Abstract
Uniform direct chill (UDC) casting method was developed by combining annular electromagnetic stirring (A-EMS) with intercooling in direct chill casting. In order to investigate effect of UDC on flow patterns, temperature profiles and solidification during the casting, a numerical model of the UDC casting process was developed and used to simulate the UDC casting process for preparing 7005 aluminum alloy billets. The comparison of the calculated results of UDC casting with normal direct chill (NDC) casting indicated that flow patterns, temperature profiles and the sump depth are modified remarkably by the application of annular electromagnetic stirring and intercooling during the direct chill casting. The sump profile and the temperature history during UDC casing were studied, and the mechanism of the casting process were discussed. The comparisons between the simulations and experimental results suggested that the proposed model provides good agreement for the sump profiles and the temperature history within the billets.
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