Abstract
The results of a numerical investigation into the temperature–temporal dependences in continuous combined casting and pressing of the AK12 experimental aluminum alloy at a different overheating temperature from startup to the instant the steady-state thermal conditions are reached by the installation are reported. Calculations are performed based on a three-dimensional computer model of a complex heat exchange in an installation of a new design equipped by a horizontal rotary crystallizer. Theoretical investigations into the effect of overheating of the poured aluminum melt on the temperature-dependent heat exchange processes are performed. The influence of the character of the heat exchange in the transient thermal mode on the temperature field of the solidified melt for its different remoteness from the pouring point is determined. It is shown that the asymmetry of the temperature field in the control metal cross section near the pressing tool with the maximal temperature to the contacting crystallizer surface increases during crystallizer heating in the transient process. It is established that the duration of the transient process during the installation startup from the cold state until the steady-state thermal mode is attained depends on the temperature of the melt being poured. The maximal limit of overheating of the poured metal is determined, above which, when implementing the continuous combined casting–pressing technology, the aluminum melt does not solidify in the crystallizer and forced cooling of installation elements should be organized. The influence of melt overheating on the character of the temperature field along the crystallizer cross section is evaluated for the entire period of the transient thermal process. The design measures ensuring the rational temperature working conditions of bearings during the installation operation are given.
Similar content being viewed by others
REFERENCES
Goodes, I.M., Continuous extrusion by the Conform process, Wire Ind., 1975, vol. 501, pp. 677–678.
Avdulov, A.A., Sergeev, N.V., Gudkov, I.S., Timofeev, V.N., Gorokhov, Yu.V., and Avdulova, Yu.S., Production technology development of wire made of special aluminum alloys based on electromagnetic mold casting method and Conform continuous extrusion process, Zh. SFU, Ser. Tekh Tekhnol., 2017, vol. 10, no. 1, pp. 85–94.
Yun, X.-B., Yao, M.-L., Wu, Y., and Song, B.-Y., Numerical simulation of continuous extrusion extending forming under the large expansion ratio for copper strip, Appl. Mech. Mater., 2011, vols. 80–81, pp. 91–95.
Raab, G.I., Raab, A.G., and Shibakov, V.G., Analysis of shear deformation scheme efficiency in plastic structure formation processes, Metalurgija, 2015, vol. 54, no. 2, pp. 423–425.
Zhou, T.G., Jiang, Z.Y., Wen, J.L., Li, H., and Tieu, A.K., Semi-solid continuous casting–extrusion of AA6201 feed rods, Mater. Sci. Eng., 2012, vol. 8, pp. 108–114.
Mitka, M., Gawlik, M., Bigaj, M., and Szymanski, W., Continuous rotary extrusion (CRE) of flat sections from 6063 alloy, Key Eng. Mater., 2015, vol. 641, pp. 183–189.
Skuratov, A.P., Potapenko, A.S., and Gorokhov, Yu.V., Research of thermal operations in continual casting installation and aluminum extrusion in the transient mode, Zh. SFU, Ser. Tekh. Tekhnol., 2017, vol. 10, no. 3, pp. 337–345.
Skuratov, A.P. and Potapenko, A.S., Heat exchange computer model for the installation of continuous casting and pressing of nonferrous metals, Zh. SFU, Ser. Tekh. Tekhnol., 2017, vol. 10, no. 8, pp. 1019–1030.
Chernomas, V.V., Lovizin, N.S., and Sosnin, A.A., Investigation into the thermal mode of the crystallizer of the installation for metal horizontal casting and deformation, Kuzn.-Shtamp. Proizv. Obrab. Mater. Davl., 2011, no. 10, pp. 39–45.
Lekhov, O.S. and Lisin, I.V., An installation for the combined continuous casting and deformation for the production of bimetallic strips, Izv. Vyssh. Uchebn. Zaved. Tsvet. Metall., 2015, no. 6, pp. 30–35.
Fomina, E.E. and Zhiganov, N.K., Modeling and investigation into the solidification of billets during discrete-continuous casting of nonferrous metals and alloys, Komp. Issled. Model., 2009, vol. 1, no. 1, pp. 67–75.
Popescu, I.N., Bratu, V., Rosso, M., Popescu, C., and Stoian, E.V., Designing and continuous extrusion forming of Al–Mg–Si contact lines for electric railway, J. Optoel. Adv. Mater., 2013, vol. 15, pp. 712–717.
Zhao, Y., Song, B.-Y., Yun, X.-B., Pei, J.-Y., Jia, C.-B., and Yan, Z.-Y., Effect of process parameters on sheath forming of continuous extrusion sheathing of aluminum, Trans. Non-Ferr. Met. Soc. China (Eng. ed.), 2012, vol. 22, no. 12), pp. 3073–3080.
Krol, M., Tanski, T., Snopinski, P., and Tomiczek, B., Structure and properties of aluminium–magnesium casting alloys after heat treatment, J. Therm. Anal. Calorim., 2017, vol. 127, no. 1, pp. 299–308.
Wan, Y.C., Xiao, H.C., Jiang, S.N., Tang, B., Liu, C.M., Chen, Z.Y., and Lu, L.W., Microstructure and mechanical properties of semi-continuous cast Mg–Gd–Y–Zr alloy, Mater. Sci. Eng., 2014, vol. 617, no. 1, pp. 243–248.
Budilov, I.N., Lukashchuk, Yu.V., and Lukashchuk, S.Yu., Simulation of the aluminum ingot formation during semicontinuous casting, Vestn. UGATU, 2011, vol. 15, no. 1 (41), pp. 87–94.
Chernomas, V.V., Khimukhin, S.N., Salikov, S.R., and Konovalov, A.V., Modeling the deformation process in forming the aluminum strip by the combined metal casting and deformation method, Tekhnol. Obrab. Met., 2012, no. 3 (56), pp. 5–11.
Liu, J. and Liu, C., Optimization of mold inverse oscillation control parameters in continuous casting process, Mater. Manuf. Proc., 2015, vol. 30, no. 4, pp. 563–568.
Kosmatskii, Ya.I. and Fokin, N.V., Mathematical modeling of the combined casting and lateral pressing process, Vestn. YuUrGU, Ser. Metall., 2015, vol. 15, no. 1, pp. 29–33.
Assungao, C., Parreiras, R., and Oliveira, G., Water distribution assessment applied to mathematical model of continuos casting of steel, in: Aistech-Iron and Steel Technology Conf. Proc., 2014, pp. 2895–2905.
Kaschnitz, E., Romansky, M., and Mergen, R., Numerical simulation of temperature distribution in a continuous casting process for the production of AlSn(Cu) alloys, High Temp. High Press., 2002, vol. 34, pp. 699–704.
Potapenko, A.S., Skuratov, A.P., and Gorokhov, Yu.V., Aluminum alloy solidification dynamics under the time-dependent thermal mode of the continuous casting and pressing installation, Vestn. IrGTU, 2017, vol. 21, no. 7, pp. 109–118.
Author information
Authors and Affiliations
Corresponding authors
Additional information
Translated by N. Korovin
About this article
Cite this article
Skuratov, A.P., Potapenko, A.S., Gorokhov, Y.V. et al. 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, 225–231 (2019). https://doi.org/10.3103/S1067821219030143
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.3103/S1067821219030143