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
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