Numerical simulation of multilayered multiple metal cast rolls in compound casting process

Compound casting consists of two techniques: horizontal centrifugal casting and gravity filling casting. In this study, a numerical model was developed for compound casting of multilayered multiple-metal cast rolls, and a 500-mm CR4 casting roll was simulated. In the simulation, the process of compound casting was divided into three stages and the development of filling flow, solidification of melt and evolution of temperature field in each stage was computed with the model. The model was then verified by comparison of (1) the simulation result with the measured temperature history on the surface of a 500-mm CR4 casting roll produced in a test process and (2) the simulated temperature history of the CR4 layer with the measured CCT (continuous cooling transformation) diagram of CR4 material. The simulation results in different stages of compound casting are also discussed for improving casting process design and defect preventing. The lower temperature at the location 15 mm away from both ends on the inner surface of the CR4 layer could cause poor merging with the intermediate layer.