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Numerical analysis of the twin-roll casting of thin aluminium-steel clad strips

Numerische Analyse des Zwei-Rollen-Bandgießens von Aluminium-Stahlverbundbändern

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Abstract

The production of thin aluminium-steel clad strips by means of twin-roll casting is one of the prospective trends in the development of sheet production. The main advantages of twin-roll casting are low specific energy and resource consumption. Besides this, the resulting compound has a high bonding strength owing to the presence of a continuous thin layer of intermetallic phases having an approximate thickness of 3 µm at the interface of the two metals. At the same time, the quality of the clad strip depends on the microstructure and properties of the aluminium layer formed directly from a melt. A deformation immediately following the solidification of the metal between the two rotated, internally water-cooled rolls has a substantial influence on this aluminium layer. Due to the complexity of observing the processes occurring in the melt pool, a numerical simulation became one of the main methods for their investigation. Simulation is widely used to describe the process of twin-roll casting of monomaterial strips, but so far it has not been used for to comprehensively analyse the process of twin-roll casting of clad strips. In the present paper, a two-dimentional finite-element simulation of the system “clad strip—water-cooled rolls” using the ANSYS software is proposed. A joint analysis is carried out of the heat transfer, viscous flow of aluminium melt, its solidification and deformation resulting in the temperature distribution in the cast metal as well as in the tool. The dependences of the deformation strain and outlet temperature of the clad strip on the main technological process parameters; obtained by numerical simulation, are shown.

Zusammenfassung

Die Herstellung von dünnen Aluminium-Stahl-Verbundbändern mittels des Zwei-Rollen-Gießverfahrens ist einer der Trends in der zukünftigen Entwicklung der Blechproduktion. Die wesentlichen Vorteile des Zwei-Rollen-Bandgießens sind geringe spezifische Energie-und Ressourcenverbräuche. Die mit dem Verfahren erzeugten Verbunde haben eine hohe Haftfestigkeit aufgrund der Entstehung auf der Kontaktfläche zwischen beiden Materialien einer kontinuierlichen dünnen Schicht von intermetallischen Phasen mit einer Dicke von ca 3 µm. Die Qualität der plattierten Bänder hängt von den Eigenschaften der dickeren Aluminiumschicht ab, die sich direkt aus der Schmelze bildet. Der entscheidende Einfluss auf die Mikrostruktur des Aluminiums hat die Umformung des gerade erstarrten Metalls zwischen den zwei rotierenden innenwassergekühlten Gießrollen. Da eine direkte Beobachtung des Prozessverlaufs zu komplex ist, hat sich die numerische Simulation zu einer Hauptmethode zur Erstarrungszonenanalyse entwickelt. Die Simulation wird häufig verwendet, um den Prozess des Bandgießens von Monometallen zu beschreiben, bisher jedoch nicht für eine umfassende Prozessanalyse zur Herstellung von Verbundbändern. In der vorliegenden Arbeit wird die zweidimensionale Finite-Elemente Simulation eines Systems „Verbundband – wassergekühlten Walzen“ mittels ANSYS Software vorgestellt. Es wird eine gemeinsame Analyse der Wärmeübertragung, des viskosen Werkstofffließens, der Erstarrung und Umformung des Aluminiums vorgenommen. Aus der numerischen Simulation resultieren die Temperaturverteilungen im Verbundband sowie im Werkzeug. Die mittels der FE-Analyse ermittelten Abhängigkeiten des Umformgrades und der Austrittstemperatur des Verbundbands von den wichtigsten technologischen Prozessparametern sind hier präsentiert worden.

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Abbreviations

a 1–10 :

Regression equation coefficients [−]

D :

Roll diameter [mm]

H :

Resulting clad strip thickness [mm]

H 0 :

Clad strip thickness prior to deformation in mold [mm]

H s :

Steel strip thickness [mm]

h :

Specific clad strip thickness [−]

h al :

Specific aluminium layer thickness [−]

h s :

Specific steel layer thickness [−]

L d :

Deformation zone length [mm]

L s :

Solidification zone length [mm]

L t :

Total pool length [mm]

l d :

Specific deformation zone length [−]

l t :

Specific melt pool length [−]

R :

Roll radii [mm]

T :

Melt inlet temperature [°C]

V :

Casting speed [m/min]

α :

Pool contact angle [Rad]

ε :

Plastic strain [%]

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Acknowledgments

The authors would like to thank the German Research Foundation (DFG) for their financial support for the work carried out here within the scope of the project SCHA 1484/21-1 “Manufacturing of the aluminium-steel compound by means of twin-roll casting”.

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Authors and Affiliations

  1. Lehrstuhl für Werkstoffkunde (Materials Science), Universität Paderborn, Pohlweg 47–49, 33098, Paderborn, Germany

    M. Stolbchenko, O. Grydin & M. Schaper

  2. National Metallurgical Academy of Ukraine, Gagarin av. 4, 49600, Dnipropetrovsk, Ukraine

    A. Samsonenko & V. Khvist

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  1. M. Stolbchenko
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Correspondence to M. Stolbchenko.

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Stolbchenko, M., Grydin, O., Samsonenko, A. et al. Numerical analysis of the twin-roll casting of thin aluminium-steel clad strips. Forsch Ingenieurwes 78, 121–130 (2014). https://doi.org/10.1007/s10010-014-0182-x

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