Computational model for multi alloy casting of aluminum rolling ingots

Direct Chill (DC) casting is the primary route to produce rolling ingots in an industrial setup. During DC casting, the temperature field, fluid flow and solidification profile strongly depends on the ingot cooling practice. Further, the temperature field affects the macro/micro structure and defects which in turn determine the quality of the ingots produced. The present work focuses on the development of a steady-state computational fluid dynamics (CFD) model which appropriately treats heat transfer, fluid flow and solidification during multi alloy DC casting. This model is rigorously validated with experimental data from laboratory tests reported elsewhere. In multi-alloy co-casting, the simulation study is done to understand the effect of the casting speed and the metal distribution system. The present model is useful in providing an insight into the thermal-fluid flow and solidification profile that can help in identifying optimum process parameters.