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 from a launder. Simultaneously, metal is withdrawn from the mold, requiring the establishment of a stable solidified shell at the mold's exit. 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
  • 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 in the mushy zone
  • Determination of the stationary temperature distribution in strand and mold, allowing the 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
  • Assistance in achieving high productivity as well as cost and energy efficiency
  • Reduced porosity, shrinkage, and optimization of launder and distribution design
  • Virtual design and optimization of the 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.

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