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<p>Cracking defects are prone to occur in large-sized Mg-RE alloy flat ingots fabricated by semi-continuous casting, which constitutes a core technical bottleneck and restricts the engineering application of relevant high-strength and high-toughness wrought components. Taking the 1050 × 400 × 1500&#xa0;mm Mg-7Gd-3Y-1Zn-0.5Zr alloy flat ingot as the research object, this study optimized casting parameters via Procast numerical simulation and determined the optimal set: pouring temperature 700&#xa0;°C, first cooling intensity 3000&#xa0;W/(m<sup>2</sup>·K), second cooling intensity 2000&#xa0;W/(m<sup>2</sup>·K), and casting speed 30&#xa0;mm/min. The results indicate distinct Gd segregation in the alloy, with minor grain size differences across ingot regions. After annealing, the tensile strength, yield strength, and elongation of the ingot’s core, half-thickness position, and edge range from 194 to 205&#xa0;MPa, 111 to 123&#xa0;MPa and 10.7-11.7%, respectively. This work quantitatively elucidates the intrinsic correlations among casting parameters, field distribution and defect formation, providing precise process guidance for stable preparation of such large-sized ingots and a general technical paradigm for cracking control of analogous light alloy ingots, and bears great scientific and engineering significance for advancing large-scale application of Mg alloys in aerospace and high-end equipment fields.</p>

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Optimization of the Semi-continuous Casting Process for Large-Scale Magnesium Rare-Earth Alloy Slabs Based on ProCAST Simulation

  • 期刊论文

  • 发表日期：

    2026年2月16日

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  • Mengen Ji,
  • Quanan Li,
  • Xiaoya Chen,
  • Jian Zeng,
  • Yibin Jia

摘要

Cracking defects are prone to occur in large-sized Mg-RE alloy flat ingots fabricated by semi-continuous casting, which constitutes a core technical bottleneck and restricts the engineering application of relevant high-strength and high-toughness wrought components. Taking the 1050 × 400 × 1500 mm Mg-7Gd-3Y-1Zn-0.5Zr alloy flat ingot as the research object, this study optimized casting parameters via Procast numerical simulation and determined the optimal set: pouring temperature 700 °C, first cooling intensity 3000 W/(m2·K), second cooling intensity 2000 W/(m2·K), and casting speed 30 mm/min. The results indicate distinct Gd segregation in the alloy, with minor grain size differences across ingot regions. After annealing, the tensile strength, yield strength, and elongation of the ingot’s core, half-thickness position, and edge range from 194 to 205 MPa, 111 to 123 MPa and 10.7-11.7%, respectively. This work quantitatively elucidates the intrinsic correlations among casting parameters, field distribution and defect formation, providing precise process guidance for stable preparation of such large-sized ingots and a general technical paradigm for cracking control of analogous light alloy ingots, and bears great scientific and engineering significance for advancing large-scale application of Mg alloys in aerospace and high-end equipment fields.