Process window prediction of solid-liquid cast-rolling bonding (SLCRB) process through numerical analysis to fabricate bimetallic clad pipes

The solid-liquid cast-rolling bonding (SLCRB) process to fabricate bimetallic clad pipes was developed, and the numerical analysis was conducted in order to reduce the exploration time of reasonable technological parameters. A 3-D steady state thermal-flow coupling simulation model of the cast-rolling area was established based on the Fluent software. The distributions of the flow field and temperature field were obtained, and the influences of molten pool height, cast-rolling speed and casting temperature on the kiss point (KP) were analyzed systematically. It indicates that the forming mechanism of the SLCRB process is mainly ascribed to the fluidity of the molten metal in the liquid zone and the plastic deformation behavior in the semisolid and solid zone. Therefore, the prediction models of the average KP height and average export temperature were established and then used to predict the available process window. Under the guidance of the theoretical analysis, the SLCRB experiments were carried out and results agree well with the simulation results. Steel/Al clad pipes, Cu/Al clad pipes, Ti/Al clad pipes, Cu/Al clad bars were fabricated successfully, which indicates that the SLCRB process provides an efficient way to fabricate bimetallic clad pipes with desired bonding effect. (C) 2018 Elsevier Ltd. All rights reserved.