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<p>Ultra-large continuous casting billets often exhibit internal defects such as shrinkage cavities and voids, which significantly deteriorate their mechanical properties. In this study, finite element simulations using DEFORM were conducted to model 42CrMo steel billets containing voids of various shapes, orientations, and configurations (single and combined). Coupled with cellular automaton (CA) simulations and stress state analyses, the upsetting process was simulated to investigate void closure behavior, microstructural evolution, and crack propagation trends. The results reveal that a single ellipsoidal void with its major axis oriented perpendicular to the compression direction exhibits the highest closure efficiency, and the surrounding region is more prone to complete dynamic recrystallization (DRX). This finding indicates that voids can effectively “consume” local strain. Moreover, when the void boundary experiences a tensile stress state, the P1 point of all voids shows a pronounced tendency for crack initiation, whereas the P2 and P3 points display a relatively lower susceptibility to crack propagation.</p>

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Finite element simulation of the evolution of microstructure and voids during the upsetting process of extra-large 42CrMo steel ingots

  • 期刊论文

  • 发表日期：

    2025年12月13日

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  • Hongyu Lan,
  • Jintang Zhou,
  • Shasha Zhang,
  • Song Xue,
  • Jue Wang,
  • Zhenyu Cheng,
  • Xingshuai Liu,
  • Guojin Xiang,
  • Jicong Zhang,
  • Xinze Li,
  • Chunda Song,
  • Zhengjun Yao

摘要

Ultra-large continuous casting billets often exhibit internal defects such as shrinkage cavities and voids, which significantly deteriorate their mechanical properties. In this study, finite element simulations using DEFORM were conducted to model 42CrMo steel billets containing voids of various shapes, orientations, and configurations (single and combined). Coupled with cellular automaton (CA) simulations and stress state analyses, the upsetting process was simulated to investigate void closure behavior, microstructural evolution, and crack propagation trends. The results reveal that a single ellipsoidal void with its major axis oriented perpendicular to the compression direction exhibits the highest closure efficiency, and the surrounding region is more prone to complete dynamic recrystallization (DRX). This finding indicates that voids can effectively “consume” local strain. Moreover, when the void boundary experiences a tensile stress state, the P1 point of all voids shows a pronounced tendency for crack initiation, whereas the P2 and P3 points display a relatively lower susceptibility to crack propagation.