Thermomechanical Modeling on AirSlip® Billet DC Casting of High-Strength Crack-Prone Aluminum Alloys

Iterations of thermomechanicalThermomechanical modelingModeling on DC castingDC Casting of high-strengthHigh strength crack-proneCrack-prone alloyAlloys billetsBillet have been conducted to understand billetBillet start-upStart-up phase thermal stressThermal stress development and to optimize tooling design. Transient thermal stressThermal stress development during cast start at the billetBillet butt, billetBillet surfaceSurface, and inside the billetBillet are investigated; Connection of cracking with stress development at billetBillet butt is presented; Effects of starting head, wiper placement, and wiper placement location on the thermal stressThermal stress development are also examined. The billetBillet surfaceSurface rebound temperatures and cast-in TC temperatures from the modelingModeling agree well with those measured in the laboratory and in the field; the castingCasting campaigns on the AirSlip®AirSlip mold package exhibit great billetBillet quality and high pit recoveryRecovery.