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Modeling Direct Chill Casting of Aluminum Alloys

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

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Modeling Direct Chill Casting of Aluminum Alloys

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

  2. Aluminum Applications • 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 Picture courtesy of Aluminum: Technology, Applications, and Environment by Dietrich G. Altenpohl

  3. 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

  4. DC Casting: Mold and Ingot Photos courtesy of M. Krane

  5. 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

  6. 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

  7. 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

  8. 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

  9. 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

  10. Wedge to Cube

  11. 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

  12. Cube Simulations • Cooling from sides and bottom • Notice liquid center (red) and solidified region (blue)

  13. Cube Simulations • Cooling from side only • Notice liquid center (red) and solidified region (blue) • Note large different between this and previous plot

  14. Resultant Velocity at 20s

  15. Liquid Fraction at 400s

  16. Thanks to: • Dr. Krane • All the grad students that have helped me when I’m stuck in the lab • Purdue 

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