Direct Chill Casting of Aluminum Alloys: Modeling and Experiments on Industrial Scale Ingots

2002 ◽  
Vol 124 (5) ◽  
pp. 947-953 ◽  
Author(s):  
Christopher J. Vreeman ◽  
J. David Schloz ◽  
Matthew John M. Krane
Keyword(s):  
Casting Process ◽  
Direct Chill ◽  
Solid Particles ◽  
Direct Chill Casting ◽  
Grain Structure ◽  
Temperature Fields ◽  
Industrial Scale ◽  
Grain Refiner ◽  
Chill Casting ◽  
Continuum Mixture Model

A continuum mixture model of the direct chill casting process is compared to experimental results from industrial scale aluminum billets. The model, which includes the transport of free-floating solid particles, can simulate the effect of a grain refiner on macrosegregation and fluid flow. It is applied to an Al-6 wt% Cu alloy and the effect of grain refiner on macrosegregation, sump profile, and temperature fields are presented. Two 45 cm diameter billets were cast under production conditions with and without grain refiner. Temperature and composition measurements and sump profiles are compared to the numerical results. The comparison shows some agreement for the grain refined case. It is believed that an incorrect assumption about the actual grain structure prevents good agreement in the non-grain refined billet.

Direct Chill Casting of Aluminum Alloys: Modeling and Experiments on Industrial Scale Ingots

2001 ◽  
Author(s):  
Christopher J. Vreeman ◽  
J. David Schloz ◽  
Matthew John M. Krane
Keyword(s):  
Casting Process ◽  
Direct Chill ◽  
Solid Particles ◽  
Direct Chill Casting ◽  
Grain Structure ◽  
Temperature Fields ◽  
Industrial Scale ◽  
Grain Refiner ◽  
Chill Casting ◽  
Continuum Mixture Model

Abstract A continuum mixture model of the direct chill casting process is compared to experimental results from industrial scale aluminum billets. The model, which includes the transport of free-floating solid particles, can simulate the effect of a grain refiner on macrosegregation and fluid flow. It is applied to an Al - 6 wt% Cu alloy and the effect of grain refiner on macrosegregation, sump profile, and temperature fields are presented. Two 45 cm diameter billets were cast under production conditions with and without grain refiner. Temperature and composition measurements and sump profiles are compared to the numerical results. The comparison shows excellent agreement for the grain refined case. It is believed that an incorrect assumption about the grain structure prevents good agreement in the non-grain refined billet.

scholarly journals Direct Chill Casting and Extrusion of AA6111 Aluminum Alloy Formulated from Taint Tabor Scrap

Materials ◽  
2020 ◽  
Vol 13 (24) ◽  
pp. 5740
Author(s):  
Kawther Al-Helal ◽  
Jayesh B. Patel ◽  
Geoff M. Scamans ◽  
Zhongyun Fan
Keyword(s):  
Extrusion Process ◽  
Direct Chill ◽  
Direct Chill Casting ◽  
Grain Structure ◽  
Chill Casting ◽  
Automotive Body ◽  
Processing Cost ◽  
Scrap Aluminum ◽  
Co Addition ◽  
Equiaxed Grains

AA6111 aluminum automotive body-sheet alloy has been formulated from 100% Taint Tabor scrap aluminum. Direct chill casting with and without high shear melt conditioning (HSMC) was used to produce the AA6111 alloy billets. Both homogenized and non-homogenized billets were extruded into sheets. The optical micrographs of the melt conditioned direct chill (MC-DC) samples showed refined equiaxed grains in comparison to direct chill (DC) cast and direct chill grain refined (DC-GR) samples. Optical metallography showed extensive peripheral coarse grain (PCG) for the DC, DC-GR and MC-DC planks extruded from the homogenized standard AA6111 billets while planks extruded from modified AA6111 billets (with recrystallization inhibitors) showed thin PCG band. The co-addition of recrystallization inhibitors Mn, Zr, and Cr with elimination of the billet homogenization step had a favorable impact on the microstructure of the AA6111 alloy following the extrusion process where a fibrous grain structure was retained across the whole section of the planks. The mechanical properties of as-cast planks extruded from non-homogenized billets were similar to those extruded from homogenized billets. Eliminating the homogenization heat treatment step prior to extrusion has important ramifications in terms of processing cost reduction.

