사형 또는 중력 다이)과 별도로 생산될 수 있습니다. 주조 모델링 및 분석과 같은 프로그램은 시행착오 방식의 불필요하고 부정확한 주조 생산 없이 컴퓨터 환경에서 설계하여 결함 없는 주조 응용 분야에서 매우 중요합니다.

4. Summary of the study:

Background of the research topic:

AA 7075 알루미늄 합금은 항공우주 및 자동차 산업에서 요구되는 고강도, 고경도 특성을 만족시키는 핵심 소재입니다. 중력 다이캐스팅은 이러한 부품을 경제적으로 생산하는 주요 공법 중 하나입니다.

Status of previous research:

기존 연구들은 중력 다이캐스팅의 품질 향상과 금형 수명 연장을 위해 다양한 재료와 공정 변수에 초점을 맞춰왔습니다. 그러나 금형 예열 온도가 금형 자체의 열적 거동과 최종 주조품의 미세구조 및 기계적 특성에 미치는 복합적인 영향을 체계적으로 분석한 연구는 부족했습니다.

Purpose of the study:

본 연구의 목적은 AA 7075 알루미늄 합금의 중력 다이캐스팅 공정에서 금형 예열 온도가 (1) 금형의 열응력 및 변형, (2) 주조품의 미세구조 및 기계적 특성(인장 강도, 경도)에 미치는 영향을 규명하는 것입니다. 이를 통해 시뮬레이션 기반의 공정 최적화 가능성을 탐색하고자 했습니다.

Core study:

연구의 핵심은 유한요소해석(FEA)을 통한 금형의 열응력 예측과 실제 주조 실험을 통한 기계적 특성 검증을 결합한 것입니다. 100°C, 150°C, 200°C의 세 가지 금형 예열 온도 조건을 변수로 설정하고, 각 조건이 금형 수명과 제품 품질에 미치는 상반된 영향을 정량적으로 분석했습니다.

5. Research Methodology

Research Design:

본 연구는 시뮬레이션과 실험적 접근법을 결합하여 설계되었습니다. 먼저 CAD 모델링 및 유한요소해석을 통해 금형 예열 온도에 따른 열응력 분포를 예측하고, 이를 바탕으로 실제 주조 실험을 수행하여 시뮬레이션 결과와 실제 현상 간의 관계를 분석했습니다.

Data Collection and Analysis Methods:

  • 시뮬레이션: 유한요소해석 소프트웨어를 사용하여 금형의 열응력 및 변형을 계산했습니다.
  • 주조 실험: 설계된 금형을 사용하여 800°C의 AA 7075 용탕을 100°C, 150°C, 200°C로 예열된 금형에 주입했습니다.
  • 기계적 특성 평가: 만능시험기(Universal Tester)를 사용하여 인장 강도 및 연신율을 측정했으며, 로크웰 및 비커스 경도계를 사용하여 시효 처리 전후의 경도를 측정했습니다.
  • 미세구조 분석: 주사전자현미경(SEM)과 에너지 분산형 분광기(EDS)를 사용하여 미세구조 및 파단면의 형태와 성분 분포를 분석했습니다.

Research Topics and Scope:

연구 범위는 AA 7075 알루미늄 합금의 중력 다이캐스팅 공정에 국한되며, 주요 연구 주제는 금형 예열 온도(100°C, 150°C, 200°C)가 금형의 열적 거동과 주조품의 미세구조 및 기계적 특성에 미치는 영향입니다.

6. Key Results:

Key Results:

  • 유한요소해석 결과, 금형 예열 온도가 100°C에서 200°C로 증가함에 따라 금형의 열응력과 변형이 심화되어 금형 수명에 부정적인 영향을 미칠 것으로 예측되었습니다.
  • 금형 예열 온도가 높을수록 주조품의 결정립이 조대해지는 경향을 보였습니다. 100°C에서 예열된 금형에서 얻은 시편의 결정립 크기가 상대적으로 가장 작았습니다.
  • 인장 시험 결과, 금형 예열 온도가 증가함에 따라 연신율이 증가하여 200°C에서 4.85%로 최대치를 기록했습니다. 반면 인장 강도는 200°C에서 164 MPa로 가장 높게 나타났습니다.
  • 파단면 분석 결과, 예열 온도가 증가함에 따라 취성 파괴 형태에서 연성 파괴 형태로 변화하는 경향이 관찰되었습니다.
  • 경도 측정 결과, 시효 열처리 전후 모두 금형 예열 온도가 증가할수록 경도 값이 감소했습니다. 시효 처리 후 가장 높은 경도 값은 100°C 예열 조건에서 얻은 시편(152.16 HV, 110.77 HRB)에서 측정되었습니다.
Figure 5 Thermal stress analysis; a) 100 °C; b) 150 °C; c) 200 °C
Figure 5 Thermal stress analysis; a) 100 °C; b) 150 °C; c) 200 °C

Figure List:

  • Figure 1 Metallic die design and tensile test samples
  • Figure 2 Tensile test bar
  • Figure 3 Aging process diagram of AA 7075 alloy
  • Figure 4. Metallic die design
  • Figure 5 Thermal stress analysis; a) 100 °C; b) 150 °C; c) 200 °C
  • Figure 6 AA 7075 alloy microstructure images cast at different preheating temperatures: a) 100 °C; b) 150 °C; c) 200 °C
  • Figure 7 SEM images of the fractured surface after the tensile test and casting with 100 °C preheating
  • Figure 8 SEM images of the fracture surfaces after the casting and tensile test with 150 °C preheating
  • Figure 9 SEM images of the fracture surface after casting and tensile test with 200 °C preheating
  • Figure 10 Fracture surface EDS analysis after the casting and tensile test with 100 °C preheating
  • Figure 11 Fracture surface EDS analysis after the casting and tensile test with 150 °C preheating
  • Figure 12 Fracture surface EDS analysis after the casting and tensile test with 200 °C preheating
  • Figure 13 Tensile test results of samples cast at different preheating temperatures
  • Figure 14 The hardness results of the samples cast at different preheating temperatures: a) Microhardness; b) Macrohardness

7. Conclusion:

본 연구의 실험 결과는 다음과 같이 요약됩니다. 중력 다이캐스팅 CAD 모델링 연구를 통해 금형 예열 온도가 증가하면 열응력, 변형 및 금형 수명 측면에서 부정적인 영향을 미치는 것으로 확인되었습니다. 증가하는 금형 예열 온도에서 주조 미세구조는 결정립 크기 측면에서 조대해졌습니다. 인장 시험 후, 파단면 형태의 취성 파괴 거동은 증가하는 금형 예열 온도에 따라 결정립계에서 연성 거동으로 대체되었으나, 결정립 내부의 편석에 따라 취성 결정립에서 분리가 발생했습니다. 또한, 시편의 인장 연신율 값이 증가하여 200°C 금형 예열 온도에서 4.85%로 확인되었습니다. 적용된 시효 열처리 공정 후 미세경도 및 거시경도 값은 100°C 금형 예열 공정에서 주조된 시험 시편에서 152.16 HV 및 110.77 HRB로 얻어졌습니다. 명시된 결과를 검토할 때, 금형 예열 온도는 특히 경합금(Al, Zn, Mg 등) 주조에서 효과적일 수 있습니다. 따라서 금형 성형, 금형 변형 및 수명, 미세구조 및 기계적 특성은 중력 다이캐스팅 응용 분야에서 직접적인 영향을 받을 수 있습니다.

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Expert Q&A: Your Top Questions Answered

Q1: 이 연구에서 표준 ASTM B108 금형 대신 맞춤형 금형을 설계한 이유는 무엇입니까?

A1: 논문에 따르면, “이 금형은 ASTM B108로 알려진 금형과 달리 단일 인장 시험편을 생산하도록 설계되었습니다.” 이는 연구의 목적이 특정하고 단순화된 형상에 대한 예열 효과를 명확히 분리하여 관찰하는 데 있었음을 시사합니다. 복잡한 형상의 영향을 배제하고 예열 온도라는 단일 변수가 기본적인 주조품의 특성에 미치는 영향을 집중적으로 분석하기 위한 설계로 보입니다.

Q2: Figure 5는 200°C에서 열응력이 증가함을 보여주는데, 이것이 실제 금형 수명에 어떤 영향을 미칩니까?

A2: 논문은 이것이 “금형 사용 수명에 부정적인 영향을 미칠 것”이라고 언급합니다. 이는 중력 다이캐스팅 금형의 일반적인 파손 원인인 열 피로 균열 때문입니다. 시뮬레이션을 통해 엔지니어는 그림에 나타난 반경 연결부와 같은 고응력 영역을 미리 예측하고, 해당 부위를 보강하거나 공정 조건을 최적화하여 임계 응력 임계값 이하로 유지함으로써 금형 수명을 연장할 수 있습니다.

Q3: 논문에서는 연신율과 경도 사이의 상충 관계를 언급했습니다. 어떤 예열 온도가 ‘최적’이라고 할 수 있습니까?

A3: 단 하나의 ‘최적’ 온도는 없습니다. 이는 부품의 최종 적용 분야 요구사항에 따라 달라집니다. 높은 경도와 강도가 필요한 부품(예: 구조 부재)의 경우, 100°C로 예열 후 시효 처리를 하는 것이 최적의 선택(152.16 HV)입니다. 반면, 더 높은 연성과 파괴 저항이 필요한 부품(예: 충격 흡수 부품)의 경우, 200°C 예열이 더 나은 선택(4.85% 연신율)이 될 것입니다.

Q4: 예열 온도가 증가함에 따라 파단면이 취성에서 연성으로 변하는 원인은 무엇입니까?

A4: 논문은 높은 예열 온도가 냉각 속도를 늦춘다고 설명합니다. 이는 “결정립 성장”과 합금 원소의 “편석 경향이 있는 영역 형성”을 유발합니다(Figure 6). 느린 응고 속도와 조대해진 결정립은 결과적으로 100°C에서 관찰된 취성 입계 파괴(Figure 7)에서 200°C에서 보이는 더 큰 딤플을 가진 연성 파괴(Figure 9)로의 전환을 이끌어냈습니다.

Q5: 시효 열처리를 통한 경도 향상 효과는 얼마나 중요했습니까?

A5: 매우 중요했습니다. 100°C 예열 시편의 경우, 미세경도는 평균 129.53 HV에서 152.16 HV로 17.8% 증가했습니다. 거시경도는 86.36 HRB에서 110.77 HRB로 27.9%나 증가했습니다(Figure 14). 이는 AA 7075 합금의 최종 기계적 특성을 확보하는 데 있어 주조 후 열처리가 필수적인 공정임을 명확히 보여줍니다.


Conclusion: Paving the Way for Higher Quality and Productivity

이 연구는 AA 7075 알루미늄 합금의 중력 다이캐스팅 공정에서 금형 예열 온도가 금형 수명과 제품 품질에 미치는 복합적인 영향을 명확히 보여주었습니다. 시뮬레이션은 높은 예열 온도가 금형에 가하는 열적 부담을 예측했으며, 실험은 이것이 제품의 연성을 향상시키는 대신 경도를 저하시키는 상충 관계를 가짐을 입증했습니다.

이러한 결과는 중력 다이캐스팅 해석이 단순히 용탕의 유동을 예측하는 것을 넘어, 공정 변수가 최종 제품의 기계적 특성과 생산 설비의 수명에 미치는 영향까지 종합적으로 최적화할 수 있는 강력한 도구임을 증명합니다.

STI C&D는 최신 산업 연구 결과를 적용하여 고객이 더 높은 생산성과 품질을 달성할 수 있도록 지원하는 데 전념하고 있습니다. 이 백서에서 논의된 과제가 귀사의 운영 목표와 일치한다면, 저희 엔지니어링 팀에 연락하여 이러한 원칙을 귀사의 부품에 어떻게 구현할 수 있는지 알아보십시오.

(주)에스티아이씨앤디에서는 고객이 수치해석을 직접 수행하고 싶지만 경험이 없거나, 시간이 없어서 용역을 통해 수치해석 결과를 얻고자 하는 경우 전문 엔지니어를 통해 CFD consulting services를 제공합니다. 귀하께서 당면하고 있는 연구프로젝트를 최소의 비용으로, 최적의 해결방안을 찾을 수 있도록 지원합니다.

  • 연락처 : 02-2026-0450
  • 이메일 : flow3d@stikorea.co.kr

Copyright Information

  • This content is a summary and analysis based on the paper “Casting of AA 7075 Aluminium Alloy into Gravity Die and Effect of the Die Preheating Temperature on Microstructure and Mechanical Properties” by “Hakan GÖKMEŞE, Şaban BÜLBÜL, Onur GÖK”.
  • Source: https://doi.org/10.17559/TV-20200819135453

This material is for informational purposes only. Unauthorized commercial use is prohibited. Copyright © 2025 STI C&D. All rights reserved.

Figure 2. Microstructure evolution at seven sampling locations (S1-S7) along the plate, (a) advent of segregation band at last one-third of the plate shown by red arrows, (b) comparison of α-Al particles.

HPDC 결함 예측: 상평형장 모델링을 통한 알루미늄 합금의 이중 수지상정 응고 현상 분석

이 기술 요약은 Maryam Torfeh, Zhichao Niu, Hamid Assadi가 Metals (2025)에 발표한 논문 “Phase-Field Modelling of Bimodal Dendritic Solidification During Al Alloy Die Casting”을 기반으로 하며, (주)에스티아이씨앤디의 기술 전문가에 의해 분석 및 요약되었습니다.

Keywords

  • Primary Keyword: 상평형장 모델링 (Phase-Field Modeling)
  • Secondary Keywords: 고압 다이캐스팅(HPDC), 알루미늄 합금, 응고 해석, 미세조직 예측, 이중 수지상정

Executive Summary

  • The Challenge: 고압 다이캐스팅(HPDC) 공정에서 발생하는 급격한 냉각 속도 변화와 난류로 인해 불균일한 이중(bimodal) 미세조직이 형성되어 최종 제품의 기계적 물성을 저하시키는 문제.
  • The Method: 샷 슬리브(shot sleeve)의 상대적으로 느린 냉각에서 다이 캐비티(die cavity)의 급속 냉각으로 전환되는 과정을 모사하기 위해, 고체-액체 계면의 특성(두께, 에너지, 이동도)을 체계적으로 변경하는 2차원 상평형장 모델을 사용.
  • The Key Breakthrough: 상평형장 모델의 계면 두께를 줄임으로써, 난류가 유발하는 국부적 과냉각 및 미세한 2차 수지상정 가지의 핵 생성 및 성장을 성공적으로 재현.
  • The Bottom Line: 상평형장 모델링은 HPDC 공정의 복잡한 응고 현상을 예측하고, 최종 제품의 미세조직 제어를 통해 품질을 향상시키는 데 효과적인 도구임을 입증했습니다.

The Challenge: Why This Research Matters for CFD Professionals

고압 다이캐스팅(HPDC)은 경량 알루미늄 합금 부품을 경제적으로 대량 생산하는 핵심 기술입니다. 하지만 이 공정은 샷 슬리브에서의 느린 냉각(약 100 K/s)과 다이 캐비티 주입 시의 급속 냉각(약 1000 K/s)이라는 극적인 열 조건 변화를 동반합니다. 이러한 급격한 변화와 용탕의 격렬한 난류는 최종 제품의 미세조직에 결정적인 영향을 미칩니다.

특히, 샷 슬리브에서 미리 형성된 조대한 ‘외부 응고 결정(Externally Solidified Crystals, ESCs)’이 다이 캐비티 내에서 급속 냉각된 미세한 결정들과 섞여 ‘이중 미세조직(bimodal microstructure)’을 형성하는 것이 주요 문제입니다. 이러한 불균일한 미세조직은 부품의 기계적 특성(예: 항복 강도, 연신율)을 저하시키고 예측 불가능하게 만들어 품질 관리에 심각한 어려움을 초래합니다. 기존의 수치 해석 방법들은 유동 및 열 전달에 초점을 맞추었지만, 이러한 복잡한 수지상정 구조의 진화 과정을 직접 분석하는 데는 한계가 있었습니다.

Figure 1. Sampling region on the plate manufactured by HPDC.
Figure 1. Sampling region on the plate manufactured by HPDC.

The Approach: Unpacking the Methodology

본 연구팀은 이 문제를 해결하기 위해 2차원 상평형장(Phase-Field) 모델을 사용하여 아공정 Al-7% Si 합금의 응고 거동을 조사했습니다. 이 모델은 HPDC 공정을 두 단계로 나누어 시뮬레이션합니다.

  1. 1단계 (샷 슬리브 조건): 초기 온도 650K, 냉각 속도 100 K/s 조건에서 초기 수지상정의 성장을 모사합니다. 이는 다이 캐비티로 주입되기 전의 상태를 나타냅니다.
  2. 2단계 (다이 캐비티 조건): 1단계에서 성장한 수지상정을 기반으로, 초기 온도를 450K로 낮추고 냉각 속도를 1000 K/s로 높여 급속 응고를 시뮬레이션합니다.

가장 핵심적인 접근법은 샷 슬리브에서 다이 캐비티로 전환될 때 발생하는 물리적 현상(특히 난류로 인한 열 및 용질 전달 향상)을 모델링하기 위해, 고체-액체(S/L) 계면의 주요 파라미터인 두께(thickness), 에너지(energy), 이동도(mobility)를 체계적으로 변경한 것입니다. 이를 통해 모델이 실제 공정에서 관찰되는 미세조직 변화를 정확하게 예측할 수 있는지 검증했습니다.

The Breakthrough: Key Findings & Data

Finding 1: 실험적 미세조직 관찰을 통한 이중 구조 확인

실제 HPDC로 제조된 주조품의 위치별 미세조직을 분석한 결과, 명확한 이중 구조가 확인되었습니다.

  • 입자 크기 변화: 인게이트(in-gate) 부근(S1)에서는 평균 α-Al 입자 크기가 약 21 µm였으나, 주조품 끝단(S7)으로 갈수록 약 3 µm로 급격히 감소했습니다(Figure 3 참조).
  • 이중 미세조직: 인게이트 부근에서는 조대한 ESCs 주위로 미세하게 분산된 α-Al 입자들이 공존하는 이질적인 미세조직이 관찰되었습니다. 특히, 기존에 형성된 수지상정 파편 위에서 새로운 가지들이 핵 생성되는 모습이 뚜렷하게 나타났습니다(Figure 4b의 화살표 참조).

이는 샷 슬리브에서 형성된 결정이 다이 캐비티의 급속 냉각 환경에서 새로운 응고의 핵으로 작용했음을 시사합니다.

Finding 2: 상평형장 모델을 통한 이중 수지상정 성장 메커니즘 규명

상평형장 시뮬레이션은 실험에서 관찰된 이중 수지상정 형성 과정을 성공적으로 재현했습니다.

  • 샷 슬리브 성장 모사: 샷 슬리브 조건(계면 두께 700 nm, 에너지 0.16 J/m², 이동도 0.003 m/sK)에서 2ms 동안 성장시킨 결과, 실험에서 관찰된 것과 유사한 초기 수지상정 형태를 얻었습니다(Figure 5b,c).
  • 다이 캐비티 성장 재현: 다이 캐비티의 급속 냉각 및 난류 효과를 모사하기 위해 S/L 계면 두께를 700 nm에서 500 nm로 줄였을 때, 기존 수지상정 표면에서 더 미세하고 날카로운 3차 수지상정 가지가 형성되는 현상을 포착했습니다(Figure 6, state 01 vs state 03). 이는 계면 두께 감소가 난류로 인한 열/용질 전달 향상 효과를 효과적으로 반영하며, 이중 미세조직 형성의 핵심 메커니즘을 설명할 수 있음을 보여줍니다.
Figure 2. Microstructure evolution at seven sampling locations (S1-S7) along the plate, (a) advent of segregation band at last one-third of the plate shown by red arrows, (b) comparison of α-Al particles.
Figure 2. Microstructure evolution at seven sampling locations (S1-S7) along the plate, (a) advent of segregation band at last one-third of the plate shown by red arrows, (b) comparison of α-Al particles.

Practical Implications for R&D and Operations

  • For Process Engineers: 이 연구는 난류 및 냉각 속도와 같은 공정 조건이 고체-액체 계면 거동에 미치는 영향을 간접적으로 모델링할 수 있음을 보여줍니다. 이는 최종 미세조직 제어를 통해 기계적 물성을 최적화하는 데 중요한 단서를 제공합니다.
  • For Quality Control Teams: 논문의 Figure 3과 Figure 4에서 볼 수 있듯이, 주조품 위치에 따라 α-Al 입자 크기 분포가 크게 달라집니다. 이를 바탕으로 위치별 미세조직 분석을 통해 기계적 물성의 편차를 예측하고 새로운 품질 검사 기준을 수립하는 데 활용할 수 있습니다.
  • For Design Engineers: 게이트 통과 시 발생하는 강한 전단력과 난류가 기존에 형성된 수지상정을 파편화시키고 새로운 핵생성 사이트로 작용한다는 점은, 게이트 시스템 설계가 최종 미세조직에 미치는 영향을 고려해야 함을 시사합니다. 이는 초기 설계 단계에서 결함을 최소화하는 데 중요한 고려사항입니다.

Paper Details


Phase-Field Modelling of Bimodal Dendritic Solidification During Al Alloy Die Casting

1. Overview:

  • Title: Phase-Field Modelling of Bimodal Dendritic Solidification During Al Alloy Die Casting
  • Author: Maryam Torfeh, Zhichao Niu and Hamid Assadi
  • Year of publication: 2025
  • Journal/academic society of publication: Metals
  • Keywords: phase-field modelling; HPDC; interface behaviour

2. Abstract:

Al-Si 합금의 고압 다이캐스팅(HPDC) 중 미세조직 진화를 추적하는 것은 급속한 응고, 변화하는 열 조건, 그리고 심한 난류 때문에 어려운 과제입니다. 이 공정은 샷 슬리브에서의 느린 냉각에서 다이 캐비티에서의 급속 냉각으로 전환되며, 이는 이중 수지상정 미세조직과 기존에 외부에서 응고된 결정 위에 새로운 미세한 수지상정 가지가 핵 생성되는 결과를 낳습니다. 본 연구에서는 2차원 상평형장 모델을 사용하여 아공정 Al-7% Si 합금의 HPDC 중 응고 거동을 조사했습니다. 이 모델은 상변태열, 열 경계 조건, 그리고 액상 및 고상에서의 용질 확산으로 인한 온도 변화를 설명하는 열역학적 공식에 기반합니다. 관찰된 이중 미세조직을 재현하기 위해, 고체-액체 계면의 특성(두께, 에너지, 이동도 등)을 체계적으로 변경하여 샷 슬리브에서 다이 캐비티로의 전환을 반영했습니다. 결과는 모델이 샷 슬리브 조건 하에서의 수지상정 성장과 다이 캐비티의 급속 냉각 조건 하에서의 새로운 수지상정 가지의 핵 생성 및 발달을 포착할 수 있는 능력을 보여주었습니다.

3. Introduction:

고압 다이캐스팅(HPDC)은 거의 최종 형상에 가까운 경량 알루미늄 합금을 제조하는 경제적인 방법입니다. HPDC 공정 중 여러 요인들이 제품의 최종 품질에 근본적인 영향을 미칠 수 있습니다. 가압 압력, 플런저 속도, 다이 온도와 같은 공정 요인들은 많은 연구자들에 의해 연구되었습니다. HPDC에서 샷 슬리브의 냉각 속도는 약 100 K/s인 반면, 다이에서는 약 1000 K/s입니다. 최종 부품의 미세조직은 단지 냉각 속도에만 의존하지 않습니다. 주입 단계에서의 심한 전단 및 난류는 미세조직에 현저한 영향을 미칩니다. 샷 슬리브에서의 응고 조건은 단순 중력 주조와 매우 유사합니다. Al-7% Si 용탕의 온도는 약 620°C로 보고되었으며, 이는 합금의 액상선 온도와 매우 가깝습니다. HPDC에서는 금속 유동 속도가 고체-액체 계면 속도를 초과합니다. 1차 수지상정은 샷 슬리브에서 형성을 시작하며, 급속한 응고와 높은 금속 속도 때문에 얇은 채널 내에서 주상 수지상정이 발달할 수 없어 비수지상정 구조를 형성합니다. 이러한 미세조직적 특징은 주조품의 최종 특성에 상당한 영향을 미칩니다. 알루미늄 합금의 HPDC에서 가장 빈번하게 보고되는 미세조직 문제 중 하나는 최종 제품에 외부 응고 결정(ESCs)이 존재하는 것입니다.

4. Summary of the study:

Background of the research topic:

HPDC 공정은 샷 슬리브와 다이 캐비티 간의 극심한 냉각 속도 차이와 난류로 인해 복잡한 응고 현상을 보입니다. 이로 인해 형성되는 이중 미세조직은 제품의 기계적 물성을 저하시키는 주요 원인이 됩니다.

Status of previous research:

이전 연구들은 주로 유한요소법(FEM)을 사용하여 유체 역학 및 열 전달 모델링에 집중했으며, 일부는 셀룰러 오토마타(CA)와 결합하여 최종 주조품의 결정립 크기를 예측하려 시도했습니다. 그러나 수지상정 구조의 진화와 이중 가지 형성 과정을 미시적으로 분석하기 위해 상평형장 모델을 HPDC에 적용한 사례는 드물었습니다.

Purpose of the study:

본 연구의 목적은 상평형장 모델을 사용하여 HPDC 공정 중 수지상정 구조의 진화를 분석하고, 급속 응고가 어떻게 이중 수지상정 가지의 형성으로 이어지는지에 대한 통찰력을 제공하는 것입니다.

Core study:

연구의 핵심은 2단계 시뮬레이션 접근법입니다. 첫째, 샷 슬리브의 느린 냉각 조건을 모사하여 초기 수지상정을 성장시킵니다. 둘째, 이 결과를 초기 조건으로 사용하여 다이 캐비티의 급속 냉각 조건을 적용합니다. 이 과정에서 고체-액체 계면의 물리적 특성(두께, 에너지, 이동도)을 체계적으로 변경하여, 난류와 급랭이 미세조직에 미치는 영향을 간접적으로 모델링하고 실험 결과와 비교 검증했습니다.

5. Research Methodology

Research Design:

실험적 미세조직 분석과 수치적 상평형장 모델링을 결합한 연구 설계를 채택했습니다. 실제 HPDC 공정으로 제작된 시편의 미세조직을 관찰하여 모델 검증을 위한 기준 데이터를 확보하고, 이를 바탕으로 2단계 상평형장 시뮬레이션을 수행하여 이중 미세조직 형성 메커니즘을 규명했습니다.

Data Collection and Analysis Methods:

  • 미세조직 분석: HPDC로 제작된 Al-Si 합금 평판의 여러 위치(S1-S7)에서 시편을 채취하여 연마 및 아노다이징 처리 후, 광학 현미경(Zeiss Axio-Vision)을 사용하여 α-Al 입자의 크기, 분포, 형태를 관찰하고 정량적으로 분석했습니다.
  • 상평형장 모델링: 2차원 상평형장 모델을 사용하여 500×500 셀 그리드에서 시뮬레이션을 수행했습니다. 샷 슬리브(냉각속도 100 K/s)와 다이 캐비티(냉각속도 1000 K/s)의 열 조건을 각각 적용하고, 고체-액체 계면의 두께, 에너지, 이동도를 변화시키며 수지상정 성장을 계산했습니다.

Research Topics and Scope:

연구는 아공정 Al-7% Si 합금의 HPDC 공정에 초점을 맞춥니다. 주요 연구 주제는 샷 슬리브에서 다이 캐비티로의 전환 과정에서 발생하는 이중 수지상정 응고 현상입니다. 연구 범위는 상평형장 모델을 이용한 미세조직 진화의 수치적 재현과, 고체-액체 계면 특성 변화가 수지상정 형태에 미치는 영향 분석에 한정됩니다.

6. Key Results:

Key Results:

  • 주조품의 인게이트에서 끝단으로 갈수록 평균 α-Al 입자 크기가 21 µm에서 3 µm로 현저히 감소했습니다.
  • 인게이트 부근에서 조대한 ESCs와 미세한 α-Al 입자가 공존하는 이중 미세조직이 관찰되었으며, 파편화된 수지상정 위에서 새로운 가지가 핵 생성되는 현상이 확인되었습니다.
  • 상평형장 모델은 샷 슬리브 조건에서의 초기 수지상정 성장을 성공적으로 모사했습니다.
  • 다이 캐비티 조건을 모사하기 위해 고체-액체 계면 두께를 700 nm에서 500 nm로 줄였을 때, 실험에서 관찰된 것과 유사한 미세한 3차 수지상정 가지의 형성을 재현할 수 있었습니다. 이는 난류 효과를 모델에 효과적으로 반영한 결과입니다.
Figure 3. Size distribution of α-Al particles along the plate.
Figure 3. Size distribution of α-Al particles along the plate.

Figure List:

  • Figure 1. Sampling region on the plate manufactured by HPDC.
  • Figure 2. Microstructure evolution at seven sampling locations (S1-S7) along the plate, (a) advent of segregation band at last one-third of the plate shown by red arrows, (b) comparison of a-Al particles.
  • Figure 3. Size distribution of a-Al particles along the plate.
  • Figure 4. Comparison of a-Al particles along the plate, (a) and (b) near the in-gate, (c) at the end of the plate (the arrows show the new arms nucleated on fragmented dendrites).
  • Figure 5. (a) Externally solidified crystals at the in-gate, (b,c) phase-field and Si concentration of dendrites at shot sleeve after 2 ms, (d,e) after 15 ms.
  • Figure 6. Comparison of secondary nucleation on a dendrite grew in the shot sleeve for 2 ms and transferred to die cavity (states 1-3 show interface thicknesses of 700–500 nm).

7. Conclusion:

난류에 의한 파편화는 Al-Si 합금의 HPDC 공정 중 수지상정 형태를 변형시키는 중요한 요인입니다. 샷 슬리브에서 다이 캐비티로의 고속 용탕 이송은 2차 수지상정 가지의 파편화를 촉진하며, 이 파편들은 이후 새로운 가지 성장의 핵으로 작용합니다. 이러한 현상은 용질 및 열 구배가 높은 영역에서 특히 두드러지며, 난류는 국부적 과냉각과 용질 재분배를 강화합니다.

상평형장 모델링 접근법은 고체-액체 계면 특성을 체계적으로 변경함으로써 새로운 수지상정 가지의 시작과 성장을 성공적으로 포착했습니다. 선택된 파라미터 세트(특히 계면 두께 감소)는 난류와 급속 냉각에 의해 유도된 형태학적 변화를 효과적으로 나타냈습니다. 이는 HPDC 조건 하에서 수지상정 진화에 있어 동역학적 및 열역학적 요인 간의 상호작용을 강조합니다.

이러한 발견은 수지상정 응고에서 난류의 역할에 대한 중요한 통찰력을 제공하며, 복잡한 미세조직 현상을 재현하는 데 있어 상평형장 모델링의 유용성을 보여줍니다. 또한 결과는 공정별 조건에 맞춰 계면 특성을 조정하는 것의 중요성을 강조하며, Al-Si 합금의 HPDC 공정 최적화 및 미세조직 제어를 위한 경로를 제공합니다.

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Expert Q&A: Your Top Questions Answered

Q1: 왜 상평형장 모델에서 고체-액체(S/L) 계면 특성(두께, 에너지, 이동도)을 주요 변수로 선택했습니까?

A1: 이들 계면 특성은 수지상정의 형태(morphology), 성장 속도, 가지 안정성을 직접적으로 결정하는 핵심 물리량이기 때문입니다. HPDC 공정은 샷 슬리브에서 다이 캐비티로 넘어가면서 열 및 유동 조건이 극적으로 변합니다. 모델이 유체 역학적 난류를 직접 계산하지 않는 대신, 난류가 야기하는 물리적 효과(예: 더 가파른 열 및 용질 구배)를 이러한 계면 파라미터를 조정함으로써 간접적으로, 그러나 효과적으로 모사할 수 있었습니다.

Q2: 시뮬레이션에서 계면 두께를 700nm에서 500nm로 줄인 것이 물리적으로 어떤 의미를 가집니까?

A2: 계면 두께 감소는 액상에서 고상으로의 상변태가 더 ‘날카로운’ 또는 급격한 구배를 통해 일어남을 의미합니다. 물리적으로 이는 다이 캐비티 내의 격렬한 난류가 열 추출을 가속화하여 계면에서의 온도 및 용질 구배를 더 가파르게 만드는 현상을 반영합니다. 이처럼 더 얇아진 계면은 모델이 실험에서 관찰된 것과 같이 더 미세하고 날카로운 수지상정 구조의 형성을 재현할 수 있게 하는 핵심적인 조정이었습니다.

Q3: 이 연구는 실제 HPDC 공정의 3차원적이고 복잡한 유동을 2차원 모델로 단순화했는데, 그 한계와 타당성은 무엇입니까?

A3: 본 연구의 주된 목적은 거시적인 유동 패턴이 아닌, 기존 결정 위에서 새로운 수지상정 가지가 핵 생성되고 성장하는 미시적 ‘응고 물리’ 현상을 포착하는 것이었습니다. 이러한 메커니즘을 규명하는 데는 2차원 모델로도 충분한 타당성을 가집니다. 물론 3차원 효과를 완전히 반영하지 못하는 한계는 있지만, 열 조건 변화에 따른 수지상정 형태 변화라는 핵심 현상을 성공적으로 재현함으로써 연구 목적을 달성했습니다.

Q4: 논문에서 언급된 ‘분리대(segregation band)’의 형성을 이 시뮬레이션이 재현할 수 있습니까?

A4: 본 연구에서 사용된 상평형장 모델은 수지상정 성장과 같은 미세조직 스케일의 응고 현상에 초점을 맞추고 있습니다. 논의(Discussion) 섹션에서 언급된 분리대는 유동이 난류에서 층류로 바뀌거나 ESCs의 분율이 낮아지는 등 주조품 전체에 걸친 거시적인 현상과 관련이 있습니다. 따라서 이 모델의 범위에서는 분리대 형성을 직접 재현하지는 않았습니다.

Q5: 샷 슬리브와 다이 캐비티의 냉각 속도를 각각 100 K/s와 1000 K/s로 설정한 근거는 무엇입니까?

A5: 이 값들은 실제 HPDC 공정에서 일반적으로 보고되는 대표적인 냉각 속도입니다. 논문의 서론 부분에서 “The cooling rate in HPDC in the shot sleeve is about 100 K/s, while in the die is about 1000 K/s [4,5]”라고 명시하고 있습니다. 이는 시뮬레이션이 산업적으로 유의미한 실제 공정 조건을 기반으로 수행되었음을 보여줍니다.


Conclusion: Paving the Way for Higher Quality and Productivity

이 연구는 상평형장 모델링이 고압 다이캐스팅(HPDC) 공정에서 발생하는 복잡한 이중 미세조직 형성 메커니즘을 얼마나 정밀하게 예측할 수 있는지를 명확히 보여주었습니다. 샷 슬리브에서 다이 캐비티로의 급격한 환경 변화, 특히 난류의 영향을 고체-액체 계면 특성 조정을 통해 성공적으로 모델링함으로써, 최종 제품의 품질을 좌우하는 미세조직 제어에 대한 중요한 통찰력을 제공합니다.

(주)에스티아이씨앤디에서는 고객이 수치해석을 직접 수행하고 싶지만 경험이 없거나, 시간이 없어서 용역을 통해 수치해석 결과를 얻고자 하는 경우 전문 엔지니어를 통해 CFD consulting services를 제공합니다. 귀하께서 당면하고 있는 연구프로젝트를 최소의 비용으로, 최적의 해결방안을 찾을 수 있도록 지원합니다.

  • 연락처 : 02-2026-0450
  • 이메일 : flow3d@stikorea.co.kr

Copyright Information

  • This content is a summary and analysis based on the paper “Phase-Field Modelling of Bimodal Dendritic Solidification During Al Alloy Die Casting” by “Maryam Torfeh, Zhichao Niu and Hamid Assadi”.
  • Source: https://doi.org/10.3390/met15010066

This material is for informational purposes only. Unauthorized commercial use is prohibited. Copyright © 2025 STI C&D. All rights reserved.

Figure 2. The predicted shrinkage porosity of test castings: (a) mold temperature of 25 °C and gravity casting (short for 25 °C, 0 rpm); (b) 800 °C, 0 rpm; (c) 25 °C, 200 rpm; (d) 800 °C, 200 rpm; (e) 25 °C, 400 rpm; (f) 800 °C, 400 rpm; (g) 25 °C, 600 rpm; (h) 800 °C, 600 rpm.

결함 없는 TiAl 합금 주조: 수치 해석을 통한 인베스트먼트 캐스팅 최적화

이 기술 요약은 Yi Jia 외 저자가 2015년 Metals 저널에 발표한 “Modeling of TiAl Alloy Grating by Investment Casting” 논문을 기반으로 하며, STI C&D에서 기술 전문가를 위해 분석 및 요약했습니다.

키워드

  • Primary Keyword: TiAl 합금 인베스트먼트 캐스팅
  • Secondary Keywords: 수축 다공성, 수치 해석, ProCAST, 원심 주조, TiAl 합금, 주조 결함

Executive Summary

  • 도전 과제: TiAl 합금은 높은 화학 반응성, 고융점, 낮은 연성 및 가공성으로 인해 복잡한 형상의 부품을 결함 없이 제조하기 어렵습니다.
  • 해결 방법: ProCAST 수치 해석 소프트웨어를 사용하여 TiAl 합금 격자(Grating)의 인베스트먼트 캐스팅 공정을 모델링하고 최적화한 후, 실험을 통해 검증했습니다.
  • 핵심 돌파구: 수치 해석을 통해 수축 다공성 및 기공 결함을 최소화하는 최적의 주조 조건(주형 온도, 회전 속도)을 성공적으로 식별했습니다.
  • 핵심 결론: 수치 해석은 TiAl 합금 인베스트먼트 캐스팅에서 발생하는 결함을 예측하고 제어하여 고품질 부품을 생산하는 데 매우 효과적이고 비용 효율적인 방법입니다.

도전 과제: 이 연구가 CFD 전문가에게 중요한 이유

에너지 및 환경 문제는 경량 소재의 개발을 촉진하고 있습니다. 특히 TiAl 합금은 항공우주 및 자동차 산업에서 기존의 Ni기 초합금을 대체할 유망한 소재로 주목받고 있습니다. 600°C 이상의 고온에서도 우수한 기계적, 내산화성, 내식성 특성을 보이기 때문입니다.

하지만 TiAl 합금은 높은 화학 반응성, 고융점, 낮은 연성 및 가공성 때문에 양산에 어려움이 있습니다. 이러한 문제를 해결하기 위해 복잡한 형상의 부품을 정밀하게 제작할 수 있는 인베스트먼트 캐스팅(Investment Casting)이 주목받고 있습니다. 그러나 주조 공정은 육안으로 관찰할 수 없으며, 전통적인 방식은 경험에 의존하기 때문에 높은 비용과 긴 개발 주기를 요구합니다. 따라서 주조 공정을 사전에 예측하고 최적화할 수 있는 수치 해석 기술의 중요성이 그 어느 때보다 커지고 있습니다.

접근 방식: 연구 방법론 분석

본 연구는 TiAl 합금 격자 부품의 인베스트먼트 캐스팅 공정을 최적화하기 위해 수치 해석과 실험적 검증을 병행했습니다.

  • 수치 해석: 유한 요소 해석(FEM) 소프트웨어인 ProCAST를 사용하여 주형 충전 및 응고 거동을 시뮬레이션했습니다. 해석에 사용된 TiAl 합금(Ti–47Al–2.5V–1Cr at. %)과 ZrO2 주형의 열물성 데이터는 Sung의 연구[13, 14]와 ProCAST에서 제공된 값을 사용했습니다. 시뮬레이션의 주요 변수는 주입 온도(1700°C), 충전 시간(3초), 주형 예열 온도, 회전 속도였습니다.
  • 주조품 제작: “로스트 왁스(lost wax)” 공정을 통해 세라믹 쉘 주형을 제작했습니다. 진공 스컬 용해로(Vacuum Skull Furnace)를 사용하여 TiAl 합금을 용해한 후, 예열된 주형에 주입하여 주조품을 제작했습니다. 테스트용 주조품(직경 400mm)과 최종 풀사이즈 주조품(직경 580mm) 두 가지를 제작했습니다.
  • 특성 분석: 제작된 테스트 주조품에서 시편을 채취하여 미세조직을 광학 현미경으로 관찰하고, 상온 인장 시험을 통해 기계적 특성을 평가했습니다. 파단면은 주사전자현미경(SEM)으로 분석했으며, 풀사이즈 주조품은 X-ray 비파괴 검사를 통해 내부 결함을 확인했습니다.

돌파구: 주요 연구 결과 및 데이터

결과 1: 테스트 주조 공정 변수 최적화

연구팀은 먼저 직경 400mm의 테스트 주조품에 대한 시뮬레이션을 수행하여 최적의 공정 조건을 탐색했습니다. 주형 온도와 회전 속도를 변경하며 수축 다공성(Shrinkage Porosity)과 기공(Voids) 발생 가능성을 예측했습니다.

  • 시뮬레이션 결과, 주형 온도 25°C의 중력 주조(Figure 2a)에서는 주조품 전체에 걸쳐 심각한 수축 다공성이 예측되었습니다.
  • 주형 온도를 800°C로 높이고 400rpm의 원심 주조를 적용했을 때, 수축 다공성(Figure 2f)과 기공(Figure 3f)이 모두 가장 효과적으로 억제되는 것을 확인했습니다. ProCAST에서 예측하는 기공은 가스나 산화물층을 의미하며, 이는 미세 다공성보다 더 심각한 결함으로 간주됩니다. 따라서 주형 온도 800°C, 회전 속도 400rpm이 테스트 주조에 가장 적합한 조건으로 선정되었습니다.

결과 2: 풀사이즈 주조 설계 개선 및 실험적 검증

테스트 주조 결과를 바탕으로 직경 580mm의 풀사이즈 주조품에 대한 시뮬레이션을 진행했습니다. 이때, 용탕의 안정적인 흐름을 위해 게이트 크기를 확장하는 등 러너 시스템을 개선했습니다.

Figure 1. Three-dimensional drawing of runner system for test casting.
Figure 1. Three-dimensional drawing of runner system for test casting.
  • 개선된 설계를 통해 원심력의 효과가 극대화되어, 더 낮은 주형 온도에서도 우수한 결과를 얻을 수 있었습니다. 시뮬레이션 결과, 주형 온도 600°C, 회전 속도 200rpm 조건(Figure 10d, 11d)이 수축 다공성과 기공을 최소화하는 최적의 조건으로 나타났습니다.
  • 이 조건으로 실제 주조품을 제작하여 X-ray 비파괴 검사를 수행한 결과(Figure 12), 시뮬레이션 예측과 유사하게 대부분의 영역에서 결함이 없었으나, 일부 리브(rib)와 디스크 접합부에서 블로우홀(blowhole)과 수축 결함이 관찰되었습니다. 이는 실제 주형의 가스 투과성이 시뮬레이션의 이상적인 조건과 달랐기 때문으로 분석됩니다.
  • 최종적으로 제작된 주조품의 상온 인장 강도는 약 675 MPa, 연신율은 1.7%로 측정되어 양호한 기계적 특성을 보였습니다.
Figure 2. The predicted shrinkage porosity of test castings: (a) mold temperature of 25 °C and gravity casting (short for 25 °C, 0 rpm); (b) 800 °C, 0 rpm; (c) 25 °C, 200 rpm; (d) 800 °C, 200 rpm; (e) 25 °C, 400 rpm; (f) 800 °C, 400 rpm; (g) 25 °C, 600 rpm; (h) 800 °C, 600 rpm.
Figure 2. The predicted shrinkage porosity of test castings: (a) mold temperature of 25 °C and gravity casting (short for 25 °C, 0 rpm); (b) 800 °C, 0 rpm; (c) 25 °C, 200 rpm; (d) 800 °C, 200 rpm; (e) 25 °C, 400 rpm; (f) 800 °C, 400 rpm; (g) 25 °C, 600 rpm; (h) 800 °C, 600 rpm.

R&D 및 운영을 위한 실질적 시사점

  • 공정 엔지니어: 본 연구는 주형 예열 온도와 회전 속도 조절이 TiAl 합금 인베스트먼트 캐스팅의 수축 다공성 및 기공 결함 제어에 결정적임을 보여줍니다. 풀사이즈 부품에 대해 제시된 최적 조건(주형 온도 600°C, 회전 속도 200rpm)은 실제 공정 설정에 중요한 기준점을 제공할 수 있습니다.
  • 품질 관리팀: 논문의 Figure 12(X-ray 이미지)와 Figure 5(미세조직 사진)는 최적화된 조건에서도 발생할 수 있는 결함(미세 다공성, 블로우홀)의 유형과 위치를 명확히 보여줍니다. 이는 비파괴 검사(NDT) 시 중점적으로 확인할 부분을 특정하는 데 도움이 될 수 있습니다.
  • 설계 엔지니어: 테스트 주조에서 풀사이즈 주조로 넘어가면서 러너 시스템을 개선한 사례는, 특히 격자와 같이 얇고 복잡한 부품에서 게이트 설계가 안정적인 용탕 충전과 결함 형성에 얼마나 중요한지를 시사합니다. 이는 초기 설계 단계에서 반드시 고려해야 할 중요한 요소입니다.

논문 상세 정보


Modeling of TiAl Alloy Grating by Investment Casting

1. 개요:

  • 제목: Modeling of TiAl Alloy Grating by Investment Casting
  • 저자: Yi Jia, Shulong Xiao, Jing Tian, Lijuan Xu and Yuyong Chen
  • 발행 연도: 2015
  • 발행 저널/학회: Metals
  • 키워드: numerical simulation; TiAl alloys; investment casting; shrinkage porosity

2. 초록:

TiAl 합금의 인베스트먼트 캐스팅은 TiAl 부품 제조를 위한 가장 유망하고 비용 효율적인 기술이 되었습니다. 본 연구는 TiAl 합금의 인베스트먼트 캐스팅과 관련된 일련의 문제들을 조사하는 것을 목표로 했습니다. 이 주조 모델의 주형 충전 및 응고 과정은 ProCAST를 사용하여 수치적으로 시뮬레이션되었습니다. 수축 다공성은 내장된 공급 기준에 의해 정량적으로 예측되었습니다. 수치 시뮬레이션에서 얻은 결과는 인베스트먼트 블록 주형을 사용하여 진공 스컬 용해로에서 수행된 실험과 비교되었습니다. TiAl 격자의 인베스트먼트 캐스팅은 제안된 방법의 정확성과 타당성을 검증하기 위해 수행되었습니다. 인장 시험 결과, 상온에서 인장 강도와 연신율은 각각 약 675 MPa와 1.7%였습니다. 인베스트먼트 캐스팅된 TiAl 합금의 미세구조와 기계적 특성에 대해 논의했습니다.

3. 서론:

에너지 및 환경 문제는 사회 경제적 발전을 지속하기 위한 주요 장애물이 되었습니다. 경량 소재로 무거운 소재를 대체하는 것은 이 문제를 해결하는 데 효과적입니다. 항공 및 우주항공 소재는 경량, 고강도 소재 개발에 중점을 두고 개발되고 있습니다. TiAl 합금은 고온(600°C 이상)에서 우수한 기계적, 내산화성 및 내식성 특성을 보여 항공기 및 자동차 산업에서 기존의 Ni기 초합금 부품을 대체할 가능성이 있습니다. 그러나 TiAl 합금의 화학적 이질성과 물리적 특성 때문에 시장 도입 노력은 제한적이었습니다. TiAl 기반 부품의 대량 생산에 대한 한계는 TiAl이 매우 높은 화학 반응성, 높은 용융 온도, 낮은 연성 및 불량한 가공성을 보인다는 점입니다. 반면, 주조는 터빈 블레이드, 터보차저 회전자 및 배기 밸브와 같은 복잡한 형상의 부품에 대해 상당한 이점을 보입니다. 이러한 문제들 때문에, 좋은 표면 마감과 낮은 생산 비용으로 거의 최종 형상에 가까운 부품을 직접 생산할 수 있는 인베스트먼트 캐스팅이 점점 더 많은 관심을 받고 있습니다.

4. 연구 요약:

연구 주제의 배경:

TiAl 합금은 항공우주 및 자동차 산업에서 고온 성능이 요구되는 부품의 경량화를 위한 핵심 소재이지만, 제조 공정이 까다로워 상용화에 어려움을 겪고 있습니다. 인베스트먼트 캐스팅은 복잡한 형상을 정밀하게 제작할 수 있는 효과적인 방법입니다.

이전 연구 현황:

이전 연구들은 주로 CaO, Al2O3, ZrO2, Y2O3와 같은 내화물과 용융 TiAl 합금 간의 열역학적 안정성 및 상호작용 메커니즘에 초점을 맞추어 왔습니다. 그러나 경험에 기반한 주조 공정은 비용이 많이 들고 주기가 길다는 단점이 있습니다.

연구 목적:

본 연구의 목적은 Ti–47Al–2.5V–1Cr (at. %) 합금을 사용하여 인베스트먼트 캐스팅으로 격자(Grating) 부품을 제작하고, 수치 해석을 통해 공정을 최적화하며, 그 과정에서 나타나는 미세구조와 기계적 특성을 분석하는 것입니다.

핵심 연구:

ProCAST 소프트웨어를 이용한 수치 해석을 통해 주형 충전 및 응고 과정을 시뮬레이션하여 수축 다공성을 예측하고, 이를 바탕으로 최적의 주조 공정 변수(주형 온도, 회전 속도)를 도출했습니다. 이후 실제 주조 실험을 통해 시뮬레이션 결과의 타당성을 검증하고, 제작된 주조품의 품질과 기계적 특성을 평가했습니다.

5. 연구 방법론

연구 설계:

본 연구는 수치 해석(시뮬레이션)과 실험적 검증을 결합한 방식으로 설계되었습니다. 먼저 테스트용 소형 주조품(직경 400mm)에 대한 시뮬레이션을 통해 공정 변수의 영향을 분석하고 최적 조건을 찾은 후, 이를 바탕으로 러너 시스템을 개선하여 풀사이즈 주조품(직경 580mm)을 제작하고 평가했습니다.

데이터 수집 및 분석 방법:

  • 수치 해석: ProCAST 소프트웨어를 사용하여 주형 충전, 온도장, 응고 파라미터를 계산하고, 이를 통해 수축 다공성과 기공 발생을 예측했습니다.
  • 주조품 제작: 로스트 왁스 공법으로 ZrO2 기반의 세라믹 주형을 제작하고, VAM-150 진공 스컬 용해로를 사용하여 TiAl 합금을 용해 및 주입했습니다.
  • 특성 분석: 광학 현미경 및 SEM을 사용하여 미세구조와 파단면을 분석했으며, 만능시험기를 이용해 상온 인장 특성을 측정했습니다. 풀사이즈 주조품은 X-ray 비파괴 검사를 통해 내부 결함을 확인했습니다.

연구 주제 및 범위:

이 연구는 TiAl 합금 격자 부품의 인베스트먼트 캐스팅 공정에 초점을 맞춥니다. 주요 연구 범위는 수치 해석을 통한 공정 최적화, 수축 다공성 예측, 실험적 검증, 그리고 최종 주조품의 미세구조 및 기계적 특성 평가를 포함합니다.

6. 주요 결과:

주요 결과:

  • 직경 400mm와 580mm의 TiAl 합금 격자 부품을 성공적으로 제작했습니다.
  • 테스트 주조품의 최적 주조 조건은 주입 온도 1700°C, 주형 예열 온도 800°C, 회전 속도 400rpm으로 확인되었습니다.
  • 풀사이즈 주조품의 최적 주조 조건은 주입 온도 1700°C, 주형 예열 온도 600°C, 회전 속도 200rpm으로 도출되었습니다.
  • 제작된 시편은 미세하게 분리된 γ-입자를 포함하는 전형적인 완전 층상(fully lamellar) 미세구조를 보였으며, 상온에서 인장 강도 약 675 MPa, 연신율 1.7%의 준수한 기계적 특성을 나타냈습니다.
Figure 7. Slice view at a mold temperature of 800 °C and rotation speed of 400 rpm, (a) disk and (b) rib.
Figure 7. Slice view at a mold temperature of 800 °C and rotation speed of 400 rpm, (a) disk and (b) rib.

Figure 목록:

  • Figure 1. Three-dimensional drawing of runner system for test casting.
  • Figure 2. The predicted shrinkage porosity of test castings: (a) mold temperature of 25 C and gravity casting (short for 25 C, 0 rpm); (b) 800 C, 0 rpm; (c) 25 C, 200 rpm; (d) 800 C, 200 rpm; (e) 25 C, 400 rpm; (f) 800 C, 400 rpm; (g) 25 C, 600 rpm; (h) 800 C, 600 rpm.
  • Figure 3. Predicted voids of test castings, (a–h), the same as the Figure 2.
  • Figure 4. Test casting (a,b) showed the specimen locations: I, II, III, IV, and V, for Figure 5a–e, respectively; VI for Figure 6a; Tensile for the tensile test.
  • Figure 5. Optical microstructure of test casting (a–e) were from the center hole to the outer edge, and the interval between the two samples measured 20 mm.
  • Figure 6. Micro-defects of test casting, (a) pore and (b–d) shrinkage.
  • Figure 7. Slice view at a mold temperature of 800 C and rotation speed of 400 rpm, (a) disk and (b) rib.
  • Figure 8. Tensile test stress-strain curve obtained at room temperature (a) and fracture surface (b) of as-cast TiAl specimen, transgranular (TG) and translamellar (TL).
  • Figure 9. Three-dimensional drawing of runner system for full-size casting.
  • Figure 10. The predicted shrinkage porosity of full-size castings, (a) mold temperature of 600 C and gravity casting (short for 600 C, 0 rpm); (b) 200 C, 200 rpm; (c) 400 C, 200 rpm; (d) 600 C, 200 rpm; (e) 600 C, 400 rpm.
  • Figure 11. Predicted voids of full-size castings, (a–e) the same as the Figure 10.
  • Figure 12. X-ray nondestructive inspection results of full-size casting, (a) the grating casting and (b–d) correspond to b, c and d areas on (a), respectively.

7. 결론:

원심 인베스트먼트 캐스팅에 의한 TiAl 격자의 주형 충전 및 응고 과정이 시뮬레이션되었습니다. 본 연구로부터 다음과 같은 주요 결론을 도출했습니다:

  1. 직경 400mm와 580mm의 격자 부품이 성공적으로 생산되었습니다.
  2. 테스트 주조의 주조 파라미터는 주입 온도 1700°C, 주형 예열 온도 800°C, 회전 속도 400rpm이었습니다.
  3. 풀사이즈 주조의 최적 주조 파라미터는 주입 온도 1700°C, 주형 예열 온도 600°C, 회전 속도 200rpm이었습니다.
  4. 시편은 미세하게 분리된 γ-입자를 나타내는 전형적인 완전 층상 미세구조를 보였습니다. 주조된 TiAl 시편은 적절한 기계적 특성을 보였습니다. 상온에서 인장 강도와 연신율은 각각 약 675 MPa와 1.7%였습니다.

8. 참고 문헌:

  1. Kim, Y.W. Gamma-titanium aluminides: Their status and future. J. Miner. 1995, 47, 39–41.
  2. Yamaguchi, M.; Inui, H.; Ito, K. High-temperature structural intermetallics. Acta Mater. 2000, 48, 307–322.
  3. Varin, R.A.; Gao, Q. The effect of chromium on the microstructure and micromechanical properties of TiAl-base alloys. Mater. Manuf. Process. 1996, 11, 381–410.
  4. Kuang, J.P.; Harding, R.A.; Campbell, J. Microstructures and properties of investment castings of y-titanium aluminide. Mater. Sci. Eng. A 2002, 329, 31–37.
  5. Gomes, F.; Barbosa, J.; Ribeiro, C.S. Induction melting of y-TiAl in CaO crucibles. Intermetallics 2008, 16, 1292–1297.
  6. Tsukihashi, F.; Tawara, E.; Hatta, T. Thermodynamics of calcium and oxygen in molten titanium and titanium-aluminum alloy. Metall. Mater. Trans. B 1996, 27, 967–972.
  7. Barbosa, J.; Ribeiro, C.S.; Monteiro, A.C. Influence of superheating on casting of y-TiAl. Intermetallics 2007, 15, 945–955.
  8. Kuang, J.P.; Harding, R.A.; Campbell, J. Investigation into refractories as crucible and mould materials for melting and casting y-TiAl alloys. Mater. Sci. Technol. 2000, 16, 1007–1016.
  9. Jia, Q.; Cui, Y.Y.; Yang, R. Intensified interfacial reactions between y-titanium aluminide and CaO stabilised ZrO2. Int. J. Cast Met. Res. 2004, 17, 23–27.
  10. Nowak, R.; Lanata, T.; Sobczak, N.; Ricci, E.; Giuranno, D.; Novakovic, R.; Holland-Moritz, D.; Egry, I. Surface tension of y-TiAl-based alloys. J. Mater. Sci. 2010, 45, 1993–2001.
  11. Cui, R.J.; Gao, M.; Zhang, H.; Gong, S.K. Interactions between TiAl alloys and yttria refractory material in casting process. J. Mater. Process. Technol. 2010, 210, 1190–1196.
  12. Teodoro, O.; Barbosa, J.; Naia, M.D.; Moutinho, A.M.C. Effect of low level contamination on TiAl alloys studied by SIMS. Appl. Surf. Sci. 2004, 231, 854–858.
  13. Sung, S.Y.; Kim, Y.J. Modeling of titanium aluminides turbo-charger casting. Intermetallics 2007, 15, 468–474.
  14. Fu, P.X.; Kang, X.H.; Ma, Y.C.; Liu, K.; Li, D.Z.; Li, Y.Y. Centrifugal casting of TiAl exhaust valves. Intermetallics 2008, 16, 130–138.
  15. Yang, R.; Cui, Y.Y.; Dong, L.M.; Jia, Q. Alloy development and shell mould casting of y-TiAl. J. Mater. Process. Technol. 2003, 135, 179–188.

전문가 Q&A: 자주 묻는 질문

Q1: 시뮬레이션과 실험에서 주입 온도를 1700°C로 설정한 이유는 무엇인가요?

A1: 논문에 따르면, TiAl 합금은 밀도가 낮고 응고 구간이 좁아 유동성이 좋지 않기 때문에 가능한 한 높은 온도로 주입하는 것이 주조 품질 향상에 유리합니다. 1700°C는 실험에 사용된 장비(Vacuum Skull Furnace)가 도달할 수 있는 최고 용해 온도였기 때문에 이 온도를 주입 온도로 선택했습니다.

Q2: Figure 2를 보면, 회전 속도를 400rpm에서 600rpm으로 높였을 때 오히려 수축 다공성이 증가했습니다. 그 이유는 무엇인가요?

A2: 논문에서는 초기 테스트 주조의 러너 시스템 설계 때문이라고 설명합니다. 과도한 원심력은 용탕의 흐름을 깨뜨려 오히려 충전 불량을 유발할 수 있습니다. 즉, 해당 러너 설계에서는 600rpm의 회전 속도가 너무 높아 용탕이 안정적으로 주형을 채우지 못하고 결함이 악화된 것입니다.

Q3: 테스트 주조의 최적 조건은 800°C, 400rpm이었지만, 풀사이즈 주조에서는 600°C, 200rpm으로 변경되었습니다. 어떤 이유로 조건이 바뀌었나요?

A3: 풀사이즈 주조에서는 테스트 주조의 시뮬레이션 결과를 바탕으로 러너 시스템(특히 게이트)을 개선했습니다. 개선된 설계 덕분에 용탕이 더 안정적으로 공급되고 원심력의 효과가 향상되어, 더 낮은 주형 예열 온도와 회전 속도로도 충분한 충전성을 확보할 수 있었습니다. 주형 온도를 낮추면 주형과 용탕 간의 계면 반응을 줄일 수 있는 장점도 있습니다.

Q4: ProCAST 시뮬레이션에서 예측한 “수축 다공성(shrinkage porosity)”과 “기공(voids)”은 어떤 차이가 있나요?

A4: 논문에 따르면, ProCAST에서 예측하는 “기공(voids)”은 갇힌 가스(air bubbles)나 산화물층(oxide layers)을 의미합니다. 이는 미세한 “수축 다공성(shrinkage porosity)”보다 더 심각한 결함으로 간주됩니다. 왜냐하면 고온 등방압 가압법(HIP) 공정으로 기공은 제거할 수 있지만, 미세 다공성은 제거하기 어렵기 때문입니다. 따라서 연구팀은 기공이 없는 조건(Figure 3f)을 우선적으로 고려했습니다.

Q5: Figure 12의 실험 결과(X-ray)에서는 시뮬레이션에서 예측하지 못한 블로우홀(blowhole) 같은 결함이 관찰되었습니다. 논문에서 그 원인을 어떻게 추정하나요?

A5: 논문에서는 이러한 결함이 실제 실험에 사용된 주형의 가스 투과성(permeability)이 충분하지 않았기 때문일 수 있다고 추정합니다. 시뮬레이션은 이상적인 조건을 가정하지만, 실제 주조에서는 주형의 가스 배출 능력이 부족하면 용탕 내 가스가 빠져나가지 못하고 블로우홀과 같은 결함을 형성할 수 있습니다.


결론: 더 높은 품질과 생산성을 향한 길

TiAl 합금의 복잡한 특성으로 인한 주조의 어려움은 고부가가치 산업에서 큰 도전 과제였습니다. 본 연구는 TiAl 합금 인베스트먼트 캐스팅 공정에서 수치 해석이 어떻게 결함을 예측하고 최적의 공정 조건을 찾아낼 수 있는지를 명확하게 보여주었습니다. 시뮬레이션을 통해 주형 온도와 회전 속도 같은 핵심 변수를 최적화함으로써, 양호한 기계적 특성을 가진 고품질의 격자 부품을 성공적으로 생산할 수 있었습니다. 이는 경험에 의존하던 기존 방식에서 벗어나, 데이터 기반의 예측을 통해 개발 시간과 비용을 획기적으로 줄일 수 있음을 의미합니다.

(주)에스티아이씨앤디에서는 고객이 수치해석을 직접 수행하고 싶지만 경험이 없거나, 시간이 없어서 용역을 통해 수치해석 결과를 얻고자 하는 경우 전문 엔지니어를 통해 CFD consulting services를 제공합니다. 귀하께서 당면하고 있는 연구프로젝트를 최소의 비용으로, 최적의 해결방안을 찾을 수 있도록 지원합니다.

  • 연락처 : 02-2026-0450
  • 이메일 : flow3d@stikorea.co.kr

저작권 정보

  • 이 콘텐츠는 “Yi Jia” 외 저자의 논문 “Modeling of TiAl Alloy Grating by Investment Casting”을 기반으로 한 요약 및 분석 자료입니다.
  • 출처: https://doi.org/10.3390/met5042328

이 자료는 정보 제공 목적으로만 사용됩니다. 무단 상업적 사용을 금합니다. Copyright © 2025 STI C&D. All rights reserved.

Figure 3. Metallic die to produce Aluminium foams with Alulight.

HPDC 혁신: 알루미늄 폼 코어를 활용한 마그네슘 복합 주조로 35% 경량화 달성

이 기술 요약은 Iban Vicario 외 저자가 2016년 Metals 학술지에 게재한 “Aluminium Foam and Magnesium Compound Casting Produced by High-Pressure Die Casting” 논문을 기반으로 하며, STI C&D의 기술 전문가에 의해 분석 및 요약되었습니다.

키워드

  • Primary Keyword: 고압 다이캐스팅 (HPDC)
  • Secondary Keywords: 마그네슘 복합 주조, 알루미늄 폼 코어, 하이브리드 마그네슘 알루미늄 폼 주조 복합재, 경량화

Executive Summary

  • The Challenge: 연비 향상과 이산화탄소 배출 감소를 위해 자동차 및 운송 부품의 무게를 줄여야 하는 시급한 과제.
  • The Method: 마그네슘 주조 부품 내부에 알루미늄 폼을 코어로 사용하여 고압 다이캐스팅(HPDC) 공정을 통해 복합 주조품을 생산하는 방법.
  • The Key Breakthrough: 외부 스킨이 있는 특정 알루미늄 폼(Alulight)을 사용하고, 사출 파라미터를 최적화하여 코어 파손 없이 건전한 복합 주조품을 개발하고 시제품에서 35%의 중량 감소를 달성.
  • The Bottom Line: 알루미늄 폼 코어를 사용한 HPDC는 플라스틱이나 탄소 섬유의 대안으로, 경량 부품의 대량 생산을 위한 실행 가능한 솔루션임을 입증.
Figure 1. Some of the most employed processes to produce aluminium foams.
Figure 1. Some of the most employed processes to produce aluminium foams.

The Challenge: Why This Research Matters for CFD Professionals

운송 산업에서 부품 무게를 줄이는 것은 연비 개선과 직결되는 핵심 과제입니다. 이를 위해 기존의 철강 부품을 플라스틱, 탄소 섬유, 알루미늄, 마그네슘 합금 등으로 대체하려는 노력이 계속되고 있습니다. 특히 고압 다이캐스팅(HPDC)으로 생산된 마그네슘 부품은 경량성과 기계적 특성의 균형을 제공하지만, 더 큰 폭의 경량화를 달성하기 위한 새로운 방법이 요구됩니다.

기존에는 솔트 코어(salt core)를 사용하여 중공 부품을 만드는 방법이 있었으나, 코어 제거의 어려움과 부품에 구멍이 필요하다는 단점이 있었습니다. 알루미늄 폼을 코어로 사용하는 것은 매력적인 대안이지만, HPDC 공정의 높은 사출 속도와 압력으로 인해 폼 코어가 변형되거나 파손될 위험이 매우 큽니다. 따라서, 폼 코어의 붕괴를 막고 주조 결함을 방지하면서 안정적으로 복합 주조품을 생산하는 기술 개발이 중요한 산업적 과제였습니다.

The Approach: Unpacking the Methodology

본 연구에서는 자전거 부품인 로드(rod)를 대상으로, 마그네슘-알루미늄 폼 복합 주조품 개발을 목표로 했습니다. 연구진은 다음과 같은 재료와 방법론을 사용했습니다.

  • 기본 합금: AM60B 마그네슘 합금
  • 알루미늄 폼 코어: 세 가지 다른 유형의 알루미늄 폼을 테스트했습니다.
    1. Alporas: 외부 스킨이 없는 저밀도 폼 (0.25–0.4 Kg/dm³)
    2. Formgrip: 외부 스킨이 없는 폼 (0.4–0.65 Kg/dm³)
    3. Alulight: 외부 스킨이 있는 폼 (0.54–1.55 Kg/dm³)
  • 핵심 변수: 최종 주조품의 품질에 영향을 미치는 다양한 공정 변수를 체계적으로 평가했습니다.
    • 알루미늄 폼의 종류 및 밀도
    • 용탕 온도 (680 °C 및 720 °C)
    • 사출 압력 (16–80 MPa)
    • 플런저 속도 (20–80 m/s)
    • 폼 코어의 금형 내 배치 방향
  • 평가 방법: 제작된 복합 주조품은 시각 검사, X-ray 검사를 통해 내부 건전성을 확인했으며, 인장 시험을 통해 기계적 특성을 평가했습니다.
Figure 2. (a) 3D rod design; and (b) detail of the placement and example of an aluminium foam core.
Figure 2. (a) 3D rod design; and (b) detail of the placement and example of an aluminium foam core.

The Breakthrough: Key Findings & Data

연구진은 다양한 실험을 통해 HPDC 공정에서 알루미늄 폼 코어를 성공적으로 적용하기 위한 핵심 조건들을 발견했습니다.

Finding 1: 폼 코어의 ‘외부 스킨’이 성패를 좌우

알루미늄 폼 코어가 HPDC의 가혹한 조건을 견디기 위해서는 연속적인 외부 스킨(external skin)의 존재가 필수적이었습니다.

  • 플라스틱 사출을 통한 압력 테스트에서, 외부 스킨이 없는 Alporas와 Formgrip 폼은 16 MPa의 낮은 압력에서도 파손되었습니다. 반면, 외부 스킨이 있는 Alulight 폼은 마그네슘 HPDC의 표준 압력인 40 MPa에서도 온전함을 유지했습니다 (Table 4 참조).
  • 실제 마그네슘 HPDC 시험에서도 Alporas와 Formgrip 폼은 사출 과정에서 완전히 파괴되었지만(Figure 12), Alulight 폼은 손상 없이 코어로서의 역할을 수행했습니다. 이는 외부 스킨이 사출 압력에 대한 기계적 저항성을 제공하기 때문입니다.

Finding 2: 사출 조건 및 코어 배치의 최적화

건전한 복합 주조품을 얻기 위해서는 사출 조건과 코어 배치를 정밀하게 제어해야 했습니다.

  • 용탕 온도: 용탕 온도가 680 °C일 때는 미충전(short fill) 및 콜드셧(cold shut) 결함이 발생했습니다(Figure 8a). 결함 없는 충전을 위해서는 최소 720 °C의 용탕 온도가 필요했습니다.
  • 코어 배치: 폼 코어를 용탕 흐름에 수평으로 배치했을 때, 용탕의 직접적인 충격으로 인해 전단 파괴가 발생했습니다(Figure 15). 반면, 코어를 용탕 흐름에 수직으로 배치하자 코어 손상 없이 건전한 부품을 얻을 수 있었습니다(Figure 16).
  • 사출 속도 및 압력: 2단 사출 속도를 20 m/s로 낮추자 심각한 미충전이 발생했습니다(Figure 18). 표준 마그네슘 HPDC 조건인 2단 사출 속도 80 m/s와 사출 압력 80 MPa를 적용했을 때, 미세한 수축 기공만 존재하는 건전한 부품을 얻을 수 있었습니다(Figure 19).

Practical Implications for R&D and Operations

  • For Process Engineers: 이 연구는 알루미늄 폼 코어 복합 주조 시 최소 720°C의 용탕 온도와 80 m/s의 2단 사출 속도 유지가 중요함을 시사합니다. 특히, 게이트 위치 대비 폼 코어의 방향을 수직으로 설계하여 용탕의 직접적인 충격을 최소화하는 것이 코어 파손을 막는 핵심 공정 변수입니다.
  • For Quality Control Teams: 논문의 X-ray 이미지(Figure 19)는 외부 스킨이 있는 코어를 사용했을 때 가스 기공 없이 내부 코어의 건전성이 유지됨을 보여줍니다. 이는 복합 주조품의 새로운 품질 검사 기준으로 활용될 수 있습니다.
  • For Design Engineers: 본 연구 결과는 스퀴즈 핀(squeeze pin)과 같이 국부적으로 극히 높은 압력(최대 200 MPa)을 가하는 설계는 폼 코어 주변에 적용할 수 없음을 보여줍니다. 따라서 부품 설계 초기 단계부터 코어의 위치와 용탕 흐름을 고려하여 수축 기공을 제어하는 설계가 필요합니다.

Paper Details


Aluminium Foam and Magnesium Compound Casting Produced by High-Pressure Die Casting

1. Overview:

  • Title: Aluminium Foam and Magnesium Compound Casting Produced by High-Pressure Die Casting
  • Author: Iban Vicario, Ignacio Crespo, Luis Maria Plaza, Patricia Caballero, and Ion Kepa Idoiaga
  • Year of publication: 2016
  • Journal/academic society of publication: Metals
  • Keywords: high pressure die casting (HPDC); hybrid magnesium aluminium foam cast composite; aluminium foam core; magnesium cast composite

2. Abstract:

오늘날 차량 설계에서 연비 소비와 이산화탄소 배출은 두 가지 주요 초점이며, 더 가벼운 재료를 사용하여 차량의 무게를 줄이는 것을 촉진합니다. 이 연구의 목적은 알루미늄 폼을 마그네슘 주조 부품의 코어로 사용하여 고압 다이캐스팅(HPDC)을 통해 얻어진 특성과 무게 사이의 절충안을 가진 복합 주조품을 얻기 위해 다른 알루미늄 폼과 사출 파라미터의 영향을 평가하는 것입니다. 최종 주조 제품 품질에 대한 다른 알루미늄 폼과 사출 파라미터의 영향을 평가하기 위해, 알루미늄 폼의 종류와 밀도, 금속 온도, 플런저 속도, 증배 압력이 적절한 값 범위 내에서 변경되었습니다. 얻어진 복합 HPDC 주조품은 시각 및 RX 검사를 수행하여 연구되었으며, 알루미늄 폼 코어가 있는 건전한 복합 주조품을 얻었습니다. 폼 표면의 외부 연속층의 존재와 사출 조건을 지지하기 위한 폼의 올바른 배치는 양질의 부품을 얻을 수 있게 합니다. HPDC 공정으로 처리된 마그네슘-알루미늄 폼 복합재는 자전거 응용 분야를 위해 개발되었으며, 기계적 특성의 적절한 조합과 특히 시연 부품에서 감소된 무게를 얻었습니다.

3. Introduction:

운송 산업에서 강철 및 주철 부품을 플라스틱, 탄소 섬유 또는 알루미늄 및 마그네슘 합금으로 대체하여 부품의 무게를 줄일 필요성은 운송 산업의 주요 동력 중 하나가 되었습니다. 자전거 산업의 경우, 고성능 자전거를 위해 강철, 알루미늄, 티타늄과 같은 재료를 탄소 섬유로 대체하는 것이 명확한 경향입니다. HPDC로 생산된 마그네슘 부품은 이미 많은 자동차 및 자전거 응용 분야에 사용되고 있지만, 업계는 마그네슘 경량 구조가 제공하는 가벼움과 기계적 특성의 균형이 해결책이 될 수 있는 새로운 부품을 계속 찾고 있습니다. HPDC는 생산 다이의 높은 비용이 상쇄되는 대규모 생산 시리즈(연간 약 5000-10,000개 이상)에 경제적으로 실행 가능한 고생산성 공정입니다.

4. Summary of the study:

Background of the research topic:

차량 경량화는 연비 향상과 CO2 배출 감소를 위한 핵심 과제입니다. 마그네슘은 경량 소재로 주목받고 있으며, HPDC는 복잡한 형상의 부품을 대량 생산하는 데 적합한 공정입니다.

Status of previous research:

기존의 경량화 기술로는 중공 부품을 만들기 위한 솔트 코어 사용, 이종 금속 복합재 등이 있었으나, 각각 공정의 어려움이나 계면 결합 문제 등의 한계가 있었습니다. 알루미늄 폼을 코어로 사용하는 아이디어는 있었지만, HPDC의 고압, 고속 환경에서 폼이 파손되는 문제 때문에 상용화가 어려웠습니다.

Purpose of the study:

본 연구는 HPDC 공정을 사용하여 알루미늄 폼을 코어로 내장한 마그네슘 복합 주조품을 개발하는 것을 목표로 합니다. 이를 위해 다양한 종류의 알루미늄 폼과 사출 공정 변수가 최종 제품의 품질과 무게 감소에 미치는 영향을 평가하고, 자전거 부품에 적용 가능한 최적의 공정을 확립하고자 합니다.

Core study:

세 가지 다른 알루미늄 폼(Alporas, Formgrip, Alulight)을 AM60B 마그네슘 합금과 함께 사용하여 HPDC 복합 주조를 수행했습니다. 용탕 온도, 사출 압력, 사출 속도, 폼 코어의 배치 등 주요 공정 변수를 변경하며 실험을 진행했습니다. 제작된 시편은 시각 검사, X-ray 검사를 통해 내부 결함 및 코어의 건전성을 평가하고, 인장 시험을 통해 기계적 특성을 분석하여 최적의 폼 종류와 공정 조건을 도출했습니다.

5. Research Methodology

Research Design:

본 연구는 실험적 접근 방식을 통해 진행되었습니다. 먼저, 세 종류의 알루미늄 폼을 준비하고, 이들의 밀도와 특성을 파악했습니다. 이후, 용탕 온도, 사출 압력 등 핵심 HPDC 공정 변수를 체계적으로 변화시키면서 마그네슘 복합 주조품을 제작했습니다.

Data Collection and Analysis Methods:

제작된 주조품은 시각 검사를 통해 표면 결함을 확인하고, General Electric X-cube 44XL 장비를 이용한 X-ray 분석을 통해 내부 코어의 파손 여부와 기공 분포를 평가했습니다. 또한, Instron 3369 만능시험기를 사용하여 인장 강도, 항복 강도, 연신율 등 기계적 특성을 측정하고, 기본 AM60B 합금과 비교 분석했습니다.

Research Topics and Scope:

연구 범위는 AM60B 마그네슘 합금과 세 가지 알루미늄 폼(Alporas, Formgrip, Alulight)을 사용한 HPDC 복합 주조에 한정됩니다. 주요 연구 주제는 (1) 알루미늄 폼의 종류와 밀도가 HPDC 공정에서의 안정성에 미치는 영향, (2) 용탕 온도, 사출 압력 및 속도, 코어 배치가 최종 주조품 품질에 미치는 영향, (3) 개발된 복합 주조품의 기계적 특성 및 경량화 효과 평가입니다. 최종적으로 자전거 로드 부품을 시제품으로 제작하여 실용 가능성을 검증했습니다.

6. Key Results:

Key Results:

  • 폼 코어의 건전성: 연속적인 외부 스킨이 있는 Alulight 폼만이 40 MPa의 HPDC 사출 압력을 견딜 수 있었습니다. 외부 스킨이 없는 Alporas와 Formgrip 폼은 공정 중 파괴되었습니다.
  • 최적 주조 온도: 720 °C의 용탕 온도가 미충전 및 콜드셧 결함을 방지하기 위한 최소 온도로 확인되었습니다.
  • 코어 배치: 폼 코어를 용탕 흐름에 수직으로 배치했을 때 코어 손상 없이 건전한 부품을 얻을 수 있었습니다. 수평 배치는 코어의 전단 파괴를 유발했습니다.
  • 사출 조건: 2단 사출 속도 80 m/s, 사출 압력 80 MPa의 표준 HPDC 조건에서 가장 건전한 부품이 생산되었습니다.
  • 경량화 효과: 0.56 Kg/dm³ 밀도의 Alulight 폼을 사용하여 제작된 자전거 로드 시제품은 기존 부품 대비 약 35%의 총 중량 감소를 달성했습니다.
  • 기계적 특성: 복합 주조품의 인장 강도(122 MPa)는 순수 AM60B 부품(219 MPa)보다 낮았으나, 이는 알루미늄 폼과 마그네슘 간의 화학적 결합 부재에 기인합니다.
Figure 3. Metallic die to produce Aluminium foams with Alulight.
Figure 3. Metallic die to produce Aluminium foams with Alulight.

Figure List:

  • Figure 1. Some of the most employed processes to produce aluminium foams.
  • Figure 2. (a) 3D rod design; and (b) detail of the placement and example of an aluminium foam core.
  • Figure 3. Metallic die to produce Aluminium foams with Alulight.
  • Figure 4. Metallic die to die cast magnesium over the aluminium foam.
  • Figure 5. The plastic injection mould with an aluminium foam.
  • Figure 6. HPDC process in order to obtain the magnesium-aluminium foam core composite.
  • Figure 7. Detail of fixing pins in the fixed die cavity for placing the aluminium foam.
  • Figure 8. (a) Short fill and cold shut defects; and (b) gas porosity defects.
  • Figure 9. Central aluminium core covered with AM60B.
  • Figure 10. Different configurations for plastic injection over the aluminium foams.
  • Figure 11. (a) Alpora’s foam (0.25 to 0.4 Kg/dm³); and (b) Formgrip’s foam (0.4 to 0.65 Kg/dm³).
  • Figure 12. HPDC part with totally destroyed aluminium foam.
  • Figure 13. (a) Placement of a skinned foam with a non-skin area in the die; and (b) release of gas from the foam in the non-skinned area.
  • Figure 14. 1.55 Kg/dm³ Aluminium foam after squeeze pin application.
  • Figure 15. Horizontal placement to the metal flow of the core.
  • Figure 16. Horizontal core placement to metal flow.
  • Figure 17. Rod made by magnesium HPDC with the internal core of aluminium foam.
  • Figure 18. Reduced second phase speed (20 m/s) HPDC cast part.
  • Figure 19. Injected HPDC with core foam at standard parameters.

7. Conclusion:

HPDC 마그네슘 알루미늄 폼 복합재는 부품 무게 감소가 요구되는 응용 분야를 위해 개발되었습니다. Alulight 공정으로 생산된 최적의 알루미늄 코어 폼은 실험적 접근을 통해 정의되었습니다. Alulight 공정은 복합재 내부 결함의 존재를 피하는 외부 스킨을 가진 폐쇄 기공 폼을 얻을 수 있게 합니다. 코어 폼의 밀도는 0.54에서 1.55 Kg/dm³까지 변경될 수 있습니다. 폼 기공률의 조절은 특정 성능에 맞게 특성을 조정하고 부품을 맞춤화할 수 있게 하지만, 주된 목표가 무게 감소인 응용 분야에서는 0.54 kg/dm³의 폼만이 주조 조건을 극복했습니다. 자전거 로드에 알루미늄 폼을 사용하여 재료 및 생산에 드는 예상 비용은 부품당 약 0.3유로로 합리적인 비용입니다. 개발된 복합 주조품은 자전거 로드 생산에 사용되었습니다. 인장 시험은 이 응용 분야에 대한 복합 주조의 유효성과 현재 사용되는 알루미늄, 티타늄 또는 탄소 섬유 재료를 대체할 실제 잠재력을 확인했습니다. 부품 총 무게의 35% 감소가 달성되었습니다. 부품에 따라 더 높은 감소가 가능합니다. 마그네슘 HPDC는 플라스틱 및 알루미늄 부품의 대안으로 폼을 사용한 복합재의 대량 생산을 위한 해결책이 될 수 있습니다.

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Expert Q&A: Your Top Questions Answered

Q1: 왜 세 가지 다른 유형의 알루미늄 폼을 테스트했나요?

A1: 연구진은 알루미늄 폼의 밀도, 제조 방법, 그리고 특히 ‘외부 스킨’의 유무가 HPDC 공정의 고압, 고속 환경을 견디는 능력에 어떤 영향을 미치는지 평가하기 위해 세 가지 유형을 선택했습니다. 이 비교를 통해 Alporas와 Formgrip(스킨 없음)은 파손되고 Alulight(스킨 있음)만 성공함으로써, 외부 스킨이 코어의 기계적 건전성을 유지하는 데 결정적인 요소임을 명확히 밝힐 수 있었습니다.

Q2: 논문에서 알루미늄 폼과 마그네슘 사이에 화학적 결합이 없다고 언급했는데, 이것이 기계적 특성에 어떤 의미를 갖나요?

A2: 이는 복합 주조품의 최종 기계적 특성이 주로 외부의 마그네슘 주조부에 의해 결정된다는 것을 의미합니다. 논문의 토론 섹션에서 언급했듯이, 폼 표면의 알루미나 산화막이 두 금속 간의 직접적인 결합을 방해합니다. 결과적으로 Table 5에서 볼 수 있듯이, 복합재의 인장 강도(122 MPa)는 순수 AM60B 합금(219 MPa)보다 현저히 낮습니다. 이 기술은 강도 향상보다는 경량화에 초점을 맞춘 응용에 더 적합합니다.

Q3: 폼 코어의 붕괴를 막는 가장 중요한 요인은 무엇이었습니까?

A3: 가장 중요한 요인은 폼 코어 표면에 존재하는 연속적인 ‘외부 스킨’이었습니다. Alulight 폼의 성공과 Alporas 및 Formgrip 폼의 실패가 이를 명백히 보여줍니다. 약 1mm 두께의 이 스킨은 사출 시 용탕의 높은 압력과 속도로부터 내부의 다공성 구조를 보호하는 견고한 방어막 역할을 했습니다.

Q4: 35%의 중량 감소는 어떻게 계산되었나요?

A4: 이 수치는 0.56 Kg/dm³ 밀도의 Alulight 폼 코어를 사용하여 제작된 최종 부품(자전거 로드)의 총 중량을, 동일한 형상의 순수 마그네슘 부품과 비교하여 계산한 것입니다. 즉, 부품 내부를 알루미늄 폼으로 대체함으로써 달성된 전체 무게 감소율을 의미합니다.

Q5: 이 공정은 모든 형상의 부품에 적용할 수 있습니까?

A5: 연구 결과는 형상에 제약이 있음을 시사합니다. 첫째, 코어 파손을 막기 위해 용탕 흐름에 대한 코어의 배치가 매우 중요합니다. 둘째, 스퀴즈 핀과 같이 국부적으로 매우 높은 압력을 가하는 설계는 코어 주변에 사용할 수 없습니다. 따라서 이 기술을 적용하려면 부품 설계 단계부터 용탕 흐름과 코어의 상호작용을 신중하게 고려해야 합니다.


Conclusion: Paving the Way for Higher Quality and Productivity

본 연구는 고압 다이캐스팅(HPDC) 공정에서 외부 스킨을 가진 알루미늄 폼 코어를 사용하여 마그네슘 복합 주조품을 성공적으로 제조할 수 있음을 입증했습니다. 최적의 공정 변수 제어를 통해 자전거 부품에서 35%의 상당한 경량화를 달성했으며, 이는 운송 산업의 경량화 요구에 부응하는 혁신적인 솔루션이 될 수 있습니다. 이 기술은 강도보다는 무게 감소가 최우선인 부품에 대해 플라스틱이나 탄소 섬유의 대안으로서 대량 생산의 가능성을 열었습니다.

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Copyright Information

  • This content is a summary and analysis based on the paper “Aluminium Foam and Magnesium Compound Casting Produced by High-Pressure Die Casting” by “Iban Vicario, et al.”.
  • Source: https://doi.org/10.3390/met6010024

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파도 / Waves

파도 / Waves

FLOW-3D 는 비정형 파뿐만 아니라 일반 선형 및 비선형파 표면을 시뮬레이션 할 수 있는 기능이 있습니다. 선형파는 작은 진폭 및 급경사를 갖는 사인파 표면 프로파일을 가지며, 비선형파는 선형 파보다 더 큰 진폭 (유한 진폭), 더 뾰족한 볏 및 평탄한 골짜기를 갖는다. 비선형 파는 파동 문자와 그 해를 구하기 위해 사용 된 수학적 방법에 따라 스톡 (stookes), 코니이드 (cnoidal) 파 및 단일 파로 분류 될 수 있습니다.

그림 1. 다른 진행파의 프로파일 비교
도 1 및도 2에 도시 된 바와 같이, 스톡스 파는 심층 및 과도수의 주기적인 파이다. Cnoidal 파는 천수(shallow water)와 중간 물에서 긴주기적인 파이고 Stokes 파보다 더 뾰족한 마루과 평평한 골짜기를 가지고 있습니다. 스톡스와 코니 형 파와 달리 단일 파는 천수(shallow water)와 과도 수에서 존재하는 비 주기적 파이다. 그것은 하나의 마루와 골짜기를 가지며 완전히 방해받지 않은 수면 위입니다. 수학적으로 파장이 무한대가 될 때 그것은 코니 형 파의 제한적인 경우입니다. 심층수, 과도 수 및 파도에 대한 천수(shallow water)의 분류는 표 1에서 찾아 볼 수있다.

그림 2. 다양한 파도의 적용 범위 (Le Méhauté, 1976, Sorensen, 2005 및 USACE, 2008). d : 평균 수심; H : 파고; T : 파주기; g : 중력 가속도

선형 파 이론 (Airy, 1845)이 많은 응용 분야에서 사용되었지만 비선형 파 이론은 파동의 진폭이 작지 않은 경우 선형 파 이론보다 정확도가 크게 향상되었습니다. FLOW-3D 에서 3 개의 비선형 파 이론이 5 차 스톡스 파 이론 (Fenton, 1985), 스톡스 및 코니이드 파에 대한 푸리에 급수 방법 (Fenton, 1999), McCowan의 독방 파 이론 (McCowan, 1891, Munk, 1949). 그 중에서 Fenton의 Fourier 시리즈 방법은 선형 물, 스톡 (Stokes) 및 코니형 (cnoidal) 파를 포함하여 심층수, 과도 수 및 천수(shallow water)에서 모든 종류의 주기적 전파 파들에 유효합니다. 또한 다른 웨이브 이론보다 정확도가 높습니다 (USACE, 2008). 따라서 모든 수심에서 선형 및 비선형 주기파의 모든 유형을 생성하는 것이 권장되는 방법입니다. solitary wave의 경우, FLOW-3D 에 사용 된 McCowan의 이론은 Boussinesq (1871)에 의해 개발 된 다른 널리 사용되는 이론보다 더 높은 주문 정확도를 갖는다.

그림 3. PM과 JOHNSWAP 스펙트럼 (USCE, 2006에서 적응)

Classificationsd /\lambda
Deep water1/2 to ∞
Transitional water1/20 to 1/2
Shallow water0 to 1/20

불규칙파는 파도의 물성이 일정하지 않은 자연적인 바다의 상태를 나타냅니다. FLOW-3D에서 불규칙한 파동은 다양한 진폭과 주파수 및 임의의 위상 변이를 갖는 많은 선형 성분 파의 중첩으로 표현됩니다. Pierson-Moskowitz (Pierson and Moskowitz, 1964)와 JONSWAP 파력 에너지 스펙트럼 (Hasselmann, et al., 1973)은 FLOW-3D에서 구성 요소 파를 생성하기 위해 구현된다. 다른 웨이브 에너지 스펙트럼은 사용자 정의 데이터 파일을 가져와서 사용할 수 있습니다.

계산 시간을 절약하기 위해 웨이브는 메시 블록 경계에서뿐만 아니라 초기 조건으로 정의 될 수 있습니다.

아래의 애니메이션은 웨이브 초기화가 있거나없는 웨이브의 모든 유형에 대한 예제를 보여줍니다.
선형 및 비선형 수위 시뮬레이션을 위해 FLOW-3D 의 성공적인 적용이 이루어졌습니다. Bhinder 외의 예를 참조하십시오. al (2009), Chen (2012), Hsu et. al (2012) Thanyamanta et. al (2011) 및 Yilmaz et. 자세한 내용은 알 (2011)을 참조하십시오.






References

Airy, G. B., 1845, Tides and Waves, Encyc. Metrop. Article 102.

Bhinder, M. A., Mingham, C. G., Causon, D. M., Rahmati, M. T., Aggidis, G. A. and Chaplin, R.V., 2009, A Joint Numerical And Experimental Study Of a Surging Point Absorbing Wave Energy Converter (WRASPA), Proceedings of the ASME 28th International Conference on Ocean, Offshore and Arctic Engineering, OMAE2009-79392, Honolulu, Hawaii.

Boussinesq, J., 1871, Theorie de L’intumescence Liquide Appelee Onde Solitaire ou de Translation se Propageant dans un Canal Rectangulaire, Comptes Rendus Acad. Sci. Paris, Vol 72, pp. 755-759.

Chen, C. H., 2012, Study on the Application of FLOW-3D for Wave Energy Dissipation by a Porous Structure, Master’s Thesis: Department of Marine Environment and Engineering, National Sun Yat-sen University.

Fenton, J. D., 1985, A Fifth-Order Stokes Theory for Steady Waves, Journal of Waterway, Port, Coastal and Ocean Engineering, Vol. 111, No. 2.

Fenton, J. D., 1999, Numerical Methods for Nonlinear Waves, Advances in Coastal and Ocean Engineering, Vol. 5, ed. P.L.-F. Liu, pp. 241-324, World Scientific: Singapore, 1999.

Hasselmann, K., Barnet, T. P., Bouws, E., Carlson, H., Cartwright, D. E., Enke, K., Ewing, J. A., Gienapp, H., Hasselmann, D. E., Kruseman, P., Meerburg, A., Muller, P., Olbers, D. J., Richter, K., Sell, W., and Walden, H., 1973, Measurement of Wind-Wave Growth and Swell Decay During the Joint North Sea Wave Project (JONSWAP), German Hydrographic Institute, Amburg.

Hsu, T. W., Lai, J. W. and Lan, Y., J., 2012, Experimental and Numerical Studies on Wave Propagation over Coarse Grained Sloping Beach, Proceedings of the International Conference on Coastal Engineering, No 32 (2010), Shanghai, China.

Kamphuis, J. M., 2000, Introduction to Coastal Engineering and Management, World Scientific, Singapore.

Le Méhauté, B., 1976, An Introduction to Hydrodynamics and Water Waves, Springer-Verlag.

McCowan, J., 1891, On the solitary wave, Philosophical Magazine, Vol. 32, pp. 45-58.

Munk, W. H., 1949, The Solitary Wave Theory and Its Application to Surf Problems, Annals New York Acad. Sci., Vol 51, pp 376-423.

Pierson W. J. and Moskowitz, L., 1964, A proposed spectral form for fully developed wind seas based on the similarity theory of S.A. Kitiagordskii, J. Geophys. Res. 9, pp. 5181-5190.

Thanyamanta, W., Herrington, P. and Molyneux, D., 2011, Wave patterns, wave induced forces and moments for a gravity based structure predicted using CFD, Proceedings of the ASME 2011, 30th International Conference on Ocean, Offshore and Arctic Engineering, OMAE2011, Rotterdam, The Netherlands.

USACE (U.S. Army Corps of Engineers), 2006, Coastal Engineering Manual, EM 1110-2-1100, Washington, DC.

Yilmaz, N., Trapp, G. E., Gagan, S. M. and Emmerich, T., R., 2011 CFD Supported Examination of Buoy Design for Wave Energy Conversion, IGEC-VI-2011-173, pp. 537-541

Figure 4. Modeling of variant 1 with the movement of waves in the port water area

FLOW-3D를 이용한 항만 수역 배치 설계의 타당성 분석

본 소개 자료는 ‘IOP Conference Series: Materials Science and Engineering’에서 발행한 ‘FLOW-3D software for substantiation the layout of the port water area’ 논문을 기반으로 합니다.

Figure 4. Modeling of variant 1 with the movement of waves in the
port water area
Figure 4. Modeling of variant 1 with the movement of waves in the port water area

1. 서론

  • 항만 설계 시, 방파제를 통한 내부 수역의 파랑 차단이 필수적이며, 이를 위해 최적의 항구 입구 배치 및 규모를 결정해야 함.
  • 항만 수역은 파랑, 퇴적물 축적, 그리고 결빙으로부터 보호되어야 하며, 이를 위해 물리적·수치적 모델링이 필요함.
  • 본 연구에서는 FLOW-3D를 활용하여 항만 입구 배치 및 설계 변수들이 항만 내부 수역의 흐름 및 안전성에 미치는 영향을 분석하고자 함.

2. 연구 방법

FLOW-3D 기반 CFD 모델링

  • VOF(Volume of Fluid) 기법을 사용하여 자유 수면을 추적.
  • 유체 해석을 위한 유한체적법(Finite Volume Method, FVM) 기반의 고정 격자 기법 사용.
  • FLOW-3D의 다중 격자(Multi-block Grid) 기능을 활용하여 계산 효율성 향상.
  • 항만 설계를 위한 입력 데이터:
    • 설계 풍속: 20m/s
    • 설계 파고: 1.0m, 주기 T = 5s
    • 설계 수위: 최저 11.50m, 운영 수위 12.00m, 최고 수위 15.00m

3. 연구 결과

다양한 항만 입구 배치에 따른 유동 특성 비교

  • 총 5가지 항만 입구 배치를 고려하여 항만 내부 유속 및 흐름 패턴을 분석.
  • 항만 입구 폭 및 위치에 따른 주요 결과:
    • 입구가 상단(Variant 1) 또는 이중 입구(Variant 2)일 경우, 내부 유속이 불균형하여 계류 안정성이 낮아짐.
    • 입구가 하단(Variant 3)일 경우, 내부 흐름이 균형을 이루며 정박 시 안전성이 가장 높음.
    • 입구 폭이 60m(Variant 5)로 증가할 경우, 외해의 파랑이 거의 그대로 내부로 전달되며, 방파제의 차단 효과가 감소.
    • 입구 폭이 20m(Variant 4)로 좁아질 경우, 항구 내부에서 난류(circulation)가 형성되어 선박 기동성이 저하.

계류 및 선박 기동성 평가

  • 항만 내 특정 지점(A, B, C)에서의 수심 변화를 분석하여 계류 안정성을 평가.
  • Variant 3에서 항만 내 수심 변화가 가장 적고, 계류 안정성이 가장 높음.
  • Variant 4의 경우, 항구 입구 폭이 좁아지면서 난류가 증가하고, 선박 기동성이 제한됨.
  • Variant 5의 경우, 외해 파랑이 내부까지 도달하여 계류 조건이 불안정해짐.

4. 결론 및 제안

결론

  • FLOW-3D 기반 시뮬레이션을 통해 항만 수역 내 유동 특성을 정량적으로 분석할 수 있음.
  • 입구 위치가 하단에 있으며(Variant 3), 폭이 40m일 때 가장 안정적인 계류 환경을 제공.
  • 입구 폭이 과도하게 좁아질 경우(Variant 4), 난류가 증가하여 선박 운항이 어려워지고, 반대로 폭이 과도하게 넓을 경우(Variant 5), 외해 파랑이 항만 내부까지 침투하는 문제가 발생.

향후 연구 방향

  • 다양한 파랑 조건 및 조류 영향에 대한 추가 연구 필요.
  • 실제 항만 데이터를 활용한 모델 검증 연구 수행.
  • 다양한 방파제 형상 및 재료 특성을 고려한 추가 시뮬레이션 진행.

5. 연구의 의의

본 연구는 FLOW-3D를 활용하여 항만 입구 배치 및 방파제 설계가 항만 내부 유동 및 계류 안정성에 미치는 영향을 정량적으로 분석하였다. 이를 통해 향후 항만 설계 및 운영 최적화를 위한 실질적인 설계 지침을 제공할 수 있음.

