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TECHNICAL PAPERS: Heat Transfer in Manufacturing

Direct Chill Casting of Aluminum Alloys: Modeling and Experiments on Industrial Scale Ingots

[+] Author and Article Information
Christopher J. Vreeman

Capstone Turbine Corporation, 21211 Nordhoff Street, Chatsworth, CA 91311

J. David Schloz

Wagstaff Engineering, 3910 North Flora Road, Spokane, WA 99216

Matthew John M. Krane

School of Materials Engineering, Purdue University, West Lafayette, IN 47907

J. Heat Transfer 124(5), 947-953 (Sep 11, 2002) (7 pages) doi:10.1115/1.1482089 History: Received September 12, 2001; Revised March 26, 2002; Online September 11, 2002
Copyright © 2002 by ASME
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References

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Yu, H., and Granger, D. A., 1986, “Macrosegregation in Aluminum Alloy Ingot Cast by the Semicontinuous Direct Chill (DC) Method,” in Aluminum Alloys-Their Physical and Mechanical Properties, EMAS, United Kingdom, pp. 17–29.
Chu, M. G., and Jacoby, J. E., 1990, “Macrosegregation Characteristics of Commercial Size Aluminum Alloy Ingot Cast by the Direct Chill Method,” in Light Metals 1990, C. M. Bickert, ed., TMS, pp. 925–930.
Dorward, R. C., and Beerntsen, D. J., 1990, “Effects of Casting Practice on Macrosegregation and Microstructure of 2024 Alloy Billet,” in Light Metals 1990, C. M. Bickert, ed., TMS, pp. 919–924.
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Vreeman,  C. J., and Incropera,  F. P., 2000, “The Effect of Free-Floating Dendrites and Convection on Macrosegregation in Direct Chill Cast Aluminum Alloys—II: Predictions for Al-Cu and Al-Mg alloys,” Int. J. Heat Mass Transf., 43, pp. 687–704.
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Vreeman,  C. J., and Incropera,  F. P., 1999, “Numerical Discretization of Species Equation Source Terms in Binary Mixture Models of Solidification and Their Impact on Macrosegregation in Semi-Continuous, Direct Chill Casting Systems,” Numer. Heat Transfer, Part B, 36(1), pp. 1–14.
Vreeman, C. J., 1997, “Modeling Macrosegregation in Direct Chill Cast Aluminum Alloys,” M.S. thesis, School of Mechanical Engineering, Purdue University, West Lafayette, IN.

Figures

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(a) Schematic of generic DC casting process; (b) AirSlip™ mold cross-section
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Mixture copper composition, streamlines, and solid fraction for billet with grain refiner, using experimental boundary conditions
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Results with grain refiner: (a) Comparison of predicted and measured temperature profiles, and (b) Calculated temperature and fraction solid contours.
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Sump profiles: (a) Grain refined billet; and (b) Comparison of predictions and experiments.
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Comparison of measured and calculated composition profiles for grain refined billet
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Mixture copper composition, streamlines, and solid fraction for billet with no grain refiner, using experimental boundary conditions
Grahic Jump Location
Comparison of measured and calculated composition profiles for billet with no grain refiner

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