A Numerical Study of 3D Turbulent Melt Flow and Solidification in a Direct Chill Slab Caster with a Porous Combo Bag Melt Distributor

Abstract

A 3D turbulent melt flow and solidification of an aluminum alloy (AA-1050) for an industrial-sized direct chill slab casting process is modeled. The melt is delivered through a rectangular submerged nozzle and a non-deformable combo bag fitted with a bottom porous filter. The non-Darcian model, incorporating the Brinkman and Forchheimer extensions, is used to characterize the turbulent melt flow behavior passing through the porous filter. The casting speed and the effective heat transfer coefficient at the metal-mold contact region within the mold are varied. The above two parameters are found to have significant influence on the solidification process.

Influence of liquid metal feeding on the flow and macrosegregation in DC casting

“…Other studies of DC casting found in the literature [11][12][13] are generally limited to cases with liquid metal introduced uniformly across the top of the domain, however, there are a few exceptions. Begum and Hasan [14,15] examined various inlet feeding systems for slabs using a turbulent, 3D model without grain motion. Constrained inlets were found to create a downward jet that retards solid growth at the centreline, producing a cliff-shaped mushy zone which widens with increased casting speed.…”