Abstract
The steady-state thermal problem associated with the direct-chill continuous casting of A6063 aluminum cylindrical ingots is solved using the numerical finite element technique. Excellent correlation is demonstrated between the numerical model and experimental data from ingots cast at two different speeds. By application of the model, effective heat transfer coefficients are calculated as a function of vertical position on the outside surface of the ingot. It is shown that direct application of these coefficients to the modeling of different casting situations will produce substantial errors in the region in which heat transfer is by nucleate boiling. Using theories of nucleate boiling with forced convection and film cooling, a method is developed to calculate the external boundary conditions in the submold region of the ingot, thus making it possible for the first time to define explicitly all of the thermal boundary conditions associated with this casting configuration. These theories are incorporated into the numerical model, and a subsequent simulation shows excellent agreement with experimental data from a third ingot.
Similar content being viewed by others
References
W. Roth:Aluminium, 1943, vol. 25, pp. 283–91.
A.I. Veynik:Theory of Special Casting Methods, ASME, New York, NY, 1962, pp. 11–145.
A.A. Sfeir and J.A. Clumpner:J. Heat Transfer, Trans. ASME, 1977, vol. 99, pp. 29–34.
R. Siegel:Int. J. Heat Mass Transfer, 1978, vol. 21, pp. 1421–30.
H. Klein:Giesserei (Techn.-Wiss. Beihefte), 1953, vol. 10, pp. 441–54.
D. Adenis, K.H. Coats, and D.V. Ragone:J. Inst. Metals, 1962–63, vol. 91, pp. 395–403.
P.G. Kroeger: in “Heat Transfer 1970”, U. Grigull and E. Hahne, eds.,Proc. 4th Int. Heat Transfer Conf., 1970, Paris, American Elsevier Publishing Co. New York, NY, 1971, vol. 1, p. CU2.7
J. Mathew and H.D. Brody:Proc. of Int. Conf. on Solidification, A. Nicholson, ed., The Metals Society, University of Sheffield, July 1977, pp. 244–49.
D.C. Weckman, R.J. Pick, and P. Niessen:Z. Metallkde., 1979, vol. 70, pp. 750–57.
H. Fossheim and E.E. Madsen:Light Metals 1979, W.S. Peterson, ed., TMS-AIME, Warrendale, PA, 1979, pp. 695–720.
E.K. Jensen:Light Metals 1980, K.J. McMinn, ed., TMS-AIME, Warrendale, PA, 1980, pp. 631–42.
V. Venkateswaran: Ph.D. thesis, University of British Columbia, Vancouver, BC, Canada, 1980.
D.A. Peel and A.E. Pengelly:Mathematical Models in Metallurgical Process Development, London, The Iron and Steel Institute, 1970, pp. 186–96.
J. Szargut and J. Skorek:Met. Tech., 1980, vol. 7, pt. 1, pp. 36–40.
J.E. Lait, J.K. Brimacombe, and F. Weinberg:Continuous Casting, K.R. Olen, ed., TMS-AIME, Warrendale, PA, 1973, pp. 151–70.
ibid, pp. 171–96.
F. Weinberg:Metall. Trans. A, 1975, vol. 6A, pp. 1971–85.
Y.S. Touloukian, ed.:Thermophysical Properties of Matter, Thermophysical Properties Research Center, Purdue University, Plenum Publishing Corp., New York, NY, 1970.
G. Fortina and F. Gatto:Light Metals 1978, K.B. Higbie, ed., TMS-AIME, Warrendale, PA, 1978, pp. 365–80.
G. Porro and P. Lombardi:Alluminio, 1954, vol. 23, pp. 23–34.
J. Mathew: Ph.D. thesis, University of Pittsburgh, Pittsburgh, PA, 1977.
E.F. Emley:Int. Met. Rev., 1976, vol. 21, pp. 75–115.
D.L.W. Collins:Metallurgia, 1967, vol. 76, pp. 137–44.
R. Bachowski and R.E. Spear:Light Metals 1975, R. Rentsch, ed., TMS-AIME, Warrendale, PA, 1975, vol. 2, pp. 111–18.
R. Mitamura, T. Ito, Y. Takahashi, and T. Hiraoka:Light Metals 1978, J.J. Miller, ed., TMS-AIME, Warrendale, PA, 1978, pp. 281–91.
R.G. Piesche:Met. Tech., 1978, vol. 5, pt. 8, pp. 257–63.
D.D. Beattie:Met. Tech., 1977, vol. 4, pp. 147–52.
D.M. Lewis:J. Inst. Metals, 1953–54, vol. 82, pp. 395–413.
W.H. McAdams, W.E. Kennel, C.S. Minden, R. Carl, P.M. Picornell, and J.E. Dew:Ind. Eng. Chem., 1949, vol. 41, pp. 1945–53.
F. Kreith:Principles of Heat Transfer, Intext Education Publishers, New York, NY, 1976, pp. 495–524.
W.M. Rohsenow:Heat Transfer with Boiling, in “Developments in Heat Transfer,” W.M. Rohsenow, ed., The M.I.T. Press, Cambridge, MA, 1964, pp. 169–260.
W.M. Rohsenow:Heat Transfer with Boiling, in “Modern Developments in Heat Transfer,” W. Ibele, ed., Academic Press, New York, NY, 1963, pp. 85–158.
W.M. Rohsenow: “Boiling,” inHandbook of Heat Transfer, W.M. Rohsenow and J.P. Harnett, eds., McGraw-Hill Book Comp., New York, NY, 1973, pp. 13-3 to 13-74.
R.B. Bird, W.E. Stewart, and E.N. Lightfoot:Transport Phenomena, John Wiley and Sons, Inc., New York, NY, 1960, p. 40.
W.H. McAdams, T.B. Drew, and G.S. Bays, Jr.:Trans. ASME, 1940, vol. 62, pp. 627–31.
W.H. McAdams:Heat Transmission, McGraw-Hill Book Comp., New York, NY, 1954, p. 244.
M. Jakob:Heat Transfer, John Wiley and Sons, Inc., New York, NY, 1959, vol. II, p. 355.
Author information
Authors and Affiliations
Rights and permissions
About this article
Cite this article
Weckman, D.C., Niessen, P. A numerical simulation of the D.C. continuous casting process including nucleate boiling heat transfer. Metall Trans B 13, 593–602 (1982). https://doi.org/10.1007/BF02650017
Received:
Issue Date:
DOI: https://doi.org/10.1007/BF02650017