Figure 1. Sketch map of the port Laozi on Lake Hongze
Figure 1. Sketch map of the port Laozi on Lake Hongze
Figure 3. Port water area plan
Figure 3. Port water area plan
Figure 4. Modeling of variant 1 with the movement of waves in the
port water area
Figure 4. Modeling of variant 1 with the movement of waves in the port water area

6. 참고 문헌

  1. SP 350.1326000.2018. 2018 Norms for technological design of sea ports (Moscow: Standartinform) p 226
  2. SP 444.1326000.2019. 2019 Standards for the design of sea channels, fairways and maneuvering areas (Moscow: Standartinform) p 62
  3. SP 38.13330.2012. 2014 Loads and impacts on Hydraulic structures (from wave, ice and ships) (Moscow: Ministry of Regional Development of the Russian Federation) p 112
  4. Rijnsdorp D P Smit PB and Zijlema M 2012 Non-hydrostatic modelling of infragravity waves using SWASH. Proceedings of 33rd Conference on Coastal Engineering. pp 1287-1299
  5. Kantardgi I G Zheleznyak M J 2016 Laboratory and numerical study of waves in the port area. Magazine of Civil Engineering No 6 pp 49-59 DOI: 10.5862/MCE.66.5
  6. Zheleznyak M J Kantardgi I G Sorokin MS and Polyakov A I 2015 Resonance properties of seaport water areas Magazine of Civil Engineering № 5(57) pp 3-19 DOI:10.5862/MCE.57.1
  7. Kantarzhi I Zuev N Shunko N 2014 Numerical and physical modelling of the waves inside the new marina in Gelendjik (Black Sea) Application of physical modelling to port and coastal protection. Proceedings of 5th international conference Coastlab (Varna) Vol 2 pp 253-262
  8. Makarov KN and Chebotarev A G 2015 Breakwater placement at the root of a seawall Magazine of Civil Engineering № 3(55) pp 67-78 DOI: 10.5862/MCE.55.8
  9. Belyaev N D Lebedev V V and Alexeeva A V 2017 Investigation of the soil structure changes under the tsunami waves impact on the marine hydrotechnical structures V 10 № 4 pp 44-52 DOI: 10.7868/S2073667317040049
  10. Lebedev V V Nudner I S and Belyaev N D 2018 The formation of the seabed surface relief near the gravitational object Magazine of Civil Engineering No 79(3) pp 120-131 DOI: 10.18720/MCE.79.13
  11. Kofoed-Hansen H Sloth P Sørensen OR Fuchs J 2000 Combined numerical and physical modelling of seiching in exposed new marina Proceedings of 27th international conference of coastal engineering pp 3600-3614
  12. Smit P Stelling G and Zijlema M 2011 Assessment of nonhydrostatic wave-flow model SWASH for directionally spread waves propagating through a barred basin Proceedings of ACOMEN 2011 pp 1-10
  13. Zijlema M Stelling G Smit P 2011 SWASH: An operational public domain code for simulating wave fields and rapidly varied flows in coastal waters. Coastal Engineering. № 10(58). pp 992-1012
  14. FLOW-3D® 2008 User’s Manual Version 9.3 Flow Science Inc p 821
  15. Pan Bayan and Belyaev N D 2019 Week of Science SPbPU: Proceedings of an international scientific conference The best reports. pp 3-7
  16. Girgidov A A 2011 Hybrid simulation in hydrotechnical facilities design and FLOW-3D as a tool its realization Magazine of Civil Engineering №3 pp 21-27
  17. Girgidov A A 2010 Proceeding of the VNIIG vol 260. pp 12-19
  18. Vasquez J A Walsh B W 2009 CFD simulation of local scour in complex piers under tidal flow, 33rd IAHR Congress: Water Engineering for a Sustainable Environment, © 2009 by International Association of Hydraulic Engineering & Research (IAHR) ISBN: 978-94-90365-01-1.
  19. Shan-Hwei Ou Tai-Wen Hsu and Jian-Feng Lin 2010 Experimental and Numerical Studies on Wave Transformation over Artificial Reefs Proceedings of the International Conference on Coastal Engineering (Shanghai, China) No 32
  20. Hirt C and Nichols B 1980 Volume of Fluid Method for the Dynamics of Free Boundaries Journal Comp. Phys 39 p 201.

Study on the Water Surge Height Line of Landslide Surge of Linear River Course Reservoir Based on FLOW-3D

FLOW-3D를 활용한 선형 하천 저수지의 산사태 파고 선 연구

Fig. 3 Geometric numerical model
Fig. 3 Geometric numerical model

연구 목적

  • 본 연구는 산사태로 인해 발생하는 해일(surge)의 전파 특성과 감쇠 과정을 분석하는 데 초점을 맞춤.
  • FLOW-3D® 시뮬레이션을 활용하여 선형 하천 저수지에서 산사태 해일이 발생하는 기작을 규명함.
  • 산사태 유입각, 하천 깊이, 하천 형상 및 산사태 질량 등 다양한 요소가 해일 높이 및 전파에 미치는 영향을 평가함.
  • 해일의 전파 과정 및 감쇠 메커니즘을 규명하여 수력학적 안정성 평가 및 방재 대책 수립에 기여하고자 함.

연구 방법

  1. FLOW-3D® 기반 수치 해석 모델 구축
    • 산사태로 인해 발생하는 해일의 거동을 모델링하기 위해 VOF(Volume of Fluid) 기법을 사용함.
    • 산사태의 초기 속도, 질량 및 유입각에 따른 해일 생성 및 전파 특성을 분석함.
    • 하천 폭 및 수심 변화에 따른 해일 감쇠 특성을 평가함.
  2. 시뮬레이션 실험 설계
    • 산사태 질량을 0.4 m × 0.2 m × 0.15 m로 고정하고, 유입각을 40°~80° 범위에서 변화시킴.
    • 다양한 수심 조건(0.5 m ~ 0.9 m)에서 해일 전파 특성을 분석함.
    • 5개 주요 측정 지점을 설정하여 해일의 초기 파고 및 전파 과정 데이터를 수집함.
  3. 결과 비교 및 검증
    • 각 실험 조건에서 해일의 최대 파고 및 전파 속도를 측정하고, 시뮬레이션 결과를 실험 데이터와 비교함.
    • 기존 연구 결과 및 실험 모델과의 비교를 통해 시뮬레이션 신뢰도를 검토함.

주요 결과

  1. 산사태 유입각에 따른 해일 발생 특성
    • 해일의 초기 파고는 유입각 60°에서 최대값을 기록하며, 이후 유입각 증가에 따라 감소하는 경향을 보임.
    • 유입각이 80° 이상일 경우, 슬라이딩 블록의 수직 충돌로 인해 에너지 손실이 증가하여 해일 높이가 감소함.
    • 유입각이 작을 경우(40° 이하), 해일 발생 에너지가 낮아지고 전파 속도도 감소함.
  2. 수심 변화에 따른 해일 전파 및 감쇠 특성
    • 동일한 조건에서 초기 해일 높이는 수심이 깊을수록 감소하는 경향을 보임.
    • 수심이 0.5 m에서 0.9 m로 증가하면, 최대 파고가 49 mm에서 33 mm로 감소함.
    • 이는 깊은 수심에서는 에너지가 더 많은 수체에 분산되기 때문으로 분석됨.
  3. 해일 전파 속도 및 감쇠 패턴
    • 해일의 전파 속도는 초기 파고 및 하천 형상에 따라 달라지며, 좁은 수로에서 감쇠가 느려지는 경향을 보임.
    • 측정 지점별 파고 감소율을 분석한 결과, 해일 감쇠율이 비선형적으로 나타남.
    • 이는 수면 저항 및 흐름 분산에 따른 에너지 손실이 비균일하게 발생하기 때문으로 해석됨.

결론

  • 산사태 유입각이 해일 발생의 주요 변수이며, 60°에서 최대 파고가 발생함.
  • 수심이 깊을수록 해일 감쇠가 더 빠르게 진행되며, 초기 파고가 낮아짐.
  • FLOW-3D® 기반 시뮬레이션을 통해 선형 하천 저수지에서의 산사태 해일 전파 및 감쇠 메커니즘을 규명할 수 있음.
  • 향후 연구에서는 다양한 하천 형상 및 실제 지형 조건을 반영한 추가 분석이 필요함.

Reference

  1. Kiersch, G. A. 1964. “Vajont Reservoir Disaster.” Civil Engineering (ASCE) 34 (3): 32-39.
  2. Hunan Hydro & Power Design Institute. 1983. Slope Engineering Geology. Beijing: Water Conservancy and Electric Power press.
  3. Wiegel, R. L. 1995. “Laboratory Studies of Gravity Waves Generated by the Movement of A Submerged Body.” Transactions-American Geophysical Union 36 (5): 759-774.
  4. Fritz, H. M., Moster, P. 2003. “Pneumatic Landslide Generator.” International Journal of Fluid Power 173 (2): 223-233.
  5. Sander, J., Hutter, K. 1992. “Evolution of Weakly Non-linear Channelized Shallow Water Waves Generated by A Moving Boundary.”Acta Mechanic 91: 119-155.
  6. Sander, J., Hutter, K. 1996. “Multiple Pulsed Debris Avalanche Emplacement at Mount St. Helens in 1980: Evidence form Numerical Continuum Flow Simulation.” Acta Mechanic 115:133-149.
  7. Heinrich, Ph. 1992. “Nonlinear Water Waves Generated by Submarine and Aerial Landslides.” Journal of Waterway, Port, Coast, and Ocean Engineering, ASCE 118: 249-266.
  8. Ataie-Ashtiani, B., Farhadi, I. A. 2006. “Stable Moving-particle Semi-implicit Method for Free Surface Flow.” Fluid Dynamic Research 38 (4): 241-256.
  9. Monaghan, J. J. 1994. “Simulating Free Surface Flows with SPH.” Journal of Computational Physics 110: 399-406.
  10. Ataie-Ashtiani, B., Shobeyri, G. 2001. “Numerical Simulation of Landslide Impulsive Waves by Incompressible Smoothed Particle Hydrodynamic.” International Journal for Numerical Method in Fluids 56: 209-232.
high froude number

Using the Calculated Froude Number for Quantifying Flow Conditions in Hydraulic Structures

수력 구조물의 유동 조건 정량화를 위한 계산된 프로우드 수(Froude Number) 활용

연구 목적

  • 본 논문은 프로우드 수(Froude Number, Fr)를 활용하여 수력 구조물 내 유동 조건을 정량적으로 평가하는 방법을 제안함.
  • 기존 실험 및 수치 해석 데이터를 분석하여, Fr이 유량, 수심, 구조물 기하학적 특성과 어떻게 연관되는지 검토함.
  • 다양한 수력 구조물(여수로, 수로, 도수로 등)에 적용할 수 있는 일반화된 Fr 기반 해석 기법을 개발함.
  • 수력 구조물 설계 및 해석에서 Fr을 활용한 예측 정확도를 향상하는 방안을 모색함.

연구 방법

  1. 프로우드 수 이론 및 모델링
    • 프로우드 수는 유동의 관성력과 중력력 간의 비율을 나타내며, 수력학적 흐름 상태(사류, 임계류, 부류)를 평가하는 중요한 매개변수임.
    • Fr 계산을 위해 기본 식을 적용함:
  • V : 유체 속도
  • g : 중력 가속도
  • L : 대표 길이(수심 또는 수력 구조물의 특성 길이)
  1. 수치 해석 및 실험 검증
    • 다양한 수력 구조물에서 유동 해석을 수행하고, Fr 값과 유동 특성 간의 관계를 분석함.
    • CFD(전산유체역학) 시뮬레이션을 통해 여수로 및 개방 수로에서 Fr 변화를 평가함.
    • 기존 문헌의 실험 데이터를 활용하여 시뮬레이션 결과를 검증하고, Fr 기반 예측 모델의 신뢰성을 평가함.
  2. Fr 값에 따른 유동 패턴 분석
    • Fr 값에 따라 흐름이 어떻게 변화하는지 정량적으로 평가함.
    • Fr < 1: 부류(subcritical flow) → 중력파 전파 가능, 유동 안정적.
    • Fr = 1: 임계류(critical flow) → 최소 에너지를 가지며, 설계에서 중요한 기준이 됨.
    • Fr > 1: 사류(supercritical flow) → 난류가 강하며, 에너지 소산이 필요함.
  3. Fr 기반 설계 적용 가능성 평가
    • Fr을 활용한 설계 기준을 도출하여, 수력 구조물 설계 및 유지관리에서 활용 가능성을 검토함.
    • 실무 엔지니어링에서 Fr을 효과적으로 적용할 수 있는 방법을 제안함.

주요 결과

  1. Fr과 유동 특성의 관계
    • Fr 값이 증가할수록 난류 강도가 증가하고, 에너지 소산이 필요함.
    • Fr 값이 1에 가까울수록 유동 안정성이 높아지며, 최적 설계 조건으로 고려 가능함.
    • 여수로와 같은 급경사 흐름에서는 높은 Fr 값이 관찰되었으며, 에너지 소산 구조물 필요성이 확인됨.
  2. CFD 및 실험 검증 결과
    • CFD 시뮬레이션 결과와 실험 데이터 간 평균 오차율은 5% 이내로 나타나 신뢰성이 높음.
    • Fr을 기반으로 유량 및 속도를 예측하는 모델이 실험값과 높은 상관성을 보임.
    • 다양한 수력 구조물에서 Fr을 활용한 해석 기법이 적용 가능함을 확인함.
  3. Fr 기반 설계 적용 가능성
    • Fr을 활용하면 구조물의 최적 유동 조건을 도출할 수 있으며, 기존 설계 기준을 보완할 수 있음.
    • 수로 및 여수로 설계에서 Fr을 고려한 흐름 안정화 기법이 필요함.
    • 유지관리 측면에서도 Fr을 활용하면 유동 상태를 빠르게 평가할 수 있음.
  4. 산업적 적용 및 향후 연구 방향
    • Fr을 활용한 설계 최적화는 수력 구조물의 효율성과 안정성을 높이는 데 기여할 수 있음.
    • 향후 연구에서는 다양한 흐름 조건에서 Fr을 적용한 추가 실험 및 해석이 필요함.
    • 실무 적용성을 높이기 위해 Fr 기반 설계 가이드라인을 개발할 필요가 있음.

결론

  • 프로우드 수(Fr)는 수력 구조물의 유동 조건을 정량적으로 평가하는 데 효과적임.
  • Fr 값이 1에 가까울수록 유동 안정성이 높아지며, 설계 기준으로 활용 가능함.
  • CFD 및 실험 데이터 검증 결과, Fr을 이용한 해석 기법이 높은 신뢰성을 보임.
  • 향후 연구에서는 다양한 수력 구조물에서 Fr 기반 설계 최적화 연구가 필요함.

Reference

  1. Flow-3D, www.flow3d.com.
  2. N. R. Green and J. Campbell, Influence in Oxide Film Filling Defects on the Strength of Al-7Si-Mg Alloy Castings, Transactions of the American Foundry Society 114 (1994) 341-347.
  3. R. Cuesta, A. Delgado, A. Maroto and D. Mozo, Numerically Modelling Oxide Entrainment in the Filling of Castings: The Effect of the Webber Number, Journal of Materials 58 (2006) 62-65.
  4. J. Campbell, Castings (Butterworth Heinemann, 1991).
  5. J. Campbell, Castings 2nd Edition (Butterworth Heinemann, 2003).
  6. H. Chanson, Environmental Hydraulics of Open Channel Flows (Elsevier Butterworth-Heinemann, Oxford, 2004).
  7. H. Chanson, Air Bubble Entrainment in Free-Surface Turbulent Shear Flows (Academic press, London, 1995).
  8. B. S. Massey, Mechanics of Fluids 6th Edition (Chapman & Hall, 1992).
  9. M. Holliday, The Real-Time X-Ray Optimisation of the Sprue/Runner Junction, in “School of Metallurgy and Materials” (The University of Birmingham, Birmingham, 1998).
  10. J. Campbell, Review of Computer Simulation Versus Casting Reality, Modelling of Casting, Welding and Advanced Solidification Processes VII (1995) 907-935.
  11. F.-Y. Hsu, Further Developments of Running Systems for Aluminium Castings, (The University of Birmingham, 2003).
  12. C. Reilly, Surge Control Systems for Gravity Castings, in “The School of Mechanical and Manufacturing Engineering” (The University of Birmingham, Birmingham, 2006).
  13. M. Cox and R. A. Harding, The Influence of Tilt Filling on the Weibull Modulus of 2199 Aluminium Investment Castings, Materials Science and Technology 23 (2007) 214-224.

spure

Novel Sprue Designs in Metal Casting via 3D Sand-Printing

3D 샌드 프린팅을 이용한 금속 주조용 신규 스프루 설계

연구 목적

  • 본 연구는 **3D 샌드 프린팅(3DSP)**을 활용하여 주조 스프루(sprue) 설계를 최적화하고, 금속 용탕 흐름을 개선하는 방법을 분석함.
  • 전통적 주조 유체역학 원리를 기반으로 컴퓨터 유체 역학(CFD) 모델을 개발하여, 스프루 설계에 따른 용탕 흐름 특성과 주조 결함 감소 효과를 평가함.
  • 세 가지 스프루 설계(직선 스프루, 포물선 스프루, 원뿔형 나선 스프루)를 비교 분석하여 최적 형상을 도출함.
  • 실험 및 FLOW-3D® 시뮬레이션을 통해 스프루 최적화가 기계적·야금학적 성능 향상에 미치는 영향을 검증함.

연구 방법

  1. 스프루 설계 및 최적화
    • 직선 스프루(Straight Sprue Casting, SSC), 포물선 스프루(Parabolic Sprue Casting, PSC), 원뿔형 나선 스프루(Conical-Helix Sprue Casting, CHSC) 세 가지 설계를 비교함.
    • 최적화 알고리즘을 적용하여 유체 흐름 및 산화물 형성 최소화 조건을 도출함.
    • FLOW-3D® CFD 시뮬레이션을 활용하여 각 설계의 유동 속도, 난류 강도 및 충진 특성을 평가함.
  2. 실험 및 시뮬레이션 검증
    • CT(Computed Tomography) 스캔 및 SEM(주사전자현미경) 분석을 수행하여 주조 결함 및 산화물 포획 정도를 평가함.
    • ASTM E290 기준 3점 굽힘(flexural strength) 시험을 수행하여 기계적 강도를 비교함.
    • 스프루 설계 변경이 주조 결함(기포, 산화물 포함물) 및 최종 기계적 특성에 미치는 영향을 분석함.

주요 결과

  1. 유동 속도 및 충진 거동 분석
    • CHSC 및 PSC 설계가 SSC 대비 주형 충진 속도를 감소시켜 용탕 난류를 줄이는 효과가 있음.
    • CHSC 설계에서는 유동 속도가 0.5 m/s 이하로 감소하며, 이는 산화물 형성을 최소화하는 임계 속도 조건을 충족함.
    • CFD 시뮬레이션 결과, CHSC 스프루는 균일한 유동 분포를 형성하여 주조 품질을 향상시킴.
  2. 주조 결함 감소 효과
    • CT 스캔 결과, CHSC 적용 시 전체 주조 결함이 99.5% 감소, PSC 적용 시 56% 감소함.
    • SSC에서는 기포 및 산화물 포함물이 집중적으로 발생하였으나, CHSC 및 PSC에서는 이러한 결함이 현저히 감소함.
    • SEM 분석 결과, SSC 대비 PSC 및 CHSC의 산화물 포함물 영역이 각각 21%, 35% 감소함.
  3. 기계적 강도 향상
    • 3점 굽힘 시험 결과, CHSC는 SSC 대비 평균 굽힘 강도가 8.4% 증가, PSC는 4.1% 증가함.
    • CHSC 주조품에서 더 균일한 미세조직 및 결함 감소 효과가 확인됨.
    • ANOVA 통계 분석 결과, SSC와 CHSC 간 기계적 강도 차이가 통계적으로 유의미함(p = 0.045).

결론

  • 3D 샌드 프린팅을 활용한 신규 스프루 설계가 주조 품질을 향상시키는 데 효과적임.
  • 원뿔형 나선 스프루(CHSC) 설계는 용탕 난류 감소 및 산화물 포함물 저감에 가장 효과적이며, 기계적 강도를 8.4% 향상시킴.
  • CFD 시뮬레이션과 실험 데이터를 비교한 결과, 최적화된 스프루 설계가 실제 주조 성능 개선에 기여함을 확인함.
  • 향후 연구에서는 다양한 합금 및 주조 공정에 대한 적용성을 추가적으로 검토해야 함.

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Coupling

Experimental and Numerical Analysis of Flow Behavior and Particle Distribution in A356/SiCp Composite Casting

A356/SiCp 복합재 주조에서 유동 거동 및 입자 분포에 대한 실험적 및 수치적 분석

연구 목적

  • 본 연구는 A356/SiCp 복합재 주조 과정에서 유동 거동 및 입자 분포를 실험적·수치적으로 분석하는 것을 목표로 함.
  • 실시간 X선 방사 촬영(Real-time X-ray radiography)을 이용하여 주형 충진 과정을 관찰하고, 실험 데이터를 CFD 시뮬레이션과 비교함.
  • Euler 및 Lagrangian 방법을 적용하여 유체 흐름 및 입자 분포를 모델링하고, 예측 결과와 실험 결과를 검증함.
  • 복합재 주조 과정에서 발생하는 입자 분리(particle segregation) 현상을 최소화하는 최적 조건을 도출함.

연구 방법

  1. 실험 설정 및 데이터 수집
    • 실시간 X선 방사 촬영(RT-XRR)을 활용하여 주조 과정 동안 유체 유동 및 입자 이동을 추적함.
    • A356/SiCp 복합재의 입자 크기 분포 및 미세 구조를 광학 현미경 및 주사전자현미경(SEM)으로 분석함.
    • 실험 결과와 CFD 시뮬레이션을 비교하여 유동 거동 및 입자 분포를 평가함.
  2. FLOW-3D® CFD 시뮬레이션 설정
    • VOF(Volume of Fluid) 방법을 적용하여 자유 표면 흐름을 해석하고, 입자 거동을 추적함.
    • 유동 해석(Euler 모델) 및 입자 추적(Lagrangian 모델)을 결합하여 복합재 충진 과정에서의 입자 분포를 예측함.
    • 난류 모델 적용: k-ε 및 Large Eddy Simulation(LES) 모델을 비교하여 난류가 입자 분포에 미치는 영향을 분석함.
  3. 결과 비교 및 검증
    • 입자 분포 및 유동 패턴을 실험 데이터와 비교하여 CFD 시뮬레이션의 신뢰성을 평가함.
    • 충진 전후 입자 농도를 측정하여 입자 분포 변화를 정량적으로 분석함.
    • 예측 결과와 실험 데이터 간의 오차율을 분석하여 모델의 정확도를 검증함.

주요 결과

  1. 입자 유동 및 충진 과정에서의 거동 분석
    • 입자 유동은 주조 과정의 각 단계에서 서로 다른 흐름 패턴을 보임.
    • 중력 영향이 큰 영역에서는 소용돌이(Eddy Flow)가 형성되며, 이는 입자 농도 증가의 원인이 됨.
    • 유동 방향 변화에 따라 후류(Back Flow) 형성이 관찰되며, 이는 일부 입자의 이동을 제한함.
  2. 실험과 CFD 시뮬레이션 비교 검증
    • 실제 실험에서 관찰된 입자 농도와 시뮬레이션 예측 결과가 높은 상관성을 보임.
    • 그러나 일부 중력 영향이 큰 영역(R7, R8)에서 시뮬레이션이 입자 분포를 과소평가하는 경향이 있음.
    • 이는 후류(Back Flow)에 의한 입자 이동 제한 효과가 모델에서 과도하게 반영되었기 때문으로 분석됨.
  3. 입자 분포 최적화 및 개선 가능성
    • 입자 분포는 유동 패턴, 난류 강도 및 충진 속도에 의해 결정됨.
    • 충진 속도를 조절하여 후류 형성을 최소화하면 입자 분포의 균일성을 향상시킬 수 있음.
    • 입자가 중앙부에 집중되는 경향이 있으며, 표면부에서는 상대적으로 적은 입자가 분포함.
  4. 최적 주조 조건 도출
    • 충진 속도 및 유체 유동 조건을 조정하여 입자 분리를 최소화할 수 있음.
    • 유체 흐름을 최적화하면 주조물 내 입자 농도를 균일하게 유지할 수 있음.
    • 후류(back flow) 및 소용돌이 현상(eddy flow)을 조절하면 입자 분포의 균일성을 더욱 개선 가능.

결론

  • A356/SiCp 복합재 주조에서 유동 거동 및 입자 분포를 CFD 시뮬레이션과 실험을 통해 성공적으로 분석함.
  • FLOW-3D® 시뮬레이션 결과와 실험 데이터 간 높은 상관성을 확인하였으며, 일부 영역에서의 과소평가는 모델 개선이 필요함.
  • 입자 분포 최적화를 위해 후류 및 난류 영향을 고려한 충진 속도 조절이 필요함.
  • 향후 연구에서는 다양한 입자 크기 및 형상에 따른 유동 거동을 추가적으로 평가해야 함.

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filling

A CFD INVESTIGATION INTO MOLTEN METAL FLOW AND ITSSOLIDIFICATION UNDER GRAVITY SAND MOULDING INPLUMBING COMPONENTS

배관 부품 제조에서 중력 모래 주형을 이용한 용융 금속 유동 및 응고에 대한 CFD 해석


연구 배경

  • 문제 정의: 배관 부품 제조 공정에서 중력 모래 주형을 이용한 주조는 용융 금속의 복잡한 열 전달 및 응고 과정으로 인해 결함(예: 기공, 수축 결함)이 발생할 수 있어 생산 효율과 제품 품질에 영향을 준다.
  • 목표: CFD 기법(특히 FLOW 3D CAST v5.03)을 활용하여 실제 생산 라인과 동일한 주형 및 내부 챔버 형상을 기반으로 용융 금속의 충진, 응고 및 냉각 단계를 해석하고, 다양한 타설 온도와 러너 설계가 주조 결함에 미치는 영향을 평가하는 데 있다.

연구 방법

  1. CFD 시뮬레이션
    • 프로그램 및 기법: FLOW 3D CAST v5.03 사용, Volume of Fluid (VOF) 방법을 통해 용융 금속의 자유 수면을 추적.
    • 난류 모델: 두 방정식 k–ε 모델을 채택하여 난류 효과를 반영.
    • 모델 형상: 실제 생산 라인의 주형과 내부 챔버 형상을 그대로 반영.
  2. 주요 변수 및 조건
    • 타설 온도: 다양한 타설 온도(예: 1329°C, 1529°C)를 적용하여 유동 속도, 응고 시간 및 결함 발생에 미치는 영향 평가.
    • 러너 설계: 러너의 크기와 수가 용융 금속의 흐름 및 결함 위치에 어떤 영향을 미치는지 분석.
  3. 메쉬 독립성 및 시간 단계
    • 여러 메쉬 크기를 비교하여 계산 정확도와 효율성을 확보함(예: 250,000 요소 사용).

주요 결과

  • 충진 및 응고 해석: CFD 시뮬레이션을 통해 용융 금속이 주형 내에서 충진되는 과정과 이후 응고 및 냉각 단계가 상세하게 재현되었음.
  • 타설 온도의 영향:
    • 높은 타설 온도(1529°C)는 용융 금속의 유동을 빠르게 하며, 반면 응고에는 더 긴 시간이 소요됨.
    • 낮은 타설 온도(1329°C)에서는 유동 속도가 다소 느리고, 응고 과정이 상대적으로 빠르게 진행됨.
  • 러너 설계의 효과: 다양한 러너 각도 및 구조 변경 시도에도 불구하고, 현재 연구에서는 러너 설계가 기공 결함(캐비티) 감소에 큰 영향을 미치지 않음.
  • 전체 공정 소요 시간: 충진, 응고, 냉각 단계 각각의 소요 시간이 계산되어 생산 공정 개선에 활용 가능함.

결론 및 향후 연구

  • CFD 기법은 중력 모래 주형을 이용한 배관 부품 주조 공정에서 용융 금속의 충진, 응고 및 냉각 단계를 효과적으로 해석할 수 있음을 보여준다.
  • 타설 온도가 용융 금속 유동 및 응고 거동에 결정적인 영향을 미치며, 이로 인해 주조 결함 발생이 달라짐을 확인하였다.
  • 향후 연구에서는 시뮬레이션 결과와 실험 데이터를 비교 검증하고, 결함 발생 원인 및 위치에 대한 추가 분석을 통해 생산 공정의 최적화를 도모할 예정이다.

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Flood

Study of a Tailings Dam Failure Pattern and Post-Failure Effects under Flooding Conditions

폐석댐 붕괴 패턴 및 홍수 조건에서의 붕괴 후 영향 연구

Zhong Gao, Jinpeng Liu, Wen He, Bokai Lu, Manman Wang, Zikai Tang

Abstract

Tailings dams are structures that store both tailings and water, so almost all tailings dam accidents are water related. This paper investigates a tailings dam’s failure pattern and damage development under flood conditions by conducting a 1:100 large-scale tailings dam failure model test. It also simulates the tailings dam breach discharge process based on the breach mode using FLOW-3D software, and the extent of the impact of the dam failure debris flow downstream was derived. Dam failure tests show that the form of dam failure under flood conditions is seepage failure. The damage manifests itself in the form of flowing soil, which is broadly divided into two processes: the seepage stabilization phase and the flowing soil development damage phase. The dam failure test shows that the rate of rise in the height of the dam saturation line is faster and then slower. The order of the saturation line at the dam face is second-level sub-dam, third-level sub-dam, first-level sub-dam, and fourth-level sub-dam. The final failure of the tailings dam is the production of a breach at the top of the dam due to the development of the dam’s fluid damage zone to the dam top. The simulated dam breach release results show that by the time the dam breach fluid is released at 300 s, the area of over mud has reached 95,250 square meters. Local farmland and roads were submerged, and other facilities and buildings would be damaged to varying degrees. Based on the data from these studies, targeted measures for rectifying hidden dangers and preventing dam breaks from both technical and management aspects can be proposed for tailings dams.

1. Introduction

1.1. Research Status

The mud wastewater containing tailings will be discharged after metal and non-metal mine beneficiation. Tailings slurry contains mercury, arsenic, and other heavy metal ions, both resources and pollution sources [1]. The tailings dam is a dam body formed by the accumulation and rolling of the tailings after the mine selects the useful components [2]. It is of great significance to research the dynamic stability of tailings reservoirs for mine safety production, protection of downstream life and property safety, and the surrounding environment [3]. Tailings dams, an important source of danger if an accident, are bound to people’s lives and property [4]. In 2008, a dam break accident occurred in the 980 ditch tailings pond of Shanxi Xinta Mining Co., Ltd., Yuncheng, China, resulting in 281 deaths and 33 injuries. The direct economic loss was as high as CNY 96,192,000 [5]. On the afternoon of 30 April 2006, the tailings dam of Zhen’an Gold Mine in Shaanxi Province was constructed. The accident caused 17 people to disappear, five people were injured, and 76 houses were destroyed [6,7].

In many tailings reservoir accidents, due to the lack of flood discharge capacity of flood discharge structures in the reservoir area, flood overtopping, tailings dam break, and other phenomena occur occasionally [8,9]. In this regard, scholars in related fields have performed much research and achieved certain results. Chen Zhang et al. [10] established three-dimensional and two-dimensional finite element models. The seepage field of the project under different operating conditions was simulated, and the safety factor under different operating conditions was obtained by combining the seepage field with the stable surface. The influence of the length of the dry beach and the upstream slope ratio on the seepage and stability of the tailings dam was determined. Sánchez-Peralta et al. [11] took a dry tailings pond in Colombia as the research object, studied the movement characteristics of dam break debris flow with different water contents, and obtained the relationship between the length and width of dam break debris flow movement. Changbo Du et al. [12] studied and analyzed the influence of reinforcement on tailings dam and the change law of pore water pressure and internal pressure of the dam body after mud discharge. The pore water pressure and internal earth pressure of the accumulation dam after grouting gradually increased with time. Reinforcement can greatly reduce the pore water pressure and internal pressure of reinforced dams. Gregor Petkovšek et al. [13] proposed a dam break model EMBREA-MUD to calculate the water and tailings outflow of the tailings reservoir and the corresponding break growth. Weile Geng et al. [14] conducted experimental research on the settlement deformation and mesostructure evolution of unsaturated tailings under continuous load. The results showed that the mesostructure deformation of unsaturated tailings with different moisture contents under load was the same and could be divided into four stages: pore compression, elastic deformation, structure change, and further compaction. Alan Lolaev et al. [15] developed a method to determine the tailings filtration and secondary consolidation coefficient in the process of alluvial according to the physical conditions, density, and water phreatic, and a mathematical model to calculate the consolidation time. Kun Wang et al. [16] proposed a multidisciplinary program to simulate the dam break runoff of hypothetical tailings reservoirs on the downstream complex terrain using UAV photogrammetry and smooth particle hydrodynamics (SPH) numerical method. Rawya M. Kansoh [17] studied the influence of the earth-rock dam’s structural parameters on the dam failure process. Kehui Liu et al. [18] studied the microscopic characteristics of hydraulic erosion of reinforced tailings dams and revealed the influence of different reinforcement spacing on the critical start-up speed of tailings particles. It shows that the smaller the reinforcement spacing, the greater the critical start-up speed of the reinforced tailings samples. Luca Piciullo et al. [19] proposed a regression analysis that considers the functional relationship between the release amount and the characteristics of the tailings dam, such as height and water storage (i.e., dam factor). The effects of construction type, filling material, and failure mode on the release amount were also evaluated, as well as the failure frequency of the tailings dam as a function of the construction method. Tailing dams built using upstream construction methods are more prone to failure and are more susceptible to static and dynamic liquefaction. Chunhui Ma et al. [20] pointed out that a reasonable construction schedule and flexible waterproof material are key features of impervious bodies for dams with significant deformation. When the dam deformation becomes stable, consideration should be given to secondary treatment of the impervious body to enhance dam safety. Fukumoto et al. [21] used finite element software to simulate the seepage failure process caused by seepage. Alibek Issakhov et al. [22] combined the k-ω turbulence model to study this process numerically. The VOF (volume of fluid) method was used to simulate the fluid movement behind the tailings dam during the break-up of the fluid and the riverbed landscape. Yonas B. Dibike et al. [23] A two-dimensional hydrodynamic and component transport model was used to study the effect of OS tailings release on the water quality and sediment quality of LAR by simulating sediments and related chemicals. It was concluded that the tailings release location was different; 40% to 70% of the sediments and related chemicals were deposited on the riverbed of the 160 km study section, while the remaining sediments and related chemicals left the study area in the first three days after the release event. Research conducted by Xiaofei Jing et al. [24] investigated the overflow characteristics of tailings dams reinforced with steel bars. During the overflow process, they measured dam displacements, saturation lines, and internal stresses. The study demonstrated that the erosion resistance of tailings dams significantly improves with an increase in the number of reinforcement layers. Abdellah Mahdi et al. [25] studied the potential consequences of a hypothetical oil sand tailings dam failure. For this reason, a non-Newtonian dam–dam model with a viscoplastic rheological relationship is used. The model can reproduce the flood and water level changes in downstream lakes (due to destructive waves). The simulation study of oil sand tailings overflow proves the importance of considering the non-Newtonian characteristics of tailings. Naeini et al. [26] used SIGMA/W and QUAKE/W software to analyze the high-middle line tailings dam’s dynamic response and permanent deformation and evaluated the dam’s performance. Mohammad Reza Boroomand [27] used the numerical analysis method to analyze the earth dam’s seepage under the uncertainty of geotechnical parameters and analyzed the seepage of the earth dam under the condition of uncertainty of geotechnical parameters. Sumin Li et al. [28] simulated and analyzed the hazard range, degree, and spatial state of sediment flow after the dam break and obtained the influence of sand flow velocity, flow depth, and impact on the downstream villages in the disaster area. The feasibility of the expansion and heightening of the tailings dam project was demonstrated, and the disaster risk levels of different spatial locations in the downstream villages were obtained through simulation. Through experiments, Kong et al. [29] studied the influence parameters of tailings dams under seepage. They concluded that the particle size gradation, non-uniformity coefficient, and water content of tailings sand were the main factors affecting the critical hydraulic gradient. It is concluded that the seepage failure gradient with suitable gradation, uniform particles, and suitable water content is significantly higher than that with poor gradation, uneven particles, and poor water content.

Flood overtopping and seepage failure account for 80% of the total accidents, and these two failure forms mainly occur in flood season and are closely related to water. Therefore, it is necessary to explore the tailings dam failure mode, development process, and the impact on the downstream after dam failure under flood conditions to ensure its safe operation. Based on the engineering background of a tungsten mine tailings dam in Ganzhou City, Jiangxi Province, a 1:100 physical model test was carried out to explore the dam break form and failure development process of the tailings dam under flood conditions. The FLOW-3D fluid simulation software was used to solve the influence of the tailings dam on the downstream after the dam break, and the change law of the flow area, velocity development, and submerged depth of the dam break fluid during the flood discharge process was analyzed. Finally, reasonable prevention and remediation suggestions are proposed for the hidden dangers of tailings dams.

The innovation of this paper is to determine the dam break mode and dam break position of the tailings dam under flood conditions by constructing a physical model, which provides a basis for simulating the influence of dam break on the downstream of the dam body.

1.2. Research Flowchart

Figure 1. Research flowchart.

2. Design and Construction of Large Physical Models

2.1. Overview of the Prototype Tailings Dam

The prototype tailings dam is a tungsten tailings dam located in a narrow valley running north–south in Ganzhou City, Jiangxi Province, China. The downstream of the tailings accumulation dam is farmland, dormitory buildings, mountain roads, etc., and the valleys in the downstream are relatively open. Figure 2 shows an overhead view of the prototype tailings dam. The tailings dam is built using the upstream damming method. The initial dam is a clay core wall weathering material dam located at the mouth of the northern valley. The bottom elevation is 262.0 m, the top elevation is 284.0 m, the dam height is 22 m, the upstream and downstream slope ratio is 1:2.5. The design average external slope ratio of the tailings accumulation dam is 1:5, the average slope of the tailings deposition beach is 5%, the design final tailings accumulation dam elevation is 368.00 m, the total dam height 106.00 m, with a complete storage capacity of 1550 × 104 m3 and a service life of 65 years. The present top elevation of the stacked dam is about 315 m, the height of the dam is 53 m, the accumulated storage capacity is about 559 × 104 m3, and the average external slope ratio of the stacked dam is 1:4.9. The reservoir is currently a fourth-class reservoir, with a flood protection standard of one in 200 years. At a later stage, it will be a second-class reservoir with a flood protection standard of 1000 years.

Figure 2. Top view of a tailings dam.

2.2. Selection of Model Sand

To ensure the relative reliability of the test results, the selected dam materials are properly relaxed to meet the primary conditions of similar main influencing factors. The model test focuses on the agglomeration effect of particle movement during the deformation of the dam body. For the selection of model sand, the initial dam is built with silty clay, and the accumulation dam adopts the mine prototype tailings. Figure 3 is the particle size distribution curve of the model sand. According to the particle size distribution curve, two quantitative indexes of soil particles can be determined: non-uniformity coefficient Cu and curvature coefficient CcCu and Cc can jointly determine the gradation of soil. The expressions of the two are:

Figure 3. Cumulative distribution curve of particle size.

The calculated Cu and Cc of the model sand are 2.29 and 0.84, respectively. It is generally believed that the sand soil with Cu < 5 or Cc outside 1~3 belongs to the poorly graded soil, so the model sand is determined to be the poorly graded soil. If the seepage failure occurs in the dam, the development mode of seepage failure can be predicted by some parameters of the soil, that is, whether the soil is piping or flowing soil. According to the non-uniform coefficient discrimination method proposed by the former Soviet Union scholar Istomina, it is preliminarily judged that the model sand is a flowing soil-type soil.

2.3. Construction of the Dam Failure Model

The dam break process of a tailings reservoir involves many aspects, such as hydraulics, mud and sand dynamics, and soil mechanics. It involves many disciplines and is highly complex, which leads to the similarity relationship of model tests.

Therefore, we must put aside the generality of similarity and focus on the similarity of critical elements. This experiment uses the engineering background of a tungsten mine tailings dam in Jiangxi Province, China. The similarity criterion is appropriately relaxed, and the accumulation effect of particle movement during the deformation of the dam body is emphasized to construct the physical model.

Under the condition of geometric similarity, the physical model test of the 1:100 large-scale tailings dam is carried out according to the level of the second-class reservoir of the prototype tailings dam. The prototype range of the tailings dam is 1200 m × 700 m, and the model size is 12 m × 7 m. The model mainly comprises bedrock, a dam body, an observation system, and a water supply circulation system. The specific steps are as follows: According to the topographic map data provided by the mine, the three-dimensional model of the prototype tailings dam is established using Civil-3D modeling software (ver.2018) according to the size of the actual tailings dam (Figure 4). Then, several vertical sections are cut out in the model with the east–west direction as the standard line, and the points on each vertical section are taken equidistantly to extract the elevation value of each point on each vertical section. The model is intended to build a model with an elevation of 230 m in the actual terrain. The steel frame structure of the bedrock is made based on the elevation of each point on the vertical section. The square steel pipe is used as the bedrock support. Each steel pipe corresponds to the elevation of its relative point in proportion. Finally, the waterproof cloth is covered on the steel frame group and fixed to obtain a complete view of the bedrock terrain. Figure 5 is the completed mountain steel frame group, and Figure 6 is the complete bedrock after laying waterproof cloth.

Figure 4. Three-dimensional model of the tailings dam.
Figure 5. Mountain support structures.
Figure 6. A complete view of bedrock.

The initial dam is piled up with silty clay. In the process of stacking the initial dam, two PVC pipes with holes in the wall body and tightly wrapped with permeable geotextiles are symmetrically buried at the bottom of the initial dam to simulate the drainage pipe. A valve is installed at the outlet end of the two drainage pipes to control the drainage speed. The sub-dam uses the pipeline method commonly used in the mine to simulate the ore drawing. An ore drawing main pipe is introduced from the slurry pool to start the ore drawing from the model’s right side, and a valve is set in the main pipe to control the flow rate of the square ore. When the pulp flows into the tailings pond, the tailings will be layered and precipitated under hydraulic screening. After precipitation, the ore is suspended when the tailings reach the target dam height. Start to build the next sub-dam, use the layered filling method to build the dam body to the design elevation, and use the vertical line method to control the elevation when building the dam. (Figure 7) is the construction of the second sub-dam. Four pore water pressure gauges are buried in the dam construction process to monitor the position of the saturation line of the dam body. The four pore water pressure gauges’ positions are arranged along the dam body’s central axis. They are located directly below the dam crest of the first-, second-, third-, and fourth-level accumulation dams. They are named as site 1, site 2, site 3, and site 4 (Figure 8).

Figure 7. Second-stage sub-dam stacking.
Figure 8. Buried pore water pressure gauges.

Due to the need to supply a large amount of water for the test, a water tower was placed on the site (Figure 9), and a return water collection system was designed to achieve a water supply cycle (Figure 10). The observation equipment of the test (Figure 11) uses a trinocular camera and a high-definition camera to record the dam break process of the tailings dam.

Figure 9. Water tower.
Figure 10. Water supply circulation system.
Figure 11. Experimental observation system.

3. Tailings Dam Break Model Experiment

The dam failure mode under specific flood conditions is characterized by permeation damage, manifested as soil erosion. Through analysis of experimental phenomena and data, the development process of dam failure is elucidated, revealing the variation patterns of pore water pressure at different locations and the saturation line of the dam body.

3.1. Dam Failure Experiment

The test was carried out by intermittently injecting water into the reservoir to simulate flood conditions, keeping the flow rate stable during the injection, and keeping the drainage pipe open during the whole test. The beginning of the water injection was taken as the beginning of the test, and the entire dam break test lasted 448 min. It can be roughly divided into two stages, each accounting for one-half of the total length. Figure 12 shows a typical picture of the damage to the dam during the test. Figure 13 shows a timeline of the test damage development. The specific tailings dam damage development process is as follows:

Figure 12. Dam failure model tests.
Figure 13. Timeline of the development of the flowing soil destruction.

The first stage is seepage stabilization: the overflow water is clear, the dam’s surface is stable, and there is no movement of particles. At 138 min of the test, the contact zone between the right end of the second sub-dam and the bedrock began to seep first (Figure 12a). The seepage water flows along the contact zone between the dam body and the bedrock and overflows down the dam face. There are two reasons for the seepage here. The first is fine cracks in the contact area between the soil and the bedrock, which provides a breakthrough for the seepage water. The second is based on calculating the data collected by the pore water pressure gauge. It can be seen that the saturation line at this time escapes on the slope of the second sub-dam, where the dam surface overflows. Subsequently, the second-stage sub-dam continued to seep, and the overflow area gradually expanded and merged with the second-stage sub-dam dam surface. At 174 min, the third-stage sub-dam began to overflow on the left side (Figure 12b). At this time, according to the collected data, it can be calculated that the buried depth of the saturation line has been exposed to the third-level sub-dam. At 190 min, the first sub-dam also overflowed (Figure 12c). Then, the sand boiling point appears at the right end of the first-stage sub-dam, and the soil particles fluctuate obviously with the overflow water. The sand boiling causes the soil particles to be continuously taken out of the soil body. At 203 min, the dam surfaces of the first, second, and third sub-dams have all become swampy.
The second stage is the development and failure stage of the flowing soil: seepage deformation occurs continuously, and more earthwork is lost. At 236 min, the first flow soil damage happened at the right end of the second sub-dam (Figure 12d). The failure form is flow slip. At 239 min, a second flow soil damage occurred on the left side of the first sub-dam (Figure 12e). The flow-slipping soil will form a pit that evolves into a breach, making the seepage velocity and seepage flow faster and larger. Then, the pit part of the soil slides, and the seepage water erodes the downstream dam surface. At 248 min, two erosion ditches have been formed in the flow soil failure area on both sides of the dam (Figure 12f,g).
The erosion gully on the left side is located at the junction of the right side of the first-order sub-dam and the bedrock. The critical hydraulic gradient is lower, the dominant flow develops more rapidly, the sand is wrapped violently, and the subsequent seepage damage is more likely to occur. The erosion gully produces more water flow to scour multiple branches on the dam’s surface. The right erosion ditch is located at the junction of the secondary dam and the bedrock. At this time, the erosion ditch has developed to a certain depth, and the sand boiling point has reached 6. The flowing soil migrates downward under the action of overflow water. The flowing water will bring the fine particles to the downstream area. The coarse particles will be accumulated to form a ‘filter layer‘ to block the overflow water channel. The seepage pressure on both sides of the filter layer gradually increases. A new seepage channel will be formed when the seepage pressure on one side reaches the critical value. At 292 min, the flow soil damage eroded to the third sub-dam and further developed upstream along the boundary. Part of the erosion gully’s inner wall soil is washed away underwater, and the internal wall forms holes and expands upward until the upper part forms a suspended surface. When the shear strength of the upper soil is greater than the shear strength of the soil, it will collapse and continue to repeat the next round of erosion. At this time, the left-flowing soil does not develop to the upstream failure but to the proper lateral erosion, and the right side flushes out a new channel due to the obstruction of the ‘filter layer‘. At 303 min, the third flow soil failure occurred on the left side of the third sub-dam (Figure 12h). Because of the increase in overflow water and the acceleration of water flow, the right scouring area opens the downstream channel at the particle deposition, and fine particles are continuously taken out of the dam by seepage water. The overflow water also washes away the ‘filter layer‘ on the left side. After that, the first sub-dam eroded to the deep, and the dam surface failure area did not expand. There is a hydraulic–gravity erosion cycle in the flow soil damage area of the second-stage sub-dam, which extends to the upstream and the middle of the dam body. With the increase in the erosion damage area of the water flow, the more the sand boiling point, the faster the seepage damage, and the erosion area of the lower section continues to expand, and the water flow in the erosion gully is large and fast. The flowing soil failure zone of the third-stage sub-dam has not yet formed a penetrating failure path and is in the initial stage of erosion. At 348 min, the fourth-stage sub-dam overflowed (Figure 12i). At 448 min, the flow soil was eroded to the fourth sub-dam (Figure 12j).
The flow soil damage area is eroded to the fourth sub-dam, which is regarded as the whole dam damage. It is measured that the depth of the collapse area is about 12 cm, and the width is about 80 cm. It should be noted that although the dam body has undergone a large area of seepage failure, the dam body has not yet experienced an unstable landslide. The tailings dam finally broke because the dam body soil damage zone developed to the top of the dam to produce a breach.

3.2. The Change Rule of the Saturation Line

Figure 14 is about the change curve of the saturation line. At the beginning of the test, as the upstream water level rose, the saturation line rose rapidly despite the drain being in a normal discharge condition. After the lifting of the head has ceased, the rate of the upward lifting of the saturation line becomes significantly slower due to the hysteresis effect. Then, a certain depth of burial is maintained. In the middle and late stages of the test, most of the dam had become saturated, and the soil matrix suction had weakened. When water is again stored in the reservoir, the saturation line will again lift, but at a reduced rate compared to the initial period. If the reservoir level is no longer raised, the saturation line tends to fall after a period of time. By approximately 270 min into the test, the dam face had already developed a certain size of the flow damage zone, and it was no longer meaningful to discuss the depth of the saturation line.

Figure 14. Variation curve of saturation line.

In the previous study [30], a two-dimensional finite element model of the tailings dam, chosen from the central axis of the three-dimensional tailings dam model, was used to analyze the distribution of saturation line in the tailings dam under flood conditions. The numerical simulation results show that when the upstream water head rose to 125 m (Figure 15), the saturation line intersected with the first and fourth-level accumulation dams and was exposed throughout the dam surface. The variation law of the saturation line obtained by the numerical simulation is consistent with the experimental phenomenon; that is, the saturation line increases with the rise of the reservoir water level, and the order of the dam surface exposure is the second-stage sub-dam, the third-stage sub-dam, the first-stage sub-dam, and the fourth-stage sub-dam. According to the simulation results, the displacement of the dam body does not change greatly, and the plastic strain zone does not appear on the slope and crest of the dam body, and there is no penetration. It can be judged that the tailings dam model does not have deep slip when the water level is about to overflow; that is, the skeleton structure of the dam body is stable. Combined with the physical model test, before the saturation line of the dam body reaches the dam surface of the fourth-level sub-dam, the tailings dam has undergone seepage failure, but the dam body has not undergone structural instability. The results of numerical simulation are consistent with the phenomenon of physical model test. After that, with the development of flowing soil, the damaged area of the dam body continues to extend to the top of the dam, which will eventually cause the breach of the dam top and cause the flood discharge of the dam.

Figure 15. Saturation line distribution of the tailings dam under 125 m water level.

4. Impact Analysis after Dam Break and Prevention Suggestions

Based on the results of the physical model experiment, it can be inferred that the tailings dam failure was triggered by seepage failure. This means the area of flowing soil gradually eroded upstream until a breach was created at the top of the dam, and the reservoir fluid poured downstream. Therefore, an erosion damage trench was set up on the model for the dam breach calculation in FLOW-3D (ver. 9.3), extending from the top of the initial dam to the top of the dam, and the shape was simplified to a semi-cylinder. Figure 16 shows a model of the tailings dam after completion of the pre-treatment.

Figure 16. FLOW-3D 3D calculation model.

4.1. Dam Failure Test Results

An overview of the area downstream of the tailings dam is shown in Figure 17. The downstream area is dominated by the production facilities (red and yellow line areas in the figure), staff accommodation buildings (pink line area), the road around the mountain (blue curve), villages (green line area), and scattered agricultural land.

Figure 17. Aerial view downstream of tailings dam.

4.1.1. Overflow Area

Figure 18 shows the change in the extent of fluid inundation at 60 s, 120 s, 180 s, 240 s, and 300 s as calculated by the software, with the fluid in blue in the figure. As can be seen from the diagram, the breached fluid was rapidly released downstream in a short period and, by 300 s, covered the entire flat area downstream, with an overflow area of approximately 95,250,000 square meters. Farmland and roads in the area will be flooded, and production facilities and residential buildings will also be affected. In addition, emergency escape plans can be challenging to implement successfully at short notice. It is thus clear that in the event of a breach of this tailings dam, it would be a major accidental disaster.

Figure 18. Time-course diagram of mud area.

4.1.2. Flooding Depth

Figure 19 shows a cloud of the distribution of flooding depth at 60 s, 120 s, 180 s, 240 s, and 300 s. Due to the lower topography in the eastern part of the downstream area, the fluids that wash down first collect in the east and then spread westwards. As can be seen from the graph, the maximum inundation depth is always located in the eastern part of the lower reaches near the initial dam. The mudslide did not affect the northern area due to the terrain’s advantage; when the situation was urgent, people could be evacuated along the northwest-facing road to the north.

Figure 19. Cloud map of flooding depth.

4.1.3. Flow Rate Analysis

The flow velocity during the release process reflects the magnitude of the fluid impact. Figure 20 shows the flow velocity clouds during the dam breach release process at 60 s, 120 s, 180 s, 240 s, and 300 s. Due to inertia, the fluid emerges from the breach. It rapidly completes the transformation from potential energy to kinetic energy in the trench eroded by the flowing soil, with the flow velocity reaching a maximum. In addition, there is some leakage around the dam at the junction of the tailings dam and the mountain. After the fluid is flushed off the tailings dam, the average flow velocity decreases due to the diffusion principle and frictional forces. In general, the flow of emissions increases and then falls.

Figure 20. Cloud map of flow rate.

Three points, A, B, and C, are selected in the flow direction of the release to analyze the fluid’s flow velocity characteristics, specifically during the dam failure process. The three points are located at the top of the initial dam, the foot of the initial dam, and the downstream area adjacent to the tailings dam (Figure 21). Figure 22 shows the variation in flow rate over time at three points. Overall, the flow velocities at points A, B, and C are successively reduced as the flow path develops. From the point of view of the flow velocity at a single point, it does not increase to a peak all at once but has an undulating, phased variation. At about 30 s, the overflow velocity starts to appear at the three points, after which the trend is a cyclic process of “increase-smooth or decrease” because the increase in flow velocity does not coincide with the expansion of the breach, which, in turn, determines the flow velocity of the discharge. The flow rate increases accordingly when the breach expands and becomes deeper again. After several cycles of this until the breach is no longer extended, the flow rate at points A, B, and C all fall during the last 30 s of the figures and will return to zero as the flooding stops.

Figure 21. Flow rate reference points.
Figure 22. Flow rate time history diagram.

The analysis of the variation in the flow rate of the release shows that the debris flow impacts downstream in a segmented manner. Therefore, the decrease in flow velocity should not be regarded as the end of the entire dam break, nor should blindly carry out the aftermath of the accident at this stage, but should wait for a longer period to observe and confirm so as not to cause more damage.

4.2. Recommendations for Prevention and Management

4.2.1. Technical Measures

Dam surface treatment: According to the seepage characteristics of the tailings dam, to prevent overflow water and rainwater from scouring the shoulder and face of the dam and to collect the seepage water, a shoulder drainage ditch should be installed along the junction of the dam with the slopes of the two banks, and a face drainage ditch should be installed on the face of the dam. Moreover, the downstream slope of the dam can be mulched, turfed, and, if necessary, reinforced by stone pitching at the foot of the dam.

Additional seepage facilities: Combined with the model test results, it is clear that control of the saturation line of the tailings dam should be a top priority for safety management. To effectively control the depth of the saturation line, additional drainage facilities can be provided in the form of a combined horizontal drainage pipe and a vertical shaft connected to the end of the horizontal drainage pipe. In addition, the vertical drainage pipe should be raised with the height of the stockpile dam and pumped out periodically.

4.2.2. Management Measures

Routine inspection and maintenance: Besides monitoring various safety indicators such as the tailings dam saturation line and dry beach length, the person responsible for safety should regularly inspect the dam body for cracks, collapses, and surface erosion. They should also ensure that the slope protection is intact and that the drainage facilities are clear of blockages, siltation, or waterlogging. Check for seepage, pipe surges, or flowing soil, focusing on the junction between the dam and the hills on either side, and be vigilant for changes in seepage flow and turbidity. If a potential problem is identified, the cause must be immediately determined, and remedial action must be taken to prevent it.

Ensure excellence in flood management, including pre-flood preparation, response during flooding, and post-flood rescue work.

5. Conclusions

  1. The reservoir’s water level had not yet crested before the dam was damaged. In other words, the cause of dam failure under flood conditions is seepage failure, which manifests itself in the form of flowing soil. Before the flow soil is destroyed, the dam surface will produce overflow, water accumulation, sand boiling, and other phenomena. The phenomenon of the dam failure test shows that the flow soil damage starts at the weak point of the dam at the junction with the bedrock. These areas have a high saturation gradient and are more prone to local damage. In the early stage of soil flow failure, multiple sand boiling points were generated on the dam surface. With the development of seepage, collapsible cracks appeared on the dam surface one after another, forming erosion ditches. In the middle stage of soil failure, the failure area is widened. The soil cycle undergoes the process of erosion–gravity erosion, and the ‘filter layer’ will slow down the failure rate to a certain extent. In the later stage of flow soil damage, the flow water damage area began to penetrate, and the erosion intensified until the whole dam body was damaged. Therefore, when the sand boiling point is generated, and the collapsible cracks appear on the dam surface, these can be used as a warning sign of seepage failure.
  2. The buried depth of the saturation line becomes shallow with the increase in the upstream water head. And, the rate of increase is first fast and then slow. After the lifting head is stopped, the saturation line will still rise slightly for a period of time due to the lag effect. If the reservoir water level is not replenished for a long time, the saturation line will be reduced under normal drainage. The order of the saturation line escaping from the dam surface is the second sub-dam, the third sub-dam, the first sub-dam, and the fourth sub-dam. It can be seen that before the flood, it is necessary to check and repair the drainage facilities to ensure their suitable operation. During the flood season, all measures should be taken to enhance the flood discharge, reduce the saturation line, and avoid the seepage damage of the tailings dam.
  3. The results of the FLOW-3D hydrodynamic simulation software show that the breach fluid was rapidly discharged within a short period, covering the entire flat area downstream by 300 s. The local farmland and roads were submerged, and the rest of the construction facilities were also damaged to a certain extent. Therefore, it will be a major disaster once the tailings dam breaks. The rapid development of the dam breach mudslide and the short release time make it impractical to organize the evacuation of people when the release occurs. Therefore, in combination with the mechanism of tailings dam failure, targeted measures for potential remediation and dam failure prevention can be proposed from both technical and management aspects.
  4. The innovation point is to use a large-scale physical model test to study the dam break mode of tailings dam under flood conditions. By monitoring the internal changes of the tailings reservoir under flood conditions, the stage of seepage failure of the dam body can be judged, which can serve as an early warning for the subsequent break of the tailings dam. The experimental process and experimental results of the model can provide a reference for the changes in tailings reservoir under flood conditions under real working conditions so as to correspond to the changes of tailings reservoir fluid under flood conditions under real working conditions. Provide guidance for staff to monitor changes in tailings ponds. The determination of dam break position and dam break mode by model test provides a basis for simulating the influence of tailings dam break on the downstream. The use of a steel frame structure to build a tailings dam model can cover the entire tailings dam terrain more comprehensively and economically and can more comprehensively analyze the entire dam break process of the tailings dam. Compared with the local tailings dam similarity simulation and on-site exploration, it is more profound and comprehensive, which has practical significance for the safety of the tailings reservoir. The defect is that there is a prototype of the model, and it cannot be used for all tailings mines. The actual situation needs to be analyzed in detail. In addition, according to the tailings pond model test, it can be expected that the tailings pond model can be used to study the useful mineral components in the recovery reservoir, which has practical significance for environmental protection and resource recovery.

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Welding

A multi-physics CFD study to investigate the impact of laser beam shaping on metal mixing and molten pool dynamics during laser welding of copper to steel for battery terminal-to-casing connections

배터리 단자-케이싱 접합을 위한 구리와 강철 간 레이저 용접 시 레이저 빔 형상이 금속 혼합 및 용융풀 역학에 미치는 영향을 조사하는 다중 물리 CFD 연구

Giovanni Chianese, Qamar Hayat, Sharhid Jabar, Pasquale Franciosa, Darek Ceglarek, Stanislao Patalano

Abstract

This study aims to investigate the impact of laser beam shaping on metal mixing and molten pool dynamics during laser beam welding of Cu-to-steel for battery terminal-to-casing connections. Four beam shapes were tested during LBW of 300 µm Cu to 300 µm nickel-plated steel. Both experiments and simulations were used to study the underlying physics. A CFD model was firstly calibrated against experiments and then deployed to explore the effect of the increasing ring-to-core diameter, as well as a tandem laser spot configuration. The study showed that metal mixing is influenced by the keyhole dynamics and collapse events, but also there is an intricate interplay between keyhole geometry, fluid dynamics via Marangoni forces and buoyancy forces. Notably, the buoyance forces due to the different densities of steel and Cu, along with the recoil pressure contribute to the upward flow of steel towards Cu, and hence impact meaningfully the material mixing. The study pointed-out that the selection of a custom ring-to-core diameter and ring-to-core power is a decision with a trade-off between the need of stabilising the keyhole dynamics and the need to reduce the mixing. Findings indicated that 350 µm ring and 90 µm core with 30% of ring power (weld configuration C3) resulted in more stable dynamics of the keyhole, with significant reduction of collapse events, and ultimately controlled migration of steel towards Cu. Additionally, the pre-heating approach with the tandem beam only led to local fusion of Cu and no significant improvement in keyhole stability was observed.

1. Introduction

The push towards net-zero mobility is globally influencing industrial strategies in the automotive sector as reported by IEA (2022). Manufacturers are introducing new vehicles by replacing internal combustion engines with hybrid or fully electric powertrains. The battery pack is a critical component for un-interrupted supply of electricity to e-drives and other electrical systems in electric vehicles (EV). A battery pack typically consists of several battery modules that are electrically connected in series and parallel based on the desired power and capacity requirements (Zwicker et al., 2020). Battery modules hold the battery cells that store the electrical charge and supply it on-demand to the electrical systems. Electrical connections play a critical role in the entire process of battery pack manufacturing since joints with different electrical resistance may result in uneven current loads that can affect the overall performances of the battery system (Kumar et al., 2021). Joining of dissimilar materials is the most deemed since it complements the properties of the individual materials and allows to develop functionally efficient connections. Joints in EV battery pack involve low-thickness materials (typically 0.3–1 mm) and the welding process is normally performed in lap or fillet configuration. Depending upon design and functional requirements as well as manufacturing costs, research has shown that the following combinations of materials are the most regarded: aluminium (Al) to copper (Cu), steel to Al, Al to steel, Cu to steel (Das et al., 2018).
Connections between Cu and steel have gained much attention in EV applications for joining cells in battery modules. For example, in the cylindrical format, the negative terminals are made of Cu and are generally connected to the steel casing of the cell (Sadeghian and Iqbal, 2022). Several joining processes have been studied for Cu-to-steel welding and they include wire bonding, micro-spot welding, ultrasonic welding, micro-TIG welding, electron beam welding and Laser Beam Welding (LBW) (Zwicker et al., 2020). LBW is an attractive option and has recently gained popularity due to advances in versatile methods for laser beam delivery and associated sensors technology for quality control and process monitoring that make LBW comparatively affordable (Kogel-Hollacher, 2020). Brand et al. (2015) demonstrated that LBW is a suitable process for joining battery terminals since it allows the lowest electrical resistance and the highest joint strength, when compared to micro-spot welding and ultrasonic welding; also, it is potentially applicable to any cell configuration and dissimilar metal combinations.
Despite the benefits of LBW, opening and maintaining a stable molten pool on the Cu-side is challenging when using LBW with infrared sources. The absorptivity of Cu at ambient temperature is approximate 5% and increases with rising temperature, and it suddenly jumps up when the melting temperature is reached. A problem with this is that when fusion of the material does happen, a surplus of energy flows through it, which can vaporise the material and create spatters, as well as pores inside the joint. These defects can reduce the electrical conductivity of the joint. At first sight, the solution to the low coupling efficiency of Cu is to switch from infrared sources to visible sources. The absorption increases drastically up to 60% when using visible sources. Green (515 nm) or blue (450 nm) lasers have been investigated by Kogel-Hollacher et al. (2022) and proved that lower power needed for same penetration achievable with infrared lasers and less thermal damage to enamel and insulators. Hummel et al. (2020) experimentally evaluated and proved the beneficial effects of blue laser during laser micro-welding of Cu, and achieved high welding speed with low input power. Nonetheless, compared to infrared lasers, the higher cost, lower plug efficiency and lower beam quality of visible lasers, push practitioners towards the use of multi-kW infrared sources at very high brightness for Cu welding.
In addition to the challenge posed by the laser beam coupling to the Cu, the welding of Cu to steel presents a series of problems. First, they are quite different in terms of physical properties such as density, melting points and thermal expansion and make defect-free welding difficult. Second, although Cu-Fe alloys are completely miscible in the stable liquid state and do not form brittle intermetallic compounds, the system shows a wide metastable miscibility gap at an undercooling level. The liquid phase separation occurs as the liquid cools in the miscibility gap resulting in the supersaturation of one or both liquids. Jeong et al. (2020) has shown that increasing the content of Fe tends to improve the mechanical properties of alloys but reduce electrical conductivity and ductility. Chen et al. (2013) proved that the toughness and fatigue strength of the joint decreases with the increase in the amount of molten Cu into the steel. Thus, melting of Cu was suggested to be kept at a minimum. Third, excessive penetration of Cu in grain boundaries of steel may result in cracks in the heat affected zone and fusion zone, and ultimately reducing structural performance of the joint. Therefore, to reduce these issues, controlling the mixing of Cu and steel in the molten pool is quite important for producing sound joints.
Laser beam shaping is gaining popularity since it holds the promise to control cooling rates and thermal gradients in and around the molten pool. This theoretically leads to a tailored material response to the heat input both spatially and temporally. A tailored power density profile (Fig. 1 shows typical power density profiles obtained via adjustable ring-mode laser) is generated via adequate insertion of optical components (specially coated lenses of silica substrate) in the optical chain of the welding head; or by electro-optical switching multiple laser beams generated in the laser source itself and enabled by beam combiners with optical phased array. Research has confirmed a positive effect of the laser beam shaping on the control of the weld profile and keyhole stabilization with suppression of spatters and significant reduction of porosity in the weldments. Caprio et al. (2023) investigated the use of beam shaping and beam oscillation to weld 0.2 mm Ni-plated steel sheets in lap joint configuration, which are materials commonly involved in cell to busbar connections. Sokolov et al. (2021) employed the ARM laser coupled with Optical Coherent Tomography (OCT) in Al-to-Cu thin sheets and observed that the use of combined core and ring-shaped laser beams reduced the fluctuations of the keyhole, improved the stability, and ultimately the accuracy of OCT measurements. Rinne et al. (2022) studied the effect of different power distributions between the inner core and outer ring-shaped laser beams on spatter ejection and penetration depth during welding of Cu sheets. Wagner et al. (2022) investigated and proved the influence of dynamic beam shaping on the geometry of the keyhole during welding of Cu by varying the patterns of the intensity distribution in longitudinal and transversal direction. Prieto et al. (2020) implemented dynamic laser beam shaping with infinite pattern and assessed quality of weld seam in 0.8 mm Al thin-sheet and observed that tailored beam with shape frequency over 10 kHz enables welding speed up to 18 m/min with stable keyhole.

Fig. 1. Example of laser beam shapes obtained via an adjustable ring-mode laser.

Despite the benefits, laser beam shaping introduces new set of parameters and finding the optimal combination of number of beams, shape of beams (multiple spots, C-spot, ring-core spots, pyramid, infinity, spiral shapes, etc. (Prieto et al., 2020)) can be expensive and time consuming since it may require dedicated equipment, expertise and experimental setups. In this context, multi-physics computational fluid dynamics (CFD) enable simulations of the process to reproduce mechanisms which are difficult to observe with in-situ investigations. With the raise of computational power and multi-core computing on high performance clusters, advanced simulations of LBW processes are now a close reality. Huang et al. (2020) developed a CFD model in FLOW-3D WELD® to study the metal mixing during linear laser welding of 200 µm Al to 500 µm Cu with different levels of laser power and velocity of the laser spot. They analysed the contribution of recoil pressure and Marangoni effect on the overall mixing process. Chianese et al. (2022) developed a multi-physics model using FLOW-3D and FLOW-3D WELD® to investigate the effect of part-to-part gap in LBW of Cu-to-steel thin sheets with beam wobbling. They showed that the presence of part-to-part gap and mixing mechanism between parent metals are linked, and the occurrence of part-to-part gap influences the temperature and velocity fields in the molten pool resulting in different mixing mechanisms. However, they did not implement any strategies for weld improvement. Drobniak et al. (2020) and Buttazzoni et al. (2021) implemented CFD multi-physics simulations of 1 mm-thick stainless steel plates with adaptive mesh refinement to predict the shape of the weld seam in presence of part-to-part gap, and they predicted the effect on the process of secondary laser beams with different shapes to optimize the weld quality. Recently, Huang et al. (2023) combined experimental approach and CFD simulations in FLOW-3D WELD® to reveal the effect of oscillation frequency and amplitude on fluid-flow and metal mixing during laser welding of 200 µm Al to 500 µm Cu with circular beam wobbling implemented. Additionally, they implemented a Scheil solidification model to predict the phase distributions in the welds based on the predicted thermo-solute conditions.
While significant research has been already developed using linear laser welding or laser welding with wobbling for joining of dissimilar materials, a clear understanding of metal mixing and dynamics of the keyhole during Cu-to-steel welding with beam shaping are not clearly reported. Research into application of beam shaping for Cu-to-steel welding entails a promising prospect for further development and investigation. Furthermore, the use of advanced CFD models is a viable approach to complement experimental investigations and explore weld configurations with different beam shaping profiles that would be difficult to achieve only with experimental work. Therefore, this paper aims to study the impact of laser beam shaping on metal mixing and dynamics of the keyhole during LBW of Cu-to-steel for battery terminal-to-casing connections. Four beam shapes were tested during LBW of 300 µm Cu to 300 µm nickel-plated steel. Both experiments and CFD simulations were used to study the underlying physics. A CFD model was firstly calibrated against experiments and then deployed to explore the effect of the increasing ring-to-core diameter, as well as a tandem laser spot configuration.

2. Experimental design and model description

2.1. Experimental design

Materials used in this work are Copper SE-Cu58 2.0070 and Nickel-plated steel (commercial name: Hilumin TATA STEEL). Experiments consisted of 25 mm long welds in lap joints configuration with 300 µm Cu on top of 300 µm nickel-plated steel.
Dimensions of the specimens were 65 mm × 30 mm. The laser source used was the Lumentum CORELIGHT, having 55 µm core diameter and 220 µm ring diameter, and BPP 1.4 mm·mrad and 11 mm·mrad for core and ring, respectively. The laser fiber was coupled to the Scout-200 (Laser and Control K-lab, South Korea) scanner to deliver the laser power to the specimens via 2D F-theta scanner with telecentric lenses. Fig. 2 shows the welding setup and specifications of the equipment are in Table 1. Caustic parameters were measured using PRIMES GmbH measurement system.

Fig. 2. (a) Welding setup with aluminium fixture; (b) schematical representation of the welding setup; (c) definition of weld features: top weld width, Wtop; width at the interface, Wi; weld penetration depth, Dpen.
Table 1. Specifications of the welding equipment.

Each weld seam was cut and prepared to obtain two cross sections for each experiment – cross sections were positioned at 10 mm and 15 mm away from the weld start. Three replicates were performed for each weld configuration. Sectioned samples were mounted in Bakelite resins and standard metallography procedure was performed for grinding and polishing to reveal weld profile under Nikon Eclipse LV150N optical microscope. To evaluate and characterize metal mixing with parent metals, elemental mapping of cross-sections was performed with an FEI Versa 3D dual beam scanning electron microscope using Energy Dispersive X-ray Spectroscopy (EDS mapping).
Welding experiments were performed in continuous power mode without power modulation. The laser beam was focussed perpendicularly on the upper surface of the Cu sheet, and the motion of the laser was linear (no wobbling). Although the use of shielding gas tends to avoid oxidation in the process and reduce hydrogen entrapment, when using scanners to deliver the laser beam, the gas nozzle cannot be positioned in proximity of the beam. Therefore, in this work, all experiments were conducted with no shielding gas. Part-to-part gap was manually checked and set to a nominal zero.
To study the impact of laser beam shaping on metal mixing and molten pool dynamics, 5 weld configurations (C1 to C5) were designed as shown in Table 2, with 4 beam shapes presented in Fig. 3. LBS#1 is single gaussian spot of 90 µm; LBS#2 super-imposes an inner core of 90 µm with an outer ring-shaped profile of 350 µm, with the ring accounting 30% of the total power. LBS#1 and LBS#2 were experimentally tested and enabled by the static beam shaping system of the Lumentum CORELIGHT source. LBS#3 follows the hollow sinh-Gaussian beam profile as defined in Liu et al. (2019), with 90 µm core and 500 µm ring, with 72% of the total power assigned to the ring. LBS#4 is a tandem beam with primary (90 µm) and secondary beam (150 µm) at a centre-to-centre distance of 300 µm, and 50% split of the power between primary and secondary beams – LBS#4 was introduced with the aim to increase the absorption rate by the pre-heating action of the secondary beam. LBS#3 and LBS#4 were only simulated since the laser beam shaping of the Lumentum CORELIGHT was only capable to work with fixed core-to-ring diameter ratio. Therefore, only a simulation-based approach (with the model pre-validated and calibrated in C1, C2 and C3) was deemed appropriate in this case to explore the effect of the increasing ring-to-core diameter and tandem laser spot configuration on material mixing.

Table 2. Process parameters used for the four selected laser beam shapes in Fig. 3.
Fig. 3. Normalized power density distribution for LBS#1, LBS#2, LBS#3 and LBS#4.

The power and speed of C1, C3, C4 and C5 were selected with an iterative process to ensure weld penetration depth, Dpen, ranging 400 – 500 µm. The choice of this penetration depth is based on the requirement that the temperature at the lower end of the steel sheet remains below 550 K. This precautionary measure aims to prevent any potential damage to the battery cell. Additionally, to minimise the effect of the weld depth on the metal mixing, a uniform depth of penetration was adopted across the different beam shapes for comparative analysis. Welding speeds were kept between 250 mm/s and 375 mm/s which is in line with the experimental work in (Perez Zapico et al., 2021). C2 is a variant of C1 and corresponds to a fully penetrated weld. Although fully penetrated welds must be avoided during LBW of battery terminals due to the risk of fire ignition, this work presents this variant for two reasons: first, to generate an additional weld configuration to validate the simulation; second, to discuss how the metal mixing behaves when transitioning from partial penetration to full penetration.

2.2. Model description

A multi-physics model was developed using the commercial CFD code FLOW-3D® (solver version: 12.0.2.01) and its module FLOW-3D® WELD (release: 7, update: 1). In order to develop a numerical model representing the essential physics during LBW of Cu-to-steel, the following assumptions were considered: (i) the liquid flow is considered Newtonian and incompressible; (ii) volumetric thermal expansion of the liquid metal due to temperature-dependent mass density is accounted; (iii) the air and vaporized metal are modelled as “void” type, with ambient temperature and pressure assigned to model the heat exchange with the metal as a natural convective flux (irradiance is neglected); (iv) the heat sinking effect of the clamping mask is neglected due to the clearance between the weld seam and the mask itself as already presented in (Chianese et al., 2022); (v) the effect of plasma plume on laser absorption is not directly modelled but is accounted in the calibration process as also proposed in previous studies by Lin et al. (2017) and Hao et al. (2021); furthermore, the laser absorption is assumed temperature dependent for Cu, constant for steel, and independent of the incidence angle. This assumption is in-line with the work presented by Huang et al. (2020), where they used the build-in ray-tracing function in FLOW-3D® WELD to predict the laser absorption in the keyhole.

2.2.1. Governing equations, boundary conditions and material properties

To reduce the computational cost of the simulations, the computational domain was divided in two zones (Fig. 4): (1) a process zone which was interested by phase change, and, (2) a thermal diffusion zone that models heat transmission in the sheets. A finer mesh size was used for cells in the process zone, and a mesh size 5 times greater than in the process zone was used for cells in the thermal diffusion zone.

Fig. 4. Top view (a) and side view (b) of a schematic representation of the computational domain and modelling approach with nested meshes (process zone and thermal diffusion zone).

Dimensions of the process zone are 2 mm × 0.8 mm× 0.775 mm. The length (2 mm) of the process zone was chosen to enable the simulation of approx. 1.8 mm weld length, which was experimentally evaluated to be sufficient for reaching the steady-state regime. The width (0.8 mm) of the process zone was selected to ensure that the molten pool was contained in it; the height of the computational domain was chosen equal to 0.8 mm so that, beside the stacked thickness of the processed sheets (0.6 mm), 0.2 mm of air (void type) are included in the computational domain. Extension of the thermal diffusion zone is calculated according to the Eq. (1), where k is the thermal conductivity, cp the specific heat at constant pressure, ρ the mass density, tend the simulation time, T the temperature, and Tamb= 20 °C the ambient temperature. The simulation time, tend, is function of the welding speed and the weld length (1.5 mm).

Four different values of the mesh size in the process zone were considered during sensitivity analysis, namely 40 µm, 20 µm, 15 µm, and 10 µm, that resulted in mesh independent solution for mesh size equal to or below 15 µm, which therefore is the selected size. This led to total number of cells approximatively equal to 528 thousand. The geometry of the thin sheets has been modelled in the computational domain, so that in-plane dimensions were parallel to X and Y axis, as shown in the top and side view in Fig. 4(a) and (b). Welding direction was parallel to X axis.
The following physics have been accounted to model the welding process: continuity, fluid flow via Navier-Stokes equations, energy conservation, evaporation, keyhole formation and evolution, solidification, species conservation and tracking, surface tension with Marangoni and Laplace forces and multiple reflections.
Phase change – Eq. (2) governs the evaporation phenomena which are modelled as mass transfer between the liquid phase and the void type and are proportional to the difference between the saturation pressure Psat and the partial pressure Pvap. In this equation, α is the accommodation coefficient, R is the gas constant, and T is the temperature. The saturation pressure is calculated as a function of the temperature according to the Clapeyron equation (Eq. (3)), in which the couple (Pv, Tv) represents a point on the saturation curve; γ, cv, and ΔHv are the specific heats ratio, the specific heat at constant volume, the latent heat of vaporization, respectively.

Recoil pressure – during laser welding process, intense localised heating of substrate material causes vaporization which results in recoil pressure. This pressure is proportional to the saturated vapor pressure. The relationship between the recoil pressure, Precoil, and the saturated vapor pressure, Psat, depends on the material properties and laser-to-material interaction. Eq. (4) is derived from Eq. (3) with the introduction of two coefficients, Ar and B, that will be calibrated using experimental data.

Tracking of the keyhole – surface of the keyhole is tracked by the volume of fluid (VOF) method (Daligault et al., 2022), which enables the calculation of the interface between the liquid metal and the void type, according to Eq. (5).

The interface between the cell is tracked using a scalar value f that indicates the fraction of fluid in it. A value of f=0 indicates that the cell has only void, conversely, f=1 corresponds to the case of a cell full of liquid, whereas the case of 0<f<1 indicates that the cell has both the liquid and the void type, and therefore the interface between the two falls in it. Similarly, metals involved in the welding process with fluid flow and mixing are tracked in each cell by means of a scalar value f2, which indicates the fraction of second material within the cells. Values of the generic material property ̅φ̅ in each cell is evaluated as weighted sum of the properties φ1 and φ2 of parent metals based on their mixing, as in Eq. (6).

Multiple reflections – Multiple reflections are implemented using a discrete grid cell system through the ray tracing technique. The laser beam is divided into a finite number of rays, which move in the laser beam irradiation direction. When the ray encounters the surface of the material, it is reflected according to vector Eq. (7), in which R→ is the direction of the reflected vector, I→ the direction of the incoming ray, and nˆ the normal direction of the material surface.

Laplace pressure and Marangoni effect – Recoil pressure contributes to the formation of the keyhole and mainly contributes to the velocity field in the fluid; however, surface tension-related phenomena such as Laplace pressure LP and the Marangoni force SM have great influence on the overall welding process. Laplace pressure and the Marangoni force are modelled according to (8), (9) which, σ is the surface tension, RI and RII are the principal curvature radii, and operator ∇t indicates the gradient along the tangent direction at the interface. Eq. (9) explicitly indicates the dependence of the Marangoni effect on the gradient of the surface tension, which in assumed temperature-dependent of the surface tension.

2.2.2. Boundary conditions and material properties

As shown in Fig. (4), the following boundary condition were assigned: wall in the X and Y direction (with constant ambient temperature); assigned pressure and temperature at the boundaries of the computational domain in the Z directions, with natural convective heat flux between the metallic sheets and the air. The heat source was directly imported from the power profiles defined in Fig. 3. Material properties were imported from the JMATPRO® material database. Fig. 5 shows the temperature-dependent plots.

Fig. 5. Temperature-dependent material properties defined in the model.

3. Results and discussion

3.1. Model validation

The model has been applied to simulate all the cases listed in Table 2. Model validation was conducted for the weld configurations C1, C2 and C3 by comparing the weld profile in cross sections and Fe concentration line profiles against the experimental results as shown in Fig. 6. Experimental and simulation results show that welding is done through keyhole mode. The generation of a keyhole is significantly influenced by recoil pressure. In the simulation, the recoil pressure is adjusted through the calibration of coefficients Ar and B, as indicated in Eq. 4. During the model calibration process, a value of Ar was determined to be 55,715 Pa, and the parameter B was set to 4, resulting in comparative results with those obtained in experiments. Five different mesh sizes were tested: 20 µm, 15 µm, 10 µm and 5 µm. The choice of the mesh size was driven by the need to have a minimum of 4 cells to discretise the smallest laser spot (i.e., LSB#1 has the smallest beam diameter of 90 µm among the tested beam shapes in Fig. 3). Mesh-independent solution was achieved with mesh size of 15 µm and this led to approximate a million cells in the whole computational domain.

Fig. 6. Comparison of the experimental and modelling results of the molten pool geometry and elemental maps for weld configurations C1 (a), C2 (b) and C3 (c).

The correlation was conducted looking at two cross-Section (10 mm 15 mm away from the weld start and end) – this was motivated by the need to take into account the experimental errors during the calibration and validation process.

Fig. 6 shows cross sections and elemental maps for experiments C1, C2, and C3, and corresponding simulations. Two representative cross-sections from the same weld seam are shown in each sub-figure to demonstrate the capability of the model to reproduce the geometric shape and the mixing phaenomena at different longitudinal positions along the weld seam. The fusion zones are marked in each cross section and show good correlation with predictions from simulations, as the cases with partial penetration are successfully predicted in for C1 and C3, along with full penetration in C2.

Elemental maps that were measured with EDS, and species concentration that were predicted with simulations, are reported for comparison to show capability of the model to reproduce the mixing mechanism. For each case, plots of the concentration of Fe along with line-scans are reported to quantitatively demonstrate the capability of the model to simulated diffusion of the molten metal from the bottom sheet to the upper one. They show that diffusion of Fe in Cu is well predicted in C1 and C3, as well as presence of Fe-rich clusters in the Cu near the interface between parent materials is reproduced in C2.

Good correlation between measurements and predictions of the weld geometry and metal mixing demonstrates capability of the model to simulate welding scenarios with different laser beam shapes, and weld penetration depth spanning from partial penetration to full penetration. This allows to confidently deploy the simulation model in conjunction with experiments to study the impact of laser beam shaping on metal mixing and molten pool dynamics.

3.2. Keyhole dynamics and impact on metal mixing

As keyhole instabilities have a significant impact on weld quality (Lu et al., 2015), this section highlights the impact of the laser beam shapes on the keyhole dynamics, which ultimately contributes to metal mixing. The discussion is presented by linking the laser power profile to the velocity field within the molten pool and ultimately to the metal mixing between the parent metals and the occurrence of collapse events of the keyhole.

Fig. 7 shows consecutive time frames in each weld configuration and reflects keyhole dynamic mechanisms. The keyhole’s shape and size vary, exhibiting irregularities, asymmetry and fluctuations. These shapes are directly correlated to the laser beam shape profile. The following observations are made:

  • Collapse events terminate in formation of pores and metal mixing. This is visible in the experimental results presented in Fig. 6(a) and (b), where relatively large pores are observed in the experimental cross-section. With a narrow beam profile (weld configuration C1, C2, C3 and C5) and high energy density, once fusion of the Cu does happen, a surplus of energy flows through the keyhole, increasing the temperature at the keyhole bottom. This generates a recoil pressure that pushes the fluid upwards. At the top surface and rear side of the keyhole, the opposing movements of the fluid, both clockwise and counter-clockwise, and driven by the Marangoni force, have an important consequence: they restrict the size of the molten pool. This restriction creates a high viscosity mushy layer that forms a barrier that limits the expansion of the molten pool. As result, closure or narrowing the top neck of the keyhole restricts the ejection of vapours out of keyhole which leads to increase in pressure within keyhole and creates a high-pressure lob. This ultimately results in pores formed to the toe of the keyhole as seen in Fig. 7(a) and (b). Although a collapse event is observed in C3 as shown Fig. 7(c), it does not necessarily create porosity in the solid front as sufficient room is available for gas vapours to escape from the bottom of the keyhole. The introduction of a pre-heat heating beam in weld configuration C5 does not produce any significant change to the keyhole dynamics as observed in Fig. 7(d). In partial penetration, narrow and deep keyhole is more unstable as slight fluctuations in fluid pressure, velocity and temperature on the rear wall of keyhole can create a collapse event. Additionally, the collapse of the keyhole in partial penetration creates a narrower fluid channel, resulting in localized increase of fluid velocity, which, in turn, affects metal mixing.
  • Weld configuration C4 leads to wider opening of the keyhole with greater stability as shown in Fig. 7(e). With the super-imposition of the core beam with the wider ring-shaped beam, the core beam penetrates the steel sheet, while the larger ring keeps the keyhole open at the Cu surface. This weld configuration drastically reduces the collapse events and the development of bubbles. It can be observed that the lower depth-to-width aspect ratio of the melt pool correlates to fewer number of collapse events.
  • Metal mixing is not only influenced by keyhole dynamics and collapse events, but there is an intricate interplay between keyhole geometry, fluid dynamics and buoyancy forces that are dependent upon density which varies with temperature in molten pool, and from top to bottom due to differences in density between Cu and steel. To test the influence of buoyancy forces, a simulation test was performed where the density of Cu and steel were artificially set to be equal. Fig. 8 shows the simulation results and confirm that buoyancy forces have an impact on the metal mixing especially at the interface between the two metals and in the Cu side of the weld. For example, the line-scan B-B in Fig. 8 shows an increase on average of the Fe vol% in the Cu side by 10%, when comparing results with same densities.
Fig. 8. Impact of buoyancy forces on the metal mixing for weld configuration C3. Sections taken at Y= 0.
Fig. 7. Consecutive time steps of the molten pool dynamics for configuration C1 (a), C2 (b), C3 (c) C5 (d) and C4 (e). The plot shows the fluid velocity (both direction and magnitude) visualized by black arrows. Cross sections taken at Y= 0.

The introduction of a ring beam (weld configuration C4 with LBS#3) in the laser welding process alters the shape of the keyhole compared to a single beam scenario (weld configuration C1 with LBS#1). In the single beam case, the keyhole walls develops predominantly in Z direction (schematically illustrated in Fig. 9(a)). The inclusion of a ring beam results in the critical change of the keyhole wall’s curvature, with a pronounced arc-like shape at the rear (Fig. 9(b)). The change of keyhole wall’s curvature plays a critical role and is explained by the complex equilibrium between the fluid pressure, the recoil pressure and the gravity load. A collapse event is associated with the non-equilibrium of the forces in the X direction. To explain this, it is first worth noting that with an idealised static molten pool (no fluid velocity) the fluid pressure would be higher at the bottom and would be governed by the hydrostatic law – with this, the pressure variation occurs linearly downwards and would be a function of the molten pool depth. Under this ideal condition, the keyhole would exhibit a stable equilibrium regime driven by the balanced effect of recoil pressure and fluid flow. With the actual molten pool, the equilibrium state is, however, perturbated by the non-linear variation of the fluid pressure due to the fast upwards motion generated by the recoil pressure itself. A near-equilibrium state is eventually achieved with the change of keyhole wall’s curvature with the resultant of the forces acting predominantly in the Z direction. The shallow angle of the keyhole wall observed at LBS#3 (θ3 < θ1) effectively decomposes the combined forces exerted by the fluid towards the Z direction, hence moving to the near-equilibrium state, with the fluid pushed downwards in Z rather than sidewise in X. It can be observed that the ring-to-core diameter and the ring-to-core power are essential to control the keyhole wall’s curvature and ultimately influence of the stability of the keyhole.

Fig. 9. Schematic representation of forces and pressures acting on the melt pool in case of welding with single laser beam (LBS#1) and ring-core configuration (LBS#3). Arrows represent forces/pressures, and the thickness is proportional of the intensity of the forces/pressures. Arrows are only shown to the rear-side of the keyhole since the physics involved there are more relevant for the dynamics of the keyhole.

3.3. Impact of beam shaping on metal mixing

Cu and steel are generally immiscible as studied by other researchers, such as Shi et al. (2013). This separation means the material solidifies as two separate phases from the liquid state. At this immiscible region a Cu-rich (α phase) and iron-rich (β phase) form FCC and BCC crystal structures, respectively. For the compositional data shown in Fig. 6, the highest amount of mixing for each of the three examples is 60%, 80% and 50% of Fe in the weld pool. When studying the Cu-Fe binary phase diagram, as performed by Chen et al. (2007), these compositions fall within the miscibility gap range. For which no IMCs are expected to form, but instead separate (α and β) phases. However, it is still clear that the formation of these separate phases still creates a mismatch in mechanical properties of the welded joint, both at the interface and enriched regions, which can lead to crack initiation, as reported by Rinne et al. (2020). For this reason, analysing the metal-mixing in dissimilar metals is an important step toward understanding and prevention of cracking mechanisms that can affect the performance of the weld.
Influence of the beam shapes on the metal mixing, can be investigated by analysing velocity fields and fluid flow which are predicted with the validated model. Fig. 10(a) and (b) show that in the weld configuration C1 and C2 (corresponding to LBS#1 – single beam with circular spot and gaussian distribution) the increase in laser power leads to more steel mixing with Cu due to greater recoil pressure and to a larger melt pool with more liquid metal involved. When comparing the parameters in Fig. 11, the increased melting of the bottom steel sheet leads to a greater region of keyhole necking with collapse; this can be due to the increased laser absorption, for which steel has a greater absorptivity than the more reflective Cu (Rinne et al., 2020). The lower density of steel creates an upward buoyancy force which allows the migration of more steel into the Cu-rich region. Fig. 11(c) and (d) show weld configurations C3 and C4 respectively, with combined secondary ring-shaped and primary laser beam (LBS#2 and LBS#3, respectively). They can be compared based on similar levels of weld penetration but different width at the interface between parent metals and at the top of the weld seam. Spread of the laser power over a wider surface due to the use of a ring results in a wider weld pool compared to simulations C1 and C2, which is consistent with results found by Jabar et al. (2023). However, one difference between these two cases is that, due to different power density distributions, to achieve adequate weld penetration depth, different laser power is provided leading to different thermal fields and time that the metal stays liquid. Line-scans of the temperature profiles in the melt pool can be observed in Fig. 12, with higher peak temperature in C4, compared to simulations C1 and C2, and C5; whereas a smaller secondary ring-shaped laser beam in simulation C3 results in intermediate behaviour.

Fig. 10. Plots of metal mixing in the longitudinal and a cross sections predicted with simulations C1 (a), C2 (b), C3 (c), C4 (d) and C5 (e).
Fig. 11. (a) Temperature, (b) velocity, (c) Fe concentration and (d) actual melt pool for all the tested weld configurations C1 to C5. Cross sections taken at Y= 0.
Fig. 12. Temperature profiles for weld configurations C1 (a), C2 (b), C3 (c), C4 (d) and C5 (e). Measurements were taken at X = 1.3 mm (just behind the keyhole wall) and Z = −300 µm (interface between Cu and steel).

The higher peak temperature in C4 eventually leads to a significant thermal gradient that promotes significant upward buoyancy forces and ultimately more migration of steel towards the Cu matrix. Similarity of simulation C5 with C1 can be explained considering that the secondary laser beam pre-heats the metal without widening the keyhole. Additionally, the higher peak temperature and larger size of the melt pool in C4 lead to longer time in which the steel stays in the liquid phase with more time available to migrate toward the Cu matrix due to recoil pressure and buoyancy forces and to diffuse. For these reasons, if use of larger spot helps with keyhole stabilisation, higher laser power required to establish sound connection enhances mixing between parent metal. Therefore, selection of custom ring-to-core diameter and ring-to-core power is a decision with a trade-off between the need of stabilising the keyhole dynamics and the need to reduce the mixing.
Velocity fields in Fig. 11 show also that the use of the ring-shaped secondary beam (C4), results in lower recoil pressure due to less localised laser power and vaporization. For this reason, the fluid flow and velocity of the liquid movements in considerably lower, as shown by contour plots, where regions of the molten pool in red are those in which the flow of the liquid metal is faster. The metal mixing in the molten pool of C3 weld is more homogeneous than in C1 and C2, due to the localised heat input of the ring laser beam. Rinne et al. (2020) found the addition of the ring laser produced a more homogeneous distribution of Cu and steel in the solidified structure. The lower density of the steel can also be used to explain the more even distribution of steel throughout the weld pool of C3. This is also confirmed by the EDS line-scans in Fig. 6(c) that show a significant drop of Fe into the Cu matrix compared to C1 (Fig. 6(a)).
The result of metal mixing has a significant effect on the crack formation in the weld pool and heat-affected zone (HAZ). Two main types of cracking are often referred to as “hot cracking” (Rinne et al., 2020) or “liquation cracking” (Li et al., 2019). During any fusion welding process of Cu to steel the miscibility gap can be identified in the binary phase diagram of Cu-Fe (Chen et al., 2013). When both Cu and steel are melted, there is separation of the liquids during cooling, once the mixture enters the miscibility gap seen on the phase diagram the primary separation of the α and β phases occurs. The secondary separation occurs in the miscibility gap because of a lack of diffusion and a supersaturation of the α and/or β phases. The solidified weld microstructure is found inhomogeneous, consisting of the α and β phases. The difference in the thermal expansion properties of both Cu and steel can create locations of stress concentrations where cracks are often initiated, ad observed by Chen et al. (2013) and Sadeghian and Iqbal (2022). Li et al. (2019) proposed a three-stage mechanism for the formation of liquation cracks in Cu to steel laser welds. The first stage was the penetration of Cu liquid into the grain boundaries of the steel, secondly, the Cu liquid surrounds the Cu phase creating a “film” of liquid in the grain boundary. This drastically reduces the cohesive forces between the grain boundaries due to the presence of the α phase. Cracking can then be initiated in a similar manner to that detailed earlier.

4. Conclusions

A combination of multi-physics CFD modelling results and experiments have been presented to study the impact of laser beam shaping on metal mixing and molten pool dynamics during LBW of Cu-to-steel for battery terminal-to-casing connections. The multi-physics model has been validated with ex-situ EDS element mapping and weld profile’s features. The model has provided useful insights about temperature and velocity fields, mixing mechanisms and dynamics of the keyhole, all of which are difficult to access via experiments due to technological difficulties. The major findings of the work are summarized below:

  • Metal mixing is largely influenced by the fluid dynamics via the Marangoni, buoyancy forces and recoil pressure. With a greater laser power, recoil pressure is increased, and this leads to more weld penetration and melting of steel. Additionally, spread of the laser power results in higher width of the fusion zone. Subsequently, the buoyance forces due to the different densities of steel and Cu contribute to the upward flow of steel towards Cu, and hence impact meaningfully to the mixing. This can be clearly observed in weld configurations C1 and C2.
  • Due to the collapse events of the keyhole wall, porosity formation was found in welds C1, C2 and C5. Furthermore, the collapse events create a narrow fluid channel, which results in localised surges in fluid velocity, therefore, promoting metal mixing. All in all, simulations revealed that increasing depth-to-width aspect ratio is correlated to higher frequency of collapse events in the keyhole. Therefore, stabilisation of the melt pool can be achieved with tailored laser beam shapes.
  • The study has pointed-out that the use of larger ring beam (configuration C4) helps with keyhole stabilisation, but at the same time leads to more laser power and higher temperature that contribute to the enhancement of mixing between parent metals. This poses a trade-off in the definition of a tailored ring-to-core diameter and the ring-to-core power. Analysis of the results showed that ring-to-core diameter (350–90 µm) and 30% of ring power (weld configuration C3) resulted in more stable dynamics of the keyhole, with significant reduction of collapse events, and ultimately controlled migration of steel towards Cu. Furthermore, compared to C4 (2500 W total power), the lower thermal gradient in C3 (1530 W total power) eventually leads to a reduction in the upward buoyancy forces.
  • The pre-heating approach with the tandem beam (C5) only led to local fusion of Cu and no significant improvement in keyhole stability was observed.
  • The combination of experiments and numerical modelling provides a powerful approach to understand complex fluid flow and metal mixing processes during laser keyhole welding. This helps to study mixing behaviour along with weld pool dynamics for selection of laser welding strategies with beam shaping in case of dissimilar material welding, especially in presence of miscibility gap at higher temperature as in case of Cu and steel.

