Aluminum DC Casting Process with MAGMA CC

The Direct Chill (DC) casting process is integral to the manufacturing of semi-finished products. In this process, liquid metal is introduced into a short, intensely cooled mold, often equipped with graphite inserts, from a launder. Simultaneously, metal is withdrawn from the mold, necessitating the assurance of a stable solidified shell at the mold's end. MAGMA CC, a fully integrated turn-key solution, plays a crucial role in simulating and optimizing both vertical and horizontal DC casting processes.

Key features:

  • Robust solutions for aluminum production with DC and CC casting processes.
  • Design process conditions for optimized flow and solidification, enhancing product quality.
  • Integrated simulation of casting stresses, including cracks and hot tears, for comprehensive process evaluation.
  • An integrated process chain for casting with subsequent forging and rolling processes.

Process Simulation Capabilities Include:

  • Realistic representation of the entire DC casting process, assessing flow conditions during start-up and strand withdrawal.
  • Consideration of forced and natural convection in the liquid metal and mushy zone.
  • Determination of stationary temperature distribution in the strand and mold, allowing evaluation of influencing parameters.
  • Accurate prediction of the sump profile and assessment of optimal process parameters for improved energy efficiency.
  • Calculation of the solidification front to prevent bleedout and evaluation of thermal gradient and cooling rate.
  • Assist in achieving high productivity, cost and energy efficiency, reduced porosity, shrinkage,and optimization of launder and distribution design.
  • Virtual design and optimization of direct chill casting process.
Publication in Area of Continuous Casting

Autonomous Mathematical Optimization of Continuous Casting Processes

Editors:

Wilfried Schäfer, Götz Hartmann, Erik Hepp, MAGMA GmbH, Aachen, Germany
Dieter G. Senk, Sonja Stratemeier, IEHK RWTH Aachen University, Germany

The publication introduces a numerical simulation based optimization strategy, following rigorous thermodynamic and thermo mechanical models as well as a strictly methodic approach.

Read Publication