Continuous Casting: Proceedings of the International Conference on Continuous Casting of Non-Ferrous Metals

385 Pages·2005·6.809 MB·English

I
Continuous Casting
Proceedings of the International
Conference on Continuous
Casting of Non-Ferrous Metals
Edited by
H. R. Müller
DeutscheGesellschaft
für Materialkunde e.V.
Continuous Casting: Proceedings of the International Conference on Continuous Casting of Non-Ferrous Metals. H. R. Müller
Copyright © 2006 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim
ISBN: 3-527-31341-9
II
Further titles of interest:
A. Hazotte (Ed.)
Solid State Transformation and Heat Treatment
ISBN 3-527-31007-X
D. M. Herlach (Ed.)
Solidification and Crystallization
ISBN 3-527-31011-8
III
Continuous Casting
Proceedings of the International Conference on
Continuous Casting of Non-Ferrous Metals
Edited by
H. R. Müller
DeutscheGesellschaft
für Materialkunde e.V.
IV
Editor:
Dr. H. R. Müller
Wieland-Werke AG
Graf-Arco-Str. 36
89079 Ulm
Germany
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© 2006 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim
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Composition: W.G.V. Verlagsdienstleistungen GmbH, Weinheim
Printing: Strauss GmbH, Mörlenbach
Bookbinding: J. Schäffer GmbH, Grünstadt
ISBN-13: 978-3-527 31341-9
ISBN-10: 3-527-31341-9
V
Preface
In 1976 the Committee for Continuous Casting of the Deutsche Gesellschaft für Materialkunde
(DGM) organised for the first time a continuous casting conference for non-ferrous metals. A
periodical update every 5 years has in the meantime been proven to be useful. Following the
very successful previous meeting in 2000 in Frankfurt, Germany, this year's conference reviews
the complete range of the processing chain covering both melt treatment and casting technology
as well as specific measures for micro-structural control. A focal point of the programme deals
with modelling and simulation that has become an integral part of modern manufacturing. Cur-
rent progress also includes spray forming as an increasingly important processing option. For
the first time poster presentations are included.
Experts from the manufacturing industry, researchers and scientists from university and indu-
stry as well as suppliers of equipment and ancillary products present information on most recent
technical and economical developments.
The organising committee thanks all authors for their contribution and last but not least the au-
dience for their discussion and comments.
Dr. Hilmar R. Müller
Chairman of the Organising Committee
VII
Contents
Melt Treatment 1
Melt Treatment of Copper and Aluminium – The Complex Step Before Casting 3
Friedrich, B., Kräutlein, C., Krone, K., IME Process Metallurgy and Metal
Recycling RWTH Aachen, Germany
A Study on Surface Defects Caused by Grain Refiners 23
Keles, O., Dundar, M., Assan Aluminum, Istanbul, Turkey
Effect of Grain Refiner on Surface Crack of 3004 Alloy during DC Casting 29
Morishita, M., Tokuda, K., Kobe Steel, Ltd, Moka-city, Tochigi, Japan
Investigation of Factors Affecting the Extent of Microporosity in an
Aluminum Casting 36
Savas, O., Kayikci, R., Sakarya University, Sakarya, Turkey
Model Studies of Gas Bubbles Physical Characteristics at Inert Gas Purging into
Molten Metals and Alloys 42
Stefanoiu, R., Geanta, V., Voiculescu, I., Politehnica University of Bucharest,
Bucharest, Romania
Casting Technology 49
Remarks about Process and Technology of Continuous Casting 51
Schliefer, H., Khoury, A., Porten, M., Norddeutsche Affinerie AG, Hamburg,
Germany; Wolber, P., Boller, K.H., SGL, Bonn, Germany; Dürrschnabel, W.,
Müller, H.R., Wieland-Werke AG Ulm, Germany; Schneider, St., Deutsche
Gießdraht GmbH, Emmerich, Germany; Müller, W.H., Schwarze , M., SMS-Meer,
Mönchengladbach, Germany; Oelmann, H., Rode, D., Frankenberg , R., KME,
Osnabrück, Germany
Continuous Strip Casting of Magnesium Alloy by a Horizontal Twin Roll Caster 70
Watari, H., Oyama National College of Technology, Oyama, Japan; Haga, T.,
Osaka Institute of Technology, Osaka, Japan; Koga, N., Nippon Institute of
Technology, Saitama, Japan; Davey, K., The University of Manchester,
Manchester, UK
Strip Casting of Mg-Al based alloy with Ca by Twin Roller Caster 77
Matsuzkai, K., Hatsushikano, K., Torisaka, Y., Hanada, K., Shimizu, T., National
Institute of Advanced Industrial Science and Technology(AIST), Tsukuba, Japan
Continuous Casting: Proceedings of the International Conference on Continuous Casting of Non-Ferrous Metals. H. R. Müller
Copyright © 2006 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim
ISBN: 3-527-31341-9
VIII
New Strip Casting Process for Magnesium Alloys 81
Bach, Fr.-W., Hepke, M., Rossberg, A., Institute of Materials Science (IW),
University of Hanover, Germany
Production of Twin Roll Cast AA6016 for Automotive Applications 87
Dündar, M., Keles, Ö., Assan Aluminum, Ýstanbul, Turkey; Anger, G.,
AMAG Automotive GmbH, Ranshofen, Austria
Magnesium Upward Direct Chill Casting 95
Bach, Fr.-W., Schacht, S., Rossberg, A., Institute of Materials Science (IW),
University of Hanover, Germany
Spray Forming of Advanced High Strength Aluminum Alloys 101
Krug, P., Commandeur, B., PEAK Werkstoff GmbH, Velbert, Germany
A Method of VDC Hot Top Mould Design and Setting of Process Conditions 106
Bainbridge, I.F., Cooperative Research Centre for Cast Metals Manufacturing
(CAST), Division of Materials, The University of Queensland, Brisbane, Australia;
Grandfield, J.F., Cooperative Research Centre for Cast Metals Manufacturing
(CAST), CSIRO, Division of Manufacturing and Infrastructure Technology,
Preston, Australia.
