Measurement of the Heat Transfer in the Primary Cooling Area of a Laboratory Direct Chill Casting Plant for Alloy Design

Abstract

The thermal transfer performance in the primary cooling area during direct chill casting plays a crucial role in the microstructure formation process and thus exerts a major impact on the mechanical properties of cast aluminium alloys. Understanding the influence of cooling rate on phase formation is essential for optimizing alloy design. This study presents a comprehensive analysis of heat transfer based on experimental results and its impact on phase formation during the solidification process of aluminium alloys. Measurements were conducted on a laboratory-scale direct chill casting plant (Indutherm VCC3000), with a focus on the primary cooling area. Therein, cooling gradients were determined using five thermocouples placed inside the graphite-mould walls and three implemented in the starter block. Tests were conducted as block casting and no evaluation of the casting speed was possible. Based on the obtained results, the influence of heat transfer on the cooling gradient of the investigated system is discussed. In this regard, the research provides valuable insights for future studies into the correlation between heat transfer, cooling rate, and phase formation during the solidification of aluminium alloys in a laboratory direct chill casting plant. The findings contribute to the optimization of alloy design, facilitating the production of aluminium alloys with tailored microstructures and improved mechanical properties.