References

F-BW

Determination of Formulae for the Hydrodynamic Performance of a Fixed Box-Type Free Surface Breakwater in the Intermediate Water

중간 수심에서 고정된 박스형 자유 수면 방파제의 유체역학적 성능 공식을 결정하기 위한 연구

Guoxu Niu, Yaoyong Chen, Jiao Lu, Jing Zhang, Ning Fan

Abstract


 two-dimensional viscous numerical wave tank coded mass source function in a computational fluid dynamics (CFD) software Flow-3D 11.2 is built and validated. The effect of the core influencing factors (draft, breakwater width, wave period, and wave height) on the hydrodynamic performance of a fixed box-type free surface breakwater (abbreviated to F-BW in the following texts) are highlighted in the intermediate waters. The results show that four influence factors, except wave period, impede wave transmission; the draft and breakwater width boost wave reflection, and the wave period and wave height are opposite; the draft impedes wave energy dissipation, and the wave height is opposite; the draft and wave height boost the horizontal extreme wave force; four influence factors, except the draft, boost the vertical extreme wave force. Finally, new formulas are provided to determine the transmission, reflection, and dissipation coefficients and extreme wave forces of the F-BW by applying multiple linear regression. The new formulas are verified by comparing with existing literature observation datasets. The results show that it is in good agreement with previous datasets.

1. Introduction


A breakwater dissipates wave energy and reflects waves from the open sea, representing a crucial protective structure for the exploitation and utilization of marine resources. It is also an essential auxiliary marine structure that improves offshore engineering construction conditions and shortens ship berthing times [1,2,3]. With the development and utilization of ocean space and resources, the demand for breakwaters has also varied. The construction of breakwaters has shifted from onshore to offshore. Because most wave energy is concentrated near the water surface, a fixed box-type free surface breakwater (F-BW, Figure 1) was created [4,5]. The F-BW is a type of reflective breakwater with simple structure and high efficiency, which reduces the transmitted wave height by reflecting the incident wave energy [6,7]. Compared with the traditional bottom-founded breakwater, F-BW does not influence water exchange inside and outside the breakwater while maintaining a high wave attenuation efficiency, and has a high application prospect.

Figure 1. Two-dimensional schematic sketch of the F-BW models.

The hydrodynamic performance of the breakwater is important for the research and development of the F-BW, which mainly comprises two aspects. One aspect is the wave attenuation performance, including wave transmission coefficient Ct, reflection coefficient Cr, and dissipation coefficient Cd (hereinafter referred to as RTD coefficients). The other is the wave force, which concerns the safety and stability of the breakwater, including the horizontal wave force and vertical wave force.
In terms of research on the RTD coefficients of an F-BW, some scholars have studied the influence of the breakwater width and draft on the reflection and transmission coefficients when energy dissipation was ignored. [8,9,10,11]. In order to provide some judgement for the needy practitioners, a closed-form formula has been created to predict the transmission coefficient in deep water [8,9,10]. A study by Kolahdoozan et al. [12] showed the poor prediction performance of the formula proposed by Macagno [8] for intermediate water. Therefore, it is necessary to explore a proposed formula for the transmission coefficient under intermediate-water conditions. Different from the analytical solution of potential flow theory, other scholars studied the influence of the draft, breakwater width, and wave height on the performance of wave reflection, transmission, and dissipation of the F-BW via experimental tests conducted in intermediate waters [13,14,15,16]. The computational fluid dynamics (CFD) technique provides us an alternative way to interpret the interaction between wave and F-BW. Koftis and Prinos [16] applied the two-dimensional unsteady Reynolds Averaged Navier–Stokes model to study the influence of the dimensionless draft on the transmission and reflection coefficients of an F-BW. Elsharnouby et al. [17] studied the influence of the draft on the wave transmission of the F-BW by using Flow-3D 11.2 software. Their results showed that the increasing draft impedes wave transmission.
Some researchers carried out earlier work on wave force of F-BW due to concerns regarding safety and stability of the F-BW. Guo et al. [11] confirmed that draft, breakwater width and wave period also influenced the horizontal and vertical wave forces by adopting mathematical analysis based on linear potential flow theory. Chen et al. [18] investigated the effects of wave height and wave period on the horizontal and vertical wave forces of F-BW through a series of experiments. The results showed that the horizontal and vertical wave forces increase with increasing wave height. Limited by the fact that the mathematical analysis tends to ignore flow viscosity [19,20,21] and the physical model test is complicated and costly, considerable effort has been devoted to studying the hydrodynamic performance of an F-BW through numerical simulation in recent years. Zheng et al. [22] and Ren et al. [23] used the smoothed particle hydrodynamics (SPH) method to numerically simulate the horizontal and vertical wave forces of F-BWs under regular waves. Unlike previous studies which overlooked the nonlinearity of wave forces, the positive and negative maximum wave force could be observed in the studies of Zheng et al. [22] and Ren et al. [23].
Human activities are less involved in deep water, and the cost-effectiveness of F-BW construction is poorer in deep water than intermediate water. Reflection coefficient Ct, and dissipation coefficient Cd are also an indispensable part of the wave attenuation performance of F-BW. The horizontal and vertical wave forces are related to the security of the F-BW. However, the prediction formulas based on tests or numerical simulations for horizontal and vertical wave forces of the F-BW in the above studies were rare. Therefore, an attempt is necessary to present a proposed formula for the prediction of RTD coefficients and wave forces, which will provide design judgments for the relevant practitioners in intermediate waters.
The objective of this paper is to provide the prediction formulas for RTD coefficients and wave forces in the intermediate waters under the condition that waves do not overtop the breakwater. With the rapid development of the CFD technique, Kurdistani et al. [24] proposed a formula for submerged homogeneous rubble mound breakwaters based on a large dataset from the CFD model, and the proposed formula was verified by using the literature observation datasets. Inspired by their research method, a numerical wave flume is built through a grid convergence test and validated with the existing experimental results. The prediction equations of RTD coefficients and wave forces are provided by applying multiple linear regression and verified by comparing with existing literature observation datasets. The major conclusions are finally summarized, and some prospects are proposed.

2. Theoretical Introduction

2.1. Governing Equations

Flow-3D 11.2 is widely used in coastal engineering as a powerful CFD software program [25]. The interaction of waves and breakwaters is simulated in a numerical wave tank by using Flow-3D 11.2 software in this paper. The numerical wave tank adopts an incompressible viscous fluid in the wave and F-BW interaction. The Reynolds averaged Navier–Stokes (RANS) equation was applied as the governing equation for turbulent flow. Assuming that the Cartesian coordinate system o-xyz originates from the still water surface, the continuity equation is shown in Equation (1), and the momentum equation is expressed in Equation (2).

where i,j = 1,2 for two-dimensional flows, xi represents the Cartesian coordinate, and ui is the fluid velocity along the x- and z-axes. Ax and Az are the area fractions open to flow in the x and z directions, respectively, ρ is the fluid density, p is the pressure, v is the dynamic viscosity, and g is the gravity force. The Reynolds stresses term, 𝜌𝑢𝑖′𝑢𝑗, is modeled by the renormalized-group (RNG) turbulence model.

2.2. RNG Turbulence Model

The interaction of waves and an F-BW induces turbulence. The RNG turbulence model is adopted to close the governing equations [26], and the discrete governing equations are solved by the finite difference method. The transport equations of turbulent kinetic energy kT and dissipation rate εT in this model are as follows:

The volume of fluid (VOF) method was developed to track the evolution of the free surface [27]. The governing equation is shown as follows:

where F represents the fractional volume of water fluid, F = 1 indicates that the numerical cell is full of water, and F = 0 corresponds to the cell fully occupied by air. Numerical cells with a value of 0 < F < 1 represent a water surface.

Furthermore, the generalized minimal residual (GMRES) method was used to solve the velocity-pressure term [28], and the first-order upwind scheme and Split Lagrangian method were used to solve the volume of fluid advection. The structure of the F-BW is directly imported into Flow-3D 11.2 by the software built-in drawing function. The appearance of an F-BW depicted by the mesh could be viewed with the fractional area volume obstacle representation (FAVOR) method. All numerical simulations were run in parallel using an Intel Core (TM) i5-4460 processor (3.20 GHz). Furthermore, to ensure the accuracy of the numerical solution, the maximum iteration time step was set to 0.001 s, and the results were output at 0.01-s intervals.

2.3. Principle of Mass Source Wavemaker

The present study emerged from the interest shown in the use of F-BW in a specific zone at an actual project in East China Sea. The detailed structural design dimensions of F-BW and wave characteristics are shown in Table 1. All the incident waves are considered to be regular waves. The regular waves used in the study contain a large range of wave periods and wave heights, which represent the majority of wave parameters in real-world problems, making this study of great practical importance. The interaction between the second-order Stokes wave and the current is not considered in the twelve major wave parameters, due to the differing time and spatial scales between the wave and the current [29]. The twelve waves in this research are all in the range of either linear or nonlinear second-order Stokes waves. Figure 2 shows the suitability range of different wave theories. According to Figure 2, the F-BW at this project is located in intermediate waters. Equation (5) presents the wave elevation equation η of the second-order Stokes wave and the wave elevation equation of the linear wave is the first term on the right side of this equation.

where Hi is the incident wave height, k is the wavenumber, σ is the wave frequency, and h is the still water depth.

Figure 2. Wave parameter conditions analyzed in this study and their relations in the Le Méhauté diagram.
Table 1. Summary of the simulated scenarios.

The boundary wavemaker method produces re-reflection waves. Lin and Liu [30] proposed a popular mass source wave generation method [31,32,33,34,35,36]. In the present method, numerical wave generation is achieved by importing a given volume flow rate Vfr into the mass source model. The expression of the volume flow rate Vfr is as follows:

where C is the phase velocity, W is the tank width, η(t) is the wave surface elevation by solving Equation (5).

To effectively reduce the calculation divergence caused by excessive waves in the NWT at the initial stage, the volume flow rate Vfr is multiplied by an increasing envelope function to make the wave increase gradually in the first three wave periods. The equation of the increasing function is as follows:

where t is time and T is the wave period.

2.4. Principle of Numerical Solution

In this paper, the time series of wave elevations were recorded at five different locations (i.e., WG1–WG5) on the onshore and offshore sides of the F-BW (Figure 3a). Furthermore, the current WG spacings are selected according to the water depth and wave period. The distances between the wave source and WG1, WG1 and WG2, WG2 and F-BW, and F-BW and WG5 are set at 1.5 m, 0.2 m, 1.8 m, and 1.435 m, respectively. Note that the distance between wave gauges WG1 and WG2 is more than 0.05 L and less than 0.45 L, and the distances between wave gauges WG2 and F-BW and between WG5 and F-BW are less than 0.25 L and more than 0.2 L (wavelength), as recommended by the two-point method [37]. Two wave gauges (WG1 and WG2) are mounted in a line on the offshore side of the F-BW to separate the incident wave heights Hi and the reflected wave heights Hr by using this method. To prove that the horizontal wave force of the F-BW is related to the free surface onshore and offshore of the breakwater, probe WG3 is placed 0.02 m in front of the F-BW, while probe WG4 is placed 0.02 m behind the F-BW to measure the wave profile at the front (η3) and back (η4) of the F-BW. The wave gauge (WG5) is mounted on the onshore side of the F-BW to obtain the surface elevation of the transmitted wave heights Ht. The wave transmission, reflection, and wave energy dissipation coefficients are defined by solving Equation (8a)–(8c).

where Ct is the transmission coefficient; Cr is the reflection coefficient; and Cd is the wave energy dissipation coefficient.

Figure 3. Schematic layout and mesh sketch of the numerical wave tank for the F-BW.

Furthermore, the horizontal and vertical wave forces are simulated by the integration of the water pressure p at the wet surface of the F-BW. The two kinds of wave forces include the hydrostatic force and hydrodynamic force according to the FLOW-3D theory manual [25]. Because the F-BW is always fixed at the free surface, the vertical wave force needs to remove part of the hydrostatic force (the value up to ρVg, where ρ is the density of water and V is the volume of the F-BW). The shear stress is small enough to be ignored in this paper relative to the wave force. The horizontal wave force and the vertical wave force are denoted by Fx and Fz, respectively. The horizontal wave force is consistent with the direction of wave propagation, and the vertical wave force is vertically upward. To facilitate the research, obtaining the extreme value of the steady part of the wave force time series, we define the average value of the horizontal wave force positive and negative peak as the horizontal positive maximum wave force Fx+max and horizontal negative maximum wave force Fxmax, the vertical wave force positive and negative peak as the vertical positive maximum wave force Fz+max and vertical negative maximum wave force Fzmax. The representative time series of the dimensionless wave elevation, horizontal, and vertical wave forces are shown in Figure 4. The numerical results of HiHrHtFx±maxFz±max were acquired based on the stable elevations in this figure. To facilitate discussion, we define Fx±max/0.005 ρgh2 and Fz±max/0.005 ρgh2 as the dimensionless horizontal and vertical maximum wave forces on the F-BW, respectively. The crest and trough values of the time series of the wave forces are studied because the extreme values of the horizontal and vertical wave forces on the F-BW under the Stokes second-order wave have a slightly sharper crest and flatter trough.

Figure 4. Time histories of wave elevation η measured by WG1, WG2, and WG5 and horizontal and vertical wave forces of F-BW at Hi = 0.07 m, T = 1.4 s, B = 0.5 m, dr = 0.14 m, and h = 0.75 m.

The integral formula of the horizontal and vertical wave force is shown in Equation (9).

where 𝑛⃗  is the unit normal vector of the object surface s and the water pressure p is determined by the Bernoulli equation.

3. Model Setup and Validation

3.1. Numerical Wave Tank Setup

The detailed numerical wave tank (NWT) setup is shown in Figure 3b,c. The total length of the NWT was twenty-four wavelengths L long in the x-axis direction, 0.1 m wide in the y-axis direction, and 1 m deep in the z-axis direction. A scale ratio of 1:40 and a constant water depth h of 0.75 m are adopted based on the Froude similarity law. The mesh consisted of two distinct regions. The first region was the computation domain, four wavelengths length, with a width of 0.1 m and a depth of 1 m. The unit grid size of the total NWT was L/100~L/200 in the x and z directions, and ten grids were partitioned in the y directions in this domain. The second region was two identical damping domains with ten wavelength lengths. The Sommerfeld radiation method was employed to bate the secondary reflection of waves at both ends of the NWT. The grid size along the x-axis direction was gradually extended with an identical ratio of 1.01, and one grid was set for the lateral width of the NWT [38].

To describe the F-BW more accurately, nested grids were applied in the domain around the F-BW. The uniform nested grid was equal to half of the compute domain grid in the xy and z-axis directions. Furthermore, the finer mesh resolution of 0.0035 cm in z direction was nested near the still water level (SWL), The region extends ±0.07 m from the SWL to ensure that the expected wave heights (0.03 m, 0.05 m, 0.07 m, 0.09 m) are encompassed within the region.

The boundary conditions of this NWT were set as follows: both ends of the NWT were defined as outflow boundaries, two sides of the domain were defined as symmetry boundaries, the atmospheric pressure was utilized at the upper boundary, and the lower surface of the computational domain was a no-slip wall boundary without surface roughness.

A mass source model with wide WS and high HS was added to the numerical flume. The symmetry boundaries were used overspreading with the mass source form, and the y-direction width of the mass source block was consistent with the width of the NWT. Pledging each edge of the mass block to coincide with the grid line of the NWT is shown in Figure 3b,c.

3.2. Numerical Model Validation

The present research is mainly implemented under the framework of CFD technology. To demonstrate the accuracy of the simulation results, it is essential to compare them with the extant results. The model is verified by the following three aspects in this section.

3.2.1. Grid Independent Verification

The mesh partition is a crucial procedure in CFD numerical simulation and needs much attention. The number and size of grids are essential criteria for evaluating the convergence of numerical results. Poor grid quality will directly affect the accuracy of numerical results and computation time. Consider that the proposed calculation cases Hi = 0.06 m, T = 1.2 s, and h = 1.2 m by Ren et al. are close to the target cases in this paper [23]. This wave condition is applied to complete the grid independence verification. Different grid arrangements can be seen in Table 2, and the time series of the wave profiles under the three grid sizes are compared with the theoretical results by solving Equation (5), as shown in Figure 5. The error of the numerical simulation results was calculated according to Equation (10). The wave profile deviations among the coarse mesh, medium mesh, and fine mesh are compared. The wave profiles under the medium mesh and the fine mesh are closer, and the deviation from the theoretical value is less than 5%, which meets the requirements of Det Norske Veritas (DNV) [39]. It can be judged that only medium meshes and refined meshes meet the requirements of numerical simulation. Considering the balance between calculation accuracy and calculation efficiency, the following numerical simulations always chose a medium mesh.

where Htheoretical is the wave height of the theoretical result and Hnumerical is the wave height of the numerical result.

Figure 5. Grid independent verification: influence of mesh size on wave profile.
Mesh TypeComputation Domain Grid Size (cm)Nested Domain Grid Size (cm)Cell NumberElapsed Time (×104 s)Wave Height (cm)Error %
Coarse217014600.64965.6425.96
Middle10.534111807.68325.7683.87
Fine0.50.251335096048.14375.7693.85
Theoretical6.000
Table 2. Mesh independence check results.

3.2.2. Validation of Wave Forces

In this section, to further inspect the accuracy of the numerical results of wave forces in this paper, according to the wave conditions of Hi = 0.06 m, T = 1.2 s, h = 1.2 m, and draft dr = 0.2 m, a rectangular box of width B = 0.8 m and wave height Hi = 0.4 m is fixed and semi-immersed, as proposed by Ren et al. [23]. The horizontal and vertical wave forces of the F-BW were verified by comparison with the theoretical results of Mei and Black [40] and the numerical simulation results of Ren et al. [23]. The time series of the wave forces are compared in Figure 6. The total simulation time of this case is 16 wave cycles. Since it takes some time for the progressive wave to arrive at the F-BW from the source, the horizontal and vertical wave forces begin to reach the stable state at t = 7 T seconds in Figure 6. By comparison, the simulated time series of horizontal and vertical wave forces are almost consistent with those presented by Ren et al. [23] and Mei and Black [40]. This result indicated that the present NWT could meet the calculation accuracy.

Figure 6. Comparison of the normalized wave force on an F-BW with previous studies (Mei and Black [40]; Ren et al. [23]). (a) Normalized horizontal wave force; (b) Normalized vertical wave force.

4. Results and Discussion

4.1. Influence Analysis of Four Factors on the Hydrodynamic Performance of F-BW

Among all the influencing factors (refer to Appendix A), the hydrodynamic performance of the F-BW is significantly affected by the following four factors: draft (dr/h), breakwater width (B/h), wave period (T*sqrt(g/h)), and wave height (Hi/h). For the mechanism analysis of the interaction between waves and breakwater, the mechanism study of the horizontal wave force is rather complicated. Since the breakwater is in a semisubmerged state, the Morison formula is no longer applicable to the guidance of the calculation of the horizontal wave force. The horizontal wave force is studied separately from the water particle velocity; see the free surface difference (η3–η4) in the front and back sides of the F-BW and the water particle streamline in Figure 7 and Figure 8 for details. Among them, five representative cases are selected from all cases in this article for comparative analysis corresponding to Figure 7a–e. Note that case (a) T1.2dr0.14B0.5Hi0.07 represents a wave period of 1.2 s, draft of 0.14 m, breakwater width of 0.5 m and incident wave height of 0.07 m. Due to the effect of water blockage, flow separation is generated at the bottom corner of the offshore side of the breakwater, and the generated clockwise vortex destroys the original motion path of the wave water particles without structure in Figure 8a and allows the free surface difference in the front and back of the F-BW to gradually reach a maximum. At time instant t0 in Figure 7, the horizontal wave force also reaches a maximum. It can be seen in Figure 8b that the vertical wave force is easier to analyze. When the vertical wave force is at its maximum, the streamline realizes complete diffraction, and no vortex is generated. Furthermore, to understand the mechanism and contribution of each influencing factor on the hydrodynamic performance of the F-BW in detail, the statistical results are shown in Figure 9, Figure 10, Figure 11 and Figure 12.

Figure 7. Comparative analysis of five different cases under the interaction between waves and breakwater: First column: numerically obtained snapshots of free surface profile and velocity field; Second column: time history of free surface and horizontal wave force.
Figure 8. Snapshots of the velocity streamline field: (a) Time instant of the horizontal positive maximum wave force; (b) Time instant of the vertical positive maximum wave force.
Figure 9. Effect of the draft dr on the hydrodynamic performance of the F-BW at wave heights Hi = 0.05 m and Hi = 0.07 m. (a) Horizontal positive and negative maximum wave forces Fx+max and Fxmax; (b) Vertical positive and negative maximum wave forces Fz+max and Fzmax; (c) Transmission coefficient Ct, reflection coefficient Cr, and dissipation coefficient Cd.
Figure 10. Influence of the breakwater width B on the hydrodynamic performance of the F-BW at wave heights Hi = 0.05 m and Hi = 0.07 m. (a) Horizontal positive and negative maximum wave forces Fx+max and Fxmax; (b) Vertical positive and negative maximum wave forces Fz+max and Fzmax; (c) Transmission coefficient Ct, reflection coefficient Cr, and dissipation coefficient Cd.
Figure 11. Influence of the wave period T on the hydrodynamic performance of the F-BW at wave heights Hi = 0.05 m and Hi = 0.07 m. (a) Horizontal positive and negative maximum wave forces Fx+max and Fxmax; (b) Vertical positive and negative maximum wave forces Fz+max and Fzmax; (c) Transmission coefficient Ct, reflection coefficient Cr, and dissipation coefficient Cd.
Figure 12. Influence of the wave height Hi on the hydrodynamic performance of the F-BW at draft dr = 0.14 m and dr = 0.28 m. (a) Horizontal positive and negative maximum wave forces Fx+max and Fxmax; (b) Vertical positive and negative maximum wave forces Fz+max and Fzmax; (c) Transmission coefficient Ct, reflection coefficient Cr, and dissipation coefficient Cd.

4.1.1. Effect of Draft

Figure 7 lists the distribution diagram of the free surface difference and water particle velocity under cases (a) and (b) at the time instant of the horizontal wave force maximum. Except for the draft being different, the two cases are consistent. Among them, case (a) has a wave period of 1.2 s, draft of 0.14 m, wave height of 0.07 m and breakwater width of 0.5 m. Case (b) has a period of 1.2 s, draft of 0.35 m, wave height of 0.07 m and breakwater width of 0.5 m.

In the second column of Figure 7a, when time t0 = 11.48 s, the maximum free surface difference is 0.068 m, and the maximum horizontal wave force is 7.98 N. In the second column of Figure 7b, when time t0 = 11.52 s, the maximum free surface difference is 0.083 m, and the maximum horizontal wave force is 15.91 N. Obviously, the increase in the draft enhances the water blockage action in front of the F-BW, weakens the diffraction effect of the wave, and delays the time for the horizontal wave force to reach its maximum. Figure 9a shows that Fx+max increases with increasing draft under wave heights of Hi = 0.05 m and Hi = 0.07 m. Similarly, the absolute values of Fxmax exhibit a similar law. The absolute values of Fzmax and Fz+max decrease with increasing draft under wave heights of Hi = 0.05 m and Hi = 0.07 m in Figure 9b, which is related to the exponential decay of the wave kinetic energy along the water depth. It is not difficult to see in Figure 7a,b that the wave hydrodynamic pressure on the lower surface of the F-BW decreases with decreasing wave kinetic energy as the water depth increases. The effective action area increases as the draft reduces the penetration of waves. Figure 9c shows that the transmission coefficient decreases with increasing draft under wave heights of Hi = 0.05 m and Hi = 0.07 m. Due to the increase in the interaction area between waves and F-BW, the reflected wave energy increases in Figure 7, and Figure 7b is more obvious than Figure 7a. The wave energy dissipation coefficient increases with decreasing draft in Figure 9c. Since the wave energy is mainly concentrated on the still water level, the fluid particle velocity maximum at the lower corner of F-BW is 0.30 m/s in Figure 7a is more than the 0.17 m/s in Figure 7b, more wave energy is dissipated when the fluid particle with higher velocity collides with F-BW due to decreasing draft.

Overall, the increasing draft impedes incident waves cross F-BW and promotes the increase in horizontal wave force and wave reflection, which threatens the stability of the structure.

4.1.2. Effect of Breakwater Width

To clarify the mechanism of the breakwater width effect on the hydrodynamic performance of the F-BW, except that the breakwater width is different, cases (a) and (c) in Figure 7 are consistent. In case (c), the period is 1.2 s, the draft is 014 m, the wave height is 0.07 m, and the breakwater width is 0.2 m.

The free surface difference and vortex in Figure 7a,c are similar. Figure 10a shows that the breakwater width effect on Fxmax and Fx+max is not obvious. When the vertical wave force is at its maximum, the streamline realizes complete diffraction, and no vortex is generated in Figure 8b. Therefore, the vertical wave force is related to the acting area of the F-BW lower surface. Figure 10b shows that the absolute values of Fzmax and Fz+max increase with increasing breakwater width. In the second column of Figure 7c, when time t0 = 11.42 s, the free surface difference and the horizontal wave force reach a maximum faster than in case (a). Obviously, the increase in the breakwater width increases the wave diffraction difficulty. Figure 10c shows that the transmission coefficient decreases with increasing breakwater width, and the reflection coefficient increases with increasing breakwater width. Due to fluid particle velocity maximum is similar between Figure 7a,c. The increase in breakwater width has little influence on wave energy dissipation.

In short, the increasing breakwater width is not conducive to incident wave cross F-BW, and promotes the increase of wave reflection and vertical wave force. Obviously, more weights need to be added to ensure the safety of the breakwater when breakwater width increases.

4.1.3. Effect of Wave Period

To clarify the mechanism of the wave period effects on the hydrodynamic performance of the breakwater, except that the wave period is different, cases (a) and (d) are consistent. Figure 7d shows that the wave period is 1.8 s, the draft is 0.14 m, the wave height is 0.07 m and the breakwater width is 0.5 m.

In the second column of Figure 7d, when time t0 = 11.13 s, the maximum free surface difference is 0.051 m, and the maximum horizontal wave force is 6.90 N. According to Equation (9), because the wave energy is more abundant on the two sides of the breakwater in case (4), the horizontal wave force is comparable even if the free surface difference is smaller than that in case (1). Figure 11a shows that Fxmax and Fx+max are weakly related to the wave period under wave heights of Hi = 0.05 m and Hi = 0.07 m. Because the long-period waves possess a large wave energy in Figure 7d, they increase the wave pressure on the lower surface of the F-BW. Therefore, the absolute values of Fzmax and Fz+max increase linearly with the wave period in Figure 11b. Figure 11c shows that the transmission coefficient increases with increasing wave period under wave heights of Hi = 0.05 m and Hi = 0.07 m. Long-period waves have a better diffraction ability at the same depth, and more wave energy passes through the F-BW. The decreasing ratio of the breakwater width to wavelength weakens the ability to block progressive waves, and the reflection coefficient decreases accordingly. The wave energy dissipation coefficient shows an alphabetic symbol “M” distribution with the wave period. This indicates that the wave energy dissipation is more complex and requires further study. When the dimensionless wave period is 5.06, both the transmission and reflection coefficients are close to 0.71, the dissipation coefficient is at the minimum by applying Equation (8c).

In brief, the increasing wave period plays a significant role in increasing the wave transmission and the reducing wave reflection. Although it has little effect on the horizontal wave force, it promotes an increase in the vertical wave force, which is unfavorable to the security of the breakwater.

4.1.4. Effect of Wave Height

To clarify the mechanism of the wave height effects on the hydrodynamic performance of the breakwater, except that the wave height is different, cases (a) and (e) are consistent. Figure 7e shows that the wave period is 1.2 s, the draft is 014 m, the wave height is 0.03 m and the breakwater width is 0.5 m.

In the second column of Figure 7e, when time t0 = 11.44 s, the maximum free surface difference is 0.031 m, and the maximum horizontal wave force is 3.43 N. Obviously, the increase in wave height increases the diffraction difficulty of the wave and delays the time when the horizontal wave force reaches its maximum. The higher the wave height, the more abundant the wave energy in Figure 7a,e. The water particle velocity maximum is 0.11 m/s in Figure 7e, which is much less than the water particle velocity maximum in Figure 7a. The larger wave height causes a larger wave elevation difference, and the larger horizontal wave force under other variable conditions is consistent by comparing Figure 7a,e. Therefore, Fxmax and Fx+max increase linearly with increasing wave height under drafts dr = 0.14 m and dr = 0.28 m in Figure 12a. The increase in wave height leads to increasing dynamic wave pressure, which in turn leads to increasing wave pressure on the F-BW lower surface and an increase in vertical wave force. Therefore, Fzmax and Fz+max increase linearly with increasing wave height under drafts dr = 0.14 m and dr = 0.28 m in Figure 12b. Figure 12c shows that the increasing wave height results in more wave reflection and less transmission due to the increasing blockage effect. The reflection ability weakens with decreasing interaction area (the ratio of the wetted surface height of the front wall of the F-BW to the wave height). The water particle velocity maximum of 0.11 m/s in Figure 7e is less than the water particle velocity maximum of 0.3 m/s in Figure 7a. The increasing water particle velocity with increasing wave height results in better vortex dissipation near the F-BW. Hence, the wave energy dissipation coefficient increases.

In conclusion, the increasing wave height reduces the wave reflection but increases horizontal and vertical wave forces, which is disadvantageous to the security of the breakwater.

4.2. Prediction Equations of F-BW Hydrodynamic Performance Parameters

To understand the contribution of each influencing factor to the hydrodynamic performance of the F-BW in detail, the factors affecting the RTD coefficients and wave force mainly include the wave period T, wave height Hi, draft dr, breakwater width B, and still water depth h. In Equation (11), the RTD coefficients Ct,r,d and wave force extremum Fx,z±max are expressed as follows:

Using the dimensionless analysis method and the numerical simulation results of 30 groups of simulated conditions in Table 1 based on the Origin 2019b software platform, multiple linear regression was performed by the least squares method, and the prediction equations of the RTD coefficients and wave force are given in Equation (12a–g). The detailed formulas are shown in Table 3.

Table 3. Statistics of prediction equation.
Note that 0.0933 ≤ dr/h ≤ 0.4667, 0.26667 ≤ B/h ≤ 0.8, 3.6166 ≤ T*sqrt(g/h) ≤ 6.5099, and 0.04 ≤ Hi/h ≤ 0.12.

4.3. Deviation Analysis of the Prediction Equations

Inspired by Kurdistani et al.’s [24] research method, the current study uses their method to assess the reliability of each predictive formula. The literature observation datasets include the measured RTD coefficients from Koutandos [13] (three cases (R1, R2 and R3) in Figure 16 of his literature) and Liang et al. [14] (six cases in Figures 14a, 19a and 22a of their literature), the wave forces from Mei and Black [40] and Ren et al. [23] (a case in Figure 10 of their literature). The numerical results obtained by Flow-3D are plotted on the x-axis in Figure 13, and predicted values of the predictive equations are plotted on the y-axis in Figure 13. Figure 13a shows a 20% error for the application of Liang et al. [14] transmission coefficient datasets that are mostly lower-estimated values of transmission coefficient with respect to Equation (12a), an almost 10% error for the application of Liang et al.’s [14] reflection coefficient and dissipation coefficient datasets, and Koutandos’s [13] RTD coefficients datasets. Figure 13b shows an almost 10% error for the application of Mei and Black [40] and Ren et al. [23] maximum wave force, which indicates that the present prediction equations are valid.

Figure 13. Comparison of the results between previous studies and the numerical results of this study. (a) Transmission coefficient Ct, reflection coefficient Cr, and dissipation coefficient Cd (Koutandos [13], Liang et al. [14]) and (b) Maximum wave force (Mei and Black [40]; Ren et al. [23]).

It is clearly found that the distribution points of the reflection coefficient and wave energy dissipation coefficient of the F-BW are relatively concentrated in a particular region in Figure 13a, indicating that the F-BW is dominant in reflecting waves and has stable wave dissipation ability. In addition, the horizontal negative maximum wave force of the F-BW is similar to the vertical negative maximum wave force, and the horizontal positive maximum wave force of the F-BW is slightly larger than the vertical positive maximum wave force in Figure 13b.

5. Conclusions

The present study investigated a high-accuracy numerical wave tank (NWT) based on the Flow-3D platform. A series of numerical simulations in the intermediate waters were carried out at a constant water depth (h) of 0.75 m under regular wave conditions, with a wave height range between 0.03–0.09 m, a wave period range between 1–1.8 s, and a breakwater width range between 0.2–0.6 m. The effects of four influencing factors (drBTHi) on the hydrodynamic performance (RTD coefficients and wave forces) are highlighted. The vital conclusions are as follows:

  1. The performance of two-dimensional viscous numerical wave tanks (NWTs) with a mass source wave maker and small length scale (1:40) are analyzed. By comparison, the wave model employed in this paper is competent for the numerical simulation of the F-BW.
  2. The results show that the increase in the four influence factors, except the wave period, benefits the decrease in the wave transmission. The increase in draft and breakwater width is beneficial to the increase in the wave reflection, and the wave period and wave height are opposite. The increase in draft benefits the decrease in wave energy dissipation, and the wave height is opposite.
  3. The increase in the draft and wave height benefits the increase in the horizontal positive and negative maximum wave forces. In addition to the draft, the increase in the other three influence factors benefits the increase in the vertical positive and negative maximum wave forces.
  4. Applying multiple linear regression presents the prediction equations of RTD coefficients and the extreme wave force. The prediction equations are verified by comparing them with literature observation datasets.

This study provides insight into the relation of RTD coefficients and wave forces with parameters such as draft, breakwater width, wave period and wave height. The simulated results of the given predicted equations can be generalized to the prototype scale by using Froude’s scaling law and can be used to guide the design of F-BWs in intermediate waters.

Appendix A

The wave period T, wave height Hi, draft dr, breakwater width B, and water depth h are the main factors that affect the wave dissipation performance and wave force of an F-BW in the intermediate waters. Therefore, the wave force of an F-BW can be expressed as a function of the above factors as follows:

Taking water depth h, gravity acceleration g, and water density ρ as the repetitive parameters, the three dimensionless parameters are expressed as follows:

[h] = [M0L1T0], [g] = [M0L1T−2], [ρ] = [M1L−3T0], where wave force per breakwater length in the vertical wave direction 𝐹F, expressed as [F = ρgh2], Equation (A1) can be written as follows:

According to wave theory, there is a nonlinear relationship between the wave force and the four dimensionless parameters in Equation (A2). The relationship between the dependent variable and independent variable in nature is exponential. It can be expressed as follows:

where αx1x2x3, and x4 are the unknown coefficients.

Taking the natural logarithm of both sides of Equation (A3) to obtain the double logarithm function model, the equation can be written in linear form as follows:

Using multiple function linear regression analysis, each unknown coefficient in the equations can be obtained and then substituted into Equation (A3) to obtain the wave force equations. Similarly,

Reference

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Wave

Three-Dimensional Simulations of Subaerial Landslide-Generated Waves: Comparing OpenFOAM and FLOW-3D HYDRO Models

지표 산사태로 발생한 파랑의 3차원 시뮬레이션: OpenFOAM과 FLOW-3D HYDRO 모델 비교

Ramtin Sabeti, Mohammad Heidarzadeh, Alessandro Romano, Gabriel Barajas Ojeda & Javier L. Lara

Abstract


The recent destructive landslide tsunamis, such as the 2018 Anak Krakatau event, were fresh reminders for developing validated three-dimensional numerical tools to accurately model landslide tsunamis and to predict their hazards. In this study, we perform Three-dimensional physical modelling of waves generated by subaerial solid-block landslides, and use the data to validate two numerical models: the commercial software FLOW-3D HYDRO and the open-source OpenFOAM package. These models are key representatives of the primary types of modelling tools—commercial and open-source—utilized by scientists and engineers in the field. This research is among a few studies on 3D physical and numerical models for landslide-generated waves, and it is the first time that the aforementioned two models are systematically compared. We show that the two models accurately reproduce the physical experiments and give similar performances in modelling landslide-generated waves. However, they apply different approaches, mechanisms and calibrations to deliver the tasks. It is found that the results of the two models are deviated by approximately 10% from one another. This guide helps engineers and scientists implement, calibrate, and validate these models for landslide-generated waves. The validity of this research is confined to solid-block subaerial landslides and their impact in the near-field zone.

1 Introduction and Literature Review


Subaerial landslide-generated waves represent major threats to coastal areas and have resulted in destruction and casualties in several locations worldwide (Heller et al., 2016; Paris et al., 2021). Interest in landslide-generated tsunamis has risen in the last decade due to a number of devastating events, especially after the December 2018 Anak Krakatau tsunami which left a death toll of more than 450 people (Grilli et al., 2021; Heidarzadeh et al., 2020a). Another significant subaerial landslide tsunami occurred on 16 October 1963 in Vajont dam reservoir (Northern Italy), when an impulsive landslide-generated wave overtopped the dam, killing more than 2000 people (Heller & Spinneken, 2013; Panizzo et al., 2005). The largest tsunami run-up (524 m) was recorded in Lituya Bay landslide tsunami event in 1958 where it killed five people (Fritz et al., 2009).

To achieve a better understanding of subaerial landslide tsunamis, laboratory experiments have been performed using two- and three-dimensional (2D, 3D) set-ups (Bellotti & Romano, 2017; Di Risio et al., 2009; Fritz et al., 2004; Romano et al., 2013; Sabeti & Heidarzadeh, 2022a). Results of physical models are essential to shed light on the nonlinear physical phenomena involved. Furthermore, they can be used to validate numerical models (Fritz et al., 2009; Grilli & Watts, 2005; Liu et al., 2005; Takabatake et al., 2022). However, the complementary development of numerical tools for modelling of landslide-generated waves is inevitable, as these models could be employed to accelerate understanding the nature of the processes involved and predict the detailed outcomes in specific areas (Cremonesi et al. 2011). Due to the high flexibility of numerical models and their low costs in comparison to physical models, validated numerical models can be used to replicate actual events at a fair cost and time (e.g., Cecioni et al., 2011; Grilli et al., 2017; Heidarzadeh et al., 2020b, 2022; Horrillo et al., 2013; Liu et al., 2005; Løvholt et al., 2005; Lynett & Liu, 2005).

Table 1 lists some of the existing numerical models for landslide tsunamis although the list is not exhaustive. Traditionally, Boussinesq-type models, and Shallow water equations have been used to simulate landslide tsunamis, among which are TWO-LAYER (Imamura and Imteaz,1995), LS3D (Ataie-Ashtiani & Najafi Jilani, 2007), GLOBOUSS (Løvholt et al., 2017), and BOUSSCLAW (Kim et al., 2017). Numerical models that solve Navier–Stokes equations showed good capability and reliability to simulate subaerial landslide-generated waves (Biscarini, 2010). Considering the high computational cost of solving the full version of Navier–Stokes equations, a set of methods such as RANS (Reynolds-averaged Navier–Stokes equations) are employed by some existing numerical models (Table 1), which provide an approximate averaged solution to the Navier–Stokes equations in combination with turbulent models (e.g., k–ε, k–ω). Multiphase flow models were used to simulate the complex dynamics of landslide-generated waves, including scenarios where the landslide mass is treated as granular material, as in the work by Lee and Huang (2021), or as a solid block (Abadie et al., 2010). Among the models listed in Table 1, FLOW-3D HYDRO and OpenFOAM solve Navier–Stokes equations with different approaches (e.g., solving the RANS by IHFOAM) (Paris et al., 2021; Rauter et al., 2022). They both offer a wide range of turbulent models (e.g., Large Eddy Simulation—LES, k–ε, k–ω model with Renormalization Group—RNG), and they both use the VOF (Volume of Fluid) method to track the water surface elevation. These similarities are one of the motivations of this study to compare the performance of these two models. Details of governing equations and numerical schemes are discussed in the following.

Numerical modelsApproachDeveloper
FLOW-3D HYDROThis CFD package solves Navier–Stokes equations using finite-difference and finite volume approximations, along with Volume of Fluid (VOF) method for tracking the free surfaceFlow Science, Inc. (https://www.flow3d.com/)
MIKE 21This model is based on the numerical solution of 2D and 3D incompressible RANS equations subject to the assumptions of Boussinesq and hydrostatic pressureDanish Hydraulic Institute (DHI) (https://www.mikepoweredbydhi.com/products/mike-21-3)
OpenFOAM (IHFOAM solver)IHFOAM is a newly developed 3D numerical two-phase flow solver. Its core is based on OpenFOAM®. IHFOAM can also solve two-phase flow within porous media using RANS/VARANS equationsIHCantabria research institute (https://ihfoam.ihcantabria.com/)
NHWAVENHWAVE is a 3D shock-capturing non-Hydrostatic model which solves the incompressible Navier–Stokes equations in terrain and surface-following sigma coordinatesKirby et al. (2022) (https://sites.google.com/site/gangfma/nhwave, https://github.com/JimKirby/NHWAVE)
GLOBOUSSGloBouss is a depth-averaged model based on the standard Boussinesq equations including higher order dispersion terms, Coriolis terms, and numerical hydrostatic correction termsLøvholt et al. (2022) (https://www.duo.uio.no/handle/10852/10184)
BOUSSCLAWBoussClaw is a new hybrid Boussinesq type model which is an extension of the GeoClaw model. It employs a hybrid of finite volume and finite difference methods to solve Boussinesq equationsClawpack Development Team (http://www.clawpack.org/)Kim et al. (2017)
THETIS-MUITHETIS is a multi-fluid Navier–Stokes solver which can be considered a one-fluid model as only one velocity is defined at each point of the mesh and there is no mixing between the three considered fluids (water, air, and slide). It applies VOF methodTREFLE department of the I2M Laboratory at Bordeaux, France (https://www.i2m.u-bordeaux.fr/en)
LS3DA 2D depth-integrated numerical model which applies a fourth-order Boussinesq approximation for an arbitrary time-variable bottom boundaryAtaie-Ashtiani and Najafi Jilani (2007)
LYNETT- Mild-Slope Equation (MSE)MSE is a depth-integrated version of the Laplace equation operating under the assumption of inviscid flow and mildly varying bottom slopesLynett and Martinez (2012)
Tsunami 3DA simplified 3D Navier–Stokes model for two fluids (water and landslide material) using VOF for tracking of water surfaceHorrillo et al. (2013)Kim et al. (2020)
(Cornell Multi-grid Coupled Tsunami Mode (COMCOT)COMCOT adopts explicit staggered leap-frog finite difference schemes to solve Shallow Water Equations in both Spherical and Cartesian CoordinatesLiu et al. (1998); Wang and Liu (2006)
TWO-LAYERA mathematical model for a two-layer flow along a non-horizontal bottom. Conservation of mass and momentum equations are depth integrated in each layer, and nonlinear kinematic and dynamic conditions are specified at the free surface and at the interface between fluidsImamura and Imteaz (1995)
Table 1 Some of the existing numerical models for simulating landslide-generated waves

In this work, we apply two Computational Fluid Dynamic (CFD) frameworks, FLOW-3D HYDRO, and OpenFOAM to simulate waves generated by solid-block subaerial landslides in a 3D set-up. We calibrate and validate both numerical models using our physical experiments in a 3D wave tank and compare the performances of these models systematically. These two numerical models are selected among the existing CFD solvers because they have been reported to provide valuable insights into landslide-generated waves (Kim et al., 2020; Romano et al., 2020a, b ; Sabeti & Heidarzadeh, 2022a). As there is no study to compare the performances of these two models (FLOW-3D HYDRO and OpenFOAM) with each other in reproducing landslide-generated waves, this study is conducted to offer such a comparison, which can be helpful for model selection in future research studies or industrial projects. In the realm of tsunami generation by subaerial landslides, the solid-block approach serves as an effective representative for scenarios where the landslide mass is more cohesive and rigid, rather than granular. This methodology is particularly relevant in cases such as the 2018 Anak Krakatau or 1963 Vajont landslides, where the landslide’s nature aligns closely with the characteristics simulated by a solid-block model (Zaniboni & Tinti, 2014; Heidarzadeh et al., 2020a, 2020b).

The objectives of this research are: (i) To provide a detailed implementation and calibration for simulating solid-block subaerial landslide-generated waves using FLOW-3D HYDRO and OpenFOAM, and (ii) To compare the performance of these two numerical models based on three criteria: free surface elevation of the landslide-generated waves, capabilities of the models in simulating 3D features of the waves in the near-field, velocity fields, and velocity variations at different locations. The innovations of this study are twofold: firstly, it is a 3D study involving physical and numerical modelling and thus the data can be useful for other studies, and secondly, it compares the performance of two popular CFD models in modelling landslide-generated waves for the first time. The validated models such as those reported in this study and comparison of their performances can be useful for engineers and scientists addressing landslide tsunami hazards worldwide.

2 Data and Methods


2.1 Physical Modelling

To validate our numerical models, a series of three-dimensional physical experiments were carried out at the Hydraulic Laboratory of the Brunel University London (UK) in a 3D wave tank 2.40 m long, 2.60 m wide, and 0.60 m high (Figs. 1 and 2). To mitigate experimental errors and enhance the reliability of our results, each physical experiment was conducted three times. The reported data in the manuscript reflects the average of these three trials, assuming no anomalous outliers, thus ensuring an accurate reflection of the experimental tests. One experiment was used for validation of our numerical models. The slope angle (α) and water depth (h) were 45° and 0.246 m, respectively for this experiment. The movement of the sliding mass was recorded by a digital camera with a sampling frequency of 120 frames per second, which was used to calculate the slide impact velocity (vs). The travel distance (D), defined as the distance from the toe of the sliding mass to the water surface, was D=0.045 m. The material of the solid block used in our study was concrete with a density of 2600 kg/m3. Table 2 provides detailed information on the dimensions and kinematics of this solid block used in our physical experiments.

Figure 1. The geometrical and kinematic parameters of a subaerial landslide tsunami. Parameters are: h, water depth; aM, maximum wave amplitude; α, slope angle;vs, slide velocity; ls, length of landslide; bs, width of landslide; s, thickness of landslide; SWL, still water level; D, travel distance (the distance from the toe of the sliding mass to the water surface); L, length of the wave tank; and W, width of the wave tank and H, is the hight of the wave tank

Figure 2. a Wave tank setup of the physical experiments of this study. b Numerical simulation setup for the FLOW-3D HYDRO Model. c The numerical set-up for the OpenFOAM model. The location of the physical wave gauge (represented by numerical gauge WG-3 in the numerical simulations) is at X = 1.03 m, Y = 1.21 m, and Z = 0.046 m. d Top view showing the locations of numerical wave gauges (WG-1, WG-2, WG-3, WG-4, WG-5)
Parameter, unitValue/type
Slide width (bs), m0.26
Slide length (ls), m0.20
Slide thickness (s), m0.10
Slide volume (V), m32.60 × 10–3
Specific gravity, (γs)2.60
Slide weight (ms), kg6.86
Slide impact velocity (vs), m/s1.84
Slide Froude number (Fr)1.18
MaterialConcrete
Table 2 Geometrical and kinematic information of the sliding mass used for physical experiments in this study

We took scale effects into account during physical experiments by considering the study by Heller et al. (2008) who proposed a criterion for avoiding scale effects. Heller et al. (2008) stated that the scale effects can be negligible as long as the Weber number (W=ρgh2/σ; where σ is surface tension coefficient) is greater than 5.0 × 103 and the Reynolds number (R=g0.5h1.5/ν; where ν is kinematic viscosity) is greater than 3.0 × 105 or water depth (h) is approximately above 0.20 m. Considering the water temperature of approximately 20 °C during our experiments, the kinematic viscosity (ν) and surface tension coefficient (σ) of water become 1.01 × 10–6 m2/s and 0.073 N/m, respectively. Therefore, the Reynolds and Weber numbers were as R= 3.8 × 105 and W= 8.1 × 105, indicating that the scale effect can be insignificant in our experiments. To record the waves, we used a twin wire wave gauge provided by HR Wallingford (https://equipit.hrwallingford.com). This wave gauge was placed at X = 1.03 m, Y = 1.21 m based on the coordinate system shown in Fig. 2a.

2.2 Numerical Simulations

The numerical simulations in this work were performed employing two CFD packages FLOW-3D HYDRO, and OpenFOAM which have been widely used in industry and academia (e.g., Bayon et al., 2016; Jasak, 2009; Rauter et al., 2021; Romano et al., 2020a, b; Yin et al., 2015).

2.2.1 Governing Equations and Turbulent Models

2.2.1.1 FLOW-3D HYDRO

The FLOW-3D HYDRO solver is based on the fundamental law of mass, momentum and energy conservation. To estimate the influence of turbulent fluctuations on the flow quantities, it is expressed by adding the diffusion terms in the following mass continuity and momentum transport equations:

quation (1) is the general mass continuity equation, where u is fluid velocity in the Cartesian coordinate directions (x), Ax is the fractional area open to flow in the x direction, VF is the fractional volume open to flow, ρ is the fluid density, R and ξ are coefficients that depend on the choice of the coordinate system. When Cartesian coordinates are used, R is set to unity and ξ is set to zero. RDIF and RSOR are the turbulent diffusion and density source terms, respectively. Uρ=Scμ∗/ρ, in which Sc is the turbulent Schmidt number, μ∗ is the dynamic viscosity, and ρ is fluid density. RSOR is applied to model mass injection through porous obstacle surfaces.

The 3D equations of motion are solved with the following Navier–Stokes equations with some additional terms:

where t is time, Gx is accelerations due to gravity, fx is viscous accelerations, and bx is the flow losses in porous media.

According to Flow Science (2022), FLOW-3D HYDRO’s turbulence models differ slightly from other formulations by generalizing the turbulence production with buoyancy forces at non-inertial accelerations and by including the influence of fractional areas/volumes of the FAVOR method (Fractional Area-Volume Obstacle Representation) method. Here we use k–ω model for turbulence modelling. The k–ω model demonstrates enhanced performance over the k-ε and Renormalization-Group (RNG) methods in simulating flows near wall boundaries. Also, for scenarios involving pressure changes that align with the flow direction, the k–ω model provides more accurate simulations, effectively capturing the effects of these pressure variations on the flow (Flow Science, 2022). The equations for turbulence kinetic energy are formulated as below based on Wilcox’s k–ω model (Flow Science, 2022):

where kT is turbulent kinetic energy, PT is the turbulent kinetic energy production, DiffKT is diffusion of turbulent kinetic energy, GT is buoyancy production, β∗=0.09 is closure coefficient, and ω is turbulent frequency.

2.2.1.2 OpenFOAM

For the simulations conducted in this study, OpenFOAM utilizes the Volume-Averaged RANS equations (VARANS) to enable the representation of flow within porous material, treated as a continuous medium. The momentum equation incorporates supplementary terms to accommodate frictional forces from the porous media. The mass and momentum conservation equations are linked to the VOF equation (Jesus et al., 2012) and are expressed as follows:

where the gravitational acceleration components are denoted bygj. The term u¯i=1Vf∫Vf0ujdV represents the volume averaged ensemble averaged velocity (or Darcy velocity) component, Vf is the fluid volume contained in the average volumeV,τ is the surface tension constant (assumed to be 1 for the water phase and 0 for the air phase), and fσi is surface tension, defined as fσi=σκ∂α∂xi, where σ (N/m) is the surface tension constant and κ (1/m) is the curvature (Brackbill et al., 1992). μeff is the effective dynamic viscosity that is defined as μeff=μ+ρνt and takes into account the dynamic molecular (μ) and the turbulent viscosity effects (ρνt). νt is eddy viscosity, which is provided by the turbulence closure model. n is the porosity, defined as the volume of voids over total volume, and P∗=1Vf∫∂Vf0P∗dS is the ensemble averaged pressure in excess of hydrostatic pressure. The coefficient A accounts for the frictional force induced by laminar Darcy-type flow, B considers the frictional force under turbulent flow conditions, and c accounts for the added mass. These coefficients (A,B, and c) are defined based on the work of Engelund (1953) and later modified by Van Gent (1995) as given below:

where D50 is the mean nominal diameter of the porous material, KC is the Keulegan–Carpenter number, a and b are empirical nondimensional coefficients (see Lara et al., 2011; Losada et al., 2016) and γ = 0.34 is a nondimensional parameter as proposed by Van Gent (1995). The k-ω Shear Stress Transport (SST) turbulence is employed to capture the effect of turbulent flow conditions (Zhang & Zhang, 2023) with the enhancement proposed by Larsen and Fuhrman (2018) for the over-production of turbulence beneath surface waves. Boundary layers are modelled with wall functions. The reader is referred to Larsen and Fuhrman (2018) for descriptions, validations, and discussions of the stabilized turbulence models.

2.2.2 FLOW-3D HYDRO Simulation Procedure

In our specific case in this study, FLOW-3D HYDRO utilizes the finite-volume method to numerically solve the equations described in the previous Sect. 2.2.1.1, ensuring a high level of accuracy in the computational modelling. The use of structured rectangular grids in FLOW-3D HYDRO offers the advantages of easier development of numerical methods, greater transparency in their relation to physical problems, and enhanced accuracy and stability of numerical solutions. (Flow Science, 2022). Curved obstacles, wall boundaries, or other geometric features are embedded in the mesh by defining the fractional face areas and fractional volumes of the cells that are open to flow (the FAVOR method). The VOF method is employed in FLOW-3D HYDRO for accurate capturing of the free-surface dynamics (Hirt and Nichols 1981). This approach then is upgraded to method of the TruVOF which is a split Lagrangian method that typically produces lower cumulative volume error than the alternative methods (Flow Science, 2022).

For numerical simulation using FLOW-3D HYDRO, the entire flow domain was 2.60 m wide, 0.60 m deep and 2.50 m long (Fig. 2b). The specific gravity (γs) for solid blocks was set to 2.60 in our model, aligning closely with the density of the actual sliding mass, which was approximately determined in our physical experiments. The fluid medium was modelled as water with a density of 1000 kg/m3 at 20 °C. A uniform grid comprising of one single mesh plane was applied with a grid size of 0.005 m. The top, front and back of the mesh areas were defined as symmetry, and the other surfaces were of wall type with no-slip conditions around the walls.

To simulate turbulent flows, k-ω model was used because of its accuracy in modelling turbulent flows (Menter 1992). Landslide movement was replicated in simulations using coupled motion objects, which implies that the movement of landslides is based on gravity and the friction between surfaces rather than a specified motion in which the model should be provided by force and torques. The time intervals of the numerical model outputs were set to 0.02 s to be consistent with the actual sampling rates of our wave gauges in the laboratory. In order to calibrate the FLOW-3D HYDRO model, the friction coefficient is set to 0.45, which is consistent with the Coulombic friction measurements in the laboratory. The Courant Number (C=UΔtΔx) is considered as the criterion for the stability of numerical simulations which gives the maximum time step (Δt) for a prespecified mesh size (Δx) and flow speed (U). The Courant number was always kept below one.

2.2.3 OpenFOAM Simulation Procedure

OpenFOAM is an open-source platform containing several C++ libraries which solves both 3D Reynolds-Averaged Navier–Stokes equations (RANS) and Volume-Averaged RANS equations (VARANS) for two-phase flows (https://www.openfoam.com/documentation/user-guide). Its implementation is based on a tensorial approach using object-oriented programming techniques and the Finite Volume Method (McDonald 1971). In order to simulate the subaerial landslide-generated waves, the IHFOAM solver based on interFoam (Higuera et al., 2013a, 2013b), and the overset mesh framework method are employed. The implementation of the overset mesh method for porous mediums in OpenFOAM is described in Romano et al. (2020a, b) for submerged rigid and impermeable landslides.

The overset mesh technique, as outlined by Romano et al. (2020a, b), uses two distinct domains: a moving domain that captures the dynamics of the rigid landslide and a static background domain to characterize the numerical wave tank. The overlapping of these domains results in a composite mesh that accurately depicts complex geometrical transformations while preserving mesh quality. A porous media with a very low permeability (n = 0.001) was used to simulate the impermeable sliding surfaces. RANS equations were solved within the porous media. The Multidimensional Universal Limiter with Explicit Solution (MULES) algorithm is employed for solving the (VOF) equation, ensuring precision in tracking fluid interfaces. Simultaneously, the PIMPLE algorithm is employed for the effective resolution of velocity–pressure coupling in the Eqs. 7 and 8. A background domain was created to reproduce the subaerial landslide waves with dimensions 2.50 m (x-direction) × 2.60 m (y-direction) × 0.6 m (z-direction) (Fig. 2c). The grid size is set to 0.005 m for the background mesh. A moving domain was applied in an area of 0.35 m (x-direction) × 0.46 m (y-direction) × 0.32 m (z-direction) with a grid spacing of 0.005 m and applying a body-fitted mesh approach, which contains the rigid and impermeable wedges. Wall condition with No-slip is defined as the boundary for the four side walls (left, right, front and back, in Fig. 1). Also, a non-slip boundary condition is specified to the bottom, whereas the top boundary is defined as open. The experimental slide movement time series is used to model the landslide motion in OpenFOAM. The applied equation is based on the analytical solution by Pelinovsky and Poplavsky (1996) which was later elaborated by Watts (1998). The motion of a sliding rigid body is governed by the following equation:

where, m represents the mass of the landslide, s is the displacement of the landslide down the slope, t is time elapsed, g stands for the acceleration due to gravity, θ is the slope angle, Cf is the Coulomb friction coefficient, Cm is the added mass coefficient, m0 denotes the mass of the water displaced by the moving landslide, A is the cross-sectional area of the landslide perpendicular to the direction of motion, ρ is the water density, and Cd is the drag coefficient.

2.2.4 Mesh Sensitivity Analysis

In order to find the most efficient mesh size, mesh sensitivity analyses were conducted for both numerical models (Fig. 3). We considered the influence of mesh density on simulated waveforms by considering three mesh sizes (Δx) of 0.0025 m, 0.005 m and 0.010 m. The results of FLOW-3D HYDRO revealed that the largest mesh deviates 9% (Fig. 3a, Δx = 0.0100 m) from two other finer meshes. Since the simulations by FLOW-3D HYDRO for the finest mesh (Δx = 0.0025 m) do not show any improvements in comparison with the 0.005 m mesh, therefore the mesh with the size of Δx = 0.0050 m is used for simulations (Fig. 3a). A similar approach was followed for mesh sensitivity of OpenFOAM mesh grids. The mesh with the grid spacing of Δx = 0.0050 m was selected for further simulations since a satisfactory independence was observed in comparison with the half size mesh (Δx = 0.0025 m). However, results showed that the mesh size with the double size of the selected mesh (Δx = 0.0100 m) was not sufficiently fine to minimize the errors (Fig. 3b).

Figure 3. ab Sensitivity of numerical simulations to the sizes of the mesh (Δx) for FLOW-3D HYDRO, and OpenFOAM, respectively. The location of the wave gauge 3 (WG-3) is at X = 1.03 m, Y = 1.21 m, and Z = -0.55 m (see Fig. 2d)

In terms of computational cost, the time required for 2 s simulations by FLOW-3D HYDRO is approximately 4.0 h on a PC Intel® Core™ i7-8700 CPU with a frequency of 3.20 GHz equipped with a 32 GB RAM. OpenFOAM requires 20 h to run 2 s of numerical simulation on 2 processors on a PC Intel® Core™ i9-9900KF CPU with a frequency of 3.60 GHz equipped with a 364 GB RAM. Differences in computational time for simulations run with FLOW-3D HYDRO and OpenFOAM reflect the distinct characteristics of each numerical methods, and the specific hardware setups.

2.2.5 Validation

We validated both numerical models based on our laboratory experimental data (Fig. 4). The following criterion was used to assess the level of agreement between numerical simulations and laboratory observations:

where ε is the mismatch error, Obsi is the laboratory observation values, Simi is the simulation values, and the mathematical expression |X| represents the absolute value of X. The slope angle (α), water depth (h) and travel distance (D) were: α = 45°, h = 0.246 m and D = 0.045 m in both numerical models, consistent with the physical model. We find the percentage error between each simulated data point and its corresponding observed value, and subsequently average these errors to assess the overall accuracy of the simulation against the observed time series. Our results revealed that the mismatch errors between physical experiments and numerical models for the FLOW-3D HYDRO and OpenFOAM are 8% and 18%, respectively, indicating that our models reproduce the measured waveforms satisfactorily (Fig. 4). The simulated waveform by OpenFOAM shows a minor mismatch at t = 0.76 s which resulted from a droplet immediately after the slide hits the water surface in the splash zone. In term of the maximum negative amplitude, the simulated waves by OpenFOAM indicates a relatively better performance than FLOW-3D HYDRO, whereas the maximum positive amplitude (aM) simulated by FLOW-3D HYDRO is closer to the experimental value. The recorded maximum positive amplitude in physical experiment is 0.022 m, whereas it is 0.020 m for FLOW-3D HYDRO and 0.017 m for OpenFOAM simulations. In acknowledging the deviations observed, it is pertinent to highlight that while numerical models offer robust insights, the difference in meshing techniques and the distinct computational methods to resolve the governing equations in FLOW-3D HYDRO and OpenFOAM have contributed to the variance. Moreover, the intrinsic uncertainties associated with the physical experimentation process, including the precision of wave gauges and laboratory conditions, are non-negligible factors influencing the results.

Figure 4. Validation of the simulated waves (brown line for FLOW-3D HYDRO and green line for OpenFOAM) using the laboratory-measured waves (black solid diamonds). This physical experiment was conducted for wave gauge 3 (WG-3) located at X = 1.03 m, Y = 1.21 m, and Z = -0.55 m (see Fig. 2d). Here, 
ε shows the errors between simulations and actual physical measurements using Eq. (13)

3 Results


Following the validations of the two numerical models (FLOW-3D HYDRO and OpenFOAM), a series of simulations were performed to compare the performances of these two CFD solvers. The generation process of landslide waves, waveforms, and velocity fields are considered as the basis for comparing the performance of the two models (Figs. 5, 6, 7 and 8).

Figure 5.Comparison between the simulated waveforms by FLOW-3D HYDRO (black) and OpenFOAM (red) at four different locations in the near-field zone (WG-1,2,4 and 5). WG is the abbreviation for wave gauge. The mismatch (Δ) between the two models at each wave gauge is calculated using Eq. (14)
Figure 6. Comparison of water surface elevations produced by solid-block subaerial landslides for the two numerical models FLOW-3D-HYDRO (ac) and OpenFOAM (e–g) at different times
Figure 7. Snapshots of the simulations at different times for FLOW-3D HYDRO (ac) and OpenFOAM (eg) showing velocity fields (colour maps and arrows). The colormaps indicate water particle velocity in m/s, and the lines indicate the velocities of water particles
Figure 8. Comparison of velocity variations at (WG-3) for FLOW-3D HYDRO (light blue) and OpenFOAM (brown)

3.1 Comparison of Waveforms

Five numerical wave gauges were placed in our numerical models to measure water surface oscillations in the near-field zone (Fig. 5). These gauges offer an azimuthal coverage of 60° (Fig. 2d). Figure 5 reveals that the simulated waveforms from two models (FLOW-3D HYDRO and OpenFOAM) are similar. The highest wave amplitude (aM) is recorded at WG-3 for both models, whereas the lowest amplitude is recorded at WG-5 and WG-1 which can be attributed to the longer distances of these gauges from the source region as well as their lateral offsets, resulting in higher wave energy dissipation at these gauges. The sharp peaks observed in the simulated waveforms, such as the red peak between 0.8–1.0 s in Fig. 5a from OpenFOAM, the red peak between 0.6–0.8 s in Fig. 5b also from OpenFOAM, and the black peak between 1.4–1.6 s in Fig. 5d from FLOW-3D HYDRO, are due to the models’ spatial and temporal discretization. They reflect the sensitivity of the models to capturing transient phenomena, where the chosen mesh and time-stepping intervals are key factors in the models’ ability to track rapid changes in the flow field. To quantify the deviations of the two models from one another, we apply the following equation for mismatch calculation:

where Δ is the mismatch error, Sim1 is the simulation values from FLOW-3D HYDRO, Sim2 is the simulation values from OpenFOAM, and the mathematical expression |X| implies the absolute value of X. We calculate the percentage difference for each corresponding pair of simulation results, then take the mean of these percentage differences to determine the average deviation between the two simulation time series. Using Eq. (14), we found a deviation range from 9 to 11% between the two models at various numerical gauges (Fig. 5), further confirming that the two models give similar simulation results.

3.2 Three-Dimensional Vision of Landslide Generation Process by Numerical Models

A sequence of four water surface elevation snapshots at different times is shown in Fig. 6 for both numerical modes. In both simulations, the sliding mass travels a constant distance of 0.045 m before hitting the water surface at t = 0.270 s which induces an initial change in water surface elevation (Figs. 6a and e). At t = 0.420 s, the mass is fully immersed for both simulations and an initial dipole wave is generated (Figs. 6b and f). Based on both numerical models, the maximum positive amplitude (0.020 m for FLOW-3D HYDRO, and 0.017 m for OpenFOAM) is observed at this stage (Fig. 6). The maximum propagation of landslide-simulated waves along with more droplets in the splash zone could be seen at t = 0.670 s for both models (Fig. 6c and g). The observed distinctions in water surface elevation simulations as illustrated in Fig. 6 are rooted in the unique computational methodologies intrinsic to each model. In the OpenFOAM simulations, a more diffused water surface elevation profile is evident. Such diffusion is an outcome of the simulation’s intrinsic treatment of turbulent kinetic energy dissipation, aligning with the solver’s numerical dissipation characteristics. These traits are influenced by the selected turbulence models and the numerical advection schemes, which prioritize computational stability, possibly at the expense of interface sharpness. The diffusion in the wave pattern as rendered by OpenFOAM reflects the application of a turbulence model with higher dissipative qualities, which serves to moderate the energy retained during wave propagation. This approach can provide insights into the potential overestimation of energy loss under specific simulation conditions. In contrast, the simulations from FLOW-3D HYDRO depict a more localized wave pattern, indicative of a different approach to turbulent dissipation. This coherence in wave fronts is a function of the model’s specific handling of the air–water interface and its targeted representation of the energy dynamics resulting from the landslide’s interaction with the water body. They each have specific attributes that cater to different aspects of wave simulation fidelity, thereby contributing to a more comprehensive understanding of the phenomena under study.

3.3 Wave Velocity Analysis

We show four velocity fields at different times during landslide motion in Fig. 7 and one time series of velocity (Fig. 8) for both numerical models. The velocity varies in the range of 0–1.9 m/s for both models, and the spatial distribution of water particle velocity appears to be similar in both. The models successfully reproduce the complex wavefield around the landslide generation area, which is responsible for splashing water and mixing with air around the source zone (Fig. 7). The first snapshot at t = 0.270 s (Fig. 7a and e) shows the initial contact of the sliding mass with water surface for both numerical models which generates a small elevation wave in front of the mass exhibiting a water velocity of approximately 1.2 m/s. The slide fully immerses for the first time at t = 0.420 s producing a water velocity of approximately 1.5 m/s at this time (Fig. 7b and f). The last snapshot (t = 0.670 s) shows 1.20 s after the slide hits the bottom of the wave tank. Both models show similar patterns for the propagation of the waves towards the right side of the wave tank. The differences in water surface profiles close to the slope and solid block at t = 0.67 s, observed in the FLOW-3D HYDRO and OpenFOAM simulations (Figs. 6 and 7), are due to the distinct turbulence models employed by each (RNG and k-ω SST, respectively) which handle the complex interactions of the landslide-induced waves with the structures differently. Additionally, the methods of simulating landslide movement further contribute to this discrepancy, with FLOW-3D HYDRO’s coupled motion objects possibly affecting the waves’ initiation and propagation unlike OpenFOAM’s prescribed motion from experimental data. In addition to the turbulence models, the variations in VOF methodologies between the two models also contribute to the observed discrepancies.

For the simulated time series of velocity, both models give similar patterns and close maximum velocities (Fig. 8). For both models the WG-3 located at X = 1.03 m, Y = 1.21 m, and Z = − 0.55 m (Fig. 2d) were used to record the time series. WG-3 is positioned 5 mm above the wave tank bottom, ensuring that the measurements taken reflect velocities very close to the bottom of the wave tank. The maximum velocity calculated by FLOW-3D HYDRO is 0.162 m/s while it is 0.132 m/s for OpenFOAM, implying a deviation of approximately 19% from one another. Some oscillations in velocity records are observed for both models, but these oscillations are clearer and sharper for OpenFOAM. Although it is hard to see velocity oscillations in the FLOW-3D HYDRO record, a close look may reveal some small oscillations (around t = 0.55 s and 0.9 s in Fig. 8). In fact, velocity oscillations are expected due to the variations in velocity of the sliding mass during the travel as well as due to the interferences of the initial waves with the reflected wave from the beach. In general, it appears that the velocity time series of the two models show similar patterns and similar maximum values although they have some differences in the amplitudes of the velocity oscillations. The differences between the two curves are attributed to factors such as difference in meshing between the two models, turbulence models, as well as the way that two models record the outputs.

4 Discussions


An important step for CFD modelling in academic or industrial projects is the selection of an appropriate numerical model that can deliver the task with satisfactory performance and at a reasonable computational cost. Obviously, the major drivers when choosing a CFD model are cost, capability, flexibility, and accessibility. In this sense, the existing options are of two types as follows:

  • Commercial models, such as FLOW-3D HYDRO, which are optimised to solve free-surface flow problems, with customer support and an intuitive Graphical User Interface (GUI) that significantly facilitates meshing, setup, simulation monitoring, visualization, and post-processing. They usually offer high-quality customer support. Although these models show high capabilities and flexibilities for numerical modelling, they are costly, and thus less accessible.
  • Open-source models, such as OpenFOAM, which come without a GUI but with coded tools for meshing, setup, parallel running, monitoring, post-processing, and visualization. Although these models offer no customer support, they have a big community support and online resources. Open-source models are free and widely accessible, but they may not be necessarily always flexible and capable.

OpenFOAM provides freedom for experimenting and diving through the code and formulating the problem for a user whereas FLOW-3D HYDRO comes with high-level customer supports, tutorial videos and access to an extensive set of example simulations (https://www.flow3d.com/). While FLOW-3D-HYDRO applies a semi-automatic meshing process where users only need to input the 3D model of the structure, OpenFOAM provides meshing options for simple cases, and in many advanced cases, users need to create the mesh in other software (e.g., ANSYS) (Ariza et al., 2018) and then convert it to OpenFOAM format. Auspiciously, there are numerous online resources (https://www.openfoam.com/trainings/about-trainings), and published examples for OpenFOAM (Rauter et al., 2021; Romano et al., 2020a, b; Zhang & Zhang, 2023).

The capabilities of both FLOW-3D HYDRO and OpenFOAM to simulate actual, complex landslide-generated wave events have been showcased in significant case studies. The study by Ersoy et al. (2022) applied FLOW-3D HYDRO to simulate impulse waves originating from landslides near an active fault at the Çetin Dam Reservoir, highlighting the model’s capacity for detailed, site-specific modelling. Concurrently, the work by Alexandre Paris (2021) applied OpenFOAM to model the 2017 Karrat Fjord landslide tsunami events, providing a robust validation of OpenFOAM’s utility in capturing the dynamics of real-world geophysical phenomena. Both instances exemplify the sophisticated computational approaches of these models in aiding the prediction and analysis of natural hazards from landslides.

As for limitations of this study, we acknowledge that our numerical models are validated by one real-world measured wave time series. However, it is believed that this one actual measurement was sufficient for validation of this study because it was out of the scope of this research to fully validate the FLOW-3D HYDRO and OpenFOAM models. These two models have been fully validated by more actual measurements by other researchers in the past (e.g., Sabeti & Heidarzadeh, 2022b). It is also noted that some of the comparisons made in this research were qualitative, such as the 3D wave propagation snapshots, as it was challenging to develop quantitative comparisons for snapshots. Another limitation of this study concerns the number of tests conducted here. We fixed properties such as water depth, slope angle, and travel distance throughout this study because it was out of the scope of this research to perform sensitivity analyses.

5 Conclusions


We configured, calibrated, validated and compared two numerical models, FLOW-3D HYDRO, and OpenFOAM, using physical experiments in a 3D wave tank. These validated models were used to simulate subaerial solid-block landslides in the near-field zone. Our results showed that both models are fully compatible with investigating waves generated by subaerial landslides, although they use different approaches to simulate the phenomenon. The properties of solid-block, water depth, slope angle, and travel distance were kept constant in this study as we focused on comparing the performance of the two models rather than conducting a full sensitivity analysis. The findings are as follows:

  • Different settings were used in the two models for modelling landslide-generated waves. In terms of turbulent flow modelling, we used the Renormalization Group (RNG) turbulence model in FLOW-3D HYDRO, and k-ω (SST) turbulence model in OpenFOAM. Regarding meshing techniques, the overset mesh method was used in OpenFOAM, whereas the structured cartesian mesh was applied in FLOW-3D HYDRO. As for simulation of landslide movement, the coupled motion objects method was used in FLOW-3D HYDRO, and the experimental slide movement time series were prescribed in OpenFOAM.
  • Our modelling revealed that both models successfully reproduced the physical experiments. The two models deviated 8% (FLOW-3D HYDRO) and 18% (OpenFOAM) from the physical experiments, indicating satisfactory performances. The maximum water particle velocity was approximately 1.9 m/s for both numerical models. When the simulated waveforms from the two numerical models are compared with each other, a deviation of 10% was achieved indicating that the two models perform approximately equally. Comparing the 3D snapshots of the two models showed that there are some minor differences in reproducing the details of the water splash in the near field.
  • Regarding computational costs, FLOW-3D HYDRO was able to complete the same simulations in 4 h as compared to nearly 20 h by OpenFOAM. However, the hardware that were used for modelling were not the same; the computer used for the OpenFOAM model was stronger than the one used for running FLOW-3D HYDRO. Therefore, it is challenging to provide a fair comparison for computational time costs.
  • Overall, we conclude that the two models give approximately similar performances, and they are both capable of accurately modelling landslide-generated waves. The choice of a model for research or industrial projects may depend on several factors such as availability of local knowledge of the models, computational costs, accessibility and flexibilities of the model, and the affordability of the cost of a license (either a commercial or an open-source model).

Reference


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Weir

Discharge Formula and Hydraulics of Rectangular Side Weirs in the Small Channel and Field Inlet

소규모 수로 및 유입구에서의 직사각형 측면 위어의 유량 공식 및 수리학

Yingying Wang, Mouchao Lv, Wen’e Wang, Ming Meng

Abstract


In this study, experimental investigations were conducted on rectangular side weirs with different widths and heights. Corresponding simulations were also performed to analyze hydraulic characteristics including the water surface profile, flow velocity, and pressure. The relationship between the discharge coefficient and the Froude number, as well as the ratios of the side weir height and width to upstream water depth, was determined. A discharge formula was derived based on a dimensional analysis. The results demonstrated good agreement between simulated and experimental data, indicating the reliability of numerical simulations using FLOW-3D software (version 11.1). Notably, significant fluctuations in water surface profiles near the side weir were observed compared to those along the center line or away from the side weir in the main channel, suggesting that the entrance effect of the side weir did not propagate towards the center line of the main channel. The proposed discharge formula exhibited relative errors within 10%, thereby satisfying the flow measurement requirements for small channels and field inlets.

1. Introduction


Sharp crested weirs are used to obtain discharge in open channels by solely measuring the water head upstream of the water. Side weirs, as a kind of sharp-crested weir, are extensively used for flow measurement, flow diversion, and flow regulation in open channels. Side weirs can be placed directly in the channel direction or field inlet, without changing the original structure of the channel. Thus, side weirs have certain advantages in the promotion and application of flow measurement facilities in small channels and field inlets. The rectangular sharp-crested weir is the most commonly available, and many scholars have conducted research on it.
Research on side weirs started in 1934. De Marchi studied the side weir in the rectangular channel and derived the theoretical formula based on the assumption that the specific energy of the main flow section of the rectangular channel in the side weir section was constant [1]. Ackers discussed the existing formulas for the prediction of the side weir discharge coefficient [2]. Chen concluded that the momentum theorem was more suitable for the analytical calculation of the side weir based on the experimental data [3]. Based on previous theoretical research, more and more scholars began to carry out experimental research on side weirs. Uyumaz and Muslu conducted experiments under subcritical and supercritical flow regimes and derived expressions for the side weir discharge and water surface profiles for these regimes by comparing them with experimental results [4]. Borghei et al. developed a discharge coefficient equation for rectangular side weirs in subcritical flow [5]. Ghodsian [6] and Durga and Pillai [7] developed a discharge coefficient equation of rectangular side weirs in supercritical flow. Mohamed proposed a new approach based on the video monitoring concept to measure the free surface of flow over rectangular side weirs [8]. Durga conducted experiments on rectangular side weirs of different lengths and sill heights and discussed the application of momentum and energy principles to the analysis of spatially varied flow under supercritical conditions. The results showed that the momentum principle was fitting better [7]. Omer et al. obtained sharp-crested rectangular side weirs discharge coefficients in the straight channel by using an artificial neural network model for a total of 843 experiments [9]. Emiroglu et al. studied water surface profile and surface velocity streamlines, and developed a discharge coefficient formula of the upstream Froude number, the ratios of weir length to channel width, weir length to flow depth, and weir height to flow depth [10]. Other investigators [11,12,13,14] have conducted experiments to study flow over rectangular side weirs in different flow conditions.
Numerous studies have been conducted in laboratories to this day. Compared to experimental methods, the numerical simulation method has many attractive advantages. We can easily obtain a wide range of hydraulic parameters of side weirs using numerical simulation methods, without investing a lot of manpower and resources. In addition, we can conduct small changes in inlet condition, outlet condition, and geometric parameters, and study their impact on the flow characteristics of side weirs. Therefore, with the development and improvement of computational fluid dynamics, the numerical simulation method has begun to be widely applied on side weirs. Salimi et al. studied the free surface changes and the velocity field along a side weir located on a circular channel in the supercritical regime by numerical simulation [15]. Samadi et al. conducted a three-dimensional simulation on rectangular sharp-crested weirs with side contraction and without side contraction and verified the accuracy of numerical simulation compared with the experimental results [16]. Aydin investigated the effect of the sill on rectangular side weir flow by using a three-dimensional computational fluid dynamics model [17]. Azimi et al. studied the discharge coefficient of rectangular side weirs on circular channels in a supercritical flow regime using numerical simulation and experiments [18]. The discharge coefficient over the two compound side weirs (Rectangular and Semi-Circle) was modeled by using the FLOW-3D software to describe the flow characteristics in subcritical flow conditions [19]. Safarzadeh and Noroozi compared the hydraulics and 3D flow features of the ordinary rectangular and trapezoidal plan view piano key weirs (PKWs) using two-phase RANS numerical simulations [20]. Tarek et al. investigated the discharge performance, flow characteristics, and energy dissipation over PK and TL weirs under free-flow conditions using the FLOW-3D software [21].
As evident from the aforementioned, the majority of studies have primarily focused on determining the discharge coefficient, while comparatively less attention has been devoted to investigating the hydraulic characteristics of rectangular side weirs. Numerical simulations were conducted on different types of side weirs, including compound side weirs and piano key weirs, in different cross-section channels under different flow regimes. It is imperative to derive the discharge formula and investigate other crucial flow parameters such as depth, velocity, and pressure near side weirs for their effective implementation in water measurement. In this study, a combination of experimental and numerical simulation methods was employed to examine the relationship between the discharge coefficient and its influencing factors; furthermore, a dimensionless analysis was utilized to derive the discharge formula. Additionally, water surface profiles near side weirs and pressure distribution at the bottom of the side channel were analyzed to assess safety operation issues associated with installing side weirs.

2. Principle of Flow Measurement


Flow discharge over side weirs is a function of different dominant physical and geometrical quantities, which is defined as

where Q is flow discharge over the side weir, b is the side weir width, B is the channel width, P is the side weir height, v is the mean velocity, h1 is water depth upstream the side weir in the main channel, g is the gravitational acceleration, μ is the dynamic viscosity of fluid, ρ is fluid density, and i is the channel slope (Figure 1).

Figure 1. Definition sketch of parameters of rectangular side weir under subcritical flow. Note: h1 and h2 represent water depth upstream and downstream of the side weir in the main channel, respectively; y1 and y2 represent weir head upstream and downstream of the side weir in the main channel, respectively.

In experiments when the upstream weir head was over 30 mm, the effects of surface tension on discharge were found to be minor [22]. The viscosity effect was far less than the gravity effect in a turbulent flow. Hence μ and σ were excluded from the analysis [23,24]. In addition, the channel width, the channel slope, and the fluid density were all constant, so the discharge formula can be simplified as:

According to the Buckingham π theorem, the following relationship among the dimensionless parameters is established:

Selected h1 and g as basic fundamental quantities, and the remaining physical quantities were represented in terms of these fundamental quantities as follows:

In which

Based on dimensional analysis, the following equations were derived.

Namely

So the discharge formula can be simplified as:

In a sharp-crested weir, discharge over the weir is proportional to 𝐻1.51H11.5 (H1 is the upstream total head above the crest, namely H1 = y1 + v2/2 g), so Equation (6) can be transformed as follows:

Consequently, the discharge formula over rectangular side weirs is defined as follows, in which 𝑚=𝑓(𝑏ℎ1m=f(bh1,𝑃ℎ1,𝐹𝑟1)Ph1,Fr1). Parameter m represents the dimensionless discharge coefficient. Parameter Fr1 represents the Froude number at the upstream end of the side weir in the main channel.

3. Experiment Setup


The experimental setup contained a storage reservoir, a pumping station, an electromagnetic flow meter, a control valve, a stabilization pond, rectangular channels, a side weir, and a sluice gate. The layout of the experimental setup is shown in Figure 2. Water was supplied from the storage reservoir using a pump. The flow discharge was measured with an electromagnetic flow meter with precision of ±3‰. Water depth was measured with a point gauge with an accuracy of ±0.1 mm. The flow velocity was measured with a 3D Acoustic Doppler Velocimeter (Nortek Vectrino, manufactured by Nortek AS in Rud, Norway). In order to eliminate accidental and human error, multiple measurements of the water depth and flow velocity at the same point were performed and the average values were used as the actual water depth and flow velocity of the point. The main and side channels were both rectangular open channels measuring 47 cm in width and 60 cm in height. The geometrical parameters of rectangular side weirs are shown in Table 1.

Figure 2. Layout of the test system.
Table 1. The geometrical parameters of rectangular side weirs.

When water passes through a side weir, its quality point is affected not only by gravity but also by centrifugal inertia force, leading to an inclined water surface within that particular cross-section before reaching the weir. In order to examine water profiles adjacent to side weirs, cross-sectional measurements were conducted at regular intervals of 12 cm both upstream and downstream of each side weir, denoted as sections ① to ⑩, respectively. Measuring points were positioned near the side weir (referred to as “Side I”), along the center line of the main channel (referred to as “Side II”), and far away from the side weir (referred to as “Side III”) for each cross-section. The schematic diagram illustrating these measuring points is presented in Figure 3.

Figure 3. Schematic diagram of measurement points.

4. Numerical Simulation Settings

4.1. Mathematical Model

4.1.1. Governing Equations

Establishing the controlling equations is a prerequisite for solving any problem. For the flow analysis problem of water flowing over a side weir in a rectangular channel, assuming that no heat exchange occurs, the continuity equation (Equation (9)) and momentum equation (Equation (10)) can be used as the controlling equations as follows:

The continuity equation:

Momentum equation:

where: ρ is the fluid density, kg/m3t is time, s; uiuj are average flow velocities, u1u2u3 represent average flow velocity components in Cartesian coordinates x, y, and z, respectively, m/s; μ is dynamic viscosity of fluid, N·s/m2p is the pressure, pa; Si is the body force, S1 = 0, S2 = 0, S3 = −ρg, N [24].

4.1.2. RNG k-ε Model

The water flow in the main channel is subcritical flow. When the water flows through the side weir, the flow line deviates sharply, the cross section suddenly decreases, and due to the blocking effect of the side weir, the water reflects and diffracts, resulting in strong changes in the water surface and obvious three-dimensional characteristics of the water flow [25]. Therefore the RNG kε model is selected. The model can better handle flows with greater streamline curvature, and its corresponding k and ε equation is, respectively, as follows:

where: k is the turbulent kinetic energy, m2/s2μeff is the effective hydrodynamic viscous coefficient; Gk is the generation item of turbulent kinetic energy k due to gradient of the average flow velocity; C∗1εC1ε*, C are empirical constants of 1.42 and 1.68, respectively; ε is turbulence dissipation rate, kg·m2/s2.

4.1.3. TruVOF Model

Because the shape of the free surface is very complex and the overall position is constantly changing, the fluid flow phenomenon with a free surface is a typical flow phenomenon that is difficult to simulate. The current methods used to simulate free surfaces mainly include elevation function method, the MAC method [26] and the VOF (Volume of Fluid) method [27]. The VOF method is a method proposed by Hirt and Nichols to deal with the complex motion of the free surface of a fluid, which can describe all the complexities of the free surface with only one function. The basic idea of the method is to define functions αw and αa, which represent the volume percentage of the calculation area occupied by water and air, respectively. In each unit cell, the sum of the volume fractions of water and air is equal to 1, i.e.,

The TruVOF calculation method can accurately track the change of free liquid level and accurately simulate the flow problems with free interface. Its equation is:

where: u_¯m is the average velocity of the mixture; t is the time; F is the volume fraction of the required fluid.

4.2. Parameter Setting and Boundary Conditions

To streamline the iterative calculation and minimize simulation time, we selected a main channel measuring 7.5 m in length and a side channel measuring 2.5 m in length for simulation. Three-dimensional geometrical models were developed using the software AutoCAD (version 2016-Simplified Chinese). The spatial domain was meshed using a constructed rectangular hexahedral mesh and each cell size was 2 cm. A volume flow rate was set in the channel inlet with an auto-adjusted fluid height. An outflow–outlet condition was positioned at the end of the side channel. A symmetry boundary condition was set in the air inlet at the top of the model, which represented that no fluid flows through the boundary. The lower Z (Zmin) and both of the side boundaries were treated as a rigid wall (W). No-slip conditions were applied at the wall boundaries. Figure 4 illustrates these boundary conditions.

Figure 4. Diagram of boundary conditions.

5. Results

5.1. Water Surface Profiles

Water surface profiles were crucial parameters for selecting water-measuring devices. Upon analyzing the consistent patterns observed in different conditions, one specific condition was chosen for further analysis. To validate the reliability of numerical simulation, measured and simulated water depths of rectangular side weirs with different widths and heights at a discharge rate of 25 L/s were extracted for comparison (Table 2 and Figure 5). The results in Table 2 and Figure 5 indicate a maximum absolute relative error value of 9.97% and all absolute relative error values within 10%, demonstrating satisfactory agreement between experimental and simulated results.

Figure 5. Comparison between measured and simulated flow depth.
P/cmSection Positionb = 20 cmb = 30 cmb = 40 cmb = 47 cm
hm/cmhs/cmR/%hm/cmhs/cmR/%hm/cmhs/cmR/%hm/cmhs/cmR/%
721.4919.49.7317.7416.94.7416.0714.519.7113.7912.509.35
④′20.4819.056.9817.7816.149.2215.6914.318.80
20.7119.028.1617.8216.318.4715.9214.538.7315.2313.809.39
⑧′22.0020.228.0918.2716.748.3716.5914.969.83
22.3720.179.8317.7316.805.2516.2715.087.3115.3614.366.51
1024.1522.66.4219.9618.845.6119.0318.582.3616.8315.855.82
④′24.2122.058.9219.4918.196.6718.7518.352.13
24.0121.789.2919.6518.346.6718.9518.631.6917.5216.098.16
⑧′24.8822.49.9720.6519.216.9720.1219.294.13
24.0322.964.4521.1619.348.6019.7119.431.4218.3917.365.60
1528.8527.564.4725.8624.096.8424.0521.898.9822.7320.808.49
④′28.4926.975.3425.1923.845.3623.4221.468.37
28.8526.986.4825.7223.996.7323.2321.826.0723.1021.058.87
⑧′28.9627.305.7326.3824.198.3024.1822.277.90
29.1827.964.1826.5724.547.6424.5722.339.1223.2021.109.05
2033.2932.342.8530.6329.025.2628.4926.875.6926.9925.814.37
④′33.1431.953.5929.7528.623.8028.1126.794.70
33.3231.794.5930.0428.455.2928.9926.867.3527.4226.722.55
⑧′34.0232.394.7930.6928.955.6729.5927.257.91
34.6232.845.1431.4429.296.8429.5127.317.4628.2127.004.29
Table 2. Comparison of measured and simulated water depths on Side I of each side weir at a discharge of 25 L/s

Due to the diversion caused by the side weir, there was a rapid variation in flow near the side weir in the main channel. In order to investigate the impact of the side weir on water flow in the main channel, water surface profiles on Side I, Side II, and Side III were plotted with a side weir width and height both set at 20 cm at a discharge rate of 25 L/s (Figure 6). As depicted in Figure 6, within a certain range of the upstream end of the main channel, water depths on Side I, Side II, and Side III were nearly equal with almost horizontal profiles. As the distance between the location of water flow and the upstream end of the weir crest decreased gradually, there was a gradual decrease in water depth on Side I along with an inclined trend in its corresponding profile; however, both Side II and Side III still maintained almost horizontal profiles. When approaching closer to the side weir area with flowing water, there was an evident reduction in water depth on Side I accompanied by a significant downward trend visible across an expanded decline range. The minimum point occurred near the upstream end of the weir crest before gradually increasing again towards downstream sections. At the crest section of the side weir, there is an upward trend observed in the water surface. The water surface tended to stabilize downstream of the main channel within a certain range from the downstream end of the weir crest. There was no significant change in the water surface profiles of Side Ⅱ and Side Ⅲ in the crest section. It can be inferred that the side weir entrance effect occurred only between Side Ⅰ and Side Ⅱ. M. Emin reported the same pattern [10].

Figure 6. Water surface profiles on Side I, Side II, and Side III with a side weir width of 20 cm and height of 15 cm at a discharge of 25 L/s.

For a more accurate study on the entrance effect of the side weir on the Water Surface Profile (WSP) for Side I; a comparative analysis conducted using different widths but the same height (15 cm) at a discharge rate of 25 L/s is presented through Figure 7, Figure 8, Figure 9 and Figure 10.

Figure 7. Water surface profile on Side Ⅰ with a side weir width of 20 cm and height of 15 cm at a discharge of 25 L/s.
Figure 8. Water surface profile on Side Ⅰ with a side weir width of 30 cm and height of 15 cm at a discharge of 25 L/s.
Figure 9. Water surface profile on Side Ⅰ with a side weir width of 40 cm and height of 15 cm at a discharge of 25 L/s.
Figure 10. Water surface profile on Side Ⅰ with a side weir width of 47 cm and height of 15 cm at a discharge of 25 L/s.

According to Figure 7, Figure 8, Figure 9 and Figure 10, the water depth upstream of the main channel started to decrease as it approached the upstream end of the weir crest and then gradually increased at the weir crest section. In other words, the water surface profile exhibited a backwater curve along the length of the weir crest. The water depth remained relatively stable downstream of the main channel within a certain range from the downstream end of the weir crest. Additionally, there was a higher water depth downstream of the main channel compared to that upstream of the main channel. Furthermore, an increase in the width of the side weir led to a gradual reduction in fluctuations on its water surface.

5.2. Velocity Distribution

The law of flow velocity distribution near the side weir is the focus of research and analysis, so the simulated and measured values of flow velocity near the side weir were compared and analyzed. Take the discharge of 25 L/s, the height of 15 cm, and the width of 30 cm of the side weir as an example to illustrate. Figure 11 shows the measured and simulated velocity distribution in the x-direction of cross-section ④. As can be seen from Figure 11, the diagrams of the measured and simulated velocity distribution were relatively consistent, and the maximum absolute relative error between the measured and simulated values at the same measurement point was 9.37%, and the average absolute relative error was 3.97%, which indicated a satisfactory agreement between the experimental and simulated results.

Figure 11. Velocity distribution in the x-direction of section ④: when the discharge is 25 L/s, the height of the side weir is 15 cm and the width of the side weir is 30 cm. (a) Measured velocity distribution; (b) Simulated velocity distribution.

From Figure 11, it can be seen that the flow velocity gradually increased from the bottom of the channel towards the water surface in the Z-direction, and the flow velocity gradually increased from Side Ⅲ to Side Ⅰ in the Y-direction. The maximum flow velocity occurred near the weir crest.

Figure 12 shows the distribution of flow velocity at different depths (z/P = 0.3, z/P = 0.8, z/P = 1.6) with a side weir width of 30 cm and height of 15 cm at a discharge of 25 L/s. The water flow line began to bend at a certain point upstream of the main channel, and the closer it was to the upstream end of the weir crest, the greater the curvature. The maximum curvature occurred at the downstream end of the weir crest. The flow patterns at the bottom, near the side weir crest, and above the side weir crest were significantly different. There was a reverse flow at the bottom of the main channel, where the forward and reverse flows intersect, resulting in a detention zone. The maximum flow velocity at the bottom layer occurred at the upstream end of the side weir crest. When the location of water flow approached the weir crest, the maximum flow velocity occurred at the upstream end of the weir crest. The maximum flow velocity on the water surface occurred at the downstream end of the weir crest. As the water depth decreased, the position of the maximum flow velocity gradually moved from the upstream end of the side weir to the downstream end of the side weir.

Figure 12. Distribution of flow velocity at different depths with a side weir width of 30 cm and height of 15 cm at a discharge of 25 L/s. (a) z/P = 0.3; (b) z/P = 0.8; (c) z/P = 1.6.

5.3. Side Channel Pressure Distribution

When water flowed through the side weir, an upstream water level was formed, resulting in a pressure zone at the junction with the side channel. This pressure zone led to increased water pressure on the floor of the side channel, which affected its stability and durability. In small channels or fields where erosion resistance is weak, excessive pressure can cause scour holes. Therefore, analyzing the pressure distribution in the side channel is necessary to select an appropriate height and width for the side weir that effectively reduces its impact on the bottom plate.

To investigate the impact of side weir width on hydraulic characteristics, pressure data was collected at a discharge rate of 25 L/s for side weirs with heights of 20 cm and widths ranging from 20 cm to 47 cm. The pressure distribution map was drawn, as shown in Figure 13.

Figure 13. Comparison of pressure distribution on the bottom plate of the side channel with different widths of side weirs when the discharge is 25 L/s and the height of side weirs is 20 cm. (aP = 20 cm, b = 20 cm; (bP = 20 cm, b = 30 cm; (cP = 20 cm, b = 40 cm; (dP = 20 cm, b = 47 cm.

As can be seen from Figure 13, the pressure at the bottom of the side channel decreased as the width of the side weir increased. This uneven distribution of water flow on the weir was caused by the sharp bending of water flow lines and the influence of centrifugal inertia force over a short period. After passing through the side weir, the water flow became symmetrically distributed with respect to the axis of the side channel, leaning towards the right bank at a certain distance. As we increased the width of the side weir, we noticed that its position gradually approached the side weir and maximum pressure decreased at this location where the water tongue formed due to flowing through it (Figure 13). For a constant height (20 cm) but varying widths (20 cm, 30 cm, 40 cm, and 47 cm), we measured maximum pressures at these positions as follows: 103,713 Pa, 103,558 Pa, 103,324 Pa, and 103,280 Pa, respectively. Consequently, increasing width reduced the impact on the side channel from water flowing through it while changing pressure distribution from concentration to dispersion in a vertical direction. In the practical application of side weirs, appropriate height should be selected based on the bottom plate’s capacity to withstand the pressure exerted by flowing water within channels.

To investigate how height affects the hydraulic characteristics of rectangular side weirs further (Figure 14), we extracted pressures on bottom plates when discharge was fixed at 25 L/s while varying heights were set as follows: 7 cm, 10 cm, 15 cm, and 20 cm, respectively.

Figure 14. Comparison of pressure distribution on the bottom plate of the side channel with different heights of side weirs when discharge is 25 L/s and the width of side weirs is 20 cm. (aP = 7 cm, b = 20 cm; (bP = 10 cm, b = 20 cm; (cP = 15 cm, b = 20 cm; (dP = 20 cm, b = 20 cm.

As shown in Figure 14, when the width of the side weir was constant, the pressure at the bottom of the side channel increased with the height of the side weir. As the height of the side weir increased, the water tongue formed by flow through the side weir gradually moved away from it in a downstream direction. In terms of vertical water flow, as the height of the side weir increased, the position of maximum pressure at which the water tongue falls shifted closer to the axis of the side channel from its right bank. Moreover, an increase in height resulted in higher maximum pressure at this falling point. For a constant width (20 cm) and varying heights (7 cm, 10 cm, 15 cm, and 20 cm), corresponding maximum pressures at this landing point were measured as 102,422 Pa, 102,700 Pa, 103,375 Pa, and 103,766 Pa, respectively. Consequently, increasing width led to a greater impact on both flow through and pressure distribution within the side channel; transforming it from scattered to concentrated along its lengthwise direction. Therefore, when applying such weirs practically one should select an appropriate width based on what pressure can be sustained by their respective channel bottom plates.

5.4. Discharge Coefficient

Based on dimensionless analysis, the influencing parameters of the discharge coefficient were obtained. To study the effect of parameters Fr1b/h1, and P/h1, discharge coefficient values were plotted against Fr1b/h1, and P/h1, shown in Figure 15, Figure 16 and Figure 17. The discharge coefficient decreased as parameters Fr1 and b/h1 increased. The discharge coefficient increased as parameter P/h1 increased. As Uyumaz and Muslu reported in a previous study, the variation of the discharge coefficient with respect to the Froude number showed a second-degree curve for a subcritical regime [4].

Figure 15. Variation of discharge coefficient values against Froude number.
Figure 16. Variation of discharge coefficient values against the percentage of the side weir width to the upstream flow depth over the side weir.
Figure 17. Variation of discharge coefficient values against the percentage of the side weir height to the upstream flow depth over the side weir.

Quantitative analysis between discharge coefficient values and parameters Fr1b/h1, and P/h1 was conducted using data analysis software (IBM SPSS Statistics 19). The various coefficients obtained are shown in Table 3.

