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A Mathematical Model for Hot Cracking of Aluminum Alloys During D.C. Casting

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Summary

A mathematical model to calculate the hot-cracking tendencies during DC casting is described. The model combines a new simplified thermal model for DC casting with the concept of solidification shrinkage not eliminated by afterfeeding (Feurer) and the concept of the critical time interval during solidification (Clyne and Davies). This model is available to calculate hot-cracking tendencies as a result of the effects of composition, casting rate, and ingot diameter. In spite of the absence of sufficient physical and solidification data, it is shown that there is a satisfactory degree of correlation between prediction and practical casting knowledge.

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Abbreviations

A:

ingot cross section (m2)

CpL, cps :

specific heat liquid, solid (J/kg°K)

ds :

dendritic arm spacing (m)

fL, fs :

volume fraction liquid, solid

h:

heat-transfer coefficient (W/m2°K)

K:

permeability of a porous medium (m2)

L:

length of porous zone (m)

Lf :

latent heat of solidification (J/kg)

po, pc pm :

atmospheric, capillary, metallostatic pressure (N/m2)

R:

ingot radius (m)

L:

volume flow rate (m3/s)

s:

thickness of solidified layer (m)

T:

temperature (°C)

Ti, To :

solid-liquid interface, surface temperature (°C)

TW :

cooling water temperature (°C)

V:

volume (m3)

vc :

casting rate (m/s)

z:

distance along ingot axis (m)

γsl :

solid-liquid interfacial energy (N/m)

η:

viscosity (Ns/m2)

ρ̅, ρl, ρs :

average, liquid, solid density

τ:

tortuosity factor

λs :

thermal conductivity of solid (W/m°K)

References

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Authors
  1. L. Katgerman
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Additional information

Laurens Katgerman, Research Associate, Department of Metals Science and Technology, Delft University of Technology, RoUerdamsE'lweg 137, 2628 RB. The Netherlands.

Mr. Katgerman received a degree in applied physics from the University of Groningen, The Netherlands. His current research interests are solidification processing, modeling of casting processes, and in particular rapid solidification processing of aluminum alloys. He was recently a visiting scientist with the Ingot Casting Division, Alcoa Technical Center, Pennsylvania. He is a member of The Metallurgical Society of AIME.

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Katgerman, L. A Mathematical Model for Hot Cracking of Aluminum Alloys During D.C. Casting. JOM 34, 46–49 (1982). https://doi.org/10.1007/BF03339110

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  • DOI: https://doi.org/10.1007/BF03339110

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