Modelling of Fluid Flow and Stress Phenomena during DC Casting of Aluminium Alloys

This paper introduces a general numerical scheme for solving convective-diffusive problems that appear in the solution of microscopic and macroscopic transport phenomena in continuous castings and the heat treatment of aluminium alloys. The numerical scheme is based on spatial discretisation that involves pointisation only. The solution is based on diffuse collocation with multi-quadric radial basis functions. The application of the method is demonstrated in a simplified model of a billet DC casting and verified by a comparison with the classical finite volume method.

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Silicon in Commercial Aluminium Alloys - What Becomes of it during DC-Casting?

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.44-45.95 ◽

1991 ◽

Vol 44-45 ◽

pp. 95-116 ◽

Cited By ~ 17

Author(s):

Y. Langsrud

Keyword(s):

Aluminium Alloys ◽

Commercial Aluminium ◽

Dc Casting

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Modelling the fluid flow, solidification and segregation behavior in electromagnetic DC casting of magnesium alloy

Simulation Modelling Practice and Theory ◽

10.1016/j.simpat.2021.102460 ◽

2021 ◽

pp. 102460

Author(s):

Wenchao Duan ◽

Yiqiang Yang ◽

Wenhong Liu ◽

Zhiqiang Zhang ◽

Jianzhong Cui

Keyword(s):

Fluid Flow ◽

Magnesium Alloy ◽

Segregation Behavior ◽

Dc Casting

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Macrosegregation Mechanisms in Direct-Chill Casting of Aluminium Alloys

Materials Science Forum ◽

10.4028/www.scientific.net/msf.630.193 ◽

2009 ◽

Vol 630 ◽

pp. 193-199 ◽

Cited By ~ 6

Author(s):

Dmitry G. Eskin ◽

Laurens Katgerman

Keyword(s):

Aluminium Alloys ◽

Review Paper ◽

Direct Chill ◽

Systematic Research ◽

Cast Billet ◽

Induced Flow ◽

Dc Casting ◽

The Impact ◽

Macrosegregation Pattern ◽

Macroscopic Parameters

This review paper summarizes the results of recent studies on different mechanisms of macrosegregation upon direct-chill (DC) casting of aluminium alloys. In general, the main mechanisms of macrosegregation have been identified quite some time ago as thermo-solutal convection, free-moving crystals, shrinkage- and deformation-induced flow, and forced convection. Despite this general knowledge, the separation of the effects of these mechanisms on the overall macrosegregation pattern and the ratio of their contribution remained largely unexplored. With the advances in computer simulations and in experimental techniques it becomes possible to look at the impact of individual mechanisms in relation to the macroscopic parameters of the transition region of a DC cast billet and to the microscopic parameters of billet structure. Our systematic research helps in interpreting the apparently contradictory experimental macrosegregation profiles reported in literature. Paper is illustrated by own experimental and computer-simulation results.

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Controlling the Formation of Iron-Bearing Intermetallics in Wrought Al Alloys by Melt Conditioned DC (MC-DC) Casting Technology

Materials Science Forum ◽

10.4028/www.scientific.net/msf.828-829.43 ◽

2015 ◽

Vol 828-829 ◽

pp. 43-47 ◽

Cited By ~ 2

Author(s):

Hu Tian Li ◽

J.B. Patel ◽

H.R. Kotadia ◽

Z. Fan

Keyword(s):

Corrosion Resistance ◽

Aluminium Alloys ◽

Downstream Processing ◽

Al Alloys ◽

Grain Refiner ◽

Casting Technology ◽

Negative Effect ◽

Dc Casting ◽

Primary Aluminium ◽

Iron Bearing

With the increasing use of recycled aluminium alloys from the end-of-life products more and more iron is accumulated into the compositions of alloys. Sometimes, recycling causes the iron levels to increase beyond the set target levels for down-stream processing. The only way to deal with this impurity currently in industry is to increase the primary aluminium added to the furnace to dilute the melt and re-add all other elements or cast it for re-melting or extrude it for products that is not surface finish critical or required higher corrosion resistance. Formation of small well dispersed spherical a- or small b- Fe-bearing intermetallics, which can be homogenised for shorter times and has no negative effect on downstream processing, would be promising even if the iron levels are above the targeted compositional limits. In the present paper, fine and dispersed Fe-bearing intermetallics have been achieved by Melt Conditioned DC (MC-DC) casting technology, instead of coarser Fe-bearing intermetallics forming network like morphology in the DC castings with grain refiner additions (DC-GR). This suggests feasibility of an increased tolerance of iron levels by melt conditioned DC casting technology.

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