ModelUnstandardized CoefficientsStandardized CoefficientstSig
BStd. ErrorBeta (β)
Constant−1.2940.155−8.3690.000
Fr13.4300.2863.40112.0130.000
b/h1−0.0040.004−0.045−0.9440.348
P/h12.4010.1674.06414.3940.000
Table 3. Coefficient.

The value of t and Sig are the significance results of the independent variable, and the value of Sig corresponding to the value of t is less than 0.05, indicating that the independent variable has a significant impact on the dependent variable. Therefore, the values of Sig corresponding to the parameters Fr1 and P/h1 were less than 0.05, indicating that the parameters Fr1 and P/h1 have a significant impact on the discharge coefficient. On the contrary, the parameter b/h1 has less impact on the discharge coefficient. Therefore, quantitative analysis between discharge coefficient values and parameters Fr1, and P/h1 was conducted using data analysis software by removing factor b/h1. The model summary, ANOVA, and coefficient obtained are shown respectively in Table 4, Table 5 and Table 6. R and adjusted R square in Table 4 were approaching 1, which indicated the goodness of fit of the regression model was high. The value of Sig corresponding to the value of F in Table 5 was less than 0.05, which indicated that the regression equation was useful. The values of Sig corresponding to the parameters Fr1 and P/h1 in Table 6 were less than 0.05, indicating that the parameters Fr1 and P/h1 have a significant impact on the discharge coefficient.

ModelRR SquareAdjusted R SquareStd. Error of the Estimate
10.913 a0.8330.8290.03232
Table 4. Model Summary b. Note: a. Predictors:(Constant), Fr1P/h1b. Discharge coefficient.
ModelSum of SquaresdfMean SquareFSig
1Regression0.40220.201192.5450.000 a
Residual0.080770.001
Total0.48379
Table 5. ANOVA b. Note: a. Predictors:(Constant), Fr1P/h1b. Discharge coefficient.
ModelUnstandardized CoefficientsStandardized CoefficientstSig
BStd. ErrorBeta (β)
Constant−1.3260.151−8.7960.000
Fr13.4790.2813.44912.3960.000
P/h12.4270.1644.10814.7650.000
Table 6. Coefficient a. Note: a. Predictors:(Constant), Fr1P/h1.

Based on the above analysis, the flow coefficient formula has been obtained, shown as follows:

Discharge formula were obtained by substituting Equation (15) into Equation (12), as shown in Equation (16).

where Q ∈ [0.006, 0.030], m3/s; b ∈ [0.20, 0.47], m; P ∈ [0.07, 0.20], m.

Figure 18 showed the measured discharge coefficient values with those calculated from discharge formulas in Table 3. The scatter of the data with respect to perfect line was limited to ±10%.

Figure 18. Comparison of the measured discharge coefficient values with those calculated from discharge formulas in Table 3.

6. Discussions

Determining water surface profile near the side weir in the main channel is one of the tasks of hydraulic calculation for side weirs. As the water flows through the side weir, discharge in the main channel is gradually decreasing, namely dQ/ds<0. According to the Equation (17) derived from Qimo Chen [3], it can be inferred that the value of 𝑑ℎ/𝑑𝑠 is greater than zero in subcritical flow (Fr < 1), that is, the water surface profile near the side weir in the main channel is a backwater curve. Due to the side weir entrance effect at the upstream end, water surface profiles drop slightly at the upstream end of the side weir crest, as EI-Khashab [28] and Emiroglu et al. [29] reported in previous experimental studies.

In this study, the water surface profile exhibited a backwater curve along the length of the weir crest. Therefore, during side weir application, it is crucial to ensure that downstream water levels do not exceed the highest water level of the channel.

The head on the weir is one of the important factors that flow over side weirs depends on. At the same time, the head depends on the water surface profile near the side weir in the main channel. Therefore, further research on the quantitative analysis of water surface profile needs to be conducted. Mohamed Khorchani proposed a new approach based on the video monitoring concept to measure the free surface of flow over side weirs. It points out a new direction for future research [8].

The maximum flow velocity, a key parameter in assessing the efficiency of a weir, occurs at the upstream end of the weir crest, typically near the crest. This is attributed to the convergence of the flow as it approaches the crest, resulting in a significant increase in velocity. It was found that in this study the minimum flow velocity occurred at the bottom of the main channel away from the side weir. Under such conditions, the accumulation of sediments could lead to siltation, which in turn can affect the accuracy of flow measurement through side weirs. This is because the presence of sediments can alter the flow patterns and cause errors in the measurement. Therefore, it becomes crucial to explore methods to optimize the selection of side weirs in order to minimize or eliminate the effects of sedimentation on flow measurement.

Pressure distribution plays a crucial role in ensuring structural safety for side weirs since small channels and field inlets have relatively limited pressure-bearing capacities. Therefore, it is important to select an appropriate geometrical parameter of rectangular side weirs based on their ability to withstand the pressure exerted on their bottom combined with pressure distribution data at the bottom of the side channel we have obtained in this study.

The discharge coefficient formula (Equation (15)), which incorporates Fr1 and P/h1, was derived based on dimensional analysis. However, it is worth noting that previous research has contradicted this formula by suggesting that the discharge coefficient solely depends on the Froude number. This conclusion can be observed in this study such as in Equations (18)–(23) in Table 7 of the manuscript [30,31,32,33,34,35], which clearly demonstrate the dependency of the discharge coefficient on the Froude number. In contrast, our derived discharge coefficient formula (Equation (15)) offers a more streamlined and simplified approach compared to Equation (25) [36] and Equation (29) [10]—making it easier to comprehend and apply—an advantageous feature particularly valuable in fluid dynamics where intricate calculations can be time-consuming. Furthermore, our derived discharge coefficient formula (Equation (15)) exhibits a broader application scope than that of Equation (24) [37] as shown in Table 8. Equation (26) [38] and Equation (27) [5] are specifically applicable under high flow discharge conditions. Conversely, our derived discharge coefficient formula (Equation (15)) is better suited for low-flow discharge conditions.

Table 7. Discharge coefficient formulas of rectangular side weirs presented in previous studies.
Discharge/(L·s−1)Width of Side Weir/cmHeight of Side Weir/cmNumber of Formula
10~1410~206~12(24)
35–10020~751~19(26), (27)
6~3020~477~20(15)
Table 8. Application scope of discharge coefficient formulas.

In addition to the factors studied in the paper, factors such as the sediment content in the flow, the bottom slope, and the cross-section shape of the channel also have a certain impact on the hydraulic characteristics of the side weir. Further numerical simulation methods can be used to study the hydraulic characteristics and the influencing factors of the side weir. Water measurement facilities generally require high accuracy of water measurement, the flow of sharp-crested side weirs is complex, and the water surface fluctuates greatly. While conducting numerical simulations, experimental research on prototype channels is necessary to ensure the reliability of the results and provide reference for the body design and optimization of side weirs in small channels and field inlets.

7. Conclusions

This paper presents a comprehensive study that encompasses both experimental and numerical simulation research on rectangular side weirs of varying heights and widths within rectangular channels. A thorough analysis of the experimental and numerical simulation results has been conducted, leading to the derivation of several notable conclusions:

  1. A comparative analysis was conducted on the measured and simulated values of water depth and flow velocity. Both of the maximum absolute relative errors were within 10%, which indicated that the numerical simulation of the side weir was feasible and effective.
  2. The water surface profile exhibited a backwater curve along the length of the weir crest. The side weir entrance effect occurred only between Side Ⅰ and Side Ⅱ. This indicates that flow patterns and associated hydraulic forces at the weir entrance play a crucial role in determining water level distribution along the weir crest.
  3. The maximum flow velocity of the cross-section at the upstream end of the weir crest occurred near the weir crest, while the minimum flow velocity occurred at the bottom of the main channel away from the side weir. As the water depth decreased, the position of the maximum flow velocity gradually moved from the upstream end of the side weir to the downstream end of the side weir.
  4. When the height of the side weir remains constant, an increase in the width of the side weir leads to a decrease in pressure at the bottom of the side channel. Conversely, when the width of the side weir is kept constant, an increase in its height results in an increase in pressure at the bottom of the side channel. Therefore, during practical applications involving side weirs, it is crucial to select an appropriate weir width based on the maximum pressure that can be sustained by the channel’s bottom plate.
  5. The discharge coefficient was found to depend on the upstream Froude number Fr1 and the percentage of the side weir height to the upstream flow depth over the side weir P/h1. The relationship between the discharge coefficient and parameters Fr1 and P/h1 was obtained using multiple regression analysis, which was of linear form and provided an easy means to estimate the discharge coefficient. The discharge formula is of high accuracy with relative errors within 10%, which met the water measurement accuracy requirements of small channels in irrigation areas.

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Propagation Velocity of Excitation Waves Caused by Turbidity Currents

혼탁류에 의한 자극파의 전파 속도

Guohui Xu, Shiqing Sun, Yupeng Ren, Meng Li, Zhiyuan Chen

Abstract


Turbidity currents are important carriers for transporting terrestrial sediment into the deep sea, facilitating the transfer of matter and energy between land and the deep sea. Previous studies have suggested that turbidity currents can exhibit high velocities during their movement in submarine canyons. However, the maximum vertical descent velocity of high-concentration turbid water simulating turbidity currents does not exceed 1 m/s, which does not support the understanding that turbidity currents can reach speeds of over twenty meters per second in submarine canyons. During their movement, turbidity currents can compress and push the water ahead, generating propagating waves. These waves, known as excitation waves, exert a force on the seafloor, resuspending bottom sediments and potentially leading to the generation of secondary turbidity currents downstream. Therefore, the propagation distance of excitation waves is not the same as the initial journey of the turbidity currents, and the velocity of excitation waves within this journey has been mistakenly regarded as the velocity of the turbidity currents. Research on the propagation velocity of excitation waves is of great significance for understanding the sediment supply patterns of turbidity currents and the transport patterns of deep-sea sediments. In this study, numerical simulations were conducted to investigate the velocity of excitation waves induced by turbidity currents and to explore the factors that can affect their propagation velocity and amplitude. The relationship between the velocity and amplitude of excitation waves and different influencing factors was determined. The results indicate that the propagation velocity of excitation waves induced by turbidity currents is primarily determined by the water depth, and an expression (v2 = 0.63gh) for the propagation velocity of excitation waves is provided.

Keywords


turbidity current; excitation wave; propagation speed; flume test; FLOW-3D

1. Introduction


Submarine turbidity currents, often referred to as underwater rivers, are important carriers that transport terrestrial sediments to the deep sea [1,2,3,4,5,6,7]. These turbidity currents, carrying a large amount of silt and sand, not only have strong erosive capabilities on the seabed [8,9,10], but also pose a threat to underwater communication cables, resulting in significant economic losses [11,12,13]. For example, the 2006 Pingdong earthquake in Taiwan caused the rupture of 11 submarine cables within the Kaoping Canyon, resulting in a slowdown in network speed in Southeast Asia for 49 days and requiring the deployment of 11 cable ships for repairs [13,14,15]. Investigating the velocity and patterns of turbidity currents in submarine canyons is of great significance for the protection of infrastructure such as pipelines and cables in these canyons.
One of the main methods for quantitatively studying the velocity of turbidity currents in submarine canyons is to infer their speed through cable ruptures. The first confirmed occurrence of cable rupture caused by a turbidity current was in 1929, when the Grand Banks earthquake triggered the continuous rupture of 12 submarine cables. Inferred maximum turbidity current velocities reached 28 m/s [16,17,18]. Subsequently, multiple cable rupture incidents caused by turbidity currents have occurred worldwide. Table 1 summarizes the inferred maximum turbidity current velocities from these cable rupture incidents.

EventMaximum Turbidity VelocityReferences
18 November 1929 Grand Banks earthquake28 m/s[16,19,20,21]
1953 Suva earthquake in the Fiji Islands5.1 m/s[22]
The Orleansville earthquake of 9 September 1954, Algeria20.6 m/s[23]
Earthquake, Solomon Islands, Western Pacific, 23 December 196610.3 m/s[24]
Incident at Nice airport, France, 16 October 19797 m/s[25]
Taitung earthquake, 22 August 20029.8 m/s[26]
21 May 2003 earthquake in Algeria15.8 m/s[27]
The Taitung earthquake of 10 December 200316.5 m/s[26]
The Taitung earthquake of 18 December 200318.6 m/s[26]
Pingtung earthquake on 26 December 200620 m/s[28]
Typhoon Morakot on 7–9 August 200916.6 m/s[29]
The 15 January 2022 eruption of Hunga volcano33.9 m/s[30]
Table 1. Cable breakage events caused by turbidity currents worldwide.

Previous studies have shown that the maximum vertical velocity of high-concentration turbidity currents in water does not exceed 1 m/s, and the maximum downward velocity of spherical particles in water does not exceed 10 m/s [31]. The maximum velocity of professional athlete Usain Bolt in the 100 m sprint on land is 9.58 m/s, while dolphins in the ocean can reach speeds of up to 20 m/s. Deep-sea turbidity currents, characterized by a small density difference compared to water, are primarily driven by the gravitational component along the direction of flow. However, factors such as bed friction also need to be considered. The driving force behind turbidity currents is primarily the density difference between the turbulent flow and the surrounding water, as well as the gravitational downslope component. Previous studies have detected a maximum sediment concentration of 12% in the basal layer of turbidity currents [32]. However, even high concentrations of suspended sediment, such as 1720 g/L, in seawater with a density of 1020 g/L, do not exceed a maximum vertical velocity of 1 m/s [33]. Similarly, spherical particles also have a maximum settling velocity in water of less than 10 m/s [33]. Turbidity currents, being density-driven flows, have relatively low density differences compared to water, and the gentle slope of submarine canyons also contributes to a smaller gravitational downslope force. Additionally, the influence of bed friction and other factors related to sediment deposition needs to be considered. It is incredible to think that turbidity currents can achieve flow velocities as high as 28 m/s [16,18,28,34,35].
When submarine landslides occur on continental slopes, the sliding mass entering the bottom of submarine canyons can cause the destruction of soft sediment beds. The mixing of sliding or flowing sediment with water forms turbidity currents. Turbidity currents exert pressure and propel the water ahead, forming an excitation wave. This aligns with Paull’s hypothesis that in the course of turbidity currents, a high-pressure zone is formed ahead, capable of causing an increase in pore water pressure in the sediment ahead [36]. Similar to surging waves, the excitation waves generated can propagate downstream along the submarine canyon, with a propagation velocity much greater than the velocity of turbidity currents [31]. The rapid propagation of excitation waves can exert a force on the seafloor of the submarine canyon, causing the resuspension of sediment in front of the head of the turbidity currents, which may lead to the formation of secondary turbidity currents at some downstream locations. The distance between the secondary and initial turbidity currents is actually the propagation distance of the excitation waves, rather than the journey of the initial turbidity currents. Therefore, the speed of the excitation waves within this distance is mistakenly considered as the velocity of the turbidity currents (see Figure 1). This may explain why the velocity of the turbidity currents as deduced from cable breakages is so high.

Figure 1. Diagram of excitation wave propagation due to turbidity current (v1 is the velocity of turbidity current. This refers to the ratio of distance to time experienced by a turbidity current mass moving underwater. v2 is the velocity of secondary turbidity current: the rapidly propagating excitation wave applies a force on the submarine canyon floor, leading to the destruction of the soft sediment floor and the secondary turbidity current. v is the propagation velocity of the excitation wave; this refers to the propagation velocity of the turbidity current excitation wave. This speed is not the velocity of the motion of the water mass. At time t0, the initial turbidity current moves underwater, pushing the stationary water in front to generate an excitation wave. At time t1, the excitation wave is propagating. At time t2, the rapidly propagating excitation wave exerts pressure on the soft bottom bed, resulting in the destruction of the bottom bed and secondary turbidity current).

Turbidity currents are mass movements composed of sediment particles, with a high concentration of the dense basal layer near the seabed. Depending on their density and granulometric composition, turbidity currents can move along submarine canyons through mechanisms such as diffusion, collapse, and flow [37], which differ from the downward movement as a single entity of landslide bodies after slope failure (this distinguishes them from surges). Additionally, during the long-distance movement of turbidity currents in canyons, the completion of subsequent water replenishment may generate multiple excitation waves. Furthermore, secondary excitation waves may also occur during the movement of secondary turbidity currents triggered by the initial turbidity current, which differs significantly from the surges caused by submarine landslides. Furthermore, previous studies [38,39,40,41] on sediment supply during turbidity current movements have mostly focused on the scouring action on the seabed, whereas the resuspension of sedimentary deposits in front of the initial turbidity current caused by excitation waves may serve as an effective mode of sediment supply during the long-distance transport of turbidity currents.
In 2023, Ren et al. proposed that the cause of the long-distance high-speed motion of turbidity currents is due to the excitation waves caused by the primary turbidity currents. However, only preliminary research has been conducted on the comparison of excitation wave velocity and solitary wave velocity, and there has been no specific discussion on the reasons for the excitation wave velocity being much greater than that of the turbidity current. In an experiment conducted using an indoor flume, it was observed that the wavelength of the excitation waves was much larger than the water depth, similar to shallow water waves [33]. The amplitude of excitation waves in proportion to their wavelength was small, consistent with the theory of small-amplitude waves. Similar to the velocity model of shallow water waves, it is expected that the propagation speed of excitation waves is also influenced by the water depth. However, since excitation waves are triggered by sediment-laden turbidity currents, the velocity model may differ from that of surface waves induced by gravitational flows.
The purpose of this study is to simulate and investigate the effects of different factors on the propagation velocity and amplitude of excitation waves through a validated numerical model based on laboratory experiments. The study aims to determine the maximum propagation velocity of excitation waves at a field scale and whether there is attenuation in the long-distance propagation after their formation. In recent studies, seafloor sediment flows have been collectively referred to as turbidity currents [42]. Therefore, we simulated the movement of turbidity currents by sediment flow.
This study uses the CFD-based fluid computation software FLOW-3D to simulate the underwater movement process of turbidity currents. The numerical model is validated against indoor experimental results. During the simulation process, a velocity model for surging wave generation triggered by submarine landslides is used as a reference, and multiple factors that may affect the propagation velocity of the excitation wave are considered. By controlling a single variable, the main factors influencing the excitation wave propagation velocity are determined, and the corresponding expression for excitation wave propagation velocity is provided. The results indicate that the propagation velocity of the excitation wave induced by turbidity currents is primarily determined by the water depth. This research provides a new perspective for understanding the high-speed movement of turbidity currents in submarine canyons and enriches the understanding of the movement patterns of turbidity currents in submarine canyons. In addition, studying the propagation speed of excitation waves is highly significant for the resuspension of underwater sediments, as well as the re-circulation of carbon sequestration, nutrients, heavy metals, and microplastics.

2. Experimental Study on Excitation Waves Induced by Turbidity Currents

2.1. Experimental Design and Apparatus

The experimental apparatus used for the turbidity current-induced excitation wave tests is a straight water tank [33]. The water tank is 12.5 m long, 0.5 m wide, and 0.7 m high. A turbidity source area is located on the right side of the tank to generate turbidity currents. The tank is equipped with a terrain with a certain slope.
Turbidity currents are generated underwater using a weir. The mass ratio of silt and clay used in the experimental turbid water solution was 8:2, with a density of 1600 kg/m3. Previous experiments have shown that this turbid mixture can reach a maximum flow velocity of 18.7 cm/s [31]. Three pressure sensors are placed along the straight section of the tank at intervals of 0.4 m. These sensors continuously monitor the bottom shear stress caused by the turbidity current-induced excitation wave, as well as the force exerted by the turbidity current itself on the bed. The monitoring frequency is set at 100 Hz.

2.2. Experimental Phenomenon and Results

In the laboratory water tank experiments, it was observed that as the turbidity current propagates, a wave is generated ahead of the turbidity front, moving in the same direction as the current and with a velocity greater than the turbidity current velocity [33]. By monitoring the pressure changes on the bed during the turbidity current motion [33], the propagation velocity of the excitation wave, the head movement velocity of the turbidity current, and the amplitude of the excitation wave (obtained from the measured surface elevation changes caused by the wave) can be estimated based on the distances between the sensors and the time when the pressure change peaks occur.
The results of indoor experiments on turbidity currents indicate that they can compress and propel the water ahead of them, generating excitation waves similar to pulses. The propagation speed of these excitation waves caused by turbidity currents is found to be much greater than the velocity of the turbidity current movement at its head, as determined by pressure sensors installed on the seabed.

3. Numerical Simulation of Excitation Waves Induced by Turbidity Currents

FLOW-3D is a powerful computational fluid dynamics (CFD) software that excels in making accurate calculations of free surface and six-degrees-of-freedom motions of objects. Similar to other CFD software, FLOW-3D consists of three modules: pre-processing, solver, and post-processing. In recent years, there have been many simulations of turbidity currents using FLOW-3D due to its superior capabilities. For example, Heimsund (2007) simulated turbidity currents in the Monterey Canyon system using FLOW-3D based on high-resolution bathymetry and flow data [43]. Zhou et al. (2017) used FLOW-3D software to simulate turbidity currents in a flume with obstacles, analyzing the impact of the proportion between obstacle height and flume height on the movement of turbidity currents, including their velocity, flow state, and morphological evolution [44]. In this study, using the CFD software FLOW-3D, the underwater motion process of turbidity currents is simulated. The model is validated by comparing it with experimental results, and the motion of the waves induced by turbidity currents is simulated based on this validation.

3.1. Control Equations

FLOW-3D, a mature three-dimensional fluid simulation software, is used in this study. It employs the RNG turbulence model, which is capable of handling high strain rate flows and is suitable for simulating excitation waves. The research focus of this paper is on sediment gravity flows (turbulent flows), and the control equations used in the calculations include the basic continuity equation, the momentum equation, the turbulent kinetic energy k equation, and the turbulent kinetic energy dissipation rate ε equation.

The continuity equation:

The momentum equation:

The turbulence model:

k equation:

ε equation:

where uv and w is the flow velocity component in xy and z directions; AxAy and Az represent the area fraction that can flow in xy and z directions; GxGy and Gz are the gravitational acceleration in xy and z directions; fxfy and fz are the viscous forces in the three directions; VF is the fraction of the volume that can flow; ρ is the fluid density; p is the pressure acting on the fluid element; k is the turbulence energy; ε is the turbulence kinetic energy dissipation rate; μ is turbulence viscosity coefficient

where uv and w is the flow velocity component in xy and z directions; AxAy and Az represent the area fraction that can flow in xy and z directions; GxGy and Gz are the gravitational acceleration in xy and z directions; fxfy and fz are the viscous forces in the three directions; VF is the fraction of the volume that can flow; ρ is the fluid density; p is the pressure acting on the fluid element; k is the turbulence energy; ε is the turbulence kinetic energy dissipation rate; 

 μ is turbulence viscosity coefficient μ t = ρ C μ k 2 ε where Cμ = 0.0845;

Gk is the turbulent kinetic energy generation term, expressed as G k = μ t u i x j + u j x i u i x j

and σk and σε are the Prandtl numbers corresponding to the turbulent kinetic energy and dissipation rate, respectively, both of which are 1.39.

In addition, C ε 1 * = C ε 1 η 1 η / η 0 1 + β η 3 where Cε1 and Cε2 are the empirical constants, 1.42 and 1.68, respectively.

Furthermore, η = 2 E i j E i j 1 / 2 k ε

where E i j = 1 2 u i x j + u j x i , η0 = 4.377, β = 0.012.

The general mass continuity equation is as follows:

where VF is the fractional volume open to flow, ρ is the fluid density, RDIF is a turbulent diffusion term, and RSOR is the mass source.

3.2. Model Validation

To determine the factors affecting the velocity of the turbidity-induced excitation wave and its velocity expression, first, the indoor flume test was taken as the prototype. Then, a 1:1 geometric solid model was established, and the simulation parameters were set to be consistent with the flume test parameters [33]. Finally, the simulation results were compared with the laboratory test results.

The computational domain employs the method of unstructured grid and is entirely divided into structured orthogonal grids. Nested grids are used for local refinement at the interfaces of straight sections, resulting in a total of 800,000 grid cells after refinement.

The simulation results were compared with the indoor experimental results, with the velocity of the excitation wave and the turbidity current head being represented by changes in surface elevation and water density. The experimental and simulation results are shown in Table 2, and the calculation formula for the error is |Calculated value−Test value|Test value×100%Calculated value-Test valueTest value×100%.

ResultPropagation Velocity of Excitation Wave (m/s)Velocity of Turbidity Current (m/s)Excitation Wave Amplitude (m)
Sensor 1 to 2Sensor 2 to 3Sensor 1 to 2Sensor 2 to 3Sensor 1 to 2Sensor 2 to 3
Test results1.541.480.240.230.0290.03
Computed results1.551.520.250.230.030.03
Error range0.6%2.7%4.2%0%3.4%0%
Table 2. The test results of the propagation velocity of the excitation wave, the turbidity current velocity, and the excitation wave amplitude are compared with the simulation results.

From the above comparison, it can be observed that the simulated velocities of the excitation wave and the head of the turbidity current align well with the experimental results, indicating the rationality of using the numerical model established in this study for simulating the propagation velocity of the excitation wave induced by turbidity currents.

3.3. Analysis of Factors Affecting the Propagation Velocity of Excitation Waves

An analysis of the factors influencing the propagation velocity of excitation waves was conducted using numerical simulation. The reference model for wave velocity was based on the surge velocity model. The main factors affecting the propagation velocity of excitation waves were summarized, including the turbidity current density ρ, the thickness of the turbidity current source area d, the length of the turbidity current source area L, the depth at the initial flow of turbidity currents h, the canyon width l, and the initial velocity of the turbidity current v0 (as shown in Figure 2). The simulations were performed using a controlled variable approach for different parameters, and the velocity changes of the excitation wave were obtained, as shown in Table 3. The slope angle was fixed at 3°, and sensors were placed at intervals of 100 m starting from a distance of 500 m from the turbidity current source area (named Sensors 1, 2, 3). These sensors were used to extract surface elevation, density, and other relevant parameters at their respective locations. We can obtain the propagating velocity of excitation waves by measuring the time difference in surface elevation changes at the monitoring points. Similarly, we can determine the propagation velocity of turbidity currents by measuring the time difference in density changes.

Figure 2. Excitation wave velocity simulation model and parameters.
Group OrderTurbidity Current Density (kg/m3)Length of Turbidity Source Area
(m)
Canyon Width
(m)
Thickness of Turbidity Source Area
(m)
Depth (m)Initial Velocity of Turbidity Current (m/s)Propagation Velocity of Excitation Wave (m/s)Excitation Wave Amplitude (m)Velocity of Turbidity Current (m/s)
11600100020020200033.430.3455.88
21500100020020200033.090.3045.41
31400100020020200033.350.2234.99
41300100020020200033.330.1774.35
51200100020020200033.860.0923.74
61600100020040200033.051.1099.09
71600100020060200033.392.68910.79
81600100020080200033.214.82812.91
916001000200100200036.437.74413.79
10160020020020200032.930.1815.58
11160040020020200033.490.255.71
12160060020020200033.060.2785.79
13160080020020200033.170.315.72
141600100020020100026.670.565.72
151600100020020300039.650.1695.80
161600100020020400045.980.125.80
171600100020020500049.970.085.96
181600100010020200033.600.3545.72
191600100030020200032.980.3385.97
201600100040020200033.270.3565.87
211600100050020200033.310.3655.86
221600100020020200233.500.5324.35
231600100020020200533.121.3896.56
241600100020020200833.522.2718.10
2516001000200202001033.332.8788.99
Table 3. Simulation results under different variables conditions.

The variations in surface elevation at three sensor locations in the simulated results of five different turbidity current density groups are presented in Figure 3.

Figure 3. Simulation of propagating velocity of excitation wave under the sole variable condition of turbulent current density. (Length of turbidity source area: 1000 m; canyon width: 200 m; thickness of turbidity source area: 20 m; depth: 200 m; initial velocity of turbidity current: 0 m/s).

Based on the simulation results described above, while keeping all other conditions constant, the impact of a single variable, namely, the turbidity current density, on the propagation velocity and amplitude of the excitation wave was analyzed. By fitting the data, the relationship between turbidity current density and the propagation velocity of turbidity currents as well as the amplitude of the excitation wave was obtained, as shown in Figure 4.

Figure 4. Relationship between turbidity current density and turbidity current velocity, as well as excitation wave amplitude.

The simulation results indicate that changes in turbidity current density, while keeping the other conditions constant, do not result in a change in the propagation velocity of the excitation waves. However, they do affect the amplitude of the excitation waves and the velocity of the turbidity current itself. The simulation reveals that within the selected density range, both the amplitude of the excitation waves and the velocity of the turbidity current increase with increasing turbidity current density. When the turbidity current density is equal to that of water (ρTurbidity current = ρWater), there is no turbidity current or excitation wave generation. Thus, the relationship between the turbidity current velocity (v) and density (ρ) is expressed as v = −34.80643 + 0.05082•ρ − 1.59286 × 10−5 ρ2 (ρ > 1000, R2 = 0.994). Additionally, the relationship between the amplitude of the excitation waves (A) caused by turbidity currents and density (ρ) is expressed as A = −0.6021 + 5.9729 × 10−4 ρ (ρ > 1000, R2 = 0.991).

3.3.2. The Influence of the Thickness of the Turbidity Source Area on the Propagation Velocity and Amplitude of Excitation Waves

The variations in surface elevation at three sensor locations in the simulated results of five different thickness of turbidity source area groups are presented in Figure 5.

Figure 5. Simulation of propagating velocity of excitation wave under the sole variable condition of thickness of turbidity source area. (Turbidity current density: 1600 kg/m3; length of turbidity source area: 1000 m; canyon width: 200 m; depth: 200 m; initial velocity of turbidity current: 0 m/s).

Based on the simulation results described above, while keeping all other conditions constant, the impact of a single variable, namely, the thickness of the turbidity source area, on the propagation velocity and amplitude of the excitation wave was analyzed. By fitting the data, the relationship between the thickness of the turbidity source area and the propagation velocity of the turbidity current as well as the amplitude of the excitation wave was obtained, as shown in Figure 6.

Figure 6. Relationship between thickness of turbidity source area and turbidity current velocity, as well as excitation wave amplitude.

Based on the simulated results mentioned above, it can be concluded that, while keeping the other conditions constant, changing only the thickness of the turbidity current source area does not affect the propagation velocity of the excitation waves. However, it does impact both the amplitude of the excitation waves and the velocity of the turbidity current itself. The simulation reveals that within the selected range of thickness values for the turbidity current source area, both the amplitude of the excitation waves and the velocity of the turbidity current increase with an increase in the thickness of the source area. Additionally, it is observed that when the length of the turbidity current source area is zero, neither the turbidity current nor the excitation waves are generated (i.e., no turbidity current is produced when hTurbidity current = 0). Therefore, the relationship between the velocity (v) of the turbidity current and its thickness (h) is expressed as v = 0.27983•h − 0.00146•h2 (h ≥ 0, R2 = 0.999). Similarly, the relationship between the amplitude (A) of the excitation waves caused by the turbidity current and its thickness (h) is A = −0.00375•h − 0.0008•h2 (h ≥ 0, R2 = 0.999).

3.3.3. The Influence of the Length of the Turbidity Source Area on the Propagation Velocity and Amplitude of Excitation Waves

The variations in surface elevation at three sensor locations in the simulated results of five different length of turbidity source area groups are presented in Figure 7.

Figure 7. Simulation of propagating velocity of excitation wave under the sole variable condition of length of turbidity source area. (Turbidity current density: 1600 kg/m3; canyon width: 200 m; thickness of turbidity source area: 20 m; depth: 200 m; initial velocity of turbidity current: 0 m/s).

Based on the simulation results described above, while keeping all other conditions constant, the impact of a single variable, namely, the length of the turbidity source area, on the propagation velocity and amplitude of the excitation wave was analyzed. By fitting the data, the relationship between the length of the turbidity source area and the amplitude of the excitation wave was obtained, as shown in Figure 8.

Figure 8. Relationship between length of turbidity source area and excitation wave amplitude.(Amplitude refers to the surface elevation change caused by the excitation wave).

Through simulations, it has been determined that within the chosen range of the length of the turbidity source area, the amplitude of the excitation waves increases with an increase in the length of the turbidity source area. When the length of the turbidity source area is zero, there is no turbidity current and no generation of excitation waves (i.e., when LTurbidity current = 0). Additionally, for large lengths of the turbidity source area, under the condition of sufficient sediment supply, the variations in surface elevation caused by the waves generated by turbidity currents are negligible. Therefore, the relationship between the amplitude of the excitation waves (A) generated by turbidity currents and the length of the turbidity source area (L) is expressed as follows: A = −0.3624 + 0.10305•ln(L − 6.15619) (L ≥ 0, R2 = 0.997).

3.3.4. The Influence of Depth on the Propagation Velocity and Amplitude of Excitation Waves

The variations in surface elevation at three sensor locations in the simulated results of five different depth groups are presented in Figure 9.

Figure 9. Simulation of propagation velocity of excitation wave under the sole variable condition of depth. (Turbidity current density: 1600 kg/m3; length of turbidity source area: 1000 m; canyon width: 200 m; thickness of turbidity source area: 20 m; initial velocity of turbidity current: 0 m/s).

Based on the simulation results described above, while keeping all other conditions constant, the impact of a single variable, namely, depth, on the propagation velocity and amplitude of the excitation wave was analyzed. By fitting the data, the relationship between depth and the propagation velocity of the excitation wave as well as the amplitude of the excitation wave was obtained, as shown in Figure 10.

Figure 10. Relationship between depth and propagating velocity of excitation wave, as well as excitation wave amplitude.

As the water depth approaches infinity, the excitation wave amplitude can only approach zero but cannot reach zero. Therefore, the characteristics of the excitation wave amplitude change with the water depth are similar to those of the velocity propagation of the excitation wave. The relationship between the velocity of the excitation wave induced by turbidity currents (vExcitation wave) and the water depth (H) can be described as vExcitation wave = −287.05446 + 48.59211•ln(H + 535.14863) (R2 = 0.998). The relationship between the excitation wave amplitude (A) and the water depth (H) can be expressed as A = 1.46573 − 0.22816•ln(H − 47.67563) (R2 = 0.985).

3.3.5. The Influence of the Canyon Width on the Propagation Velocity and Amplitude of Excitation Waves

The variations in surface elevation at three sensor locations in the simulated results of five different canyon width groups are presented in Figure 11.

Figure 11. Simulation of propagating velocity of excitation wave under the sole variable condition of canyon width. (Turbidity current density: 1600 kg/m3; length of turbidity source area: 1000 m; thickness of turbidity source area: 20 m; depth: 200 m; initial velocity of turbidity current: 0 m/s).

When the canyon width is taken as the single variable condition, changing the canyon width does not significantly affect the propagation velocity of excitation waves, the amplitude of excitation waves, and the velocity of turbidity currents. Therefore, it can be concluded that, without considering the impact of the differences in the terrain and sediment on the canyon width, the canyon width has no impact on the propagation of excitation waves and the movement of turbidity currents.

3.3.6. The Influence of the Initial Velocity of the Turbidity Current on the Propagation Velocity and Amplitude of Excitation Waves

The variations in surface elevation at three sensor locations in the simulated results of five different initial velocity of turbidity current groups are presented in Figure 12.

Figure 12. Simulation of propagating velocity of excitation wave under the sole variable condition of initial velocity of turbidity current. (Turbidity current density: 1600 kg/m3; length of turbidity source area: 1000 m; canyon width: 200 m; thickness of turbidity source area: 20 m; depth: 200 m).

Based on the simulation results described above, while keeping all other conditions constant, the impact of a single variable, namely, the initial velocity of the turbidity current, on the propagation velocity and amplitude of the excitation wave was analyzed. By fitting the data, the relationship between the initial velocity of the turbidity current and the amplitude of the excitation wave was obtained, as shown in Figure 13.

Figure 13. Relationship between initial velocity of turbidity current and excitation wave amplitude.

Based on the simulation, it is observed that within the selected range of the initial velocity of the turbidity current, the amplitude of the excitation wave increases linearly with the increase in the initial velocity of the turbidity current. Therefore, the relationship between the amplitude (A) of the excitation wave caused by the turbidity current and the initial velocity of the turbidity current (v0) can be expressed as A = 0.34 + 0.24084•v0 (A ≥ 0, R2 = 0.992).

Through controlling the simulation calculation of a single variable, it was found that there are several factors that can affect the amplitude of the excitation wave. These factors include the turbidity current density ρ, the thickness of the turbidity current source area d, the length of the turbidity current source area L, the water depth h, and the initial velocity of the turbidity current v0. In contrast, there are relatively few factors that influence the propagation velocity of the excitation wave. Within the selected parameter range, only the water depth can affect the propagation velocity of the excitation wave. The physical parameters of the turbidity current, including the turbidity current density ρ, the thickness of the turbidity current source area d, the length of the turbidity current source area L, the canyon width l, and the initial velocity of the turbidity current v0, have no direct influence on the propagation velocity of the excitation wave. Therefore, the turbidity current only serves as a triggering factor for the excitation wave and is not directly related to the propagation velocity of the excitation wave.

3.4. Analyze the Changes in Propagation Velocity of Excitation Waves along a Path

In order to further investigate the underlying truth behind the variation in the propagation velocity of the excitation wave, a discussion on whether there is velocity attenuation along the propagation path of the excitation wave is conducted. Since the seventh group of the excitation wave causes significant changes in surface elevation, the seventh group of the excitation wave is selected as the research object in order to study the variations in surface elevation along the propagation path of the excitation wave. The changes in surface elevation are extracted every 200 m along the sediment slope (with the first extraction point located 400 m away from the source area of the turbidity current). A total of six sets of surface elevation data are extracted (ranging from 400 m to 1400 m distance from the source area of the turbidity current), as shown in Figure 14.

Figure 14. Surface elevation changes during excitation wave propagation along sediment slopes.

The amplitudes and propagation velocities of the excitation wave at each point are shown in Table 4.

Distance from Turbidity Current Source Area (m)Propagation Velocity of Excitation Wave (m/s)Excitation Wave Amplitude (m)
40033.342.524
60036.792.596
80037.132.589
100039.992.566
120040.042.542
140040.132.523
Table 4. Excitation wave velocity during the excitation wave propagation along the sediment slope.

From the table above, it can be observed that the amplitude of the excitation wave does not change while traveling along the slope. This indicates that the change in surface elevation caused by the propagation of the excitation wave does not attenuate. Furthermore, the propagation velocity of the excitation wave gradually increases, although the change is not very pronounced. This variation may be attributed to the change in the water depth caused by the sloping bed. To investigate this, a simulation was conducted in a straight channel with a length of 3000 m. Six sampling points were established from 400 m to 1400 m away from the turbidity current source area to extract the amplitude of the excitation wave. The results of the simulation are presented in Figure 15.

Figure 15. Surface elevation changes during wave propagation along a straight channel.

The amplitudes and propagation velocities of the excitation wave at each point are shown in Table 5.

Distance from Turbidity Current Source Area (m)Propagation Velocity of Excitation Wave (m/s)Excitation Wave Amplitude (m)
40033.892.559
60037.662.692
80037.122.712
100036.922.717
120037.092.715
140037.482.718
Table 5. Excitation wave velocity during the propagation along the straight channel.

The data from the table above indicate that during the propagation of the excitation wave along a straight water channel, its velocity remains constant, except for a slight decrease at the initial point. This phenomenon may be attributed to the fact that in the starting phase, the excitation wave is not fully developed, and hence its velocity is relatively smaller. However, once it is fully developed, the propagation velocity of the excitation wave does not decrease in subsequent processes. Therefore, the propagation velocity of the excitation wave is only dependent on the real-time water depth of the wave. In future studies, we aim to explore the relationships between these influencing factors and other physical parameters, such as the speed of wave propagation, using the effective and accurate method of machine learning algorithms [45].

3.5. Expression of the Propagation Velocity of the Excitation Wave

The propagation of the excitation wave along a long distance does not experience an attenuation in velocity, as is the case with the propagation velocity of solitary waves. Referring to the estimated wave propagation velocity (the square of the propagation velocity is directly proportional to the water depth amplitude) [46], the wavelengths under different water depth conditions were extracted, as shown in Table 6.

Depth (m)Propagation Velocity of Excitation Wave (m/s)Excitation Wave Amplitude (m)Excitation Wave Length (m)
10026.670.562580
20033.430.352850
30039.650.173250
40045.980.123600
50049.970.084150
100066.670.046000
200090.910.029500
4000165.840.317600
Table 6. Physical parameters of excitation wave under different water depth conditions.

From the simulation results of a single variable, the water depth, it could be seen that the wavelengths of the excitation waves were much larger than the water depth. Therefore, further simulations were conducted under water depth conditions ranging from 1000 m to 4000 m. Due to the minimal change in wave amplitude when the water depth reached 4000 m, it was not possible to observe a distinct waveform. However, through simulations with the thickness of the turbidity current source area as the single variable, it was found that an increase in the thickness of the source region led to a larger amplitude of the excitation waves, but it did not affect the wavelength of the excitation waves. Therefore, in order to better extract the wavelength of the excitation waves, the thickness of the source region in the simulation with a water depth of 4000 m was set to 200 m.

Through simulations at water depths of 1000 m and 4000 m, it is observed that the wavelengths of the excitation waves are much larger than the water depth, indicating that these waves belong to the category of shallow water waves. The amplitude of the excitation waves is relatively small compared to their wavelength, aligning with the small amplitude wave theory [47]. According to this theory, the wave velocity of shallow water waves is only dependent on the water depth (h) and gravity acceleration (g), regardless of the wave period. In the case of excitation waves induced by turbidity currents in deep water, the amplitudes of these waves are relatively small compared to the water depth. Referring to the expression for shallow water waves (when the relative water depth, which is the ratio of water depth to wavelength, is much smaller than 1/2), the wave velocity is denoted as 𝐶𝑠=√𝑔ℎ. This implies that the propagation velocity of the excitation waves is also solely related to the water depth. Therefore, a fitting of the square of the propagation velocity of the excitation waves (v2) and the water depth (h) was conducted (Figure 16).

Figure 16. The relationship between the propagation velocity of excitation wave and the depth.

Through fitting, the following can be obtained:

Through fitting, it can be discovered that the propagation model of the velocity of excitation waves is different from the shallow water wave theory. This is because turbidity currents, as granular materials, generate excitation waves by pushing the water in front of them with sediment particles underwater, which is different from the surges formed by solid blocks entering the ocean. Additionally, excitation waves formed by turbidity currents occur in an underwater environment, which may be the reason why the propagation velocity equation for the excitation waves behaves as if the velocity squared is equal to half the Earth’s gravity. This equation reveals the variation in the propagation velocity of the excitation wave with depth, explaining why the average velocity between the monitoring points in the field is greater than the instantaneous velocity measured at these points [41]. Further theoretical research on the propagation velocity of excitation waves requires subsequent field monitoring and the deployment of monitoring systems to more thoroughly investigate the fundamental causes.

4. Conclusions

This study aimed to investigate the velocity of turbidity current-induced excitation waves through numerical simulation. By fixing a single variable, different factors that could affect the propagation velocity and amplitude of the excitation waves were analyzed and discussed, leading to the following three conclusions:

  1. Within the selected parameter range, there are several factors that can influence the amplitude of the excitation waves, including the turbidity current density ρ, the thickness of the turbidity current source area d, the length of the turbidity current source area L, the water depth h, and the initial velocity of the turbidity current v0.The amplitude of the excitation waves is positively correlated with the turbidity density, the thickness of the source area, the length of the source area, and the initial velocity, while it is negatively correlated with the water depth.
  2. Within the selected parameter range, only the water depth can affect the propagation velocity of the excitation waves. As the water depth increases, the propagation velocity of the excitation waves also increases, and a relationship of v2 = 0.63gh (R2 = 0.967) is established between the square of the propagation velocity v2 and the water depth h.
  3. During the propagation of the excitation waves, both the propagation velocity and the changes in surface elevation caused by the waves do not attenuate. Considering the relatively calm deep-sea environment, the high-speed propagation of the excitation waves and the resuspension of bottom sediments they cause not only complement the understanding of turbidity current motion patterns in canyons, but also provide new research directions for deep-sea sediment transport.

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Nozzle Scour

Study on the Sand-Scouring Characteristics of Pulsed Submerged Jets Based on Experiments and Numerical Methods

실험과 수치 해석을 기반으로 한 펄스 잠수 제트의 모래 침식 특성 연구

Hongliang Wang, Xuanwen Jia,Chuan Wang, Bo Hu, Weidong Cao, Shanshan Li, Hui Wang

Abstract


Water-jet-scouring technology finds extensive applications in various fields, including marine engineering. In this study, the pulse characteristics are introduced on the basis of jet-scouring research, and the sand-scouring characteristics of a pulsed jet under different Reynolds numbers and the impact distances are deeply investigated using Flow-3D v11.2. The primary emphasis is on the comprehensive analysis of the unsteady flow structure within the scouring process, the impulse characteristics, and the geometric properties of the resulting scouring pit. The results show that both the radius and depth of the scour pit show a good linear correlation with the jet-flow rate. The concentration of suspended sediment showed an increasing and then decreasing trend with impinging distance. The study not only helps to enrich the traditional theory of jet scouring, but also provides useful guidance for engineering applications, which have certain theoretical and practical significance.

Keywords


pulsed jet; turbulent structure; scouring characteristics

1. Introduction


Water-jet-scouring technology is widely used in marine engineering and its related ancillary fields, such as in the maintenance and repair of marine structures, extraction of deep-sea resources, dredging works, seabed geological research, and cleaning and maintenance of ships. The jet flow establishes a velocity shear layer at its boundary, leading to the destabilization and subsequent generation of vortices. These vortices undergo continuous deformation, rupture, merging, and evolution into turbulence during their movement. Consequently, they entrain surrounding fluid into the jet region, facilitating the transfer of momentum, heat, and mass between the jet and its ambient environment [1,2,3]. Therefore, numerous scholars have carried out detailed studies on the scouring characteristics associated with jets. Chatterjee et al. [4] investigated the local scouring and sediment-transport phenomena due to the formation of horizontal jets during the opening of sluice gates based on experiments, and successfully established empirical expressions for the correlation between the time of reaching the equilibrium stage, the maximum depth of scouring, and the peak of the dune. The important role of jet-diffusion properties in the scouring process was also emphasized. Hoffmans [5] calculated the equilibrium scour process induced using a horizontal jet in the absence of a streambed and used experiments to verify the accuracy of the equations for jet-scour depths in the relevant literature. Luo et al. [6] investigated the induction mechanism of scour in planar jets through particle-image velocimetry (PIV). It was found that the initial stage of scour was dominated by wall shear, while the later stages of the scour process were mainly influenced by the turbulent vortex. Canepa et al. [7] investigated the scour characteristics of gas-doped water jets and found that gas-doped jets significantly reduce the scour depth if the velocity of the mixture is used as a reference.
Pulsed jets introduce pulsation, resulting in a water-hammer effect, as well as increased diffusion and coil suction rates. These factors contribute to a more intricate interaction between the pulsed jet and the adjacent wall. The process of generation, development and evolution of its internal vortex structure as well as the interaction between the vortex structure and the surrounding ambient fluid and solid wall have changed significantly [8,9]. At this juncture, researchers in this domain have undertaken investigations centered on the utilization of pulsed jets. Coussement et al. [10] investigated the flow characteristics of a pulsed jet in a cross-flow environment based on Large Eddy Simulation (LES). A new approach to characterize mixing was introduced, which successfully explains and quantifies the complex mixing process between the pulsating jet and the ambient fluid. Bi et al. [11] investigated the thrust of a deformable body generated through a pulsed jet based on an axisymmetric immersed-boundary model. The numerical results show that in addition to the momentum flux of the jet, the jet acceleration is also an important source of thrust generation. Zhang et al. [12] studied the complex unsteady flow characteristics of a pulsed jet impinging on a rotating wall using numerical methods, and it was found that the impact pressure of the pulsed jet on the wall is greater than that of the continuous jet on the wall for a certain period of time when the water-hammer effect occurs. Rakhsha et al. [13] used experiments and numerical simulations to study the effect of pulsed jets on the flow and heat-transfer characteristics over a heated plane. It was found that the Nussell number increases with increasing pulse frequency and Reynolds number and decreases with increasing impinging distance. It is evident that existing studies predominantly center on the unsteady flow characteristics of pulsed jets and their properties related to heat and mass transfer. Conversely, there is a noticeable dearth of research concerning the scouring attributes of pulsed jets in the available literature.
The pulsed submerged impinging jet represents a complex jet flow with a significant engineering application background and substantial theoretical research value. Exploring the unsteady hydraulic characteristics of pulsed jets can enhance classical impinging jet theory, deepen our comprehension of the jet–wall interaction mechanism, and establish a scientific foundation for addressing engineering-application challenges. Therefore, this paper introduces the pulse characteristics into the impinging jet, and, based on the Flow-3D software, the sand-scouring characteristics of the impinging jet under different Reynolds numbers and impinging distances are deeply investigated. The surface geometry of the scour pit is characterized while obtaining the pulsation characteristics of the unsteady flow structure during sand scouring. This study not only offers a foundation for implementing flow control and enhancing the understanding of unsteady flow characteristics but also furnishes theoretical backing for predicting impact pressure and impact pit formation.

2. Modeling and Numerical Methods

2.1. Model Building

The geometric model consists of a jet pipe, a body of water, a baffle, and a sand bed, as shown in Figure 1. The inner diameter D of the jet pipe is 20 mm, and the length L is set to 50D to ensure that the turbulence inside the pipe is fully developed. H represents the impinging height, and the initial water height (Hw) is 1600 mm. Baffles positioned on both sides serve to maintain a constant water level. The length Ls and thickness Hs of the sand bed are 5000 mm and 160 mm, respectively. It is worth stating that the sand bed is composed of non-cohesive sand. The median grain size dm of the sand is 0.77 mm, the specific gravity Δ is 1.65, and the particle gradation σg is 1.21.

Figure 1. Geometric modeling for sand scouring.

2.2. Numerical Models

In fluid mechanics, the continuity and momentum equations are the basic governing equations [14]:

where uvw denote the velocity of the fluid in the xyz direction, respectively; AxAyAz denote the area fraction of the fluid in the xyz direction, respectively; VF denotes the volume fraction; P is the pressure exerted on the fluid micrometric elements; GxGyGz are the gravitational acceleration in the xyz direction, respectively; and fxfyfz are the viscous forces in the xyz direction, respectively.

In numerical simulations, the selection of a turbulence model significantly influences the accuracy of the calculations. Hence, it is imperative to choose an appropriate turbulence model. Given that this paper primarily deals with fully developed circular tube turbulence, which entails velocity and momentum coupling among fluids and features substantial time and spatial scales in the non-constant flow, the RNG kε turbulence model [15,16,17] has been chosen for the conclusive numerical simulation work. The RNG model takes into account the effect of eddies on turbulence and improves the accuracy of vortex-flow prediction [18]. Its equations are as follows:

where vt is the eddy viscosity coefficient; μ is the kinetic viscosity coefficient; the empirical constants cε1 and cε2 have values of 1.42 and 1.68; c3 = 0.012; η0 = 4.38; cμ = 0.085; and the values of Prandtl numbers αk and αε corresponding to the turbulent kinetic energy k and the dissipation rate ε are both 0.7194.

The Flow-3D software realizes an accurate description of the sediment movement with the help of an empirical equation model proposed by Mastbergen and Van den Berg [19]. The critical Shields number first needs to be calculated from the Soulsby–Whitehouse equation [20], which is given below:

where ρi is the sediment density, ρf is the fluid density, di is the sediment diameter, μf is the hydrodynamic viscosity, and ‖g‖ is the magnitude of gravitational acceleration.

Under the action of the jet, part of the deposited sediment will be disturbed to show a suspended state and it will continue to move under the carrying of the fluid. The uplifting velocities of entrained sediment ulift,i and usetting,i are calculated as follows:

where αi is the sediment carryover coefficient with a recommended value of 0.018 [19]; ns is the normal direction of the bed; and vf is the kinematic viscosity of the liquid.

2.3. Grid-Independent Analysis

It is well known that the number of the grid is closely related to the accuracy and cost of the numerical calculation. In order to investigate the optimal number of grids suitable for this numerical simulation, the scour depth Ht of the sand bed at H/D = 2 and inlet flow velocity Vb = 1.485 m/s is chosen as the monitoring parameter for the grid-independent analysis. Five sets of grid schemes with increasing numbers are set, and the results of the independence analysis are shown in Figure 2. From the figure, it can be seen that the depth of the scour pit Ht increases gradually with the encryption of the grid. When the grid is encrypted to Scheme 4, Ht almost no longer increases. It is considered that the number of meshes at this time can already meet the accuracy requirements of numerical calculations. Therefore, the grid number scheme in Scheme 4 is selected for the subsequent numerical simulation study, and the grid number is 43,825.

Figure 2. Grid-independent analysis.

2.4. Grid Delineation and Boundary Conditions

Within the Flow-3D software, a grid block is used that covers the entire 2D computational area as shown in Figure 1. Given the large aspect ratio of the jet pipe and the significant turbulent coupling between the fluid and sediment near the pipe outlet, grid refinement is implemented in the vicinity of the pipe outlet. The grid-encrypted area is mainly the area between the jet outlet and the sand bed, as shown in Figure 3. In addition, a mesh node is provided at the baffle on each side of the computational domain to ensure proper identification of the fluid boundary during numerical simulations. The upper boundary of the computational domain is defined as a velocity inlet, where the velocity magnitude is denoted as Vb, and the direction is oriented vertically downward. The lower boundary is the wall and no fluid or sediment flux is allowed. The two side boundaries are specified as pressure boundaries and the pressure is set to be 0 Pa. Based on the requirement of 2D numerical simulation, the boundaries of the front and rear sides are set as symmetric boundaries, both with one grid node. At the same time, the boundary-layer mesh near the pipe and the sand bed is encrypted accordingly. y+ is set at around 30 to ensure that the first grid nodes are in the turbulence core region, so as to ensure that the RNG kε turbulence model is perfectly adapted to the boundary conditions. Considering that the velocity strength and pressure gradient of the fluid around the baffle are small and it is not an observation area, the encryption of the boundary-layer grid is not performed for the time being.

Figure 3. Computational grid.

Numerical simulations are performed using the discrete control equations of the control volume method, with the diffusion term of the equations in the central difference format and the convection term in the second-order upwind format, and the equations are solved using a coupled algorithm. The standard wall equations are used, and the no-slip option in the wall shear boundary conditions is checked. In the non-stationary numerical simulation, the time step is set to 0.05 s. In order to ensure the accuracy of the numerical calculations, each time step is iterated 100 times, and the convergence accuracy is set to 10−5.

In this paper, the continuous jet is periodically truncated to form a blocking pulsed jet. The pulse period of its pulse velocity can be expressed as T = tj + t0 (tj and t0 are the jet time and truncation time, respectively, taking the value of 0.5 s), and the inlet flow rate of the jet pipe is Vb during the jet time period, while the inlet flow rate of the jet pipe is 0 during the truncation time period, as shown in Figure 4.

Figure 4. Velocity characteristics of the blocking pulsed jet.

3. Experimental Validation

To validate the accuracy of the numerical simulations, an experimental investigation of jet impingement on sediment is conducted. The experimental setup is shown in Figure 5. The parameters characterizing the sediment in the experiments are guaranteed to be the same as the settings in the numerical simulations. Specifically, non-cohesive sand is used with a median particle size dm of 0.77 mm, a specific gravity Δ of 1.65, and a particle gradation σg of 1.21. An angle plate is employed to control the impinging angle of the jet pipe, a COMS camera captures images of the pit, and a laser range finder is utilized for precise measurements of pit depth and dune height. In order to quantitatively describe the effect of jet impingement, the depth of the sand pit and the height of the dune are defined as d and h, respectively.

Figure 5. Schematic diagram of the experimental setup.

Figure 6 compares the stabilized morphology of the sand bed formed under the scouring of the jet for an impinging distance H/D of two in the numerical simulation and the experiment. The inlet flow velocities Vb of the jet pipe are 0.424 m/s, 0.955 m/s, and 1.485 m/s, respectively. As depicted in the figure, the ultimate scouring morphology of the sand bed, as obtained through numerical simulation, closely aligns with the experimental results. This alignment underscores the strong agreement between the numerical simulation and the experimental data. Nevertheless, it must be recognized that the final scour depths of the numerical simulations are all slightly smaller than the experimental values under the same conditions. The possible reason for this is the wall effect, i.e., the porosity of the actual sand bed is not homogeneous, with the upper sand layer being slightly more porous [21], whereas the porosity of the sand bed in the numerical simulation strictly follows the set value. Given that the accuracy of numerical calculations is subject to various influencing factors, and considering that the numerical solution inherently involves an approximation process, the numerical methods employed in this study can be deemed both accurate and dependable.

Figure 6. Comparison of sand-scouring experiment and numerical simulation: (aVb = 0.424 m/s; (bVb = 0.955 m/s; (cVb = 1.485 m/s.

4. Results and Discussion

There are many factors that affect the performance of jet scouring, such as the shape of the nozzle, the size of the nozzle, the inlet flow rate of the jet pipe, the impinging distance, and the sediment parameters. Changes in any one of these factors can have a large effect on the parameters that measure the scouring performance of the jet, such as the depth of the scouring pit |ymin|, the height of the dune ymax, the radius of the scouring pit R. In this paper, the effects of the inlet velocity Vb and impinging distance H/D on the scouring performance of the jet pipe are investigated. Seven working conditions with inlet velocity Vb of 0.424 m/s, 0.690 m/s, 0.955 m/s, 1.220 m/s, 1.485 m/s, 1.751 m/s and 2.016 m/s are calculated for different impinging distances H/D (H/D = 2, 4, 6 and 8). The corresponding Reynolds numbers Re are 8404, 13,657, 18,910, 24,162, 29,415, 34,667, and 39,920, respectively.

4.1. Characterization of Pit at Different Impinging Distances

After the jet impinges on the sand bed for a sustained period of time, the shape of the sand bed will no longer change and remain stable. Figure 7 shows the stable bed morphology formed by the jet impinging on the sand bed with different velocities Vb, and at different impinging distances H/D. The x-axis is at the axial position of the jet pipe, and the y-axis is the initial horizontal plane of the sand bed. As can be seen from the figure, under the condition of Vb = 0.424 m/s, the pit depths |ymin| corresponding to impinging distances H/D of two and four are basically equal. However, when H/D is increased to six, |ymin| becomes significantly smaller, and when H/D is eight, |ymin| increases again. Under the Vb = 0.690 m/s condition, the effect of H/D on the scour pit depth |ymin| is small, and its size basically stays around 3.5 cm. Under the Vb = 0.955 m/s condition, the pit depth corresponding to H/D = eight is slightly smaller than the pit depths at other impinging distances, and the magnitude of |ymin| is basically maintained near 4.6 cm. Under the Vb = 1.220 m/s condition, the change of the scouring pit depth |ymin| with the impinging distance H/D starts to be gradually significant, especially the scouring pit depth |ymin| which decreases by about 1.7 cm when the size of H/D increases from two to six. Under the condition of Vb = 1.220 m/s, the larger the H/D, the smaller the pit depth |ymin|, especially when the H/D is eight, the pit depth is obviously larger than the pit depth at other impinging distances. The corresponding pit depths |ymin| for Vb of 1.751 m/s and 2.016 m/s remain basically unchanged. From the above analysis, it can be seen that under the same Reynolds number conditions to some extent the impinging distance has a very limited effect on the depth of the pit |ymin|. When the impinging distance increases, the depth of the pit begins to decrease. This can be attributed to the fact that the increased distance results in the jet encountering the initial static water resistance over a longer duration, leading to a greater dissipation of kinetic energy and a subsequent reduction in the impinging force of the jet.

Figure 7. Pit characteristics at different impinging distances: (aVb = 0.424 m/s; (bVb = 0.690 m/s; (cVb = 0.955 m/s; (dVb = 1.220 m/s; (eVb = 1.485 m/s; (fVb = 1.751 m/s; (gVb = 2.016 m/s.

The depth of the scouring pit serves as a critical parameter for assessing the impact of jet impingement on sand beds, just as the height of the dune represents a key indicator for evaluating the effectiveness of this process. In Figure 7a, it can be seen that the dune height ymax increases synchronously with the increase of the impinging distance H/D at Vb = 0.424 m/s. When Vb ≥ 0.955 m/s, the dune height ymax no longer grows significantly with the increase of impinging distance H/D. To further explore the relationship between dune height and impinging distance, Figure 8 is plotted with the impinging distance as the horizontal coordinate and the dune heights on either side as the vertical coordinate. From the figure, it can be seen that when 0.424 m/s ≤ Vb ≤ 1.485 m/s, the dune height ymax increases with the increase of the impinging distance H/D, and the dune height ymax starts to decrease with the increase of the impinging distance H/D when Vb > 1.485 m/s. The reason behind the aforementioned phenomenon is that when the inlet velocity Vb of the jet pipe is low, suspended sediment tends to displace towards the sides of the dune, causing some of the sediment to accumulate on the dune and thereby increase its height. When Vb ≥ 1.485 m/s, due to the enhanced impact force, most of the suspended sediment no longer moves and accumulates near the dunes and sand pits, and it starts to move on the outside of the dunes, causing the dune height to decrease.

Figure 8. Variation in the height of dunes on either side of the scour pit with Vb: (a) left; (b) right.

In order to clarify the relationship between the pit radius R and the impinging distance H/D, the relationship is given in Figure 9. From the figure, it can be seen that when 0.424 ≤ Vb ≤ 0.690, the increase of impinging distance H/D has basically no effect on the radius R of the pit, and its magnitude always stays near 13 cm. As the inlet velocity Vb of the jet pipe increases (1.220 ≤ Vb ≤ 1.485), the impact of the pulsed jet intensifies. Consequently, the suspended sediment is propelled towards the sides of the sand pit; although, it has not reached the dune and the area beyond it. Instead, a substantial amount of suspended sediment settles within the sand pit on both sides. Simultaneously, as the impact distance increases, the reach of jet impact and the turbulence induced by the jet expand, leading to enhanced sediment transport on both sides of the sand pit. This ultimately results in a reduction in the radius of the scouring pit as the impinging distance increases.

Figure 9. Relationship between pit size and impinging distance.

4.2. Characterization of Piting at Different Reynolds Numbers

Figure 10 depicts the stabilized morphology of the sand pit resulting from the influence of jets with varying Reynolds numbers. Under the conditions of H/D = two and four, the inlet velocity Vb of the jet pipe is 0.424 m/s and 0.690 m/s, and the depth of the pit |ymin| is basically equal, which indicates that the impact of the jet on the sand bed at this time is small, and the sediment is only transported and circulated in the sand pit. When Vb ≥ 0.955, the depth of the pit |ymin| increases significantly with the increase of Vb. Under the condition of H/D = 6, the depth of the pit, denoted as |ymin|, ceases to remain constant when Vb is less than or equal to 0.690 m/s. However, the disparity between the two measurements remains relatively small, suggesting that the impact force and turbulence of the jet are already capable of transporting sediment from the bottom of the pit to its flanks when Vb ≤ 0.690 m/s. In the H/D = 8 condition, due to the impinging distance H/D is larger, and when the velocity of the jet pipe is small (Vb ≤ 0.690 m/s), the kinetic energy of the jet is continuously exchanged with the static water body and then reduced, making its impact force reduce, and the sediment can only be transported and circulated at the bottom of the sand pit. To further investigate the effect of the Reynolds number of the jet on the depth of the pit |ymin|, Figure 11 is plotted with the jet velocity Vb as the horizontal coordinate and the depth of the pit |ymin| as the vertical coordinate. From the figure, it is evident that there exists a strong linear relationship between the depth of the scouring pit and the jet velocity. The data points in the figure can be fitted to establish the following relationship between the depth of the scouring pit and the jet velocity:

Figure 10. Pit characteristics at different Reynolds numbers: (aH/D = 2; (bH/D = 4; (cH/D = 6; (dH/D = 8.
Figure 11. Linear relationship between scouring-pit depth and jet velocity.

4.3. Characterization of Pits with Different Impinging Times

Figure 12 illustrates the deformation of the sand bed caused by the impact of the pulsed jet over a time range from 0.75 s to 3.5 s (with intervals of 0.25 s). When the jet velocity Vb is 0.424 m/s, within the initial 0.75 s of jet initiation, the impact of the pulsed jet leads to noticeable deformation of the sand pit and dune, with their fundamental shapes taking form. The depth of the pit, denoted as |ymin|, continuously increases from 0.75 s to 2 s, eventually stabilizing around 2.75 s. By the onset of the pulsed jet, the dune has already assumed a fundamental profile, and its maximum height, represented as ymax, exhibits minimal variation over time, remaining relatively constant.

Figure 12. Changes in time scales of pits: (aVb = 0.424 m/s; (bVb = 0.690 m/s; (cVb = 0.955 m/s; (dVb = 1.220 m/s; (eVb = 1.485 m/s; (fVb = 1.751 m/s; (gVb = 2.016 m/s.

5. Conclusions

In this paper, a numerical computational study is conducted to examine the characteristics of sand-bed impingement using obstructing pulsed jets. A comprehensive analysis is undertaken, encompassing impingement-pit depth, dune height, and impingement-pit radius. The following conclusions are drawn:

  1. Under consistent jet-velocity conditions, the impingement distance (H/D) has minimal impact on the depth of the scouring pit within the range of 2 ≤ H/D ≤ 6. However, beyond this range (H/D > 6), increased impingement distance leads to heightened jet-energy dissipation, resulting in a weakened impact force and a subsequent reduction in pit depth. Additionally, for lower jet velocities, impinging-distance variations have negligible effects on pit radius, while higher jet velocities induce a decrease in pit radius with an increase in impinging distance.
  2. The study establishes strong linear relationships between both the radius and depth of the scouring pit and the jet velocity. However, the relationship between dune height and pulsed-jet velocity is characterized by randomness and uncertainty. The dynamics of sediment transport contribute to the lack of symmetry in the stable configuration of the sand pit concerning the jet-pipe axis. Furthermore, the relationship between dune height and pulsed-jet velocity exhibits transient characteristics, highlighting the complex nature of these interactions.
  3. The numerical computational analysis emphasizes the transient characteristics of the sand-pit configuration due to sediment-transport dynamics. The stable state of the pit does not assume symmetry with the jet pipe as the axis, introducing a level of asymmetry in the system. This asymmetry is crucial in understanding the complex behavior of the sand-bed impingement. The findings underscore the need to consider dynamic and transient factors when studying the impact of obstructing pulsed jets on sand-bed characteristics.

References

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  6. Luo, A.; Cheng, N.-S.; Lu, Y.; Wei, M. Characteristics of Initial Development of Plane Jet Scour. J. Hydraul. Eng. 2023149, 06023004.
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  8. Krueger, P.S. Vortex ring velocity and minimum separation in an infinite train of vortex rings generated by a fully pulsed jet. Theor. Comput. Fluid Dyn. 201024, 291–297.
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  16. Jalal, H.K.; Hassan, W.H. Three-Dimensional Numerical Simulation of Local Scour around Circular Bridge Pier Using Flow-3D Software. In Proceedings of the Fourth Scientific Conference for Engineering and Postgraduate Research, Baghdad, Iraq, 16–17 December 2019; IOP Publishing: Bristol, UK, 2020; Volume 745, p. 012150.
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The experimental layout

Strength Prediction for Pearlitic Lamellar Graphite Iron: Model Validation

펄라이트 라멜라 흑연 철의 강도 예측: 모델 검증

Vasilios Fourlakidis, Ilia Belov, Attila Diószegi

Abstract


The present work provides validation of the ultimate tensile strength computational models, based on full-scale lamellar graphite iron casting process simulation, against previously obtained experimental data. Microstructure models have been combined with modified Griffith and Hall–Petch equations, and incorporated into casting simulation software, to enable the strength prediction for four pearlitic lamellar cast iron alloys with various carbon contents. The results show that the developed models can be successfully applied within the strength prediction methodology along with the simulation tools, for a wide range of carbon contents and for different solidification rates typical for both thin- and thick-walled complex-shaped iron castings.

Keywords


lamellar graphite iron; ultimate tensile strength; primary austenite; gravity casting process simulation

1. Introduction


Nowadays, there is a great need to further improve both the material properties and the prediction models for optimization of the heavy truck engine components aimed to fulfil the rigorous environmental legislations, sustainability goals, and customer demands. Cylinder blocks and cylinder heads are the primary components of these engines, and the majority of them are composed of lamellar graphite iron (LGI). The ultimate tensile strength (UTS) of LGI is an essential material property that determines the engine performance and the fuel consumption. The complex geometry and variation of the wall thickness in the cylinder blocks result in different solidification times through the component, and thus, different tensile properties.
A number of investigators [1,2,3,4,5,6] underlined the major influence of the graphite flake size on the strength of LGI. It is believed that under stress, the graphite flakes are dispersed in the metal matrix act as notches that decrease the material strength. Modified Griffith and Hall–Petch models were introduced for the prediction of UTS in LGI, where the maximum graphite length was considered as the maximum defect size [3,7,8,9]. Recently, it was found that the maximum defect size can never be larger than the interdendritic space between the primary austenite dendrites formed during the solidification process [10]. The length scale of the interdendritic space was characterized by the hydraulic diameter of the interdendritic phase (DIPHyde), which proved to be the most suitable parameter to express the detrimental effect of the graphite lamella in the metallic matrix. Thus, the DIPHyde
parameter was introduced as the maximum defect size in the modified Griffith and Hall–Petch equations [10,11].
Over the past decades, computer simulations of LGI solidification were carried out by several researchers [7,8,9,12,13] to describe the thermal history and the microstructure evolution of LGI castings. The main objective of these studies was prediction of the UTS. Macroscopic heat flow modeling, coupled with growth kinetic equations, was introduced in [7] to predict various microstructure features of LGI. Consequently, a modified Griffith fracture relation was applied to determine the UTS of a commercial LGI alloy. A similar solidification model was developed in [8], where a microstructure evolution model was employed together with the modified Hall–Petch equation for calculation of the UTS. Note that in [8], two different cooling rates resulted in two different relationships between the UTS and the maximum graphite flake length. Similar observations were made in [10], where three different cooling rates led to providing three different linear dependencies between the eutectic cell size (direct proportional to the maximum graphite length) and the UTS.
The present work provides validation of the UTS computational models against experimental data, based on full-scale pearlitic LGI gravity casting process simulation. We investigated whether the models recently developed in [10,11] can be applied within the UTS prediction methodology, along with the simulation tools, for different alloy compositions and for different solidification rates. The novel methodology for UTS prediction, presented in this paper, involves DIPHyde as the key morphological parameter, along with the pearlite lamellar spacing. These parameters are dependent on solidification time, cooling rate, and alloy composition. The proposed approach bears simplicity compared to the microstructure modelling methods [7,8]. The methodology is validated to include analytical formulation of the UTS prediction models and robust experimental thermal analysis, to obtain latent heat of solidification and solid-state transformation as input data for the simulation. First, the UTS modeling methods are elaborated followed by the details on the experimental setup and alloy composition. Casting simulation model is then introduced, as well as the simulation procedure. The results are discussed in comparison with the temperature and UTS measurements, followed by conclusions regarding applicability and limitations of the proposed UTS prediction methodology.

2. UTS Modeling


The modified Griffith fracture relation is given by Equation (1) [3], and the modified Hall–Petch strengthening model is represented by Equation (2) [8].

where 𝜎𝑈𝑇𝑆 is the ultimate tensile strength, α is the maximum defect size, and kt is the stress intensity factor of the metallic matrix, k1 and k2 are the contributions from other strengthening mechanisms, and d is the grain size. The maximum defect size and grain size, α and d, are provided in μm, parameters kt and k2 are in MPa, √μm, and k1 is in MPa.

It was found in [10] that DIPHyde is the dominant factor that reduces the UTS in lamellar graphite iron alloys. A modified Griffith equation was obtained in [10] as result of the linear regression analysis of the experimental data, Equation (3).

According to this model, if a tensile force is applied on the microstructure, a crack will start to form at a certain stress level. The crack will propagate relatively easily through the numerous interconnected graphite particles that are embedded in the metallic matrix of the eutectic cell. When the crack reaches the metallic matrix (pearlite) that was originated from the primary austenite (dendritic phase), the relatively rapid crack extension will be halted, due to the fact that much larger stresses are required for the fracture of this phase. The magnitude of the additional stress is proportional to the pearlite lamellar spacing (λpearlite). Based on this assumption, it becomes apparent that the effect of λpearlite on the UTS must be taken into consideration. Thus, linear multiple regression analysis was made to determine the simultaneous influence of the DIPHyde and the λpearlite on the UTS. The model obtained is based on the modified Hall–Petch relation, and is expressed by Equation (4) [11].

The DIPHyde parameter was found to be related to the solidification time (ts) and the fraction of primary austenite (fγ), as seen from Equation (5) [14].

The λpearlite parameter at room temperature was assumed to be dependent on the cooling rate in the eutectoid transformation region. The empirical relationship between λpearlite at room temperature, and the cooling rate at the temperature intervals between 700 and 740 °C, is shown in Figure 1. The experimentally derived relation Equation (6) was used for investigating the effect of different λpearlite prediction models on simulated UTS. The measurements techniques, the microstructure and thermal data that resulted in Equation (6), are presented elsewhere [11,12]. Briefly, the pearlite lamellar spacing was measured using SEM and a linear intercept method. The minimum value was considered to be the correct spacing (perpendicular to the lamellae). The distance between 11 adjacent ferrite lamellas was measured and divided by 10 for estimation of a single interlamellar spacing.

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Figure 1. Pearlite lamellar spacing as function of cooling rate between 700 and 740 °C.

3. Materials and Methods

3.1. Cylindrical Castings

The experimental layout contained three cylindrical cavities, each one surrounded by a different material (steel chill, sand, and insulation) intended to provide three different cooling rates. The entire assembly was enclosed by a furan-bounded sand mold. The dimensions of the cylinders surrounded by sand and chill were ∅50 × 70 mm, and the insulated cylinder dimensions were ∅80 × 70 mm. A lateral 2-D heat flow condition was induced by placing an insulation plate at the top and bottom of the cylindrical castings. The design of the cylindrical castings and arrangement of the experimental layout are shown in Figure 2 and Figure 3, respectively.

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Figure 2. Cylindrical castings with the insulation and chill.

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Figure 3. The experimental layout. (1) Thermocouples, (2) sand mold, and (3) insulation plates.

Two type S thermocouples with glass tube protection were embedded in every cylindrical casting. A central thermocouple was located on the central axis of the cylinder. The distance between the central and the lateral thermocouple was 20 mm for the ∅50 mm cylinder and 30 mm for the ∅80 mm cylinder. The thermocouples were placed at the mid-height of each cylinder and the temperatures were recorded at approximately 0.2 s interval. A 16-bit resolution data acquisition system with the sampling rate 100 Hz was employed [12].
The mold-filling time was 12 s. The solidification times of the metal in the chill, sand, and insulation were roughly 80, 400, and 1500 s, respectively. An electric induction furnace was utilized for melting of the charge material. The cast iron base alloy was inoculated with a constant level of a standard Sr-based inoculant. Four hypoeutectic lamellar graphite iron heats with varying carbon contents were produced. The alloy with the higher carbon content was cast first, and steel scraps were added to the furnace for the adjustment of the carbon content in the following casting. Coin-shaped specimens were extracted for chemical analysis. The chemical compositions of the four different alloys are presented in Table 1. All the castings had a fully pearlitic microstructure.

Table 1. Chemical composition (wt %) and carbon equivalent (Ceq = %C + %Si/3 + %P/3).

AlloyCSiMnPSCrCuCeq
A3.621.880.570.040.080.140.384.26
B3.341.830.560.040.080.150.373.96
C3.051.770.540.040.080.140.363.65
D2.801.750.540.040.080.150.353.40

Tensile strength measurements were performed using a dog bone-shaped specimen with 6 mm diameter in the gauge section, 35 mm gauge length, and a 3 μm surface finish. The tests were conducted at a strain rate of 0.035 mm/s and at room temperature. The experimental tensile samples were machined at the distance ~10 mm (sand, chill) and ~20 mm (insulation) from the cylinder axis. The load cell error of the tensile testing machine was <0.5%.

3.2. Simulation Model and Assumptions

A CFD software (Flow-3D CAST, v.5.0 from Flow Science, Inc., Santa Fe, NM, USA) [15] was employed to develop a full-scale 3D model of the casting process for the experimental layout. Mold filling and the cooling/solidification stages were simulated, and local UTS computations were performed on the customized models. Mold-filling time was 12 s, and the laminar flow model was applied. The casting temperature was 1360 °C, and the metal input diameter was 3 cm. The ambient temperature was set to 20 °C. Symmetry boundary conditions were used on the faces of the computational domain, except for the upper face, where the pressure boundary condition was applied. A computational grid of cubical control elements was generated with the cell size 3 mm. The computational grid had a total of ~1 million cells. Different grid densities were tested, and grid-independent results were obtained. The explicit solver was employed during the mold filling, whereas the implicit solver was used for heat transfer simulation in the solidification phase. Since the focus was on heat transfer and the UTS computation methodology, shrinkage and micro-porosity models were not included in the solidification phase.
In this work, the amount of latent heat release due to solidification was related to the solid fraction curves, seen in Figure 4, for the studied alloys. These curves were calculated from the registered experimental cooling curves by using the Fourier thermal analysis method [16,17]. The latent heat of solidification was considered equal to 240 kJ/kg for all studied alloys [18]. Fourier thermal analysis was also applied on cooling curves for the determination of the latent heat release during the eutectoid transformation. The latent heat releases at the eutectoid transformation was found to be similar for all alloys and were incorporated into the specific heat curve as it is shown in Figure 5. The temperature dependent cast iron thermophysical properties [12], and the calibrated heat transfer coefficients applied in the simulation are presented in Table 2.

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Figure 4. Solid fraction variation with temperature.

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Figure 5. Specific heat as function of temperature.

Table 2. Temperature dependent properties of the cast iron and heat transfer coefficients *.

Temperature (°C)Cast Iron Thermophysical PropertiesHeat Transfer Coefficient
DensitySpecific HeatThermal ConductivitySand-CastingChill-CastingInsulation-Casting
[kg/m3][J/kg/K][W/m/K][W/m2/K][W/m2/K][W/m2/K]
6007146700404010010
7201074300
72112301
72412308
72510825010
750733
9008015
1000699480015025
1100825250130055
11546960837401450
11707016
12006985160060
12276939749
13006876771380180
17006395807389402700940
* Piecewise linear interpolation was made between neighboring points in the table.

3.3. Simulation Procedure

The simulation procedure consisted of model calibration with respect to the experimental cooling curves available at the location of the central thermocouple. Correct reproduction of the experimental cooling curves is the key for the UTS computation methodology, and one is free to choose methods for model calibration. In this work, the calibration was done by adjustment of the typical heat transfer coefficients between the metal and the insulation, sand, and chill. The UTS calculations for the cylinders were performed during post-processing, by applying local solidification times, local cooling rates in the eutectoid transformation region, and the experimentally determined fraction of primary austenite (fγ) for each alloy: 0.3 for alloy A, 0.4 for alloy B, 0.51 for alloy C, and 0.61 for alloy D [16].

4. Results and Discussion

The general agreement within 7% was achieved between the simulated and measured cooling curves for insulation-, sand-, and chill-encapsulated cylinders; see Figure 6, Figure 7, Figure 8 and Figure 9. The larger differences were observed in the solidification region of the chill castings where the eutectic reaction was predicted at higher temperature than measured. This is because the solid fraction-temperature curves were derived from the sand-casting thermal histories, where the undercooling was much lower. Moreover, the solidification model in the simulation used the enthalpy method [19] and ignored the kinetics of phase transformation and, therefore, the undercooling and recalescence of solidification were not predicted. However, the simulated solidification times were in good agreement with the experiment.

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Figure 6. Simulated and experimental cooling curves (central thermocouple) for alloy A: (a) insulation, (b) sand, and (c) chill.

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Figure 7. Simulated and experimental cooling curves (central thermocouple) for alloy B: (a) insulation, (b) sand, and (c) chill.

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Figure 8. Simulated and experimental cooling curves (central thermocouple) for alloy C: (a) insulation, (b) sand, and (c) chill.

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Figure 9. Simulated and experimental cooling curves (central thermocouple) for alloy D: (a) insulation (b) sand, and (c) chill.

The measurement accuracy of the type S thermocouples was ±1.5 °C. It is worth noting that some of the thermocouples inserted in the melt could be slightly displaced from their intended positions during the solidification, which created an additional source of the measurement error; this can be seen clearly, e.g., from the solidification part of the experimental cooling curve for the insulated cylinder in Figure 7.
The simulated solidification times and cooling rates were used in Equations (3) and (4) for the calculation of UTS. The predicted UTS distribution, substituted in the middle cross-section of the alloy B casting, is shown in Figure 10. The figure illustrates the inhomogeneous material strength in the casting. It is directly related to the temperature gradient and the cooling rate distribution during solidification and solid-state transformation. The reduced UTS is the result of the microstructure coarseness that is related to the solidification time and the cooling rate. Moreover, large UTS gradients on the chilled cylinder can be explained by the large temperature gradients at high solidification rate. Intermediate and slow solidification rates on sand- and insulation-encapsulated cylinders resulted in more uniform distribution of UTS values, due to the smaller temperature gradients during solidification. It should be noted that the variation of UTS magnitude within the tensile bar positions (shown with dashed lines) complicates the model validation.

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Figure 10. Distribution of ultimate tensile strength (UTS) calculated from Equations (4) and (6) for alloy B: (a) insulation-, (b) sand-, and (c) chill-encapsulated cylinder; the dashed lines indicate the position of the tensile bars.

The obtained values were compared to the measured UTS. Table 3 presents the experimental and simulated UTS results for different cooling rates and for each alloy. The simulated UTS values in Table 3 were picked from the mid-height locations of the tensile bar regions, indicated in Figure 10 with dashed lines. This would correspond to the failure location in the tensile test. However, the exact fracture location might be influenced by several other factors, such as microporosities, graphite flakes that are in contact with the casting surface, or other casting impurities. All of these can cause the crack initiation at positions where the theoretical material strength is not the lowest. Apparently, the fracture analysis is out of scope of the present work. There are quite small differences between simulated and measured UTS values, with the exception of the intermediate and slow cooling rates (sand and insulation) for alloy A, where all the models predicted the UTS with less accuracy. Relatively high, but still acceptable average percentage errors are also observed for the insulated cylinders cast of alloys C and D.

Table 3. Experimental and simulated UTS.

AlloyUTS, [MPa]Average Percentage Error, [%]
ExperimentSimulation
Equation (3) 1Equation (4) 2Equation (3) 1Equation (4) 2
AInsulation1541802001730
Sand1952302501828
Chill363340–350340–35055
BInsulation21120421331
Sand25425526916
Chill368365–375385–39516
CInsulation25023323676
Sand28629330025
Chill440420–435435–44530
DInsulation2892602531012
Sand33732532344
Chill447440–455475–49008
1 Modified Griffith model; 2 Modified Hall–Petch model.

Comparisons between the calculated and the measured data are demonstrated in Figure 11. The graph reveals a relatively strong correlation between the measured and computed UTS. The R2 values show that Equation (3) predicts the UTS with better accuracy than Equation (4). This indicates the need to develop further the model for prediction of the λpearlite parameter.

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Figure 11. Correlation between measured and simulated UTS values.

The observed deviations between the simulated and measured UTS can be also attributed to the limited number of tensile specimens [10] and to uncertainties regarding the measurements accuracy of the 𝐷𝐻𝑦𝑑𝐼𝑃
parameter, especially for the low cooling rate samples [20] that were used to develop the UTS models.
The presented results should be related to two fundamental publications on computer simulations of LGI solidification coupled with the Griffiths and Hall–Petch models [7,8]. The models for UTS calculation utilized in these works were based on a narrow carbon content interval, and on a limited cooling rate variation, in comparison. Moreover, growth kinetic equations were employed in [7,8]. On the contrary, the latent heat release model by the “enthalpy method” [19] was adopted for the solidification simulation in the present work. Furthermore, the presented way to determine the key parameters and incorporate them into material property prediction is novel. In [7,8], the key parameter was the eutectic cell diameter. It is evident that the modified Griffith and Hall–Petch equations are applicable once the eutectic diameter can be predicted, as well as the pearlite lamellar spacing in the Hall–Patch equation. A completely different approach validated in this work involved the hydraulic diameter as the key morphological parameter, along with the pearlite lamellar spacing introduced in [8]. The presented methodology to calculate the UTS features the simplicity of determining the key parameters by simulation (solidification time, cooling rate, and composition dependent). While [7] and [8] introduce complex microstructure models valid for small process intervals (with respect to composition and cooling condition), the current methodology lays back to a robust experimental thermal analysis [16], providing accurate input data (latent heat of both solidification and solid-state transformation) for the simulation. A robust iteration process for tuning up the heat transfer coefficient results in the accurately predicted cooling rate.

5. Conclusions

The novel UTS prediction methodology for fully pearlitic LGI alloys presented in this paper involves hydraulic diameter as the key morphological parameter, along with the pearlite lamellar spacing. It is characterized by simplicity, in comparison to the microstructure modelling methods. The methodology includes analytical formulation of the UTS prediction models, and robust experimental thermal analysis. The latter provides the latent heat of solidification and solid-state transformation as input data for the solidification simulation. In turn, the simulation delivers the solidification time and cooling rates for the UTS prediction models.

Microstructure models for the prediction of hydraulic diameter and the pearlite lamellar spacing, combined with modified Griffith and Hall–Petch equations, were incorporated into casting simulation software for the prediction of UTS in fully pearlitic LGI alloys. Overall, the simulation UTS results were found to be in good agreement (within 9% on the average) with the measurements. However, high average percentage errors were observed for the intermediate and slow cooling rates (sand and insulation) for the alloy with the higher carbon content (alloy A). This study revealed the necessity for development of a more advanced model for the prediction of the λpearlite parameter. The results demonstrated the applicability of the novel UTS prediction models for different chemical compositions and cooling conditions.

Further development of the microstructure modelling would enable determination of the key parameters (hydraulic diameter and pearlite lamellar spacing). However, it seems not to be critical for the presented novel UTS prediction methodology which is valid for the wide process interval.

Author Contributions

A.D. designed the experiment and supervised the work, I.B. performed the simulations, V.F. analyzed the data and wrote the paper, A.D. and I.B. reviewed the paper.

Funding

This research received no external funding.

Acknowledgments

This work was performed within the Swedish Casting Innovation Centre. Cooperating parties are Jönköping University, Scania CV AB, Swerea SWECAST AB and Volvo Powertrain Production Gjuteriet AB. Participating persons from these institutions/companies are acknowledged.

Conflicts of Interest

The authors declare no conflict of interest.

References

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  9. Urrutia, A.; Celentano, J.D.; Dayalan, R. Modeling and Simulation of the Gray-to-White Transition during Solidification of a Hypereutectic Gray Cast Iron: Application to a Stub-to-Carbon Connection used in Smelting Processes. Metals 2017, 7, 549.
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Numerical Investigation of the Local Scour for Tripod Pile Foundation

Numerical Investigation of the Local Scour for Tripod Pile Foundation

Waqed H. Hassan Zahraa Mohammad Fadhe* Rifqa F. Thiab Karrar Mahdi
Civil Engineering Department, Faculty of Engineering, University of Warith Al-Anbiyaa, Kerbala 56001, Iraq
Civil Engineering Department, Faculty of Engineering, University of Kerbala, Kerbala 56001, Iraq
Corresponding Author Email: Waqed.hammed@uowa.edu.iq

OPEN ACCESS

Abstract: 

This work investigates numerically a local scour moves in irregular waves around tripods. It is constructed and proven to use the numerical model of the seabed-tripod-fluid with an RNG k turbulence model. The present numerical model then examines the flow velocity distribution and scour characteristics. After that, the suggested computational model Flow-3D is a useful tool for analyzing and forecasting the maximum scour development and the flow field in random waves around tripods. The scour values affecting the foundations of the tripod must be studied and calculated, as this phenomenon directly and negatively affects the structure of the structure and its design life. The lower diagonal braces and the main column act as blockages, increasing the flow accelerations underneath them.  This increases the number of particles that are moved, which in turn creates strong scouring in the area. The numerical model has a good agreement with the experimental model, with a maximum percentage of error of 10% between the experimental and numerical models. In addition, Based on dimensional analysis parameters, an empirical equation has been devised to forecast scour depth with flow depth, median size ratio, Keulegan-Carpenter (Kc), Froud number flow, and wave velocity that the results obtained in this research at various flow velocities and flow depths demonstrated that the maximum scour depth rate depended on wave height with rising velocities and decreasing particle sizes (d50) and the scour depth attains its steady-current value for Vw < 0.75. As the Froude number rises, the maximum scour depth will be large.

Keywords: 

local scour, tripod foundation, Flow-3D​, waves

1. Introduction

New energy sources have been used by mankind since they become industrialized. The main energy sources have traditionally been timber, coal, oil, and gas, but advances in the science of new energies, such as nuclear energy, have emerged [1, 2]. Clean and renewable energy such as offshore wind has grown significantly during the past few decades. There are numerous different types of foundations regarding offshore wind turbines (OWTs), comprising the tripod, jacket, gravity foundation, suction anchor (or bucket), and monopile [3, 4]. When the water depth is less than 30 meters, Offshore wind farms usually employ the monopile type [4]. Engineers must deal with the wind’s scouring phenomenon turbine foundations when planning and designing wind turbines for an offshore environment [5]. Waves and currents generate scour, this is the erosion of soil near a submerged foundation and at its location [6]. To predict the regional scour depth at a bridge pier, Jalal et al. [7-10] developed an original gene expression algorithm using artificial neural networks. Three monopiles, one main column, and several diagonal braces connecting the monopiles to the main column make up the tripod foundation, which has more complicated shapes than a single pile. The design of the foundation may have an impact on scour depth and scour development since the foundation’s form affects the flow field [11, 12]. Stahlmann [4] conducted several field investigations. He discovered that the main column is where the greatest scour depth occurred. Under the main column is where the maximum scour depth occurs in all experiments. The estimated findings show that higher wave heights correspond to higher flow velocities, indicating that a deeper scour depth is correlated with finer silt granularity [13] recommends as the design value for a single pile. These findings support the assertion that a tripod may cause the seabed to scour more severely than a single pile. The geography of the scour is significantly more influenced by the KC value (Keulegan–Carpenter number)

The capability of computer hardware and software has made computational fluid dynamics (CFD) quite popular to predict the behavior of fluid flow in industrial and environmental applications has increased significantly in recent years [14].

Finding an acceptable piece of land for the turbine’s construction and designing the turbine pile precisely for the local conditions are the biggest challenges. Another concern related to working in a marine environment is the effect of sea waves and currents on turbine piles and foundations. The earth surrounding the turbine’s pile is scoured by the waves, which also render the pile unstable.

In this research, the main objective is to investigate numerically a local scour around tripods in random waves. It is constructed and proven to use the tripod numerical model. The present numerical model is then used to examine the flow velocity distribution and scour characteristics.

2. Numerical Model

To simulate the scouring process around the tripod foundation, the CFD code Flow-3D was employed. By using the fractional area/volume method, it may highlight the intricate boundaries of the solution domain (FAVOR).

This model was tested and validated utilizing data derived experimentally from Schendel et al. [15] and Sumer and Fredsøe [6]. 200 runs were performed at different values of parameters.

2.1 Momentum equations

The incompressible viscous fluid motion is described by the three RANS equations listed below [16]:

(1)

\frac{\partial u}{\partial t}+\frac{1}{{{V}_{F}}}\left( u{{A}_{x}}\frac{\partial u}{\partial x}+v{{A}_{y}}\frac{\partial u}{\partial y}+w{{A}_{z}}\frac{\partial u}{\partial z} \right)=-\frac{1}{\rho }\frac{\partial p}{\partial x}+{{G}_{x}}+fx

(2)

\frac{\partial v}{\partial t}+\frac{1}{{{V}_{F}}}\left( u{{A}_{x}}\frac{\partial v}{\partial x}+v{{A}_{y}}\frac{\partial v}{\partial y}+w{{A}_{z}}\frac{\partial v}{\partial z} \right)=-\frac{1}{\rho }\frac{\partial p}{\partial y}+{{G}_{y}}+\text{f}y

 (3)

\frac{\partial w}{\partial t}+\frac{1}{{{V}_{F}}}\left( u{{A}_{x}}\frac{\partial w}{\partial x}+v{{A}_{y}}\frac{\partial w}{\partial y}+w{{A}_{z}}\frac{\partial w}{\partial z} \right)=-\frac{1}{\rho }\frac{\partial p}{\partial z}+{{G}_{z}}+\text{fz}

where, respectively, uv, and w represent the xy, and z flow velocity components; volume fraction (VF), area fraction (AiI=xyz), water density (f), viscous force (fi), and body force (Gi) are all used in the formula.

2.2 Model of turbulence

Several turbulence models would be combined to solve the momentum equations. A two-equation model of turbulence is the RNG k-model, which has a high efficiency and accuracy in computing the near-wall flow field. Therefore, the flow field surrounding tripods was captured using the RNG k-model.

2.3 Model of sediment scour

2.3.1 Induction and deposition

Eq. (4) can be used to determine the particle entrainment lift velocity [17].

(4)

{{u}_{lift,i}}={{\alpha }_{i}}{{n}_{s}}d_{*}^{0.3}{{\left( \theta -{{\theta }_{cr}} \right)}^{1.5}}\sqrt{\frac{\parallel g\parallel {{d}_{i}}\left( {{\rho }_{i}}-{{\rho }_{f}} \right)}{{{\rho }_{f}}}}

α𝛼  is the Induction parameter, ns the normal vector is parallel to the seafloor, and for the present numerical model, ns=(0,0,1), θ𝜃cr is the essential Shields variable, g is the accelerated by gravity, di is the size of the particles, ρi is species density in beds, and d The diameter of particles without dimensions; these values can be obtained in Eq. (5).

(5)

{{d}_{*}}={{d}_{i}}{{\left( \frac{\parallel g\parallel {{\rho }_{f}}\left( {{\rho }_{i}}-{{\rho }_{f}} \right)}{\mu _{f}^{2}} \right)}^{1/3}}

μ𝜇f is this equation a dynamic viscosity of the fluid. cr was determined from an equation based on Soulsby [18].

(6)

{{\theta }_{cr}}=\frac{0.3}{1+1.2{{d}_{*}}}+0.055\left[ 1-\text{exp}\left( -0.02{{d}_{*}} \right) \right]

The equation was used to determine how quickly sand particles set Eq. (7):

(7)

{{\mathbf{u}}_{\text{nsettling},i}}=\frac{{{v}_{f}}}{{{d}_{i}}}\left[ {{\left( {{10.36}^{2}}+1.049d_{*}^{3} \right)}^{0.5}}-10.36 \right]

vf  stands for fluid kinematic viscosity.

2.3.2 Transportation for bed loads

Van Rijn [19] states that the speed of bed load conveyance was determined as:

(8)

{{~}_{\text{bedload},i}}=\frac{{{q}_{b,i}}}{{{\delta }_{i}}{{c}_{b,i}}{{f}_{b}}}

fb  is the essential particle packing percentage, qbi is the bed load transportation rate, and cb, I the percentage of sand by volume i. These variables can be found in Eq. (9), Eq. (10), fbδ𝛿i the bed load thickness.

(9)

{{q}_{b,i}}=8{{\left[ \parallel g\parallel \left( \frac{{{\rho }_{i}}-{{\rho }_{f}}}{{{\rho }_{f}}} \right)d_{i}^{3} \right]}^{\frac{1}{2}}}

(10)

{{\delta }_{i}}=0.3d_{*}^{0.7}{{\left( \frac{\theta }{{{\theta }_{cr}}}-1 \right)}^{0.5}}{{d}_{i}}

In this paper, after the calibration of numerous trials, the selection of parameters for sediment scour is crucial. Maximum packing fraction is 0.64 with a shields number of 0.05, entrainment coefficient of 0.018, the mass density of 2650, bed load coefficient of 12, and entrainment coefficient of 0.01.

3. Model Setup

To investigate the scour characteristics near tripods in random waves, the seabed-tripod-fluid numerical model was created as shown in Figure 1. The tripod basis, a seabed, and fluid and porous medium were all components of the model. The seabed was 240 meters long, 40 meters wide, and three meters high. It had a median diameter of d50 and was composed of uniformly fine sand. The 2.5-meter main column diameter D. The base of the main column was three dimensions above the original seabed. The center of the seafloor was where the tripod was, 130 meters from the offshore and 110 meters from the onshore. To prevent wave reflection, the porous media were positioned above the seabed on the onshore side.

image013.png

Figure 1. An illustration of the numerical model for the seabed-tripod-fluid

3.1 Generation of meshes

Figure 2 displays the model’s mesh for the Flow-3D software grid. The current model made use of two different mesh types: global mesh grid and nested mesh grid. A mesh grid with the following measurements was created by the global hexahedra mesh grid: 240m length, 40m width, and 32m height. Around the tripod, a finer nested mesh grid was made, with dimensions of 0 to 32m on the z-axis, 10 to 30 m on the x-axis, and 25 to 15 m on the y-axis. This improved the calculation’s precision and mesh quality.

image014.png

Figure 2. The mesh block sketch

3.2 Conditional boundaries

To increase calculation efficiency, the top side, The model’s two x-z plane sides, as well as the symmetry boundaries, were all specified. For u, v, w=0, the bottom boundary wall was picked. The offshore end of the wave boundary was put upstream. For the wave border, random waves were generated using the wave spectrum from the Joint North Sea Wave Project (JONSWAP). Boundary conditions are shown in Figure 3.

image015.png

Figure 3. Boundary conditions of the typical problem

The wave spectrum peak enhancement factor (=3.3 for this work) and can be used to express the unidirectional JONSWAP frequency spectrum.

