Skip to main content
SpringerLink
Log in

Numerical analysis of the non-stationary thermal state of the tool in the combined casting and extrusion of aluminum alloy

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

The results of a numerical analysis of unsteady heat transfer in the “metal-mold-environment” system during continuous combined casting and extrusion of an aluminum alloy in an installation with a horizontal carousel mold are presented. The heat engineering zones characterized by different intensity of heat transfer between the melt and the surface of the mold have been determined. A quantitative assessment of the influence of the rate of heating of the crystallizer on the temperature-time characteristics during the period of the transient thermal process is given. It is shown that an increase in the productivity of the installation reduces the duration of the transient thermal process when starting the installation from a cold state until it reaches a stationary thermal regime. The dependence of the time at which the installation reaches the stationary thermal regime on the rotation speed of the crystallizer wheel has been obtained.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6

Similar content being viewed by others

References

  1. de Sousa Rocha JR, de Souza EEB, Marcondes F, de Castro JA (2019) Modeling and computational simulation of fluid flow, heat transfer and inclusions trajectories in a tundish of a steel continuous casting machine. J Mater Res Technol 8(5):4209–4220. https://doi.org/10.1016/j.jmrt.2019.07.029

  2. Jiang Y, Mao X, Yu L, Liu X, Xie J (2019) Microstructure and mechanical property evolutions of CuNi10Fe1.8Mn1 alloy tube produced by HCCM horizontal continuous casting during drawing and its deformation mechanism. J Alloys Compd 771:905–913. https://doi.org/10.1016/j.jallcom.2018.09.041

  3. Reznik PL, Ovsyannikov BV (2020) Influence of homogenization heat treatment and cooling modes on microstructure of AA7475 aluminum alloy ingot. Mater Sci Forum 989:335–340. https://doi.org/10.4028/www.scientific.net/MSF.989.335

  4. Wang F, Ma Q, Meng W, Han Z (2017) Experimental study on the heat transfer behavior and contact pressure at the casting-mold interface in squeeze casting of aluminum alloy. Int J Heat Mass Transf 112:1032–1043. https://doi.org/10.1016/j.ijheatmasstransfer.2017.05.051

  5. Luo Y, Zhang Z (2019) Numerical modeling of annular electromagnetic stirring with intercooling in direct chill casting of 7005 aluminum alloy billet. Progress in Natural Science: Materials International 29(1):81–87. https://doi.org/10.1016/j.pnsc.2019.01.007

  6. Garg P, Jamwal A, Kumar D, Sadasivuni KK, Hussain CM, Gupta P (2019) Advance research progresses in aluminium matrixcomposites: manufacturing & applications. J Mater Res Technol 8(5):4924–4939. https://doi.org/10.1016/j.jmrt.2019.06.028

  7. Cheng G, Lu Y, Cinkilic E, Miao J, Luo AA (2019) Predicting grain structure in high pressure die casting of aluminum alloys: a coupled cellular automaton and process model. Comput Mater Sci 161:64–75. https://doi.org/10.1016/j.commatsci.2019.01.029

  8. Dong X, Yang H, Zhu X, Ji S (2019) High strength and ductility aluminium alloy processed by high pressure die casting. J Alloys Compd 773:86–96. https://doi.org/10.1016/j.jallcom.2018.09.260

  9. Kryukov IY, Naumova MG, Vdovin KN, Larina TP (2016) Development of mathematical model of thermal state of crystallizing blank rectangular in shape in horizontal semi-continuous casting machine. Fundamental Research 10(2):306–311. https://www.fundamental-research.ru/en/article/view?id=40850. Accessed 23 Jun 2021

  10. Dovzenko NN, Sidelnikov SB, Belyaev SV, Soldatov SV, Bespalov VM, Leonov VV (2012) Improvement of construction of the pilot industrial plant SLIPP-2,5. J Sib Fed Univ Eng Technol 5(7):817–828. http://elib.sfu-kras.ru/bitstream/handle/2311/9537/16_Dovzenko.pdf;jsessionid=3650F3307F352954C5A309BCEAEA9E1C?sequence=1. Accessed 23 Jun 2021

  11. Sidelnikov SB, Galiev RI, Bersenev AS, Voroshilov DS (2018) Application and research twin roll casting-extruding process for production longish deformed semi-finished products from aluminum alloys. Mater Sci Forum 918:13–20. https://doi.org/10.4028/www.scientific.net/MSF.918.13

  12. Rappaz M, Jarry P, Kurtuldu G, Zollinger J (2020) Solidification of metallic alloys: does the structure of the liquid matter? Metallurgical and materials transactions a: physical metallurgy and materials science 51:2651–2664. https://doi.org/10.1007/s11661-020-05770-9

  13. Jarry P, Rappaz M (2018) Recent advances in the metallurgy of aluminium alloys. Part I: solidification and casting | Développements récents en métallurgie des alliages d'aluminium. Première partie : coulée et solidification. Comptes Rendus Physique 19(8):672–687. https://doi.org/10.1016/j.crhy.2018.09.003

