Experimental and Numerical Investigation of Effect of Melter Temperature and Casting Speed on Pull-In (Concavity) of AA1050 Ingot During Direct Chill Casting

Minimizing the pull-in effect is an important consideration in continuous casting, as it can have a significant impact on the quality of the final product. This paper examines the issue of pull-in defects, specifically concavity, in aluminum alloy rolling ingots during direct chill casting. A study was undertaken to examine how the concavity of the AA1050 rolling ingot is affected by certain parameters of the direct chill process, such as the melting temperature and casting speed. Three different combinations of the melting temperature (690 ℃, 700 ℃ and 715 ℃) and casting speeds (55, 65 and 75 mm/min) were selected, and experimental tests and numerical simulations were conducted on the rolling ingots. Experimental tests and numerical simulation measured the pull-in defect regarding the concavity radius. The results of numerical analysis have been compared with the experimental test results and found a good agreement. It was revealed that there is a significant impact of melting temperature and casting speeds on the concavity of the ingot. The ingots with a 55 mm/min casting speed and a temperature of 700 ℃ showed the lowest concavity. Furthermore, the lowest pull-in radius (21.025 mm) was recorded for AA1050 ingot with a casting speed of 55 mm/min and 700 ℃ melting temperature.