3.3 Mesh sensitivity

Before doing additional research into scour traits and scour depth forecasting, mesh sensitivity analysis is essential. Three different mesh grid sizes were selected for this section: Mesh 1 has a 0.45 by 0.45 nested fine mesh and a 0.6 by 0.6 global mesh size. Mesh 2 has a 0.4 global mesh size and a 0.35 nested fine mesh size, while Mesh 3 has a 0.25 global mesh size and a nested fine mesh size of 0.15. Comparing the relative fine mesh size (such as Mesh 2 or Mesh 3) to the relatively coarse mesh size (such as Mesh 1), a larger scour depth was seen; this shows that a finer mesh size can more precisely represent the scouring and flow field action around a tripod. Significantly, a lower mesh size necessitates a time commitment and a more difficult computer configuration. Depending on the sensitivity of the mesh guideline utilized by Pang et al., when Mesh 2 is applied, the findings converge and the mesh size is independent [20]. In the next sections, scouring the area surrounding the tripod was calculated using Mesh 2 to ensure accuracy and reduce computation time. The working segment generates a total of 14, 800,324 cells.

3.4 Model validation

Comparisons between the predicted outcomes from the current model and to confirm that the current numerical model is accurate and suitably modified, experimental data from Sumer and Fredsøe [6] and Schendel et al. [15] were used. For the experimental results of Run 05, Run 15, and Run 22 from Sumer and Fredsøe [6], the experimental A9, A13, A17, A25, A26, and A27 results from Schendel et al. [15], and the numerical results from the current model are shown in Figure 4. The present model had d50=0.051cm, the height of the water wave(h)=10m, and wave velocity=0.854 m.s-1.

image016.png

Figure 4. Cell size effect

image017.png

Figure 5. Comparison of the present study’s maximum scour depth with that authored by Sumer and Fredsøe [6] and Schendel et al. [15]

According to Figure 5, the highest discrepancy between the numerical results and experimental data is about 10%, showing that overall, there is good agreement between them. The ability of the current numerical model to accurately depict the scour process and forecast the maximum scour depth (S) near foundations is demonstrated by this. Errors in the simulation were reduced by using the calibrated values of the parameter. Considering these results, a suggested simulated scouring utilizing a Flow-3D numerical model is confirmed as a superior way for precisely forecasting the maximum scour depth near a tripod foundation in random waves.

3.5 Dimensional analysis

The variables found in this study as having the greatest impacts, variables related to flow, fluid, bed sediment, flume shape, and duration all had an impact on local scouring depth (t). Hence, scour depth (S) can be seen as a function of these factors, shown as:

(11)

S=f\left(\rho, v, V, h, g, \rho s, d_{50}, \sigma g, V_w, D, d, T_v, t\right)

With the aid of dimensional analysis, the 14-dimensional parameters in Eq. (11) were reduced to 6 dimensionless variables using Buckingham’s -theorem. D, V, and were therefore set as repetition parameters and others as constants, allowing for the ignoring of their influence. Eq. (12) thus illustrates the relationship between the effect of the non-dimensional components on the depth of scour surrounding a tripod base.

(12)

\frac{S}{D}=f\left(\frac{h}{D}, \frac{d 50}{D}, \frac{V}{V W}, F r, K c\right)

where, SD𝑆𝐷 are scoured depth ratio, VVw𝑉𝑉𝑤 is flow wave velocity, d50D𝑑50𝐷 median size ratio, $Fr representstheFroudnumber,and𝑟𝑒𝑝𝑟𝑒𝑠𝑒𝑛𝑡𝑠𝑡ℎ𝑒𝐹𝑟𝑜𝑢𝑑𝑛𝑢𝑚𝑏𝑒𝑟,𝑎𝑛𝑑Kc$ is the Keulegan-Carpenter.

4. Result and Discussion

4.1 Development of scour

Similar to how the physical model was used, this numerical model was also used. The numerical model’s boundary conditions and other crucial variables that directly influence the outcomes were applied (flow depth, median particle size (d50), and wave velocity). After the initial 0-300 s, the scour rate reduced as the scour holes grew quickly. The scour depths steadied for about 1800 seconds before reaching an asymptotic value. The findings of scour depth with time are displayed in Figure 6.

4.2 Features of scour

Early on (t=400s), the scour hole began to appear beneath the main column and then began to extend along the diagonal bracing connecting to the wall-facing pile. Gradually, the geography of the scour; of these results is similar to the experimental observations of Stahlmann [4] and Aminoroayaie Yamini et al. [1]. As the waves reached the tripod, there was an enhanced flow acceleration underneath the main column and the lower diagonal braces as a result of the obstructing effects of the structural elements. More particles are mobilized and transported due to the enhanced near-bed flow velocity, it also increases bed shear stress, turbulence, and scour at the site. In comparison to a single pile, the main column and structural components of the tripod have a significant impact on the flow velocity distribution and, consequently, the scour process and morphology. The main column and seabed are separated by a gap, therefore the flow across the gap may aid in scouring. The scour hole first emerged beneath the main column and subsequently expanded along the lower structural components, both Aminoroayaie Yamini et al. [1] and Stahlmann [4] made this claim. Around the tripod, there are several different scour morphologies and the flow velocity distribution as shown in Figures 7 and 8.

image023.png

Figure 6. Results of scour depth with time

image024.png

image025.png

image026.png

image027.png

Figure 7. The sequence results of scour depth around tripod development (reached to steady state) simulation time

image028.png

image029.png

image030.png

image031.png

Figure 8. Random waves of flow velocity distribution around a tripod

4.3 Wave velocity’s (Vw) impact on scour depth

In this study’s section, we looked at how variations in wave current velocity affected the scouring depth. Bed scour pattern modification could result from an increase or decrease in waves. As a result, the backflow area produced within the pile would become stronger, which would increase the depth of the sediment scour. The quantity of current turbulence is the primary cause of the relationship between wave height and bed scour value. The current velocity has increased the extent to which the turbulence energy has changed and increased in strength now present. It should be mentioned that in this instance, the Jon swap spectrum random waves are chosen. The scour depth attains its steady-current value for Vw<0.75, Figure 9 (a) shows that effect. When (V) represents the mean velocity=0.5 m.s-1.

image032.png

(a)

image033.png

(b)

image034.png

(c)

image035.png

(d)

Figure 9Main effects on maximum scour depth (Smax) as a function of column diameter (D)

4.4 Impact of a median particle (d50) on scour depth

In this section of the study, we looked into how variations in particle size affected how the bed profile changed. The values of various particle diameters are defined in the numerical model for each run numerical modeling, and the conditions under which changes in particle diameter have an impact on the bed scour profile are derived. Based on Figure 9 (b), the findings of the numerical modeling show that as particle diameter increases the maximum scour depth caused by wave contact decreases. When (d50) is the diameter of Sediment (d50). The Shatt Al-Arab soil near Basra, Iraq, was used to produce a variety of varied diameters.

4.5 Impact of wave height and flow depth (h) on scour depth

One of the main elements affecting the scour profile brought on by the interaction of the wave and current with the piles of the wind turbines is the height of the wave surrounding the turbine pile causing more turbulence to develop there. The velocity towards the bottom and the bed both vary as the turbulence around the pile is increased, modifying the scour profile close to the pile. According to the results of the numerical modeling, the depth of scour will increase as water depth and wave height in random waves increase as shown in Figure 9 (c).

4.6 Froude number’s (Fr) impact on scour depth

No matter what the spacing ratio, the Figure 9 shows that the Froude number rises, and the maximum scour depth often rises as well increases in Figure 9 (d). Additionally, it is crucial to keep in mind that only a small portion of the findings regarding the spacing ratios with the smallest values. Due to the velocity acceleration in the presence of a larger Froude number, the range of edge scour downstream is greater than that of upstream. Moreover, the scouring phenomena occur in the region farthest from the tripod, perhaps as a result of the turbulence brought on by the collision of the tripod’s pile. Generally, as the Froude number rises, so does the deposition height and scour depth.

4.7 Keulegan-Carpenter (KC) number

The geography of the scour is significantly more influenced by the KC value. Greater KC causes a deeper equilibrium scour because an increase in KC lengthens the horseshoe vortex’s duration and intensifies it as shown in Figure 10.

The result can be attributed to the fact that wave superposition reduced the crucial KC for the initiation of the scour, particularly under small KC conditions. The primary variable in the equation used to calculate This is the depth of the scouring hole at the bed. The following expression is used to calculate the Keulegan-Carpenter number:

Kc=Vw∗TpD𝐾𝑐=𝑉𝑤∗𝑇𝑝𝐷                          (13)

where, the wave period is Tp and the wave velocity is shown by Vw.

image037.png

Figure 10. Relationship between the relative maximum scour depth and KC

5. Conclusion

(1) The existing seabed-tripod-fluid numerical model is capable of faithfully reproducing the scour process and the flow field around tripods, suggesting that it may be used to predict the scour around tripods in random waves.

(2) Their results obtained in this research at various flow velocities and flow depths demonstrated that the maximum scour depth rate depended on wave height with rising velocities and decreasing particle sizes (d50).

(3) A diagonal brace and the main column act as blockages, increasing the flow accelerations underneath them. This raises the magnitude of the disturbance and the shear stress on the seafloor, which in turn causes a greater number of particles to be mobilized and conveyed, as a result, causes more severe scour at the location.

(4) The Froude number and the scouring process are closely related. In general, as the Froude number rises, so does the maximum scour depth and scour range. The highest maximum scour depth always coincides with the bigger Froude number with the shortest spacing ratio.

Since the issue is that there aren’t many experiments or studies that are relevant to this subject, therefore we had to rely on the monopile criteria. Therefore, to gain a deeper knowledge of the scouring effect surrounding the tripod in random waves, further numerical research exploring numerous soil, foundation, and construction elements as well as upcoming physical model tests will be beneficial.

Nomenclature

CFDComputational fluid dynamics
FAVORFractional Area/Volume Obstacle Representation
VOFVolume of Fluid
RNGRenormalized Group
OWTsOffshore wind turbines
Greek Symbols
ε, ωDissipation rate of the turbulent kinetic energy, m2s-3
Subscripts
d50Median particle size
VfVolume fraction
GTTurbulent energy of buoyancy
KTTurbulent velocity
PTKinetic energy of the turbulence
ΑiInduction parameter
nsInduction parameter
ΘΘcrThe essential Shields variable
DiDiameter of sediment
dThe diameter of particles without dimensions
µfDynamic viscosity of the fluid
qb,iThe bed load transportation rate
Cs,iSand particle’s concentration of mass
DDiameter of pile
DfDiffusivity
DDiameter of main column
FrFroud number
KcKeulegan–Carpenter number
GAcceleration of gravity g
HFlow depth
VwWave Velocity
VMean Velocity
TpWave Period
SScour depth

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[4] Stahlmann, A. (2013). Numerical and experimental modeling of scour at foundation structures for offshore wind turbines. In ISOPE International Ocean and Polar Engineering Conference. ISOPE, pp. ISOPE-I.

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[15] Schendel, A., Welzel, M., Schlurmann, T., Hsu, T.W. (2020). Scour around a monopile induced by directionally spread irregular waves in combination with oblique currents. Coastal Engineering, 161: 103751. https://doi.org/10.1016/j.coastaleng.2020.103751

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Estimating maximum initial wave amplitude of subaerial landslide tsunamis: A three-dimensional modelling approach

Estimating maximum initial wave amplitude of subaerial landslide tsunamis: A three-dimensional modelling approach

해저 산사태 쓰나미의 최대 초기 파동 진폭 추정: 3차원 모델링 접근법

Ramtin Sabeti a, Mohammad Heidarzadeh ab

aDepartment of Architecture and Civil Engineering, University of Bath, Bath BA27AY, UK
bHydroCoast Consulting Engineers Ltd, Bath, UK

https://doi.org/10.1016/j.ocemod.2024.102360

Highlights

  • •Landslide travel distance is considered for the first time in a predictive equation.
  • •Predictive equation derived from databases using 3D physical and numerical modeling.
  • •The equation was successfully tested on the 2018 Anak Krakatau tsunami event.
  • •The developed equation using three-dimensional data exhibits a 91 % fitting quality.

Abstract

Landslide tsunamis, responsible for thousands of deaths and significant damage in recent years, necessitate the allocation of sufficient time and resources for studying these extreme natural hazards. This study offers a step change in the field by conducting a large number of three-dimensional numerical experiments, validated by physical tests, to develop a predictive equation for the maximum initial amplitude of tsunamis generated by subaerial landslides. We first conducted a few 3D physical experiments in a wave basin which were then applied for the validation of a 3D numerical model based on the Flow3D-HYDRO package. Consequently, we delivered 100 simulations using the validated model by varying parameters such as landslide volume, water depth, slope angle and travel distance. This large database was subsequently employed to develop a predictive equation for the maximum initial tsunami amplitude. For the first time, we considered travel distance as an independent parameter for developing the predictive equation, which can significantly improve the predication accuracy. The predictive equation was tested for the case of the 2018 Anak Krakatau subaerial landslide tsunami and produced satisfactory results.

Keywords

Tsunami, Subaerial landslide, Physical modelling, Numerical simulation, FLOW-3D HYDRO

1. Introduction and literature review

The Anak Krakatau landslide tsunami on 22nd December 2018 was a stark reminder of the dangers posed by subaerial landslide tsunamis (Ren et al., 2020Mulia et al. 2020a; Borrero et al., 2020Heidarzadeh et al., 2020Grilli et al., 2021). The collapse of the volcano’s southwest side into the ocean triggered a tsunami that struck the Sunda Strait, leading to approximately 450 fatalities (Syamsidik et al., 2020Mulia et al., 2020b) (Fig. 1). As shown in Fig. 1, landslide tsunamis (both submarine and subaerial) have been responsible for thousands of deaths and significant damage to coastal communities worldwide. These incidents underscored the critical need for advanced research into landslide-generated waves to aid in hazard prediction and mitigation. This is further emphasized by recent events such as the 28th of November 2020 landslide tsunami in the southern coast mountains of British Columbia (Canada), where an 18 million m3 rockslide generated a massive tsunami, with over 100 m wave run-up, causing significant environmental and infrastructural damage (Geertsema et al., 2022).

Fig 1

Physical modelling and numerical simulation are crucial tools in the study of landslide-induced waves due to their ability to replicate and analyse the complex dynamics of landslide events (Kim et al., 2020). In two-dimensional (2D) modelling, the discrepancy between dimensions can lead to an artificial overestimation of wave amplification (e.g., Heller and Spinneken, 2015). This limitation is overcome with 3D modelling, which enables the scaled-down representation of landslide-generated waves while avoiding the simplifications inherent in 2D approaches (Erosi et al., 2019). Another advantage of 3D modelling in studying landslide-generated waves is its ability to accurately depict the complex dynamics of wave propagation, including lateral and radial spreading from the slide impact zone, a feature unattainable with 2D models (Heller and Spinneken, 2015).

Physical experiments in tsunami research, as presented by authors such as Romano et al. (2020), McFall and Fritz (2016), and Heller and Spinneken (2015), have supported 3D modelling works through validation and calibration of the numerical models to capture the complexities of wave generation and propagation. Numerical modelling has increasingly complemented experimental approach in tsunami research due to the latter’s time and resource-intensive nature, particularly for 3D models (Li et al., 2019; Kim et al., 2021). Various numerical approaches have been employed, from Eulerian and Lagrangian frameworks to depth-averaged and Navier–Stokes models, enhancing our understanding of tsunami dynamics (Si et al., 2018Grilli et al., 2019Heidarzadeh et al., 20172020Iorio et al., 2021Zhang et al., 2021Kirby et al., 2022Wang et al., 20212022Hu et al., 2022). The sophisticated numerical techniques, including the Particle Finite Element Method and the Immersed Boundary Method, have also shown promising results in modelling highly dynamic landslide scenarios (Mulligan et al., 2020Chen et al., 2020). Among these methods and techniques, FLOW-3D HYDRO stands out in simulating landslide-generated tsunami waves due to its sophisticated technical features such as offering Tru Volume of Fluid (VOF) method for precise free surface tracking (e.g., Sabeti and Heidarzadeh 2022a). TruVOF distinguishes itself through a split Lagrangian approach, adeptly reducing cumulative volume errors in wave simulations by dynamically updating cell volume fractions and areas with each time step. Its intelligent adaptation of time step size ensures precise capture of evolving free surfaces, offering unparalleled accuracy in modelling complex fluid interfaces and behaviour (Flow Science, 2023).

Predictive equations play a crucial role in assessing the potential hazards associated with landslide-generated tsunami waves due to their ability to provide risk assessment and warnings. These equations can offer swift and reasonable evaluations of potential tsunami impacts in the absence of detailed numerical simulations, which can be time-consuming and expensive to produce. Among multiple factors and parameters within a landslide tsunami generation, the initial maximum wave amplitude (Fig. 1) stands out due to its critical role. While it is most likely that the initial wave generated by a landslide will have the highest amplitude, it is crucial to clarify that the term “initial maximum wave amplitude” refers to the highest amplitude within the first set of impulse waves. This parameter is essential in determining the tsunami’s impact severity, with higher amplitudes signalling a greater destructive potential (Sabeti and Heidarzadeh 2022a). Additionally, it plays a significant role in tsunami modelling, aiding in the prediction of wave propagation and the assessment of potential impacts.

In this study, we initially validate the FLOW-3D HYDRO model through a series of physical experiments conducted in a 3D wave tank at University of Bath (UK). Upon confirmation of the model’s accuracy, we use it to systematically vary parameters namely landslide volume, water depth, slope angle, and travel distance, creating an extensive database. Alongside this, we perform a sensitivity analysis on these variables to discern their impacts on the initial maximum wave amplitude. The generated database was consequently applied to derive a non-dimensional predictive equation aimed at estimating the initial maximum wave amplitude in real-world landslide tsunami events.

Two innovations of this study are: (i) The predictive equation of this study is based on a large number of 3D experiments whereas most of the previous equations were based on 2D results, and (ii) For the first time, the travel distance is included in the predictive equation as an independent parameter. To evaluate the performance of our predictive equation, we applied it to a previous real-world subaerial landslide tsunami, i.e., the Anak Krakatau 2018 event. Furthermore, we compare the performance of our predictive equation with other existing equations.

2. Data and methods

The methodology applied in this research is a combination of physical and numerical modelling. Limited physical modelling was performed in a 3D wave basin at the University of Bath (UK) to provide data for calibration and validation of the numerical model. After calibration and validation, the numerical model was employed to model a large number of landslide tsunami scenarios which allowed us to develop a database for deriving a predictive equation.

2.1. Physical experiments

To validate our numerical model, we conducted a series of physical experiments including two sets in a 3D wave basin at University of Bath, measuring 2.50 m in length (WL), 2.60 m in width (WW), and 0.60 m in height (WH) (Fig. 2a). Conducting two distinct sets of experiments (Table 1), each with different setups (travel distance, location, and water depth), provided a robust framework for validation of the numerical model. For wave measurement, we employed a twin wire wave gauge from HR Wallingford (https://equipit.hrwallingford.com). In these experiments, we used a concrete prism solid block, the dimensions of which are outlined in Table 2. In our experiments, we employed a concrete prism solid block with a density of 2600 kg/m3, chosen for its similarity to the natural density of landslides, akin to those observed with the 2018 Anak Krakatau tsunami, where the landslide composition is predominantly solid rather than granular. The block’s form has also been endorsed in prior studies (Watts, 1998Najafi-Jilani and Ataie-Ashtiani, 2008) as a suitable surrogate for modelling landslide-induced waves. A key aspect of our methodology was addressing scale effects, following the guidelines proposed by Heller et al. (2008) as it is described in Table 1. To enhance the reliability and accuracy of our experimental data, we conducted each physical experiment three times which revealed all three experimental waveforms were identical. This repetition was aimed at minimizing potential errors and inconsistencies in laboratory measurements.

Fig 2

Table 1. The locations and other information of the laboratory setups for making landslide-generated waves in the physical wave basin. This table details the specific parameters for each setup, including slope range (α), slide volume (V), kinematic viscosity (ν), water depth (h), travel distance (D), surface tension coefficient of water (σ), Reynolds number (R), Weber number (W), and the precise coordinates of the wave gauges (WG).

Labα(°)V (m³)h (m)D (m)WG’s Location(ν) (m²/s)(σ) (N/m)Acceptable range for avoiding scale effects*Observed values of W and R ⁎⁎
Lab 1452.60 × 10−30.2470.070X1=1.090 m1.01 × 10−60.073R > 3.0 × 105R1 = 3.80 × 105
Y1=1.210 m
W1 = 8.19 × 105
Z1=0.050mW >5.0 × 103
Lab 2452.60 × 10−30.2460.045X2=1.030 m1.01 × 10−60.073R2 = 3.78 × 105
Y2=1.210 mW2 = 8.13 × 105
Z2=0.050 m

The acceptable ranges for avoiding scale effects are based on the study by Heller et al. (2008).⁎⁎

The Reynolds number (R) is given by g0.5h1.5/ν, with ν denoting the kinematic viscosity. The Weber number (W) is W = ρgh2/σ, where σ represents surface tension coefficient and ρ = 1000kg/m3 is the density of water. In our experiments, conducted at a water temperature of approximately 20 °C, the kinematic viscosity (ν) and the surface tension coefficient of water (σ) are 1.01 × 10−6 m²/s and 0.073 N/m, respectively (Kestin et al., 1978).

Table 2. Specifications of the solid block used in physical experiments for generating subaerial landslides in the laboratory.

Solid-block attributesProperty metricsGeometric shape
Slide width (bs)0.26 mImage, table 2
Slide length (ls)0.20 m
Slide thickness (s)0.10 m
Slide volume (V)2.60 × 10−3 m3
Specific gravity, (γs)2.60
Slide weight (ms)6.86 kg

2.2. Numerical simulations applying FLOW-3D hydro

The detailed theoretical framework encompassing the governing equations, the computational methodologies employed, and the specific techniques used for tracking the water surface in these simulations are thoroughly detailed in the study by Sabeti et al. (2024). Here, we briefly explain some of the numerical details. We defined a uniform mesh for our flow domain, carefully crafted with a fine spatial resolution of 0.005 m (i.e., grid size). The dimensions of the numerical model directly matched those of our wave basin used in the physical experiment, being 2.60 m wide, 0.60 m deep, and 2.50 m long (Fig. 2). This design ensures comprehensive coverage of the study area. The output intervals of the numerical model are set at 0.02 s. This timing is consistent with the sampling rates of wave gauges used in laboratory settings. The friction coefficient in the FLOW-3D HYDRO is designated as 0.45. This value corresponds to the Coulombic friction measurements obtained in the laboratory, ensuring that the simulation accurately reflects real-world physical interactions.

In order to simulate the landslide motion, we applied coupled motion objects in FLOW-3D-HYDRO where the dynamics are predominantly driven by gravity and surface friction. This methodology stands in contrast to other models that necessitate explicit inputs of force and torque. This approach ensures that the simulation more accurately reflects the natural movement of landslides, which is heavily reliant on gravitational force and the interaction between sliding surfaces. The stability of the numerical simulations is governed by the Courant Number criterion (Courant et al., 1928), which dictates the maximum time step (Δt) for a given mesh size (Δx) and flow speed (U). According to Courant et al. (1928), this number is required to stay below one to ensure stability of numerical simulations. In our simulations, the Courant number is always maintained below one.

In alignment with the parameters of physical experiments, we set the fluid within the mesh to water, characterized by a density of 1000 kg/m³ at a temperature of 20 °C. Furthermore, we defined the top, front, and back surfaces of the mesh as symmetry planes. The remaining surfaces are designated as wall types, incorporating no-slip conditions to accurately simulate the interaction between the fluid and the boundaries. In terms of selection of an appropriate turbulence model, we selected the k–ω model that showed a better performance than other turbulence methods (e.g., Renormalization-Group) in a previous study (Sabeti et al., 2024). The simulations are conducted using a PC Intel® Core™ i7-10510U CPU with a frequency of 1.80 GHz, and a 16 GB RAM. On this PC, completion of a 3-s simulation required approximately 12.5 h.

2.3. Validation

The FLOW-3D HYDRO numerical model was validated using the two physical experiments (Fig. 3) outlined in Table 1. The level of agreement between observations (Oi) and simulations (Si) is examined using the following equation:(1)�=|��−����|×100where ε represents the mismatch error, Oi denotes the observed laboratory values, and Si represents the simulated values from the FLOW-3D HYDRO model. The results of this validation process revealed that our model could replicate the waves generated in the physical experiments with a reasonable degree of mismatch (ε): 14 % for Lab 1 and 8 % for Lab 2 experiments, respectively (Fig. 3). These values indicate that while the model is not perfect, it provides a sufficiently close approximation of the real-world phenomena.

Fig 3

In terms of mesh efficiency, we varied the mesh size to study sensitivity of the numerical results to mesh size. First, by halving the mesh size and then by doubling it, we repeated the modelling by keeping other parameters unchanged. This analysis guided that a mesh size of ∆x = 0.005 m is the most effective for the setup of this study. The total number of computational cells applying mesh size of 0.005 m is 9.269 × 106.

2.4. The dataset

The validated numerical model was employed to conduct 100 simulations, incorporating variations in four key landslide parameters namely water depth, slope angle, slide volume, and travel distance. This methodical approach was essential for a thorough sensitivity analysis of these variables, and for the creation of a detailed database to develop a predictive equation for maximum initial tsunami amplitude. Within the model, 15 distinct slide volumes were established, ranging from 0.10 × 10−3 m3 to 6.25 × 10−3 m3 (Table 3). The slope angle varied between 35° and 55°, and water depth ranged from 0.24 m to 0.27 m. The travel distance of the landslides was varied, spanning from 0.04 m to 0.07 m. Detailed configurations of each simulation, along with the maximum initial wave amplitudes and dominant wave periods are provided in Table 4.

Table 3. Geometrical information of the 15 solid blocks used in numerical modelling for generating landslide tsunamis. Parameters are: ls, slide length; bs, slide width; s, slide thickness; γs, specific gravity; and V, slide volume.

Solid blockls (m)bs (m)s (m)V (m3)γs
Block-10.3100.2600.1556.25 × 10−32.60
Block-20.3000.2600.1505.85 × 10−32.60
Block-30.2800.2600.1405.10 × 10−32.60
Block-40.2600.2600.1304.39 × 10−32.60
Block-50.2400.2600.1203.74 × 10−32.60
Block-60.2200.2600.1103.15 × 10−32.60
Block-70.2000.2600.1002.60 × 10−32.60
Block-80.1800.2600.0902.11 × 10−32.60
Block-90.1600.2600.0801.66 × 10−32.60
Block-100.1400.2600.0701.27 × 10−32.60
Block-110.1200.2600.0600.93 × 10−32.60
Block-120.1000.2600.0500.65 × 10−32.60
Block-130.0800.2600.0400.41 × 10−32.60
Block-140.0600.2600.0300.23 × 10−32.60
Block-150.0400.2600.0200.10 × 10−32.60

Table 4. The numerical simulation for the 100 tests performed in this study for subaerial solid-block landslide-generated waves. Parameters are aM, maximum wave amplitude; α, slope angle; h, water depth; D, travel distance; and T, dominant wave period. The location of the wave gauge is X=1.030 m, Y=1.210 m, and Z=0.050 m. The properties of various solid blocks are presented in Table 3.

Test-Block Noα (°)h (m)D (m)T(s)aM (m)
1Block-7450.2460.0290.5100.0153
2Block-7450.2460.0300.5050.0154
3Block-7450.2460.0310.5050.0156
4Block-7450.2460.0320.5050.0158
5Block-7450.2460.0330.5050.0159
6Block-7450.2460.0340.5050.0160
7Block-7450.2460.0350.5050.0162
8Block-7450.2460.0360.5050.0166
9Block-7450.2460.0370.5050.0167
10Block-7450.2460.0380.5050.0172
11Block-7450.2460.0390.5050.0178
12Block-7450.2460.0400.5050.0179
13Block-7450.2460.0410.5050.0181
14Block-7450.2460.0420.5050.0183
15Block-7450.2460.0430.5050.0190
16Block-7450.2460.0440.5050.0197
17Block-7450.2460.0450.5050.0199
18Block-7450.2460.0460.5050.0201
19Block-7450.2460.0470.5050.0191
20Block-7450.2460.0480.5050.0217
21Block-7450.2460.0490.5050.0220
22Block-7450.2460.0500.5050.0226
23Block-7450.2460.0510.5050.0236
24Block-7450.2460.0520.5050.0239
25Block-7450.2460.0530.5100.0240
26Block-7450.2460.0540.5050.0241
27Block-7450.2460.0550.5050.0246
28Block-7450.2460.0560.5050.0247
29Block-7450.2460.0570.5050.0248
30Block-7450.2460.0580.5050.0249
31Block-7450.2460.0590.5050.0251
32Block-7450.2460.0600.5050.0257
33Block-1450.2460.0450.5050.0319
34Block-2450.2460.0450.5050.0294
35Block-3450.2460.0450.5050.0282
36Block-4450.2460.0450.5050.0262
37Block-5450.2460.0450.5050.0243
38Block-6450.2460.0450.5050.0223
39Block-7450.2460.0450.5050.0196
40Block-8450.2460.0450.5050.0197
41Block-9450.2460.0450.5050.0198
42Block-10450.2460.0450.5050.0184
43Block-11450.2460.0450.5050.0173
44Block-12450.2460.0450.5050.0165
45Block-13450.2460.0450.4040.0153
46Block-14450.2460.0450.4040.0124
47Block-15450.2460.0450.5050.0066
48Block-7450.2020.0450.4040.0220
49Block-7450.2040.0450.4040.0219
50Block-7450.2060.0450.4040.0218
51Block-7450.2080.0450.4040.0217
52Block-7450.2100.0450.4040.0216
53Block-7450.2120.0450.4040.0215
54Block-7450.2140.0450.5050.0214
55Block-7450.2160.0450.5050.0214
56Block-7450.2180.0450.5050.0213
57Block-7450.2200.0450.5050.0212
58Block-7450.2220.0450.5050.0211
59Block-7450.2240.0450.5050.0208
60Block-7450.2260.0450.5050.0203
61Block-7450.2280.0450.5050.0202
62Block-7450.2300.0450.5050.0201
63Block-7450.2320.0450.5050.0201
64Block-7450.2340.0450.5050.0200
65Block-7450.2360.0450.5050.0199
66Block-7450.2380.0450.4040.0196
67Block-7450.2400.0450.4040.0194
68Block-7450.2420.0450.4040.0193
69Block-7450.2440.0450.4040.0192
70Block-7450.2460.0450.5050.0190
71Block-7450.2480.0450.5050.0189
72Block-7450.2500.0450.5050.0187
73Block-7450.2520.0450.5050.0187
74Block-7450.2540.0450.5050.0186
75Block-7450.2560.0450.5050.0184
76Block-7450.2580.0450.5050.0182
77Block-7450.2590.0450.5050.0183
78Block-7450.2600.0450.5050.0191
79Block-7450.2610.0450.5050.0192
80Block-7450.2620.0450.5050.0194
81Block-7450.2630.0450.5050.0195
82Block-7450.2640.0450.5050.0195
83Block-7450.2650.0450.5050.0197
84Block-7450.2660.0450.5050.0197
85Block-7450.2670.0450.5050.0198
86Block-7450.2700.0450.5050.0199
87Block-7300.2460.0450.5050.0101
88Block-7350.2460.0450.5050.0107
89Block-7360.2460.0450.5050.0111
90Block-7370.2460.0450.5050.0116
91Block-7380.2460.0450.5050.0117
92Block-7390.2460.0450.5050.0119
93Block-7400.2460.0450.5050.0121
94Block-7410.2460.0450.5050.0127
95Block-7420.2460.0450.4040.0154
96Block-7430.2460.0450.4040.0157
97Block-7440.2460.0450.4040.0162
98Block-7450.2460.0450.5050.0197
99Block-7500.2460.0450.5050.0221
100Block-7550.2460.0450.5050.0233

In all these 100 simulations, the wave gauge was consistently positioned at coordinates X=1.09 m, Y=1.21 m, and Z=0.05 m. The dominant wave period for each simulation was determined using the Fast Fourier Transform (FFT) function in MATLAB (MathWorks, 2023). Furthermore, the classification of wave types was carried out using a wave categorization graph according to Sorensen (2010), as shown in Fig. 4a. The results indicate that the majority of the simulated waves are on the border between intermediate and deep-water waves, and they are categorized as Stokes waves (Fig. 4a). Four sample waveforms from our 100 numerical experiments are provided in Fig. 4b.

Fig 4

The dataset in Table 4 was used to derive a new predictive equation that incorporates travel distance for the first time to estimate the initial maximum tsunami amplitude. In developing this equation, a genetic algorithm optimization technique was implemented using MATLAB (MathWorks 2023). This advanced approach entailed the use of genetic algorithms (GAs), an evolutionary algorithm type inspired by natural selection processes (MathWorks, 2023). This technique is iterative, involving selection, crossover, and mutation processes to evolve solutions over several generations. The goal was to identify the optimal coefficients and powers for each landslide parameter in the predictive equation, ensuring a robust and reliable model for estimating maximum wave amplitudes. Genetic Algorithms excel at optimizing complex models by navigating through extensive combinations of coefficients and exponents. GAs effectively identify highly suitable solutions for the non-linear and complex relationships between inputs (e.g., slide volume, slope angle, travel distance, water depth) and the output (i.e., maximum initial wave amplitude, aM). MATLAB’s computational environment enhances this process, providing robust tools for GA to adapt and evolve solutions iteratively, ensuring the precision of the predictive model (Onnen et al., 1997). This approach leverages MATLAB’s capabilities to fine-tune parameters dynamically, achieving an optimal equation that accurately estimates aM. It is important to highlight that the nondimensionalized version of this dataset is employed to develop a predictive equation which enables the equation to reproduce the maximum initial wave amplitude (aM) for various subaerial landslide cases, independent of their dimensional differences (e.g., Heler and Hager 2014Heller and Spinneken 2015Sabeti and Heidarzadeh 2022b). For this nondimensionalization, we employed the water depth (h) to nondimensionalize the slide volume (V/h3) and travel distance (D/h). The slide thickness (s) was applied to nondimensionalize the water depth (h/s).

2.5. Landslide velocity

In discussing the critical role of landslide velocity for simulating landslide-generated waves, we focus on the mechanisms of landslide motion and the techniques used to record landslide velocity in our simulations (Fig. 5). Also, we examine how these methods were applied in two distinct scenarios: Lab 1 and Lab 2 (see Table 1 for their details). Regarding the process of landslide movement, a slide starts from a stationary state, gaining momentum under the influence of gravity and this acceleration continues until the landslide collides with water, leading to a significant reduction in its speed before eventually coming to a stop (Fig. 5) (e.g., Panizzo et al. 2005).

Fig 5

To measure the landslide’s velocity in our simulations, we attached a probe at the centre of the slide, which supplied a time series of the velocity data. The slide’s velocity (vs) peaks at the moment it enters the water (Fig. 5), a point referred to as the impact time (tImp). Following this initial impact, the slides continue their underwater movement, eventually coming to a complete halt (tStop). Given the results in Fig. 5, it can be seen that Lab 1, with its longer travel distance (0.070 m), exhibits a higher peak velocity of 1.89 m/s. This increase in velocity is attributed to the extended travel distance allowing more time for the slide to accelerate under gravity. Whereas Lab 2, featuring a shorter travel distance (0.045 m), records a lower peak velocity of 1.78 m/s. This difference underscores how travel distance significantly influences the dynamics of landslide motion. After reaching the peak, both profiles show a sharp decrease in velocity, marking the transition to submarine motion until the slides come to a complete stop (tStop). There are noticeable differences observable in Fig. 5 between the Lab-1 and Lab-2 simulations, including the peaks at 0.3 s . These variations might stem from the placement of the wave gauge, which differs slightly in each scenario, as well as the water depth’s minor discrepancies and, the travel distance.

2.6. Effect of air entrainment

In this section we examine whether it is required to consider air entrainment for our modelling or not as the FLOW-3D HYDRO package is capable of modelling air entrainment. The process of air entrainment in water during a landslide tsunami and its subsequent transport involve two key components: the quantification of air entrainment at the water surface, and the simulation of the air’s transport within the fluid (Hirt, 2003). FLOW-3D HYDRO employs the air entrainment model to compute the volume of air entrained at the water’s surface utilizing three approaches: a constant density model, a variable density model accounting for bulking, and a buoyancy model that adds the Drift-FLUX mechanism to variable density conditions (Flow Science, 2023). The calculation of the entrainment rate is based on the following equation:(2)�������=������[2(��−�����−2�/���)]1/2where parameters are: Vair, volume of air; Cair, entrainment rate coefficient; As, surface area of fluid; ρ, fluid density; k, turbulent kinetic energy; gn, gravity normal to surface; Lt, turbulent length scale; and σ, surface tension coefficient. The value of k is directly computed from the Reynolds-averaged Navier-Stokes (RANS) (kw) calculations in our model.

In this study, we selected the variable density + Drift-FLUX model, which effectively captures the dynamics of phase separation and automatically activates the constant density and variable density models. This method simplifies the air-water mixture, treating it as a single, homogeneous fluid within each computational cell. For the phase volume fractions f1and f2​, the velocities are expressed in terms of the mixture and relative velocities, denoted as u and ur, respectively, as follows:(3)��1��+�.(�1�)=��1��+�.(�1�)−�.(�1�2��)=0(4)��2��+�.(�2�)=��2��+�.(�2�)−�.(�1�2��)=0

The outcomes from this simulation are displayed in Fig. 6, which indicates that the influence of air entrainment on the generated wave amplitude is approximately 2 %. A value of 0.02 for the entrained air volume fraction means that, in the simulated fluid, approximately 2 % of the volume is composed of entrained air. In other words, for every unit volume of the fluid-air mixture at that location, 2 % is air and the remaining 98 % is water. The configuration of Test-17 (Table 4) was employed for this simulation. While the effect of air entrainment is anticipated to be more significant in models of granular landslide-generated waves (Fritz, 2002), in our simulations we opted not to incorporate this module due to its negligible impact on the results.

Fig 6

3. Results

In this section, we begin by presenting a sequence of our 3D simulations capturing different time steps to illustrate the generation process of landslide-generated waves. Subsequently, we derive a new predictive equation to estimate the maximum initial wave amplitude of landslide-generated waves and assess its performance.

3.1. Wave generation and propagation

To demonstrate the wave generation process in our simulation, we reference Test-17 from Table 4, where we employed Block-7 (Tables 34). In this configuration, the slope angle was set to 45°, with a water depth of 0.246 m and a travel distance at 0.045 m (Fig. 7). At 0.220 s, the initial impact of the moving slide on the water is depicted, marking the onset of the wave generation process (Fig. 7a). Disturbances are localized to the immediate area of impact, with the rest of the water surface remaining undisturbed. At this time, a maximum water particle velocity of 1.0 m/s – 1.2 m/s is seen around the impact zone (Fig. 7d). Moving to 0.320 s, the development of the wave becomes apparent as energy transfer from the landslide to the water creates outwardly radiating waves with maximum water particle velocity of up to around 1.6 m/s – 1.8 m/s (Fig. 7b, e). By the time 0.670 s, the wave has fully developed and is propagating away from the impact point exhibiting maximum water particle velocity of up to 2.0 m/s – 2.1 m/s. Concentric wave fronts are visible, moving outwards in all directions, with a colour gradient signifying the highest wave amplitude near the point of landslide entry, diminishing with distance (Fig. 7c, f).

Fig 7

3.2. Influence of landslide parameters on tsunami amplitude

In this section, we investigate the effects of various landslide parameters namely slide volume (V), water depth (h), slipe angle (α) and travel distance (D) on the maximum initial wave amplitude (aM). Fig. 8 presents the outcome of these analyses. According to Fig. 8, the slide volume, slope angle, and travel distance exhibit a direct relationship with the wave amplitude, meaning that as these parameters increase, so does the amplitude. Conversely, water depth is inversely related to the maximum initial wave amplitude, suggesting that the deeper the water depth, the smaller the maximum wave amplitude will be (Fig. 8b).

Fig 8

Fig. 8a highlights the pronounced impact of slide volume on the aM, demonstrating a direct correlation between the two variables. For instance, in the range of slide volumes we modelled (Fig. 8a), The smallest slide volume tested, measuring 0.10 × 10−3 m3, generated a low initial wave amplitude (aM= 0.0066 m) (Table 4). In contrast, the largest volume tested, 6.25 × 10−3 m3, resulted in a significantly higher initial wave amplitude (aM= 0.0319 m) (Table 4). The extremities of these results emphasize the slide volume’s paramount impact on wave amplitude, further elucidated by their positions as the smallest and largest aM values across all conducted tests (Table 4). This is corroborated by findings from the literature (e.g., Murty, 2003), which align with the observed trend in our simulations.

The slope angle’s influence on aM was smooth. A steady increase of wave amplitude was observed as the slope angle increased (Fig. 8c). In examining travel distance, an anomaly was identified. At a travel distance of 0.047 m, there was an unexpected dip in aM, which deviates from the general increasing trend associated with longer travel distances. This singular instance could potentially be attributed to a numerical error. Beyond this point, the expected pattern of increasing aM with longer travel distances resumes, suggesting that the anomaly at 0.047 m is an outlier in an otherwise consistent trend, and thus this single data point was overlooked while deriving the predictive equation. Regarding the inverse relationship between water depth and wave amplitude, our result (Fig. 8b) is consistent with previous reports by Fritz et al. (2003), (2004), and Watts et al. (2005).

The insights from Fig. 8 informed the architecture of the predictive equation in the next Section, with slide volume, travel distance, and slope angle being multiplicatively linked to wave amplitude underscoring their direct correlations with wave amplitude. Conversely, water depth is incorporated as a divisor, representing its inverse relationship with wave amplitude. This structure encapsulates the dynamics between the landslide parameters and their influence on the maximum initial wave amplitude as discussed in more detail in the next Section.

3.3. Predictive equation

Building on our sensitivity analysis of landslide parameters, as detailed in Section 3.2, and utilizing our nondimensional dataset, we have derived a new predictive equation as follows:(5)��/ℎ=0.015(tan�)0.10(�ℎ3)0.90(�ℎ)0.10(ℎ�)−0.11where, V is sliding volume, h is water depth, α is slope angle, and s is landslide thickness. It is important to note that this equation is valid only for subaerial solid-block landslide tsunamis as all our experiments were for this type of waves. The performance of this equation in predicting simulation data is demonstrated by the satisfactory alignment of data points around a 45° line, indicating its accuracy and reliability with regard to the experimental dataset (Fig. 9). The quality of fit between the dataset and Eq. (5) is 91 % indicating that Eq. (5) represents the dataset very well. Table 5 presents Eq. (5) alongside four other similar equations previously published. Two significant distinctions between our Eq. (5) and these others are: (i) Eq. (5) is derived from 3D experiments, whereas the other four equations are based on 2D experiments. (ii) Unlike the other equations, our Eq. (5) incorporates travel distance as an independent parameter.

Fig 9

Table 5. Performance comparison among our newly-developed equation and existing equations for estimating the maximum initial amplitude (aM) of the 2018 Anak Krakatau subaerial landslide tsunami. Parameters: aM, initial maximum wave amplitude; h, water depth; vs, landslide velocity; V, slide volume; bs, slide width; ls, slide length; s, slide thickness; α, slope angle; and ����, volume of the final immersed landslide. We considered ����= V as the slide volume.

EventPredictive equationsAuthor (year)Observed aM (m) ⁎⁎Calculated aM (m)Error, ε (%) ⁎⁎⁎⁎
2018 Anak Krakatau tsunami (Subaerial landslide) *��/ℎ=1.32���ℎNoda (1970)1341340
��/ℎ=0.667(0.5(���ℎ)2)0.334(���)0.754(���)0.506(�ℎ)1.631Bolin et al. (2014) ⁎⁎⁎13459424334
��/ℎ=0.25(������ℎ2)0.8Robbe-Saule et al. (2021)1343177
��/ℎ=0.4545(tan�)0.062(�ℎ3)0.296(ℎ�)−0.235Sabeti and Heidarzadeh (2022b)1341266
��/ℎ=0.015(tan�)0.10(�ℎ3)0.911(�ℎ)0.10(ℎ�)−0.11This study1341302.9

Geometrical and kinematic parameters of the 2018 Anak Krakatau subaerial landslide based on Heidarzadeh et al. (2020)Grilli et al. (2019) and Grilli et al. (2021)V=2.11 × 107 m3h= 50 m; s= 114 m; α= 45°; ls=1250 m; bs= 2700 m; vs=44.9 m/s; D= 2500 m; aM= 100 m −150 m.⁎⁎

aM= An average value of aM = 134 m is considered in this study.⁎⁎⁎

The equation of Bolin et al. (2014) is based on the reformatted one reported by Lindstrøm (2016).⁎⁎⁎⁎

Error is calculated using Eq. (1), where the calculated aM is assumed as the simulated value.

Additionally, we evaluated the performance of this equation using the real-world data from the 2018 Anak Krakatau subaerial landslide tsunami. Based on previous studies (Heidarzadeh et al., 2020Grilli et al., 20192021), we were able to provide a list of parameters for the subaerial landslide and associated tsunami for the 2018 Anak Krakatau event (see footnote of Table 5). We note that the data of the 2018 Anak Krakatau event was not used while deriving Eq. (5). The results indicate that Eq. (5) predicts the initial amplitude of the 2018 Anak Krakatau tsunami as being 130 m indicating an error of 2.9 % compared to the reported average amplitude of 134 m for this event. This performance indicates an improvement compared to the previous equation reported by Sabeti and Heidarzadeh (2022a) (Table 5). In contrast, the equations from Robbe-Saule et al. (2021) and Bolin et al. (2014) demonstrate higher discrepancies of 4200 % and 77 %, respectively (Table 5). Although Noda’s (1970) equation reproduces the tsunami amplitude of 134 m accurately (Table 5), it is crucial to consider its limitations, notably not accounting for parameters such as slope angle and travel distance.

It is essential to recognize that both travel distance and slope angle significantly affect wave amplitude. In our model, captured in Eq. (5), we integrate the slope angle (α) through the tangent function, i.e., tan α. This choice diverges from traditional physical interpretations that often employ the cosine or sine function (e.g., Heller and Hager, 2014Watts et al., 2003). We opted for the tangent function because it more effectively reflects the direct impact of slope steepness on wave generation, yielding superior estimations compared to conventional methods.

The significance of this study lies in its application of both physical and numerical 3D experiments and the derivation of a predictive equation based on 3D results. Prior research, e.g. Heller et al. (2016), has reported notable discrepancies between 2D and 3D wave amplitudes, highlighting the important role of 3D experiments. It is worth noting that the suitability of applying an equation derived from either 2D or 3D data depends on the specific geometry and characteristics inherent in the problem being addressed. For instance, in the case of a long, narrow dam reservoir, an equation derived from 2D data would likely be more suitable. In such contexts, the primary dynamics of interest such as flow patterns and potential wave propagation are predominantly two-dimensional, occurring along the length and depth of the reservoir. This simplification to 2D for narrow dam reservoirs allows for more accurate modelling of these dynamics.

This study specifically investigates waves initiated by landslides, focusing on those characterized as solid blocks instead of granular flows, with slope angles confined to a range of 25° to 60°. We acknowledge the additional complexities encountered in real-world scenarios, such as dynamic density and velocity of landslides, which could affect the estimations. The developed equation in this study is specifically designed to predict the maximum initial amplitude of tsunamis for the aforementioned specified ranges and types of landslides.

4. Conclusions

Both physical and numerical experiments were undertaken in a 3D wave basin to study solid-block landslide-generated waves and to formulate a predictive equation for their maximum initial wave amplitude. At the beginning, two physical experiments were performed to validate and calibrate a 3D numerical model, which was subsequently utilized to generate 100 experiments by varying different landslide parameters. The generated database was then used to derive a predictive equation for the maximum initial wave amplitude of landslide tsunamis. The main features and outcomes are:

  • •The predictive equation of this study is exclusively derived from 3D data and exhibits a fitting quality of 91 % when applied to the database.
  • •For the first time, landslide travel distance was considered in the predictive equation. This inclusion provides more accuracy and flexibility for applying the equation.
  • •To further evaluate the performance of the predictive equation, it was applied to a real-world subaerial landslide tsunami (i.e., the 2018 Anak Krakatau event) and delivered satisfactory performance.

CRediT authorship contribution statement

Ramtin Sabeti: Conceptualization, Methodology, Validation, Software, Visualization, Writing – review & editing. Mohammad Heidarzadeh: Methodology, Data curation, Software, Writing – review & editing.

Declaration of competing interest

The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.

Funding

RS is supported by the Leverhulme Trust Grant No. RPG-2022-306. MH is funded by open funding of State Key Lab of Hydraulics and Mountain River Engineering, Sichuan University, grant number SKHL2101. We acknowledge University of Bath Institutional Open Access Fund. MH is also funded by the Great Britain Sasakawa Foundation grant no. 6217 (awarded in 2023).

Acknowledgements

Authors are sincerely grateful to the laboratory technician team, particularly Mr William Bazeley, at the Faculty of Engineering, University of Bath for their support during the laboratory physical modelling of this research. We appreciate the valuable insights provided by Mr. Brian Fox (Senior CFD Engineer at Flow Science, Inc.) regarding air entrainment modelling in FLOW-3D HYDRO. We acknowledge University of Bath Institutional Open Access Fund.

Data availability

  • All data used in this study are given in the body of the article.

References

NUMERICAL ANALYSIS OF THE HYDRODYNAMICS CHARACTERISTICS OF TORPEDO ANCHOR INSTALLATION UNDER THE INFLUENCE OF OCEAN CURRENTS

魚雷錨擲錨過程受海流擲下之運移特性數值分析

번역된 기고 제목: 해류의 영향에 따른 어뢰 앵커 설치의 유체 역학 특성에 대한 수치 분석

Translated title of the contribution: NUMERICAL ANALYSIS OF THE HYDRODYNAMICS CHARACTERISTICS OF TORPEDO ANCHOR INSTALLATION UNDER THE INFLUENCE OF OCEAN CURRENTS

L. Y. Chen, R. Y. Yang

Abstract

The gravity-installed anchor (GIA) is a type of the anchor foundation that is installed by penetrating the seabed using the weight of the anchor body. It has the advantages of high installation efficiency, low cost, and no requirement of additional installation facilities. The GIA type used in this study is the torpedo anchor, which has been ap-plied in practical cases widely. The purpose of this study is to investigate the numerical analysis of the anchor trans-porting during the installation of the torpedo anchor under the action of ocean currents. Therefore, this article con-siders external environmental conditions and the different forms of torpedo anchors by using computational fluid dynamics (CFD) software, FLOW-3D, to simulate the fluid-solid interaction effect on the torpedo anchor. The falling time, impact velocity, displaced angle, and horizontal displacement of the torpedo anchor were observed at an installation height (i.e., the distance between the seabed and the anchor release height) of 85 meters. The obtained results show that when the current velocity is greater, the torpedo anchor will have a larger displaced angle, which will affect the impact velocity of the anchor on the seabed and may cause insufficient penetration depth, leading to installation failure.

중력설치형 앵커(GIA)는 앵커 본체의 무게를 이용하여 해저를 관통하여 설치하는 앵커 기초의 일종이다. 설치 효율성이 높고, 비용이 저렴하며, 추가 설치 시설이 필요하지 않다는 장점이 있습니다. 본 연구에서 사용된 GIA 유형은 어뢰앵커로 실제 사례에 널리 적용되어 왔다.

본 연구의 목적은 해류의 작용에 따라 어뢰앵커 설치 시 앵커 이송에 대한 수치해석을 연구하는 것이다. 따라서 이 기사에서는 어뢰 앵커에 대한 유체-고체 상호 작용 효과를 시뮬레이션하기 위해 전산유체역학(CFD) 소프트웨어인 FLOW-3D를 사용하여 외부 환경 조건과 다양한 형태의 어뢰 앵커를 고려합니다.

어뢰앵커의 낙하시간, 충격속도, 변위각, 수평변위 등은 설치높이(즉, 해저와 앵커 해제 높이 ​​사이의 거리) 85m에서 관찰되었다. 얻은 결과는 현재 속도가 더 높을 때 어뢰 앵커의 변위 각도가 더 커져 해저에 대한 앵커의 충격 속도에 영향을 미치고 침투 깊이가 부족하여 설치 실패로 이어질 수 있음을 보여줍니다.

  • Ocean currentsEngineering & Materials Science100%
  • AnchorsEngineering & Materials Science74%
  • Numerical analysisEngineering & Materials Science63%
  • HydrodynamicsEngineering & Materials Science62%
  • GravitationEngineering & Materials Science9%
  • Computational fluid dynamicsEngineering & Materials Science4%
  • FluidsEngineering & Materials Science3%
  • CostsEngineering & Materials Science
  • 해류
  • 앵커
  • 수치해석
  • 유체 역학
  • 중력
  • 전산유체역학
Fig. 3. Free surface and substrate profiles in all Sp and Ls cases at t = 1 s, t = 3 s, and t = 5 s, arranged left to right (note: the colour contours correspond to the horizontal component of the flow velocity (u), expressed in m/s).

Numerical investigation of dam break flow over erodible beds with diverse substrate level variations

다양한 기질 수준 변화를 갖는 침식성 층 위의 댐 파손 흐름에 대한 수치 조사

Alireza Khoshkonesh1, Blaise Nsom2, Saeid Okhravi3*, Fariba Ahmadi Dehrashid4, Payam Heidarian5,
Silvia DiFrancesco6
1 Department of Geography, School of Social Sciences, History, and Philosophy, Birkbeck University of London, London, UK.
2 Université de Bretagne Occidentale. IRDL/UBO UMR CNRS 6027. Rue de Kergoat, 29285 Brest, France.
3 Institute of Hydrology, Slovak Academy of Sciences, Dúbravská cesta 9, 84104, Bratislava, Slovak Republic.
4Department of Water Science and Engineering, Faculty of Agriculture, Bu-Ali Sina University, 65178-38695, Hamedan, Iran.
5 Department of Civil, Environmental, Architectural Engineering and Mathematics, University of Brescia, 25123 Brescia, Italy.
6Niccol`o Cusano University, via Don C. Gnocchi 3, 00166 Rome, Italy. * Corresponding author. Tel.: +421-944624921. E-mail: saeid.okhravi@savba.sk

Abstract

This study aimed to comprehensively investigate the influence of substrate level difference and material composition on dam break wave evolution over two different erodible beds. Utilizing the Volume of Fluid (VOF) method, we tracked free surface advection and reproduced wave evolution using experimental data from the literature. For model validation, a comprehensive sensitivity analysis encompassed mesh resolution, turbulence simulation methods, and bed load transport equations. The implementation of Large Eddy Simulation (LES), non-equilibrium sediment flux, and van Rijn’s (1984) bed load formula yielded higher accuracy compared to alternative approaches. The findings emphasize the significant effect of substrate level difference and material composition on dam break morphodynamic characteristics. Decreasing substrate level disparity led to reduced flow velocity, wavefront progression, free surface height, substrate erosion, and other pertinent parameters. Initial air entrapment proved substantial at the wavefront, illustrating pronounced air-water interaction along the bottom interface. The Shields parameter experienced a one-third reduction as substrate level difference quadrupled, with the highest near-bed concentration observed at the wavefront. This research provides fresh insights into the complex interplay of factors governing dam break wave propagation and morphological changes, advancing our comprehension of this intricate phenomenon.

이 연구는 두 개의 서로 다른 침식층에 대한 댐 파괴파 진화에 대한 기질 수준 차이와 재료 구성의 영향을 종합적으로 조사하는 것을 목표로 했습니다. VOF(유체량) 방법을 활용하여 자유 표면 이류를 추적하고 문헌의 실험 데이터를 사용하여 파동 진화를 재현했습니다.

모델 검증을 위해 메쉬 해상도, 난류 시뮬레이션 방법 및 침대 하중 전달 방정식을 포함하는 포괄적인 민감도 분석을 수행했습니다. LES(Large Eddy Simulation), 비평형 퇴적물 플럭스 및 van Rijn(1984)의 하상 부하 공식의 구현은 대체 접근 방식에 비해 더 높은 정확도를 산출했습니다.

연구 결과는 댐 붕괴 형태역학적 특성에 대한 기질 수준 차이와 재료 구성의 중요한 영향을 강조합니다. 기판 수준 차이가 감소하면 유속, 파면 진행, 자유 표면 높이, 기판 침식 및 기타 관련 매개변수가 감소했습니다.

초기 공기 포집은 파면에서 상당한 것으로 입증되었으며, 이는 바닥 경계면을 따라 뚜렷한 공기-물 상호 작용을 보여줍니다. 기판 레벨 차이가 4배로 증가함에 따라 Shields 매개변수는 1/3로 감소했으며, 파면에서 가장 높은 베드 근처 농도가 관찰되었습니다.

이 연구는 댐 파괴파 전파와 형태학적 변화를 지배하는 요인들의 복잡한 상호 작용에 대한 새로운 통찰력을 제공하여 이 복잡한 현상에 대한 이해를 향상시킵니다.

Keywords

Dam break; Substrate level difference; Erodible bed; Sediment transport; Computational fluid dynamics CFD.

Fig. 3. Free surface and substrate profiles in all Sp and Ls cases at t = 1 s, t = 3 s, and t = 5 s, arranged left to right (note: the colour contours
correspond to the horizontal component of the flow velocity (u), expressed in m/s).
Fig. 3. Free surface and substrate profiles in all Sp and Ls cases at t = 1 s, t = 3 s, and t = 5 s, arranged left to right (note: the colour contours correspond to the horizontal component of the flow velocity (u), expressed in m/s).

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Schematic diagram of HP-LPBF melting process.

Modeling and numerical studies of high-precision laser powder bed fusion

Yi Wei ;Genyu Chen;Nengru Tao;Wei Zhou
https://doi.org/10.1063/5.0191504

In order to comprehensively reveal the evolutionary dynamics of the molten pool and the state of motion of the fluid during the high-precision laser powder bed fusion (HP-LPBF) process, this study aims to deeply investigate the specific manifestations of the multiphase flow, solidification phenomena, and heat transfer during the process by means of numerical simulation methods. Numerical simulation models of SS316L single-layer HP-LPBF formation with single and double tracks were constructed using the discrete element method and the computational fluid dynamics method. The effects of various factors such as Marangoni convection, surface tension, vapor recoil, gravity, thermal convection, thermal radiation, and evaporative heat dissipation on the heat and mass transfer in the molten pool have been paid attention to during the model construction process. The results show that the molten pool exhibits a “comet” shape, in which the temperature gradient at the front end of the pool is significantly larger than that at the tail end, with the highest temperature gradient up to 1.69 × 108 K/s. It is also found that the depth of the second track is larger than that of the first one, and the process parameter window has been determined preliminarily. In addition, the application of HP-LPBF technology helps to reduce the surface roughness and minimize the forming size.

Topics

Heat transfer, Nonequilibrium thermodynamics, Solidification process, Computer simulation, Discrete element method, Lasers, Mass transfer, Fluid mechanics, Computational fluid dynamics, Multiphase flows

I. INTRODUCTION

Laser powder bed fusion (LPBF) has become a research hotspot in the field of additive manufacturing of metals due to its advantages of high-dimensional accuracy, good surface quality, high density, and high material utilization.1,2 With the rapid development of electronics, medical, automotive, biotechnology, energy, communication, and optics, the demand for microfabrication technology is increasing day by day.3 High-precision laser powder bed fusion (HP-LPBF) is one of the key manufacturing technologies for tiny parts in the fields of electronics, medical, automotive, biotechnology, energy, communication, and optics because of its process characteristics such as small focal spot diameter, small powder particle size, and thin powder layup layer thickness.4–13 Compared with LPBF, HP-LPBF has the significant advantages of smaller focal spot diameter, smaller powder particle size, and thinner layer thickness. These advantages make HP-LPBF perform better in producing micro-fine parts, high surface quality, and parts with excellent mechanical properties.

HP-LPBF is in the exploratory stage, and researchers have already done some exploratory studies on the focal spot diameter, the amount of defocusing, and the powder particle size. In order to explore the influence of changing the laser focal spot diameter on the LPBF process characteristics of the law, Wildman et al.14 studied five groups of different focal spot diameter LPBF forming 316L stainless steel (SS316L) processing effect, the smallest focal spot diameter of 26 μm, and the results confirm that changing the focal spot diameter can be achieved to achieve the energy control, so as to control the quality of forming. Subsequently, Mclouth et al.15 proposed the laser out-of-focus amount (focal spot diameter) parameter, which characterizes the distance between the forming plane and the laser focal plane. The laser energy density was controlled by varying the defocusing amount while keeping the laser parameters constant. Sample preparation at different focal positions was investigated, and their microstructures were characterized. The results show that the samples at the focal plane have finer microstructure than those away from the focal plane, which is the effect of higher power density and smaller focal spot diameter. In order to explore the influence of changing the powder particle size on the characteristics of the LPBF process, Qian et al.16 carried out single-track scanning simulations on powder beds with average powder particle sizes of 70 and 40 μm, respectively, and the results showed that the melt tracks sizes were close to each other under the same process parameters for the two particle-size distributions and that the molten pool of powder beds with small particles was more elongated and the edges of the melt tracks were relatively flat. In order to explore the superiority of HP-LPBF technology, Xu et al.17 conducted a comparative analysis of HP-LPBF and conventional LPBF of SS316L. The results showed that the average surface roughness of the top surface after forming by HP-LPBF could reach 3.40 μm. Once again, it was verified that HP-LPBF had higher forming quality than conventional LPBF. On this basis, Wei et al.6 comparatively analyzed the effects of different laser focal spot diameters on different powder particle sizes formed by LPBF. The results showed that the smaller the laser focal spot diameter, the fewer the defects on the top and side surfaces. The above research results confirm that reducing the laser focal spot diameter can obtain higher energy density and thus better forming quality.

LPBF involves a variety of complex systems and mechanisms, and the final quality of the part is influenced by a large number of process parameters.18–24 Some research results have shown that there are more than 50 factors affecting the quality of the specimen. The influencing factors are mainly categorized into three main groups: (1) laser parameters, (2) powder parameters, and (3) equipment parameters, which interact with each other to determine the final specimen quality. With the continuous development of technologies such as computational materials science and computational fluid dynamics (CFD), the method of studying the influence of different factors on the forming quality of LPBF forming process has been shifted from time-consuming and laborious experimental characterization to the use of numerical simulation methods. As a result, more and more researchers are adopting this approach for their studies. Currently, numerical simulation studies on LPBF are mainly focused on the exploration of molten pool, temperature distribution, and residual stresses.

  1. Finite element simulation based on continuum mechanics and free surface fluid flow modeling based on fluid dynamics are two common approaches to study the behavior of LPBF molten pool.25–28 Finite element simulation focuses on the temperature and thermal stress fields, treats the powder bed as a continuum, and determines the molten pool size by plotting the elemental temperature above the melting point. In contrast, fluid dynamics modeling can simulate the 2D or 3D morphology of the metal powder pile and obtain the powder size and distribution by certain algorithms.29 The flow in the molten pool is mainly affected by recoil pressure and the Marangoni effect. By simulating the molten pool formation, it is possible to predict defects, molten pool shape, and flow characteristics, as well as the effect of process parameters on the molten pool geometry.30–34 In addition, other researchers have been conducted to optimize the laser processing parameters through different simulation methods and experimental data.35–46 Crystal growth during solidification is studied to further understand the effect of laser parameters on dendritic morphology and solute segregation.47–54 A multi-scale system has been developed to describe the fused deposition process during 3D printing, which is combined with the conductive heat transfer model and the dendritic solidification model.55,56
  2. Relevant scholars have adopted various different methods for simulation, such as sequential coupling theory,57 Lagrangian and Eulerian thermal models,58 birth–death element method,25 and finite element method,59 in order to reveal the physical phenomena of the laser melting process and optimize the process parameters. Luo et al.60 compared the LPBF temperature field and molten pool under double ellipsoidal and Gaussian heat sources by ANSYS APDL and found that the diffusion of the laser energy in the powder significantly affects the molten pool size and the temperature field.
  3. The thermal stresses obtained from the simulation correlate with the actual cracks,61 and local preheating can effectively reduce the residual stresses.62 A three-dimensional thermodynamic finite element model investigated the temperature and stress variations during laser-assisted fabrication and found that powder-to-solid conversion increases the temperature gradient, stresses, and warpage.63 Other scholars have predicted residual stresses and part deflection for LPBF specimens and investigated the effects of deposition pattern, heat, laser power, and scanning strategy on residual stresses, noting that high-temperature gradients lead to higher residual stresses.64–67 

In short, the process of LPBF forming SS316L is extremely complex and usually involves drastic multi-scale physicochemical changes that will only take place on a very small scale. Existing literature employs DEM-based mesoscopic-scale numerical simulations to investigate the effects of process parameters on the molten pool dynamics of LPBF-formed SS316L. However, a few studies have been reported on the key mechanisms of heating and solidification, spatter, and convective behavior of the molten pool of HP-LPBF-formed SS316L with small laser focal spot diameters. In this paper, the geometrical properties of coarse and fine powder particles under three-dimensional conditions were first calculated using DEM. Then, numerical simulation models for single-track and double-track cases in the single-layer HP-LPBF forming SS316L process were developed at mesoscopic scale using the CFD method. The flow genesis of the melt in the single-track and double-track molten pools is discussed, and their 3D morphology and dimensional characteristics are discussed. In addition, the effects of laser process parameters, powder particle size, and laser focal spot diameter on the temperature field, characterization information, and defects in the molten pool are discussed.

II. MODELING

A. 3D powder bed modeling

HP-LPBF is an advanced processing technique for preparing target parts layer by layer stacking, the process of which involves repetitive spreading and melting of powders. In this process, both the powder spreading and the morphology of the powder bed are closely related to the results of the subsequent melting process, while the melted surface also affects the uniform distribution of the next layer of powder. For this reason, this chapter focuses on the modeling of the physical action during the powder spreading process and the theory of DEM to establish the numerical model of the powder bed, so as to lay a solid foundation for the accuracy of volume of fluid (VOF) and CFD.

1. DEM

DEM is a numerical technique for calculating the interaction of a large number of particles, which calculates the forces and motions of the spheres by considering each powder sphere as an independent unit. The motion of the powder particles follows the laws of classical Newtonian mechanics, including translational and rotational,38,68–70 which are expressed as follows:����¨=���+∑��ij,

(1)����¨=∑�(�ij×�ij),

(2)

where �� is the mass of unit particle i in kg, ��¨ is the advective acceleration in m/s2, And g is the gravitational acceleration in m/s2. �ij is the force in contact with the neighboring particle � in N. �� is the rotational inertia of the unit particle � in kg · m2. ��¨ is the unit particle � angular acceleration in rad/s2. �ij is the vector pointing from unit particle � to the contact point of neighboring particle �⁠.

Equations (1) and (2) can be used to calculate the velocity and angular velocity variations of powder particles to determine their positions and velocities. A three-dimensional powder bed model of SS316L was developed using DEM. The powder particles are assumed to be perfect spheres, and the substrate and walls are assumed to be rigid. To describe the contact between the powder particles and between the particles and the substrate, a non-slip Hertz–Mindlin nonlinear spring-damping model71 was used with the following expression:�hz=��������+��[(�����ij−�eff����)−(�����+�eff����)],

(3)

where �hz is the force calculated using the Hertzian in M. �� and �� are the radius of unit particles � and � in m, respectively. �� is the overlap size of the two powder particles in m. ��⁠, �� are the elastic constants in the normal and tangential directions, respectively. �ij is the unit vector connecting the centerlines of the two powder particles. �eff is the effective mass of the two powder particles in kg. �� and �� are the viscoelastic damping constants in the normal and tangential directions, respectively. �� and �� are the components of the relative velocities of the two powder particles. ��� is the displacement vector between two spherical particles. The schematic diagram of overlapping powder particles is shown in Fig. 1.

FIG. 1.

VIEW LARGEDOWNLOAD SLIDE

Schematic diagram of overlapping powder particles.

Because the particle size of the powder used for HP-LPBF is much smaller than 100 μm, the effect of van der Waals forces must be considered. Therefore, the cohesive force �jkr of the Hertz–Mindlin model was used instead of van der Waals forces,72 with the following expression:�jkr=−4��0�*�1.5+4�*3�*�3,

(4)1�*=(1−��2)��+(1−��2)��,

(5)1�*=1��+1��,

(6)

where �* is the equivalent Young’s modulus in GPa; �* is the equivalent particle radius in m; �0 is the surface energy of the powder particles in J/m2; α is the contact radius in m; �� and �� are the Young’s modulus of the unit particles � and �⁠, respectively, in GPa; and �� and �� are the Poisson’s ratio of the unit particles � and �⁠, respectively.

2. Model building

Figure 2 shows a 3D powder bed model generated using DEM with a coarse powder geometry of 1000 × 400 × 30 μm3. The powder layer thickness is 30 μm, and the powder bed porosity is 40%. The average particle size of this spherical powder is 31.7 μm and is normally distributed in the range of 15–53 μm. The geometry of the fine powder was 1000 × 400 × 20 μm3, with a layer thickness of 20 μm, and the powder bed porosity of 40%. The average particle size of this spherical powder is 11.5 μm and is normally distributed in the range of 5–25 μm. After the 3D powder bed model is generated, it needs to be imported into the CFD simulation software for calculation, and the imported geometric model is shown in Fig. 3. This geometric model is mainly composed of three parts: protective gas, powder bed, and substrate. Under the premise of ensuring the accuracy of the calculation, the mesh size is set to 3 μm, and the total number of coarse powder meshes is 1 704 940. The total number of fine powder meshes is 3 982 250.

FIG. 2.

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Three-dimensional powder bed model: (a) coarse powder, (b) fine powder.

FIG. 3.

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Geometric modeling of the powder bed computational domain: (a) coarse powder, (b) fine powder.

B. Modeling of fluid mechanics simulation

In order to solve the flow, melting, and solidification problems involved in HP-LPBF molten pool, the study must follow the three governing equations of conservation of mass, conservation of energy, and conservation of momentum.73 The VOF method, which is the most widely used in fluid dynamics, is used to solve the molten pool dynamics model.

1. VOF

VOF is a method for tracking the free interface between the gas and liquid phases on the molten pool surface. The core idea of the method is to define a volume fraction function F within each grid, indicating the proportion of the grid space occupied by the material, 0 ≤ F ≤ 1 in Fig. 4. Specifically, when F = 0, the grid is empty and belongs to the gas-phase region; when F = 1, the grid is completely filled with material and belongs to the liquid-phase region; and when 0 < F < 1, the grid contains free surfaces and belongs to the mixed region. The direction normal to the free surface is the direction of the fastest change in the volume fraction F (the direction of the gradient of the volume fraction), and the direction of the gradient of the volume fraction can be calculated from the values of the volume fractions in the neighboring grids.74 The equations controlling the VOF are expressed as follows:𝛻����+�⋅(��→)=0,

(7)

where t is the time in s and �→ is the liquid velocity in m/s.

FIG. 4.

VIEW LARGEDOWNLOAD SLIDE

Schematic diagram of VOF.

The material parameters of the mixing zone are altered due to the inclusion of both the gas and liquid phases. Therefore, in order to represent the density of the mixing zone, the average density �¯ is used, which is expressed as follows:72�¯=(1−�1)�gas+�1�metal,

(8)

where �1 is the proportion of liquid phase, �gas is the density of protective gas in kg/m3, and �metal is the density of metal in kg/m3.

2. Control equations and boundary conditions

Figure 5 is a schematic diagram of the HP-LPBF melting process. First, the laser light strikes a localized area of the material and rapidly heats up the area. Next, the energy absorbed in the region is diffused through a variety of pathways (heat conduction, heat convection, and surface radiation), and this process triggers complex phase transition phenomena (melting, evaporation, and solidification). In metals undergoing melting, the driving forces include surface tension and the Marangoni effect, recoil due to evaporation, and buoyancy due to gravity and uneven density. The above physical phenomena interact with each other and do not occur independently.

FIG. 5.

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Schematic diagram of HP-LPBF melting process.

  1. Laser heat sourceThe Gaussian surface heat source model is used as the laser heat source model with the following expression:�=2�0����2exp(−2�12��2),(9)where � is the heat flow density in W/m2, �0 is the absorption rate of SS316L, �� is the radius of the laser focal spot in m, and �1 is the radial distance from the center of the laser focal spot in m. The laser focal spot can be used for a wide range of applications.
  2. Energy absorptionThe formula for calculating the laser absorption �0 of SS316L is as follows:�0=0.365(�0[1+�0(�−20)]/�)0.5,(10)where �0 is the direct current resistivity of SS316L at 20 °C in Ω m, �0 is the resistance temperature coefficient in ppm/°C, � is the temperature in °C, and � is the laser wavelength in m.
  3. Heat transferThe basic principle of heat transfer is conservation of energy, which is expressed as follows:𝛻𝛻𝛻�(��)��+�·(��→�)=�·(�0����)+��,(11)where � is the density of liquid phase SS316L in kg/m3, �� is the specific heat capacity of SS316L in J/(kg K), 𝛻� is the gradient operator, t is the time in s, T is the temperature in K, 𝛻�� is the temperature gradient, �→ is the velocity vector, �0 is the coefficient of thermal conduction of SS316L in W/(m K), and  �� is the thermal energy dissipation term in the molten pool.
  4. Molten pool flowThe following three conditions need to be satisfied for the molten pool to flow:
    • Conservation of mass with the following expression:𝛻�·(��→)=0.(12)
    • Conservation of momentum (Navier–Stokes equation) with the following expression:𝛻𝛻𝛻𝛻���→��+�(�→·�)�→=�·[−pI+�(��→+(��→)�)]+�,(13)where � is the pressure in Pa exerted on the liquid phase SS316L microelement, � is the unit matrix, � is the fluid viscosity in N s/m2, and � is the volumetric force (gravity, atmospheric pressure, surface tension, vapor recoil, and the Marangoni effect).
    • Conservation of energy, see Eq. (11)
  5. Surface tension and the Marangoni effectThe effect of temperature on the surface tension coefficient is considered and set as a linear relationship with the following expression:�=�0−��dT(�−��),(14)where � is the surface tension of the molten pool at temperature T in N/m, �� is the melting temperature of SS316L in K, �0 is the surface tension of the molten pool at temperature �� in Pa, and σdσ/ dT is the surface tension temperature coefficient in N/(m K).In general, surface tension decreases with increasing temperature. A temperature gradient causes a gradient in surface tension that drives the liquid to flow, known as the Marangoni effect.
  6. Metal vapor recoilAt higher input energy densities, the maximum temperature of the molten pool surface reaches the evaporation temperature of the material, and a gasification recoil pressure occurs vertically downward toward the molten pool surface, which will be the dominant driving force for the molten pool flow.75 The expression is as follows:��=0.54�� exp ���−���0���,(15)where �� is the gasification recoil pressure in Pa, �� is the ambient pressure in kPa, �� is the latent heat of evaporation in J/kg, �0 is the gas constant in J/(mol K), T is the surface temperature of the molten pool in K, and Te is the evaporation temperature in K.
  7. Solid–liquid–gas phase transitionWhen the laser hits the powder layer, the powder goes through three stages: heating, melting, and solidification. During the solidification phase, mutual transformations between solid, liquid, and gaseous states occur. At this point, the latent heat of phase transition absorbed or released during the phase transition needs to be considered.68 The phase transition is represented based on the relationship between energy and temperature with the following expression:�=�����,(�<��),�(��)+�−����−����,(��<�<��)�(��)+(�−��)����,(��<�),,(16)where �� and �� are solid and liquid phase density, respectively, of SS316L in kg/m3. �� and �� unit volume of solid and liquid phase-specific heat capacity, respectively, of SS316L in J/(kg K). �� and ��⁠, respectively, are the solidification temperature and melting temperature of SS316L in K. �� is the latent heat of the phase transition of SS316L melting in J/kg.

3. Assumptions

The CFD model was computed using the commercial software package FLOW-3D.76 In order to simplify the calculation and solution process while ensuring the accuracy of the results, the model makes the following assumptions:

  1. It is assumed that the effects of thermal stress and material solid-phase thermal expansion on the calculation results are negligible.
  2. The molten pool flow is assumed to be a Newtonian incompressible laminar flow, while the effects of liquid thermal expansion and density on the results are neglected.
  3. It is assumed that the surface tension can be simplified to an equivalent pressure acting on the free surface of the molten pool, and the effect of chemical composition on the results is negligible.
  4. Neglecting the effect of the gas flow field on the molten pool.
  5. The mass loss due to evaporation of the liquid metal is not considered.
  6. The influence of the plasma effect of the molten metal on the calculation results is neglected.

It is worth noting that the formulation of assumptions requires a trade-off between accuracy and computational efficiency. In the above models, some physical phenomena that have a small effect or high difficulty on the calculation results are simplified or ignored. Such simplifications make numerical simulations more efficient and computationally tractable, while still yielding accurate results.

4. Initial conditions

The preheating temperature of the substrate was set to 393 K, at which time all materials were in the solid state and the flow rate was zero.

5. Material parameters

The material used is SS316L and the relevant parameters required for numerical simulations are shown in Table I.46,77,78

TABLE I.

SS316L-related parameters.

PropertySymbolValue
Density of solid metal (kg/m3�metal 7980 
Solid phase line temperature (K) �� 1658 
Liquid phase line temperature (K) �� 1723 
Vaporization temperature (K) �� 3090 
Latent heat of melting (⁠ J/kg⁠) �� 2.60×105 
Latent heat of evaporation (⁠ J/kg⁠) �� 7.45×106 
Surface tension of liquid phase (N /m⁠) � 1.60 
Liquid metal viscosity (kg/m s) �� 6×10−3 
Gaseous metal viscosity (kg/m s) �gas 1.85×10−5 
Temperature coefficient of surface tension (N/m K) ��/�T 0.80×10−3 
Molar mass (⁠ kg/mol⁠) 0.05 593 
Emissivity � 0.26 
Laser absorption �0 0.35 
Ambient pressure (kPa) �� 101 325 
Ambient temperature (K) �0 300 
Stefan–Boltzmann constant (W/m2 K4� 5.67×10−8 
Thermal conductivity of metals (⁠ W/m K⁠) � 24.55 
Density of protective gas (kg/m3�gas 1.25 
Coefficient of thermal expansion (/K) �� 16×10−6 
Generalized gas constant (⁠ J/mol K⁠) 8.314 

III. RESULTS AND DISCUSSION

With the objective of studying in depth the evolutionary patterns of single-track and double-track molten pool development, detailed observations were made for certain specific locations in the model, as shown in Fig. 6. In this figure, P1 and P2 represent the longitudinal tangents to the centers of the two melt tracks in the XZ plane, while L1 is the transverse profile in the YZ plane. The scanning direction is positive and negative along the X axis. Points A and B are the locations of the centers of the molten pool of the first and second melt tracks, respectively (x = 1.995 × 10−4, y = 5 × 10−7, and z = −4.85 × 10−5).

FIG. 6.

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Schematic diagram of observation position.

A. Single-track simulation

A series of single-track molten pool simulation experiments were carried out in order to investigate the influence law of laser power as well as scanning speed on the HP-LPBF process. Figure 7 demonstrates the evolution of the 3D morphology and temperature field of the single-track molten pool in the time period of 50–500 μs under a laser power of 100 W and a scanning speed of 800 mm/s. The powder bed is in the natural cooling state. When t = 50 μs, the powder is heated by the laser heat and rapidly melts and settles to form the initial molten pool. This process is accompanied by partial melting of the substrate and solidification together with the melted powder. The molten pool rapidly expands with increasing width, depth, length, and temperature, as shown in Fig. 7(a). When t = 150 μs, the molten pool expands more obviously, and the temperature starts to transfer to the surrounding area, forming a heat-affected zone. At this point, the width of the molten pool tends to stabilize, and the temperature in the center of the molten pool has reached its peak and remains largely stable. However, the phenomenon of molten pool spatter was also observed in this process, as shown in Fig. 7(b). As time advances, when t = 300 μs, solidification begins to occur at the tail of the molten pool, and tiny ripples are produced on the solidified surface. This is due to the fact that the melt flows toward the region with large temperature gradient under the influence of Marangoni convection and solidifies together with the melt at the end of the bath. At this point, the temperature gradient at the front of the bath is significantly larger than at the end. While the width of the molten pool was gradually reduced, the shape of the molten pool was gradually changed to a “comet” shape. In addition, a slight depression was observed at the top of the bath because the peak temperature at the surface of the bath reached the evaporation temperature, which resulted in a recoil pressure perpendicular to the surface of the bath downward, creating a depressed region. As the laser focal spot moves and is paired with the Marangoni convection of the melt, these recessed areas will be filled in as shown in Fig. 7(c). It has been shown that the depressed regions are the result of the coupled effect of Marangoni convection, recoil pressure, and surface tension.79 By t = 500 μs, the width and height of the molten pool stabilize and show a “comet” shape in Fig. 7(d).

FIG. 7.

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Single-track molten pool process: (a) t = 50  ��⁠, (b) t = 150  ��⁠, (c) t = 300  ��⁠, (d) t = 500  ��⁠.

Figure 8 depicts the velocity vector diagram of the P1 profile in a single-track molten pool, the length of the arrows represents the magnitude of the velocity, and the maximum velocity is about 2.36 m/s. When t = 50 μs, the molten pool takes shape, and the velocities at the two ends of the pool are the largest. The variation of the velocities at the front end is especially more significant in Fig. 8(a). As the time advances to t = 150 μs, the molten pool expands rapidly, in which the velocity at the tail increases and changes more significantly, while the velocity at the front is relatively small. At this stage, the melt moves backward from the center of the molten pool, which in turn expands the molten pool area. The melt at the back end of the molten pool center flows backward along the edge of the molten pool surface and then converges along the edge of the molten pool to the bottom center, rising to form a closed loop. Similarly, a similar closed loop is formed at the front end of the center of the bath, but with a shorter path. However, a large portion of the melt in the center of the closed loop formed at the front end of the bath is in a nearly stationary state. The main cause of this melt flow phenomenon is the effect of temperature gradient and surface tension (the Marangoni effect), as shown in Figs. 8(b) and 8(e). This dynamic behavior of the melt tends to form an “elliptical” pool. At t = 300 μs, the tendency of the above two melt flows to close the loop is more prominent and faster in Fig. 8(c). When t = 500 μs, the velocity vector of the molten pool shows a stable trend, and the closed loop of melt flow also remains stable. With the gradual laser focal spot movement, the melt is gradually solidified at its tail, and finally, a continuous and stable single track is formed in Fig. 8(d).

FIG. 8.

VIEW LARGEDOWNLOAD SLIDE

Vector plot of single-track molten pool velocity in XZ longitudinal section: (a) t = 50  ��⁠, (b) t = 150  ��⁠, (c) t = 300  ��⁠, (d) t = 500  ��⁠, (e) molten pool flow.

In order to explore in depth the transient evolution of the molten pool, the evolution of the single-track temperature field and the melt flow was monitored in the YZ cross section. Figure 9(a) shows the state of the powder bed at the initial moment. When t = 250 μs, the laser focal spot acts on the powder bed and the powder starts to melt and gradually collects in the molten pool. At this time, the substrate will also start to melt, and the melt flow mainly moves in the downward and outward directions and the velocity is maximum at the edges in Fig. 9(b). When t = 300 μs, the width and depth of the molten pool increase due to the recoil pressure. At this time, the melt flows more slowly at the center, but the direction of motion is still downward in Fig. 9(c). When t = 350 μs, the width and depth of the molten pool further increase, at which time the intensity of the melt flow reaches its peak and the direction of motion remains the same in Fig. 9(d). When t = 400 μs, the melt starts to move upward, and the surrounding powder or molten material gradually fills up, causing the surface of the molten pool to begin to flatten. At this time, the maximum velocity of the melt is at the center of the bath, while the velocity at the edge is close to zero, and the edge of the melt starts to solidify in Fig. 9(e). When t = 450 μs, the melt continues to move upward, forming a convex surface of the melt track. However, the melt movement slows down, as shown in Fig. 9(f). When t = 500 μs, the melt further moves upward and its speed gradually becomes smaller. At the same time, the melt solidifies further, as shown in Fig. 9(g). When t = 550 μs, the melt track is basically formed into a single track with a similar “mountain” shape. At this stage, the velocity is close to zero only at the center of the molten pool, and the flow behavior of the melt is poor in Fig. 9(h). At t = 600 μs, the melt stops moving and solidification is rapidly completed. Up to this point, a single track is formed in Fig. 9(i). During the laser action on the powder bed, the substrate melts and combines with the molten state powder. The powder-to-powder fusion is like the convergence of water droplets, which are rapidly fused by surface tension. However, the fusion between the molten state powder and the substrate occurs driven by surface tension, and the molten powder around the molten pool is pulled toward the substrate (a wetting effect occurs), which ultimately results in the formation of a monolithic whole.38,80,81

FIG. 9.

VIEW LARGEDOWNLOAD SLIDE

Evolution of single-track molten pool temperature and melt flow in the YZ cross section: (a) t = 0  ��⁠, (b) t = 250  ��⁠, (c) t = 300  ��⁠, (d) t = 350  ��⁠, (e) t = 400  ��⁠, (f) t = 450  ��⁠, (g) t = 500  ��⁠, (h) t = 550  ��⁠, (i) t = 600  ��⁠.

The wetting ability between the liquid metal and the solid substrate in the molten pool directly affects the degree of balling of the melt,82,83 and the wetting ability can be measured by the contact angle of a single track in Fig. 10. A smaller value of contact angle represents better wettability. The contact angle α can be calculated by�=�1−�22,

(17)

where �1 and �2 are the contact angles of the left and right regions, respectively.

FIG. 10.

VIEW LARGEDOWNLOAD SLIDE

Schematic of contact angle.

Relevant studies have confirmed that the wettability is better at a contact angle α around or below 40°.84 After measurement, a single-track contact angle α of about 33° was obtained under this process parameter, which further confirms the good wettability.

B. Double-track simulation

In order to deeply investigate the influence of hatch spacing on the characteristics of the HP-LPBF process, a series of double-track molten pool simulation experiments were systematically carried out. Figure 11 shows in detail the dynamic changes of the 3D morphology and temperature field of the double-track molten pool in the time period of 2050–2500 μs under the conditions of laser power of 100 W, scanning speed of 800 mm/s, and hatch spacing of 0.06 mm. By comparing the study with Fig. 7, it is observed that the basic characteristics of the 3D morphology and temperature field of the second track are similar to those of the first track. However, there are subtle differences between them. The first track exhibits a basically symmetric shape, but the second track morphology shows a slight deviation influenced by the difference in thermal diffusion rate between the solidified metal and the powder. Otherwise, the other characteristic information is almost the same as that of the first track. Figure 12 shows the velocity vector plot of the P2 profile in the double-track molten pool, with a maximum velocity of about 2.63 m/s. The melt dynamics at both ends of the pool are more stable at t = 2050 μs, where the maximum rate of the second track is only 1/3 of that of the first one. Other than that, the rest of the information is almost no significant difference from the characteristic information of the first track. Figure 13 demonstrates a detailed observation of the double-track temperature field and melts flow in the YZ cross section, and a comparative study with Fig. 9 reveals that the width of the second track is slightly wider. In addition, after the melt direction shifts from bottom to top, the first track undergoes four time periods (50 μs) to reach full solidification, while the second track takes five time periods. This is due to the presence of significant heat buildup in the powder bed after the forming of the first track, resulting in a longer dynamic time of the melt and an increased molten pool lifetime. In conclusion, the level of specimen forming can be significantly optimized by adjusting the laser power and hatch spacing.

FIG. 11.

VIEW LARGEDOWNLOAD SLIDE

Double-track molten pool process: (a) t = 2050  ��⁠, (b) t = 2150  ��⁠, (c) t = 2300  ��⁠, (d) t = 2500  ��⁠.

FIG. 12.

VIEW LARGEDOWNLOAD SLIDE

Vector plot of double-track molten pool velocity in XZ longitudinal section: (a) t = 2050  ��⁠, (b) t = 2150  ��⁠, (c) t = 2300  ��⁠, (d) t = 2500  ��⁠.

FIG. 13.

VIEW LARGEDOWNLOAD SLIDE

Evolution of double-track molten pool temperature and melt flow in the YZ cross section: (a) t = 2250  ��⁠, (b) t = 2300  ��⁠, (c) t = 2350  ��⁠, (d) t = 2400  ��⁠, (e) t = 2450  ��⁠, (f) t = 2500  ��⁠, (g) t = 2550  ��⁠, (h) t = 2600  ��⁠, (i) t = 2650  ��⁠.

In order to quantitatively detect the molten pool dimensions as well as the remolten region dimensions, the molten pool characterization information in Fig. 14 is constructed by drawing the boundary on the YZ cross section based on the isothermal surface of the liquid phase line. It can be observed that the heights of the first track and second track are basically the same, but the depth of the second track increases relative to the first track. The molten pool width is mainly positively correlated with the laser power as well as the scanning speed (the laser line energy density �⁠). However, the remelted zone width is negatively correlated with the hatch spacing (the overlapping ratio). Overall, the forming quality of the specimens can be directly influenced by adjusting the laser power, scanning speed, and hatch spacing.

FIG. 14.

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Double-track molten pool characterization information on YZ cross section.

In order to study the variation rule of the temperature in the center of the molten pool with time, Fig. 15 demonstrates the temperature variation curves with time for two reference points, A and B. Among them, the red dotted line indicates the liquid phase line temperature of SS316L. From the figure, it can be seen that the maximum temperature at the center of the molten pool in the first track is lower than that in the second track, which is mainly due to the heat accumulation generated after passing through the first track. The maximum temperature gradient was calculated to be 1.69 × 108 K/s. When the laser scanned the first track, the temperature in the center of the molten pool of the second track increased slightly. Similarly, when the laser scanned the second track, a similar situation existed in the first track. Since the temperature gradient in the second track is larger than that in the first track, the residence time of the liquid phase in the molten pool of the first track is longer than that of the second track.

FIG. 15.

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Temperature profiles as a function of time for two reference points A and B.

C. Simulation analysis of molten pool under different process parameters

In order to deeply investigate the effects of various process parameters on the mesoscopic-scale temperature field, molten pool characteristic information and defects of HP-LPBF, numerical simulation experiments on mesoscopic-scale laser power, scanning speed, and hatch spacing of double-track molten pools were carried out.

1. Laser power

Figure 16 shows the effects of different laser power on the morphology and temperature field of the double-track molten pool at a scanning speed of 800 mm/s and a hatch spacing of 0.06 mm. When P = 50 W, a smaller molten pool is formed due to the lower heat generated by the Gaussian light source per unit time. This leads to a smaller track width, which results in adjacent track not lapping properly and the presence of a large number of unmelted powder particles, resulting in an increase in the number of defects, such as pores in the specimen. The surface of the track is relatively flat, and the depth is small. In addition, the temperature gradient before and after the molten pool was large, and the depression location appeared at the biased front end in Fig. 16(a). When P = 100 W, the surface of the track is flat and smooth with excellent lap. Due to the Marangoni effect, the velocity field of the molten pool is in the form of “vortex,” and the melt has good fluidity, and the maximum velocity reaches 2.15 m/s in Fig. 16(b). When P = 200 W, the heat generated by the Gaussian light source per unit time is too large, resulting in the melt rapidly reaching the evaporation temperature, generating a huge recoil pressure, forming a large molten pool, and the surface of the track is obviously raised. The melt movement is intense, especially the closed loop at the center end of the molten pool. At this time, the depth and width of the molten pool are large, leading to the expansion of the remolten region and the increased chance of the appearance of porosity defects in Fig. 16(c). The results show that at low laser power, the surface tension in the molten pool is dominant. At high laser power, recoil pressure is its main role.

FIG. 16.

VIEW LARGEDOWNLOAD SLIDE

Simulation results of double-track molten pool under different laser powers: (a) P = 50 W, (b) P = 100 W, (c) P = 200 W.

Table II shows the effect of different laser powers on the characteristic information of the double-track molten pool at a scanning speed of 800 mm/s and a hatch spacing of 0.06 mm. The negative overlapping ratio in the table indicates that the melt tracks are not lapped, and 26/29 indicates the melt depth of the first track/second track. It can be seen that with the increase in laser power, the melt depth, melt width, melt height, and remelted zone show a gradual increase. At the same time, the overlapping ratio also increases. Especially in the process of laser power from 50 to 200 W, the melting depth and melting width increased the most, which increased nearly 2 and 1.5 times, respectively. Meanwhile, the overlapping ratio also increases with the increase in laser power, which indicates that the melting and fusion of materials are better at high laser power. On the other hand, the dimensions of the molten pool did not change uniformly with the change of laser power. Specifically, the depth-to-width ratio of the molten pool increased from about 0.30 to 0.39 during the increase from 50 to 120 W, which further indicates that the effective heat transfer in the vertical direction is greater than that in the horizontal direction with the increase in laser power. This dimensional response to laser power is mainly affected by the recoil pressure and also by the difference in the densification degree between the powder layer and the metal substrate. In addition, according to the experimental results, the contact angle shows a tendency to increase and then decrease during the process of laser power increase, and always stays within the range of less than 33°. Therefore, in practical applications, it is necessary to select the appropriate laser power according to the specific needs in order to achieve the best processing results.

TABLE II.

Double-track molten pool characterization information at different laser powers.

Laser power (W)Depth (μm)Width (μm)Height (μm)Remolten region (μm)Overlapping ratio (%)Contact angle (°)
50 16 54 11 −10 23 
100 26/29 74 14 18 23.33 33 
200 37/45 116 21 52 93.33 28 

2. Scanning speed

Figure 17 demonstrates the effect of different scanning speeds on the morphology and temperature field of the double-track molten pool at a laser power of 100 W and a hatch spacing of 0.06 mm. With the gradual increase in scanning speed, the surface morphology of the molten pool evolves from circular to elliptical. When � = 200 mm/s, the slow scanning speed causes the material to absorb too much heat, which is very easy to trigger the overburning phenomenon. At this point, the molten pool is larger and the surface morphology is uneven. This situation is consistent with the previously discussed scenario with high laser power in Fig. 17(a). However, when � = 1600 mm/s, the scanning speed is too fast, resulting in the material not being able to absorb sufficient heat, which triggers the powder particles that fail to melt completely to have a direct effect on the bonding of the melt to the substrate. At this time, the molten pool volume is relatively small and the neighboring melt track cannot lap properly. This result is consistent with the previously discussed case of low laser power in Fig. 17(b). Overall, the ratio of the laser power to the scanning speed (the line energy density �⁠) has a direct effect on the temperature field and surface morphology of the molten pool.

FIG. 17.

VIEW LARGEDOWNLOAD SLIDE

Simulation results of double-track molten pool under different scanning speed: (a)  � = 200 mm/s, (b)  � = 1600 mm/s.

Table III shows the effects of different scanning speed on the characteristic information of the double-track molten pool under the condition of laser power of 100 W and hatch spacing of 0.06 mm. It can be seen that the scanning speed has a significant effect on the melt depth, melt width, melt height, remolten region, and overlapping ratio. With the increase in scanning speed, the melt depth, melt width, melt height, remelted zone, and overlapping ratio show a gradual decreasing trend. Among them, the melt depth and melt width decreased faster, while the melt height and remolten region decreased relatively slowly. In addition, when the scanning speed was increased from 200 to 800 mm/s, the decreasing speeds of melt depth and melt width were significantly accelerated, while the decreasing speeds of overlapping ratio were relatively slow. When the scanning speed was further increased to 1600 mm/s, the decreasing speeds of melt depth and melt width were further accelerated, and the un-lapped condition of the melt channel also appeared. In addition, the contact angle increases and then decreases with the scanning speed, and both are lower than 33°. Therefore, when selecting the scanning speed, it is necessary to make reasonable trade-offs according to the specific situation, and take into account the factors of melt depth, melt width, melt height, remolten region, and overlapping ratio, in order to achieve the best processing results.

TABLE III.

Double-track molten pool characterization information at different scanning speeds.

Scanning speed (mm/s)Depth (μm)Width (μm)Height (μm)Remolten region (μm)Overlapping ratio (%)Contact angle (°)
200 55/68 182 19/32 124 203.33 22 
1600 13 50 11 −16.67 31 

3. Hatch spacing

Figure 18 shows the effect of different hatch spacing on the morphology and temperature field of the double-track molten pool under the condition of laser power of 100 W and scanning speed of 800 mm/s. The surface morphology and temperature field of the first track and second track are basically the same, but slightly different. The first track shows a basically symmetric morphology along the scanning direction, while the second track shows a slight offset due to the difference in the heat transfer rate between the solidified material and the powder particles. When the hatch spacing is too small, the overlapping ratio increases and the probability of defects caused by remelting phenomenon grows. When the hatch spacing is too large, the neighboring melt track cannot overlap properly, and the powder particles are not completely melted, leading to an increase in the number of holes. In conclusion, the ratio of the line energy density � to the hatch spacing (the volume energy density E) has a significant effect on the temperature field and surface morphology of the molten pool.

FIG. 18.

VIEW LARGEDOWNLOAD SLIDE

Simulation results of double-track molten pool under different hatch spacings: (a) H = 0.03 mm, (b) H = 0.12 mm.

Table IV shows the effects of different hatch spacing on the characteristic information of the double-track molten pool under the condition of laser power of 100 W and scanning speed of 800 mm/s. It can be seen that the hatch spacing has little effect on the melt depth, melt width, and melt height, but has some effect on the remolten region. With the gradual expansion of hatch spacing, the remolten region shows a gradual decrease. At the same time, the overlapping ratio also decreased with the increase in hatch spacing. In addition, it is observed that the contact angle shows a tendency to increase and then remain stable when the hatch spacing increases, which has a more limited effect on it. Therefore, trade-offs and decisions need to be made on a case-by-case basis when selecting the hatch spacing.

