Development of a continuous composite casting process for the production of bilayer aluminium strips

The special bilayer mould system was manufactured and implemented into an existing continuous casting device upgraded by a second furnace to hold the additional pure aluminium. A stable casting process was achieved. The quality of the manufactured compound was assessed by metallographic specimens cut from the obtained bilayers. Based on temperature measurements, a full 3D finite element model was developed to gain a more realistic description of the temperature and fluid flow conditions in the composite casting, especially in the margin regions.