Abstract
In this research study, numerical modelling and experimental casting of AA6111 strips, 250 mm wide, 6 mm thick, was conducted. The velocity of the molten AA6111 alloy at the nozzle slot outlet was raised to 2 m/s, whilst the belt speed was kept at 0.3 m/s. The numerical model demonstrates considerable turbulence/fluctuations in the flow of the molten AA6111 alloy in the HSBC process, rendering its free surface highly non-uniform and uneven. These discontinuites in the flow resulted from the sudden impact of molten metal onto the inclined refractory plane, and then onto the slowly moving belt. However, it has been determined that these surface variations are rapidly damped, and as such are not detrimental to final strip surface quality. Any surface perturbations remaining can be eliminated via hot plastic deformation. The experimental findings are in accordance with the model predictions. Furthermore, at high metal heads inside the delivery launder, the molten metal was observed to be flowing inwards towards the center of the strip, thereby filling the centre depression region, formed otherwise. The model predictions were validated against experimental findings. A surface roughness and microstructural analysis was also conducted to determine the surface and bulk quality of the as-cast strip.
Highlights
Near net shape casting (NNSC) processes can be regarded as an ideal method for metal sheet production
Operating parameters and assumptions made in the model [2,13]. It was observed through numerical simulation studies that in the Horizontal Single Belt Casting (HSBC) process, the molten
The magnitude of the velocity to the friction offered by the moving belt, which tends to slow down the velocity of the molten metal around the edges, for both cases, is high as compared to the center
Summary
Near net shape casting (NNSC) processes can be regarded as an ideal method for metal sheet production Apart from their low energy requirements, lower capital and operating costs, and smaller plant footprints than those associated with slab casters (Fe), and DC casters (Al), they have promising metallurgical characteristics associated with much higher cooling rates possible [1,2,3,4,5]. They can have drawbacks, regarding surface quality, which conventional plants can overcome, by scarfing and multi-pass rolling, to the final quality strip [6]. The three most commonly used NNSC processes, Processes 2020, 8, 529; doi:10.3390/pr8050529 www.mdpi.com/journal/processes
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