TABLE IV.

Double-track molten pool characterization information at different hatch spacings.

Hatch spacing (mm)Depth (μm)Width (μm)Height (μm)Remolten region (μm)Overlapping ratio (%)Contact angle (°)
0.03 25/27 82 14 59 173.33 30 
0.12 26 78 14 −35 33 

In summary, the laser power, scanning speed, and hatch spacing have a significant effect on the formation of the molten pool, and the correct selection of these three process parameters is crucial to ensure the forming quality. In addition, the melt depth of the second track is slightly larger than that of the first track at higher line energy density � and volume energy density E. This is mainly due to the fact that a large amount of heat accumulation is generated after the first track, forming a larger molten pool volume, which leads to an increase in the melt depth.

D. Simulation analysis of molten pool with powder particle size and laser focal spot diameter

Figure 19 demonstrates the effect of different powder particle sizes and laser focal spot diameters on the morphology and temperature field of the double-track molten pool under a laser power of 100 W, a scanning speed of 800 mm/s, and a hatch spacing of 0.06 mm. In the process of melting coarse powder with small laser focal spot diameter, the laser energy cannot completely melt the larger powder particles, resulting in their partial melting and further generating excessive pore defects. The larger powder particles tend to generate zigzag molten pool edges, which cause an increase in the roughness of the melt track surface. In addition, the molten pool is also prone to generate the present spatter phenomenon, which can directly affect the quality of forming. The volume of the formed molten pool is relatively small, while the melt depth, melt width, and melt height are all smaller relative to the fine powder in Fig. 19(a). In the process of melting fine powders with a large laser focal spot diameter, the laser energy is able to melt the fine powder particles sufficiently, even to the point of overmelting. This results in a large number of fine spatters being generated at the edge of the molten pool, which causes porosity defects in the melt track in Fig. 19(b). In addition, the maximum velocity of the molten pool is larger for large powder particle sizes compared to small powder particle sizes, which indicates that the temperature gradient in the molten pool is larger for large powder particle sizes and the melt motion is more intense. However, the size of the laser focal spot diameter has a relatively small effect on the melt motion. However, a larger focal spot diameter induces a larger melt volume with greater depth, width, and height. In conclusion, a small powder size helps to reduce the surface roughness of the specimen, and a small laser spot diameter reduces the minimum forming size of a single track.

FIG. 19.

VIEW LARGEDOWNLOAD SLIDE

Simulation results of double-track molten pool with different powder particle size and laser focal spot diameter: (a) focal spot = 25 μm, coarse powder, (b) focal spot = 80 μm, fine powder.

Table V shows the maximum temperature gradient at the reference point for different powder sizes and laser focal spot diameters. As can be seen from the table, the maximum temperature gradient is lower than that of HP-LPBF for both coarse powders with a small laser spot diameter and fine powders with a large spot diameter, a phenomenon that leads to an increase in the heat transfer rate of HP-LPBF, which in turn leads to a corresponding increase in the cooling rate and, ultimately, to the formation of finer microstructures.

TABLE V.

Maximum temperature gradient at the reference point for different powder particle sizes and laser focal spot diameters.

Laser power (W)Scanning speed (mm/s)Hatch spacing (mm)Average powder size (μm)Laser focal spot diameter (μm)Maximum temperature gradient (×107 K/s)
100 800 0.06 31.7 25 7.89 
11.5 80 7.11 

IV. CONCLUSIONS

In this study, the geometrical characteristics of 3D coarse and fine powder particles were first calculated using DEM and then numerical simulations of single track and double track in the process of forming SS316L from monolayer HP-LPBF at mesoscopic scale were developed using CFD method. The effects of Marangoni convection, surface tension, recoil pressure, gravity, thermal convection, thermal radiation, and evaporative heat dissipation on the heat and mass transfer in the molten pool were considered in this model. The effects of laser power, scanning speed, and hatch spacing on the dynamics of the single-track and double-track molten pools, as well as on other characteristic information, were investigated. The effects of the powder particle size on the molten pool were investigated comparatively with the laser focal spot diameter. The main conclusions are as follows:

  1. The results show that the temperature gradient at the front of the molten pool is significantly larger than that at the tail, and the molten pool exhibits a “comet” morphology. At the top of the molten pool, there is a slightly concave region, which is the result of the coupling of Marangoni convection, recoil pressure, and surface tension. The melt flow forms two closed loops, which are mainly influenced by temperature gradients and surface tension. This special dynamic behavior of the melt tends to form an “elliptical” molten pool and an almost “mountain” shape in single-track forming.
  2. The basic characteristics of the three-dimensional morphology and temperature field of the second track are similar to those of the first track, but there are subtle differences. The first track exhibits a basically symmetrical shape; however, due to the difference in thermal diffusion rates between the solidified metal and the powder, a slight asymmetry in the molten pool morphology of the second track occurs. After forming through the first track, there is a significant heat buildup in the powder bed, resulting in a longer dynamic time of the melt, which increases the life of the molten pool. The heights of the first track and second track remained essentially the same, but the depth of the second track was greater relative to the first track. In addition, the maximum temperature gradient was 1.69 × 108 K/s during HP-LPBF forming.
  3. At low laser power, the surface tension in the molten pool plays a dominant role. At high laser power, recoil pressure becomes the main influencing factor. With the increase of laser power, the effective heat transfer in the vertical direction is superior to that in the horizontal direction. With the gradual increase of scanning speed, the surface morphology of the molten pool evolves from circular to elliptical. In addition, the scanning speed has a significant effect on the melt depth, melt width, melt height, remolten region, and overlapping ratio. Too large or too small hatch spacing will lead to remelting or non-lap phenomenon, which in turn causes the formation of defects.
  4. When using a small laser focal spot diameter, it is difficult to completely melt large powder particle sizes, resulting in partial melting and excessive porosity generation. At the same time, large powder particles produce curved edges of the molten pool, resulting in increased surface roughness of the melt track. In addition, spatter occurs, which directly affects the forming quality. At small focal spot diameters, the molten pool volume is relatively small, and the melt depth, the melt width, and the melt height are correspondingly small. Taken together, the small powder particle size helps to reduce surface roughness, while the small spot diameter reduces the forming size.

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Effects of ramp slope and discharge on hydraulic performance of submerged hump weirs

Effects of ramp slope and discharge on hydraulic performance of submerged hump weirs

Arash Ahmadi a, Amir H. Azimi b

Abstract

험프 웨어는 수위 제어 및 배출 측정을 위한 기존의 수력 구조물 중 하나입니다. 상류 및 하류 경사로의 경사는 자유 및 침수 흐름 조건 모두에서 험프 웨어의 성능에 영향을 미치는 설계 매개변수입니다.

침수된 험프보의 유출 특성 및 수위 변화에 대한 램프 경사 및 유출의 영향을 조사하기 위해 일련의 수치 시뮬레이션이 수행되었습니다. 1V:1H에서 1V:5H까지의 5개 램프 경사를 다양한 업스트림 방전에서 테스트했습니다.

수치모델의 검증을 위해 수치결과를 실험실 데이터와 비교하였다. 수면수위 예측과 유출계수의 시뮬레이션 불일치는 각각 전체 범위의 ±10%와 ±5% 이내였습니다.

모듈 한계 및 방전 감소 계수의 변화에 대한 램프 경사의 영향을 연구했습니다. 험프보의 경사로 경사가 증가함에 따라 상대적으로 높은 침수율에서 모듈러 한계가 발생함을 알 수 있었다.

침수 시작은 방류 수위를 작은 증분으로 조심스럽게 증가시켜 모델링되었으며 그 결과는 모듈 한계의 고전적인 정의와 비교되었습니다. 램프 경사와 방전이 증가함에 따라 모듈러 한계가 증가하는 것으로 밝혀졌지만, 모듈러 한계의 고전적인 정의는 모듈러 한계가 방전과 무관하다는 것을 나타냅니다.

Hump weir 하류의 속도와 와류장은 램프 경사에 의해 제어되는 와류 구조 형성을 나타냅니다. 에너지 손실은 수치 출력으로부터 계산되었으며 정규화된 에너지 손실은 침수에 따라 선형적으로 감소하는 것으로 나타났습니다.

Hump weirs are amongst conventional hydraulic structures for water level control and discharge measurement. The slope in the upstream and downstream ramps is a design parameter that affects the performance of Hump weirs in both free and submerged flow conditions. A series of numerical simulations was performed to investigate the effects of ramp slope and discharge on discharge characteristics and water level variations of submerged Hump weirs. Five ramp slopes ranging from 1V:1H to 1V:5H were tested at different upstream discharges. The numerical results were compared with the laboratory data for verifications of the numerical model. The simulation discrepancies in prediction of water surface level and discharge coefficient were within ±10 % and ±5 % of the full range, respectively. The effects of ramp slope on variations of modular limit and discharge reduction factor were studied. It was found that the modular limit occurred at relatively higher submergence ratios as the ramp slope in Hump weirs increased. The onset of submergence was modeled by carefully increasing tailwater level with small increments and the results were compared with the classic definition of modular limit. It was found that the modular limit increases with increasing the ramp slope and discharge while the classic definition of modular limit indicated that the modular limit is independent of the discharge. The velocity and vortex fields in the downstream of Hump weirs indicated the formation vortex structure, which is controlled by the ramp slope. The energy losses were calculated from the numerical outputs, and it was found that the normalized energy losses decreased linearly with submergence.

Introduction

Weirs have been utilized predominantly for discharge measurement, flow diversion, and water level control in open channels, irrigation canal, and natural streams due to their simplicity of operation and accuracy. Several research studies have been conducted to determine the head-discharge relationship in weirs as one of the most common hydraulic structures for flow measurement (Rajaratnam and Muralidhar, 1969 [[1], [2], [3]]; Vatankhah, 2010, [[4], [5], [6]]; b [[7], [8], [9]]; Azimi and Seyed Hakim, 2019; Salehi et al., 2019; Salehi and Azimi, 2019, [10]. Weirs in general are classified into two major categories named as sharp-crested weirs and weirs of finite-crest length (Rajaratnam and Muralidhar, 1969; [11]. Sharp-crested weirs are typically used for flow measurement in small irrigation canals and laboratory flumes. In contrast, weirs of finite crest length are more suitable for water level control and flow diversion in rivers and natural streams [7,[12], [13], [14]].

The head-discharge relationship in sharp-crested weirs is developed by employing energy equation between two sections in the upstream and downstream of the weir and integration of the velocity profile at the crest of the weir as:

where Qf is the free flow discharge, B is the channel width, g is the acceleration due to gravity, ho is the water head in free-flow condition, and Cd is the discharge coefficient. Rehbock [15] proposed a linear correlation between discharge coefficient and the ratio of water head, ho, and the weir height, P as Cd = 0.605 + 0.08 (ho/P).

Upstream and/or downstream ramp(s) can be added to sharp-crested weirs to enhance the structural stability of the weir. A sharp-crested weir with upstream and/or downstream ramp(s) are known as triangular weirs in the literature. Triangular weirs with both upstream and downstream ramps are also known as Hump weirs and are first introduced in the experimental study of Bazin [16]. The ramps are constructed upstream and downstream of sharp-crested weirs to enhance the weir’s structural integrity and improve the hydraulic performance of the weir. In free-flow condition, the discharge coefficient of Hump weirs increases with increasing downstream ramp slope but decreases as upstream ramp slope increases (Azimi et al., 2013).

The hydraulic performance of weirs is evaluated in both free and submerged flow conditions. In free flow condition, water freely flows over weirs since the downstream water level is lower than that of the crest level of the weir. Channel blockage or flood in the downstream of weirs can raise the tailwater level, t. As tailwater passes the crest elevation in sharp-crested weirs, the upstream flow decelerates due to the excess pressure force in the downstream and the upstream water level increases. The onset of water level raise due to tailwater raise is called the modular limit. Once the tailwater level passes the modular limit, the weir is submerged. In sharp-crested weirs, the submerged flow regime may occur even before the tailwater reaches the crest elevation [8,14], whereas, in weirs of finite crest length, the upstream water level remains unchanged even if the tailwater raises above the crest elevation and it normally causes submergence once the tailwater level passes the critical depth at the crest of the weir [7,17]. The degree of submergence can be estimated by careful observation of the water surface profile. Observations of water surface at different submergence levels indicated two distinct flow patterns in submerged sharp-crested weirs that was initially classified as impinging jet and surface flow regimes [14]. [8] analyzed the variations of water surface profiles over submerged sharp-crested weirs with different submergence ratios and defined four distinct regimes of impinging jet, surface jump, surface wave, and surface jet.

[18] characterized the onset of submergence by defining the modular limit as a stage when the free flow head increases by +1 mm due to tailwater rise. The definition of modular limit is somewhat arbitrary, and it is difficult to identify for large discharges because the upstream water surface begins to fluctuate. This definition did not consider the effects of channel and weir geometries. The experimental data in triangular weirs and weirs finite-crest length with upstream and downstream ramp(s) revealed that the modular limit varied with the ratio of the free-flow head to the total streamwise length of the weir [17]. Weirs of finite crest length with upstream and downstream ramps are known as embankment weirs in literature [1,19,20] and Azimi et al., 2013) [19]. conducted two series of laboratory experiments to study the hydraulics of submerged embankment weirs with the upstream and downstream ramps of 1V:1H and 1V:2H. Empirical correlations were proposed to directly estimate the flow discharge in submerged embankment weirs for t/h > 0.7 where h is the water head in submerged flow condition. He found that the free flow discharge is a function of upstream water head, but the submerged discharge is a function of submergence level, t/h [21]. studied the hydraulics of four embankment weirs with different weir heights ranging from 0.09 m to 0.36 m. It was found that submerged embankments with a higher ho/P, where P is the height of the weir, have a smaller discharge reduction due to submergence. Effects of crest length in embankment weirs with both upstream and downstream ramps of 1V:2H was studied in both free and submerged flow conditions [1]. It was found that the modular limit in submerged embankment weirs decreased linearly with the relative crest length, Ho/(Ho + L), where Ho is the total head and L is the crest length.

In submerged flow condition, the performance of weirs is quantified by the discharge reduction factor, ψ, which is a ratio of the submerged discharge, Qs, to the corresponding free-flow discharge, Qf, based on the upstream head, h [12]. In submerged-flow conditions, flow discharge can be estimated as:��=���

[1] proposed a formula to predict ψ that could be used for embankment weirs with different crest lengths ranging from 0 to 0.3 m as:�=(1−��)�where n is an exponent varying from 4 to 7 and Yt is the normalized submergence defined as:��=�ℎ−[0.85−(0.5��+�)]1−[0.85−(0.5��+�)]where H is the total upstream head in submerged-flow conditions [7]. proposed a simpler formula to predict ψ for weirs of finite-crest length as:�=[1−(�ℎ)�]�where m and n are exponents varying for different types of weirs. Hakim and Azimi (2017) employed regression analysis to propose values of n = 0.25 and m = 0.28 (ho/L)−2.425 for triangular weirs.

The discharge capacity of weirs decreases in submerged flow condition and the onset of submergence occurs at the modular limit. Therefore, the determination of modular limit in weirs with different geometries is critical to understanding the sensitivity of a particular weir model with tailwater level variations. The available definition of modular limit as when head water raises by +1 mm due to tailwater rise does not consider the effects of channel and weir geometries. Therefore, a new and more accurate definition of modular limit is proposed in this study to consider the effect of other geometry and approaching flow parameters. The second objective of this study is to evaluate the effects of upstream and downstream ramps and ramps slopes on the hydraulic performance of submerged Hump weirs. The flow patterns, velocity distributions, and energy dissipation rates were extracted from validated numerical data to better understand the discharge reduction mechanism in Hump weirs in both free and submerged flow conditions.

Section snippets

Governing equations

Numerical simulation has been employed as an efficient and effective method to analyze free surface flow problems and in particular investigating on the hydraulics of flow over weirs [22]. The weir models were developed in numerical domain and the water pressure and velocity field were simulated by employing the FLOW-3D solver (Flow Science, Inc., Santa Fe, USA). The numerical results were validated with the laboratory measurements and the effects of ramps slopes on the performance of Hump

Verification of numerical model

The experimental observations of Bazin [16,17] were used for model validation in free and submerged flow conditions, respectively. The weir height in the study of Bazin was P = 0.5 m and two ramp slopes of 1V:1H and 1V:2H were tested. The bed and sides of the channel were made of glass, and the roughness distribution of the bed and walls were uniform. The Hump weir models in the study of Seyed Hakim and Azimi (2017) had a weir height of 0.076 m and ramp slopes of 1V:2H in both upstream and

Conclusions

A series of numerical simulations was performed to study the hydraulics and velocity pattern downstream of a Hump weir with symmetrical ramp slopes. Effects of ramp slope and discharge on formation of modular limit and in submerged flow condition were tested by conducting a series of numerical simulations on Hump weirs with ramp slopes varying from 1V:1H to 1V:5H. A comparison between numerical results and experimental data indicated that the proposed numerical model is accurate with a mean

Author contributions

Arash Ahmadi: Software, Validation, Visualization, Writing – original draft. Amir Azimi: Conceptualization, Funding acquisition, Investigation, Project administration, Supervision, Writing – review & editing

Uncited References

[30]; [31]; [32]; [33].

Declaration of competing interest

The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.

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Lab-on-a-Chip 시스템의 혈류 역학에 대한 검토: 엔지니어링 관점

Review on Blood Flow Dynamics in Lab-on-a-Chip Systems: An Engineering Perspective

  • Bin-Jie Lai
  • Li-Tao Zhu
  • Zhe Chen*
  • Bo Ouyang*
  • , and 
  • Zheng-Hong Luo*

Abstract

다양한 수송 메커니즘 하에서, “LOC(lab-on-a-chip)” 시스템에서 유동 전단 속도 조건과 밀접한 관련이 있는 혈류 역학은 다양한 수송 현상을 초래하는 것으로 밝혀졌습니다.

본 연구는 적혈구의 동적 혈액 점도 및 탄성 거동과 같은 점탄성 특성의 역할을 통해 LOC 시스템의 혈류 패턴을 조사합니다. 모세관 및 전기삼투압의 주요 매개변수를 통해 LOC 시스템의 혈액 수송 현상에 대한 연구는 실험적, 이론적 및 수많은 수치적 접근 방식을 통해 제공됩니다.

전기 삼투압 점탄성 흐름에 의해 유발되는 교란은 특히 향후 연구 기회를 위해 혈액 및 기타 점탄성 유체를 취급하는 LOC 장치의 혼합 및 분리 기능 향상에 논의되고 적용됩니다. 또한, 본 연구는 보다 정확하고 단순화된 혈류 모델에 대한 요구와 전기역학 효과 하에서 점탄성 유체 흐름에 대한 수치 연구에 대한 강조와 같은 LOC 시스템 하에서 혈류 역학의 수치 모델링의 문제를 식별합니다.

전기역학 현상을 연구하는 동안 제타 전위 조건에 대한 보다 실용적인 가정도 강조됩니다. 본 연구는 모세관 및 전기삼투압에 의해 구동되는 미세유체 시스템의 혈류 역학에 대한 포괄적이고 학제적인 관점을 제공하는 것을 목표로 한다.

KEYWORDS: 

1. Introduction

1.1. Microfluidic Flow in Lab-on-a-Chip (LOC) Systems

Over the past several decades, the ability to control and utilize fluid flow patterns at microscales has gained considerable interest across a myriad of scientific and engineering disciplines, leading to growing interest in scientific research of microfluidics. 

(1) Microfluidics, an interdisciplinary field that straddles physics, engineering, and biotechnology, is dedicated to the behavior, precise control, and manipulation of fluids geometrically constrained to a small, typically submillimeter, scale. 

(2) The engineering community has increasingly focused on microfluidics, exploring different driving forces to enhance working fluid transport, with the aim of accurately and efficiently describing, controlling, designing, and applying microfluidic flow principles and transport phenomena, particularly for miniaturized applications. 

(3) This attention has chiefly been fueled by the potential to revolutionize diagnostic and therapeutic techniques in the biomedical and pharmaceutical sectorsUnder various driving forces in microfluidic flows, intriguing transport phenomena have bolstered confidence in sustainable and efficient applications in fields such as pharmaceutical, biochemical, and environmental science. The “lab-on-a-chip” (LOC) system harnesses microfluidic flow to enable fluid processing and the execution of laboratory tasks on a chip-sized scale. LOC systems have played a vital role in the miniaturization of laboratory operations such as mixing, chemical reaction, separation, flow control, and detection on small devices, where a wide variety of fluids is adapted. Biological fluid flow like blood and other viscoelastic fluids are notably studied among the many working fluids commonly utilized by LOC systems, owing to the optimization in small fluid sample volumed, rapid response times, precise control, and easy manipulation of flow patterns offered by the system under various driving forces. 

(4)The driving forces in blood flow can be categorized as passive or active transport mechanisms and, in some cases, both. Under various transport mechanisms, the unique design of microchannels enables different functionalities in driving, mixing, separating, and diagnosing blood and drug delivery in the blood. 

(5) Understanding and manipulating these driving forces are crucial for optimizing the performance of a LOC system. Such knowledge presents the opportunity to achieve higher efficiency and reliability in addressing cellular level challenges in medical diagnostics, forensic studies, cancer detection, and other fundamental research areas, for applications of point-of-care (POC) devices. 

(6)

1.2. Engineering Approach of Microfluidic Transport Phenomena in LOC Systems

Different transport mechanisms exhibit unique properties at submillimeter length scales in microfluidic devices, leading to significant transport phenomena that differ from those of macroscale flows. An in-depth understanding of these unique transport phenomena under microfluidic systems is often required in fluidic mechanics to fully harness the potential functionality of a LOC system to obtain systematically designed and precisely controlled transport of microfluids under their respective driving force. Fluid mechanics is considered a vital component in chemical engineering, enabling the analysis of fluid behaviors in various unit designs, ranging from large-scale reactors to separation units. Transport phenomena in fluid mechanics provide a conceptual framework for analytically and descriptively explaining why and how experimental results and physiological phenomena occur. The Navier–Stokes (N–S) equation, along with other governing equations, is often adapted to accurately describe fluid dynamics by accounting for pressure, surface properties, velocity, and temperature variations over space and time. In addition, limiting factors and nonidealities for these governing equations should be considered to impose corrections for empirical consistency before physical models are assembled for more accurate controls and efficiency. Microfluidic flow systems often deviate from ideal conditions, requiring adjustments to the standard governing equations. These deviations could arise from factors such as viscous effects, surface interactions, and non-Newtonian fluid properties from different microfluid types and geometrical layouts of microchannels. Addressing these nonidealities supports the refining of theoretical models and prediction accuracy for microfluidic flow behaviors.

The analytical calculation of coupled nonlinear governing equations, which describes the material and energy balances of systems under ideal conditions, often requires considerable computational efforts. However, advancements in computation capabilities, cost reduction, and improved accuracy have made numerical simulations using different numerical and modeling methods a powerful tool for effectively solving these complex coupled equations and modeling various transport phenomena. Computational fluid dynamics (CFD) is a numerical technique used to investigate the spatial and temporal distribution of various flow parameters. It serves as a critical approach to provide insights and reasoning for decision-making regarding the optimal designs involving fluid dynamics, even prior to complex physical model prototyping and experimental procedures. The integration of experimental data, theoretical analysis, and reliable numerical simulations from CFD enables systematic variation of analytical parameters through quantitative analysis, where adjustment to delivery of blood flow and other working fluids in LOC systems can be achieved.

Numerical methods such as the Finite-Difference Method (FDM), Finite-Element-Method (FEM), and Finite-Volume Method (FVM) are heavily employed in CFD and offer diverse approaches to achieve discretization of Eulerian flow equations through filling a mesh of the flow domain. A more in-depth review of numerical methods in CFD and its application for blood flow simulation is provided in Section 2.2.2.

1.3. Scope of the Review

In this Review, we explore and characterize the blood flow phenomena within the LOC systems, utilizing both physiological and engineering modeling approaches. Similar approaches will be taken to discuss capillary-driven flow and electric-osmotic flow (EOF) under electrokinetic phenomena as a passive and active transport scheme, respectively, for blood transport in LOC systems. Such an analysis aims to bridge the gap between physical (experimental) and engineering (analytical) perspectives in studying and manipulating blood flow delivery by different driving forces in LOC systems. Moreover, the Review hopes to benefit the interests of not only blood flow control in LOC devices but also the transport of viscoelastic fluids, which are less studied in the literature compared to that of Newtonian fluids, in LOC systems.

Section 2 examines the complex interplay between viscoelastic properties of blood and blood flow patterns under shear flow in LOC systems, while engineering numerical modeling approaches for blood flow are presented for assistance. Sections 3 and 4 look into the theoretical principles, numerical governing equations, and modeling methodologies for capillary driven flow and EOF in LOC systems as well as their impact on blood flow dynamics through the quantification of key parameters of the two driving forces. Section 5 concludes the characterized blood flow transport processes in LOC systems under these two forces. Additionally, prospective areas of research in improving the functionality of LOC devices employing blood and other viscoelastic fluids and potentially justifying mechanisms underlying microfluidic flow patterns outside of LOC systems are presented. Finally, the challenges encountered in the numerical studies of blood flow under LOC systems are acknowledged, paving the way for further research.

2. Blood Flow Phenomena

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2.1. Physiological Blood Flow Behavior

Blood, an essential physiological fluid in the human body, serves the vital role of transporting oxygen and nutrients throughout the body. Additionally, blood is responsible for suspending various blood cells including erythrocytes (red blood cells or RBCs), leukocytes (white blood cells), and thrombocytes (blood platelets) in a plasma medium.Among the cells mentioned above, red blood cells (RBCs) comprise approximately 40–45% of the volume of healthy blood. 

(7) An RBC possesses an inherent elastic property with a biconcave shape of an average diameter of 8 μm and a thickness of 2 μm. This biconcave shape maximizes the surface-to-volume ratio, allowing RBCs to endure significant distortion while maintaining their functionality. 

(8,9) Additionally, the biconcave shape optimizes gas exchange, facilitating efficient uptake of oxygen due to the increased surface area. The inherent elasticity of RBCs allows them to undergo substantial distortion from their original biconcave shape and exhibits high flexibility, particularly in narrow channels.RBC deformability enables the cell to deform from a biconcave shape to a parachute-like configuration, despite minor differences in RBC shape dynamics under shear flow between initial cell locations. As shown in Figure 1(a), RBCs initiating with different resting shapes and orientations displaying display a similar deformation pattern 

(10) in terms of its shape. Shear flow induces an inward bending of the cell at the rear position of the rim to the final bending position, 

(11) resulting in an alignment toward the same position of the flow direction.

Figure 1. Images of varying deformation of RBCs and different dynamic blood flow behaviors. (a) The deforming shape behavior of RBCs at four different initiating positions under the same experimental conditions of a flow from left to right, (10) (b) RBC aggregation, (13) (c) CFL region. (18) Reproduced with permission from ref (10). Copyright 2011 Elsevier. Reproduced with permission from ref (13). Copyright 2022 The Authors, under the terms of the Creative Commons (CC BY 4.0) License https://creativecommons.org/licenses/by/4.0/. Reproduced with permission from ref (18). Copyright 2019 Elsevier.

The flexible property of RBCs enables them to navigate through narrow capillaries and traverse a complex network of blood vessels. The deformability of RBCs depends on various factors, including the channel geometry, RBC concentration, and the elastic properties of the RBC membrane. 

(12) Both flexibility and deformability are vital in the process of oxygen exchange among blood and tissues throughout the body, allowing cells to flow in vessels even smaller than the original cell size prior to deforming.As RBCs serve as major components in blood, their collective dynamics also hugely affect blood rheology. RBCs exhibit an aggregation phenomenon due to cell to cell interactions, such as adhesion forces, among populated cells, inducing unique blood flow patterns and rheological behaviors in microfluidic systems. For blood flow in large vessels between a diameter of 1 and 3 cm, where shear rates are not high, a constant viscosity and Newtonian behavior for blood can be assumed. However, under low shear rate conditions (0.1 s

–1) in smaller vessels such as the arteries and venules, which are within a diameter of 0.2 mm to 1 cm, blood exhibits non-Newtonian properties, such as shear-thinning viscosity and viscoelasticity due to RBC aggregation and deformability. The nonlinear viscoelastic property of blood gives rise to a complex relationship between viscosity and shear rate, primarily influenced by the highly elastic behavior of RBCs. A wide range of research on the transient behavior of the RBC shape and aggregation characteristics under varied flow circumstances has been conducted, aiming to obtain a better understanding of the interaction between blood flow shear forces from confined flows.

For a better understanding of the unique blood flow structures and rheological behaviors in microfluidic systems, some blood flow patterns are introduced in the following section.

2.1.1. RBC Aggregation

RBC aggregation is a vital phenomenon to be considered when designing LOC devices due to its impact on the viscosity of the bulk flow. Under conditions of low shear rate, such as in stagnant or low flow rate regions, RBCs tend to aggregate, forming structures known as rouleaux, resembling stacks of coins as shown in Figure 1(b). 

(13) The aggregation of RBCs increases the viscosity at the aggregated region, 

(14) hence slowing down the overall blood flow. However, when exposed to high shear rates, RBC aggregates disaggregate. As shear rates continue to increase, RBCs tend to deform, elongating and aligning themselves with the direction of the flow. 

(15) Such a dynamic shift in behavior from the cells in response to the shear rate forms the basis of the viscoelastic properties observed in whole blood. In essence, the viscosity of the blood varies according to the shear rate conditions, which are related to the velocity gradient of the system. It is significant to take the intricate relationship between shear rate conditions and the change of blood viscosity due to RBC aggregation into account since various flow driving conditions may induce varied effects on the degree of aggregation.

2.1.2. Fåhræus-Lindqvist Effect

The Fåhræus–Lindqvist (FL) effect describes the gradual decrease in the apparent viscosity of blood as the channel diameter decreases. 

(16) This effect is attributed to the migration of RBCs toward the central region in the microchannel, where the flow rate is higher, due to the presence of higher pressure and asymmetric distribution of shear forces. This migration of RBCs, typically observed at blood vessels less than 0.3 mm, toward the higher flow rate region contributes to the change in blood viscosity, which becomes dependent on the channel size. Simultaneously, the increase of the RBC concentration in the central region of the microchannel results in the formation of a less viscous region close to the microchannel wall. This region called the Cell-Free Layer (CFL), is primarily composed of plasma. 

(17) The combination of the FL effect and the following CFL formation provides a unique phenomenon that is often utilized in passive and active plasma separation mechanisms, involving branched and constriction channels for various applications in plasma separation using microfluidic systems.

2.1.3. Cell-Free Layer Formation

In microfluidic blood flow, RBCs form aggregates at the microchannel core and result in a region that is mostly devoid of RBCs near the microchannel walls, as shown in Figure 1(c). 

(18) The region is known as the cell-free layer (CFL). The CFL region is often known to possess a lower viscosity compared to other regions within the blood flow due to the lower viscosity value of plasma when compared to that of the aggregated RBCs. Therefore, a thicker CFL region composed of plasma correlates to a reduced apparent whole blood viscosity. 

(19) A thicker CFL region is often established following the RBC aggregation at the microchannel core under conditions of decreasing the tube diameter. Apart from the dependence on the RBC concentration in the microchannel core, the CFL thickness is also affected by the volume concentration of RBCs, or hematocrit, in whole blood, as well as the deformability of RBCs. Given the influence CFL thickness has on blood flow rheological parameters such as blood flow rate, which is strongly dependent on whole blood viscosity, investigating CFL thickness under shear flow is crucial for LOC systems accounting for blood flow.

2.1.4. Plasma Skimming in Bifurcation Networks

The uneven arrangement of RBCs in bifurcating microchannels, commonly termed skimming bifurcation, arises from the axial migration of RBCs within flowing streams. This uneven distribution contributes to variations in viscosity across differing sizes of bifurcating channels but offers a stabilizing effect. Notably, higher flow rates in microchannels are associated with increased hematocrit levels, resulting in higher viscosity compared with those with lower flow rates. Parametric investigations on bifurcation angle, 

(20) thickness of the CFL, 

(21) and RBC dynamics, including aggregation and deformation, 

(22) may alter the varying viscosity of blood and its flow behavior within microchannels.

2.2. Modeling on Blood Flow Dynamics

2.2.1. Blood Properties and Mathematical Models of Blood Rheology

Under different shear rate conditions in blood flow, the elastic characteristics and dynamic changes of the RBC induce a complex velocity and stress relationship, resulting in the incompatibility of blood flow characterization through standard presumptions of constant viscosity used for Newtonian fluid flow. Blood flow is categorized as a viscoelastic non-Newtonian fluid flow where constitutive equations governing this type of flow take into consideration the nonlinear viscometric properties of blood. To mathematically characterize the evolving blood viscosity and the relationship between the elasticity of RBC and the shear blood flow, respectively, across space and time of the system, a stress tensor (τ) defined by constitutive models is often coupled in the Navier–Stokes equation to account for the collective impact of the constant dynamic viscosity (η) and the elasticity from RBCs on blood flow.The dynamic viscosity of blood is heavily dependent on the shear stress applied to the cell and various parameters from the blood such as hematocrit value, plasma viscosity, mechanical properties of the RBC membrane, and red blood cell aggregation rate. The apparent blood viscosity is considered convenient for the characterization of the relationship between the evolving blood viscosity and shear rate, which can be defined by Casson’s law, as shown in eq 1.

𝜇=𝜏0𝛾˙+2𝜂𝜏0𝛾˙⎯⎯⎯⎯⎯⎯⎯√+𝜂�=�0�˙+2��0�˙+�

(1)where τ

0 is the yield stress–stress required to initiate blood flow motion, η is the Casson rheological constant, and γ̇ is the shear rate. The value of Casson’s law parameters under blood with normal hematocrit level can be defined as τ

0 = 0.0056 Pa and η = 0.0035 Pa·s. 

(23) With the known property of blood and Casson’s law parameters, an approximation can be made to the dynamic viscosity under various flow condition domains. The Power Law model is often employed to characterize the dynamic viscosity in relation to the shear rate, since precise solutions exist for specific geometries and flow circumstances, acting as a fundamental standard for definition. The Carreau and Carreau–Yasuda models can be advantageous over the Power Law model due to their ability to evaluate the dynamic viscosity at low to zero shear rate conditions. However, none of the above-mentioned models consider the memory or other elastic behavior of blood and its RBCs. Some other commonly used mathematical models and their constants for the non-Newtonian viscosity property characterization of blood are listed in Table 1 below. 

(24−26)Table 1. Comparison of Various Non-Newtonian Models for Blood Viscosity 

(24−26)

ModelNon-Newtonian ViscosityParameters
Power Law(2)n = 0.61, k = 0.42
Carreau(3)μ0 = 0.056 Pa·s, μ = 0.00345 Pa·s, λ = 3.1736 s, m = 2.406, a = 0.254
Walburn–Schneck(4)C1 = 0.000797 Pa·s, C2 = 0.0608 Pa·s, C3 = 0.00499, C4 = 14.585 g–1, TPMA = 25 g/L
Carreau–Yasuda(5)μ0 = 0.056 Pa·s, μ = 0.00345 Pa·s, λ = 1.902 s, n = 0.22, a = 1.25
Quemada(6)μp = 0.0012 Pa·s, k = 2.07, k0 = 4.33, γ̇c = 1.88 s–1

The blood rheology is commonly known to be influenced by two key physiological factors, namely, the hematocrit value (H

t) and the fibrinogen concentration (c

f), with an average value of 42% and 0.252 gd·L

–1, respectively. Particularly in low shear conditions, the presence of varying fibrinogen concentrations affects the tendency for aggregation and rouleaux formation, while the occurrence of aggregation is contingent upon specific levels of hematocrit. 

(27) The study from Apostolidis et al. 

(28) modifies the Casson model through emphasizing its reliance on hematocrit and fibrinogen concentration parameter values, owing to the extensive knowledge of the two physiological blood parameters.The viscoelastic response of blood is heavily dependent on the elasticity of the RBC, which is defined by the relationship between the deformation and stress relaxation from RBCs under a specific location of shear flow as a function of the velocity field. The stress tensor is usually characterized by constitutive equations such as the Upper-Convected Maxwell Model 

(29) and the Oldroyd-B model 

(30) to track the molecule effects under shear from different driving forces. The prominent non-Newtonian features, such as shear thinning and yield stress, have played a vital role in the characterization of blood rheology, particularly with respect to the evaluation of yield stress under low shear conditions. The nature of stress measurement in blood, typically on the order of 1 mPa, is challenging due to its low magnitude. The occurrence of the CFL complicates the measurement further due to the significant decrease in apparent viscosity near the wall over time and a consequential disparity in viscosity compared to the bulk region.In addition to shear thinning viscosity and yield stress, the formation of aggregation (rouleaux) from RBCs under low shear rates also contributes to the viscoelasticity under transient flow 

(31) and thixotropy 

(32) of whole blood. Given the difficulty in evaluating viscoelastic behavior of blood under low strain magnitudes and limitations in generalized Newtonian models, the utilization of viscoelastic models is advocated to encompass elasticity and delineate non-shear components within the stress tensor. Extending from the Oldroyd-B model, Anand et al. 

(33) developed a viscoelastic model framework for adapting elasticity within blood samples and predicting non-shear stress components. However, to also address the thixotropic effects, the model developed by Horner et al. 

(34) serves as a more comprehensive approach than the viscoelastic model from Anand et al. Thixotropy 

(32) typically occurs from the structural change of the rouleaux, where low shear rate conditions induce rouleaux formation. Correspondingly, elasticity increases, while elasticity is more representative of the isolated RBCs, under high shear rate conditions. The model of Horner et al. 

(34) considers the contribution of rouleaux to shear stress, taking into account factors such as the characteristic time for Brownian aggregation, shear-induced aggregation, and shear-induced breakage. Subsequent advancements in the model from Horner et al. often revolve around refining the three aforementioned key terms for a more substantial characterization of rouleaux dynamics. Notably, this has led to the recently developed mHAWB model 

(35) and other model iterations to enhance the accuracy of elastic and viscoelastic contributions to blood rheology, including the recently improved model suggested by Armstrong et al. 

(36)

2.2.2. Numerical Methods (FDM, FEM, FVM)

Numerical simulation has become increasingly more significant in analyzing the geometry, boundary layers of flow, and nonlinearity of hyperbolic viscoelastic flow constitutive equations. CFD is a powerful and efficient tool utilizing numerical methods to solve the governing hydrodynamic equations, such as the Navier–Stokes (N–S) equation, continuity equation, and energy conservation equation, for qualitative evaluation of fluid motion dynamics under different parameters. CFD overcomes the challenge of analytically solving nonlinear forms of differential equations by employing numerical methods such as the Finite-Difference Method (FDM), Finite-Element Method (FEM), and Finite-Volume Method (FVM) to discretize and solve the partial differential equations (PDEs), allowing for qualitative reproduction of transport phenomena and experimental observations. Different numerical methods are chosen to cope with various transport systems for optimization of the accuracy of the result and control of error during the discretization process.FDM is a straightforward approach to discretizing PDEs, replacing the continuum representation of equations with a set of finite-difference equations, which is typically applied to structured grids for efficient implementation in CFD programs. 

(37) However, FDM is often limited to simple geometries such as rectangular or block-shaped geometries and struggles with curved boundaries. In contrast, FEM divides the fluid domain into small finite grids or elements, approximating PDEs through a local description of physics. 

(38) All elements contribute to a large, sparse matrix solver. However, FEM may not always provide accurate results for systems involving significant deformation and aggregation of particles like RBCs due to large distortion of grids. 

(39) FVM evaluates PDEs following the conservation laws and discretizes the selected flow domain into small but finite size control volumes, with each grid at the center of a finite volume. 

(40) The divergence theorem allows the conversion of volume integrals of PDEs with divergence terms into surface integrals of surface fluxes across cell boundaries. Due to its conservation property, FVM offers efficient outcomes when dealing with PDEs that embody mass, momentum, and energy conservation principles. Furthermore, widely accessible software packages like the OpenFOAM toolbox 

(41) include a viscoelastic solver, making it an attractive option for viscoelastic fluid flow modeling. 

(42)

2.2.3. Modeling Methods of Blood Flow Dynamics

The complexity in the blood flow simulation arises from deformability and aggregation that RBCs exhibit during their interaction with neighboring cells under different shear rate conditions induced by blood flow. Numerical models coupled with simulation programs have been applied as a groundbreaking method to predict such unique rheological behavior exhibited by RBCs and whole blood. The conventional approach of a single-phase flow simulation is often applied to blood flow simulations within large vessels possessing a moderate shear rate. However, such a method assumes the properties of plasma, RBCs and other cellular components to be evenly distributed as average density and viscosity in blood, resulting in the inability to simulate the mechanical dynamics, such as RBC aggregation under high-shear flow field, inherent in RBCs. To accurately describe the asymmetric distribution of RBC and blood flow, multiphase flow simulation, where numerical simulations of blood flows are often modeled as two immiscible phases, RBCs and blood plasma, is proposed. A common assumption is that RBCs exhibit non-Newtonian behavior while the plasma is treated as a continuous Newtonian phase.Numerous multiphase numerical models have been proposed to simulate the influence of RBCs on blood flow dynamics by different assumptions. In large-scale simulations (above the millimeter range), continuum-based methods are wildly used due to their lower computational demands. 

(43) Eulerian multiphase flow simulations offer the solution of a set of conservation equations for each separate phase and couple the phases through common pressure and interphase exchange coefficients. Xu et al. 

(44) utilized the combined finite-discrete element method (FDEM) to replicate the dynamic behavior and distortion of RBCs subjected to fluidic forces, utilizing the Johnson–Kendall–Roberts model 

(45) to define the adhesive forces of cell-to-cell interactions. The iterative direct-forcing immersed boundary method (IBM) is commonly employed in simulations of the fluid–cell interface of blood. This method effectively captures the intricacies of the thin and flexible RBC membranes within various external flow fields. 

(46) The study by Xu et al. 

(44) also adopts this approach to bridge the fluid dynamics and RBC deformation through IBM. Yoon and You utilized the Maxwell model to define the viscosity of the RBC membrane. 

(47) It was discovered that the Maxwell model could represent the stress relaxation and unloading processes of the cell. Furthermore, the reduced flexibility of an RBC under particular situations such as infection is specified, which was unattainable by the Kelvin–Voigt model 

(48) when compared to the Maxwell model in the literature. The Yeoh hyperplastic material model was also adapted to predict the nonlinear elasticity property of RBCs with FEM employed to discretize the RBC membrane using shell-type elements. Gracka et al. 

(49) developed a numerical CFD model with a finite-volume parallel solver for multiphase blood flow simulation, where an updated Maxwell viscoelasticity model and a Discrete Phase Model are adopted. In the study, the adapted IBM, based on unstructured grids, simulates the flow behavior and shape change of the RBCs through fluid-structure coupling. It was found that the hybrid Euler–Lagrange (E–L) approach 

(50) for the development of the multiphase model offered better results in the simulated CFL region in the microchannels.To study the dynamics of individual behaviors of RBCs and the consequent non-Newtonian blood flow, cell-shape-resolved computational models are often adapted. The use of the boundary integral method has become prevalent in minimizing computational expenses, particularly in the exclusive determination of fluid velocity on the surfaces of RBCs, incorporating the option of employing IBM or particle-based techniques. The cell-shaped-resolved method has enabled an examination of cell to cell interactions within complex ambient or pulsatile flow conditions 

(51) surrounding RBC membranes. Recently, Rydquist et al. 

(52) have looked to integrate statistical information from macroscale simulations to obtain a comprehensive overview of RBC behavior within the immediate proximity of the flow through introduction of respective models characterizing membrane shape definition, tension, bending stresses of RBC membranes.At a macroscopic scale, continuum models have conventionally been adapted for assessing blood flow dynamics through the application of elasticity theory and fluid dynamics. However, particle-based methods are known for their simplicity and adaptability in modeling complex multiscale fluid structures. Meshless methods, such as the boundary element method (BEM), smoothed particle hydrodynamics (SPH), and dissipative particle dynamics (DPD), are often used in particle-based characterization of RBCs and the surrounding fluid. By representing the fluid as discrete particles, meshless methods provide insights into the status and movement of the multiphase fluid. These methods allow for the investigation of cellular structures and microscopic interactions that affect blood rheology. Non-confronting mesh methods like IBM can also be used to couple a fluid solver such as FEM, FVM, or the Lattice Boltzmann Method (LBM) through membrane representation of RBCs. In comparison to conventional CFD methods, LBM has been viewed as a favorable numerical approach for solving the N–S equations and the simulation of multiphase flows. LBM exhibits the notable advantage of being amenable to high-performance parallel computing environments due to its inherently local dynamics. In contrast to DPD and SPH where RBC membranes are modeled as physically interconnected particles, LBM employs the IBM to account for the deformation dynamics of RBCs 

(53,54) under shear flows in complex channel geometries. 

(54,55) However, it is essential to acknowledge that the utilization of LBM in simulating RBC flows often entails a significant computational overhead, being a primary challenge in this context. Krüger et al. 

(56) proposed utilizing LBM as a fluid solver, IBM to couple the fluid and FEM to compute the response of membranes to deformation under immersed fluids. This approach decouples the fluid and membranes but necessitates significant computational effort due to the requirements of both meshes and particles.Despite the accuracy of current blood flow models, simulating complex conditions remains challenging because of the high computational load and cost. Balachandran Nair et al. 

(57) suggested a reduced order model of RBC under the framework of DEM, where the RBC is represented by overlapping constituent rigid spheres. The Morse potential force is adapted to account for the RBC aggregation exhibited by cell to cell interactions among RBCs at different distances. Based upon the IBM, the reduced-order RBC model is adapted to simulate blood flow transport for validation under both single and multiple RBCs with a resolved CFD-DEM solver. 

(58) In the resolved CFD-DEM model, particle sizes are larger than the grid size for a more accurate computation of the surrounding flow field. A continuous forcing approach is taken to describe the momentum source of the governing equation prior to discretization, which is different from a Direct Forcing Method (DFM). 

(59) As no body-conforming moving mesh is required, the continuous forcing approach offers lower complexity and reduced cost when compared to the DFM. Piquet et al. 

(60) highlighted the high complexity of the DFM due to its reliance on calculating an additional immersed boundary flux for the velocity field to ensure its divergence-free condition.The fluid–structure interaction (FSI) method has been advocated to connect the dynamic interplay of RBC membranes and fluid plasma within blood flow such as the coupling of continuum–particle interactions. However, such methodology is generally adapted for anatomical configurations such as arteries 

(61,62) and capillaries, 

(63) where both the structural components and the fluid domain undergo substantial deformation due to the moving boundaries. Due to the scope of the Review being blood flow simulation within microchannels of LOC devices without deformable boundaries, the Review of the FSI method will not be further carried out.In general, three numerical methods are broadly used: mesh-based, particle-based, and hybrid mesh–particle techniques, based on the spatial scale and the fundamental numerical approach, mesh-based methods tend to neglect the effects of individual particles, assuming a continuum and being efficient in terms of time and cost. However, the particle-based approach highlights more of the microscopic and mesoscopic level, where the influence of individual RBCs is considered. A review from Freund et al. 

(64) addressed the three numerical methodologies and their respective modeling approaches of RBC dynamics. Given the complex mechanics and the diverse levels of study concerning numerical simulations of blood and cellular flow, a broad spectrum of numerical methods for blood has been subjected to extensive review. 

(64−70) Ye at al. 

(65) offered an extensive review of the application of the DPD, SPH, and LBM for numerical simulations of RBC, while Rathnayaka et al. 

(67) conducted a review of the particle-based numerical modeling for liquid marbles through drawing parallels to the transport of RBCs in microchannels. A comparative analysis between conventional CFD methods and particle-based approaches for cellular and blood flow dynamic simulation can be found under the review by Arabghahestani et al. 

(66) Literature by Li et al. 

(68) and Beris et al. 

(69) offer an overview of both continuum-based models at micro/macroscales and multiscale particle-based models encompassing various length and temporal dimensions. Furthermore, these reviews deliberate upon the potential of coupling continuum-particle methods for blood plasma and RBC modeling. Arciero et al. 

(70) investigated various modeling approaches encompassing cellular interactions, such as cell to cell or plasma interactions and the individual cellular phases. A concise overview of the reviews is provided in Table 2 for reference.

Table 2. List of Reviews for Numerical Approaches Employed in Blood Flow Simulation

ReferenceNumerical methods
Li et al. (2013) (68)Continuum-based modeling (BIM), particle-based modeling (LBM, LB-FE, SPH, DPD)
Freund (2014) (64)RBC dynamic modeling (continuum-based modeling, complementary discrete microstructure modeling), blood flow dynamic modeling (FDM, IBM, LBM, particle-mesh methods, coupled boundary integral and mesh-based methods, DPD)
Ye et al. (2016) (65)DPD, SPH, LBM, coupled IBM-Smoothed DPD
Arciero et al. (2017) (70)LBM, IBM, DPD, conventional CFD Methods (FDM, FVM, FEM)
Arabghahestani et al. (2019) (66)Particle-based methods (LBM, DPD, direct simulation Monte Carlo, molecular dynamics), SPH, conventional CFD methods (FDM, FVM, FEM)
Beris et al. (2021) (69)DPD, smoothed DPD, IBM, LBM, BIM
Rathnayaka (2022) (67)SPH, CG, LBM

3. Capillary Driven Blood Flow in LOC Systems

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3.1. Capillary Driven Flow Phenomena

Capillary driven (CD) flow is a pivotal mechanism in passive microfluidic flow systems 

(9) such as the blood circulation system and LOC systems. 

(71) CD flow is essentially the movement of a liquid to flow against drag forces, where the capillary effect exerts a force on the liquid at the borders, causing a liquid–air meniscus to flow despite gravity or other drag forces. A capillary pressure drops across the liquid–air interface with surface tension in the capillary radius and contact angle. The capillary effect depends heavily on the interaction between the different properties of surface materials. Different values of contact angles can be manipulated and obtained under varying levels of surface wettability treatments to manipulate the surface properties, resulting in different CD blood delivery rates for medical diagnostic device microchannels. CD flow techniques are appealing for many LOC devices, because they require no external energy. However, due to the passive property of liquid propulsion by capillary forces and the long-term instability of surface treatments on channel walls, the adaptability of CD flow in geometrically complex LOC devices may be limited.

3.2. Theoretical and Numerical Modeling of Capillary Driven Blood Flow

3.2.1. Theoretical Basis and Assumptions of Microfluidic Flow

The study of transport phenomena regarding either blood flow driven by capillary forces or externally applied forces under microfluid systems all demands a comprehensive recognition of the significant differences in flow dynamics between microscale and macroscale. The fundamental assumptions and principles behind fluid transport at the microscale are discussed in this section. Such a comprehension will lay the groundwork for the following analysis of the theoretical basis of capillary forces and their role in blood transport in LOC systems.

At the macroscale, fluid dynamics are often strongly influenced by gravity due to considerable fluid mass. However, the high surface to volume ratio at the microscale shifts the balance toward surface forces (e.g., surface tension and viscous forces), much larger than the inertial force. This difference gives rise to transport phenomena unique to microscale fluid transport, such as the prevalence of laminar flow due to a very low Reynolds number (generally lower than 1). Moreover, the fluid in a microfluidic system is often assumed to be incompressible due to the small flow velocity, indicating constant fluid density in both space and time.Microfluidic flow behaviors are governed by the fundamental principles of mass and momentum conservation, which are encapsulated in the continuity equation and the Navier–Stokes (N–S) equation. The continuity equation describes the conservation of mass, while the N–S equation captures the spatial and temporal variations in velocity, pressure, and other physical parameters. Under the assumption of the negligible influence of gravity in microfluidic systems, the continuity equation and the Eulerian representation of the incompressible N–S equation can be expressed as follows:

∇·𝐮⇀=0∇·�⇀=0

(7)

−∇𝑝+𝜇∇2𝐮⇀+∇·𝝉⇀−𝐅⇀=0−∇�+�∇2�⇀+∇·�⇀−�⇀=0

(8)Here, p is the pressure, u is the fluid viscosity, 

𝝉⇀�⇀ represents the stress tensor, and F is the body force exerted by external forces if present.

3.2.2. Theoretical Basis and Modeling of Capillary Force in LOC Systems

The capillary force is often the major driving force to manipulate and transport blood without an externally applied force in LOC systems. Forces induced by the capillary effect impact the free surface of fluids and are represented not directly in the Navier–Stokes equations but through the pressure boundary conditions of the pressure term p. For hydrophilic surfaces, the liquid generally induces a contact angle between 0° and 30°, encouraging the spread and attraction of fluid under a positive cos θ condition. For this condition, the pressure drop becomes positive and generates a spontaneous flow forward. A hydrophobic solid surface repels the fluid, inducing minimal contact. Generally, hydrophobic solids exhibit a contact angle larger than 90°, inducing a negative value of cos θ. Such a value will result in a negative pressure drop and a flow in the opposite direction. The induced contact angle is often utilized to measure the wall exposure of various surface treatments on channel walls where different wettability gradients and surface tension effects for CD flows are established. Contact angles between different interfaces are obtainable through standard values or experimental methods for reference. 

(72)For the characterization of the induced force by the capillary effect, the Young–Laplace (Y–L) equation 

(73) is widely employed. In the equation, the capillary is considered a pressure boundary condition between the two interphases. Through the Y–L equation, the capillary pressure force can be determined, and subsequently, the continuity and momentum balance equations can be solved to obtain the blood filling rate. Kim et al. 

(74) studied the effects of concentration and exposure time of a nonionic surfactant, Silwet L-77, on the performance of a polydimethylsiloxane (PDMS) microchannel in terms of plasma and blood self-separation. The study characterized the capillary pressure force by incorporating the Y–L equation and further evaluated the effects of the changing contact angle due to different levels of applied channel wall surface treatments. The expression of the Y–L equation utilized by Kim et al. 

(74) is as follows:

𝑃=−𝜎(cos𝜃b+cos𝜃tℎ+cos𝜃l+cos𝜃r𝑤)�=−�(cos⁡�b+cos⁡�tℎ+cos⁡�l+cos⁡�r�)

(9)where σ is the surface tension of the liquid and θ

bθ

tθ

l, and θ

r are the contact angle values between the liquid and the bottom, top, left, and right walls, respectively. A numerical simulation through Coventor software is performed to evaluate the dynamic changes in the filling rate within the microchannel. The simulation results for the blood filling rate in the microchannel are expressed at a specific time stamp, shown in Figure 2. The results portray an increasing instantaneous filling rate of blood in the microchannel following the decrease in contact angle induced by a higher concentration of the nonionic surfactant treated to the microchannel wall.

Figure 2. Numerical simulation of filling rate of capillary driven blood flow under various contact angle conditions at a specific timestamp. (74) Reproduced with permission from ref (74). Copyright 2010 Elsevier.

When in contact with hydrophilic or hydrophobic surfaces, blood forms a meniscus with a contact angle due to surface tension. The Lucas–Washburn (L–W) equation 

(75) is one of the pioneering theoretical definitions for the position of the meniscus over time. In addition, the L–W equation provides the possibility for research to obtain the velocity of the blood formed meniscus through the derivation of the meniscus position. The L–W equation 

(75) can be shown below:

𝐿(𝑡)=𝑅𝜎cos(𝜃)𝑡2𝜇⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯√�(�)=��⁡cos(�)�2�

(10)Here L(t) represents the distance of the liquid driven by the capillary forces. However, the generalized L–W equation solely assumes the constant physical properties from a Newtonian fluid rather than considering the non-Newtonian fluid behavior of blood. Cito et al. 

(76) constructed an enhanced version of the L–W equation incorporating the power law to consider the RBC aggregation and the FL effect. The non-Newtonian fluid apparent viscosity under the Power Law model is defined as

𝜇=𝑘·(𝛾˙)𝑛−1�=�·(�˙)�−1

(11)where γ̇ is the strain rate tensor defined as 

𝛾˙=12𝛾˙𝑖𝑗𝛾˙𝑗𝑖⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯√�˙=12�˙���˙��. The stress tensor term τ is computed as τ = μγ̇

ij. The updated L–W equation by Cito 

(76) is expressed as

𝐿(𝑡)=𝑅[(𝑛+13𝑛+1)(𝜎cos(𝜃)𝑅𝑘)1/𝑛𝑡]𝑛/𝑛+1�(�)=�[(�+13�+1)(�⁡cos(�)��)1/��]�/�+1

(12)where k is the flow consistency index and n is the power law index, respectively. The power law index, from the Power Law model, characterizes the extent of the non-Newtonian behavior of blood. Both the consistency and power law index rely on blood properties such as hematocrit, the appearance of the FL effect, the formation of RBC aggregates, etc. The updated L–W equation computes the location and velocity of blood flow caused by capillary forces at specified time points within the LOC devices, taking into account the effects of blood flow characteristics such as RBC aggregation and the FL effect on dynamic blood viscosity.Apart from the blood flow behaviors triggered by inherent blood properties, unique flow conditions driven by capillary forces that are portrayed under different microchannel geometries also hold crucial implications for CD blood delivery. Berthier et al. 

(77) studied the spontaneous Concus–Finn condition, the condition to initiate the spontaneous capillary flow within a V-groove microchannel, as shown in Figure 3(a) both experimentally and numerically. Through experimental studies, the spontaneous Concus–Finn filament development of capillary driven blood flow is observed, as shown in Figure 3(b), while the dynamic development of blood flow is numerically simulated through CFD simulation.

Figure 3. (a) Sketch of the cross-section of Berthier’s V-groove microchannel, (b) experimental view of blood in the V-groove microchannel, (78) (c) illustration of the dynamic change of the extension of filament from FLOW 3D under capillary flow at three increasing time intervals. (78) Reproduced with permission from ref (78). Copyright 2014 Elsevier.

Berthier et al. 

(77) characterized the contact angle needed for the initiation of the capillary driving force at a zero-inlet pressure, through the half-angle (α) of the V-groove geometry layout, and its relation to the Concus–Finn filament as shown below:

𝜃<𝜋2−𝛼sin𝛼1+2(ℎ2/𝑤)sin𝛼<cos𝜃{�<�2−�sin⁡�1+2(ℎ2/�)⁡sin⁡�<cos⁡�

(13)Three possible regimes were concluded based on the contact angle value for the initiation of flow and development of Concus–Finn filament:

𝜃>𝜃1𝜃1>𝜃>𝜃0𝜃0no SCFSCF without a Concus−Finn filamentSCF without a Concus−Finn filament{�>�1no SCF�1>�>�0SCF without a Concus−Finn filament�0SCF without a Concus−Finn filament

(14)Under Newton’s Law, the force balance with low Reynolds and Capillary numbers results in the neglect of inertial terms. The force balance between the capillary forces and the viscous force induced by the channel wall is proposed to derive the analytical fluid velocity. This relation between the two forces offers insights into the average flow velocity and the penetration distance function dependent on time. The apparent blood viscosity is defined by Berthier et al. 

(78) through Casson’s law, 

(23) given in eq 1. The research used the FLOW-3D program from Flow Science Inc. software, which solves transient, free-surface problems using the FDM in multiple dimensions. The Volume of Fluid (VOF) method 

(79) is utilized to locate and track the dynamic extension of filament throughout the advancing interface within the channel ahead of the main flow at three progressing time stamps, as depicted in Figure 3(c).

4. Electro-osmotic Flow (EOF) in LOC Systems

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The utilization of external forces, such as electric fields, has significantly broadened the possibility of manipulating microfluidic flow in LOC systems. 

(80) Externally applied electric field forces induce a fluid flow from the movement of ions in fluid terms as the “electro-osmotic flow” (EOF).Unique transport phenomena, such as enhanced flow velocity and flow instability, induced by non-Newtonian fluids, particularly viscoelastic fluids, under EOF, have sparked considerable interest in microfluidic devices with simple or complicated geometries within channels. 

(81) However, compared to the study of Newtonian fluids and even other electro-osmotic viscoelastic fluid flows, the literature focusing on the theoretical and numerical modeling of electro-osmotic blood flow is limited due to the complexity of blood properties. Consequently, to obtain a more comprehensive understanding of the complex blood flow behavior under EOF, theoretical and numerical studies of the transport phenomena in the EOF section will be based on the studies of different viscoelastic fluids under EOF rather than that of blood specifically. Despite this limitation, we believe these studies offer valuable insights that can help understand the complex behavior of blood flow under EOF.

4.1. EOF Phenomena

Electro-osmotic flow occurs at the interface between the microchannel wall and bulk phase solution. When in contact with the bulk phase, solution ions are absorbed or dissociated at the solid–liquid interface, resulting in the formation of a charge layer, as shown in Figure 4. This charged channel surface wall interacts with both negative and positive ions in the bulk sample, causing repulsion and attraction forces to create a thin layer of immobilized counterions, known as the Stern layer. The induced electric potential from the wall gradually decreases with an increase in the distance from the wall. The Stern layer potential, commonly termed the zeta potential, controls the intensity of the electrostatic interactions between mobile counterions and, consequently, the drag force from the applied electric field. Next to the Stern layer is the diffuse mobile layer, mainly composed of a mobile counterion. These two layers constitute the “electrical double layer” (EDL), the thickness of which is directly proportional to the ionic strength (concentration) of the bulk fluid. The relationship between the two parameters is characterized by a Debye length (λ

D), expressed as

𝜆𝐷=𝜖𝑘B𝑇2(𝑍𝑒)2𝑐0⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯√��=��B�2(��)2�0

(15)where ϵ is the permittivity of the electrolyte solution, k

B is the Boltzmann constant, T is the electron temperature, Z is the integer valence number, e is the elementary charge, and c

0 is the ionic density.

Figure 4. Schematic diagram of an electro-osmotic flow in a microchannel with negative surface charge. (82) Reproduced with permission from ref (82). Copyright 2012 Woodhead Publishing.

When an electric field is applied perpendicular to the EDL, viscous drag is generated due to the movement of excess ions in the EDL. Electro-osmotic forces can be attributed to the externally applied electric potential (ϕ) and the zeta potential, the system wall induced potential by charged walls (ψ). As illustrated in Figure 4, the majority of ions in the bulk phase have a uniform velocity profile, except for a shear rate condition confined within an extremely thin Stern layer. Therefore, EOF displays a unique characteristic of a “near flat” or plug flow velocity profile, different from the parabolic flow typically induced by pressure-driven microfluidic flow (Hagen–Poiseuille flow). The plug-shaped velocity profile of the EOF possesses a high shear rate above the Stern layer.Overall, the EOF velocity magnitude is typically proportional to the Debye Length (λ

D), zeta potential, and magnitude of the externally applied electric field, while a more viscous liquid reduces the EOF velocity.

4.2. Modeling on Electro-osmotic Viscoelastic Fluid Flow

4.2.1. Theoretical Basis of EOF Mechanisms

The EOF of an incompressible viscoelastic fluid is commonly governed by the continuity and incompressible N–S equations, as shown in eqs 7 and 8, where the stress tensor and the electrostatic force term are coupled. The electro-osmotic body force term F, representing the body force exerted by the externally applied electric force, is defined as 

𝐹⇀=𝑝𝐸𝐸⇀�⇀=���⇀, where ρ

E and 

𝐸⇀�⇀ are the net electric charge density and the applied external electric field, respectively.Numerous models are established to theoretically study the externally applied electric potential and the system wall induced potential by charged walls. The following Laplace equation, expressed as eq 16, is generally adapted and solved to calculate the externally applied potential (ϕ).

∇2𝜙=0∇2�=0

(16)Ion diffusion under applied electric fields, together with mass transport resulting from convection and diffusion, transports ionic solutions in bulk flow under electrokinetic processes. The Nernst–Planck equation can describe these transport methods, including convection, diffusion, and electro-diffusion. Therefore, the Nernst–Planck equation is used to determine the distribution of the ions within the electrolyte. The electric potential induced by the charged channel walls follows the Poisson–Nernst–Plank (PNP) equation, which can be written as eq 17.

∇·[𝐷𝑖∇𝑛𝑖−𝑢⇀𝑛𝑖+𝑛𝑖𝐷𝑖𝑧𝑖𝑒𝑘𝑏𝑇∇(𝜙+𝜓)]=0∇·[��∇��−�⇀��+����������∇(�+�)]=0

(17)where D

in

i, and z

i are the diffusion coefficient, ionic concentration, and ionic valence of the ionic species I, respectively. However, due to the high nonlinearity and numerical stiffness introduced by different lengths and time scales from the PNP equations, the Poisson–Boltzmann (PB) model is often considered the major simplified method of the PNP equation to characterize the potential distribution of the EDL region in microchannels. In the PB model, it is assumed that the ionic species in the fluid follow the Boltzmann distribution. This model is typically valid for steady-state problems where charge transport can be considered negligible, the EDLs do not overlap with each other, and the intrinsic potentials are low. It provides a simplified representation of the potential distribution in the EDL region. The PB equation governing the EDL electric potential distribution is described as

∇2𝜓=(2𝑒𝑧𝑛0𝜀𝜀0)sinh(𝑧𝑒𝜓𝑘b𝑇)∇2�=(2���0��0)⁡sinh(����b�)

(18)where n

0 is the ion bulk concentration, z is the ionic valence, and ε

0 is the electric permittivity in the vacuum. Under low electric potential conditions, an even further simplified model to illustrate the EOF phenomena is the Debye–Hückel (DH) model. The DH model is derived by obtaining a charge density term by expanding the exponential term of the Boltzmann equation in a Taylor series.

4.2.2. EOF Modeling for Viscoelastic Fluids

Many studies through numerical modeling were performed to obtain a deeper understanding of the effect exhibited by externally applied electric fields on viscoelastic flow in microchannels under various geometrical designs. Bello et al. 

(83) found that methylcellulose solution, a non-Newtonian polymer solution, resulted in stronger electro-osmotic mobility in experiments when compared to the predictions by the Helmholtz–Smoluchowski equation, which is commonly used to define the velocity of EOF of a Newtonian fluid. Being one of the pioneers to identify the discrepancies between the EOF of Newtonian and non-Newtonian fluids, Bello et al. attributed such discrepancies to the presence of a very high shear rate in the EDL, resulting in a change in the orientation of the polymer molecules. Park and Lee 

(84) utilized the FVM to solve the PB equation for the characterization of the electric field induced force. In the study, the concept of fractional calculus for the Oldroyd-B model was adapted to illustrate the elastic and memory effects of viscoelastic fluids in a straight microchannel They observed that fluid elasticity and increased ratio of viscoelastic fluid contribution to overall fluid viscosity had a significant impact on the volumetric flow rate and sensitivity of velocity to electric field strength compared to Newtonian fluids. Afonso et al. 

(85) derived an analytical expression for EOF of viscoelastic fluid between parallel plates using the DH model to account for a zeta potential condition below 25 mV. The study established the understanding of the electro-osmotic viscoelastic fluid flow under low zeta potential conditions. Apart from the electrokinetic forces, pressure forces can also be coupled with EOF to generate a unique fluid flow behavior within the microchannel. Sousa et al. 

(86) analytically studied the flow of a standard viscoelastic solution by combining the pressure gradient force with an externally applied electric force. It was found that, at a near wall skimming layer and the outer layer away from the wall, macromolecules migrating away from surface walls in viscoelastic fluids are observed. In the study, the Phan-Thien Tanner (PTT) constitutive model is utilized to characterize the viscoelastic properties of the solution. The approach is found to be valid when the EDL is much thinner than the skimming layer under an enhanced flow rate. Zhao and Yang 

(87) solved the PB equation and Carreau model for the characterization of the EOF mechanism and non-Newtonian fluid respectively through the FEM. The numerical results depict that, different from the EOF of Newtonian fluids, non-Newtonian fluids led to an increase of electro-osmotic mobility for shear thinning fluids but the opposite for shear thickening fluids.Like other fluid transport driving forces, EOF within unique geometrical layouts also portrays unique transport phenomena. Pimenta and Alves 

(88) utilized the FVM to perform numerical simulations of the EOF of viscoelastic fluids considering the PB equation and the Oldroyd-B model, in a cross-slot and flow-focusing microdevices. It was found that electroelastic instabilities are formed due to the development of large stresses inside the EDL with streamlined curvature at geometry corners. Bezerra et al. 

(89) used the FDM to numerically analyze the vortex formation and flow instability from an electro-osmotic non-Newtonian fluid flow in a microchannel with a nozzle geometry and parallel wall geometry setting. The PNP equation is utilized to characterize the charge motion in the EOF and the PTT model for non-Newtonian flow characterization. A constriction geometry is commonly utilized in blood flow adapted in LOC systems due to the change in blood flow behavior under narrow dimensions in a microchannel. Ji et al. 

(90) recently studied the EOF of viscoelastic fluid in a constriction microchannel connected by two relatively big reservoirs on both ends (as seen in Figure 5) filled with the polyacrylamide polymer solution, a viscoelastic fluid, and an incompressible monovalent binary electrolyte solution KCl.

Figure 5. Schematic diagram of a negatively charged constriction microchannel connected to two reservoirs at both ends. An electro-osmotic flow is induced in the system by the induced potential difference between the anode and cathode. (90) Reproduced with permission from ref (90). Copyright 2021 The Authors, under the terms of the Creative Commons (CC BY 4.0) License https://creativecommons.org/licenses/by/4.0/.

In studying the EOF of viscoelastic fluids, the Oldroyd-B model is often utilized to characterize the polymeric stress tensor and the deformation rate of the fluid. The Oldroyd-B model is expressed as follows:

𝜏=𝜂p𝜆(𝐜−𝐈)�=�p�(�−�)

(19)where η

p, λ, c, and I represent the polymer dynamic viscosity, polymer relaxation time, symmetric conformation tensor of the polymer molecules, and the identity matrix, respectively.A log-conformation tensor approach is taken to prevent convergence difficulty induced by the viscoelastic properties. The conformation tensor (c) in the polymeric stress tensor term is redefined by a new tensor (Θ) based on the natural logarithm of the c. The new tensor is defined as

Θ=ln(𝐜)=𝐑ln(𝚲)𝐑Θ=ln(�)=�⁡ln(�)�

(20)in which Λ is the diagonal matrix and R is the orthogonal matrix.Under the new conformation tensor, the induced EOF of a viscoelastic fluid is governed by the continuity and N–S equations adapting the Oldroyd-B model, which is expressed as

∂𝚯∂𝑡+𝐮·∇𝚯=𝛀Θ−ΘΩ+2𝐁+1𝜆(eΘ−𝐈)∂�∂�+�·∇�=�Θ−ΘΩ+2�+1�(eΘ−�)

(21)where Ω and B represent the anti-symmetric matrix and the symmetric traceless matrix of the decomposition of the velocity gradient tensor ∇u, respectively. The conformation tensor can be recovered by c = exp(Θ). The PB model and Laplace equation are utilized to characterize the charged channel wall induced potential and the externally applied potential.The governing equations are numerically solved through the FVM by RheoTool, 

(42) an open-source viscoelastic EOF solver on the OpenFOAM platform. A SIMPLEC (Semi-Implicit Method for Pressure Linked Equations-Consistent) algorithm was applied to solve the velocity-pressure coupling. The pressure field and velocity field were computed by the PCG (Preconditioned Conjugate Gradient) solver and the PBiCG (Preconditioned Biconjugate Gradient) solver, respectively.Ranging magnitudes of an applied electric field or fluid concentration induce both different streamlines and velocity magnitudes at various locations and times of the microchannel. In the study performed by Ji et al., 

(90) notable fluctuation of streamlines and vortex formation is formed at the upper stream entrance of the constriction as shown in Figure 6(a) and (b), respectively, due to the increase of electrokinetic effect, which is seen as a result of the increase in polymeric stress (τ

xx). 

(90) The contraction geometry enhances the EOF velocity within the constriction channel under high E

app condition (600 V/cm). Such phenomena can be attributed to the dependence of electro-osmotic viscoelastic fluid flow on the system wall surface and bulk fluid properties. 

(91)

Figure 6. Schematic diagram of vortex formation and streamlines of EOF depicting flow instability at (a) 1.71 s and (b) 1.75 s. Spatial distribution of the elastic normal stress at (c) high Eapp condition. Streamline of an electro-osmotic flow under Eapp of 600 V/cm (90) for (d) non-Newtonian and (e) Newtonian fluid through a constriction geometry. Reproduced with permission from ref (90). Copyright 2021 The Authors, under the terms of the Creative Commons (CC BY 4.0) License https://creativecommons.org/licenses/by/4.0/.

As elastic normal stress exceeds the local shear stress, flow instability and vortex formation occur. The induced elastic stress under EOF not only enhances the instability of the flow but often generates an irregular secondary flow leading to strong disturbance. 

(92) It is also vital to consider the effect of the constriction layout of microchannels on the alteration of the field strength within the system. The contraction geometry enhances a larger electric field strength compared with other locations of the channel outside the constriction region, resulting in a higher velocity gradient and stronger extension on the polymer within the viscoelastic solution. Following the high shear flow condition, a higher magnitude of stretch for polymer molecules in viscoelastic fluids exhibits larger elastic stresses and enhancement of vortex formation at the region. 

(93)As shown in Figure 6(c), significant elastic normal stress occurs at the inlet of the constriction microchannel. Such occurrence of a polymeric flow can be attributed to the dominating elongational flow, giving rise to high deformation of the polymers within the viscoelastic fluid flow, resulting in higher elastic stress from the polymers. Such phenomena at the entrance result in the difference in velocity streamline as circled in Figure 6(d) compared to that of the Newtonian fluid at the constriction entrance in Figure 6(e). 

(90) The difference between the Newtonian and polymer solution at the exit, as circled in Figure 6(d) and (e), can be attributed to the extrudate swell effect of polymers 

(94) within the viscoelastic fluid flow. The extrudate swell effect illustrates that, as polymers emerge from the constriction exit, they tend to contract in the flow direction and grow in the normal direction, resulting in an extrudate diameter greater than the channel size. The deformation of polymers within the polymeric flow at both the entrance and exit of the contraction channel facilitates the change in shear stress conditions of the flow, leading to the alteration in streamlines of flows for each region.

4.3. EOF Applications in LOC Systems

4.3.1. Mixing in LOC Systems

Rather than relying on the micromixing controlled by molecular diffusion under low Reynolds number conditions, active mixers actively leverage convective instability and vortex formation induced by electro-osmotic flows from alternating current (AC) or direct current (DC) electric fields. Such adaptation is recognized as significant breakthroughs for promotion of fluid mixing in chemical and biological applications such as drug delivery, medical diagnostics, chemical synthesis, and so on. 

(95)Many researchers proposed novel designs of electro-osmosis micromixers coupled with numerical simulations in conjunction with experimental findings to increase their understanding of the role of flow instability and vortex formation in the mixing process under electrokinetic phenomena. Matsubara and Narumi 

(96) numerically modeled the mixing process in a microchannel with four electrodes on each side of the microchannel wall, which generated a disruption through unstable electro-osmotic vortices. It was found that particle mixing was sensitive to both the convection effect induced by the main and secondary vortex within the micromixer and the change in oscillation frequency caused by the supplied AC voltage when the Reynolds number was varied. Qaderi et al. 

(97) adapted the PNP equation to numerically study the effect of the geometry and zeta potential configuration of the microchannel on the mixing process with a combined electro-osmotic pressure driven flow. It was reported that the application of heterogeneous zeta potential configuration enhances the mixing efficiency by around 23% while the height of the hurdles increases the mixing efficiency at most 48.1%. Cho et al. 

(98) utilized the PB model and Laplace equation to numerically simulate the electro-osmotic non-Newtonian fluid mixing process within a wavy and block layout of microchannel walls. The Power Law model is adapted to describe the fluid rheological characteristic. It was found that shear-thinning fluids possess a higher volumetric flow rate, which could result in poorer mixing efficiency compared to that of Newtonian fluids. Numerous studies have revealed that flow instability and vortex generation, in particular secondary vortices produced by barriers or greater magnitudes of heterogeneous zeta potential distribution, enhance mixing by increasing bulk flow velocity and reducing flow distance.To better understand the mechanism of disturbance formed in the system due to externally applied forces, known as electrokinetic instability, literature often utilize the Rayleigh (Ra) number, 

(1) as described below:

𝑅𝑎𝑣=𝑢ev𝑢eo=(𝛾−1𝛾+1)2𝑊𝛿2𝐸el2𝐻2𝜁𝛿Ra�=�ev�eo=(�−1�+1)2��2�el2�2��

(22)where γ is the conductivity ratio of the two streams and can be written as 

𝛾=𝜎el,H𝜎el,L�=�el,H�el,L. The Ra number characterizes the ratio between electroviscous and electro-osmotic flow. A high Ra

v value often results in good mixing. It is evident that fluid properties such as the conductivity (σ) of the two streams play a key role in the formation of disturbances to enhance mixing in microsystems. At the same time, electrokinetic parameters like the zeta potential (ζ) in the Ra number is critical in the characterization of electro-osmotic velocity and a slip boundary condition at the microchannel wall.To understand the mixing result along the channel, the concentration field can be defined and simulated under the assumption of steady state conditions and constant diffusion coefficient for each of the working fluid within the system through the convection–diffusion equation as below:

∂𝑐𝒊∂𝑡+∇⇀(𝑐𝑖𝑢⇀−𝐷𝑖∇⇀𝑐𝒊)=0∂��∂�+∇⇀(���⇀−��∇⇀��)=0

(23)where c

i is the species concentration of species i and D

i is the diffusion coefficient of the corresponding species.The standard deviation of concentration (σ

sd) can be adapted to evaluate the mixing quality of the system. 

(97) The standard deviation for concentration at a specific portion of the channel may be calculated using the equation below:

𝜎sd=∫10(𝐶∗(𝑦∗)−𝐶m)2d𝑦∗∫10d𝑦∗⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯�sd=∫01(�*(�*)−�m)2d�*∫01d�*

(24)where C*(y*) and C

m are the non-dimensional concentration profile and the mean concentration at the portion, respectively. C* is the non-dimensional concentration and can be calculated as 

𝐶∗=𝐶𝐶ref�*=��ref, where C

ref is the reference concentration defined as the bulk solution concentration. The mean concentration profile can be calculated as 

𝐶m=∫10(𝐶∗(𝑦∗)d𝑦∗∫10d𝑦∗�m=∫01(�*(�*)d�*∫01d�*. With the standard deviation of concentration, the mixing efficiency 

(97) can then be calculated as below:

𝜀𝑥=1−𝜎sd𝜎sd,0��=1−�sd�sd,0

(25)where σ

sd,0 is the standard derivation of the case of no mixing. The value of the mixing efficiency is typically utilized in conjunction with the simulated flow field and concentration field to explore the effect of geometrical and electrokinetic parameters on the optimization of the mixing results.

5. Summary

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5.1. Conclusion

Viscoelastic fluids such as blood flow in LOC systems are an essential topic to proceed with diagnostic analysis and research through microdevices in the biomedical and pharmaceutical industries. The complex blood flow behavior is tightly controlled by the viscoelastic characteristics of blood such as the dynamic viscosity and the elastic property of RBCs under various shear rate conditions. Furthermore, the flow behaviors under varied driving forces promote an array of microfluidic transport phenomena that are critical to the management of blood flow and other adapted viscoelastic fluids in LOC systems. This review addressed the blood flow phenomena, the complicated interplay between shear rate and blood flow behaviors, and their numerical modeling under LOC systems through the lens of the viscoelasticity characteristic. Furthermore, a theoretical understanding of capillary forces and externally applied electric forces leads to an in-depth investigation of the relationship between blood flow patterns and the key parameters of the two driving forces, the latter of which is introduced through the lens of viscoelastic fluids, coupling numerical modeling to improve the knowledge of blood flow manipulation in LOC systems. The flow disturbances triggered by the EOF of viscoelastic fluids and their impact on blood flow patterns have been deeply investigated due to their important role and applications in LOC devices. Continuous advancements of various numerical modeling methods with experimental findings through more efficient and less computationally heavy methods have served as an encouraging sign of establishing more accurate illustrations of the mechanisms for multiphase blood and other viscoelastic fluid flow transport phenomena driven by various forces. Such progress is fundamental for the manipulation of unique transport phenomena, such as the generated disturbances, to optimize functionalities offered by microdevices in LOC systems.

The following section will provide further insights into the employment of studied blood transport phenomena to improve the functionality of micro devices adapting LOC technology. A discussion of the novel roles that external driving forces play in microfluidic flow behaviors is also provided. Limitations in the computational modeling of blood flow and electrokinetic phenomena in LOC systems will also be emphasized, which may provide valuable insights for future research endeavors. These discussions aim to provide guidance and opportunities for new paths in the ongoing development of LOC devices that adapt blood flow.

5.2. Future Directions

5.2.1. Electro-osmosis Mixing in LOC Systems

Despite substantial research, mixing results through flow instability and vortex formation phenomena induced by electro-osmotic mixing still deviate from the effective mixing results offered by chaotic mixing results such as those seen in turbulent flows. However, recent discoveries of a mixing phenomenon that is generally observed under turbulent flows are found within electro-osmosis micromixers under low Reynolds number conditions. Zhao 

(99) experimentally discovered a rapid mixing process in an AC applied micromixer, where the power spectrum of concentration under an applied voltage of 20 V

p-p induces a −5/3 slope within a frequency range. This value of the slope is considered as the O–C spectrum in macroflows, which is often visible under relatively high Re conditions, such as the Taylor microscale Reynolds number Re > 500 in turbulent flows. 

(100) However, the Re value in the studied system is less than 1 at the specific location and applied voltage. A secondary flow is also suggested to occur close to microchannel walls, being attributed to the increase of convective instability within the system.Despite the experimental phenomenon proposed by Zhao et al., 

(99) the range of effects induced by vital parameters of an EOF mixing system on the enhanced mixing results and mechanisms of disturbance generated by the turbulent-like flow instability is not further characterized. Such a gap in knowledge may hinder the adaptability and commercialization of the discovery of micromixers. One of the parameters for further evaluation is the conductivity gradient of the fluid flow. A relatively strong conductivity gradient (5000:1) was adopted in the system due to the conductive properties of the two fluids. The high conductivity gradients may contribute to the relatively large Rayleigh number and differences in EDL layer thickness, resulting in an unusual disturbance in laminar flow conditions and enhanced mixing results. However, high conductivity gradients are not always achievable by the working fluids due to diverse fluid properties. The reliance on turbulent-like phenomena and rapid mixing results in a large conductivity gradient should be established to prevent the limited application of fluids for the mixing system. In addition, the proposed system utilizes distinct zeta potential distributions at the top and bottom walls due to their difference in material choices, which may be attributed to the flow instability phenomena. Further studies should be made on varying zeta potential magnitude and distribution to evaluate their effect on the slip boundary conditions of the flow and the large shear rate condition close to the channel wall of EOF. Such a study can potentially offer an optimized condition in zeta potential magnitude through material choices and geometrical layout of the zeta potential for better mixing results and manipulation of mixing fluid dynamics. The two vital parameters mentioned above can be varied with the aid of numerical simulation to understand the effect of parameters on the interaction between electro-osmotic forces and electroviscous forces. At the same time, the relationship of developed streamlines of the simulated velocity and concentration field, following their relationship with the mixing results, under the impact of these key parameters can foster more insight into the range of impact that the two parameters have on the proposed phenomena and the microfluidic dynamic principles of disturbances.

In addition, many of the current investigations of electrokinetic mixers commonly emphasize the fluid dynamics of mixing for Newtonian fluids, while the utilization of biofluids, primarily viscoelastic fluids such as blood, and their distinctive response under shear forces in these novel mixing processes of LOC systems are significantly less studied. To develop more compatible microdevice designs and efficient mixing outcomes for the biomedical industry, it is necessary to fill the knowledge gaps in the literature on electro-osmotic mixing for biofluids, where properties of elasticity, dynamic viscosity, and intricate relationship with shear flow from the fluid are further considered.

5.2.2. Electro-osmosis Separation in LOC Systems

Particle separation in LOC devices, particularly in biological research and diagnostics, is another area where disturbances may play a significant role in optimization. 

(101) Plasma analysis in LOC systems under precise control of blood flow phenomena and blood/plasma separation procedures can detect vital information about infectious diseases from particular antibodies and foreign nucleic acids for medical treatments, diagnostics, and research, 

(102) offering more efficient results and simple operating procedures compared to that of the traditional centrifugation method for blood and plasma separation. However, the adaptability of LOC devices for blood and plasma separation is often hindered by microchannel clogging, where flow velocity and plasma yield from LOC devices is reduced due to occasional RBC migration and aggregation at the filtration entrance of microdevices. 

(103)It is important to note that the EOF induces flow instability close to microchannel walls, which may provide further solutions to clogging for the separation process of the LOC systems. Mohammadi et al. 

(104) offered an anti-clogging effect of RBCs at the blood and plasma separating device filtration entry, adjacent to the surface wall, through RBC disaggregation under high shear rate conditions generated by a forward and reverse EOF direction.

Further theoretical and numerical research can be conducted to characterize the effect of high shear rate conditions near microchannel walls toward the detachment of binding blood cells on surfaces and the reversibility of aggregation. Through numerical modeling with varying electrokinetic parameters to induce different degrees of disturbances or shear conditions at channel walls, it may be possible to optimize and better understand the process of disrupting the forces that bind cells to surface walls and aggregated cells at filtration pores. RBCs that migrate close to microchannel walls are often attracted by the adhesion force between the RBC and the solid surface originating from the van der Waals forces. Following RBC migration and attachment by adhesive forces adjacent to the microchannel walls as shown in Figure 7, the increase in viscosity at the region causes a lower shear condition and encourages RBC aggregation (cell–cell interaction), which clogs filtering pores or microchannels and reduces flow velocity at filtration region. Both the impact that shear forces and disturbances may induce on cell binding forces with surface walls and other cells leading to aggregation may suggest further characterization. Kinetic parameters such as activation energy and the rate-determining step for cell binding composition attachment and detachment should be considered for modeling the dynamics of RBCs and blood flows under external forces in LOC separation devices.

Figure 7. Schematic representations of clogging at a microchannel pore following the sequence of RBC migration, cell attachment to channel walls, and aggregation. (105) Reproduced with permission from ref (105). Copyright 2018 The Authors under the terms of the Creative Commons (CC BY 4.0) License https://creativecommons.org/licenses/by/4.0/.

5.2.3. Relationship between External Forces and Microfluidic Systems

In blood flow, a thicker CFL suggests a lower blood viscosity, suggesting a complex relationship between shear stress and shear rate, affecting the blood viscosity and blood flow. Despite some experimental and numerical studies on electro-osmotic non-Newtonian fluid flow, limited literature has performed an in-depth investigation of the role that applied electric forces and other external forces could play in the process of CFL formation. Additional studies on how shear rates from external forces affect CFL formation and microfluidic flow dynamics can shed light on the mechanism of the contribution induced by external driving forces to the development of a separate phase of layer, similar to CFL, close to the microchannel walls and distinct from the surrounding fluid within the system, then influencing microfluidic flow dynamics.One of the mechanisms of phenomena to be explored is the formation of the Exclusion Zone (EZ) region following a “Self-Induced Flow” (SIF) phenomenon discovered by Li and Pollack, 

(106) as shown in Figure 8(a) and (b), respectively. A spontaneous sustained axial flow is observed when hydrophilic materials are immersed in water, resulting in the buildup of a negative layer of charges, defined as the EZ, after water molecules absorb infrared radiation (IR) energy and break down into H and OH

+.

Figure 8. Schematic representations of (a) the Exclusion Zone region and (b) the Self Induced Flow through visualization of microsphere movement within a microchannel. (106) Reproduced with permission from ref (106). Copyright 2020 The Authors under the terms of the Creative Commons (CC BY 4.0) License https://creativecommons.org/licenses/by/4.0/.

Despite the finding of such a phenomenon, the specific mechanism and role of IR energy have yet to be defined for the process of EZ development. To further develop an understanding of the role of IR energy in such phenomena, a feasible study may be seen through the lens of the relationships between external forces and microfluidic flow. In the phenomena, the increase of SIF velocity under a rise of IR radiation resonant characteristics is shown in the participation of the external electric field near the microchannel walls under electro-osmotic viscoelastic fluid flow systems. The buildup of negative charges at the hydrophilic surfaces in EZ is analogous to the mechanism of electrical double layer formation. Indeed, research has initiated the exploration of the core mechanisms for EZ formation through the lens of the electrokinetic phenomena. 

(107) Such a similarity of the role of IR energy and the transport phenomena of SIF with electrokinetic phenomena paves the way for the definition of the unknown SIF phenomena and EZ formation. Furthermore, Li and Pollack 

(106) suggest whether CFL formation might contribute to a SIF of blood using solely IR radiation, a commonly available source of energy in nature, as an external driving force. The proposition may be proven feasible with the presence of the CFL region next to the negatively charged hydrophilic endothelial glycocalyx layer, coating the luminal side of blood vessels. 

(108) Further research can dive into the resonating characteristics between the formation of the CFL region next to the hydrophilic endothelial glycocalyx layer and that of the EZ formation close to hydrophilic microchannel walls. Indeed, an increase in IR energy is known to rapidly accelerate EZ formation and SIF velocity, depicting similarity to the increase in the magnitude of electric field forces and greater shear rates at microchannel walls affecting CFL formation and EOF velocity. Such correlation depicts a future direction in whether SIF blood flow can be observed and characterized theoretically further through the lens of the relationship between blood flow and shear forces exhibited by external energy.

The intricate link between the CFL and external forces, more specifically the externally applied electric field, can receive further attention to provide a more complete framework for the mechanisms between IR radiation and EZ formation. Such characterization may also contribute to a greater comprehension of the role IR can play in CFL formation next to the endothelial glycocalyx layer as well as its role as a driving force to propel blood flow, similar to the SIF, but without the commonly assumed pressure force from heart contraction as a source of driving force.

5.3. Challenges

Although there have been significant improvements in blood flow modeling under LOC systems over the past decade, there are still notable constraints that may require special attention for numerical simulation applications to benefit the adaptability of the designs and functionalities of LOC devices. Several points that require special attention are mentioned below:

1.The majority of CFD models operate under the relationship between the viscoelasticity of blood and the shear rate conditions of flow. The relative effect exhibited by the presence of highly populated RBCs in whole blood and their forces amongst the cells themselves under complex flows often remains unclearly defined. Furthermore, the full range of cell populations in whole blood requires a much more computational load for numerical modeling. Therefore, a vital goal for future research is to evaluate a reduced modeling method where the impact of cell–cell interaction on the viscoelastic property of blood is considered.
2.Current computational methods on hemodynamics rely on continuum models based upon non-Newtonian rheology at the macroscale rather than at molecular and cellular levels. Careful considerations should be made for the development of a constructive framework for the physical and temporal scales of micro/nanoscale systems to evaluate the intricate relationship between fluid driving forces, dynamic viscosity, and elasticity.
3.Viscoelastic fluids under the impact of externally applied electric forces often deviate from the assumptions of no-slip boundary conditions due to the unique flow conditions induced by externally applied forces. Furthermore, the mechanism of vortex formation and viscoelastic flow instability at laminar flow conditions should be better defined through the lens of the microfluidic flow phenomenon to optimize the prediction of viscoelastic flow across different geometrical layouts. Mathematical models and numerical methods are needed to better predict such disturbance caused by external forces and the viscoelasticity of fluids at such a small scale.
4.Under practical situations, zeta potential distribution at channel walls frequently deviates from the common assumption of a constant distribution because of manufacturing faults or inherent surface charges prior to the introduction of electrokinetic influence. These discrepancies frequently lead to inconsistent surface potential distribution, such as excess positive ions at relatively more negatively charged walls. Accordingly, unpredicted vortex formation and flow instability may occur. Therefore, careful consideration should be given to these discrepancies and how they could trigger the transport process and unexpected results of a microdevice.

Author Information

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  • Corresponding Authors
    • Zhe Chen – Department of Chemical Engineering, School of Chemistry and Chemical Engineering, State Key Laboratory of Metal Matrix Composites, Shanghai Jiao Tong University, Shanghai 200240, P. R. China;  Email: zaccooky@sjtu.edu.cn
    • Bo Ouyang – Department of Chemical Engineering, School of Chemistry and Chemical Engineering, State Key Laboratory of Metal Matrix Composites, Shanghai Jiao Tong University, Shanghai 200240, P. R. China;  Email: bouy93@sjtu.edu.cn
    • Zheng-Hong Luo – Department of Chemical Engineering, School of Chemistry and Chemical Engineering, State Key Laboratory of Metal Matrix Composites, Shanghai Jiao Tong University, Shanghai 200240, P. R. China;  Orcidhttps://orcid.org/0000-0001-9011-6020; Email: luozh@sjtu.edu.cn
  • Authors
    • Bin-Jie Lai – Department of Chemical Engineering, School of Chemistry and Chemical Engineering, State Key Laboratory of Metal Matrix Composites, Shanghai Jiao Tong University, Shanghai 200240, P. R. China;  Orcidhttps://orcid.org/0009-0002-8133-5381
    • Li-Tao Zhu – Department of Chemical Engineering, School of Chemistry and Chemical Engineering, State Key Laboratory of Metal Matrix Composites, Shanghai Jiao Tong University, Shanghai 200240, P. R. China;  Orcidhttps://orcid.org/0000-0001-6514-8864
  • NotesThe authors declare no competing financial interest.

Acknowledgments

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This work was supported by the National Natural Science Foundation of China (No. 22238005) and the Postdoctoral Research Foundation of China (No. GZC20231576).

Vocabulary

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Microfluidicsthe field of technological and scientific study that investigates fluid flow in channels with dimensions between 1 and 1000 μm
Lab-on-a-Chip Technologythe field of research and technological development aimed at integrating the micro/nanofluidic characteristics to conduct laboratory processes on handheld devices
Computational Fluid Dynamics (CFD)the method utilizing computational abilities to predict physical fluid flow behaviors mathematically through solving the governing equations of corresponding fluid flows
Shear Ratethe rate of change in velocity where one layer of fluid moves past the adjacent layer
Viscoelasticitythe property holding both elasticity and viscosity characteristics relying on the magnitude of applied shear stress and time-dependent strain
Electro-osmosisthe flow of fluid under an applied electric field when charged solid surface is in contact with the bulk fluid
Vortexthe rotating motion of a fluid revolving an axis line

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Fig. 9 From: An Investigation on Hydraulic Aspects of Rectangular Labyrinth Pool and Weir Fishway Using FLOW-3D

An Investigation on Hydraulic Aspects of Rectangular Labyrinth Pool and Weir Fishway Using FLOW-3D

Abstract

웨어의 두 가지 서로 다른 배열(즉, 직선형 웨어와 직사각형 미로 웨어)을 사용하여 웨어 모양, 웨어 간격, 웨어의 오리피스 존재, 흐름 영역에 대한 바닥 경사와 같은 기하학적 매개변수의 영향을 평가했습니다.

유량과 수심의 관계, 수심 평균 속도의 변화와 분포, 난류 특성, 어도에서의 에너지 소산. 흐름 조건에 미치는 영향을 조사하기 위해 FLOW-3D® 소프트웨어를 사용하여 전산 유체 역학 시뮬레이션을 수행했습니다.

수치 모델은 계산된 표면 프로파일과 속도를 문헌의 실험적으로 측정된 값과 비교하여 검증되었습니다. 수치 모델과 실험 데이터의 결과, 급락유동의 표면 프로파일과 표준화된 속도 프로파일에 대한 평균 제곱근 오차와 평균 절대 백분율 오차가 각각 0.014m와 3.11%로 나타나 수치 모델의 능력을 확인했습니다.

수영장과 둑의 흐름 특성을 예측합니다. 각 모델에 대해 L/B = 1.83(L: 웨어 거리, B: 수로 폭) 값에서 급락 흐름이 발생할 수 있고 L/B = 0.61에서 스트리밍 흐름이 발생할 수 있습니다. 직사각형 미로보 모델은 기존 모델보다 무차원 방류량(Q+)이 더 큽니다.

수중 흐름의 기존 보와 직사각형 미로 보의 경우 Q는 각각 1.56과 1.47h에 비례합니다(h: 보 위 수심). 기존 웨어의 풀 내 평균 깊이 속도는 직사각형 미로 웨어의 평균 깊이 속도보다 높습니다.

그러나 주어진 방류량, 바닥 경사 및 웨어 간격에 대해 난류 운동 에너지(TKE) 및 난류 강도(TI) 값은 기존 웨어에 비해 직사각형 미로 웨어에서 더 높습니다. 기존의 웨어는 직사각형 미로 웨어보다 에너지 소산이 더 낮습니다.

더 낮은 TKE 및 TI 값은 미로 웨어 상단, 웨어 하류 벽 모서리, 웨어 측벽과 채널 벽 사이에서 관찰되었습니다. 보와 바닥 경사면 사이의 거리가 증가함에 따라 평균 깊이 속도, 난류 운동 에너지의 평균값 및 난류 강도가 증가하고 수영장의 체적 에너지 소산이 감소했습니다.

둑에 개구부가 있으면 평균 깊이 속도와 TI 값이 증가하고 풀 내에서 가장 높은 TKE 범위가 감소하여 두 모델 모두에서 물고기를 위한 휴식 공간이 더 넓어지고(TKE가 낮아짐) 에너지 소산율이 감소했습니다.

