Eulerian two-phase flow simulation and experimental validation of semisolid slurry generation process using cooling slope

Experimental and numerical studies of slurry generation using a cooling slope are presented in the paper. The slope having stainless steel body has been designed and constructed to produce semisolid A356 Al alloy slurry. The pouring temperature of molten metal, slope angle of the cooling slope and slope wall temperature were varied during the experiment. A multiphase numerical model, considering liquid metal and air, has been developed to simulate the liquid metal flow along the cooling channel using an Eulerian two-phase flow approach. Solid fraction evolution of the solidifying melt is tracked at different locations of the cooling channel following Schiel's equation. The continuity, momentum and energy equations are solved considering thin wall boundary condition approach. During solidification of the melt, based on the liquid fraction and latent heat of the alloy, temperature of the alloy is modified continuously by introducing a modified temperature recovery method. Numerical simulations has been carried out for semisolid slurry formation by varying the process parameters such as angle of the cooling slope, cooling slope wall temperature and melt superheat temperature, to understand the effect of process variables on cooling slope semisolid slurry generation process such as temperature distribution, velocity distribution and solid fraction of the solidifying melt. Experimental validation performed for some chosen cases reveals good agreement with the numerical simulations.

Studies on rheocasting using cooling slope

In the present work, a cooling channel is employed to produce semi-solid A356 alloy slurry. To understand the transport process involved, a 3D non-isothermal, multiphase volume averaging model has been developed for simulation of the semi-solid slurry generation process in the cooling channel. For simulation purpose, the three phases considered are the parent melt, the nearly spherical grains and air as separated but highly coupled interpenetrating continua. The conservation equations of mass, momentum, energy and species have been solved for each phase and the thermal and mechanical interactions (drag force) among the phases have been considered using appropriate model. The superheated liquid alloy is poured at the top of the cooling slope/channel, where specified velocity inlet boundary condition is used in the model, and allowed to flow along gravity through the channel. The melt loses its superheat and becomes semisolid up to the end of cooling channel due to the evolving -Al grains with decreasing temperature. The air phase forms a definable air/liquid melt interface, i.e. free surface, due its low density. The results obtained from the present model includes volume fractions of three different phases considered, grain evolution, grain growth rate, size and distribution of solid grains. The effect of key process variables such as pouring temperature, slope angle of the cooling channel and cooling channel wall temperature on temperature distribution, velocity distribution, grain formation and volume fraction of different phases are also studied. The results obtained from the simulations are validated by microstructure study using SEM and quantitative image analysis of the semi-solid slurry microstructure obtained from the experimental set-up.

Assessment of Seismically Induced Landslide Hazard for the State of Karnataka Using GIS Technique

Landslide hazards are a major natural disaster that affects most of the hilly regions around the world. In India, significant damages due to earthquake induced landslides have been reported in the Himalayan region and also in the Western Ghat region. Thus there is a requirement of a quantitative macro-level landslide hazard assessment within the Indian subcontinent in order to identify the regions with high hazard. In the present study, the seismic landslide hazard for the entire state of Karnataka, India was assessed using topographic slope map, derived from the Digital Elevation Model (DEM) data. The available ASTER DEM data, resampled to 50 m resolution, was used for deriving the slope map of the entire state. Considering linear source model, deterministic seismic hazard analysis was carried out to estimate peak horizontal acceleration (PHA) at bedrock, for each of the grid points having terrain angle 10A degrees and above. The surface level PHA was estimated using nonlinear site amplification technique, considering B-type NEHRP site class. Based on the surface level PHA and slope angle, the seismic landslide hazard for each grid point was estimated in terms of the static factor of safety required to resist landslide, using Newmark's analysis. The analysis was carried out at the district level and the landslide hazard map for all the districts in the Karnataka state was developed first. These were then merged together to obtain a quantitative seismic landslide hazard map of the entire state of Karnataka. Spatial variations in the landslide hazard for all districts as well as for the entire state Karnataka is presented in this paper. The present study shows that the Western Ghat region of the Karnataka state is found to have high landslide hazard where the static factor of safety required to resist landslide is very high.

Semisolid Processing of A380 Al Alloy Using Cooling Slope

This study is aimed toward obtaining near spherical microstructural features of Rheocast A380 aluminum alloy. Cooling slope (CS) technique has been used to generate semisolid slurry from the superheated alloy melt. Spherodization of primary grains is the heart of semisolid processing which improves mechanical properties significantly in the parts cast from semisolid state compared to the conventional casting processes. Keeping in view of the desired microstructural morphology, i.e., rosette or spherical shape of primary alpha-Al phase, successive slurry samples have been collected during melt flow and oil quenched to investigate the microstructure evolution mechanism. Conventionally cast A380 Al alloy sample shows dendritic grains surrounded by large eutectic phase whereas finer, near spherical grains have been observed within the cooling slope processed slurry and also in the solidified castings which confirms the effectiveness of semisolid processing of the alloy following cooling slope technique. Grain refiner addition into the alloy melt is found to have favorable effect which leads to the generation of finer primary grains within the slurry with higher degree of sphericity.

