1 Institute for Advanced Materials and Technology, University of Science and Technology Beijing, Beijing 100083, China 2 Key Laboratory for Advanced Materials Processing (MOE), University of Science and Technology Beijing, Beijing 100083, China
Cite this article:
Xinhua LIU, Huadong FU, Xingqun HE, Xintong FU, Yanqing JIANG, Jianxin XIE. Numerical Simulation Analysis of Continuous Casting Cladding Forming for Cu-Al Composites. Acta Metall Sin, 2018, 54(3): 470-484.
High performance Cu-Al composites have widely applied in aviation, aerospace and other fields, at the same time the continuous casting as one of composite forming technologies has been also developed in recent years. Obviously, it is an effective and cheap way to numerically simulate the solidification process of short process continuous casting for manufacturing Cu-Al composites before fabricating them. To meet the need of simulation, in this work, a numerical method for theoretically describing the Cu-Al composite forming in continuous casting processes was proposed. The vertical continuous casting of copper clad aluminum bar billet and the horizontal continuous casting of copper and aluminum composite plate were performed. Based on this method, the steady state temperature fields in solidification processes in the above two kinds of casting technologies were numerically simulated by using proCAST software package. In this work the effects of the theoretical parameters on the steady state temperature fields and then on the performance of Cu-Al composites fabricated by using the above two casting technologies were carefully discussed. It is found that the experimental and simulated results are in good agreement. For the cases of the copper clad aluminum bar billet with a cross section of 100 mm×100 mm, and the copper or aluminum plate with a thickness of 20 mm and a width of 75 mm (coat thicknesses of 4~7 mm), the feasible parameters for producing high performance Cu-Al composites, for examples, are as follows: for the former the temperature of copper liquid is 1250 ℃, the temperature of aluminum liquid is 750 ℃, the length of crystallizer is 200 mm, the length of graphite mandrel tube is 290 mm, the flux of the first cooling water is 1600~2000 L/h, the flux of the second cooling water is 900~1300 L/h, the distance from the second cooling water to the exit of crystallizer is 30 mm, and the withdrawing speed is 60~80 mm/min. For the latter the temperature of copper melt was 1250 ℃, the temperatures of aluminum melt are 760~800 ℃, the withdrawing speed is 40~80 mm/min, and the length of aluminum duct is 20 mm.
Fund: Supported by National High Technology Research and Development Program of China (No.2013AA030706), Beijing Science and Technology (No.Z141100004214003) and Science and Technology Cooperation Project of Yunnan Province (No.2015IB012)
Fig.2 Geometry of the VCFCC processing model for fabricating CCA composites (1—graphite casting mold, 2—tcopper sheath, 3—graphite mandrel tube, 4—water-cooling copper chiller of crystallizer, 5—aluminum core, 6—copper liquid, 7—aluminum liquid, 8—crucible, L0—length of crystallizer; L1—copper solidification position; L2—aluminum solidification position; L3—length of compound zone) (a) external form of 3D Geometric model (b) internal form of 3D Geometric model
Fig.3 Schematics of the boundary conditions (left) and interface conditions (right) for simulation of the steady-state temperature in VCFCC processing for manufacturing CCA composites (1~6 are the boundary conditions for simulation of temperature of aluminum liquid, temperature of copper liquid, primary cooling water, secondary cooling water and geometric symmetry plane, respectively. I~IV are the interfaces between the aluminum core and the graphite mandrel tube, between the solidified copper sheath and the graphite mandrel tube, between the solidified copper sheath and the graphite cast mould, and between the graphite cast mould and the copper chiller of crystallizer, respectively)
Fig.4 Simulated steady state temperature field in solidification process of VCFCC for producing CCA composites, using proCAST software package (TAl—aluminum liquid temperature) (a) temperature nephogram (b) solidification map
L0 / mm
s / mm
h / mm
v / (mm?min-1)
L2 / mm
80
50
180
130
132.0
100
50
180
130
120.8
100
10
180
130
72.2
100
50
180
130
70.8
100
50
180
100
93.8
100
50
190
130
106.9
150
50
180
130
47.7
150
10
180
130
47.5
150
10
240
130
8.1
150
10
180
100
30.5
150
10
240
100
-12.2
200
50
270
130
99.8
200
50
310
100
35.4
200
10
270
130
48.3
200
10
310
100
16.8
250
50
310
130
103.5
250
50
380
100
16.2
250
10
310
130
64.5
250
10
380
100
-5.8
Table 1 Effect of the length of crystallizer on solidified position of copper and aluminum
h mm
Q1 Lh-1
Q2 Lh-1
TAl ℃
v mmmin-1
L1 mm
L2 mm
L3 mm
Ts ℃
250
1600
900
750
60
73.5
78.15
67.08
740
270
1600
900
750
60
73.5
69.26
47.61
710
290
1600
900
750
60
73.5
35.82
27.92
685
310
1600
900
750
60
73.5
18.62
5.93
650
330
1600
900
750
60
73.4
6.43
-3.24
630
Table 2 Effect of length of mandrel tube on solidified position of copper and aluminum
No.