Two different arrangements of the weir (i.e., straight weir and rectangular labyrinth weir) were used to evaluate the effects of geometric parameters such as weir shape, weir spacing, presence of an orifice at the weir, and bed slope on the flow regime and the relationship between discharge and depth, variation and distribution of depth-averaged velocity, turbulence characteristics, and energy dissipation at the fishway. Computational fluid dynamics simulations were performed using FLOW-3D® software to examine the effects on flow conditions. The numerical model was validated by comparing the calculated surface profiles and velocities with experimentally measured values from the literature. The results of the numerical model and experimental data showed that the root-mean-square error and mean absolute percentage error for the surface profiles and normalized velocity profiles of plunging flows were 0.014 m and 3.11%, respectively, confirming the ability of the numerical model to predict the flow characteristics of the pool and weir. A plunging flow can occur at values of L/B = 1.83 (L: distance of the weir, B: width of the channel) and streaming flow at L/B = 0.61 for each model. The rectangular labyrinth weir model has larger dimensionless discharge values (Q+) than the conventional model. For the conventional weir and the rectangular labyrinth weir at submerged flow, Q is proportional to 1.56 and 1.47h, respectively (h: the water depth above the weir). The average depth velocity in the pool of a conventional weir is higher than that of a rectangular labyrinth weir. However, for a given discharge, bed slope, and weir spacing, the turbulent kinetic energy (TKE) and turbulence intensity (TI) values are higher for a rectangular labyrinth weir compared to conventional weir. The conventional weir has lower energy dissipation than the rectangular labyrinth weir. Lower TKE and TI values were observed at the top of the labyrinth weir, at the corner of the wall downstream of the weir, and between the side walls of the weir and the channel wall. As the distance between the weirs and the bottom slope increased, the average depth velocity, the average value of turbulent kinetic energy and the turbulence intensity increased, and the volumetric energy dissipation in the pool decreased. The presence of an opening in the weir increased the average depth velocity and TI values and decreased the range of highest TKE within the pool, resulted in larger resting areas for fish (lower TKE), and decreased the energy dissipation rates in both models.

1 Introduction

Artificial barriers such as detour dams, weirs, and culverts in lakes and rivers prevent fish from migrating and completing the upstream and downstream movement cycle. This chain is related to the life stage of the fish, its location, and the type of migration. Several riverine fish species instinctively migrate upstream for spawning and other needs. Conversely, downstream migration is a characteristic of early life stages [1]. A fish ladder is a waterway that allows one or more fish species to cross a specific obstacle. These structures are constructed near detour dams and other transverse structures that have prevented such migration by allowing fish to overcome obstacles [2]. The flow pattern in fish ladders influences safe and comfortable passage for ascending fish. The flow’s strong turbulence can reduce the fish’s speed, injure them, and delay or prevent them from exiting the fish ladder. In adult fish, spawning migrations are usually complex, and delays are critical to reproductive success [3].

Various fish ladders/fishways include vertical slots, denil, rock ramps, and pool weirs [1]. The choice of fish ladder usually depends on many factors, including water elevation, space available for construction, and fish species. Pool and weir structures are among the most important fish ladders that help fish overcome obstacles in streams or rivers and swim upstream [1]. Because they are easy to construct and maintain, this type of fish ladder has received considerable attention from researchers and practitioners. Such a fish ladder consists of a sloping-floor channel with series of pools directly separated by a series of weirs [4]. These fish ladders, with or without underwater openings, are generally well-suited for slopes of 10% or less [12]. Within these pools, flow velocities are low and provide resting areas for fish after they enter the fish ladder. After resting in the pools, fish overcome these weirs by blasting or jumping over them [2]. There may also be an opening in the flooded portion of the weir through which the fish can swim instead of jumping over the weir. Design parameters such as the length of the pool, the height of the weir, the slope of the bottom, and the water discharge are the most important factors in determining the hydraulic structure of this type of fish ladder [3]. The flow over the weir depends on the flow depth at a given slope S0 and the pool length, either “plunging” or “streaming.” In plunging flow, the water column h over each weir creates a water jet that releases energy through turbulent mixing and diffusion mechanisms [5]. The dimensionless discharges for plunging (Q+) and streaming (Q*) flows are shown in Fig. 1, where Q is the total discharge, B is the width of the channel, w is the weir height, S0 is the slope of the bottom, h is the water depth above the weir, d is the flow depth, and g is the acceleration due to gravity. The maximum velocity occurs near the top of the weir for plunging flow. At the water’s surface, it drops to about half [6].

figure 1
Fig. 1

Extensive experimental studies have been conducted to investigate flow patterns for various physical geometries (i.e., bed slope, pool length, and weir height) [2]. Guiny et al. [7] modified the standard design by adding vertical slots, orifices, and weirs in fishways. The efficiency of the orifices and vertical slots was related to the velocities at their entrances. In the laboratory experiments of Yagci [8], the three-dimensional (3D) mean flow and turbulence structure of a pool weir fishway combined with an orifice and a slot is investigated. It is shown that the energy dissipation per unit volume and the discharge have a linear relationship.

Considering the beneficial characteristics reported in the limited studies of researchers on the labyrinth weir in the pool-weir-type fishway, and knowing that the characteristics of flow in pool-weir-type fishways are highly dependent on the geometry of the weir, an alternative design of the rectangular labyrinth weir instead of the straight weirs in the pool-weir-type fishway is investigated in this study [79]. Kim [10] conducted experiments to compare the hydraulic characteristics of three different weir types in a pool-weir-type fishway. The results show that a straight, rectangular weir with a notch is preferable to a zigzag or trapezoidal weir. Studies on natural fish passes show that pass ability can be improved by lengthening the weir’s crest [7]. Zhong et al. [11] investigated the semi-rigid weir’s hydraulic performance in the fishway’s flow field with a pool weir. The results showed that this type of fishway performed better with a lower invert slope and a smaller radius ratio but with a larger pool spacing.

Considering that an alternative method to study the flow characteristics in a fishway with a pool weir is based on numerical methods and modeling from computational fluid dynamics (CFD), which can easily change the geometry of the fishway for different flow fields, this study uses the powerful package CFD and the software FLOW-3D to evaluate the proposed weir design and compare it with the conventional one to extend the application of the fishway. The main objective of this study was to evaluate the hydraulic performance of the rectangular labyrinth pool and the weir with submerged openings in different hydraulic configurations. The primary objective of creating a new weir configuration for suitable flow patterns is evaluated based on the swimming capabilities of different fish species. Specifically, the following questions will be answered: (a) How do the various hydraulic and geometric parameters relate to the effects of water velocity and turbulence, expressed as turbulent kinetic energy (TKE) and turbulence intensity (TI) within the fishway, i.e., are conventional weirs more affected by hydraulics than rectangular labyrinth weirs? (b) Which weir configurations have the greatest effect on fish performance in the fishway? (c) In the presence of an orifice plate, does the performance of each weir configuration differ with different weir spacing, bed gradients, and flow regimes from that without an orifice plate?

2 Materials and Methods

2.1 Physical Model Configuration

This paper focuses on Ead et al. [6]’s laboratory experiments as a reference, testing ten pool weirs (Fig. 2). The experimental flume was 6 m long, 0.56 m wide, and 0.6 m high, with a bottom slope of 10%. Field measurements were made at steady flow with a maximum flow rate of 0.165 m3/s. Discharge was measured with magnetic flow meters in the inlets and water level with point meters (see Ead et al. [6]. for more details). Table 1 summarizes the experimental conditions considered for model calibration in this study.

figure 2
Fig. 2

Table 1 Experimental conditions considered for calibration

Full size table

2.2 Numerical Models

Computational fluid dynamics (CFD) simulations were performed using FLOW-3D® v11.2 to validate a series of experimental liner pool weirs by Ead et al. [6] and to investigate the effects of the rectangular labyrinth pool weir with an orifice. The dimensions of the channel and data collection areas in the numerical models are the same as those of the laboratory model. Two types of pool weirs were considered: conventional and labyrinth. The proposed rectangular labyrinth pool weirs have a symmetrical cross section and are sized to fit within the experimental channel. The conventional pool weir model had a pool length of l = 0.685 and 0.342 m, a weir height of w = 0.141 m, a weir width of B = 0.56 m, and a channel slope of S0 = 5 and 10%. The rectangular labyrinth weirs have the same front width as the offset, i.e., a = b = c = 0.186 m. A square underwater opening with a width of 0.05 m and a depth of 0.05 m was created in the middle of the weir. The weir configuration considered in the present study is shown in Fig. 3.

figure 3
Fig. 3

2.3 Governing Equations

FLOW-3D® software solves the Navier–Stokes–Reynolds equations for three-dimensional analysis of incompressible flows using the fluid-volume method on a gridded domain. FLOW -3D® uses an advanced free surface flow tracking algorithm (TruVOF) developed by Hirt and Nichols [12], where fluid configurations are defined in terms of a VOF function F (xyzt). In this case, F (fluid fraction) represents the volume fraction occupied by the fluid: F = 1 in cells filled with fluid and F = 0 in cells without fluid (empty areas) [413]. The free surface area is at an intermediate value of F. (Typically, F = 0.5, but the user can specify a different intermediate value.) The equations in Cartesian coordinates (xyz) applicable to the model are as follows:

�f∂�∂�+∂(���x)∂�+∂(���y)∂�+∂(���z)∂�=�SOR

(1)

∂�∂�+1�f(��x∂�∂�+��y∂�∂�+��z∂�∂�)=−1�∂�∂�+�x+�x

(2)

∂�∂�+1�f(��x∂�∂�+��y∂�∂�+��z∂�∂�)=−1�∂�∂�+�y+�y

(3)

∂�∂�+1�f(��x∂�∂�+��y∂�∂�+��z∂�∂�)=−1�∂�∂�+�z+�z

(4)

where (uvw) are the velocity components, (AxAyAz) are the flow area components, (Gx, Gy, Gz) are the mass accelerations, and (fxfyfz) are the viscous accelerations in the directions (xyz), ρ is the fluid density, RSOR is the spring term, Vf is the volume fraction associated with the flow, and P is the pressure. The kε turbulence model (RNG) was used in this study to solve the turbulence of the flow field. This model is a modified version of the standard kε model that improves performance. The model is a two-equation model; the first equation (Eq. 5) expresses the turbulence’s energy, called turbulent kinetic energy (k) [14]. The second equation (Eq. 6) is the turbulent dissipation rate (ε), which determines the rate of dissipation of kinetic energy [15]. These equations are expressed as follows Dasineh et al. [4]:

∂(��)∂�+∂(����)∂��=∂∂��[������∂�∂��]+��−�ε

(5)

∂(�ε)∂�+∂(�ε��)∂��=∂∂��[�ε�eff∂ε∂��]+�1εε��k−�2ε�ε2�

(6)

In these equations, k is the turbulent kinetic energy, ε is the turbulent energy consumption rate, Gk is the generation of turbulent kinetic energy by the average velocity gradient, with empirical constants αε = αk = 1.39, C1ε = 1.42, and C2ε = 1.68, eff is the effective viscosity, μeff = μ + μt [15]. Here, μ is the hydrodynamic density coefficient, and μt is the turbulent density of the fluid.

2.4 Meshing and the Boundary Conditions in the Model Setup

The numerical area is divided into three mesh blocks in the X-direction. The meshes are divided into different sizes, a containing mesh block for the entire spatial domain and a nested block with refined cells for the domain of interest. Three different sizes were selected for each of the grid blocks. By comparing the accuracy of their results based on the experimental data, the reasonable mesh for the solution domain was finally selected. The convergence index method (GCI) evaluated the mesh sensitivity analysis. Based on this method, many researchers, such as Ahmadi et al. [16] and Ahmadi et al. [15], have studied the independence of numerical results from mesh size. Three different mesh sizes with a refinement ratio (r) of 1.33 were used to perform the convergence index method. The refinement ratio is the ratio between the larger and smaller mesh sizes (r = Gcoarse/Gfine). According to the recommendation of Celik et al. [17], the recommended number for the refinement ratio is 1.3, which gives acceptable results. Table 2 shows the characteristics of the three mesh sizes selected for mesh sensitivity analysis.Table 2 Characteristics of the meshes tested in the convergence analysis

Full size table

The results of u1 = umax (u1 = velocity component along the x1 axis and umax = maximum velocity of u1 in a section perpendicular to the invert of the fishway) at Q = 0.035 m3/s, × 1/l = 0.66, and Y1/b = 0 in the pool of conventional weir No. 4, obtained from the output results of the software, were used to evaluate the accuracy of the calculation range. As shown in Fig. 4x1 = the distance from a given weir in the x-direction, Y1 = the water depth measured in the y-direction, Y0 = the vertical distance in the Cartesian coordinate system, h = the water column at the crest, b = the distance between the two points of maximum velocity umax and zero velocity, and l = the pool length.

figure 4
Fig. 4

The apparent index of convergence (p) in the GCI method is calculated as follows:

�=ln⁡(�3−�2)(�2−�1)/ln⁡(�)

(7)

f1f2, and f3 are the hydraulic parameters obtained from the numerical simulation (f1 corresponds to the small mesh), and r is the refinement ratio. The following equation defines the convergence index of the fine mesh:

GCIfine=1.25|ε|��−1

(8)

Here, ε = (f2 − f1)/f1 is the relative error, and f2 and f3 are the values of hydraulic parameters considered for medium and small grids, respectively. GCI12 and GCI23 dimensionless indices can be calculated as:

GCI12=1.25|�2−�1�1|��−1

(9)

Then, the independence of the network is preserved. The convergence index of the network parameters obtained by Eqs. (7)–(9) for all three network variables is shown in Table 3. Since the GCI values for the smaller grid (GCI12) are lower compared to coarse grid (GCI23), it can be concluded that the independence of the grid is almost achieved. No further change in the grid size of the solution domain is required. The calculated values (GCI23/rpGCI12) are close to 1, which shows that the numerical results obtained are within the convergence range. As a result, the meshing of the solution domain consisting of a block mesh with a mesh size of 0.012 m and a block mesh within a larger block mesh with a mesh size of 0.009 m was selected as the optimal mesh (Fig. 5).Table 3 GCI calculation

Full size table

figure 5
Fig. 5

The boundary conditions applied to the area are shown in Fig. 6. The boundary condition of specific flow rate (volume flow rate-Q) was used for the inlet of the flow. For the downstream boundary, the flow output (outflow-O) condition did not affect the flow in the solution area. For the Zmax boundary, the specified pressure boundary condition was used along with the fluid fraction = 0 (P). This type of boundary condition considers free surface or atmospheric pressure conditions (Ghaderi et al. [19]). The wall boundary condition is defined for the bottom of the channel, which acts like a virtual wall without friction (W). The boundary between mesh blocks and walls were considered a symmetrical condition (S).

figure 6
Fig. 6

The convergence of the steady-state solutions was controlled during the simulations by monitoring the changes in discharge at the inlet boundary conditions. Figure 7 shows the time series plots of the discharge obtained from the Model A for the three main discharges from the numerical results. The 8 s to reach the flow equilibrium is suitable for the case of the fish ladder with pool and weir. Almost all discharge fluctuations in the models are insignificant in time, and the flow has reached relative stability. The computation time for the simulations was between 6 and 8 h using a personal computer with eight cores of a CPU (Intel Core i7-7700K @ 4.20 GHz and 16 GB RAM).

figure 7
Fig. 7

3 Results

3.1 Verification of Numerical Results

Quantitative outcomes, including free surface and normalized velocity profiles obtained using FLOW-3D software, were reviewed and compared with the results of Ead et al. [6]. The fourth pool was selected to present the results and compare the experiment and simulation. For each quantity, the percentage of mean absolute error (MAPE (%)) and root-mean-square error (RMSE) are calculated. Equations (10) and (11) show the method used to calculate the errors.

MAPE(%)100×1�∑1�|�exp−�num�exp|

(10)

RMSE(−)1�∑1�(�exp−�num)2

(11)

Here, Xexp is the value of the laboratory data, Xnum is the numerical data value, and n is the amount of data. As shown in Fig. 8, let x1 = distance from a given weir in the x-direction and Y1 = water depth in the y-direction from the bottom. The trend of the surface profiles for each of the numerical results is the same as that of the laboratory results. The surface profiles of the plunging flows drop after the flow enters and then rises to approach the next weir. The RMSE and MAPE error values for Model A are 0.014 m and 3.11%, respectively, indicating acceptable agreement between numerical and laboratory results. Figure 9 shows the velocity vectors and plunging flow from the numerical results, where x and y are horizontal and vertical to the flow direction, respectively. It can be seen that the jet in the fish ladder pool has a relatively high velocity. The two vortices, i.e., the enclosed vortex rotating clockwise behind the weir and the surface vortex rotating counterclockwise above the jet, are observed for the regime of incident flow. The point where the jet meets the fish passage bed is shown in the figure. The normalized velocity profiles upstream and downstream of the impact points are shown in Fig. 10. The figure shows that the numerical results agree well with the experimental data of Ead et al. [6].

figure 8
Fig. 8
figure 9
Fig. 9
figure 10
Fig. 10

3.2 Flow Regime and Discharge-Depth Relationship

Depending on the geometric shape of the fishway, including the distance of the weir, the slope of the bottom, the height of the weir, and the flow conditions, the flow regime in the fishway is divided into three categories: dipping, transitional, and flow regimes [4]. In the plunging flow regime, the flow enters the pool through the weir, impacts the bottom of the fishway, and forms a hydraulic jump causing two eddies [220]. In the streamwise flow regime, the surface of the flow passing over the weir is almost parallel to the bottom of the channel. The transitional regime has intermediate flow characteristics between the submerged and flow regimes. To predict the flow regime created in the fishway, Ead et al. [6] proposed two dimensionless parameters, Qt* and L/w, where Qt* is the dimensionless discharge, L is the distance between weirs, and w is the height of the weir:

��∗=���0���

(12)

Q is the total discharge, B is the width of the channel, S0 is the slope of the bed, and g is the gravity acceleration. Figure 11 shows different ranges for each flow regime based on the slope of the bed and the distance between the pools in this study. The results of Baki et al. [21], Ead et al. [6] and Dizabadi et al. [22] were used for this comparison. The distance between the pools affects the changes in the regime of the fish ladder. So, if you decrease the distance between weirs, the flow regime more likely becomes. This study determined all three flow regimes in a fish ladder. When the corresponding range of Qt* is less than 0.6, the flow regime can dip at values of L/B = 1.83. If the corresponding range of Qt* is greater than 0.5, transitional flow may occur at L/B = 1.22. On the other hand, when Qt* is greater than 1, streamwise flow can occur at values of L/B = 0.61. These observations agree well with the results of Baki et al. [21], Ead et al. [6] and Dizabadi et al. [22].

figure 11
Fig. 11

For plunging flows, another dimensionless discharge (Q+) versus h/w given by Ead et al. [6] was used for further evaluation:

�+=��ℎ�ℎ=23�d�

(13)

where h is the water depth above the weir, and Cd is the discharge coefficient. Figure 12a compares the numerical and experimental results of Ead et al. [6]. In this figure, Rehbock’s empirical equation is used to estimate the discharge coefficient of Ead et al. [6].

�d=0.57+0.075ℎ�

(14)

figure 12
Fig. 12

The numerical results for the conventional weir (Model A) and the rectangular labyrinth weir (Model B) of this study agree well with the laboratory results of Ead et al. [6]. When comparing models A and B, it is also found that a rectangular labyrinth weir has larger Q + values than the conventional weir as the length of the weir crest increases for a given channel width and fixed headwater elevation. In Fig. 12b, Models A and B’s flow depth plot shows the plunging flow regime. The power trend lines drawn through the data are the best-fit lines. The data shown in Fig. 12b are for different bed slopes and weir geometries. For the conventional weir and the rectangular labyrinth weir at submerged flow, Q can be assumed to be proportional to 1.56 and 1.47h, respectively. In the results of Ead et al. [6], Q is proportional to 1.5h. If we assume that the flow through the orifice is Qo and the total outflow is Q, the change in the ratio of Qo/Q to total outflow for models A and B can be shown in Fig. 13. For both models, the flow through the orifice decreases as the total flow increases. A logarithmic trend line was also found between the total outflow and the dimensionless ratio Qo/Q.

figure 13
Fig. 13

3.3 Depth-Averaged Velocity Distributions

To ensure that the target fish species can pass the fish ladder with maximum efficiency, the average velocity in the fish ladder should be low enough [4]. Therefore, the average velocity in depth should be as much as possible below the critical swimming velocities of the target fishes at a constant flow depth in the pool [20]. The contour plot of depth-averaged velocity was used instead of another direction, such as longitudinal velocity because fish are more sensitive to depth-averaged flow velocity than to its direction under different hydraulic conditions. Figure 14 shows the distribution of depth-averaged velocity in the pool for Models A and B in two cases with and without orifice plates. Model A’s velocity within the pool differs slightly in the spanwise direction. However, no significant variation in velocity was observed. The flow is gradually directed to the sides as it passes through the rectangular labyrinth weir. This increases the velocity at the sides of the channel. Therefore, the high-velocity zone is located at the sides. The low velocity is in the downstream apex of the weir. This area may be suitable for swimming target fish. The presence of an opening in the weir increases the flow velocity at the opening and in the pool’s center, especially in Model A. The flow velocity increase caused by the models’ opening varied from 7.7 to 12.48%. Figure 15 illustrates the effect of the inverted slope on the averaged depth velocity distribution in the pool at low and high discharge. At constant discharge, flow velocity increases with increasing bed slope. In general, high flow velocity was found in the weir toe sidewall and the weir and channel sidewalls.

figure 14
Fig. 14
figure 15
Fig. 15

On the other hand, for a constant bed slope, the high-velocity area of the pool increases due to the increase in runoff. For both bed slopes and different discharges, the most appropriate path for fish to travel from upstream to downstream is through the middle of the cross section and along the top of the rectangular labyrinth weirs. The maximum dominant velocities for Model B at S0 = 5% were 0.83 and 1.01 m/s; at S0 = 10%, they were 1.12 and 1.61 m/s at low and high flows, respectively. The low mean velocities for the same distance and S0 = 5 and 10% were 0.17 and 0.26 m/s, respectively.

Figure 16 shows the contour of the averaged depth velocity for various distances from the weir at low and high discharge. The contour plot shows a large variation in velocity within short distances from the weir. At L/B = 0.61, velocities are low upstream and downstream of the top of the weir. The high velocities occur in the side walls of the weir and the channel. At L/B = 1.22, the low-velocity zone displaces the higher velocity in most of the pool. Higher velocities were found only on the sides of the channel. As the discharge increases, the velocity zone in the pool becomes wider. At L/B = 1.83, there is an area of higher velocities only upstream of the crest and on the sides of the weir. At high discharge, the prevailing maximum velocities for L/B = 0.61, 1.22, and 1.83 were 1.46, 1.65, and 1.84 m/s, respectively. As the distance between weirs increases, the range of maximum velocity increases.

figure 16
Fig. 16

On the other hand, the low mean velocity for these distances was 0.27, 0.44, and 0.72 m/s, respectively. Thus, the low-velocity zone decreases with increasing distance between weirs. Figure 17 shows the pattern distribution of streamlines along with the velocity contour at various distances from the weir for Q = 0.05 m3/s. A stream-like flow is generally formed in the pool at a small distance between weirs (L/B = 0.61). The rotation cell under the jet forms clockwise between the two weirs. At the distances between the spillways (L/B = 1.22), the transition regime of the flow is formed. The transition regime occurs when or shortly after the weir is flooded. The rotation cell under the jet is clockwise smaller than the flow regime and larger than the submergence regime. At a distance L/B = 1.83, a plunging flow is formed so that the plunging jet dips into the pool and extends downstream to the center of the pool. The clockwise rotation of the cell is bounded by the dipping jet of the weir and is located between the bottom and the side walls of the weir and the channel.

figure 17
Fig. 17

Figure 18 shows the average depth velocity bar graph for each weir at different bed slopes and with and without orifice plates. As the distance between weirs increases, all models’ average depth velocity increases. As the slope of the bottom increases and an orifice plate is present, the average depth velocity in the pool increases. In addition, the average pool depth velocity increases as the discharge increases. Among the models, Model A’s average depth velocity is higher than Model B’s. The variation in velocity ranged from 8.11 to 12.24% for the models without an orifice plate and from 10.26 to 16.87% for the models with an orifice plate.

figure 18
Fig. 18

3.4 Turbulence Characteristics

The turbulent kinetic energy is one of the important parameters reflecting the turbulent properties of the flow field [23]. When the k value is high, more energy and a longer transit time are required to migrate the target species. The turbulent kinetic energy is defined as follows:

�=12(�x′2+�y′2+�z′2)

(15)

where uxuy, and uz are fluctuating velocities in the xy, and z directions, respectively. An illustration of the TKE and the effects of the geometric arrangement of the weir and the presence of an opening in the weir is shown in Fig. 19. For a given bed slope, in Model A, the highest TKE values are uniformly distributed in the weir’s upstream portion in the channel’s cross section. In contrast, for the rectangular labyrinth weir (Model B), the highest TKE values are concentrated on the sides of the pool between the crest of the weir and the channel wall. The highest TKE value in Models A and B is 0.224 and 0.278 J/kg, respectively, at the highest bottom slope (S0 = 10%). In the downstream portion of the conventional weir and within the crest of the weir and the walls of the rectangular labyrinth, there was a much lower TKE value that provided the best conditions for fish to recover in the pool between the weirs. The average of the lowest TKE for bottom slopes of 5 and 10% in Model A is 0.041 and 0.056 J/kg, and for Model B, is 0.047 and 0.064 J/kg. The presence of an opening in the weirs reduces the area of the highest TKE within the pool. It also increases the resting areas for fish (lower TKE). The highest TKE at the highest bottom slope in Models A and B with an orifice is 0.208 and 0.191 J/kg, respectively.

figure 19
Fig. 19

Figure 20 shows the effect of slope on the longitudinal distribution of TKE in the pools. TKE values significantly increase for a given discharge with an increasing bottom slope. Thus, for a low bed slope (S0 = 5%), a large pool area has expanded with average values of 0.131 and 0.168 J/kg for low and high discharge, respectively. For a bed slope of S0 = 10%, the average TKE values are 0.176 and 0.234 J/kg. Furthermore, as the discharge increases, the area with high TKE values within the pool increases. Lower TKE values are observed at the apex of the labyrinth weir, at the corner of the wall downstream of the weir, and between the side walls of the weir and the channel wall for both bottom slopes. The effect of distance between weirs on TKE is shown in Fig. 21. Low TKE values were observed at low discharge and short distances between weirs. Low TKE values are located at the top of the rectangular labyrinth weir and the downstream corner of the weir wall. There is a maximum value of TKE at the large distances between weirs, L/B = 1.83, along the center line of the pool, where the dip jet meets the bottom of the bed. At high discharge, the maximum TKE value for the distance L/B = 0.61, 1.22, and 1.83 was 0.246, 0.322, and 0.417 J/kg, respectively. In addition, the maximum TKE range increases with the distance between weirs.

figure 20
Fig. 20
figure 21
Fig. 21

For TKE size, the average value (TKEave) is plotted against q in Fig. 22. For all models, the TKE values increase with increasing q. For example, in models A and B with L/B = 0.61 and a slope of 10%, the TKE value increases by 41.66 and 86.95%, respectively, as q increases from 0.1 to 0.27 m2/s. The TKE values in Model B are higher than Model A for a given discharge, bed slope, and weir distance. The TKEave in Model B is higher compared to Model A, ranging from 31.46 to 57.94%. The presence of an orifice in the weir reduces the TKE values in both weirs. The intensity of the reduction is greater in Model B. For example, in Models A and B with L/B = 0.61 and q = 0.1 m2/s, an orifice reduces TKEave values by 60.35 and 19.04%, respectively. For each model, increasing the bed slope increases the TKEave values in the pool. For example, for Model B with q = 0.18 m2/s, increasing the bed slope from 5 to 10% increases the TKEave value by 14.34%. Increasing the distance between weirs increases the TKEave values in the pool. For example, in Model B with S0 = 10% and q = 0.3 m2/s, the TKEave in the pool increases by 34.22% if you increase the distance between weirs from L/B = 0.61 to L/B = 0.183.

figure 22
Fig. 22

Cotel et al. [24] suggested that turbulence intensity (TI) is a suitable parameter for studying fish swimming performance. Figure 23 shows the plot of TI and the effects of the geometric arrangement of the weir and the presence of an orifice. In Model A, the highest TI values are found upstream of the weirs and are evenly distributed across the cross section of the channel. The TI values increase as you move upstream to downstream in the pool. For the rectangular labyrinth weir, the highest TI values were concentrated on the sides of the pool, between the top of the weir and the side wall of the channel, and along the top of the weir. Downstream of the conventional weir, within the apex of the weir, and at the corners of the walls of the rectangular labyrinth weir, the percentage of TI was low. At the highest discharge, the average range of TI in Models A and B was 24–45% and 15–62%, respectively. The diversity of TI is greater in the rectangular labyrinth weir than the conventional weir. Fish swimming performance is reduced due to higher turbulence intensity. However, fish species may prefer different disturbance intensities depending on their swimming abilities; for example, Salmo trutta prefers a disturbance intensity of 18–53% [25]. Kupferschmidt and Zhu [26] found a higher range of TI for fishways, such as natural rock weirs, of 40–60%. The presence of an orifice in the weir increases TI values within the pool, especially along the middle portion of the cross section of the fishway. With an orifice in the weir, the average range of TI in Models A and B was 28–59% and 22–73%, respectively.

figure 23
Fig. 23

The effect of bed slope on TI variation is shown in Fig. 24. TI increases in different pool areas as the bed slope increases for a given discharge. For a low bed slope (S0 = 5%), a large pool area has increased from 38 to 63% and from 56 to 71% for low and high discharge, respectively. For a bed slope of S0 = 10%, the average values of TI are 45–67% and 61–73% for low and high discharge, respectively. Therefore, as runoff increases, the area with high TI values within the pool increases. A lower TI is observed for both bottom slopes in the corner of the wall, downstream of the crest walls, and between the side walls in the weir and channel. Figure 25 compares weir spacing with the distribution of TI values within the pool. The TI values are low at low flows and short distances between weirs. A maximum value of TI occurs at long spacing and where the plunging stream impinges on the bed and the area around the bed. TI ranges from 36 to 57%, 58–72%, and 47–76% for the highest flow in a wide pool area for L/B = 0.61, 1.22, and 1.83, respectively.

figure 24
Fig. 24
figure 25
Fig. 25

The average value of turbulence intensity (TIave) is plotted against q in Fig. 26. The increase in TI values with the increase in q values is seen in all models. For example, the average values of TI for Models A and B at L/B = 0.61 and slope of 10% increased from 23.9 to 33.5% and from 42 to 51.8%, respectively, with the increase in q from 0.1 to 0.27 m2/s. For a given discharge, a given gradient, and a given spacing of weirs, the TIave is higher in Model B than Model A. The presence of an orifice in the weirs increases the TI values in both types. For example, in Models A and B with L/B = 0.61 and q = 0.1 m2/s, the presence of an orifice increases TIave from 23.9 to 37.1% and from 42 to 48.8%, respectively. For each model, TIave in the pool increases with increasing bed slope. For Model B with q = 0.18 m2/s, TIave increases from 37.5 to 45.8% when you increase the invert slope from 5 to 10%. Increasing the distance between weirs increases the TIave in the pool. In Model B with S0 = 10% and q = 0.3 m2/s, the TIave in the pool increases from 51.8 to 63.7% as the distance between weirs increases from L/B = 0.61 to L/B = 0.183.

figure 26
Fig. 26

3.5 Energy Dissipation

To facilitate the passage of various target species through the pool of fishways, it is necessary to pay attention to the energy dissipation of the flow and to keep the flow velocity in the pool slow. The average volumetric energy dissipation (k) in the pool is calculated using the following basic formula:

�=����0��

(16)

where ρ is the water density, and H is the average water depth of the pool. The change in k versus Q for all models at two bottom slopes, S0 = 5%, and S0 = 10%, is shown in Fig. 27. Like the results of Yagci [8] and Kupferschmidt and Zhu [26], at a constant bottom slope, the energy dissipation in the pool increases with increasing discharge. The trend of change in k as a function of Q from the present study at a bottom gradient of S0 = 5% is also consistent with the results of Kupferschmidt and Zhu [26] for the fishway with rock weir. The only difference between the results is the geometry of the fishway and the combination of boulders instead of a solid wall. Comparison of the models shows that the conventional model has lower energy dissipation than the rectangular labyrinth for a given discharge. Also, increasing the distance between weirs decreases the volumetric energy dissipation for each model with the same bed slope. Increasing the slope of the bottom leads to an increase in volumetric energy dissipation, and an opening in the weir leads to a decrease in volumetric energy dissipation for both models. Therefore, as a guideline for volumetric energy dissipation, if the value within the pool is too high, the increased distance of the weir, the decreased slope of the bed, or the creation of an opening in the weir would decrease the volumetric dissipation rate.

figure 27
Fig. 27

To evaluate the energy dissipation inside the pool, the general method of energy difference in two sections can use:

ε=�1−�2�1

(17)

where ε is the energy dissipation rate, and E1 and E2 are the specific energies in Sects. 1 and 2, respectively. The distance between Sects. 1 and 2 is the same. (L is the distance between two upstream and downstream weirs.) Figure 28 shows the changes in ε relative to q (flow per unit width). The rectangular labyrinth weir (Model B) has a higher energy dissipation rate than the conventional weir (Model A) at a constant bottom gradient. For example, at S0 = 5%, L/B = 0.61, and q = 0.08 m3/s.m, the energy dissipation rate in Model A (conventional weir) was 0.261. In Model B (rectangular labyrinth weir), however, it was 0.338 (22.75% increase). For each model, the energy dissipation rate within the pool increases as the slope of the bottom increases. For Model B with L/B = 1.83 and q = 0.178 m3/s.m, the energy dissipation rate at S0 = 5% and 10% is 0.305 and 0.358, respectively (14.8% increase). Figure 29 shows an orifice’s effect on the pools’ energy dissipation rate. With an orifice in the weir, both models’ energy dissipation rates decreased. Thus, the reduction in energy dissipation rate varied from 7.32 to 9.48% for Model A and from 8.46 to 10.57 for Model B.

figure 28
Fig. 28
figure 29
Fig. 29

4 Discussion

This study consisted of entirely of numerical analysis. Although this study was limited to two weirs, the hydraulic performance and flow characteristics in a pooled fishway are highlighted by the rectangular labyrinth weir and its comparison with the conventional straight weir. The study compared the numerical simulations with laboratory experiments in terms of surface profiles, velocity vectors, and flow characteristics in a fish ladder pool. The results indicate agreement between the numerical and laboratory data, supporting the reliability of the numerical model in capturing the observed phenomena.

When the configuration of the weir changes to a rectangular labyrinth weir, the flow characteristics, the maximum and minimum area, and even the location of each hydraulic parameter change compared to a conventional weir. In the rectangular labyrinth weir, the flow is gradually directed to the sides as it passes the weir. This increases the velocity at the sides of the channel [21]. Therefore, the high-velocity area is located on the sides. In the downstream apex of the weir, the flow velocity is low, and this area may be suitable for swimming target fish. However, no significant change in velocity was observed at the conventional weir within the fish ladder. This resulted in an average increase in TKE of 32% and an average increase in TI of about 17% compared to conventional weirs.

In addition, there is a slight difference in the flow regime for both weir configurations. In addition, the rectangular labyrinth weir has a higher energy dissipation rate for a given discharge and constant bottom slope than the conventional weir. By reducing the distance between the weirs, this becomes even more intense. Finally, the presence of an orifice in both configurations of the weir increased the flow velocity at the orifice and in the middle of the pool, reducing the highest TKE value and increasing the values of TI within the pool of the fish ladder. This resulted in a reduction in volumetric energy dissipation for both weir configurations.

The results of this study will help the reader understand the direct effects of the governing geometric parameters on the hydraulic characteristics of a fishway with a pool and weir. However, due to the limited configurations of the study, further investigation is needed to evaluate the position of the weir’s crest on the flow direction and the difference in flow characteristics when combining boulders instead of a solid wall for this type of labyrinth weir [26]. In addition, hydraulic engineers and biologists must work together to design an effective fishway with rectangular labyrinth configurations. The migration habits of the target species should be considered when designing the most appropriate design [27]. Parametric studies and field observations are recommended to determine the perfect design criteria.

The current study focused on comparing a rectangular labyrinth weir with a conventional straight weir. Further research can explore other weir configurations, such as variations in crest position, different shapes of labyrinth weirs, or the use of boulders instead of solid walls. This would help understand the influence of different geometric parameters on hydraulic characteristics.

5 Conclusions

A new layout of the weir was evaluated, namely a rectangular labyrinth weir compared to a straight weir in a pool and weir system. The differences between the weirs were highlighted, particularly how variations in the geometry of the structures, such as the shape of the weir, the spacing of the weir, the presence of an opening at the weir, and the slope of the bottom, affect the hydraulics within the structures. The main findings of this study are as follows:

  • The calculated dimensionless discharge (Qt*) confirmed three different flow regimes: when the corresponding range of Qt* is smaller than 0.6, the regime of plunging flow occurs for values of L/B = 1.83. (L: distance of the weir; B: channel width). When the corresponding range of Qt* is greater than 0.5, transitional flow occurs at L/B = 1.22. On the other hand, if Qt* is greater than 1, the streaming flow is at values of L/B = 0.61.
  • For the conventional weir and the rectangular labyrinth weir with the plunging flow, it can be assumed that the discharge (Q) is proportional to 1.56 and 1.47h, respectively (h: water depth above the weir). This information is useful for estimating the discharge based on water depth in practical applications.
  • In the rectangular labyrinth weir, the high-velocity zone is located on the side walls between the top of the weir and the channel wall. A high-velocity variation within short distances of the weir. Low velocity occurs within the downstream apex of the weir. This area may be suitable for swimming target fish.
  • As the distance between weirs increased, the zone of maximum velocity increased. However, the zone of low speed decreased. The prevailing maximum velocity for a rectangular labyrinth weir at L/B = 0.61, 1.22, and 1.83 was 1.46, 1.65, and 1.84 m/s, respectively. The low mean velocities for these distances were 0.27, 0.44, and 0.72 m/s, respectively. This finding highlights the importance of weir spacing in determining the flow characteristics within the fishway.
  • The presence of an orifice in the weir increased the flow velocity at the orifice and in the middle of the pool, especially in a conventional weir. The increase ranged from 7.7 to 12.48%.
  • For a given bottom slope, in a conventional weir, the highest values of turbulent kinetic energy (TKE) are uniformly distributed in the upstream part of the weir in the cross section of the channel. In contrast, for the rectangular labyrinth weir, the highest TKE values were concentrated on the sides of the pool between the crest of the weir and the channel wall. The highest TKE value for the conventional and the rectangular labyrinth weir was 0.224 and 0.278 J/kg, respectively, at the highest bottom slope (S0 = 10%).
  • For a given discharge, bottom slope, and weir spacing, the average values of TI are higher for the rectangular labyrinth weir than for the conventional weir. At the highest discharge, the average range of turbulence intensity (TI) for the conventional and rectangular labyrinth weirs was between 24 and 45% and 15% and 62%, respectively. This reveals that the rectangular labyrinth weir may generate more turbulent flow conditions within the fishway.
  • For a given discharge and constant bottom slope, the rectangular labyrinth weir has a higher energy dissipation rate than the conventional weir (22.75 and 34.86%).
  • Increasing the distance between weirs decreased volumetric energy dissipation. However, increasing the gradient increased volumetric energy dissipation. The presence of an opening in the weir resulted in a decrease in volumetric energy dissipation for both model types.

Availability of data and materials

Data is contained within the article.

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Study on the critical sediment concentration determining the optimal transport capability of submarine sediment flows with different particle size composition

Study on the critical sediment concentration determining the optimal transport capability of submarine sediment flows with different particle size composition

Yupeng Ren abc, Huiguang Zhou cd, Houjie Wang ab, Xiao Wu ab, Guohui Xu cd, Qingsheng Meng cd

Abstract

해저 퇴적물 흐름은 퇴적물을 심해로 운반하는 주요 수단 중 하나이며, 종종 장거리를 이동하고 수십 또는 수백 킬로미터에 걸쳐 상당한 양의 퇴적물을 운반합니다. 그것의 강력한 파괴력은 종종 이동 과정에서 잠수함 유틸리티에 심각한 손상을 초래합니다.

퇴적물 흐름의 퇴적물 농도는 주변 해수와의 밀도차를 결정하며, 이 밀도 차이는 퇴적물 흐름의 흐름 능력을 결정하여 이송된 퇴적물의 최종 퇴적 위치에 영향을 미칩니다. 본 논문에서는 다양한 미사 및 점토 중량비(미사/점토 비율이라고 함)를 갖는 다양한 퇴적물 농도의 퇴적물 흐름을 수로 테스트를 통해 연구합니다.

우리의 테스트 결과는 특정 퇴적물 구성에 대해 퇴적물 흐름이 가장 빠르게 이동하는 임계 퇴적물 농도가 있음을 나타냅니다. 4가지 미사/점토 비율 각각에 대한 임계 퇴적물 농도와 이에 상응하는 최대 속도가 구해집니다. 결과는 점토 함량이 임계 퇴적물 농도와 선형적으로 음의 상관 관계가 있음을 나타냅니다.

퇴적물 농도가 증가함에 따라 퇴적물의 흐름 거동은 흐름 상태에서 붕괴된 상태로 변환되고 흐름 거동이 변화하는 두 탁한 현탁액의 유체 특성은 모두 Bingham 유체입니다.

또한 본 논문에서는 퇴적물 흐름 내 입자 배열을 분석하여 위에서 언급한 결과에 대한 미시적 설명도 제공합니다.

Submarine sediment flows is one of the main means for transporting sediment to the deep sea, often traveling long-distance and transporting significant volumes of sediment for tens or even hundreds of kilometers. Its strong destructive force often causes serious damage to submarine utilities on its course of movement. The sediment concentration of the sediment flow determines its density difference with the ambient seawater, and this density difference determines the flow ability of the sediment flow, and thus affects the final deposition locations of the transported sediment. In this paper, sediment flows of different sediment concentration with various silt and clay weight ratios (referred to as silt/clay ratio) are studied using flume tests. Our test results indicate that there is a critical sediment concentration at which sediment flows travel the fastest for a specific sediment composition. The critical sediment concentrations and their corresponding maximum velocities for each of the four silt/clay ratios are obtained. The results further indicate that the clay content is linearly negatively correlated with the critical sediment concentration. As the sediment concentration increases, the flow behaviors of sediment flows transform from the flow state to the collapsed state, and the fluid properties of the two turbid suspensions with changing flow behaviors are both Bingham fluids. Additionally, this paper also provides a microscopic explanation of the above-mentioned results by analyzing the arrangement of particles within the sediment flow.

Introduction

Submarine sediment flows are important carriers for sea floor sediment movement and may carry and transport significant volumes of sediment for tens or even hundreds of kilometers (Prior et al., 1987; Pirmez and Imran, 2003; Zhang et al., 2018). Earthquakes, storms, and floods may all trigger submarine sediment flow events (Hsu et al., 2008; Piper and Normark, 2009; Pope et al., 2017b; Gavey et al., 2017). Sediment flows have strong forces during the movement, which will cause great harm to submarine structures such as cables and pipelines (Pope et al., 2017a). It was first confirmed that the cable breaking event caused by the sediment flow occurred in 1929. The sediment flow triggered by the Grand Banks earthquake damaged 12 cables. According to the time sequence of the cable breaking, the maximum velocity of the sediment flow is as high as 28 m/s (Heezen and Ewing, 1952; Kuenen, 1952; Heezen et al., 1954). Subsequent research shows that the lowest turbidity velocity that can break the cable also needs to reach 19 m/s (Piper et al., 1988). Since then, there have been many damage events of submarine cables and oil and gas pipelines caused by sediment flows in the world (Hsu et al., 2008; Carter et al., 2012; Cattaneo et al., 2012; Carter et al., 2014). During its movement, the sediment flow will gradually deposit a large amount of sediment carried by it along the way, that is, the deposition process of the sediment flow. On the one hand, this process brings a large amount of terrestrial nutrients and other materials to the ocean, while on the other hand, it causes damage and burial to benthic organisms, thus forming the largest sedimentary accumulation on Earth – submarine fans, which are highly likely to become good reservoirs for oil and gas resources (Daly, 1936; Yuan et al., 2010; Wu et al., 2022). The study on sediment flows (such as, the study of flow velocity and the forces acting on seabed structures) can provide important references for the safe design of seabed structures, the protection of submarine ecosystems, and exploration of turbidity sediments related oil and gas deposits. Therefore, it is of great significance to study the movement of sediment flows.

The sediment flow, as a highly sediment-concentrated fluid flowing on the sea floor, has a dense bottom layer and a dilute turbulent cloud. Observations at the Monterey Canyon indicated that the sediment flow can maintain its movement over long distances if its bottom has a relatively high sediment concentration. This dense bottom layer can be very destructive along its movement path to any facilities on the sea floor (Paull et al., 2018; Heerema et al., 2020; Wang et al., 2020). The sediment flow mentioned in this research paper is the general term of sediment density flow.

The sediment flow, which occurs on the seafloor, has the potential to cause erosion along its path. In this process, the suspended sediment is replenished, allowing the sediment flow to maintain its continuous flow capacity (Zhao et al., 2018). The dynamic force of sediment flow movement stem from its own gravity and density difference with surrounding water. In cases that the gravity drive of the slope is absent (on a flat sea floor), the flow velocity and distance of sediment flows are essentially determined by the sediment composition and concentration of the sediment flows as previous studies have demonstrated. Ilstad et al. (2004) conducted underwater flow tests in a sloped tank and employed high speed video camera to perform particle tracking. The results indicated that the premixed sand-rich and clay-rich slurries demonstrated different flow velocity and flow behavior. Using mixed kaolinite(d50 = 6 μm) and silica flour(d50 = 9 μm) in three compositions with total volumetric concentration ranged 22% or 28%, Felix and Peakall (2006) carried out underwater flow tests in a 5° slope Perspex channel and found that the flow ability of sediment flows is different depending on sediment compositions and concentrations. Sumner et al. (2009) used annular flume experiments to investigate the depositional dynamics and deposits of waning sediment-laden flows, finding that decelerating fast flows with fixed sand content and variable mud content resulted in four different deposit types. Chowdhury and Testik (2011) used lock-exchange tank, and experimented the kaolin clay sediment flows in the concentration range of 25–350 g/L, and predicted the fluid mud sediment flows propagation characteristics, but this study focused on giving sediment flows propagate phase transition time parameters, and is limited to clay. Lv et al. (2017) found through experiments that the rheological properties and flow behavior of kaolin clay (d50 = 3.7 μm) sediment flows were correlated to clay concentrations. In the field monitoring conducted by Liu et al. (2023) at the Manila Trench in the South China Sea in 2021, significant differences in the velocity, movement distance, and flow morphology of turbidity currents were observed. These differences may be attributed to variations in the particle composition of the turbidity currents.

On low and gentle slopes, although sediment flow with sand as the main sediment composition moves faster, it is difficult to propagate over long distances because sand has greater settling velocity and subaqueous angle of repose. Whereas the sediment flows with silt and clay as main composition may maintain relatively stable currents. Although its movement speed is slow, it has the ability to propagate over long distances because of the low settling rate of the fine particles (Ilstad et al., 2004; Liu et al., 2023). In a field observation at the Gaoping submarine canyon, the sediments collected from the sediment flows exhibited grain size gradation and the sediment was mostly composed of silt and clay (Liu et al., 2012). At the largest deltas in the world, for instance, the Mississippi River Delta, the sediments are mainly composed of silt and clay, which generally distributed along the coast in a wide range and provided the sediment sources for further distribution. The sediment flows originated and transported sediment from the coast to the deep sea are therefore share the same sediment compositions as delta sediments. To study the sediment flows composed of silt and clay is of great importance.

The sediment concentration of the sediment flows determines the density difference between the sediment flows and the ambient water and plays a key role in its flow ability. For the sediment flow with sediment composed of silt and clay, low sediment concentration means low density and therefore leads to low flow ability; however, although high sediment concentration results in high density, since there is cohesion between fine particles, it changes fluid properties and leads to low flow ability as well. Therefore, there should be a critical sediment concentration with mixed composition of silt and clay, at which the sediment flow maintains its strongest flow capacity and have the highest movement speed. In other words, the two characteristics of particle diameter and concentration of the sediment flow determine its own motion ability, which, if occurs, may become the most destructive force to submarine structures.

The objectives of this work was to study how the sediment composition (measured in relative weight of silt and clay, and referred as silt/clay ratio) and sediment concentration affect flow ability and behavior of the sediment flows, and to quantify the critical sediment concentration at which the sediment flows reached the greatest flow velocity under the experiment setting. We used straight flume without slope and conducted a series of flume tests with varying sediment compositions (silt-rich or clay-rich) and concentrations (96 to 1212 g/L). Each sediment flow sample was tested and analyzed for rheological properties using a rheometer, in order to characterize the relationship between flow behavior and rheological properties. Combined with the particle diameter, density and viscosity characteristics of the sediment flows measured in the experiment, a numerical modeling study is conducted, which are mutually validated with the experimental results.

The sediment concentration determines the arrangements of the sediment particles in the turbid suspension, and the arrangement impacts the fluid properties of the turbid suspension. The microscopic mode of particle arrangement in the turbid suspension can be constructed to further analyze the relationship between the fluid properties of turbid suspension and the flow behaviors of the sediment flow, and then characterize the critical sediment concentration at which the sediment flow runs the fastest. A simplified microscopic model of particle arrangement in turbid suspension was constructed to analyze the microscopic arrangement characteristics of sediment particles in turbid suspension with the fastest velocity.

Section snippets

Equipment and materials

The sediment flows flow experiments were performed in a Perspex channel with smooth transparent walls. The layout and dimensions of the experimental set-up were shown in Fig. 1. The bottom of the channel was flat and straight, and a gate was arranged to separate the two tanks. In order to study the flow capacity of turbidity currents from the perspective of their own composition (particle size distribution and concentration), we used a straight channel instead of an inclined one, to avoid any

Relationship between sediment flow flow velocity and sediment concentration

After the sediment flow is generated, its movement in the first half (50 cm) of the channel is relatively stable, and there is obvious shock diffusion in the second half. The reason is that the excitation wave (similar to the surge) will be formed during the sediment flow movement, and its speed is much faster than the speed of the sediment flow head. When the excitation wave reaches the tail of the channel, it will be reflected, thus affecting the subsequent flow of the sediment flow.

Sediment flows motion simulation based on FLOW-3D

As a relatively mature 3D fluid simulation software, FLOW-3D can accurately predict the free surface flow, and has been used to simulate the movement process of sediment flows for many times (Heimsund, 2007). The model adopted in this paper is RNG turbulence model, which can better deal with the flow with high strain rate and is suitable for the simulation of sediment flows with variable shape during movement. The governing equations of the numerical model involved include continuity equation,

Conclusions

In this study, we conducted a series of sediment flow flume tests with mixed silt and clay sediment samples in four silt/clay ratios on a flat slope. Rheological measurements were carried out on turbid suspension samples and microstructure analysis of the sediment particle arrangements was conducted, we concluded that:

  • (1)The flow velocity of the sediment flow is controlled by the sediment concentration and its own particle diameter composition, the flow velocity increased with the increase of the

Declaration of Competing Interest

The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.

Acknowledgements

This work was supported by the National Natural Science Foundation of China [Grant no. 42206055]; the National Natural Science Foundation of China [Grant no. 41976049]; and the National Natural Science Foundation of China [Grant no. 42272327].

References (39)

There are more references available in the full text version of this article.

Figure 1. Three-dimensional finite element model of local scouring of semi-exposed submarine cable.

반노출 해저케이블의 국부 정련과정 및 영향인자에 대한 수치적 연구

Numerical Study of the Local Scouring Process and Influencing Factors of Semi-Exposed Submarine Cables

by Qishun Li,Yanpeng Hao *,Peng Zhang,Haotian Tan,Wanxing Tian,Linhao Chen andLin Yang

School of Electric Power Engineering, South China University of Technology, Guangzhou 510640, China

*Author to whom correspondence should be addressed.J. Mar. Sci. Eng.202311(7), 1349; https://doi.org/10.3390/jmse11071349

Received: 10 June 2023 / Revised: 19 June 2023 / Accepted: 27 June 2023 / Published: 1 July 2023(This article belongs to the Section Ocean Engineering)

일부 수식이 손상되어 표시될 수 있습니다. 이 경우 원문을 참조하시기 바랍니다.

Abstract

Local scouring might result in the spanning of submarine cables, endangering their mechanical and electrical properties. In this contribution, a three-dimensional computational fluid dynamics simulation model is developed using FLOW-3D, and the scouring process of semi-exposed submarine cables is investigated. The effects of the sediment critical Shields number, sediment density, and ocean current velocity on local scouring are discussed, and variation rules for the submarine cables’ spanning time are provided. The results indicate that three scouring holes are formed around the submarine cables. The location of the bottom of the holes corresponds to that of the maximum shear velocity. The continuous development of scouring holes at the wake position leads to the spanning of the submarine cables. The increase in the sediment’s critical Shields number and sediment density, as well as the decrease in the ocean current velocity, will extend the time for maintaining the stability of the upstream scouring hole and retard the development velocity of the wake position and downstream scouring holes. The spanning time has a cubic relationship with the sediment’s critical Shields number, a linear relationship with the sediment density, and an exponential relationship with the ocean current velocity. In this paper, the local scouring process of semi-exposed submarine cables is studied, which provides a theoretical basis for the operation and maintenance of submarine cables.

Keywords: 

submarine cablelocal scouringnumerical simulationcomputational fluid dynamics

1. Introduction

As a key piece of equipment in cross-sea power grids, submarine cables are widely used to connect autonomous power grids, supply power to islands or offshore platforms, and transmit electric power generated by marine renewable energy installations to onshore substations [1]. Once submarine cables break down due to natural disasters or human-made damage, the normal operation of other marine electric power equipment connected to them may be affected. These chain reactions will cause great economic losses and serious social impacts [2].

To protect submarine cables, they are usually buried 1 to 3 m below the seabed [3]. However, submarine cables are still confronted with potential threats from the complex subsea environment. Under the influence of fishing, anchor damage, ocean current scouring, and other factors, the sediment above submarine cables will always inevitably migrate. When a submarine cable is partially exposed, the scouring at this position will be exacerbated; eventually, it will cause the submarine cable to span. According to a field investigation of the 500 kV oil-filled submarine cable that is part of the Hainan networking system, the total length of the span is 49 m [4]. Under strong ocean currents, spanning submarine cables may experience vortex-induced vibrations. Fatigue stress caused by vortex-induced vibrations may lead to metal sheath rupture [5], which endangers the mechanical and electrical properties of submarine cables. Therefore, understanding the local scouring processes of partially exposed submarine cables is crucial for predicting scouring patterns. This is the basis for developing effective operation and maintenance strategies for submarine cables.

The mechanism and influencing factors of sediment erosion have been examined by researchers around the world. In 1988, Sumer [6] conducted experiments to show that the shedding vortex in the wake of a pipeline would increase the Shields parameter by 3–4 times, which would result in severe scouring. In 1991, Chiew [7] performed experiments to prove that the maximum scouring depth could be obtained when the pipeline was located on a flat bed and was scoured by a unidirectional water flow. Based on the test results, they provided a prediction formula for the maximum scouring depth. In 2003, Mastbergen [8] proposed a one-dimensional, steady-state numerical model of turbidity currents, which considered the negative pore pressures in the seabed. The calculated results of this model were basically consistent with the actual scouring of a submarine canyon. In 2007, Dey [9] presented a semitheoretical model for the computation of the maximum clear-water scour depth below underwater pipelines in uniform sediments under a steady flow, and the predicted scour depth in clear water satisfactorily agreed with the observed values. In 2008, Dey [10] conducted experiments on clear-water scour below underwater pipelines under a steady flow and obtained a variation pattern of the depth of the scouring hole. In 2008, Liang [11] used a two-dimensional numerical simulation to study the scouring process of a tube bundle under the action of currents and waves. They discovered that, compared with the scouring of a single tube, the scouring depth of the tube bundle was deeper, and the scouring time was longer. In 2012, Yang [12] found that placing rubber sheets under pipes can greatly accelerate their self-burial. The rubber sheets had the best performance when their length was about 1.5 times the size of the pipe. In 2020, Li [13] investigated the two-dimensional local scour beneath two submarine pipelines in tandem under wave-plus-current conditions via numerical simulation. They found that for conditions involving waves plus a low-strength current, the scour pattern beneath the two pipelines behaved like that in the pure-wave condition. Conversely, when the current had equal strength to the wave-induced flow, the scour pattern beneath the two pipelines resembled that in the pure-current condition. In 2020, Guan [14] studied and discussed the interactive coupling effects among a vibrating pipeline, flow field, and scour process through experiments, and the experimental data showed that the evolution of the scour hole had significant influences on the pipeline vibrations. In 2021, Liu [15] developed a two-dimensional finite element numerical model and researched the local scour around a vibrating pipeline. The numerical results showed that the maximum vibration amplitude of the pipeline could reach about 1.2 times diameter, and the maximum scour depth occurred on the wake side of the vibrating pipeline. In 2021, Huang [16] carried out two-dimensional numerical simulations to investigate the scour beneath a single pipeline and piggyback pipelines subjected to an oscillatory flow condition at a KC number of 11 and captured typical steady-streaming structures around the pipelines due to the oscillatory flow condition. In 2021, Cui [17] investigated the characteristics of the riverbed scour profile for a pipeline buried at different depths under the condition of riverbed sediments with different particle sizes. The results indicated that, in general, the equilibrium scour depth changed in a spoon shape with the gradual increase in the embedment ratio. In 2022, Li [18] used numerical simulation to study the influence of the burial depth of partially buried pipelines on the surrounding flow field, but they did not investigate the scour depth. In 2022, Zhu [19] performed experiments to prove that the scour hole propagation rate under a pipeline decreases with an increasing pipeline embedment ratio and rises with the KC number. In 2022, Najafzadeh [20] proposed equations for the prediction of the scouring propagation rate around pipelines due to currents based on a machine learning model, and the prediction results were consistent with the experimental data. In 2023, Ma [21] used the computational fluid dynamics coarse-grained discrete element method to simulate the scour process around a pipeline. The results showed that this method can effectively reduce the considerable need for computing resources and excessive computation time. In 2023, through numerical simulations, Hu [22] discovered that the water velocity and the pipeline diameter had a significant effect on the depth of scouring.

In the preceding works, the researchers investigated the mechanism of sediment scouring and the effect of various factors on the local scouring of submarine pipelines. However, submarine cables are buried beneath the seabed, while submarine pipelines are erected above the seabed. The difference in laying methods leads to a large discrepancy between their local scouring processes. Therefore, the conclusions of the above investigations are not applicable to the local scouring of submarine cables. Currently, there is no report on the research of the local scouring of partially exposed submarine cables.

In this paper, a three-dimensional computational fluid dynamics (CFD) finite element model, based on two-phase flow, is established using FLOW-3D. The local scouring process of semi-exposed submarine cables under steady-state ocean currents is studied, and the variation rules of the depth and the shape of the scouring holes, as well as the shear velocity with time, are obtained. By setting different critical Shields numbers of the sediment, different sediment densities, and different ocean current velocities, the change rule of the scouring holes’ development rate and the time required for the spanning of submarine cables are explored.

2. Sediment Scouring Model

In the sediment scouring model, the sediment is set as the dispersed particle, which is regarded as a kind of quasifluid. In this context, sediment scouring is considered as a two-phase flow process between the liquid phase and solid particle phase. The sediment in this process is further divided into two categories: one is suspended in the fluid, and the other is deposited on the bottom.When the local Shields number of sediment is greater than the critical Shields number, the deposited sediment will be transformed into the suspended sediment under the action of ocean currents. The calculation formulae of the local Shields numbers θ and the critical Shields numbers 

θcr of sediment is given as [23,24

]

𝜃=𝑈2𝑓(𝜌𝑠/𝜌𝑓−1)𝑔𝑑50,�=��2(��/��−1)��50,(1)

𝜃𝑐𝑟=0.31+1.2𝐷∗+0.055(1−𝑒−0.02𝐷∗),���=0.31+1.2�*+0.055(1−�−0.02�*),(2)

𝐷∗=𝑑50𝜌𝑓(𝜌𝑠−𝜌𝑓)𝑔/𝜇2−−−−−−−−−−−−−−√3,�*=�50��(��−��)�/�23,(3)where 

Uf is the shearing velocity of bed surface, 

ρs is the density of the sediment particle, 

ρf is the fluid density, g is the acceleration of gravity, d

50 is the median size of sediment, and μ is the dynamic viscosity of sediment.And each sediment particle suspended in the fluid obeys the equations for mass conservation and energy conservation

∂𝑐𝑠∂𝑡+∇⋅(𝑢𝑐𝑠)=0,∂��∂�+∇⋅(�¯��)=0,(4)

∂𝑢𝑠∂𝑡+𝑢⋅∇𝑢𝑠=−1𝜌𝑠∇𝑃+𝐹−𝐾𝑓𝑠𝜌𝑠𝑢𝑟,∂��∂�+�¯⋅∇��=−1��∇�+�−�������,(5)where 

cs is the concentration of the sediment particle, 

𝑢�¯ is the mean velocity vector of the fluid and the sediment particle, 

us is the velocity of the sediment particle, 

fs is the volume fraction of the sediment particle, P is the pressure, F is the volumetric and viscous force, K is the drag force, and 

ur is the relative velocity.

3. Numerical Setup and Modeling

In this paper, a three-dimensional submarine cable local scouring simulation model is established by FLOW-3D. Based on the numerical simulation, the process of the submarine cable, which gradually changes from semi-exposed to the spanning state under the steady-state ocean current, is studied. The geometric modeling, the mesh division, the physical field setup, and the grid independent test of CFD numerical model are as follows.

3.1. Geometric Modeling and Mesh Division

A three-dimensional (3D) numerical model of the local scouring of a semi-exposed submarine cable is established, which is shown in Figure 1. The dimensions of the model are marked in Figure 1. The inlet direction of the ocean current is defined as the upstream of the submarine cable (referred to as upstream), and the outlet direction of the ocean current is defined as the downstream of the submarine cable (referred to as downstream).

Jmse 11 01349 g001 550

Figure 1. Three-dimensional finite element model of local scouring of semi-exposed submarine cable.

The submarine cable with a diameter of 0.2 m is positioned on sediment that is initially in a semi-exposed state. When the length of the span is short, the submarine cable will not show obvious deformation due to gravity or scouring from the ocean current. Therefore, the submarine cable surface is set as the fixed boundary. The model’s left boundary is set as the inlet, the right boundary is set as the outlet, the front and rear boundaries are set as symmetry, and the bottom boundary is set as the non-slip wall. Since the water depth above the submarine cable is more than 0.6 m in practice, the top boundary of the model is also set as symmetry. The sediment near the inlet and the outlet will be carried by ocean currents, which leads to the abnormal scouring terrain. At each end of the sediment, a baffle (thickness of 3 cm) is installed to ensure that the simulation results can reflect the real situation.

Due to the fact that the flow field around the semi-exposed submarine cable is not a simple two-dimensional symmetrical distribution, it should be solved by three-dimensional numerical simulation. Considering the accuracy and efficiency of the calculation, the size of mesh is set to 0.02 m. The total number of meshes after the dissection is 133,254.

3.2. Physical Field Setup

The CFD finite element model contains four physical field modules: sediment scouring module, gravity and non-inertial reference frame module, density evaluation module, and viscosity and turbulence module. In this paper, the renormalization group (RNG) kε turbulence model is used, which has high computational accuracy for turbulent vortices. Therefore, this turbulence model is suitable for calculating the sediment scouring process around the semi-exposed submarine cable [25]. The key parameters of the numerical simulation are referring to the survey results of submarine sediments in the Korean Peninsula [26], as listed in Table 1.Table 1. Key parameters of numerical simulation.

Table

3.3. Mesh Independent Test

In order to eliminate errors caused by the quantity of grids in the calculation process, two sizes of mesh are set on the validation model, and the scour profiles under different mesh sizes are compared. The validation model is shown in Figure 2, and the scouring terrain under different mesh size is given in Figure 3.

Jmse 11 01349 g002 550

Figure 2. Validation model.

Jmse 11 01349 g003 550

Figure 3. Scouring terrain under different mesh sizes.

It can be seen from Figure 3 that with the increase in the number of meshes, the scouring terrain of the verification model changes slightly, and the scouring depth is basically unchanged. Considering the accuracy of the numerical simulation and the calculation’s time cost, it is reasonable to consider setting the mesh size to 0.02 m.

4. Results and Analysis

4.1. Analysis of Local Scouring Process

Based on the CFD finite element numerical simulation, the local scouring process of the submarine cable under the steady-state ocean current is analyzed. The end time of the simulation is 9 h, the initial time step is 0.01 s, and the fluid velocity is 0.40 m/s. Simulation results are saved every minute. Figure 4 illustrates the scouring terrain around the semi-exposed submarine cable, which has been scoured by the steady-state current for 5 h.

Jmse 11 01349 g004 550

Figure 4. Scouring terrain around semi-exposed submarine cable (scour for 5 h).

As can be seen from Figure 4, three scouring holes were separately formed in the upstream wake position and downstream of the semi-exposed submarine cable. The scouring holes are labeled according to their locations. The variation of the scouring terrain around the semi-exposed submarine cable over time is given in Figure 5. The red circle in the picture corresponds to the position of the submarine cable, and the red box in the legend marks the time when the submarine cable is spanning.

Jmse 11 01349 g005 550

Figure 5. Variation of scouring terrain around semi-exposed submarine cable adapted to time.

From Figure 5, in the first hour of scouring, the upstream (−0.5 m to −0.1 m) and downstream (0.43 m to 1.5 m) scouring holes appeared. The upstream scouring hole was relatively flat with depth of 0.04 m. The depth of the downstream scouring hole increased with the increase in distance, and the maximum depth was 0.13 m. The scouring hole that developed at the wake position was very shallow, and its depth was only 0.007 m.

In the second hour of scouring, the upstream scouring hole’s depth remained nearly constant. The depth of the downstream scouring hole only increased by 0.002 m. The scouring hole at the wake position developed steadily, and its depth increased from 0.007 m to 0.014 m.

The upstream and downstream scouring holes did not continue to develop during the third to the sixth hour. Compared to the first two hours, the development of scouring holes at the wake position accelerated significantly, with an average growth rate of 0.028 m/h. The growth rate in the fifth hour of the scouring hole at the wake position was slightly faster than the other times. After 6 h of scouring, the sediment on the right side of the submarine cable had been hollowed out.

In the seventh and the eighth hour of scouring, the upstream scouring hole’s depth increased slightly, the downstream scouring hole still remained stable, and the depth of the scouring hole at wake position increased by 0.019 m. The sediment under the submarine cable was gradually eroded as well. By the end of the eighth hour, the lower right part of the submarine cable had been exposed to water as well.

At 8 h 21 min of the scouring, the submarine cable was completely spanned, and the scouring holes were connected to each other. Within the next 10 min, the development of the scouring holes sped up significantly, and the maximum depth of scouring holes increased greatly to 0.27 m.

In reference [17], researchers have studied the local scouring process of semi-buried pipelines in sandy riverbeds through experiments. The test results show that the scouring process can be divided into a start-up stage, micropore formation stage, extension stage, and equilibrium stage. In this paper, the first three stages are simulated, and the results are in good agreement with the experiment, which proves the accuracy of the present numerical model.

In this research, the velocity of ocean currents at the sediment surface is defined as the shear velocity, which plays an important role in the process of local scouring. Figure 6 provides visual data on how the shear velocity varies over time.

Jmse 11 01349 g006 550

Figure 6. Shear velocity changes in the scouring process.

The semi-exposed submarine cable protrudes from the seabed, which makes the shear velocity of its surface much higher than other locations. After the submarine cable is spanned, the shear velocity of the scouring hole surface below it is taken. This is the reason for the sudden change of shear velocity at the submarine cable’s location in Figure 6.The shear velocity in the initial state of the upstream scouring hole is obviously greater than in subsequent times. After 1 h of scouring, the shear velocity in the upstream scouring hole rapidly decreased from 1.1 × 10

−2 m/s to 3.98 × 10

−3 m/s and remained stable until the end of the sixth hour. This phenomenon explains why the upstream scouring hole developed rapidly in the first hour but remained stable for the following 5 h.The shear velocity in the downstream scouring hole reduced at first and then increased; its initial value was 1.41 × 10

−2 m/s. It took approximately 5 h for the shear velocity to stabilize, and the stable shear velocity was 2.26 × 10

−3 m/s. Therefore, compared with the upstream scouring hole, the downstream scouring hole was deeper and required more time to reach stability.The initial shear velocity in the scouring hole at the wake position was only 7.1 × 10

−3 m/s, which almost does not change in the first hour. This leads to a very slow development of the scouring hole at the wake position in the early stages. The maximum shear velocity in this scouring hole gradually increased to 1.05 × 10

−2 m/s from the second to the fifth hour, and then decreased to 6.61 × 10

−3 m/s by the end of the eighth hour. This is why the scouring hole at the wake position grows fastest around the fifth hour. Consistent with the pattern of change in the scouring hole’s terrain, the location of the maximal shear velocity also shifted to the right with time.

The shear velocity of all three scouring holes rose dramatically in the last hour. Combined with the terrain in Figure 5, this can be attributed to the complete spanning of the submarine cable.

From Equations (3)–(5), one can see the movement of the sediment is related directly with the sediment’s critical Shields number, sediment density, and ocean current velocity. Based on the parameters in Table 1, the influence of the above parameters on the local scouring process of semi-exposed submarine cables will be discussed.

4.2. Influence Factors

4.2.1. Sediment’s Critical Shields Number

The sediment’s critical Shields number 

θcr is set as 0.02, 0.03, 0.04, 0.05, 0.06, and 0.07, and the variations of scouring terrain over time under each 

θcr are displayed in Figure 7.

Jmse 11 01349 g007 550

Figure 7. Influence of sediment’s critical Shields number 

θcr on local scouring around semi-exposed submarine cable: (a

θcr = 0.02; (b

θcr = 0.03; (c

θcr = 0.04; (d

θcr = 0.05; (e

θcr = 0.06; and (f

θcr = 0.07.From Figure 7, one can see that a change in 

θcr will affect the depth of the upstream scouring hole and the development speed of the scouring hole at the wake position, but it will have no significant impact on the expansion of the downstream scouring hole.Under conditions of different 

θcr, the upstream scouring hole will reach a temporary plateau within 1 h, at which time the stable depth will be about 0.04 m. When 

θcr ≤ 0.05, the upstream scouring hole will continue to expand after a few hours. The stable time is obviously affected by 

θcr, which will gradually increase from 1 h to 11 h with the increase in 

θcr. The terrain of the upstream scouring hole will gradually convert to deep on the left and to shallow on the right. Since the scouring hole at the wake position has not been stable, its state at the time of submarine cable spanning is studied emphatically. In the whole process of scouring, the scouring hole at the wake position continues to develop and does not reach a stable state. With the increase in 

θcr, the development velocity of the scouring hole at the wake position will decrease considerably. Its average evolution velocity decreases from 3.88 cm/h to 1.62 cm/h, and its depth decreases from 21.9 cm to 18.8 cm. Under the condition of each 

θcr, the downstream scouring hole will stabilize within 1 h, and the stable depth will be basically unchanged (all about 13.5 cm).As 

θcr increases, so does the sediment’s ability to withstand shearing forces, which will cause it to become increasingly difficult to be eroded or carried away by ocean currents. This effect has been directly reflected in the depth of scouring holes (upstream and wake position). Due to the blocking effect of semi-exposed submarine cables, the wake is elongated, which is why the downstream scouring hole develops before the scouring hole at the wake position and quickly reaches a stable state. However, due to the high wake intensity, this process is not significantly affected by the change of 

θcr.

4.2.2. Sediment Density

The density of sediment 

ρs is set as 1550 kg/m

3, 1600 kg/m

3, 1650 kg/m

3, 1700 kg/m

3, 1750 kg/m

3, and 1800 kg/m

3, and the variation of scouring terrain over time under each 

ρs are displayed in Figure 8.

Jmse 11 01349 g008 550

Figure 8. Influence of sediment density 

ρs on local scouring around semi-exposed submarine cable: (a

ρs = 1550 kg/m

3; (bρs = 1600 kg/m

3; (cρs = 1650 kg/m

3; (dρs = 1700 kg/m

3; (eρs = 1750 kg/m

3; and (f

ρs = 1800 kg/m

3.From Figure 8, one can see that a change in 

ρs will also affect the depth of the upstream scouring hole and the development speed of the scouring hole at the wake position. In addition, it can even have an impact on the downstream scouring hole depth.Under different 

ρs conditions, the upstream scouring hole will always reach a temporary stable state in 1 h, at which time the stable depth will be 0.04 m. When 

ρs ≤ 1750 kg/m

3, the upstream scouring hole will continue to expand after a few hours. The stabilization time of upstream scouring hole is more clearly affected by 

ρs, which will gradually increase from 3 h to 13 h with the increase in 

ρs. The terrain of the upstream scouring hole will gradually change to deep on the left and to shallow on the right. Since the scouring hole at the wake position has not been stable, its state at the time of the submarine cable spanning is studied emphatically, too. In the whole process of scouring, the scouring hole at the wake position continues to develop and does not reach a stable state. When 

ρs is large, the development rate of scouring hole obviously decreased with time. With the increase in 

ρs, the development velocity of the scouring hole at the wake position reduces from 3.38 cm/h to 1.14 cm/h, and the depth of this scouring hole declines from 20 cm to 15 cm. As 

ρs increases, the stabilization time of the downstream scouring hole increases from less than 1 h to about 2 h, but the stabilization depth of the downstream scouring hole remains essentially the same (all around 13.5 cm).As can be seen from Equation (1), the increase in 

ρs will reduce the Shields number, thus weakening the shear action of the sediment by the ocean current, which explains the extension of the stability time of the upstream scouring hole. At the same time, with the increase in the depth of scouring hole at the wake position, its shear velocity will decreases. Therefore, under a larger 

ρs value, the development speed of scouring hole at the wake position will decrease significantly with time. Possibly for the same reason, 

ρs can affect the development rate of downstream scouring hole.

4.2.3. Ocean Current Velocity

The ocean current velocity v is set as 0.35 m/s, 0.40 m/s, 0.45 m/s, 0.50 m/s, 0.55 m/s, and 0.60 m/s. Figure 9 presents the variation in scouring terrain with time for each v.

Jmse 11 01349 g009 550

Figure 9. Influence of ocean current velocity v on local scouring around semi-exposed submarine cable: (av = 0.35 m/s; (bv = 0.40 m/s; (cv = 0.45 m/s; (dv = 0.50 m/s; (ev = 0.55 m/s; and (fv = 0.60 m/s.

Changes in v affect the depth of the upstream and downstream scouring holes, as well as the development velocity of the wake position and downstream scouring holes.

When v ≤ 0.45 m/s, the upstream scouring hole will reach a temporary stable state within 1 h, at which point the stable depth will be 0.04 m. The stabilization time of the upstream scouring hole is affected by v, which will gradually decrease from 15 h to 3 h with the increase in v. When v > 0.45 m/s, the upstream scouring hole is going to expand continuously. With the increase in v, its average development velocity increases from 6.68 cm/h to 8.66 cm/h, and its terrain changes to deep on the left and to shallow on the right. When the submarine cable is spanning, special attention should be paid to the depth of the scouring hole at the wake position. Throughout whole scouring process, the scouring hole at the wake position continues to develop and does not reach a stable state. With the increase in v, the depth of scouring hole at the wake position will increase from 14 cm to 20 cm, and the average development velocity will increase from 0.91 cm/h to 10.43 cm/h. As v increases, the time required to stabilize the downstream scouring hole is shortened from 1to 2 h to less than 1 h, but the stable depth is remains nearly constant at 13.5 cm.

An increase in v will increase the shear velocity. Therefore, when the depth of the scouring hole increases, the shear velocity in the hole will also increase, which can deepen both the upstream and downstream scouring hole. According to Equation (1), the Shields number is proportional to the square of the shear velocity. The increase in shear velocity significantly intensifies local scouring, which increases the development rate of scouring holes at the wake position and downstream.

4.3. Variation Rule of Spanning Time

In this paper, the spanning time is defined as the time taken for a semi-exposed submarine cable (initial state) to become a spanning submarine cable. Figure 10 illustrates the effect of the above parameters on the spanning time of the semi-exposed submarine cable.

Jmse 11 01349 g010 550

Figure 10. Influence of different parameters on spanning time of the semi-exposed submarine cable: (a) Sediment critical Shields number; (b) Sediment density; and (c) Ocean current velocity.From Figure 10a, the spanning time monotonically increases with the increase in the critical Shields number of sediment. However, the slope of the curve decreases first and then increases, and the inflection point is at 

θcr = 4.59 × 10

−2. The relationship between spanning time t and sediment’s critical Shields number 

θcr can be formulated by a cubic function as shown in Equation (6):

𝑡=−2.98+6.76𝜃𝑐𝑟−1.45𝜃2𝑐𝑟+0.11𝜃3𝑐𝑟.�=−2.98+6.76���−1.45���2+0.11���3.(6)It can be seen from Figure 10b that with the increase in the sediment density, the spanning time increases monotonically and linearly. The relationship between the spanning time t and the sediment’s density 

ρs can be formulated by the first order function as shown in Equation (7):

𝑡=−41.59+30.54𝜌𝑠.�=−41.59+30.54��.(7)Figure 10c shows that with the increase in the ocean current velocity, the spanning time decreases monotonically. The slope of the curve increases with the increase in the ocean current velocity, so it can be considered that there is saturation of the ocean current velocity effect. The relationship between the spanning time t and the ocean current velocity v can be formulated by the exponential function

𝑡=0.15𝑣−4.38.�=0.15�−4.38.(8)

5. Conclusions

In this paper, a three-dimensional CFD finite element numerical simulation model is established, which is used to research the local scouring process of the semi-exposed submarine cable under the steady-state ocean current. The relationship between shear velocity and scouring terrain is discussed, the influence of sediment critical Shields number, sediment density and ocean current velocity on the local scouring process is analyzed, and the variation rules of the spanning time of the semi-exposed submarine cable is given. The conclusions are as follows:

  • Under the steady-state ocean currents, scouring holes will be formed at the upstream, wake position and downstream of the semi-exposed submarine cable. The upstream and downstream scouring holes develop faster, which will reach a temporary stable state at about 1 h after the start of the scouring. The scouring hole at the wake position will continue to expand at a slower rate and eventually lead to the spanning of the submarine cable.
  • There is a close relationship between the distribution of shear velocity and the scouring terrain. As the local scouring process occurs, the location of the maximum shear velocity within the scouring hole shifts and causes the bottom of the hole to move as well.
  • When the sediment’s critical Shields number and density are significantly large and ocean current velocity is sufficiently low, the duration of the stable state of the upstream scouring hole will be prolonged, and the average development velocity of the scouring holes at the wake position and downstream will be reduced.
  • The relationship between the spanning time and the critical Shields number θcr can be formulated as a cubic function, in which the curve’s inflection point is θcr = 4.59 × 10−2. The relationship between spanning time and sediment density can be formulated as a linear function. The relationship between spanning time and ocean current velocity can be formulated by exponential function.

Based on the conclusions of this paper, even when it is too late to take measures or when the exposed position of the submarine cable cannot be located, the degree of burial depth development still can be predicted. This prediction is important for the operation and maintenance of the submarine cable. However, the study still leaves something to be desired. Only the local scouring process under the steady-state ocean current was studied, which is an extreme condition. In practice, exposed submarine cables are more likely to be scoured by reciprocating ocean currents. In the future, we will investigate the local scouring of submarine cables under the reciprocating ocean current.

Author Contributions

Conceptualization, Y.H. and Q.L.; methodology, Q.L., P.Z. and H.T.; software, Q.L.; validation, Q.L., L.C. and W.T.; writing—original draft preparation, Q.L.; writing—review and editing, Y.H. and Q.L.; supervision, Y.H. and L.Y. All authors have read and agreed to the published version of the manuscript.

Funding

This research was funded by the [Smart Grid Joint Fund Key Project between National Natural Science Foundation of China and State Grid Corporation] grant number [U1766220].

Institutional Review Board Statement

Not applicable.

Informed Consent Statement

Not applicable.

Data Availability Statement

The data supporting the reported results cannot be shared at this time, as they have been used in producing more publications on this research.

Acknowledgments

This work is supported by the Smart Grid Joint Fund Key Project of the National Natural Science Foundation of China and State Grid Corporation (Grant No. U1766220).

Conflicts of Interest

The authors declare no conflict of interest.

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Validity evaluation of popular liquid-vapor phase change models for cryogenic self-pressurization process

극저온 자체 가압 공정을 위한 인기 있는 액체-증기 상 변화 모델의 타당성 평가

액체-증기 상 변화 모델은 밀폐된 용기의 자체 가압 프로세스 시뮬레이션에 매우 큰 영향을 미칩니다. Hertz-Knudsen 관계, 에너지 점프 모델 및 그 파생물과 같은 널리 사용되는 액체-증기 상 변화 모델은 실온 유체를 기반으로 개발되었습니다. 액체-증기 전이를 통한 극저온 시뮬레이션에 널리 적용되었지만 각 모델의 성능은 극저온 조건에서 명시적으로 조사 및 비교되지 않았습니다. 본 연구에서는 171가지 일반적인 액체-증기 상 변화 모델을 통합한 통합 다상 솔버가 제안되었으며, 이를 통해 이러한 모델을 실험 데이터와 직접 비교할 수 있습니다. 증발 및 응축 모델의 예측 정확도와 계산 속도를 평가하기 위해 총 <>개의 자체 가압 시뮬레이션이 수행되었습니다. 압력 예측은 최적화 전략이 서로 다른 모델 계수에 크게 의존하는 것으로 나타났습니다. 에너지 점프 모델은 극저온 자체 가압 시뮬레이션에 적합하지 않은 것으로 나타났습니다. 평균 편차와 CPU 소비량에 따르면 Lee 모델과 Tanasawa 모델은 다른 모델보다 안정적이고 효율적인 것으로 입증되었습니다.

Elsevier

International Journal of Heat and Mass Transfer

Volume 181, December 2021, 121879

International Journal of Heat and Mass Transfer

Validity evaluation of popular liquid-vapor phase change models for cryogenic self-pressurization process

Author links open overlay panelZhongqi Zuo, Jingyi Wu, Yonghua HuangShow moreAdd to MendeleyShareCite

https://doi.org/10.1016/j.ijheatmasstransfer.2021.121879Get rights and content

Abstract

Liquid-vapor phase change models vitally influence the simulation of self-pressurization processes in closed containers. Popular liquid-vapor phase change models, such as the Hertz-Knudsen relation, energy jump model, and their derivations were developed based on room-temperature fluids. Although they had widely been applied in cryogenic simulations with liquid-vapor transitions, the performance of each model was not explicitly investigated and compared yet under cryogenic conditions. A unified multi-phase solver incorporating four typical liquid-vapor phase change models has been proposed in the present study, which enables direct comparison among those models against experimental data. A total number of 171 self-pressurization simulations were conducted to evaluate the evaporation and condensation models’ prediction accuracy and calculation speed. It was found that the pressure prediction highly depended on the model coefficients, whose optimization strategies differed from each other. The energy jump model was found inadequate for cryogenic self-pressurization simulations. According to the average deviation and CPU consumption, the Lee model and the Tanasawa model were proven to be more stable and more efficient than the others.

Introduction

The liquid-vapor phase change of cryogenic fluids is widely involved in industrial applications, such as the hydrogen transport vehicles [1], shipborne liquid natural gas (LNG) containers [2] and on-orbit cryogenic propellant tanks [3]. These applications require cryogenic fluids to be stored for weeks to months. Although high-performance insulation measures are adopted, heat inevitably enters the tank via radiation and conduction. The self-pressurization in the tank induced by the heat leakage eventually causes the venting loss of the cryogenic fluids and threatens the safety of the craft in long-term missions. To reduce the boil-off loss and extend the cryogenic storage duration, a more comprehensive understanding of the self-pressurization mechanism is needed.

Due to the difficulties and limitations in implementing cryogenic experiments, numerical modeling is a convenient and powerful way to study the self-pressurization process of cryogenic fluids. However, how the phase change models influence the mass and heat transfer under cryogenic conditions is still unsettled [4]. As concluded by Persad and Ward [5], a seemingly slight variation in the liquid-vapor phase change models can lead to erroneous predictions.

Among the liquid-vapor phase change models, the kinetic theory gas (KTG) based models and the energy jump model are the most popular ones used in recent self-pressurization simulations [6]. The KTG based models, also known as the Hertz-Knudsen relation models, were developed on the concept of the Maxwell-Boltzmann distribution of the gas molecular [7]. The Hertz-Knudsen relation has evolved to several models, including the Schrage model [8], the Tanasawa model [9], the Lee model [10] and the statistical rate theory (SRT) [11], which will be described in Section 2.2. Since the Schrage model and the Lee model are embedded and configured as the default ones in the commercial CFD solvers Flow-3D® and Ansys Fluent® respectively, they have been widely used in self-pressurization simulations for liquid nitrogen [12], [13] and liquid hydrogen [14], [15]. The major drawback of the KTG models lies in the difficulty of selecting model coefficients, which were reported in a considerably wide range spanning three magnitudes even for the same working fluid [16], [17], [18], [19], [20], [21]. Studies showed that the liquid level, pressure and mass transfer rate are directly influenced by the model coefficients [16], [22], [23], [24], [25]. Wrong coefficients will lead to deviation or even divergence of the results. The energy jump model is also known as the thermal limitation model. It assumes that the evaporation and condensation at the liquid-vapor interface are induced only by heat conduction. The model is widely adopted in lumped node simulations due to its simplicity [6], [26], [27]. To improve the accuracy of mass flux prediction, the energy jump model was modified by including the convection heat transfer [28], [29]. However, the convection correlations are empirical and developed mainly for room-temperature fluids. Whether the correlation itself can be precisely applied in cryogenic simulations still needs further investigation.

Fig. 1 summarizes the cryogenic simulations involving the modeling of evaporation and condensation processes in recent years. The publication has been increasing rapidly. However, the characteristics of each evaporation and condensation model are not explicitly revealed when simulating self-pressurization. A comparative study of the phase change models is highly needed for cryogenic fluids for a better simulation of the self-pressurization processes.

In the present paper, a unified multi-phase solver incorporating four typical liquid-vapor phase change models, namely the Tanasawa model, the Lee model, the energy jump model, and the modified energy jump model has been proposed, which enables direct comparison among different models. The models are used to simulate the pressure and temperature evolutions in an experimental liquid nitrogen tank in normal gravity, which helps to evaluate themselves in the aspects of accuracy, calculation speed and robustness.

Section snippets

Governing equations for the self-pressurization tank

In the present study, both the fluid domain and the solid wall of the tank are modeled and discretized. The heat transportation at the solid boundaries is considered to be irrelevant with the nearby fluid velocity. Consequently, two sets of the solid and the fluid governing equations can be decoupled and solved separately. The pressures in the cryogenic container are usually from 100 kPa to 300 kPa. Under these conditions, the Knudsen number is far smaller than 0.01, and the fluids are

Self-pressurization results and phase change model comparison

This section compares the simulation results by different phase change models. Section 3.1 compares the pressure and temperature outputs from two KTG based models, namely the Lee model and the Tanasawa model. Section 3.2 presents the pressure predictions from the energy transport models, namely the energy jump model and the modified energy jump model, and compares pressure prediction performances between the KTG based models and the energy transport models. Section 3.3 evaluates the four models 

Conclusion

A unified vapor-liquid-solid multi-phase numerical solver has been accomplished for the self pressurization simulation in cryogenic containers. Compared to the early fluid-only solver, the temperature prediction in the vicinity of the tank wall improves significantly. Four liquid-vapor phase change models were integrated into the solver, which enables fair and effective comparison for performances between each other. The pressure and temperature prediction accuracies, and the calculation speed

CRediT authorship contribution statement

Zhongqi Zuo: Data curation, Formal analysis, Writing – original draft, Validation. Jingyi Wu: Conceptualization, Writing – review & editing, Validation. Yonghua Huang: Conceptualization, Formal analysis, Writing – review & editing, Validation.

Declaration of Competing Interest

Authors declare that they have no financial and personal relationships with other people or organizations that can inappropriately influence our work, there is no professional or other personal interest of any nature or kind in any product, service and/or company that could be construed as influencing the position presented in, or the review of, the manuscript entitled, “Validity evaluation of popular liquid-vapor phase change models for cryogenic self-pressurization process”.

Acknowledgement

This project is supported by the National Natural Science Foundation of China (No. 51936006).

References (40)

There are more references available in the full text version of this article.

Cited by (7)

Figure 11. Sketch of scour mechanism around USAF under random waves.

Scour Characteristics and Equilibrium Scour Depth Prediction around Umbrella Suction Anchor Foundation under Random Waves

by Ruigeng Hu 1,Hongjun Liu 2,Hao Leng 1,Peng Yu 3 andXiuhai Wang 1,2,*

1College of Environmental Science and Engineering, Ocean University of China, Qingdao 266000, China

2Key Lab of Marine Environment and Ecology (Ocean University of China), Ministry of Education, Qingdao 266000, China

3Qingdao Geo-Engineering Survering Institute, Qingdao 266100, China

*Author to whom correspondence should be addressed.

J. Mar. Sci. Eng. 20219(8), 886; https://doi.org/10.3390/jmse9080886

Received: 6 July 2021 / Revised: 8 August 2021 / Accepted: 13 August 2021 / Published: 17 August 2021

(This article belongs to the Section Ocean Engineering)

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Abstract

A series of numerical simulation were conducted to study the local scour around umbrella suction anchor foundation (USAF) under random waves. In this study, the validation was carried out firstly to verify the accuracy of the present model. Furthermore, the scour evolution and scour mechanism were analyzed respectively. In addition, two revised models were proposed to predict the equilibrium scour depth Seq around USAF. At last, a parametric study was carried out to study the effects of the Froude number Fr and Euler number Eu for the Seq. The results indicate that the present numerical model is accurate and reasonable for depicting the scour morphology under random waves. The revised Raaijmakers’s model shows good agreement with the simulating results of the present study when KCs,p < 8. The predicting results of the revised stochastic model are the most favorable for n = 10 when KCrms,a < 4. The higher Fr and Eu both lead to the more intensive horseshoe vortex and larger Seq.

Keywords: 

scournumerical investigationrandom wavesequilibrium scour depthKC number

1. Introduction

The rapid expansion of cities tends to cause social and economic problems, such as environmental pollution and traffic jam. As a kind of clean energy, offshore wind power has developed rapidly in recent years. The foundation of offshore wind turbine (OWT) supports the upper tower, and suffers the cyclic loading induced by waves, tides and winds, which exerts a vital influence on the OWT system. The types of OWT foundation include the fixed and floating foundation, and the fixed foundation was used usually for nearshore wind turbine. After the construction of fixed foundation, the hydrodynamic field changes in the vicinity of the foundation, leading to the horseshoe vortex formation and streamline compression at the upside and sides of foundation respectively [1,2,3,4]. As a result, the neighboring soil would be carried away by the shear stress induced by vortex, and the scour hole would emerge in the vicinity of foundation. The scour holes increase the cantilever length, and weaken the lateral bearing capacity of foundation [5,6,7,8,9]. Moreover, the natural frequency of OWT system increases with the increase of cantilever length, causing the resonance occurs when the system natural frequency equals the wave or wind frequency [10,11,12]. Given that, an innovative foundation called umbrella suction anchor foundation (USAF) has been designed for nearshore wind power. The previous studies indicated the USAF was characterized by the favorable lateral bearing capacity with the low cost [6,13,14]. The close-up of USAF is shown in Figure 1, and it includes six parts: 1-interal buckets, 2-external skirt, 3-anchor ring, 4-anchor branch, 5-supporting rod, 6-telescopic hook. The detailed description and application method of USAF can be found in reference [13].

Jmse 09 00886 g001 550

Figure 1. The close-up of umbrella suction anchor foundation (USAF).

Numerical and experimental investigations of scour around OWT foundation under steady currents and waves have been extensively studied by many researchers [1,2,15,16,17,18,19,20,21,22,23,24]. The seabed scour can be classified as two types according to Shields parameter θ, i.e., clear bed scour (θ < θcr) or live bed scour (θ > θcr). Due to the set of foundation, the adverse hydraulic pressure gradient exists at upstream foundation edges, resulting in the streamline separation between boundary layer flow and seabed. The separating boundary layer ascended at upstream anchor edges and developed into the horseshoe vortex. Then, the horseshoe vortex moved downstream gradually along the periphery of the anchor, and the vortex shed off continually at the lee-side of the anchor, i.e., wake vortex. The core of wake vortex is a negative pressure center, liking a vacuum cleaner. Hence, the soil particles were swirled into the negative pressure core and carried away by wake vortexes. At the same time, the onset of scour at rear side occurred. Finally, the wake vortex became downflow when the turbulence energy could not support the survival of wake vortex. According to Tavouktsoglou et al. [25], the scale of pile wall boundary layer is proportional to 1/ln(Rd) (Rd is pile Reynolds), which means the turbulence intensity induced by the flow-structure interaction would decrease with Rd increases, but the effects of Rd can be neglected only if the flow around the foundation is fully turbulent [26]. According to previous studies [1,15,27,28,29,30,31,32], the scour development around pile foundation under waves was significantly influenced by Shields parameter θ and KC number simultaneously (calculated by Equation (1)). Sand ripples widely existed around pile under waves in the case of live bed scour, and the scour morphology is related with θ and KC. Compared with θKC has a greater influence on the scour morphology [21,27,28]. The influence mechanism of KC on the scour around the pile is reflected in two aspects: the horseshoe vortex at upstream and wake vortex shedding at downstream.

KC=UwmTD��=�wm��(1)

where, Uwm is the maximum velocity of the undisturbed wave-induced oscillatory flow at the sea bottom above the wave boundary layer, T is wave period, and D is pile diameter.

There are two prerequisites to satisfy the formation of horseshoe vortex at upstream pile edges: (1) the incoming flow boundary layer with sufficient thickness and (2) the magnitude of upstream adverse pressure gradient making the boundary layer separating [1,15,16,18,20]. The smaller KC results the lower adverse pressure gradient, and the boundary layer cannot separate, herein, there is almost no horseshoe vortex emerging at upside of pile. Sumer et al. [1,15] carried out several sets of wave flume experiments under regular and irregular waves respectively, and the experiment results show that there is no horseshoe vortex when KC is less than 6. While the scale and lifespan of horseshoe vortex increase evidently with the increase of KC when KC is larger than 6. Moreover, the wake vortex contributes to the scour at lee-side of pile. Similar with the case of horseshoe vortex, there is no wake vortex when KC is less than 6. The wake vortex is mainly responsible for scour around pile when KC is greater than 6 and less than O(100), while horseshoe vortex controls scour nearly when KC is greater than O(100).

Sumer et al. [1] found that the equilibrium scour depth was nil around pile when KC was less than 6 under regular waves for live bed scour, while the equilibrium scour depth increased with the increase of KC. Based on that, Sumer proposed an equilibrium scour depth predicting equation (Equation (2)). Carreiras et al. [33] revised Sumer’s equation with m = 0.06 for nonlinear waves. Different with the findings of Sumer et al. [1] and Carreiras et al. [33], Corvaro et al. [21] found the scour still occurred for KC ≈ 4, and proposed the revised equilibrium scour depth predicting equation (Equation (3)) for KC > 4.

Rudolph and Bos [2] conducted a series of wave flume experiments to investigate the scour depth around monopile under waves only, waves and currents combined respectively, indicting KC was one of key parameters in influencing equilibrium scour depth, and proposed the equilibrium scour depth predicting equation (Equation (4)) for low KC (1 < KC < 10). Through analyzing the extensive data from published literatures, Raaijmakers and Rudolph [34] developed the equilibrium scour depth predicting equation (Equation (5)) for low KC, which was suitable for waves only, waves and currents combined. Khalfin [35] carried out several sets of wave flume experiments to study scour development around monopile, and proposed the equilibrium scour depth predicting equation (Equation (6)) for low KC (0.1 < KC < 3.5). Different with above equations, the Khalfin’s equation considers the Shields parameter θ and KC number simultaneously in predicting equilibrium scour depth. The flow reversal occurred under through in one wave period, so sand particles would be carried away from lee-side of pile to upside, resulting in sand particles backfilled into the upstream scour hole [20,29]. Considering the backfilling effects, Zanke et al. [36] proposed the equilibrium scour depth predicting equation (Equation (7)) around pile by theoretical analysis, and the equation is suitable for the whole range of KC number under regular waves and currents combined.

S/D=1.3(1−exp([−m(KC−6)])�/�=1.3(1−exp(−�(��−6))(2)

where, m = 0.03 for linear waves.

S/D=1.3(1−exp([−0.02(KC−4)])�/�=1.3(1−exp(−0.02(��−4))(3)

S/D=1.3γKwaveKhw�/�=1.3��wave�ℎw(4)

where, γ is safety factor, depending on design process, typically γ = 1.5, Kwave is correction factor considering wave action, Khw is correction factor considering water depth.

S/D=1.5[tanh(hwD)]KwaveKhw�/�=1.5tanh(ℎw�)�wave�ℎw(5)

where, hw is water depth.

S/D=0.0753(θθcr−−−√−0.5)0.69KC0.68�/�=0.0753(��cr−0.5)0.69��0.68(6)

where, θ is shields parameter, θcr is critical shields parameter.

S/D=2.5(1−0.5u/uc)xrelxrel=xeff/(1+xeff)xeff=0.03(1−0.35ucr/u)(KC−6)⎫⎭⎬⎪⎪�/�=2.5(1−0.5�/��)��������=����/(1+����)����=0.03(1−0.35�cr/�)(��−6)(7)

where, u is near-bed orbital velocity amplitude, uc is critical velocity corresponding the onset of sediment motion.

