Modeling Direct Chill Casting of Aluminum Alloys

Modeling Direct Chill Casting of Aluminum Alloys

Modeling Direct Chill Casting of Aluminum Alloys Cathryn Karashin Advisor: Dr. Krane Aluminum Applications

Picture courtesy of Aluminum: Technology, Applications, and Environment by Dietrich G. Altenpohl Beverage cans, planes, trains, automobiles, boats, spacecraft parts Used as the mold material in Al casting Al is very lightweight (1/3

the weight of steel) so it is very useful Direct Chill Casting Direct chill (DC) casting process is used for 68% of the aluminum ingots processed in the US Ingot scrap from stress cracks and butt

deformation account for a 5% loss in production Control of scrap levels is important both in terms of energy usage and cost savings DC Casting: Mold and Ingot Photos courtesy of M. Krane Sump Depth

Sump depth at start up? Flood et al. believe the sump increases at start up, then decreases and plateaus

Through modeling, we hope to have a more definite answer A scaling Analysis for the Heat Flow, Solidification & Convection in Continuous Casting of Aluminum by Flood, Davidson, & Rogers Physica Version 2.11

Models thermal and mechanical properties Puts continuous equations into discrete parts; breaking down into simple algebraic

terms Produces a results file that can be used to generate graphs and analyze data Photo courtesy of http://www.gre.ac.uk/~physica Project Objectives To

model heat transfer and solidification phenomena in direct chill casting using Physica software To study sump shapes during start up as basis for future stress analysis Progress of Models 1st Model: pure Al, simple cooling using fixed

values 2nd Model: pure Al, simple cooling using fixed values, solidification 3rd Model: Al-Cu 5%, cooling using heat transfer coefficient, solidification Wedge Gone Bad

Started using simulations with a wedge Axisymmetric properties of wedge made it ideal Problem with geometry of translating smaller wedge to larger wedge

Wedge to Cube Simulations with the Cube pure Al, simple cooling using fixed values, solidification Pure Al, simple cooling using fixed values, solidification, fluid flow

Pure Al, simple cooling using fixed values from only side mold wall, solidification, fluid flow Cube Simulations Cooling from sides and bottom Notice liquid center (red)

and solidified region (blue) Cube Simulations Cooling from side only

Notice liquid center (red) and solidified region (blue) Note large different between this and previous plot Resultant Velocity at 20s Liquid Fraction at 400s

Thanks to: Dr. Krane All the grad students that have helped me when Im stuck in the lab Purdue

Recently Viewed Presentations

  • Momentum and Impulse

    Momentum and Impulse

    Kinetic and Potential Energy What is Energy? What does it mean if you have a lot of energy? For students it means you can run around, lift weights and scream.
  • Introduction to Astronomy - Weber State University

    Introduction to Astronomy - Weber State University

    Dark Matter and Dark Energy 4 December 2006 Today: Dark matter: evidence and possible forms Dark energy: evidence and possible forms Weighing Galaxies "Dark Matter" In the solar system (all mass at the center), outer planets move slower than inner...
  • Biblical Wisdom - d C. Stancil

    Biblical Wisdom - d C. Stancil

    Biblical Wisdom "Skill in the art of godly living—that orientation which allows one to live in harmonious accord with God's ordering of the world." - ESV Study Bible. Hebrew Wisdom Literature. Proverbial Wisdom: PROVERBS. Philosophical Wisdom: JOB; ECCLESIASTES. Lyric Wisdom:...
  • CREATIVITY TAKES COURAGE WHERE YOU CAN FOLLOW ME:

    CREATIVITY TAKES COURAGE WHERE YOU CAN FOLLOW ME:

    Sir Ken Robinson has quite famously given two TED talks on the subject matter of Creativity in Education. I could spend the next 30 minutes reciting his keynotes but I am pretty sure that would not be value for money....
  • 2nd Grade Language Arts (ELA)

    2nd Grade Language Arts (ELA)

    Keep at Home. will have items for your information to be kept at home-Return to school. will have items that need your signature or response and homework. Planner - will have daily conduct sheet:-Should be signed DAILY this will reflect...
  • Addiction pyschiatrist - storage.googleapis.com

    Addiction pyschiatrist - storage.googleapis.com

    Myplan.com. Salary of psychiatrist . Psychiatrist Salaries. What is the average annual salary for Psychiatrist? How much does a Psychiatrist make? The median annual Psychiatrist salary is $212,259, as of March 31, 2017, with a range usually between $190,205-$237,434, however...
  • Adverbs and Conjunctions

    Adverbs and Conjunctions

    The Adverb. An adverb modifies a verb, an adjective, or another adverb.. An adverb tells . where, when, how, or . to what extent (how long. or . how much). Adverbs may NOT follow linking verbs
  • Alice's storyboard - University of Leicester

    Alice's storyboard - University of Leicester

    Alice's storyboard LU1 Focus 1 LU2 Focus 2 LU3 Focus 3 LU4 Focus 4 LU5 Focus 5 Time line Home Page LU1 Focus 1 LU2 Focus 2 LU3 Focus 3 LU4 Focus 4 LU5 Focus 5 Time line Home Page...