The steady-state temperature field of horizontal core-filling continuous casting （HCFC） for producing copper cladding aluminum rods was simulated by finite element method to investigate the effects of key processing...The steady-state temperature field of horizontal core-filling continuous casting （HCFC） for producing copper cladding aluminum rods was simulated by finite element method to investigate the effects of key processing parameters on the positions of solid-liquid interfaces （SLIs） of copper and aluminum. It is found that mandrel tube length and mean withdrawing speed have significant effects on the SLI positions of both copper and aluminum. Aluminum casting temperature （TAI） （1003-1123 K） and secondary cooling water flux （600-900 L.h-1） have little effect on the SLI of copper but cause the SLI of aluminum to move 2-4 mm. When TA1 is in a range of 1043-1123 K, the liquid aluminum can fill continuously into the pre-solidified copper tube. Based on the numerical simulation, reasonable processing parameters were determined.展开更多
Cooling heat flux effect in both primary and secondary cooling zone has been studied in semi-continuous casting of copper billet. Sufficient cooling is essential to reduce casting defects and to get high productivity,...Cooling heat flux effect in both primary and secondary cooling zone has been studied in semi-continuous casting of copper billet. Sufficient cooling is essential to reduce casting defects and to get high productivity, however low rate of solidification is aimed in order to get coarser grain size and softer metal for less losses in extrusion. A three-dimensional numerical model has been developed including solidification behavior of copper through mushy zone. At steady state and constant casting speed, solid shell thickness is monitored during the reduction of cooling rate at mould region to avoid breaking out. Heat flux intensity at mould plays important role not only in the formation of solid shell thickness. But, pool length and mushy zone thickness can be significantly increased by decreasing primary cooling intensity. Increase intensity of secondary cooling zone for two particular cases of primary cooling is tested. First case is tested at mould inlet water temperature of 38°C, and second case at water temperature of 63°C. Results showed that the combination of increasing secondary cooling intensity and reduction of primary cooling intensity can increase pool length and mushy zone thickness. Also, it is shown that, secondary cooling intensity can be magnified by up to 1.5 times for cooling water temperature of 63°C to get pool length close to that of water temperature of 38°C.展开更多
In this paper,it presents the results of calculation of solidification process of copper continuous cast bar by cross section size 120 mm × 70 mm with application of Pro Cast 2010 software. The estimation of moul...In this paper,it presents the results of calculation of solidification process of copper continuous cast bar by cross section size 120 mm × 70 mm with application of Pro Cast 2010 software. The estimation of mould design effect on solidification process of continuos copper cast bar is completed at various speeds of casting.Profiles of liquid metal cavities and temperature allocations in the cast bar at various casting speeds are defined.The analysis of received liquid metal cavity profiles shows that a new mold construction allows significantly decrease of the length of the liquid metal cavity during continuous copper casting at HAZELETTcasting machine and the increase of maximum casting speed from 10 to 11 m / min. Adequacy of the results of copper continuous cast bar solidification process calculation is confirmed by the experimental data.展开更多
基金financially supported by the National High Technology Research and Development Program of China (No. 2013AA030706 and No. 2009AA03Z532)the Fundamental Research Funds for the Central Universities of China (No. FRF-TP-12-146A)
文摘The steady-state temperature field of horizontal core-filling continuous casting （HCFC） for producing copper cladding aluminum rods was simulated by finite element method to investigate the effects of key processing parameters on the positions of solid-liquid interfaces （SLIs） of copper and aluminum. It is found that mandrel tube length and mean withdrawing speed have significant effects on the SLI positions of both copper and aluminum. Aluminum casting temperature （TAI） （1003-1123 K） and secondary cooling water flux （600-900 L.h-1） have little effect on the SLI of copper but cause the SLI of aluminum to move 2-4 mm. When TA1 is in a range of 1043-1123 K, the liquid aluminum can fill continuously into the pre-solidified copper tube. Based on the numerical simulation, reasonable processing parameters were determined.
文摘Cooling heat flux effect in both primary and secondary cooling zone has been studied in semi-continuous casting of copper billet. Sufficient cooling is essential to reduce casting defects and to get high productivity, however low rate of solidification is aimed in order to get coarser grain size and softer metal for less losses in extrusion. A three-dimensional numerical model has been developed including solidification behavior of copper through mushy zone. At steady state and constant casting speed, solid shell thickness is monitored during the reduction of cooling rate at mould region to avoid breaking out. Heat flux intensity at mould plays important role not only in the formation of solid shell thickness. But, pool length and mushy zone thickness can be significantly increased by decreasing primary cooling intensity. Increase intensity of secondary cooling zone for two particular cases of primary cooling is tested. First case is tested at mould inlet water temperature of 38°C, and second case at water temperature of 63°C. Results showed that the combination of increasing secondary cooling intensity and reduction of primary cooling intensity can increase pool length and mushy zone thickness. Also, it is shown that, secondary cooling intensity can be magnified by up to 1.5 times for cooling water temperature of 63°C to get pool length close to that of water temperature of 38°C.
文摘In this paper,it presents the results of calculation of solidification process of copper continuous cast bar by cross section size 120 mm × 70 mm with application of Pro Cast 2010 software. The estimation of mould design effect on solidification process of continuos copper cast bar is completed at various speeds of casting.Profiles of liquid metal cavities and temperature allocations in the cast bar at various casting speeds are defined.The analysis of received liquid metal cavity profiles shows that a new mold construction allows significantly decrease of the length of the liquid metal cavity during continuous copper casting at HAZELETTcasting machine and the increase of maximum casting speed from 10 to 11 m / min. Adequacy of the results of copper continuous cast bar solidification process calculation is confirmed by the experimental data.
