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The equilibrium concentration can be neglected in this case and the kinetic rate constant is simply NO2/c, about 0.49 3 10 3 cm s21. The oxygen flux is thus about 0.10 gO2 cm 22 s21 or 3.2 3 1023 mol cm22 s21. The rate corresponds to an oxidation flux of iron of 0.36 gFe cm22 s21 at a temperature of 1600 ☌. by levitating a 1 g sphere iron in 838 K.
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It is concluded that rheomixing by a TSE can be successfully employed for casting immiscible engineering alloys due to its unique characteristics of reorientation and surface renewal. Numerical results show good qualitative agreement with experimental results.
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It is verified that TSE is a better mixing device than single screw extruder (SSE) and can achieve finer droplets. This revealed that continuous reorientation in the TSE process could produce fine droplets and the best mixing efficiency. Fundamental hydrodynamic micro-mechanisms in a TSE are simulated by a piecewise linear (PLIC) volume-of-fluid (VOF) method coupled with the continuum surface force (CFS) algorithm. A brief review of fabrication methods for immiscible alloys is given, and fluid flow aspects of a novel fabrication method – rheomixing by twin-screw extruder (TSE) are analysed. The concept of multi-controll is proposed for classifying complex processes and identifying individual processes in an immiscible alloy system in order to perform simulations. This paper presents a hydrodynamic analysis of binary immiscible metallurgical flow by a numerical simulation of the rheomixing process.