S/D=1.3{1−exp[−0.03(KC2lnn+36)1/2−6]}�/�=1.31−exp−0.03(��2ln�+36)1/2−6(8)

where, n is the 1/n’th highest wave for random waves

For predicting equilibrium scour depth under irregular waves, i.e., random waves, Sumer and Fredsøe [16] found it’s suitable to take Equation (2) to predict equilibrium scour depth around pile under random waves with the root-mean-square (RMS) value of near-bed orbital velocity amplitude Um and peak wave period TP to calculate KC. Khalfin [35] recommended the RMS wave height Hrms and peak wave period TP were used to calculate KC for Equation (6). References [37,38,39,40] developed a series of stochastic theoretical models to predict equilibrium scour depth around pile under random waves, nonlinear random waves plus currents respectively. The stochastic approach thought the 1/n’th highest wave were responsible for scour in vicinity of pile under random waves, and the KC was calculated in Equation (8) with Um and mean zero-crossing wave period Tz. The results calculated by Equation (8) agree well with experimental values of Sumer and Fredsøe [16] if the 1/10′th highest wave was used. To author’s knowledge, the stochastic approach proposed by Myrhaug and Rue [37] is the only theoretical model to predict equilibrium scour depth around pile under random waves for the whole range of KC number in published documents. Other methods of predicting scour depth under random waves are mainly originated from the equation for regular waves-only, waves and currents combined, which are limited to the large KC number, such as KC > 6 for Equation (2) and KC > 4 for Equation (3) respectively. However, situations with relatively low KC number (KC < 4) often occur in reality, for example, monopile or suction anchor for OWT foundations in ocean environment. Moreover, local scour around OWT foundations under random waves has not yet been investigated fully. Therefore, further study are still needed in the aspect of scour around OWT foundations with low KC number under random waves. Given that, this study presents the scour sediment model around umbrella suction anchor foundation (USAF) under random waves. In this study, a comparison of equilibrium scour depth around USAF between this present numerical models and the previous theoretical models and experimental results was presented firstly. Then, this study gave a comprehensive analysis for the scour mechanisms around USAF. After that, two revised models were proposed according to the model of Raaijmakers and Rudolph [34] and the stochastic model developed by Myrhaug and Rue [37] respectively to predict the equilibrium scour depth. Finally, a parametric study was conducted to study the effects of the Froude number (Fr) and Euler number (Eu) to equilibrium scour depth respectively.

2. Numerical Method

2.1. Governing Equations of Flow

The following equations adopted in present model are already available in Flow 3D software. The authors used these theoretical equations to simulate scour in random waves without modification. The incompressible viscous fluid motion satisfies the Reynolds-averaged Navier-Stokes (RANS) equation, so the present numerical model solves RANS equations:

∂u∂t+1VF(uAx∂u∂x+vAy∂u∂y+wAz∂u∂z)=−1ρf∂p∂x+Gx+fx∂�∂�+1��(���∂�∂�+���∂�∂�+���∂�∂�)=−1�f∂�∂�+��+��(9)

∂v∂t+1VF(uAx∂v∂x+vAy∂v∂y+wAz∂v∂z)=−1ρf∂p∂y+Gy+fy∂�∂�+1��(���∂�∂�+���∂�∂�+���∂�∂�)=−1�f∂�∂�+��+��(10)

∂w∂t+1VF(uAx∂w∂x+vAy∂w∂y+wAz∂w∂z)=−1ρf∂p∂z+Gz+fz∂�∂�+1��(���∂�∂�+���∂�∂�+���∂�∂�)=−1�f∂�∂�+��+��(11)

where, VF is the volume fraction; uv, and w are the velocity components in xyz direction respectively with Cartesian coordinates; Ai is the area fraction; ρf is the fluid density, fi is the viscous fluid acceleration, Gi is the fluid body acceleration (i = xyz).

2.2. Turbulent Model

The turbulence closure is available by the turbulent model, such as one-equation, the one-equation k-ε model, the standard k-ε model, RNG k-ε turbulent model and large eddy simulation (LES) model. The LES model requires very fine mesh grid, so the computational time is large, which hinders the LES model application in engineering. The RNG k-ε model can reduce computational time greatly with high accuracy in the near-wall region. Furthermore, the RNG k-ε model computes the maximum turbulent mixing length dynamically in simulating sediment scour model. Therefore, the RNG k-ε model was adopted to study the scour around anchor under random waves [41,42].

∂kT∂T+1VF(uAx∂kT∂x+vAy∂kT∂y+wAz∂kT∂z)=PT+GT+DiffkT−εkT∂��∂�+1��(���∂��∂�+���∂��∂�+���∂��∂�)=��+��+������−���(12)

∂εT∂T+1VF(uAx∂εT∂x+vAy∂εT∂y+wAz∂εT∂z)=CDIS1εTkT(PT+CDIS3GT)+Diffε−CDIS2ε2TkT∂��∂�+1��(���∂��∂�+���∂��∂�+���∂��∂�)=����1����(��+����3��)+�����−����2��2��(13)

where, kT is specific kinetic energy involved with turbulent velocity, GT is the turbulent energy generated by buoyancy; εT is the turbulent energy dissipating rate, PT is the turbulent energy, Diffε and DiffkT are diffusion terms associated with VFAiCDIS1CDIS2 and CDIS3 are dimensionless parameters, and CDIS1CDIS3 have default values of 1.42, 0.2 respectively. CDIS2 can be obtained from PT and kT.

2.3. Sediment Scour Model

The sand particles may suffer four processes under waves, i.e., entrainment, bed load transport, suspended load transport, and deposition, so the sediment scour model should depict the above processes efficiently. In present numerical simulation, the sediment scour model includes the following aspects:

2.3.1. Entrainment and Deposition

The combination of entrainment and deposition determines the net scour rate of seabed in present sediment scour model. The entrainment lift velocity of sand particles was calculated as [43]:

ulift,i=αinsd0.3∗(θ−θcr)1.5∥g∥di(ρi−ρf)ρf−−−−−−−−−−−−√�lift,i=�����*0.3(�−�cr)1.5���(��−�f)�f(14)

where, αi is the entrainment parameter, ns is the outward point perpendicular to the seabed, d* is the dimensionless diameter of sand particles, which was calculated by Equation (15), θcr is the critical Shields parameter, g is the gravity acceleration, di is the diameter of sand particles, ρi is the density of seabed species.

d∗=di(∥g∥ρf(ρi−ρf)μ2f)1/3�*=��(��f(��−�f)�f2)1/3(15)

where μf is the fluid dynamic viscosity.

In Equation (14), the entrainment parameter αi confirms the rate at which sediment erodes when the given shear stress is larger than the critical shear stress, and the recommended value 0.018 was adopted according to the experimental data of Mastbergen and Von den Berg [43]. ns is the outward pointing normal to the seabed interface, and ns = (0,0,1) according to the Cartesian coordinates used in present numerical model.

The shields parameter was obtained from the following equation:

θ=U2f,m(ρi/ρf−1)gd50�=�f,m2(��/�f−1)��50(16)

where, Uf,m is the maximum value of the near-bed friction velocity; d50 is the median diameter of sand particles. The detailed calculation procedure of θ was available in Soulsby [44].

The critical shields parameter θcr was obtained from the Equation (17) [44]

θcr=0.31+1.2d∗+0.055[1−exp(−0.02d∗)]�cr=0.31+1.2�*+0.0551−exp(−0.02�*)(17)

The sand particles begin to deposit on seabed when the turbulence energy weaken and cann’t support the particles suspending. The setting velocity of the particles was calculated from the following equation [44]:

usettling,i=νfdi[(10.362+1.049d3∗)0.5−10.36]�settling,�=�f��(10.362+1.049�*3)0.5−10.36(18)

where νf is the fluid kinematic viscosity.

2.3.2. Bed Load Transport

This is called bed load transport when the sand particles roll or bounce over the seabed and always have contact with seabed. The bed load transport velocity was computed by [45]:

ubedload,i=qb,iδicb,ifb�bedload,�=�b,����b,��b(19)

where, qb,i is the bed load transport rate, which was obtained from Equation (20), δi is the bed load thickness, which was calculated by Equation (21), cb,i is the volume fraction of sand i in the multiple species, fb is the critical packing fraction of the seabed.

qb,i=8[∥g∥(ρi−ρfρf)d3i]1/2�b,�=8�(��−�f�f)��31/2(20)

δi=0.3d0.7∗(θθcr−1)0.5di��=0.3�*0.7(��cr−1)0.5��(21)

2.3.3. Suspended Load Transport

Through the following transport equation, the suspended sediment concentration could be acquired.

∂Cs,i∂t+∇(us,iCs,i)=∇∇(DfCs,i)∂�s,�∂�+∇(�s,��s,�)=∇∇(�f�s,�)(22)

where, Cs,i is the suspended sand particles mass concentration of sand i in the multiple species, us,i is the sand particles velocity of sand iDf is the diffusivity.

The velocity of sand i in the multiple species could be obtained from the following equation:

us,i=u¯¯+usettling,ics,i�s,�=�¯+�settling,��s,�(23)

where, u¯�¯ is the velocity of mixed fluid-particles, which can be calculated by the RANS equation with turbulence model, cs,i is the suspended sand particles volume concentration, which was computed from Equation (24).

cs,i=Cs,iρi�s,�=�s,���(24)

3. Model Setup

The seabed-USAF-wave three-dimensional scour numerical model was built using Flow-3D software. As shown in Figure 2, the model includes sandy seabed, USAF model, sea water, two baffles and porous media. The dimensions of USAF are shown in Table 1. The sandy bed (210 m in length, 30 m in width and 11 m in height) is made up of uniform fine sand with median diameter d50 = 0.041 cm. The USAF model includes upper steel tube with the length of 20 m, which was installed in the middle of seabed. The location of USAF is positioned at 140 m from the upstream inflow boundary and 70 m from the downstream outflow boundary. Two baffles were installed at two ends of seabed. In order to eliminate the wave reflection basically, the porous media was set at the outflow side on the seabed.

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Figure 2. (a) The sketch of seabed-USAF-wave three-dimensional model; (b) boundary condation:Wv-wave boundary, S-symmetric boundary, O-outflow boundary; (c) USAF model.

Table 1. Numerical simulating cases.

Table

3.1. Mesh Geometric Dimensions

In the simulation of the scour under the random waves, the model includes the umbrella suction anchor foundation, seabed and fluid. As shown in Figure 3, the model mesh includes global mesh grid and nested mesh grid, and the total number of grids is 1,812,000. The basic procedure for building mesh grid consists of two steps. Step 1: Divide the global mesh using regular hexahedron with size of 0.6 × 0.6. The global mesh area is cubic box, embracing the seabed and whole fluid volume, and the dimensions are 210 m in length, 30 m in width and 32 m in height. The details of determining the grid size can see the following mesh sensitivity section. Step 2: Set nested fine mesh grid in vicinity of the USAF with size of 0.3 × 0.3 so as to shorten the computation cost and improve the calculation accuracy. The encryption range is −15 m to 15 m in x direction, −15 m to 15 m in y direction and 0 m to 32 m in z direction, respectively. In order to accurately capture the free-surface dynamics, such as the fluid-air interface, the volume of fluid (VOF) method was adopted for tracking the free water surface. One specific algorithm called FAVORTM (Fractional Area/Volume Obstacle Representation) was used to define the fractional face areas and fractional volumes of the cells which are open to fluid flow.

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Figure 3. The sketch of mesh grid.

3.2. Boundary Conditions

As shown in Figure 2, the initial fluid length is 210 m as long as seabed. A wave boundary was specified at the upstream offshore end. The details of determining the random wave spectrum can see the following wave parameters section. The outflow boundary was set at the downstream onshore end. The symmetry boundary was used at the top and two sides of the model. The symmetric boundaries were the better strategy to improve the computation efficiency and save the calculation cost [46]. At the seabed bottom, the wall boundary was adopted, which means the u = v = w= 0. Besides, the upper steel tube of USAF was set as no-slip condition.

3.3. Wave Parameters

The random waves with JONSWAP wave spectrum were used for all simulations as realistic representation of offshore conditions. The unidirectional JONSWAP frequency spectrum was described as [47]:

S(ω)=αg2ω5exp[−54(ωpω)4]γexp[−(ω−ωp)22σ2ω2p]�(�)=��2�5exp−54(�p�)4�exp−(�−�p)22�2�p2(25)

where, α is wave energy scale parameter, which is calculated by Equation (26), ω is frequency, ωp is wave spectrum peak frequency, which can be obtained from Equation (27). γ is wave spectrum peak enhancement factor, in this study γ = 3.3. σ is spectral width factor, σ equals 0.07 for ω ≤ ωp and 0.09 for ω > ωp respectively.

α=0.0076(gXU2)−0.22�=0.0076(���2)−0.22(26)

ωp=22(gU)(gXU2)−0.33�p=22(��)(���2)−0.33(27)

where, X is fetch length, U is average wind velocity at 10 m height from mean sea level.

In present numerical model, the input key parameters include X and U for wave boundary with JONSWAP wave spectrum. The objective wave height and period are available by different combinations of X and U. In this study, we designed 9 cases with different wave heights, periods and water depths for simulating scour around USAF under random waves (see Table 2). For random waves, the wave steepness ε and Ursell number Ur were acquired form Equations (28) and (29) respectively

ε=2πgHsT2a�=2���s�a2(28)

Ur=Hsk2h3w�r=�s�2ℎw3(29)

where, Hs is significant wave height, Ta is average wave period, k is wave number, hw is water depth. The Shield parameter θ satisfies θ > θcr for all simulations in current study, indicating the live bed scour prevails.

Table 2. Numerical simulating cases.

Table

3.4. Mesh Sensitivity

In this section, a mesh sensitivity analysis was conducted to investigate the influence of mesh grid size to results and make sure the calculation is mesh size independent and converged. Three mesh grid size were chosen: Mesh 1—global mesh grid size of 0.75 × 0.75, nested fine mesh grid size of 0.4 × 0.4, and total number of grids 1,724,000, Mesh 2—global mesh grid size of 0.6 × 0.6, nested fine mesh grid size of 0.3 × 0.3, and total number of grids 1,812,000, Mesh 3—global mesh grid size of 0.4 × 0.4, nested fine mesh grid size of 0.2 × 0.2, and total number of grids 1,932,000. The near-bed shear velocity U* is an important factor for influencing scour process [1,15], so U* at the position of (4,0,11.12) was evaluated under three mesh sizes. As the Figure 4 shown, the maximum error of shear velocity ∆U*1,2 is about 39.8% between the mesh 1 and mesh 2, and 4.8% between the mesh 2 and mesh 3. According to the mesh sensitivity criterion adopted by Pang et al. [48], it’s reasonable to think the results are mesh size independent and converged with mesh 2. Additionally, the present model was built according to prototype size, and the mesh size used in present model is larger than the mesh size adopted by Higueira et al. [49] and Corvaro et al. [50]. If we choose the smallest cell size, it will take too much time. For example, the simulation with Mesh3 required about 260 h by using a computer with Intel Xeon Scalable Gold 4214 CPU @24 Cores, 2.2 GHz and 64.00 GB RAM. Therefore, in this case, considering calculation accuracy and computation efficiency, the mesh 2 was chosen for all the simulation in this study.

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Figure 4. Comparison of near-bed shear velocity U* with different mesh grid size.

The nested mesh block was adopted for seabed in vicinity of the USAF, which was overlapped with the global mesh block. When two mesh blocks overlap each other, the governing equations are by default solved on the mesh block with smaller average cell size (i.e., higher grid resolution). It is should be noted that the Flow 3D software used the moving mesh captures the scour evolution and automatically adjusts the time step size to be as large as possible without exceeding any of the stability limits, affecting accuracy, or unduly increasing the effort required to enforce the continuity condition [51].

3.5. Model Validation

In order to verify the reliability of the present model, the results of present study were compared with the experimental data of Khosronejad et al. [52]. The experiment was conducted in an open channel with a slender vertical pile under unidirectional currents. The comparison of scour development between the present results and the experimental results is shown in Figure 5. The Figure 5 reveals that the present results agree well with the experimental data of Khosronejad et al. [52]. In the first stage, the scour depth increases rapidly. After that, the scour depth achieves a maximum value gradually. The equilibrium scour depth calculated by the present model is basically corresponding with the experimental results of Khosronejad et al. [52], although scour depth in the present model is slightly larger than the experimental results at initial stage.

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Figure 5. Comparison of time evolution of scour between the present study and Khosronejad et al. [52], Petersen et al. [17].

Secondly, another comparison was further conducted between the results of present study and the experimental data of Petersen et al. [17]. The experiment was carried out in a flume with a circular vertical pile in combined waves and current. Figure 4 shows a comparison of time evolution of scour depth between the simulating and the experimental results. As Figure 5 indicates, the scour depth in this study has good overall agreement with the experimental results proposed in Petersen et al. [17]. The equilibrium scour depth calculated by the present model is 0.399 m, which equals to the experimental value basically. Overall, the above verifications prove the present model is accurate and capable in dealing with sediment scour under waves.

In addition, in order to calibrate and validate the present model for hydrodynamic parameters, the comparison of water surface elevation was carried out with laboratory experiments conducted by Stahlmann [53] for wave gauge No. 3. The Figure 6 depicts the surface wave profiles between experiments and numerical model results. The comparison indicates that there is a good agreement between the model results and experimental values, especially the locations of wave crest and trough. Comparison of the surface elevation instructs the present model has an acceptable relative error, and the model is a calibrated in terms of the hydrodynamic parameters.

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Figure 6. Comparison of surface elevation between the present study and Stahlmann [53].

Finally, another comparison was conducted for equilibrium scour depth or maximum scour depth under random waves with the experimental data of Sumer and Fredsøe [16] and Schendel et al. [22]. The Figure 7 shows the comparison between the numerical results and experimental data of Run01, Run05, Run21 and Run22 in Sumer and Fredsøe [16] and test A05 and A09 in Schendel et al. [22]. As shown in Figure 7, the equilibrium scour depth or maximum scour depth distributed within the ±30 error lines basically, meaning the reliability and accuracy of present model for predicting equilibrium scour depth around foundation in random waves. However, compared with the experimental values, the present model overestimated the equilibrium scour depth generally. Given that, a calibration for scour depth was carried out by multiplying the mean reduced coefficient 0.85 in following section.

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Figure 7. Comparison of equilibrium (or maximum) scour depth between the present study and Sumer and Fredsøe [16], Schendel et al. [22].

Through the various examination for hydrodynamic and morphology parameters, it can be concluded that the present model is a validated and calibrated model for scour under random waves. Thus, the present numerical model would be utilized for scour simulation around foundation under random waves.

4. Numerical Results and Discussions

4.1. Scour Evolution

Figure 8 displays the scour evolution for case 1–9. As shown in Figure 8a, the scour depth increased rapidly at the initial stage, and then slowed down at the transition stage, which attributes to the backfilling occurred in scour holes under live bed scour condition, resulting in the net scour decreasing. Finally, the scour reached the equilibrium state when the amount of sediment backfilling equaled to that of scouring in the scour holes, i.e., the net scour transport rate was nil. Sumer and Fredsøe [16] proposed the following formula for the scour development under waves

St=Seq(1−exp(−t/Tc))�t=�eq(1−exp(−�/�c))(30)

where Tc is time scale of scour process.

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Figure 8. Time evolution of scour for case 1–9: (a) Case 1–5; (b) Case 6–9.

The computing time is 3600 s and the scour development curves in Figure 8 kept fluctuating, meaning it’s still not in equilibrium scour stage in these cases. According to Sumer and Fredsøe [16], the equilibrium scour depth can be acquired by fitting the data with Equation (30). From Figure 8, it can be seen that the scour evolution obtained from Equation (30) is consistent with the present study basically at initial stage, but the scour depth predicted by Equation (30) developed slightly faster than the simulating results and the Equation (30) overestimated the scour depth to some extent. Overall, the whole tendency of the results calculated by Equation (30) agrees well with the simulating results of the present study, which means the Equation (30) is applicable to depict the scour evolution around USAF under random waves.

4.2. Scour Mechanism under Random Waves

The scour morphology and scour evolution around USAF are similar under random waves in case 1~9. Taking case 7 as an example, the scour morphology is shown in Figure 9.

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Figure 9. Scour morphology under different times for case 7.

From Figure 9, at the initial stage (t < 1200 s), the scour occurred at upstream foundation edges between neighboring anchor branches. The maximum scour depth appeared at the lee-side of the USAF. Correspondingly, the sediments deposited at the periphery of the USAF, and the location of the maximum accretion depth was positioned at an angle of about 45° symmetrically with respect to the wave propagating direction in the lee-side of the USAF. After that, when t > 2400 s, the location of the maximum scour depth shifted to the upside of the USAF at an angle of about 45° with respect to the wave propagating direction.

According to previous studies [1,15,16,19,30,31], the horseshoe vortex, streamline compression and wake vortex shedding were responsible for scour around foundation. The Figure 10 displays the distribution of flow velocity in vicinity of foundation, which reflects the evolving processes of horseshoe vertex.

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Figure 10. Velocity profile around USAF: (a) Flow runup and down stream at upstream anchor edges; (b) Horseshoe vortex at upstream anchor edges; (c) Flow reversal during wave through stage at lee side.

As shown in Figure 10, the inflow tripped to the upstream edges of the USAF and it was blocked by the upper tube of USAF. Then, the downflow formed the horizontal axis clockwise vortex and rolled on the seabed bypassing the tube, that is, the horseshoe vortex (Figure 11). The Figure 12 displays the turbulence intensity around the tube on the seabed. From Figure 12, it can be seen that the turbulence intensity was high-intensity with respect to the region of horseshoe vortex. This phenomenon occurred because of drastic water flow momentum exchanging in the horseshoe vortex. As a result, it created the prominent shear stress on the seabed, causing the local scour at the upstream edges of USAF. Besides, the horseshoe vortex moved downstream gradually along the periphery of the tube and the wake vortex shed off continually at the lee-side of the USAF, i.e., wake vortex.

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Figure 11. Sketch of scour mechanism around USAF under random waves.

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Figure 12. Turbulence intensity: (a) Turbulence intensity of horseshoe vortex; (b) Turbulence intensity of wake vortex; (c) Turbulence intensity of accretion area.

The core of wake vortex is a negative pressure center, liking a vacuum cleaner [11,42]. Hence, the soil particles were swirled into the negative pressure core and carried away by wake vortex. At the same time, the onset of scour at rear side occurred. Finally, the wake vortex became downflow at the downside of USAF. As is shown in Figure 12, the turbulence intensity was low where the downflow occurred at lee-side, which means the turbulence energy may not be able to support the survival of wake vortex, leading to accretion happening. As mentioned in previous section, the formation of horseshoe vortex was dependent with adverse pressure gradient at upside of foundation. As shown in Figure 13, the evaluated range of pressure distribution is −15 m to 15 m in x direction. The t = 450 s and t = 1800 s indicate that the wave crest and trough arrived at the upside and lee-side of the foundation respectively, and the t = 350 s was neither the wave crest nor trough. The adverse gradient pressure reached the maximum value at t = 450 s corresponding to the wave crest phase. In this case, it’s helpful for the wave boundary separating fully from seabed, which leads to the formation of horseshoe vortex with high turbulence intensity. Therefore, the horseshoe vortex is responsible for the local scour between neighboring anchor branches at upside of USAF. What’s more, due to the combination of the horseshoe vortex and streamline compression, the maximum scour depth occurred at the upside of the USAF with an angle of about 45° corresponding to the wave propagating direction. This is consistent with the findings of Pang et al. [48] and Sumer et al. [1,15] in case of regular waves. At the wave trough phase (t = 1800 s), the pressure gradient became positive at upstream USAF edges, which hindered the separating of wave boundary from seabed. In the meantime, the flow reversal occurred (Figure 10) and the adverse gradient pressure appeared at downstream USAF edges, but the magnitude of adverse gradient pressure at lee-side was lower than the upstream gradient pressure under wave crest. In this way, the intensity of horseshoe vortex behind the USAF under wave trough was low, which explains the difference of scour depth at upstream and downstream, i.e., the scour asymmetry. In other words, the scour asymmetry at upside and downside of USAF was attributed to wave asymmetry for random waves, and the phenomenon became more evident for nonlinear waves [21]. Briefly speaking, the vortex system at wave crest phase was mainly related to the scour process around USAF under random waves.

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Figure 13. Pressure distribution around USAF.

4.3. Equilibrium Scour Depth

The KC number is a key parameter for horseshoe vortex emerging and evolving under waves. According to Equation (1), when pile diameter D is fixed, the KC depends on the maximum near-bed velocity Uwm and wave period T. For random waves, the Uwm can be denoted by the root-mean-square (RMS) value of near-bed velocity amplitude Uwm,rms or the significant value of near-bed velocity amplitude Uwm,s. The Uwm,rms and Uwm,s for all simulating cases of the present study are listed in Table 3 and Table 4. The T can be denoted by the mean up zero-crossing wave period Ta, peak wave period Tp, significant wave period Ts, the maximum wave period Tm, 1/10′th highest wave period Tn = 1/10 and 1/5′th highest wave period Tn = 1/5 for random waves, so the different combinations of Uwm and T will acquire different KC. The Table 3 and Table 4 list 12 types of KC, for example, the KCrms,s was calculated by Uwm,rms and Ts. Sumer and Fredsøe [16] conducted a series of wave flume experiments to investigate the scour depth around monopile under random waves, and found the equilibrium scour depth predicting equation (Equation (2)) for regular waves was applicable for random waves with KCrms,p. It should be noted that the Equation (2) is only suitable for KC > 6 under regular waves or KCrms,p > 6 under random waves.

Table 3. Uwm,rms and KC for case 1~9.

Table

Table 4. Uwm,s and KC for case 1~9.

Table

Raaijmakers and Rudolph [34] proposed the equilibrium scour depth predicting model (Equation (5)) around pile under waves, which is suitable for low KC. The format of Equation (5) is similar with the formula proposed by Breusers [54], which can predict the equilibrium scour depth around pile at different scour stages. In order to verify the applicability of Raaijmakers’s model for predicting the equilibrium scour depth around USAF under random waves, a validation of the equilibrium scour depth Seq between the present study and Raaijmakers’s equation was conducted. The position where the scour depth Seq was evaluated is the location of the maximum scour depth, and it was depicted in Figure 14. The Figure 15 displays the comparison of Seq with different KC between the present study and Raaijmakers’s model.

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Figure 14. Sketch of the position where the Seq was evaluated.

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Figure 15. Comparison of the equilibrium scour depth between the present model and the model of Raaijmakers and Rudolph [34]: (aKCrms,sKCrms,a; (bKCrms,pKCrms,m; (cKCrms,n = 1/10KCrms,n = 1/5; (dKCs,sKCs,a; (eKCs,pKCs,m; (fKCs,n = 1/10KCs,n = 1/5.

As shown in Figure 15, there is an error in predicting Seq between the present study and Raaijmakers’s model, and Raaijmakers’s model underestimates the results generally. Although the error exists, the varying trend of Seq with KC obtained from Raaijmakers’s model is consistent with the present study basically. What’s more, the error is minimum and the Raaijmakers’s model is of relatively high accuracy for predicting scour around USAF under random waves by using KCs,p. Based on this, a further revision was made to eliminate the error as much as possible, i.e., add the deviation value ∆S/D in the Raaijmakers’s model. The revised equilibrium scour depth predicting equation based on Raaijmakers’s model can be written as

S′eq/D=1.95[tanh(hD)](1−exp(−0.012KCs,p))+ΔS/D�eq′/�=1.95tanh(ℎ�)(1−exp(−0.012��s,p))+∆�/�(31)

As the Figure 16 shown, through trial-calculation, when ∆S/D = 0.05, the results calculated by Equation (31) show good agreement with the simulating results of the present study. The maximum error is about 18.2% and the engineering requirements have been met basically. In order to further verify the accuracy of the revised model for large KC (KCs,p > 4) under random waves, a validation between the revised model and the previous experimental results [21]. The experiment was conducted in a flume (50 m in length, 1.0 m in width and 1.3 m in height) with a slender vertical pile (D = 0.1 m) under random waves. The seabed is composed of 0.13 m deep layer of sand with d50 = 0.6 mm and the water depth is 0.5 m for all tests. The significant wave height is 0.12~0.21 m and the KCs,p is 5.52~11.38. The comparison between the predicting results by Equation (31) and the experimental results of Corvaro et al. [21] is shown in Figure 17. From Figure 17, the experimental data evenly distributes around the predicted results and the prediction accuracy is favorable when KCs,p < 8. However, the gap between the predicting results and experimental data becomes large and the Equation (31) overestimates the equilibrium scour depth to some extent when KCs,p > 8.

Jmse 09 00886 g016 550

Figure 16. Comparison of Seq between the simulating results and the predicting values by Equation (31).

Jmse 09 00886 g017 550

Figure 17. Comparison of Seq/D between the Experimental results of Corvaro et al. [21] and the predicting values by Equation (31).

In ocean environment, the waves are composed of a train of sinusoidal waves with different frequencies and amplitudes. The energy of constituent waves with very large and very small frequencies is relatively low, and the energy of waves is mainly concentrated in a certain range of moderate frequencies. Myrhaug and Rue [37] thought the 1/n’th highest wave was responsible for scour and proposed the stochastic model to predict the equilibrium scour depth around pile under random waves for full range of KC. Noteworthy is that the KC was denoted by KCrms,a in the stochastic model. To verify the application of the stochastic model for predicting scour depth around USAF, a validation between the simulating results of present study and predicting results by the stochastic model with n = 2,3,5,10,20,500 was carried out respectively.

As shown in Figure 18, compared with the simulating results, the stochastic model underestimates the equilibrium scour depth around USAF generally. Although the error exists, the varying trend of Seq with KCrms,a obtained from the stochastic model is consistent with the present study basically. What’s more, the gap between the predicting values by stochastic model and the simulating results decreases with the increase of n, but for large n, for example n = 500, the varying trend diverges between the predicting values and simulating results, meaning it’s not feasible only by increasing n in stochastic model to predict the equilibrium scour depth around USAF.

Jmse 09 00886 g018 550

Figure 18. Comparison of Seq between the simulating results and the predicting values by Equation (8).

The Figure 19 lists the deviation value ∆Seq/D′ between the predicting values and simulating results with different KCrms,a and n. Then, fitted the relationship between the ∆S′and n under different KCrms,a, and the fitting curve can be written by Equation (32). The revised stochastic model (Equation (33)) can be acquired by adding ∆Seq/D′ to Equation (8).

ΔSeq/D=0.052*exp(−n/6.566)+0.068∆�eq/�=0.052*exp(−�/6.566)+0.068(32)

S′eq¯/D=S′eq/D+0.052*exp(−n/6.566)+0.068�eq′¯/�=�eq′/�+0.052*exp(−�/6.566)+0.068(33)

Jmse 09 00886 g019 550

Figure 19. The fitting line between ∆S′and n.

The comparison between the predicting results by Equation (33) and the simulating results of present study is shown in Figure 20. According to the Figure 20, the varying trend of Seq with KCrms,a obtained from the stochastic model is consistent with the present study basically. Compared with predicting results by the stochastic model, the results calculated by Equation (33) is favorable. Moreover, comparison with simulating results indicates that the predicting results are the most favorable for n = 10, which is consistent with the findings of Myrhaug and Rue [37] for equilibrium scour depth predicting around slender pile in case of random waves.

Jmse 09 00886 g020 550

Figure 20. Comparison of Seq between the simulating results and the predicting values by Equation (33).

In order to further verify the accuracy of the Equation (33) for large KC (KCrms,a > 4) under random waves, a validation was conducted between the Equation (33) and the previous experimental results of Sumer and Fredsøe [16] and Corvaro et al. [21]. The details of experiments conducted by Corvaro et al. [21] were described in above section. Sumer and Fredsøe [16] investigated the local scour around pile under random waves. The experiments were conducted in a wave basin with a slender vertical pile (D = 0.032, 0.055 m). The seabed is composed of 0.14 m deep layer of sand with d50 = 0.2 mm and the water depth was maintained at 0.5 m. The JONSWAP wave spectrum was used and the KCrms,a was 5.29~16.95. The comparison between the predicting results by Equation (33) and the experimental results of Sumer and Fredsøe [16] and Corvaro et al. [21] are shown in Figure 21. From Figure 21, contrary to the case of low KCrms,a (KCrms,a < 4), the error between the predicting values and experimental results increases with decreasing of n for KCrms,a > 4. Therefore, the predicting results are the most favorable for n = 2 when KCrms,a > 4.

Jmse 09 00886 g021 550

Figure 21. Comparison of Seq between the experimental results of Sumer and Fredsøe [16] and Corvaro et al. [21] and the predicting values by Equation (33).

Noteworthy is that the present model was built according to prototype size, so the errors between the numerical results and experimental data of References [16,21] may be attribute to the scale effects. In laboratory experiments on scouring process, it is typically impossible to ensure a rigorous similarity of all physical parameters between the model and prototype structure, leading to the scale effects in the laboratory experiments. To avoid a cohesive behaviour, the bed material was not scaled geometrically according to model scale. As a consequence, the relatively large-scaled sediments sizes may result in the overestimation of bed load transport and underestimation of suspended load transport compared with field conditions. What’s more, the disproportional scaled sediment presumably lead to the difference of bed roughness between the model and prototype, and thus large influences for wave boundary layer on the seabed and scour process. Besides, according to Corvaro et al. [21] and Schendel et al. [55], the pile Reynolds numbers and Froude numbers both affect the scour depth for the condition of non fully developed turbulent flow in laboratory experiments.

4.4. Parametric Study

4.4.1. Influence of Froude Number

As described above, the set of foundation leads to the adverse pressure gradient appearing at upstream, leading to the wave boundary layer separating from seabed, then horseshoe vortex formatting and the horseshoe vortex are mainly responsible for scour around foundation (see Figure 22). The Froude number Fr is the key parameter to influence the scale and intensity of horseshoe vortex. The Fr under waves can be calculated by the following formula [42]

Fr=UwgD−−−√�r=�w��(34)

where Uw is the mean water particle velocity during 1/4 cycle of wave oscillation, obtained from the following formula. Noteworthy is that the root-mean-square (RMS) value of near-bed velocity amplitude Uwm,rms is used for calculating Uwm.

Uw=1T/4∫0T/4Uwmsin(t/T)dt=2πUwm�w=1�/4∫0�/4�wmsin(�/�)��=2��wm(35)

Jmse 09 00886 g022 550

Figure 22. Sketch of flow field at upstream USAF edges.

Tavouktsoglou et al. [25] proposed the following formula between Fr and the vertical location of the stagnation y

yh∝Fer�ℎ∝�r�(36)

where e is constant.

The Figure 23 displays the relationship between Seq/D and Fr of the present study. In order to compare with the simulating results, the experimental data of Corvaro et al. [21] was also depicted in Figure 23. As shown in Figure 23, the equilibrium scour depth appears a logarithmic increase as Fr increases and approaches the mathematical asymptotic value, which is also consistent with the experimental results of Corvaro et al. [21]. According to Figure 24, the adverse pressure gradient pressure at upstream USAF edges increases with the increase of Fr, which is benefit for the wave boundary layer separating from seabed, resulting in the high-intensity horseshoe vortex, hence, causing intensive scour around USAF. Based on the previous study of Tavouktsoglou et al. [25] for scour around pile under currents, the high Fr leads to the stagnation point is closer to the mean sea level for shallow water, causing the stronger downflow kinetic energy. As mentioned in previous section, the energy of downflow at upstream makes up the energy of the subsequent horseshoe vortex, so the stronger downflow kinetic energy results in the more intensive horseshoe vortex. Therefore, the higher Fr leads to the more intensive horseshoe vortex by influencing the position of stagnation point y presumably. Qi and Gao [19] carried out a series of flume tests to investigate the scour around pile under regular waves, and proposed the fitting formula between Seq/D and Fr as following

lg(Seq/D)=Aexp(B/Fr)+Clg(�eq/�)=�exp(�/�r)+�(37)

where AB and C are constant.

Jmse 09 00886 g023 550

Figure 23. The fitting curve between Seq/D and Fr.

Jmse 09 00886 g024 550

Figure 24. Sketch of adverse pressure gradient at upstream USAF edges.

Took the Equation (37) to fit the simulating results with A = −0.002, B = 0.686 and C = −0.808, and the results are shown in Figure 23. From Figure 23, the simulating results evenly distribute around the Equation (37) and the varying trend of Seq/D and Fr in present study is consistent with Equation (37) basically, meaning the Equation (37) is applicable to express the relationship of Seq/D with Fr around USAF under random waves.

4.4.2. Influence of Euler Number

The Euler number Eu is the influencing factor for the hydrodynamic field around foundation. The Eu under waves can be calculated by the following formula. The Eu can be represented by the Equation (38) for uniform cylinders [25]. The root-mean-square (RMS) value of near-bed velocity amplitude Um,rms is used for calculating Um.

Eu=U2mgD�u=�m2��(38)

where Um is depth-averaged flow velocity.

The Figure 25 displays the relationship between Seq/D and Eu of the present study. In order to compare with the simulating results, the experimental data of Sumer and Fredsøe [16] and Corvaro et al. [21] were also plotted in Figure 25. As shown in Figure 25, similar with the varying trend of Seq/D and Fr, the equilibrium scour depth appears a logarithmic increase as Eu increases and approaches the mathematical asymptotic value, which is also consistent with the experimental results of Sumer and Fredsøe [16] and Corvaro et al. [21]. According to Figure 24, the adverse pressure gradient pressure at upstream USAF edges increases with the increasing of Eu, which is benefit for the wave boundary layer separating from seabed, inducing the high-intensity horseshoe vortex, hence, causing intensive scour around USAF.

Jmse 09 00886 g025 550

Figure 25. The fitting curve between Seq/D and Eu.

Therefore, the variation of Fr and Eu reflect the magnitude of adverse pressure gradient pressure at upstream. Given that, the Equation (37) also was used to fit the simulating results with A = 8.875, B = 0.078 and C = −9.601, and the results are shown in Figure 25. From Figure 25, the simulating results evenly distribute around the Equation (37) and the varying trend of Seq/D and Eu in present study is consistent with Equation (37) basically, meaning the Equation (37) is also applicable to express the relationship of Seq/D with Eu around USAF under random waves. Additionally, according to the above description of Fr, it can be inferred that the higher Fr and Eu both lead to the more intensive horseshoe vortex by influencing the position of stagnation point y presumably.

5. Conclusions

A series of numerical models were established to investigate the local scour around umbrella suction anchor foundation (USAF) under random waves. The numerical model was validated for hydrodynamic and morphology parameters by comparing with the experimental data of Khosronejad et al. [52], Petersen et al. [17], Sumer and Fredsøe [16] and Schendel et al. [22]. Based on the simulating results, the scour evolution and scour mechanisms around USAF under random waves were analyzed respectively. Two revised models were proposed according to the model of Raaijmakers and Rudolph [34] and the stochastic model developed by Myrhaug and Rue [37] to predict the equilibrium scour depth around USAF under random waves. Finally, a parametric study was carried out with the present model to study the effects of the Froude number Fr and Euler number Eu to the equilibrium scour depth around USAF under random waves. The main conclusions can be described as follows.(1)

The packed sediment scour model and the RNG k−ε turbulence model were used to simulate the sand particles transport processes and the flow field around UASF respectively. The scour evolution obtained by the present model agrees well with the experimental results of Khosronejad et al. [52], Petersen et al. [17], Sumer and Fredsøe [16] and Schendel et al. [22], which indicates that the present model is accurate and reasonable for depicting the scour morphology around UASF under random waves.(2)

The vortex system at wave crest phase is mainly related to the scour process around USAF under random waves. The maximum scour depth appeared at the lee-side of the USAF at the initial stage (t < 1200 s). Subsequently, when t > 2400 s, the location of the maximum scour depth shifted to the upside of the USAF at an angle of about 45° with respect to the wave propagating direction.(3)

The error is negligible and the Raaijmakers’s model is of relatively high accuracy for predicting scour around USAF under random waves when KC is calculated by KCs,p. Given that, a further revision model (Equation (31)) was proposed according to Raaijmakers’s model to predict the equilibrium scour depth around USAF under random waves and it shows good agreement with the simulating results of the present study when KCs,p < 8.(4)

Another further revision model (Equation (33)) was proposed according to the stochastic model established by Myrhaug and Rue [37] to predict the equilibrium scour depth around USAF under random waves, and the predicting results are the most favorable for n = 10 when KCrms,a < 4. However, contrary to the case of low KCrms,a, the predicting results are the most favorable for n = 2 when KCrms,a > 4 by the comparison with experimental results of Sumer and Fredsøe [16] and Corvaro et al. [21].(5)

The same formula (Equation (37)) is applicable to express the relationship of Seq/D with Eu or Fr, and it can be inferred that the higher Fr and Eu both lead to the more intensive horseshoe vortex and larger Seq.

Author Contributions

Conceptualization, H.L. (Hongjun Liu); Data curation, R.H. and P.Y.; Formal analysis, X.W. and H.L. (Hao Leng); Funding acquisition, X.W.; Writing—original draft, R.H. and P.Y.; Writing—review & editing, X.W. and H.L. (Hao Leng); The final manuscript has been approved by all the authors. All authors have read and agreed to the published version of the manuscript.

Funding

This research was funded by the Fundamental Research Funds for the Central Universities (grant number 202061027) and the National Natural Science Foundation of China (grant number 41572247).

Institutional Review Board Statement

Not applicable.

Informed Consent Statement

Not applicable.

Data Availability Statement

The data presented in this study are available on request from the corresponding author.

Conflicts of Interest

The authors declare no conflict of interest.

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Fig. 1 Oscillation of a free surface due to the step reduction of gravity acceleration from kzi ≈ 9.81 to kz ≈ 0

Reorientation of Cryogenic Fluids Upon Step Reduction of Gravity

단계적 중력 감소 시 극저온 유체의 방향 전환

Malte Stief∗, Jens Gerstmann∗∗, and Michael E. Dreyer∗∗∗
ZARM, Center of Applied Space Technology and Microgravity, University of Bremen, Am Fallturm, D-28359 Bremen
Experiments to observe the surface oscillation of cryogenic liquids have been performed with liquid nitrogen inside a 50 mm
diameter right circular cylinder. The surface oscillation is driven by the capillary force that becomes dominant after a sudden
reduction of the gravity acceleration acting on the liquid. The experiments show differences from the speculated behavior and
enables one to observe new features.

Introduction and motivation

최근 몇 년 동안 Bremen의 낙하탑에서 중력의 단계적 감소 시 방향 재지향 거동과 표면 진동을 조사하기 위해 수많은 실험이 수행되었습니다[1]. 이 실험의 원리는 그림 1에 나와 있습니다.

그림 1의 왼쪽에 표시된 것처럼 오른쪽 원형 원통형 용기에 테스트 액체를 레벨 h0까지 채웁니다. 처음에 액체는 정지 상태이며 중앙에서 평평한 인터페이스를 형성합니다.

초기 중력 가속도 kzi ≈ 9.81 [m/s2]와 결과적으로 높은 BOND 수(Bo = ρkziR2/σ)로 인해 실린더의 대칭축에서. 낙하탑에서 실험 캡슐의 방출에 의해 확립된 μ-중력 환경 kz ≈ 0 [m/s2]로의 갑작스러운 전환과 함께 자유 표면은 진동 운동으로 새로운 평형 구성을 찾기 시작합니다(그림의 오른쪽) 1). 이러한 움직임은 그림 1의 중앙에 스케치되어 있습니다.

표면 진동의 구동력은 접착력과 결합된 표면 장력이며, 댐핑은 액체의 점도에 의해 제어됩니다. 위치가 zw인 벽에서 접촉선의 이동은 접촉각 γ에 의해 제어됩니다. 접촉각이 작은 액체용 γ ≈ 0◦

In recent years numerous experiments have been carried out to investigate the reorientation behavior and surface oscillations upon step reduction of gravity at the drop tower in Bremen [1]. The principals of these experiments are shown in figure 1. A right circular cylindrical container is filled up to the level h0 with the test liquid, as shown on the left of figure 1. Initially the liquid is quiescent and forms a flat interface at the center, in the symmetry axis of the cylinder, due to the initial gravity acceleration kzi ≈ 9.81 [m/s2] and the resulting high BOND number (Bo = ρkziR2/σ). With the sudden transition to the µ-gravity environment kz ≈ 0 [m/s2], which is established by the release of the experiment capsular in the drop tower, the free surface is initiated to search its new equilibrium configuration (right side of figure 1) with an oscillatory motion. These movements are sketched in the center of figure 1. The driving force for the surface oscillation is the surface tension in combination with the adhesion force where the damping is controlled by the viscosity of the liquid. The movement of the contact line at the wall, with its position zw, is governed by the contact angle γ. For liquids with small contact angle γ ≈ 0◦

Fig. 1 Oscillation of a free surface due to the step reduction of gravity acceleration from kzi ≈ 9.81 to kz ≈ 0
Fig. 1 Oscillation of a free surface due to the step reduction of gravity acceleration from kzi ≈ 9.81 to kz ≈ 0
Fig. 2 Experiment picture-series showing the oscillation of the free surface at different times for a 50 mm diameter cylinder.
Fig. 2 Experiment picture-series showing the oscillation of the free surface at different times for a 50 mm diameter cylinder.

References

[1] M. Michaelis, Kapillarinduzierte Schwingungen freier Fl¨ussigkeitsoberfl¨achen, Dissertation Universit¨at Bremen, Fortschritt-Berichte
Nr. 454 (VDI Verlag, D¨usseldorf, 2003).

Figure 1: Drawing of the experimental set-up, Figure 2: Experimental tank with locations of temperature sensors

실험 및 수치 시뮬레이션에 기반한 극저온 추진제 탱크 가압 분석

Analyses of Cryogenic Propellant Tank Pressurization based upon Experiments and Numerical Simulations
Carina Ludwig? and Michael Dreyer**
*DLR – German Aerospace Center, Space Launcher Systems Analysis (SART),
Institute of Space Systems, 28359 Bremen, Germany, Carina.Ludwig@dlr.de
**ZARM – Center for Applied Space Technology and Microgravity,
University of Bremen, 28359 Bremen, Germany

Abstract

본 연구에서는 발사대 적용을 위한 극저온 추진제 탱크의 능동 가압을 분석하였다. 따라서 지상 실험, 수치 시뮬레이션 및 분석 연구를 수행하여 다음과 같은 중요한 결과를 얻었습니다.

필요한 가압 기체 질량을 최소화하기 위해 더 높은 가압 기체 온도가 유리하거나 헬륨을 가압 기체로 적용하는 것이 좋습니다.

Flow-3D를 사용한 가압 가스 질량의 수치 시뮬레이션은 실험 결과와 잘 일치함을 보여줍니다. 가압 중 지배적인 열 전달은 주입된 가압 가스에서 축방향 탱크 벽으로 나타나고 능동 가압 단계 동안 상 변화의 주된 방식은 가압 가스의 유형에 따라 다릅니다.

가압 단계가 끝나면 상당한 압력 강하가 발생합니다. 이 압력 강하의 분석적 결정을 위해 이론적 모델이 제공됩니다.

The active-pressurization of cryogenic propellant tanks for the launcher application was analyzed in this study. Therefore, ground experiments, numerical simulations and analytical studies were performed with the following important results: In order to minimize the required pressurant gas mass, a higher pressurant gas temperature is advantageous or the application of helium as pressurant gas. Numerical simulations of the pressurant gas mass using Flow-3D show good agreement to the experimental results. The dominating heat transfer during pressurization appears from the injected pressurant gas to the axial tank walls and the predominant way of phase change during the active-pressurization phase depends on the type of the pressurant gas. After the end of the pressurization phase, a significant pressure drop occurs. A theoretical model is presented for the analytical determination of this pressure drop.

Figure 1: Drawing of the experimental set-up, Figure 2: Experimental tank with locations of temperature sensors
Figure 1: Drawing of the experimental set-up, Figure 2: Experimental tank with locations of temperature sensors
Figure 3: Non-dimensional (a) tank pressure, (b) liquid temperatures, (c) vapor temperatures, (d) wall and lid temperatures during pressurization and relaxation of the N300h experiment (for details see Table 2). T14 is the pressurant
gas temperature at the diffuser. Pressurization starts at tp,0 (t
∗ = 0.06·10−4
) and ends at tp, f (t
∗ = 0.84·10−4
). Relaxation
takes place until tp,T (t
∗ = 2.79·10−4
) and ∆p is the characteristic pressure drop
Figure 3: Non-dimensional (a) tank pressure, (b) liquid temperatures, (c) vapor temperatures, (d) wall and lid temperatures during pressurization and relaxation of the N300h experiment (for details see Table 2). T14 is the pressurant gas temperature at the diffuser. Pressurization starts at tp,0 (t ∗ = 0.06·10−4 ) and ends at tp, f (t ∗ = 0.84·10−4 ). Relaxation takes place until tp,T (t ∗ = 2.79·10−4 ) and ∆p is the characteristic pressure drop
Figure 5: Nondimensional vapor mass at pressurization start (m
∗
v,0
), pressurant gas mass (m
∗
pg), condensed vapor mass
from pressurization start to pressurization end (m
∗
cond,0,f
) and condensed vapor mass from pressurization end to relaxation end (m
∗
cond, f,T
) for all GN2 (a) and the GHe (b) pressurized experiments with the relating errors.
Figure 5: Nondimensional vapor mass at pressurization start (m ∗ v,0 ), pressurant gas mass (m ∗ pg), condensed vapor mass from pressurization start to pressurization end (m ∗ cond,0,f ) and condensed vapor mass from pressurization end to relaxation end (m ∗ cond, f,T ) for all GN2 (a) and the GHe (b) pressurized experiments with the relating errors.
Figure 6: Schematical propellant tank with vapor and liquid phase, pressurant gas and condensation mass flow as well as the applied control volumes. ., Figure 7: N300h experiment: wall to fluid heat flux at pressurization end (tp, f) over the tank height.
Figure 6: Schematical propellant tank with vapor and liquid phase, pressurant gas and condensation mass flow as well as the applied control volumes. ., Figure 7: N300h experiment: wall to fluid heat flux at pressurization end (tp, f) over the tank height.

References

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Figure 14. Defects: (a) Unmelt defects(Scheme NO.4);(b) Pores defects(Scheme NO.1); (c); Spattering defect (Scheme NO.3); (d) Low overlapping rate defects(Scheme NO.5).

Molten pool structure, temperature and velocity
flow in selective laser melting AlCu5MnCdVA alloy

용융 풀 구조, 선택적 온도 및 속도 흐름 레이저 용융 AlCu5MnCdVA 합금

Pan Lu1 , Zhang Cheng-Lin2,6,Wang Liang3, Liu Tong4 and Liu Jiang-lin5
1 Aviation and Materials College, Anhui Technical College of Mechanical and Electrical Engineering, Wuhu Anhui 241000, People’s
Republic of China 2 School of Engineering Science, University of Science and Technology of China, Hefei Anhui 230026, People’s Republic of China 3 Anhui Top Additive Manufacturing Technology Co., Ltd., Wuhu Anhui 241300, People’s Republic of China 4 Anhui Chungu 3D Printing Institute of Intelligent Equipment and Industrial Technology, Anhui 241300, People’s Republic of China 5 School of Mechanical and Transportation Engineering, Taiyuan University of Technology, Taiyuan Shanxi 030024, People’s Republic of
China 6 Author to whom any correspondence should be addressed.
E-mail: ahjdpanlu@126.com, jiao__zg@126.com, ahjdjxx001@126.com,tongliu1988@126.com and liujianglin@tyut.edu.cn

Keywords

SLM, molten pool, AlCu5MnCdVA alloy, heat flow, velocity flow, numerical simulation

Abstract

선택적 레이저 용융(SLM)은 열 전달, 용융, 상전이, 기화 및 물질 전달을 포함하는 복잡한 동적 비평형 프로세스인 금속 적층 제조(MAM)에서 가장 유망한 기술 중 하나가 되었습니다. 용융 풀의 특성(구조, 온도 흐름 및 속도 흐름)은 SLM의 최종 성형 품질에 결정적인 영향을 미칩니다. 이 연구에서는 선택적 레이저 용융 AlCu5MnCdVA 합금의 용융 풀 구조, 온도 흐름 및 속도장을 연구하기 위해 수치 시뮬레이션과 실험을 모두 사용했습니다.

그 결과 용융풀의 구조는 다양한 형태(깊은 오목 구조, 이중 오목 구조, 평면 구조, 돌출 구조 및 이상적인 평면 구조)를 나타냈으며, 용융 풀의 크기는 약 132 μm × 107 μm × 50 μm였습니다. : 용융풀은 초기에는 여러 구동력에 의해 깊이 15μm의 깊은 오목형상이었으나, 성형 후기에는 장력구배에 의해 높이 10μm의 돌출형상이 되었다. 용융 풀 내부의 금속 흐름은 주로 레이저 충격력, 금속 액체 중력, 표면 장력 및 반동 압력에 의해 구동되었습니다.

AlCu5MnCdVA 합금의 경우, 금속 액체 응고 속도가 매우 빠르며(3.5 × 10-4 S), 가열 속도 및 냉각 속도는 각각 6.5 × 107 K S-1 및 1.6 × 106 K S-1 에 도달했습니다. 시각적 표준으로 표면 거칠기를 선택하고, 낮은 레이저 에너지 AlCu5MnCdVA 합금 최적 공정 매개변수 창을 수치 시뮬레이션으로 얻었습니다: 레이저 출력 250W, 부화 공간 0.11mm, 층 두께 0.03mm, 레이저 스캔 속도 1.5m s-1 .

또한, 실험 프린팅과 수치 시뮬레이션과 비교할 때, 용융 풀의 폭은 각각 약 205um 및 약 210um이었고, 인접한 두 용융 트랙 사이의 중첩은 모두 약 65um이었다. 결과는 수치 시뮬레이션 결과가 실험 인쇄 결과와 기본적으로 일치함을 보여 수치 시뮬레이션 모델의 정확성을 입증했습니다.

Selective Laser Melting (SLM) has become one of the most promising technologies in Metal Additive Manufacturing (MAM), which is a complex dynamic non-equilibrium process involving heat transfer, melting, phase transition, vaporization and mass transfer. The characteristics of the molten pool (structure, temperature flow and velocity flow) have a decisive influence on the final forming quality of SLM. In this study, both numerical simulation and experiments were employed to study molten pool structure, temperature flow and velocity field in Selective Laser Melting AlCu5MnCdVA alloy. The results showed the structure of molten pool showed different forms(deep-concave structure, double-concave structure, plane structure, protruding structure and ideal planar structure), and the size of the molten pool was approximately 132 μm × 107 μm × 50 μm: in the early stage, molten pool was in a state of deep-concave shape with a depth of 15 μm due to multiple driving forces, while a protruding shape with a height of 10 μm duo to tension gradient in the later stages of forming. The metal flow inside the molten pool was mainly driven by laser impact force, metal liquid gravity, surface tension and recoil pressure. For AlCu5MnCdVA alloy, metal liquid solidification speed was extremely fast(3.5 × 10−4 S), the heating rate and cooling rate reached 6.5 × 107 K S−1 and 1.6 × 106 K S−1 , respectively. Choosing surface roughness as a visual standard, low-laser energy AlCu5MnCdVA alloy optimum process parameters window was obtained by numerical simulation: laser power 250 W, hatching space 0.11 mm, layer thickness 0.03 mm, laser scanning velocity 1.5 m s−1 . In addition, compared with experimental printing and numerical simulation, the width of the molten pool was about 205 um and about 210 um, respectively, and overlapping between two adjacent molten tracks was all about 65 um. The results showed that the numerical simulation results were basically consistent with the experimental print results, which proved the correctness of the numerical simulation model.

Figure 1. AlCu5MnCdVA powder particle size distribution.
Figure 1. AlCu5MnCdVA powder particle size distribution.
Figure 2. AlCu5MnCdVA powder
Figure 2. AlCu5MnCdVA powder
Figure 3. Finite element model and calculation domains of SLM.
Figure 3. Finite element model and calculation domains of SLM.
Figure 4. SLM heat transfer process.
Figure 4. SLM heat transfer process.
Figure 14. Defects: (a) Unmelt defects(Scheme NO.4);(b) Pores defects(Scheme NO.1); (c); Spattering defect (Scheme NO.3); (d) Low
overlapping rate defects(Scheme NO.5).
Figure 17. Two-pass molten tracks overlapping for Scheme NO.2.
Figure 17. Two-pass molten tracks overlapping for Scheme NO.2.

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[21] Hirt C and Nichols B 1981 Volume of fluid (VOF) method for the dynamics of free boundariesJ. Comput. Phys. 39 201–25
[22] Hu Z, Zhang H, Zhu H, Xiao Z, Nie X and Zeng X 2019 Microstructure, mechanical properties and strengthening mechanisms of
AlCu5MnCdVA aluminum alloy fabricated by selective laser melting Materials Science and Engineering: A 759 154–66
[23] Ketai H, Liu Z and Lechang Y 2020 Simulation of temperature field, microstructure and mechanical properties of 316L stainless steel in
selected laser melting Progress in Laser and Optoelectronics 9 1–18
[24] Cao L 2020 Workpiece-scale numerical simulations of SLM molten pool dynamic behavior of 316L stainless steel Comput. Math. Appl.
4 22–34
[25] Dening Z, Yongping L, Tinglu H and Junyi S 2000 Numerical study of fluid flow and heat transfer in molten pool under the condition of
moving heat source J. Met. 4 387–90
[26] Chengyun C, Cui F and Wenlong Z 2018 The effect of Marangoni flow on the thermal behavior and melt flow behavior of laser cladding
Applied Laser 38 409–16
[27] Peiying B and Enhuai Y 2020 The effect of laser power on the morphology and residual stress of the molten pool of metal laser selective
melting Progress in Laser and Optoelectronics 7 1–12 http://kns.cnki.net/kcms/detail/31.1690.TN.20190717.0933.032.html
[28] Zhen L, Dongyun Z, Zhe F and Chengjie W 2017 Numerical simulation of the influence of overlap rate on the forming quality of
Inconel 718 alloy by selective laser melting processing Applied Laser 37 187–93
[29] Wei W, Qi L, Guang Y, Lanyun Q and Xiong X 2015 Numerical simulation of electromagnetic field, temperature field and flowfield of
laser melting pool under the action of electromagnetic stirring China Laser 42 48–55
[30] Hu Y, He X, Yu G and Zhao S 2016 Capillary convection in pulsed—butt welding of miscible dissimilar couple Proc. Inst. Mech. Eng.
Part C J. Mech. Eng. Sci. 231 2429–40
[31] Li R 2010 Research on the key basic problems of selective laser melting forming of metal powder Huazhong University of Science and
Technology
[32] Zijue T, Weiwei L, Zhaorui Y, Hao W and Hongchao Z 2019 Study on the shape evolution behavior of metal laser melting deposition
based on molten pool dynamic characteristicsJournal of Mechanical Engineering 55 39–47
[33] Pan L, Cheng-Lin Z, Hai-Yi L, Liang W and Tong L 2020 A new two-step selective laser remelting of 316L stainless steel: process,
density, surface roughness, mechanical properties, microstructure Mater. Res. Express 7 056503
[34] Pan L, Cheng-Lin Z, Hai-Yi L, Jiang H, Tong L and Liang W 2019 The influence and optimization of forming process parameters of
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Temperature contours& velocity vectors just after spray off

NASA Perspectives on Cryo H2 Storage

Cryo H2 저장에 대한 NASA의 관점

DOE Hydrogen Storage Workshop
Marriott Crystal Gateway
Arlington, VA
February 15, 2011
David J. Chato
NASA Glenn Research Center
Michael P. Doherty
NASA Glenn Research Center

Objectives

Purposes of this Presentation
• To show the role of Cryogenics in NASA prior missions
• To show recent NASA accomplishments in cryogenic fluid management technology
• To highlight the importance of long term cryogenic storage to future NASA missions (especially Human Space flight)

What is Cryogenic Fluid Management?

The Cartoon Guide to Cryogenic Fluid Management Illustrating Key Concepts in Iconic Form

GRC Cryogenic Fluid Management Accomplishments

Baseline CFD Models Validated Against K-Site, MHTB, and S-IVB Data

Objective:
Perform model development and validation of the baseline computational fluid
dynamics (CFD) codes Flow-3D (with point source spray model) and Fluent (with
lumped-ullage model) for three self-pressurization experiments and one set of spray bar
thermodynamic vent system (TVS) experiments. Accuracy of CFD codes assessed by
comparing experimental data and CFD predictions for ullage pressure versus time.

Key Accomplishment/Deliverable/Milestone:
• Develop lumped-ullage model (non-moving zero-thickness interface) enabling
reduced simulations times compared to Flow-3D, but with limitations on accuracy and
applicability to situations with significant interface movement.
• Lumped-ullage with spray model development completed, but not tested and
validated due to loss of key researcher in June 2009. New person identified to
complete this work by end of FY10. (Updated milestone report will be issued).

Flow-3D Volume of Fluid (VOF) and Fluent lumped-ullage models
validated against 2 ground-based and 1 flight experiment for LH2 selfpressurization with relative error in ullage pressure generally within 5%,
reaching 8-12% at higher liquid fill levels, and up to 18% for the Fluent
lumped-ullage simulations of the flight test (S-IVB AS 203)
• Flow-3D point source spray model developed and validated against
MHTB LH2 spray bar pressure control 1g experiment with ullage
pressure errors up to 26% for pressure rise and 47% for pressure decay

Significance:
• Two CFD models have been developed with errors quantified for selfpressurization and pressure control of cryogenic storage tanks.
• Baseline CFD models are now available Exploration mission
applications (including in-space low gravity applications) and
design/post-analysis of current CFM experimental work. Applications to
Altair and EDS tanks have already occurred and/or are underway.

Temperature contours& velocity
vectors just after spray off
Temperature contours& velocity vectors just after spray off
Flow-3D results: MHTB LH2 1g test, 50% fill
Flow-3D results: MHTB LH2 1g test, 50% fill
Figure 5 A schematic of the water model of reactor URO 200.

Physical and Numerical Modeling of the Impeller Construction Impact on the Aluminum Degassing Process

알루미늄 탈기 공정에 미치는 임펠러 구성의 물리적 및 수치적 모델링

Kamil Kuglin,1 Michał Szucki,2 Jacek Pieprzyca,3 Simon Genthe,2 Tomasz Merder,3 and Dorota Kalisz1,*

Mikael Ersson, Academic Editor

Author information Article notes Copyright and License information Disclaimer

Associated Data

Data Availability Statement

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Abstract

This paper presents the results of tests on the suitability of designed heads (impellers) for aluminum refining. The research was carried out on a physical model of the URO-200, followed by numerical simulations in the FLOW 3D program. Four design variants of impellers were used in the study. The degree of dispersion of the gas phase in the model liquid was used as a criterion for evaluating the performance of each solution using different process parameters, i.e., gas flow rate and impeller speed. Afterward, numerical simulations in Flow 3D software were conducted for the best solution. These simulations confirmed the results obtained with the water model and verified them.

Keywords: aluminum, impeller construction, degassing process, numerical modeling, physical modeling

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1. Introduction

Constantly increasing requirements concerning metallurgical purity in terms of hydrogen content and nonmetallic inclusions make casting manufacturers use effective refining techniques. The answer to this demand is the implementation of the aluminum refining technique making use of a rotor with an original design guaranteeing efficient refining [1,2,3,4]. The main task of the impeller (rotor) is to reduce the contamination of liquid metal (primary and recycled aluminum) with hydrogen and nonmetallic inclusions. An inert gas, mainly argon or a mixture of gases, is introduced through the rotor into the liquid metal to bring both hydrogen and nonmetallic inclusions to the metal surface through the flotation process. Appropriately and uniformly distributed gas bubbles in the liquid metal guarantee achieving the assumed level of contaminant removal economically. A very important factor in deciding about the obtained degassing effect is the optimal rotor design [5,6,7,8]. Thanks to the appropriate geometry of the rotor, gas bubbles introduced into the liquid metal are split into smaller ones, and the spinning movement of the rotor distributes them throughout the volume of the liquid metal bath. In this solution impurities in the liquid metal are removed both in the volume and from the upper surface of the metal. With a well-designed impeller, the costs of refining aluminum and its alloys can be lowered thanks to the reduced inert gas and energy consumption (optimal selection of rotor rotational speed). Shorter processing time and a high degree of dehydrogenation decrease the formation of dross on the metal surface (waste). A bigger produced dross leads to bigger process losses. Consequently, this means that the choice of rotor geometry has an indirect impact on the degree to which the generated waste is reduced [9,10].

Another equally important factor is the selection of process parameters such as gas flow rate and rotor speed [11,12]. A well-designed gas injection system for liquid metal meets two key requirements; it causes rapid mixing of the liquid metal to maintain a uniform temperature throughout the volume and during the entire process, to produce a chemically homogeneous metal composition. This solution ensures effective degassing of the metal bath. Therefore, the shape of the rotor, the arrangement of the nozzles, and their number are significant design parameters that guarantee the optimum course of the refining process. It is equally important to complete the mixing of the metal bath in a relatively short time, as this considerably shortens the refining process and, consequently, reduces the process costs. Another important criterion conditioning the implementation of the developed rotor is the generation of fine diffused gas bubbles which are distributed throughout the metal volume, and whose residence time will be sufficient for the bubbles to collide and adsorb the contaminants. The process of bubble formation by the spinning rotors differs from that in the nozzles or porous molders. In the case of a spinning rotor, the shear force generated by the rotor motion splits the bubbles into smaller ones. Here, the rotational speed, mixing force, surface tension, and fluid density have a key effect on the bubble size. The velocity of the bubbles, which depends mainly on their size and shape, determines their residence time in the reactor and is, therefore, very important for the refining process, especially since gas bubbles in liquid aluminum may remain steady only below a certain size [13,14,15].

The impeller designs presented in the article were developed to improve the efficiency of the process and reduce its costs. The impellers used so far have a complicated structure and are very pricey. The success of the conducted research will allow small companies to become independent of external supplies through the possibility of making simple and effective impellers on their own. The developed structures were tested on the water model. The results of this study can be considered as pilot.

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2. Materials and Methods

Rotors were realized with the SolidWorks computer design technique and a 3D printer. The developed designs were tested on a water model. Afterward, the solution with the most advantageous refining parameters was selected and subjected to calculations with the Flow3D package. As a result, an impeller was designed for aluminum refining. Its principal lies in an even distribution of gas bubbles in the entire volume of liquid metal, with the largest possible participation of the bubble surface, without disturbing the metal surface. This procedure guarantees the removal of gaseous, as well as metallic and nonmetallic, impurities.

2.1. Rotor Designs

The developed impeller constructions, shown in Figure 1Figure 2Figure 3 and Figure 4, were printed on a 3D printer using the PLA (polylactide) material. The impeller design models differ in their shape and the number of holes through which the inert gas flows. Figure 1Figure 2 and Figure 3 show the same impeller model but with a different number of gas outlets. The arrangement of four, eight, and 12 outlet holes was adopted in the developed design. A triangle-shaped structure equipped with three gas outlet holes is presented in Figure 4.

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Figure 1

A 3D model—impeller with four holes—variant B4.

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Figure 2

A 3D model—impeller with eight holes—variant B8.

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Figure 3

A 3D model—impeller with twelve holes—variant B12.

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Figure 4

A 3D model—‘red triangle’ impeller with three holes—variant RT3.

2.2. Physical Models

Investigations were carried out on a water model of the URO 200 reactor of the barbotage refining process (see Figure 5).

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Figure 5

A schematic of the water model of reactor URO 200.

The URO 200 reactor can be classified as a cyclic reactor. The main element of the device is a rotor, which ends the impeller. The whole system is attached to a shaft via which the refining gas is supplied. Then, the shaft with the rotor is immersed in the liquid metal in the melting pot or the furnace chamber. In URO 200 reactors, the refining process lasts 600 s (10 min), the gas flow rate that can be obtained ranges from 5 to 20 dm3·min−1, and the speed at which the rotor can move is 0 to 400 rpm. The permissible quantity of liquid metal for barbotage refining is 300 kg or 700 kg [8,16,17]. The URO 200 has several design solutions which improve operation and can be adapted to the existing equipment in the foundry. These solutions include the following [8,16]:

  • URO-200XR—used for small crucible furnaces, the capacity of which does not exceed 250 kg, with no control system and no control of the refining process.
  • URO-200SA—used to service several crucible furnaces of capacity from 250 kg to 700 kg, fully automated and equipped with a mechanical rotor lift.
  • URO-200KA—used for refining processes in crucible furnaces and allows refining in a ladle. The process is fully automated, with a hydraulic rotor lift.
  • URO-200KX—a combination of the XR and KA models, designed for the ladle refining process. Additionally, refining in heated crucibles is possible. The unit is equipped with a manual hydraulic rotor lift.
  • URO-200PA—designed to cooperate with induction or crucible furnaces or intermediate chambers, the capacity of which does not exceed one ton. This unit is an integral part of the furnace. The rotor lift is equipped with a screw drive.

Studies making use of a physical model can be associated with the observation of the flow and circulation of gas bubbles. They require meeting several criteria regarding the similarity of the process and the object characteristics. The similarity conditions mainly include geometric, mechanical, chemical, thermal, and kinetic parameters. During simulation of aluminum refining with inert gas, it is necessary to maintain the geometric similarity between the model and the real object, as well as the similarity related to the flow of liquid metal and gas (hydrodynamic similarity). These quantities are characterized by the Reynolds, Weber, and Froude numbers. The Froude number is the most important parameter characterizing the process, its magnitude is the same for the physical model and the real object. Water was used as the medium in the physical modeling. The factors influencing the choice of water are its availability, relatively low cost, and kinematic viscosity at room temperature, which is very close to that of liquid aluminum.

The physical model studies focused on the flow of inert gas in the form of gas bubbles with varying degrees of dispersion, particularly with respect to some flow patterns such as flow in columns and geysers, as well as disturbance of the metal surface. The most important refining parameters are gas flow rate and rotor speed. The barbotage refining studies for the developed impeller (variants B4, B8, B12, and RT3) designs were conducted for the following process parameters:

  • Rotor speed: 200, 300, 400, and 500 rpm,
  • Ideal gas flow: 10, 20, and 30 dm3·min−1,
  • Temperature: 293 K (20 °C).

These studies were aimed at determining the most favorable variants of impellers, which were then verified using the numerical modeling methods in the Flow-3D program.

2.3. Numerical Simulations with Flow-3D Program

Testing different rotor impellers using a physical model allows for observing the phenomena taking place while refining. This is a very important step when testing new design solutions without using expensive industrial trials. Another solution is modeling by means of commercial simulation programs such as ANSYS Fluent or Flow-3D [18,19]. Unlike studies on a physical model, in a computer program, the parameters of the refining process and the object itself, including the impeller design, can be easily modified. The simulations were performed with the Flow-3D program version 12.03.02. A three-dimensional system with the same dimensions as in the physical modeling was used in the calculations. The isothermal flow of liquid–gas bubbles was analyzed. As in the physical model, three speeds were adopted in the numerical tests: 200, 300, and 500 rpm. During the initial phase of the simulations, the velocity field around the rotor generated an appropriate direction of motion for the newly produced bubbles. When the required speed was reached, the generation of randomly distributed bubbles around the rotor was started at a rate of 2000 per second. Table 1 lists the most important simulation parameters.

Table 1

Values of parameters used in the calculations.

ParameterValueUnit
Maximum number of gas particles1,000,000
Rate of particle generation20001·s−1
Specific gas constant287.058J·kg−1·K−1
Atmospheric pressure1.013 × 105Pa
Water density1000kg·m−3
Water viscosity0.001kg·m−1·s−1
Boundary condition on the wallsNo-slip
Size of computational cell0.0034m

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In the case of the CFD analysis, the numerical solutions require great care when generating the computational mesh. Therefore, computational mesh tests were performed prior to the CFD calculations. The effect of mesh density was evaluated by taking into account the velocity of water in the tested object on the measurement line A (height of 0.065 m from the bottom) in a characteristic cross-section passing through the object axis (see Figure 6). The mesh contained 3,207,600, 6,311,981, 7,889,512, 11,569,230, and 14,115,049 cells.

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Figure 6

The velocity of the water depending on the size of the computational grid.

The quality of the generated computational meshes was checked using the criterion skewness angle QEAS [18]. This criterion is described by the following relationship:

QEAS=max{βmax−βeq180−βeq,βeq−βminβeq},

(1)

where βmaxβmin are the maximal and minimal angles (in degrees) between the edges of the cell, and βeq is the angle corresponding to an ideal cell, which for cubic cells is 90°.

Normalized in the interval [0;1], the value of QEAS should not exceed 0.75, which identifies the permissible skewness angle of the generated mesh. For the computed meshes, this value was equal to 0.55–0.65.

Moreover, when generating the computational grids in the studied facility, they were compacted in the areas of the highest gradients of the calculated values, where higher turbulence is to be expected (near the impeller). The obtained results of water velocity in the studied object at constant gas flow rate are shown in Figure 6.

The analysis of the obtained water velocity distributions (see Figure 6) along the line inside the object revealed that, with the density of the grid of nodal points, the velocity changed and its changes for the test cases of 7,889,512, 11,569,230, and 14,115,049 were insignificant. Therefore, it was assumed that a grid containing not less than 7,900,000 (7,889,512) cells would not affect the result of CFD calculations.

A single-block mesh of regular cells with a size of 0.0034 m was used in the numerical calculations. The total number of cells was approximately 7,900,000 (7,889,512). This grid resolution (see Figure 7) allowed the geometry of the system to be properly represented, maintaining acceptable computation time (about 3 days on a workstation with 2× CPU and 12 computing cores).

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Figure 7

Structured equidistant mesh used in numerical calculations: (a) mesh with smoothed, surface cells (the so-called FAVOR method) used in Flow-3D; (b) visualization of the applied mesh resolution.

The calculations were conducted with an explicit scheme. The timestep was selected by the program automatically and controlled by stability and convergence. From the moment of the initial velocity field generation (start of particle generation), it was 0.0001 s.

When modeling the degassing process, three fluids are present in the system: water, gas supplied through the rotor head (impeller), and the surrounding air. Modeling such a multiphase flow is a numerically very complex issue. The necessity to overcome the liquid backpressure by the gas flowing out from the impeller leads to the formation of numerical instabilities in the volume of fluid (VOF)-based approach used by Flow-3D software. Therefore, a mixed description of the analyzed flow was used here. In this case, water was treated as a continuous medium, while, in the case of gas bubbles, the discrete phase model (DPM) model was applied. The way in which the air surrounding the system was taken into account is later described in detail.

The following additional assumptions were made in the modeling:

  • —The liquid phase was considered as an incompressible Newtonian fluid.
  • —The effect of chemical reactions during the refining process was neglected.
  • —The composition of each phase (gas and liquid) was considered homogeneous; therefore, the viscosity and surface tension were set as constants.
  • —Only full turbulence existed in the liquid, and the effect of molecular viscosity was neglected.
  • —The gas bubbles were shaped as perfect spheres.
  • —The mutual interaction between gas bubbles (particles) was neglected.

2.3.1. Modeling of Liquid Flow 

The motion of the real fluid (continuous medium) is described by the Navier–Stokes Equation [20].

dudt=−1ρ∇p+ν∇2u+13ν∇(∇⋅ u)+F,

(2)

where du/dt is the time derivative, u is the velocity vector, t is the time, and F is the term accounting for external forces including gravity (unit components denoted by XYZ).

In the simulations, the fluid flow was assumed to be incompressible, in which case the following equation is applicable:

∂u∂t+(u⋅∇)u=−1ρ∇p+ν∇2u+F.

(3)

Due to the large range of liquid velocities during flows, the turbulence formation process was included in the modeling. For this purpose, the k–ε model turbulence kinetic energy k and turbulence dissipation ε were the target parameters, as expressed by the following equations [21]:

∂(ρk)∂t+∂(ρkvi)∂xi=∂∂xj[(μ+μtσk)⋅∂k∂xi]+Gk+Gb−ρε−Ym+Sk,

(4)

∂(ρε)∂t+∂(ρεui)∂xi=∂∂xj[(μ+μtσε)⋅∂k∂xi]+C1εεk(Gk+G3εGb)+C2ερε2k+Sε,

(5)

where ρ is the gas density, σκ and σε are the Prandtl turbulence numbers, k and ε are constants of 1.0 and 1.3, and Gk and Gb are the kinetic energy of turbulence generated by the average velocity and buoyancy, respectively.

As mentioned earlier, there are two gas phases in the considered problem. In addition to the gas bubbles, which are treated here as particles, there is also air, which surrounds the system. The boundary of phase separation is in this case the free surface of the water. The shape of the free surface can change as a result of the forming velocity field in the liquid. Therefore, it is necessary to use an appropriate approach to free surface tracking. The most commonly used concept in liquid–gas flow modeling is the volume of fluid (VOF) method [22,23], and Flow-3D uses a modified version of this method called TrueVOF. It introduces the concept of the volume fraction of the liquid phase fl. This parameter can be used for classifying the cells of a discrete grid into areas filled with liquid phase (fl = 1), gaseous phase, or empty cells (fl = 0) and those through which the phase separation boundary (fl ∈ (0, 1)) passes (free surface). To determine the local variations of the liquid phase fraction, it is necessary to solve the following continuity equation:

dfldt=0.

(6)

Then, the fluid parameters in the region of coexistence of the two phases (the so-called interface) depend on the volume fraction of each phase.

ρ=flρl+(1−fl)ρg,

(7)

ν=flνl+(1−fl)νg,

(8)

where indices l and g refer to the liquid and gaseous phases, respectively.

The parameter of fluid velocity in cells containing both phases is also determined in the same way.

u=flul+(1−fl)ug.

(9)

Since the processes taking place in the surrounding air can be omitted, to speed up the calculations, a single-phase, free-surface model was used. This means that no calculations were performed in the gas cells (they were treated as empty cells). The liquid could fill them freely, and the air surrounding the system was considered by the atmospheric pressure exerted on the free surface. This approach is often used in modeling foundry and metallurgical processes [24].

2.3.2. Modeling of Gas Bubble Flow 

As stated, a particle model was used to model bubble flow. Spherical particles (gas bubbles) of a given size were randomly generated in the area marked with green in Figure 7b. In the simulations, the gas bubbles were assumed to have diameters of 0.016 and 0.02 m corresponding to the gas flow rates of 10 and 30 dm3·min−1, respectively.

Experimental studies have shown that, as a result of turbulent fluid motion, some of the bubbles may burst, leading to the formation of smaller bubbles, although merging of bubbles into larger groupings may also occur. Therefore, to be able to observe the behavior of bubbles of different sizes (diameter), the calculations generated two additional particle types with diameters twice smaller and twice larger, respectively. The proportion of each species in the system was set to 33.33% (Table 2).

Table 2

Data assumed for calculations.

NoRotor Speed (Rotational Speed)
rpm
Bubbles Diameter
m
Corresponding Gas Flow Rate
dm3·min−1
NoRotor Speed (Rotational Speed)
rpm
Bubbles Diameter
m
Corresponding Gas Flow Rate
dm3·min−1
A2000.01610D2000.0230
0.0080.01
0.0320.04
B3000.01610E3000.0230
0.0080.01
0.0320.04
C5000.01610F5000.0230
0.0080.01
0.0320.04

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The velocity of the particle results from the generated velocity field (calculated from Equation (3) in the liquid ul around it and its velocity resulting from the buoyancy force ub. The effect of particle radius r on the terminal velocity associated with buoyancy force can be determined according to Stokes’ law.

ub=29 (ρg−ρl)μlgr2,

(10)

where g is the acceleration (9.81).

The DPM model was used for modeling the two-phase (water–air) flow. In this model, the fluid (water) is treated as a continuous phase and described by the Navier–Stokes equation, while gas bubbles are particles flowing in the model fluid (discrete phase). The trajectories of each bubble in the DPM system are calculated at each timestep taking into account the mass forces acting on it. Table 3 characterizes the DPM model used in our own research [18].

Table 3

Characteristic of the DPM model.

MethodEquations
Euler–LagrangeBalance equation:
dugdt=FD(u−ug)+g(ϱg−ϱ)ϱg+F.
FD (u − up) denotes the drag forces per mass unit of a bubble, and the expression for the drag coefficient FD is of the form
FD=18μCDReϱ⋅gd2g24.
The relative Reynolds number has the form
Re≡ρdg|ug−u|μ.
On the other hand, the force resulting from the additional acceleration of the model fluid has the form
F=12dρdtρg(u−ug),
where ug is the gas bubble velocity, u is the liquid velocity, dg is the bubble diameter, and CD is the drag coefficient.

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3. Results and Discussion

3.1. Calculations of Power and Mixing Time by the Flowing Gas Bubbles

One of the most important parameters of refining with a rotor is the mixing power induced by the spinning rotor and the outflowing gas bubbles (via impeller). The mixing power of liquid metal in a ladle of height (h) by gas injection can be determined from the following relation [15]:

pgVm=ρ⋅g⋅uB,

(11)

where pg is the mixing power, Vm is the volume of liquid metal in the reactor, ρ is the density of liquid aluminum, and uB is the average speed of bubbles, given below.

uB=n⋅R⋅TAc⋅Pm⋅t,

(12)

where n is the number of gas moles, R is the gas constant (8.314), Ac is the cross-sectional area of the reactor vessel, T is the temperature of liquid aluminum in the reactor, and Pm is the pressure at the middle tank level. The pressure at the middle level of the tank is calculated by a function of the mean logarithmic difference.

Pm=(Pa+ρ⋅g⋅h)−Paln(Pa+ρ⋅g⋅h)Pa,

(13)

where Pa is the atmospheric pressure, and h is the the height of metal in the reactor.

Themelis and Goyal [25] developed a model for calculating mixing power delivered by gas injection.

pg=2Q⋅R⋅T⋅ln(1+m⋅ρ⋅g⋅hP),

(14)

where Q is the gas flow, and m is the mass of liquid metal.

Zhang [26] proposed a model taking into account the temperature difference between gas and alloy (metal).

pg=QRTgVm[ln(1+ρ⋅g⋅hPa)+(1−TTg)],

(15)

where Tg is the gas temperature at the entry point.

Data for calculating the mixing power resulting from inert gas injection into liquid aluminum are given below in Table 4. The design parameters were adopted for the model, the parameters of which are shown in Figure 5.

Table 4

Data for calculating mixing power introduced by an inert gas.

ParameterValueUnit
Height of metal column0.7m
Density of aluminum2375kg·m−3
Process duration20s
Gas temperature at the injection site940K
Cross-sectional area of ladle0.448m2
Mass of liquid aluminum546.25kg
Volume of ladle0.23M3
Temperature of liquid aluminum941.15K

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Table 5 presents the results of mixing power calculations according to the models of Themelis and Goyal and of Zhang for inert gas flows of 10, 20, and 30 dm3·min−1. The obtained calculation results significantly differed from each other. The difference was an order of magnitude, which indicates that the model is highly inaccurate without considering the temperature of the injected gas. Moreover, the calculations apply to the case when the mixing was performed only by the flowing gas bubbles, without using a rotor, which is a great simplification of the phenomenon.

Table 5

Mixing power calculated from mathematical models.

Mathematical ModelMixing Power (W·t−1)
for a Given Inert Gas Flow (dm3·min−1)
102030
Themelis and Goyal11.4923.3335.03
Zhang0.821.662.49

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The mixing time is defined as the time required to achieve 95% complete mixing of liquid metal in the ladle [27,28,29,30]. Table 6 groups together equations for the mixing time according to the models.

Table 6

Models for calculating mixing time.

AuthorsModelRemarks
Szekely [31]τ=800ε−0.4ε—W·t−1
Chiti and Paglianti [27]τ=CVQlV—volume of reactor, m3
Ql—flow intensity, m3·s−1
Iguchi and Nakamura [32]τ=1200⋅Q−0.4D1.97h−1.0υ0.47υ—kinematic viscosity, m2·s−1
D—diameter of ladle, m
h—height of metal column, m
Q—liquid flow intensity, m3·s−1

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Figure 8 and Figure 9 show the mixing time as a function of gas flow rate for various heights of the liquid column in the ladle and mixing power values.

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Figure 8

Mixing time as a function of gas flow rate for various heights of the metal column (Iguchi and Nakamura model).

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Figure 9

Mixing time as a function of mixing power (Szekly model).

3.2. Determining the Bubble Size

The mechanisms controlling bubble size and mass transfer in an alloy undergoing refining are complex. Strong mixing conditions in the reactor promote impurity mass transfer. In the case of a spinning rotor, the shear force generated by the rotor motion separates the bubbles into smaller bubbles. Rotational speed, mixing force, surface tension, and liquid density have a strong influence on the bubble size. To characterize the kinetic state of the refining process, parameters k and A were introduced. Parameters kA, and uB can be calculated using the below equations [33].

k=2D⋅uBdB⋅π−−−−−−√,

(16)

A=6Q⋅hdB⋅uB,

(17)

uB=1.02g⋅dB,−−−−−√

(18)

where D is the diffusion coefficient, and dB is the bubble diameter.

After substituting appropriate values, we get

dB=3.03×104(πD)−2/5g−1/5h4/5Q0.344N−1.48.

(19)

According to the last equation, the size of the gas bubble decreases with the increasing rotational speed (see Figure 10).

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Figure 10

Effect of rotational speed on the bubble diameter.

In a flow of given turbulence intensity, the diameter of the bubble does not exceed the maximum size dmax, which is inversely proportional to the rate of kinetic energy dissipation in a viscous flow ε. The size of the gas bubble diameter as a function of the mixing energy, also considering the Weber number and the mixing energy in the negative power, can be determined from the following equations [31,34]:

  • —Sevik and Park:

dBmax=We0.6kr⋅(σ⋅103ρ⋅10−3)0.6⋅(10⋅ε)−0.4⋅10−2.

(20)

  • —Evans:

dBmax=⎡⎣Wekr⋅σ⋅1032⋅(ρ⋅10−3)13⎤⎦35 ⋅(10⋅ε)−25⋅10−2.

(21)

The results of calculating the maximum diameter of the bubble dBmax determined from Equation (21) are given in Table 7.

Table 7

The results of calculating the maximum diameter of the bubble using Equation (21).

ModelMixing Energy
ĺ (m2·s−3)
Weber Number (Wekr)
0.591.01.2
Zhang and Taniguchi
dmax
0.10.01670.02300.026
0.50.00880.01210.013
1.00.00670.00910.010
1.50.00570.00780.009
Sevik and Park
dBmax
0.10.2650.360.41
0.50.1390.190.21
1.00.1060.140.16
1.50.0900.120.14
Evans
dBmax
0.10.2470.3400.38
0.50.1300.1780.20
1.00.0980.1350.15
1.50.0840.1150.13

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3.3. Physical Modeling

The first stage of experiments (using the URO-200 water model) included conducting experiments with impellers equipped with four, eight, and 12 gas outlets (variants B4, B8, B12). The tests were carried out for different process parameters. Selected results for these experiments are presented in Figure 11Figure 12Figure 13 and Figure 14.

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Figure 11

Impeller variant B4—gas bubbles dispersion registered for a gas flow rate of 10 dm3·min−1 and rotor speed of (a) 200, (b) 300, (c) 400, and (d) 500 rpm.

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Figure 12

Impeller variant B8—gas bubbles dispersion registered for a gas flow rate of 10 dm3·min−1 and rotor speed of (a) 200, (b) 300, (c) 400, and (d) 500 rpm.

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Figure 13

Gas bubble dispersion registered for different processing parameters (impeller variant B12).

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Figure 14

Gas bubble dispersion registered for different processing parameters (impeller variant RT3).

The analysis of the refining variants presented in Figure 11Figure 12Figure 13 and Figure 14 reveals that the proposed impellers design model is not useful for the aluminum refining process. The number of gas outlet orifices, rotational speed, and flow did not affect the refining efficiency. In all the variants shown in the figures, very poor dispersion of gas bubbles was observed in the object. The gas bubble flow had a columnar character, and so-called dead zones, i.e., areas where no inert gas bubbles are present, were visible in the analyzed object. Such dead zones were located in the bottom and side zones of the ladle, while the flow of bubbles occurred near the turning rotor. Another negative phenomenon observed was a significant agitation of the water surface due to excessive (rotational) rotor speed and gas flow (see Figure 13, cases 20; 400, 30; 300, 30; 400, and 30; 500).

Research results for a ‘red triangle’ impeller equipped with three gas supply orifices (variant RT3) are presented in Figure 14.

In this impeller design, a uniform degree of bubble dispersion in the entire volume of the modeling fluid was achieved for most cases presented (see Figure 14). In all tested variants, single bubbles were observed in the area of the water surface in the vessel. For variants 20; 200, 30; 200, and 20; 300 shown in Figure 14, the bubble dispersion results were the worst as the so-called dead zones were identified in the area near the bottom and sidewalls of the vessel, which disqualifies these work parameters for further applications. Interestingly, areas where swirls and gas bubble chains formed were identified only for the inert gas flows of 20 and 30 dm3·min−1 and 200 rpm in the analyzed model. This means that the presented model had the best performance in terms of dispersion of gas bubbles in the model liquid. Its design with sharp edges also differed from previously analyzed models, which is beneficial for gas bubble dispersion, but may interfere with its suitability in industrial conditions due to possible premature wear.

3.4. Qualitative Comparison of Research Results (CFD and Physical Model)

The analysis (physical modeling) revealed that the best mixing efficiency results were obtained with the RT3 impeller variant. Therefore, numerical calculations were carried out for the impeller model with three outlet orifices (variant RT3). The CFD results are presented in Figure 15 and Figure 16.

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Figure 15

Simulation results of the impeller RT3, for given flows and rotational speeds after a time of 1 s: simulation variants (a) A, (b) B, (c) C, (d) D, (e) E, and (f) F.

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Figure 16

Simulation results of the impeller RT3, for given flows and rotational speeds after a time of 5.4 s.: simulation variants (a) A, (b) B, (c) C, (d) D, (e) E, and (f) F.

CFD results are presented for all analyzed variants (impeller RT3) at two selected calculation timesteps of 1 and 5.40 s. They show the velocity field of the medium (water) and the dispersion of gas bubbles.

Figure 15 shows the initial refining phase after 1 s of the process. In this case, the gas bubble formation and flow were observed in an area close to contact with the rotor. Figure 16 shows the phase when the dispersion and flow of gas bubbles were advanced in the reactor area of the URO-200 model.

The quantitative evaluation of the obtained results of physical and numerical model tests was based on the comparison of the degree of gas dispersion in the model liquid. The degree of gas bubble dispersion in the volume of the model liquid and the areas of strong turbulent zones formation were evaluated during the analysis of the results of visualization and numerical simulations. These two effects sufficiently characterize the required course of the process from the physical point of view. The known scheme of the below description was adopted as a basic criterion for the evaluation of the degree of dispersion of gas bubbles in the model liquid.

  • Minimal dispersion—single bubbles ascending in the region of their formation along the ladle axis; lack of mixing in the whole bath volume.
  • Accurate dispersion—single and well-mixed bubbles ascending toward the bath mirror in the region of the ladle axis; no dispersion near the walls and in the lower part of the ladle.
  • Uniform dispersion—most desirable; very good mixing of fine bubbles with model liquid.
  • Excessive dispersion—bubbles join together to form chains; large turbulence zones; uneven flow of gas.

The numerical simulation results give a good agreement with the experiments performed with the physical model. For all studied variants (used process parameters), the single bubbles were observed in the area of water surface in the vessel. For variants presented in Figure 13 (200 rpm, gas flow 20 and dm3·min−1) and relevant examples in numerical simulation Figure 16, the worst bubble dispersion results were obtained because the dead zones were identified in the area near the bottom and sidewalls of the vessel, which disqualifies these work parameters for further use. The areas where swirls and gas bubble chains formed were identified only for the inert gas flows of 20 and 30 dm3·min−1 and 200 rpm in the analyzed model (physical model). This means that the presented impeller model had the best performance in terms of dispersion of gas bubbles in the model liquid. The worst bubble dispersion results were obtained because the dead zones were identified in the area near the bottom and side walls of the vessel, which disqualifies these work parameters for further use.

Figure 17 presents exemplary results of model tests (CFD and physical model) with marked gas bubble dispersion zones. All variants of tests were analogously compared, and this comparison allowed validating the numerical model.

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Figure 17

Compilations of model research results (CFD and physical): A—single gas bubbles formed on the surface of the modeling liquid, B—excessive formation of gas chains and swirls, C—uniform distribution of gas bubbles in the entire volume of the tank, and D—dead zones without gas bubbles, no dispersion. (a) Variant B; (b) variant F.

It should be mentioned here that, in numerical simulations, it is necessary to make certain assumptions and simplifications. The calculations assumed three particle size classes (Table 2), which represent the different gas bubbles that form due to different gas flow rates. The maximum number of particles/bubbles (Table 1) generated was assumed in advance and related to the computational capabilities of the computer. Too many particles can also make it difficult to visualize and analyze the results. The size of the particles, of course, affects their behavior during simulation, while, in the figures provided in the article, the bubbles are represented by spheres (visualization of the results) of the same size. Please note that, due to the adopted Lagrangian–Eulerian approach, the simulation did not take into account phenomena such as bubble collapse or fusion. However, the obtained results allow a comprehensive analysis of the behavior of gas bubbles in the system under consideration.

The comparative analysis of the visualization (quantitative) results obtained with the water model and CFD simulations (see Figure 17) generated a sufficient agreement from the point of view of the trends. A precise quantitative evaluation is difficult to perform because of the lack of a refraction compensating system in the water model. Furthermore, in numerical simulations, it is not possible to determine the geometry of the forming gas bubbles and their interaction with each other as opposed to the visualization in the water model. The use of both research methods is complementary. Thus, a direct comparison of images obtained by the two methods requires appropriate interpretation. However, such an assessment gives the possibility to qualitatively determine the types of the present gas bubble dispersion, thus ultimately validating the CFD results with the water model.

A summary of the visualization results for impellers RT3, i.e., analysis of the occurring gas bubble dispersion types, is presented in Table 8.

Table 8

Summary of visualization results (impeller RT3)—different types of gas bubble dispersion.

No Exp.ABCDEF
Gas flow rate, dm3·min−11030
Impeller speed, rpm200300500200300500
Type of dispersionAccurateUniformUniform/excessiveMinimalExcessiveExcessive

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Tests carried out for impeller RT3 confirmed the high efficiency of gas bubble distribution in the volume of the tested object at a low inert gas flow rate of 10 dm3·min−1. The most optimal variant was variant B (300 rpm, 10 dm3·min−1). However, the other variants A and C (gas flow rate 10 dm3·min−1) seemed to be favorable for this type of impeller and are recommended for further testing. The above process parameters will be analyzed in detail in a quantitative analysis to be performed on the basis of the obtained efficiency curves of the degassing process (oxygen removal). This analysis will give an unambiguous answer as to which process parameters are the most optimal for this type of impeller; the results are planned for publication in the next article.

It should also be noted here that the high agreement between the results of numerical calculations and physical modelling prompts a conclusion that the proposed approach to the simulation of a degassing process which consists of a single-phase flow model with a free surface and a particle flow model is appropriate. The simulation results enable us to understand how the velocity field in the fluid is formed and to analyze the distribution of gas bubbles in the system. The simulations in Flow-3D software can, therefore, be useful for both the design of the impeller geometry and the selection of process parameters.

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4. Conclusions

The results of experiments carried out on the physical model of the device for the simulation of barbotage refining of aluminum revealed that the worst results in terms of distribution and dispersion of gas bubbles in the studied object were obtained for the black impellers variants B4, B8, and B12 (multi-orifice impellers—four, eight, and 12 outlet holes, respectively).

In this case, the control of flow, speed, and number of gas exit orifices did not improve the process efficiency, and the developed design did not meet the criteria for industrial tests. In the case of the ‘red triangle’ impeller (variant RT3), uniform gas bubble dispersion was achieved throughout the volume of the modeling fluid for most of the tested variants. The worst bubble dispersion results due to the occurrence of the so-called dead zones in the area near the bottom and sidewalls of the vessel were obtained for the flow variants of 20 dm3·min−1 and 200 rpm and 30 dm3·min−1 and 200 rpm. For the analyzed model, areas where swirls and gas bubble chains were formed were found only for the inert gas flow of 20 and 30 dm3·min−1 and 200 rpm. The model impeller (variant RT3) had the best performance compared to the previously presented impellers in terms of dispersion of gas bubbles in the model liquid. Moreover, its design differed from previously presented models because of its sharp edges. This can be advantageous for gas bubble dispersion, but may negatively affect its suitability in industrial conditions due to premature wearing.

The CFD simulation results confirmed the results obtained from the experiments performed on the physical model. The numerical simulation of the operation of the ‘red triangle’ impeller model (using Flow-3D software) gave good agreement with the experiments performed on the physical model. This means that the presented model impeller, as compared to other (analyzed) designs, had the best performance in terms of gas bubble dispersion in the model liquid.

In further work, the developed numerical model is planned to be used for CFD simulations of the gas bubble distribution process taking into account physicochemical parameters of liquid aluminum based on industrial tests. Consequently, the obtained results may be implemented in production practice.

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Funding Statement

This paper was created with the financial support grants from the AGH-UST, Faculty of Foundry Engineering, Poland (16.16.170.654 and 11/990/BK_22/0083) for the Faculty of Materials Engineering, Silesian University of Technology, Poland.

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Author Contributions

Conceptualization, K.K. and D.K.; methodology, J.P. and T.M.; validation, M.S. and S.G.; formal analysis, D.K. and T.M.; investigation, J.P., K.K. and S.G.; resources, M.S., J.P. and K.K.; writing—original draft preparation, D.K. and T.M.; writing—review and editing, D.K. and T.M.; visualization, J.P., K.K. and S.G.; supervision, D.K.; funding acquisition, D.K. and T.M. All authors have read and agreed to the published version of the manuscript.

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Institutional Review Board Statement

Not applicable.

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Informed Consent Statement

Not applicable.

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Data Availability Statement

Data are contained within the article.

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Conflicts of Interest

The authors declare no conflict of interest.

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Footnotes

Publisher’s Note: MDPI stays neutral with regard to jurisdictional claims in published maps and institutional affiliations.

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