h mm
Q1 Lh-1
Q2 Lh-1
TAl ℃
v mmmin-1
L1 mm
L2 mm
L3 mm
Ts ℃
1
290
1400
900
750
60
72.5
37.94
28.95
690
2
290
1600
900
750
60
74.0
35.82
27.92
685
3
290
1800
900
750
60
74.5
34.95
26.83
683
4
290
2000
900
750
60
74.5
33.86
26.82
680
Table 3 Effect of flux of primary cooling water on solidified position of copper and aluminum
No.
h mm
Q1 Lh-1
Q2 Lh-1
TAl ℃
v mmmin-1
L1 mm
L2 mm
L3 mm
Ts ℃
1
290
1600
700
750
60
75.5
35.94
27.93
690
2
290
1600
900
750
60
75.0
35.82
27.92
685
3
290
1600
1100
750
60
73.5
35.12
26.83
687
4
290
1600
1300
750
60
73.5
34.95
26.83
684
5
290
1600
1500
750
60
73.5
33.84
25.83
680
Table 4 Effect of flux of secondary cooling water on solidified position of copper and aluminum
No.
h mm
Q1 Lh-1
Q2 Lh-1
TAl ℃
v mmmin-1
L1 mm
L2 mm
L3 mm
Ts ℃
1
290
1600
900
750
40
55.5
-11.51
0
-
2
290
1600
900
750
60
75.0
35.82
27.92
685
3
290
1600
900
750
80
80.0
59.07
51.85
725
4
290
1600
900
750
100
81.0
76.93
62.97
770
5
290
1600
900
750
120
82.5
87.49
70.39
790
Table 5 Effect of continuous casting speed on solidified position of copper and aluminum
Fig.5 Cross section morphologies of CCA samples manufactured in different cooling water flows (a) 1000 L/h (b) 1600 L/h (c) 2000 L/h
Fig.6 Schematic of horizontal continuous casting process for fabricating Cu-Al composite slab
Fig.7 Geometry of horizontal continuous casting for fabricating Cu-Al composite slab
Fig.8 Effects of length of aluminum liquid ducts on solidification position of copper and aluminum in horizontal continuous casting as shown in Fig.7 (a1, a2) 10 mm (b1, b2) 20 mm (c1, c2) 30 mm
Fig.9 Effects of casting speeds on solidification position of copper and aluminum in horizontal continuous casting as shown in Fig.7 (a1, a2) 40 mm/min (b1, b2) 60 mm/min (c1, c2) 80 mm/min (d1, d2) 100 mm/min (e1, e2) 120 mm/min
Fig.10 Effects of temperatures of aluminum liquid on solidification position of copper and aluminum in horizontal continuous casting as shown in Fig.7 (a1, a2) 760 ℃ (b1, b2) 780 ℃ (c1, c2) 800 ℃ (d1, d2) 820 ℃ (e1, e2) 850 ℃
Fig.11 Morphologies of binding layers (a1~d1) and surface quality (a2~d2) of slabs with casting speeds of 40 mm/min (a1, a2), 60 mm/min (b1, b2), 80 mm/min (c1, c2) and 100 mm/min (d1, d2) in horizontal continuous casting as shown in Fig.7
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