  14. Niinomi M (2019) Casting. Metals for biomedical devices (Second edition), 2019, 311–330. https://doi.org/10.1016/B978-0-08-102666-3.00011-0

  15. Jensrud O (2012) High strength aluminium alloys extrusions - a review of the thermo-mechanical-process in high performance profile manufacturing. Key Eng Mater 491:11–18. https://doi.org/10.4028/www.scientific.net/KEM.491.11

  16. Yun X-B, Yao M-L, Wu Y, Song B-Y (2011) Numerical simulation of continuous extrusion extending forming under the large expansion ratio for copper strip. Appl Mech Mater 80-81:91–95. https://doi.org/10.4028/www.scientific.net/AMM.80-81.91

  17. Mitka M, Gawlik M, Bigaj M, Szymanski W (2014) Continuous rotary extrusion (CRE) of flat sections from 6063 alloy. Key Eng Mater 641:183–189. https://doi.org/10.4028/www.scientific.net/KEM.641.183

  18. Popescu IN, Bratu V, Rosso M, Popescu C, Stoian EV (2013) Designing and continuous extrusion forming of Al-Mg-Si contact lines for electric railway. J Optoelectron Adv Mater 15(7-8):712–717

    Google Scholar 

  19. Zhao Y, Song B-Y, Yun X-B, Pei J-Y, Jia C-B, Yan Z-Y (2012) Effect of process parameters on sheath forming of continuous extrusion sheathing of aluminum. Transactions of Nonferrous Metals Society of China (English Edition) 22(12):3073–3080. https://doi.org/10.1016/S1003-6326(11)61573-2

  20. Zhao D, Lü S, Li J, Guo W, Wu S (2021) A novel continuous squeeze casting-extrusion process for grain refinement and property improvement in AZ31 alloy. Mater Sci Eng A 808:140942. https://doi.org/10.1016/j.msea.2021.140942

  21. Fastikovskiy AR, Selivanova EV, Fedorov AA, Peretyatko VN, Evstifeev VV, Efimov OY (2018) Improvement of continuous forming the “Conform” method. IOP Conference Series: Materials Science and Engineering 411(1):012082. https://doi.org/10.1088/1757-899X/411/1/012082

    Article  Google Scholar 

  22. Ji C, Huang H (2020) A review of the twin-roll casting process for complex section products. ISIJ Int 60(10):2165–2175 https://www.jstage.jst.go.jp/article/isijinternational/60/10/60_ISIJINT-2020-149/_article. Accessed 23 Jun 2021

    Article  Google Scholar 

  23. Sidelnikov S, Sokolov R, Voroshilov D, Motkov M, Bespalov V, Voroshilova M, Sokolova S, Rudnitskiy E, Lebedeva O, Borisyuk V (2020) Modeling the process of obtaining bars from aluminum alloy 01417 by combined rolling-extruding method with application of the deform-3D complex. Key Eng Mater 861:540–546. https://doi.org/10.4028/www.scientific.net/KEM.861.540

  24. Sidelnikov SB, Voroshilov DS, Pervukhin MV, Motkov MM (2019) Development and research of technology for producing electrotechnical wire from alloys of the Al – REM system, obtained with the application of combined machining methods. Tsvetnye metally 9:63–68. https://www.rudmet.ru/journal/1853/article/31547/. Accessed 23 Jun 2021

    Article  Google Scholar 

  25. Gorokhov YV, Belyaev SV, Uskov IV, Konstantinov IL, Gubanov IY, Gorokhova TY, Hramtsov PA (2017) Application of combined casting–pressing for the fabrication of aluminum wire for soldering waveguides. Russ J Non-ferrous Metals 58(1):75–79. https://doi.org/10.3103/S1067821217010059

  26. Zhang X, Guan R, Cui T, Zhou T (2011) Microstructure and mechanical properties of Al-Mg-Sc alloy processed by semi-solid continuous casting-extrusion. Adv Mater Res 299–300:139–142. https://doi.org/10.4028/www.scientific.net/AMR.299-300.139

  27. Skuratov AP, Gorokhov YV, Potapenko AS, Belyaev SV, Gubanov IY, Ivanov AG (2018) Thermal control device for continuous casting and pressing of non-ferrous metals and alloys: Pat. 2657396 (RF)

  28. Potapenko AS, Skuratov AP, Gorokhov YV (2017) Aluminum alloy solidification dynamics under transient heat mode of continuous casting and moulding equipment. Proceedings of Irkutsk State Technical University, 2017, 21(7), 109–118. http://journals.istu.edu/vestnik_irgtu/journals/2017/07/articles/10. Accessed 23 Jun 2021

  29. Skuratov AP, Potapenko AS, Gorokhov YV (2017) The research of thermal operations in the equipment of continual casting & aluminum extrusion in transitional mode. Journal of Siberian Federal University Engineering & Technologies 10(3):337–345/ http://elib.sfu-kras.ru/bitstream/handle/2311/32627/05_Skuratov.pdf?sequence=1. Accessed 23 Jun 2021

