ADVANCED CFD MODELING OF DC CASTING OF ALUMINUM ALLOYS

A 3-D CFD model for the simulation of vertical direct chill (DC) slab casting of aluminum alloys is developed. The basis of the model is the 3D time-averaged turbulent transport equations. An in-house developed CID code is used to solve the modeled equations. The model is qualitatively and quantitatively verified by comparing the computed results with a physical water model and a real casting experiment of independent researchers. Each of the comparisons showed a good agreement. A parametric study has been carried out for a DC slab caster of aspect ratio 2.0 fitted with a combo bag for melt distribution from the nozzle. The primary and the secondary cooling zones are simulated by changing the heat transfer coefficient on the slab surface. An in-depth understanding is gained of some behaviors of the melt flow and solidification profile in the steady state operational phase of the commercial DC casting process.