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<p>Aluminum horizontal direct-chill casting (HDCC) faces challenges in achieving uniform solidification because of the non-uniform distribution of cooling water, leading to varying cooling rates at the top and bottom surfaces of the ingot. Here, hot cracking defects in HDCC are addressed using advanced simulation techniques. Using a three-dimensional finite element model, the impact of various casting parameters on hot cracking sensitivity (HCS) in aluminum billets was investigated. The model incorporates the energy equation, Navier-Stokes equation, and phase change theory to simulate the HDCC process, while the Magnin theory is applied to analyze hot cracking. Simulation results suggest that at a casting speed of 120&#xa0;mm/min, a maximum HCS of 1.2 occurs at the billet center. This observation corresponds to experimental findings of hot cracking. However, reducing the casting speed to 80&#xa0;mm/min significantly decreases the HCS to 0.59, effectively eliminating hot cracking in the billet. Additionally, the initial melt temperature minimally affects sump depth and mushy zone thickness, with only marginal changes in HCS observed. By optimizing the casting speed to 80&#xa0;mm/min, defect-free aluminum billets were produced, confirmed by the absence of hot cracking in a cross-sectional examination of the billet.</p>

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Hot Cracking in Aluminum HDCC: Challenges and Solutions Through Process Modifications

  • 期刊论文

  • 发表日期：

    2025年1月27日

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  • Amir Reza Ansari Dezfoli

摘要

Aluminum horizontal direct-chill casting (HDCC) faces challenges in achieving uniform solidification because of the non-uniform distribution of cooling water, leading to varying cooling rates at the top and bottom surfaces of the ingot. Here, hot cracking defects in HDCC are addressed using advanced simulation techniques. Using a three-dimensional finite element model, the impact of various casting parameters on hot cracking sensitivity (HCS) in aluminum billets was investigated. The model incorporates the energy equation, Navier-Stokes equation, and phase change theory to simulate the HDCC process, while the Magnin theory is applied to analyze hot cracking. Simulation results suggest that at a casting speed of 120 mm/min, a maximum HCS of 1.2 occurs at the billet center. This observation corresponds to experimental findings of hot cracking. However, reducing the casting speed to 80 mm/min significantly decreases the HCS to 0.59, effectively eliminating hot cracking in the billet. Additionally, the initial melt temperature minimally affects sump depth and mushy zone thickness, with only marginal changes in HCS observed. By optimizing the casting speed to 80 mm/min, defect-free aluminum billets were produced, confirmed by the absence of hot cracking in a cross-sectional examination of the billet.