Understanding and development of high shear technology for liquid metal processing

Abstract

Oxide films in aluminium melts are unavoidable. A new technology developed by BCAST suggests breaking films into small fragments or particles which play a role as the grain refiner. Mechanical breakage is realised by using a high-shear mixer (HSM) with the rotor-stator impeller. In the presented thesis, the positive role of small oxide particles is shown by the computer modelling. The defragmentation potency of HSM is demonstrated by physical modelling with powders checked by optical analyses (microscopy) and SEM (Scanning Electron Microscopy). The flow has been analysed by optical recording and by PIV (Particle Image Velocimetry) to find the best conditions to cause a satisfying oxides distribution in all volume of liquid metal processed by the HSM. A new model to estimate the mixed volume has been proposed and checked by experiments with liquid metals. The model was checked by the PIV observations and by direct experiments in the liquid metal and is found to be in good agreement with reality. Optimisation methods are considered and a new design of HSM is proposed according to the experimental findings. This design improves the uniformity of mixing in the pseudo-cavern volume and exhibits the dispersion efficiency better than the design used currently by BCAST. Understanding and development of high shear technology for liquid metals processing is an important part of BCAST research and is of great interest for industry. Up to now, this method was found to give good experimental results but it was a lack of information about physical basics behind this process. The goal of this thesis is to answer why and how to apply HSM in metallurgy and to propose new condition and design solutions associated with the specific requirements of the liquid metal process.