Integrated 3D model to simulate solidification and predict hot cracking during DC casting of aluminum alloys

Zhengdong Long, Qingyou Han, Srinath Viswanathan, Shridas Ningileri, Subodh Das, Kazunori Kuwana, Mohamed Hassan, Marwan Khraisheh, Adrian Sabau, Kozo Saito

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Abstract

An integrated 3D Direct Chill (DC) casting model was used to simulate the heat transfer, fluid flow, solidification, and thermal stress during casting. Temperature measurements were performed in an industrial casting facility to setup and validate the model. The key features such as heat transfer between cooling water and the ingot surface as a function of surface temperature, cooling water flow rate, air gaps caused by mold and bottom block design were also considered in the model. An elasto-viscoplastic constitutive model, which was determined based on mechanical testing, was used to calculate the evolution of stress during casting. The stress evolution was compared at various locations and correlated with physical phenomena associated with the casting process. An Ingot Cracking Index, which represents the ingot hot cracking propensity, was established based on the ratio of stress to strength. The Index calculation results were consistent with observations in industrial casting practice.

Original languageEnglish
Title of host publicationLight Metals 2005 - Proceedings of the Technical Sessions Presented by the TMS Aluminium Committee
EditorsH. Kvande
Pages1057-1062
Number of pages6
Publication statusPublished - 16 Aug 2005
Event134th TMS Annual Meeting - San Francisco, CA, United States
Duration: 13 Feb 200517 Feb 2005

Publication series

NameTMS Light Metals
ISSN (Print)0147-0809

Other

Other134th TMS Annual Meeting
CountryUnited States
CitySan Francisco, CA
Period13/2/0517/2/05

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Keywords

  • Aluminum 3004 alloy
  • DC casting
  • Hot cracking
  • Modeling

ASJC Scopus subject areas

  • Condensed Matter Physics
  • Metals and Alloys
  • Materials Chemistry

Cite this

Long, Z., Han, Q., Viswanathan, S., Ningileri, S., Das, S., Kuwana, K., Hassan, M., Khraisheh, M., Sabau, A., & Saito, K. (2005). Integrated 3D model to simulate solidification and predict hot cracking during DC casting of aluminum alloys. In H. Kvande (Ed.), Light Metals 2005 - Proceedings of the Technical Sessions Presented by the TMS Aluminium Committee (pp. 1057-1062). (TMS Light Metals).