Horizontal continuous casting process has been successfully implemented in Alcan for
the production of T-ingots of primary aluminium and foundry alloys. Ability to achieve increased
productivity targets and reduce production costs relies on a fundamental understanding of key
process characteristics and operating parameters. Thanks to the long-standing experience in vertical
DC Casting, numerical modelling appeared as a powerful approach to understand phenomena
related to metal flow, solidification and ultimately defect formation.
As part of a collaborative R&D program, a global model of horizontal casting process, integrating
specialized sub-models on critical aspects of the process such as meniscus dynamics, is being
developed. Experimental characterization of primary and secondary cooling is performed in parallel
with modelling work to provide the information necessary to properly characterize mould heat
transfer. This paper will present the development of a 3D process model of T-ingot casting along
with its application to solve specific process challenges that have emerged during the first years of
production in the plant.
