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Research Papers: Heat Transfer in Manufacturing

Numerical and Analytical Modeling of Free-Jet Melt Spinning for Fe75−Si10−B15 (at. %) Metallic Glasses

[+] Author and Article Information
Chunbai Wang

Department of Aerospace Engineering,
Iowa State University,
Ames, IA 50011
e-mail: chbwang@iastate.edu

Ambar K. Mitra

Professor
Department of Aerospace Engineering,
Iowa State University,
Ames, IA 50011
e-mail: akmitra@iastate.edu

Contributed by the Heat Transfer Division of ASME for publication in the JOURNAL OF HEAT TRANSFER. Manuscript received March 27, 2013; final manuscript received March 6, 2014; published online April 9, 2014. Assoc. Editor: Wilson K. S. Chiu.

J. Heat Transfer 136(7), 072101 (Apr 09, 2014) (11 pages) Paper No: HT-13-1165; doi: 10.1115/1.4027151 History: Received March 27, 2013; Revised March 06, 2014

Amorphous fiber, ribbon, or film is produced through melt spinning. In this manufacturing process, a continuous delivery of amorphous material is simultaneously dependent on the wheel spinning rate, metallic liquid viscosity, surface tension force, heat transfer inside the melt pool and along the substrate, and other parameters. An analysis of a free-jet melt spinning for fiber manufacture has been performed to relate the process control parameters with amorphous formation. We present a numerical simulation of transient impingement of a free melt jet with a rapidly rotating wheel, along with theoretical estimates of melt ribbon thickness, to investigate dynamical characteristics of the flow in melt pool. The nucleation temperature and the critical cooling rate are predicted in the paper for alloy Fe75–Si10–B15 (at. %). Thermal conduction is found to dominate undercooling in melt spinning by comparing the temperature and velocity measurements with our numerical simulation and the analytical solutions.

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Figures

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Fig. 1

Schematic of free-jet melt spinning with larger gap, jet impingement, and steady melt pool

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Fig. 2

Illustration of a ribbon formation on a substrate

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Fig. 3

Ratio Z/w at various wheel speeds from Kramer et al. [10]

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Fig. 4

Melt jet evolution and impingement (wheel speed Uw = 25 m/s) (Photograph courtesy of Ames Lab, U.S. DOE)

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Fig. 5

Geometry of a fully developed free-jet melt spinning (not to scale), the wheel rotates at Uw to right and the ribbon departs the wheel at point F (Photograph courtesy of Ames Lab, U.S. DOE)

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Fig. 6

Melt spinning chamber

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Fig. 7

Evolution of free melt jet after releasing

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Fig. 8

Melt pool and ribbon gestate after touchdown (Uw = 4 and 10 m/s)

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Fig. 9

Flow velocity vectors in the melt pool

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Fig. 10

Ribbon thickness as a function of Re given S/Z, F/Z, and Uw>>Ud

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Fig. 11

The TTT diagram for Fe75−Si10−B15

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Fig. 12

Momentum and heat transport in solid and hollow arrows, respectively, (not to scale)

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Fig. 13

Normalized temperature profile due to heat conduction in comparison with experimental results, the ambient temperature at the copper wheel center Ta = 293 K

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Fig. 14

Comparison of ribbon thickness δ and thermal layer δn under various Peclet numbers

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Fig. 15

Isothermal and velocity diagram after touchdown

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Fig. 16

Cooling rate of the alloy at T = 1419 K

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Fig. 17

Heat transfer coefficient along the melt–wheel contact

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