Mathematical predictions of brass/steel ingot structures

Metallographic studies performed on a cross-section of static steel ingot allow the observation of the following morphological zones: a) columnar grains (treated as austenite single crystals), b) zone of the columnar into equiaxed grains transformation (CET), and c) equiaxed grains at the ingot axis. These zones are reproduced theoretically by the numerical simulation. The simulation is based on the calculation of both the temperature field in a solidifying large steel ingot and the thermal gradient field obtained for the same boundary conditions. In particular, a new, innovative method based on the mathematical treatment applied to different functions resulting from both the aforementioned fields, are used in the structural predictions. The method developed, firstly for the massive steel ingot, has subsequently been applied to theoretically predict the structural zones in continuously cast brass ingots. In the case of continuously cast brass ingots three different morphologies were revealed experimentally: a) columnar structures, b) equiaxed structures preceded by the CET (sharp transition), and c) single crystals situated axially. The above model for the structural zones prediction is useful in plastic deformation design for: a) steel forging ingots assigned for the crankshafts applied to the ship engines, and b) continuously cast brass ingots assigned for special applications in the shipbuilding industry.