Estimation of ice thickness using surface velocities and slope: case study at Gangotri Glacier, India

We estimate the distribution of ice thickness for a Himalayan glacier using surface velocities, slope and the ice flow law. Surface velocities over Gangotri Glacier were estimated using sub-pixel correlation of Landsat TM and ETM+ imagery. Velocities range from similar to 14-85 m a(-1) in the accumulation region to similar to 20-30 ma(-1) near the snout. Depth profiles were calculated using the equation of laminar flow. Thickness varies from similar to 540 m in the upper reaches to similar to 50-60 m near the snout. The volume of the glacier is estimated to be 23.2 +/- 4.2 km(3).

Optimization of degree of sphericity of primary phase during cooling slope casting of A356 Al alloy: Taguchi method and regression analysis

The present work presents the results of experimental investigation of semi-solid rheocasting of A356 Al alloy using a cooling slope. The experiments have been carried out following Taguchi method of parameter design (orthogonal array of L-9 experiments). Four key process variables (slope angle, pouring temperature, wall temperature, and length of travel of the melt) at three different levels have been considered for the present experimentation. Regression analysis and analysis of variance (ANOVA) has also been performed to develop a mathematical model for degree of sphericity evolution of primary alpha-Al phase and to find the significance and percentage contribution of each process variable towards the final outcome of degree of sphericity, respectively. The best processing condition has been identified for optimum degree of sphericity (0.83) as A(3), B-3, C-2, D-1 i.e., slope angle of 60 degrees, pouring temperature of 650 degrees C, wall temperature 60 degrees C, and 500 mm length of travel of the melt, based on mean response and signal to noise ratio (SNR). ANOVA results shows that the length of travel has maximum impact on degree of sphericity evolution. The predicted sphericity obtained from the developed regression model and the values obtained experimentally are found to be in good agreement with each other. The sphericity values obtained from confirmation experiment, performed at 95% confidence level, ensures that the optimum result is correct and also the confirmation experiment values are within permissible limits. (c) 2014 Elsevier Ltd. All rights reserved.

Wear Behavior of Cooling Slope Rheocast A356 Al Alloy

In the present study, the dry sliding wear behavior of rheocast A356 Al alloys, cast using a cooling slope, as well as gravity cast A356 Al alloy have been investigated at a low sliding speed of 1ms(-1), against a hardened EN 31 disk at different loads. The wear mechanism involves microcutting-abrasion and adhesion at lower load for all of the alloys studied in the present work. On the other hand, at higher load, mainly adhesive wear along with oxide formation is observed for gravity cast A356 Al alloy and rheocast A356 Al alloy, cast using a 45 degrees slope angle. Unlike other alloys, 60 degrees slope rheocast A356 Al alloy is found to undergo mainly abrasive wear at higher load. Accordingly, the rheocast sample, cast using a 60 degrees cooling slope, exhibits a remarkably lower wear rate at higher load compared to gravity cast and 45 degrees slope rheocast samples. This is attributed to the dominance of abrasive wear at higher load in the case of rheocast A356 Al alloy cast using a 60 degrees slope. The presence of finer and more spherical primary Al grain morphology is found to resist adhesive wear in case of 60 degrees cooling slope processed rheocast alloy and thereby delay the transition of the wear regime from normal wear to severe wear.

Macro-Level Assessment of Seismically Induced Landslide Hazard for the State of Sikkim, India Based On GIS Technique

This paper presents a macro-level seismic landslide hazard assessment for the entire state of Sikkim, India, based on the Newmark's methodology. The slope map of Sikkim was derived from ASTER Global Digital Elevation Model (GDEM). Seismic shaking in terms of peak horizontal acceleration (PHA) at bedrock level was estimated from deterministic seismic hazard analysis (DSHA), considering point source model. Peak horizontal acceleration at the surface level for the study area was estimated based on nonlinear site amplification technique, considering B-type NEHRP site class. The PHA at surface was considered to induce driving forces on slopes, thus causing landslides. Knowing the surface level PHA and slope angle, the seismic landslide hazard assessment for each grid point was carried out using Newmark's analysis. The critical static factor of safety required to resist landslide for the PHA (obtained from deterministic analysis) was evaluated and its spatial variation throughout the study area is presented. For any slope in the study area, if the in-situ (available) static factor of safety is greater than the static factor of safety required to resist landslide as predicted in the present study, that slope is considered to be safe.

Numerical Analysis of Rainfall Infiltration in the Slope with a Fracture

With the finite volume method, a 2D numerical model for seepage in unsaturated soil has been established to study the rainfall infiltration in the fractured slope.The result shows that more rain may infiltrate into the slope due to existing fracture and then the pore pressure rises correspondingly. Very probably, it is one of the crucial factors accounting for slope failure. Furthermore a preliminary study has been conducted to investigate the influence of various fracture and rainfall factors such as the depth, width and location of a crack, surface condition, rainfall intensity and duration. Pore pressure and water volumetric content during the transient seepage are carefully examined to reveal the intrinsic mechanism.