  30. Skuratov AP, Potapenko AS, Gorokhov YV, Popiyakova NP (2019) Numerical Investigation into the influence of overheating of aluminum melt on the heat exchange in the continuous combined casting and pressing. Russ J Non-ferrous Metals 60(3):225–231. https://doi.org/10.3103/S1067821219030143

  31. Gorokhov YV, Skuratov AP, Belyaev SV, Gubanov IY, Uskov IV, Lesiv EM, Ivanov AG, Kirko VI, Koptseva NP, Potapenko AS (2017) Analysis of combined metal casting thermal conditions: the pressing process during conform installation. ARPN Journal of Engineering and Applied Sciences 12(16):4742–4746 http://www.arpnjournals.org/jeas/research_papers/rp_2017/jeas_0817_6269.pdf. Accessed 23 Jun 2021

    Google Scholar 

  32. Stetsenko VY (2013) Mechanisms of the crystallization process of metals and alloys. Casting and Metallurgy 1:48–54

    Google Scholar 

  33. Semashko MY, Chigintsev PA (2016) A comprehensive study of the process of severe plastic deformation of aluminum alloy. Bulletin of the South Ural State University Ser Metallurgy 16(2):63–67. (in Russ.) https://doi.org/10.14529/met160209

  34. Fomina EE, Zhiganov NK (2016) A modification of the simpler algorithm for solving the problem of modeling the process of continuous casting of non-ferrous metals. The Bulletin of Voronezh State Technical University 12(1):32–35 https://cchgeu.ru/science/nauchnye-izdaniya/vestnik-voronezhskogo-gosudarstvennogo-tekhnicheskogo-universiteta-/fayly/vypuski/12_1.pdf. Accessed 23 Jun 2021

    Google Scholar 

  35. Minakov AV, Pervukhin MV, Platonov DV, Khatsayuk MY (2015) Mathematical model and numerical simulation of aluminum casting and solidification in magnetic fields with allowance for free surface dynamics. Comput Math Math Phys 2066–2079:55. https://doi.org/10.1134/S096554251512009X

  36. Torgovets AK, Pikalova IA, Yusupova YS (2016) Simulation in continuous casting processes. Karaganda State Industrial University 6(28):88–95

    Google Scholar 

  37. Ershov AA, Loginov YN (2018) Simulation of the conform-type pressing process by using the QFORM VX software complex. Metallurgist 62(3-4):207–211. https://doi.org/10.1007/s11015-018-0646-6

  38. Gorokhov YV, Sherkunov VG, Dovzhenko NN et al (2013) Fundamentals of designing processes for continuous extrusion of metals: monograph. Krasnoyarsk: SibFU

Download references

Funding

The reported study was funded by the RFBR, the Government of Krasnoyarsk Territory, Krasnoyarsk Regional Fund and LLC “Research and Production Center of Magnetic Hydrodynamics”, project number 20-48-242903.

Author information

Authors and Affiliations

  1. Siberian Federal University, Region, Krasnoyarsk, Krasnoyarsk, Russian Federation, 660025

    Alexander Petrovich Skuratov, Natal’ya Petrovna Popiyakova, Alexander Sergeevich Potapenko, Yuriy Vasilyevich Gorokhov, Mikhail Yur’yevich Kuchinskii, Sergey Vladimirovich Belyaev, Denis Sergeevich Voroshilov, Igor Lazarevich Konstantinov, Alexander Vadimovich Ivlev & Dmitriy Nikolaevich Bozhko

Authors
  1. Alexander Petrovich Skuratov
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Natal’ya Petrovna Popiyakova
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Alexander Sergeevich Potapenko
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Yuriy Vasilyevich Gorokhov
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Mikhail Yur’yevich Kuchinskii
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Sergey Vladimirovich Belyaev
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Denis Sergeevich Voroshilov
    View author publications

    You can also search for this author in PubMed Google Scholar

  8. Igor Lazarevich Konstantinov
    View author publications

    You can also search for this author in PubMed Google Scholar

  9. Alexander Vadimovich Ivlev
    View author publications

    You can also search for this author in PubMed Google Scholar

  10. Dmitriy Nikolaevich Bozhko
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

The authors declare that they are all participants in the work and none of them performed only administrative functions.

Corresponding author

Correspondence to Denis Sergeevich Voroshilov.

Ethics declarations

Ethical approval

The work contains no libelous or unlawful statements and does not infringe on the rights of others, or contain material or instructions that might cause harm or injury.

Consent to participate

The authors consent to participate.

Consent to publish

The authors consent to publish.

Competing interests

The authors declare no competing interests.

Data availability

Not applicable.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Skuratov, A.P., Popiyakova, N.P., Potapenko, A.S. et al. Numerical analysis of the non-stationary thermal state of the tool in the combined casting and extrusion of aluminum alloy. Int J Adv Manuf Technol 117, 295–303 (2021). https://doi.org/10.1007/s00170-021-07634-x

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-021-07634-x

Keywords

Search

Navigation