Accounting for Melt Flow Pattern and Solid Fraction Evolution in DC Casting of Al-Cu Alloy Using $$ v^{2}{-}f $$
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ill (DC) casting is the primary process for producing aluminum billets that can be subsequently used in manufacturing operations such as extrusion, rolling, and remelting. Every year, a majority of aluminum castings are manufactured worldwide by the DC casting process. This process can also be used for the casting of other non-ferrous metals such as copper, zinc, and magnesium; therefore, it is an example of a technology that was developed just in time to serve the needs of the industry.[1] DC casting bridges the gap between liquid metal that is obtained from a secondary production unit or scrap melting system and semi-fabrication. DC casting enables acquisition of a finer grain structure on account of the direct cooling provided by a water jet impinging on the casting; this consequently
G.C. NZEBUKA is with the Department of Mechatronics Engineering, Federal University of Technology Owerri, Owerri, Imo State, Nigeria. Contact e-mail: [email protected] M.A. WAHEED and S.I. KUYE are with the Department of Mechanical Engineering, Federal University of Agriculture Abeokuta, Abeokuta, Ogun State, Nigeria. B.I. OLAJUWON is with the Department of Mathematics, Federal University of Agriculture Abeokuta, Abeokuta, Ogun State, Nigeria. Manuscript submitted September 19, 2018.
METALLURGICAL AND MATERIALS TRANSACTIONS B
results in a much higher heat extraction rate and eventually leads to reduced microstructural variations and segregation.[2] With the aim of investigating casting parameters that affect the quality of the cast billet, in the past decades, several researchers have employed experimental methods and different numerical modeling approaches to study the effects of casting parameters on the sump depth, distance between the liquidus and the solidus, liquid pool depth, and macrosegregation. Devendas and Grandfield[3] used the finite element method under the assumption of laminar flow to study the DC casting of aluminum alloys. Flood et al. were the first to perform numerical modeling of solidification and macrosegregation in DC casting.[4] Vreeman et al.[5] developed a sophisticated model that described the relative flow of solid and liquid phases; their model was used for modeling the macrosegregation in an aluminum alloy cast in a DC machine.[6] Rerko et al.[7] conducted an experimental benchmark study on the effects of melt convection and solid transport on the solidification of Al-Cu alloys. Zaloznik et al.[8] used the finite volume method to simulate macrosegregation in the DC casting of binary aluminum alloys. In their model, they solved thermosolutal convection in two-dimensional (2D) axisymmetric laminar flow. Eskin et al.[9] conducted an experimental study on the effects of casting speed and water flow rate on the structure formation and macrosegregation in a DC-cast Al-Cu alloy system. Their findings revealed that the casting speed affects the
sump depth. Du et al.[10] modeled the effects of ramping casting speed and casting melt temperature on the temperature distribution and melt flow patterns in the sump region of
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