The Computational Fluid Dynamic (CFD) Modeling of the Horizontal Single Belt Casting (HSBC) Processing of Al-Mg-Sc-Zr Al
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ODUCTION
STRIP casting is a form of near-net-shape casting (NNSC) process that allows for a significant reduction in the processing steps conventionally needed to produce strips via direct chill (DC) casting. As well as reducing capital and operating costs, and manufacturing times, it enables post-casting size-reduction and minimizing the need for consecutive annealing and rolling steps, thereby dramatically lowering production costs and energy consumption. It also eliminates inverse segregation problems, etc., associated with thick section solidification of aluminum parts. As such, NNSC is one of the most promising research areas in process metallurgy. Driven by its inherent advantages in terms of cost, energy, and pollution reduction, over conventional casting processes, strip casting, especially the HSBC process, is a prime candidate for the future of steel and aluminum sheet metal production.[1] Computational fluid dynamics (CFD) has proven to be extremely useful in modeling the HSBC process. In the present study, ANSYS Fluent 14.5 was used to develop a three-dimensional, transient mathematical model of the HSBC system, in order to simulate and predict various transport phenomena associated with the single belt casting process. The model couples various important aspects of the process: (1) liquid metal flow and dynamic interactions between the metal, substrate, and air, in order to determine interfa-
cial/meniscus behavior, (2) the effect of turbulence on molten metal flow and the stability of the triple-point meniscus, (3) the effect of substrate surface roughness on molten metal flow behavior and subsequent as-cast strip quality, and (4) heat transfer between the metal and the substrate and the prediction of solidification behavior of the molten metal. Transient simulations were performed to monitor the process, the volume of fluid (VOF) method being used for free surface tracking. The reliability and robustness of the present mathematical model has been tested against experimental casting results performed on both the HSBC simulator and on the pilot-scale caster now operating at the McGill Metals Processing Centre’s (MMPC) Stinson laboratories. The casting metal investigated in this study is a novel aluminum alloy, based on the medium-strength 5000series. It contains magnesium, which imparts high ductility, good corrosion resistance, and good weldability to the aluminum alloy. The further additions of Sc and Zr to these alloys substantially improve their strength, workability, and high temperature resistance.[2–5] As a result, Al-Mg-Sc-Zr-based alloys are important candidates for aerospace and other applications.[6]
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PROCESS OVERVIEW AND MODEL SET-UP
A. Overview of the HSBC Process S. GE, Ph.D. Student, M. ISAC, Associate Director, and R.I.L. GUTHRIE, Director, are with the McGill Metals Processing Centre, McGill University, 3610 University Street, Montreal, QC H3A 2B2, Canada. Contact e-mail: [email protected] Manuscript submitted April 22, 2015. Article published online May 28, 2015. 2264—VOLUME 46B,
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