Abstract
In this paper, a new approach that using hot-top DC casting process to produce multi-alloy ingots is present. The different type and size of composite and cladding ingots (4045/3004/4045 three-layer composite ingots with section 630mm by 1500mm and 4045/3003 cladding ingot with Φ140mm/Φ110mm in diameter) are fabricated by this approach. The macro-morphologies and microstructures of the ingots, the temperature distribution and the element distribution in the interface zone were investigated, and the interface bonding strength was measured. The results show that the solid supporting layer formed on the cooling plates plays a key role in the casting process of composite ingots. The solid supporting layer can prevent the blending of two melts by resisting the impact of alloy melt, which ensures the stable casting process and casting high quality composite ingots, because the contact height is increased using hot-top DC casting. In addition, fabrication and properties of 4045/3004/4045 three-layer composite ingots with section 630mm by 1500mm are reported in detail.
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