A mathematical model of the heat and fluid flows in direct-chill casting of aluminum sheet ingots and billets

  • Dag Mortensen
Article
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Abstract

A finite-element method model for the time-dependent heat and fluid flows that develop during direct-chill (DC) semicontinuous casting of aluminium ingots is presented. Thermal convection and turbulence are included in the model formulation and, in the mushy zone, the momentum equations are modified with a Darcy-type source term dependent on the liquid fraction. The boundary conditions involve calculations of the air gap along the mold wall as well as the heat transfer to the falling water film with forced convection, nucleate boiling, and film boiling. The mold wall and the starting block are included in the computational domain. In the start-up period of the casting, the ingot domain expands over the starting-block level. The numerical method applies a fractional-step method for the dynamic Navier-Stokes equations and the “streamline upwind Petrov-Galerkin” (SUPG) method for mixed diffusion and convection in the momentum and energy equations. The modeling of the start-up period of the casting is demonstrated and compared to temperature measurements in an AA1050 200×600 mm sheet ingot.

Keywords

Material Transaction Heat Mass Transfer Mushy Zone Mold Wall Bottom Block 
These keywords were added by machine and not by the authors. This process is experimental and the keywords may be updated as the learning algorithm improves.
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Copyright information

© ASM International & TMS-The Minerals, Metals and Materials Society 1999

Authors and Affiliations

  • Dag Mortensen
    • 1
  1. 1.the Department of Materials and Corrosion TechnologyInstitute for Energy TechnologyKjellerNorway

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