Simulation Study of Al-1Mn/Al-10Si Circular Clad Ingots Prepared by Direct Chill Casting
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ALUMINUM clad products have been successfully used in the automotive industry and others, since they exhibit an excellent combination of physical, chemical, and mechanical properties that cannot be achieved by a monolithic material.[1] The automotive heat exchanger is an important application of the aluminum clad product which is made from a corrosion-resistant alloy at internal layer with a thin clad layer of a brazing alloy. The main conventional method for cladding products is roll bonding,[2,3] which has served the industry well for decades. However, a major disadvantage is that roll bonding is a very time intensive and expensive process, and it is impossible to remove all of the oxides at the interface.[4] For the past few years, the process of simultaneous casting was developed for the manufacturing of clad products. This casting process has the distinct advantages of both cost reduction and interface improvement. For example, a new Novelis FusionTM Technology for the manufacturing of clad aluminum products was LI WU, Ph.D. Student, YING FU, Postdoctoral Fellow, and TONGMIN WANG, Professor, are with the Key Laboratory of Solidification Control and Digital Preparation Technology (Liaoning Province), School of Materials Science and Engineering, Dalian University of Technology, No. 2 Linggong Road, Ganjingzi District, Dalian City, Liaoning Province 116024, P. R. China. Contact e-mail: [email protected] HUIJUN KANG, Lecturer, and ZONGNING CHEN, Postdoctoral Fellow, are with the Laboratory of Special Processing of Raw Materials, Dalian University of Technology, Dalian 116024, P. R. China. Manuscript submitted January 23, 2015. Article published online October 13, 2015. METALLURGICAL AND MATERIALS TRANSACTIONS B
introduced in some literature.[5,6] The copper cladding aluminum rods were fabricated by Su et al. using horizontal core-filling continuous casting technology.[7] The clad aluminum hollow billets were prepared by Liu et al. using horizontal continuous casting.[8] An 8090/ 3003 bimetal slab with consistent mechanical properties was prepared by Wang et al. using a modified direct chill casting process.[9] A continuous composite casting process was developed by Nerl et al. for the production of bilayer aluminum strips.[10] In order to understand the casting process, several models were developed to analyze the casting process by many researchers with the development of powerful numerical methods and computers.[11–16] For instance, Yoon[12] reviewed the applications of numerical simulations to continuous casting technology in steel production. Foroozmehr et al.[15] described a coupled dissolution and diffusion model of solutionizing and solute redistribution in a co-cast bilayer aluminum alloy system. Baserinia et al.[14] developed a steady-state thermofluids model of the FusionTM Technology co-casting process to simulate the casting of rectangular bimetallic ingots. Caron et al.[16] used the three-dimensional numerical thermofluids model to simulate the co-casting of AA3003/AA4045 clad rectangular ingots via F
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