Effect of Rock Mass Structure and Block Size on the Slope Stability-Physical Modeling and Discrete Element Simulation

This paper studies the stability of jointed rock slopes by using our improved three-dimensional discrete element methods (DEM) and physical modeling. Results show that the DEM can simulate all failure modes of rock slopes with different joint configurations. The stress in each rock block is not homogeneous and blocks rotate in failure development. Failure modes depend on the configuration of joints. Toppling failure is observed for the slope with straight joints and sliding failure is observed for the slope with staged joints. The DEM results are also compared with those of limit equilibrium method (LEM). Without considering the joints in rock masses, the LEM predicts much higher factor of safety than physical modeling and DEM. The failure mode and factor of safety predicted by the DEM are in good agreement with laboratory tests for any jointed rock slope.

三峡永久船闸高边坡开挖三维离散元数值模拟:3-D Simulation of the Excavation of High Steep Slope of Three-Gorges Permanent Lock by Distinct Element Method

采用面一面接触的三维离散元刚性块体模型,从实测节理面中取出其中的三组,按照其倾向、倾角和节理间距将三峡永久船闸未开挖的区域划分为10~5个离散单元,通过施加力边界条件,给出了与实测初始地应力场接近的数值模拟结果；然后,分4步模拟了永久船闸的开挖过程。计算结果表明：开挖过程会引起节理面出现张开趋势,个别岩体还会沿着节理面滑移。岩体位移的不对称现象较为自然地说明了由节理引起的岩体各向异性特征。

Effect of Microtopography, Slope Length and Gradient, and Vegetative Cover on Overland Flow Through Simulation

Overland flow on a hillslope is significantly influenced by its microtopography, slope length and gradient, and vegetative cover. A 1D kinematic wave model in conjunction with a revised form of the Green-Ampt infiltration equation was employed to evaluate the effect of these surface conditions. The effect of these conditions was treated through the resistance parameter in the kinematic wave model. The resistance in this paper was considered to be made up of grain resistance, form resistance, and wave resistance. It was found that irregular slopes with microtopography eroded more easily than did regular slopes. The effect of the slope gradient on flow velocity and flow shear stress could be negative or positive. With increasing slope gradient, the flow velocity and shear stress first increased to a peak value, then decreased again, suggesting that there exists a critical slope gradient for flow velocity and shear stress. The vegetative cover was found to protect soil from erosion primarily by enhancing erosion-resisting capacity rather than by decreasing the eroding capability of overland flow.

A Dynamic Comprehensive Method for Landslide Control

A slope failure is developed due to progressive external loads and deteriorations of slope geomaterials, thus forming a progressive and dynamic development and occurrence of landslides. Site geological properties and other active factors such as hydrodynamic load and human activities are complex and usually unknown, thus this dynamic development and occurrence of landslides can only be understood through the progressive accumulation of knowledge on the landslides. For such a progressive process, this paper proposes a dynamic comprehensive control method for landslide control. This control method takes full advantage of updated monitoring data and site investigations of landslides, and emphasizes the implementation of possible measures for landslide control at reasonable stages and in different groups. These measures are to prevent the occurrence of a landslide disaster. As a case study, a landslide project at the Panluo open-pit iron mine is analyzed to illustrate this dynamic comprehensive control method.

Experimental study on pore pressure in rock-soil slope during reservoir water level fluctuation

A test system was developed for measuring the pore pressure in porous media, and a new model was devised for the pore pressure testing in both saturated and unsaturated rock-soil. Laboratory experiments were carried out to determine the pore pressure during water level fluctuation. The variations of transient pore pressure vs. time at different locations of the simulated rock-soil system were acquired and processed, and meanwhile the deformation and failure of the model are observed. The experiment results show that whether the porous media are saturated or not, the transient pore pressure is mainly dependent on the water level fluctuation, and coupled with the variation of the stress field.

An Extension of 2D Janbu’s Generalized Procedure of Slices for 3D Slope Stability Analysis II—Numerical Method and Applications

This paper provides a numerical approach on achieving the limit equilibrium method for 3D slope stability analysis proposed in the theoretical part of the previous paper. Some programming techniques are presented to ensure the maneuverability of the method. Three examples are introduced to illustrate the use of this method. The results are given in detail such as the local factor of safety and local potential sliding direction for a slope. As the method is an extension of 2D Janbu's generalized procedure of slices (GPS), the results obtained by GPS for the longitudinal sections of a slope are also given for comparison with the 3D results. A practical landslide in Yunyang, the Three Gorges, of China, is also analyzed by the present method. Moreover, the proposed method has the advantages and disadvantages of GPS. The problem frequently encountered in calculation process is still about the convergency, especially in analyzing the stability of a cutting corner. Some advice on discretization is given to ensure convergence when the present method is used. However, the problem about convergency still needs to be further explored based on the rigorous theoretical background.