Development of an 8090/3003 bimetal slab using a modified direct-chill casting process

2014 ◽  
Vol 214 (9) ◽  
pp. 1806-1811 ◽  
Author(s):  
Tongmin Wang ◽  
Chunhui Liang ◽  
Zongning Chen ◽  
Yuanping Zheng ◽  
Huijun Kang ◽  
...  
Keyword(s):  
Casting Process ◽  
Direct Chill ◽  
Direct Chill Casting ◽  
Chill Casting ◽  
Direct Chill Casting Process

Effects of Low Frequency Electromagnetic Field on Segregation Layer during Hot-Top Casting of Aluminium Alloy

2011 ◽  
Vol 189-193 ◽  
pp. 3795-3798
Author(s):  
Xiang Jie Wang ◽  
Jian Zhong Cui ◽  
Hai Tao Zhang ◽  
Hui Xue Jiang ◽  
Gao Song Wang
Keyword(s):  
Electromagnetic Field ◽  
Aluminium Alloy ◽  
Surface Segregation ◽  
Low Frequency ◽  
Casting Process ◽  
Direct Chill ◽  
Direct Chill Casting ◽  
Chill Casting ◽  
Direct Chill Casting Process

Surface segregation layer are frequently encountered during aluminium alloy direct chill casting process, and the removal of the surface segregation layer before further processing of the ingot decreases the ingot yield. In this work, the low frequency electromagnetic field was applied to study the effects of low frequency electromagnetic field on segregation layer during the direct chill casting process. The results show that under the effect of the low frequency electromagnetic field, the surface quality of ingot is improved, the structure of the ingot is refined, and the thickness of segregation layer is decreased.

Heat-Transfer Measurements in the Primary Cooling Phase of the Direct-Chill Casting Process

2012 ◽  
Vol 43 (5) ◽  
pp. 1202-1213 ◽  
Author(s):  
Etienne J. F. R. Caron ◽  
Amir R. Baserinia ◽  
Harry Ng ◽  
Mary A. Wells ◽  
David C. Weckman
Keyword(s):  
Heat Transfer ◽  
Casting Process ◽  
Direct Chill ◽  
Direct Chill Casting ◽  
Chill Casting ◽  
Cooling Phase ◽  
Direct Chill Casting Process

Fabrication of Cladding Billet in Diameter of 160mm/148mm by Direct Chill Casting Process

2016 ◽  
Vol 877 ◽  
pp. 3-8
Author(s):  
Jian Zhong Cui ◽  
Xing Han
Keyword(s):  
Casting Process ◽  
Direct Chill ◽  
Bonding Interface ◽  
Direct Chill Casting ◽  
Interfacial Region ◽  
Chill Casting ◽  
Metallurgical Bonding ◽  
Shearing Strength ◽  
Interface Bonding Strength ◽  
Direct Chill Casting Process

The AA4045/AA3003 cladding billet, which has a low clad ratio of 7.5% in size of φ160mm/φ148mm, was prepared successfully by the modified direct chill casting process. Microstructures, elements distribution and mechanical properties of the bonding interface were examined. The results show that metallurgical bonding interface can be obtained with the optimal parameters. The metallurgical bonding interface is free of any discontinuities due to the elements diffusion across the interface. The hardness of the interfacial region is higher than that of the AA3003 but lower than that of AA4045, suggesting that the interface bonding strength is higher than the strength of AA3003. The shearing strength is 82.3 MPa, indicating excellent metallurgical bonding.

Study on Fabrication of AA4032/AA6069 Cladding Billet Using Direct Chill Casting Process

2016 ◽  
Vol 25 (4) ◽  
pp. 1317-1326 ◽  
Author(s):  
Xing Han ◽  
Haitao Zhang ◽  
Bo Shao ◽  
Lei Li ◽  
Xuan Liu ◽  
...  
Keyword(s):  
Casting Process ◽  
Direct Chill ◽  
Direct Chill Casting ◽  
Chill Casting ◽  
Direct Chill Casting Process
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