Continuous Casting of Non Ferrous Metal Micro Wrought Shapes 112
Bast, J., TU Bergakademie Freiberg, Germany; Bombach, E., Deutsche Solar
AG Freiberg, Germany
Influence of Quality of Water and Surface Roughness on Quenching Rate 118
Król, J., Specht, E., Otto-von-Guericke-University, Magdeburg, Germany
Electromagnetic Casting of Aluminum and Steel Billet Using Slit Mold 124
Park, J., Kim, M., Research Institute of Industrial Science and Technology;
Jeong, H., Kim, G., POSCO
Aluminium Alloy Strip Casting Using an Unequal Diameter Twin Roll Caster 131
Haga, T., Osaka Institute of Technology, Osaka, Japan; Watari, H., Oyama
National College of Technology, Oyama city, Japan; Kumai, S., Tokyo Institute
of Technology, Kanagawa, Japan
Fabrication of High Purity Copper Rod with Unidirectional Solidification
Structure by Continuous Casting Using Cooled Mold 137
Hoon Cho, Duck-young Hwang, Han-shin Choi, Shae K. Kim, Hyung-ho Jo,
Korea Institute of Industrial Technology,Yeonsu-gu Incheon, Korea
IX
High Speed Roll Casting of Al Alloy and Mg Alloy Strips 143
Haga, T., Osaka Institute of technology, Osaka city, Japan; Watari, H.,
Oyama national collage of Technology, Oyama city, Japan; Kumai, S., Tokyo
Institute of Technology, Kanagawa, Japan
Simulation / Modeling 149
State-of-the-Art in the Modelling of Aluminium and Copper Continuous
Casting Processes 151
Drezet, J.-M., Computational Materials Laboratory, Ecole Polytechnique
Fédérale de Lausanne and Calcom-ESI SA, Lausanne, Switzerland; Gremaud, M.,
Calcom-ESI SA, Parc Scientifique, Lausanne, Switzerland; Rappaz, M.,
Computational Materials Laboratory, Ecole Polytechnique Fédérale de Lausanne,
Lausanne, Switzerland
Numerical Simulation of the Growth of Interacting, Equiaxed Dendrites with a
Two-Scale Model 162
Jurgk, M., Max-Planck-Institut fur Physik komplexer Systeme, Dresden;
Emmerich, H., Siquieri, R., RWTH Aachen, Germany
Monte Carlo Simulation of Grain Growth in Three Dimensions 168
Zöllner, D., Streitenberger, P., Otto-von-Guericke-Universität Magdeburg,
Fakultät für Naturwissenschaften, Magdeburg, Germany
Thermal Conductivity of Ternary and Multi-Component Aluminum Alloys up to
and above the Melting Temperature 174
Brandt, R., Neuer, G., Institute for Nuclear Technology and Energy Systems (IKE),
University of Stuttgart, Stuttgart, Germany; Bender, W., Grün, G.-U., Hydro
Aluminium GmbH, Bonn, Germany
FEM Simulation of Near Net Shape DC Billet of High Strength Al-Mg-Si Alloy 182
Nagaumi, H., Takeda, Y., Nippon Light Metal Company Ltd., Kambara, Japan;
Suvanchai , P., Umeda, T., Chulalongkorn University, Bangkok, Thailand
Numerical Simulation of DC casting 189
Boender, W., Burghardt, A., van Klaveren, E.P., Corus RD&T, IJmuiden,
The Netherlands
Continuous Casting of Hypermonotectic AlBiZn Alloys: Experimental
Investigations and Numerical Simulation 194
Gruber-Pretzler, M., Mayer, F., Wu, M., Ludwig, A., University of Leoben,
Leoben, Austria; Moiseev, J., Tonn, B., Clausthal University of Technology,
Clausthal-Zellerfeld, Germany
X
Numerical Simulation of the Upward Continuous Casting of Magnesium Alloys 202
Landaberea, A., Pedrós, P., Anglada, E., Garmendia, I., INASMET Foundation,
San Sebastian, Spain
New Possibilities in the Simulation of Continuous Casting Processes with
WinCast-Conti 209
Ricken, H., Technische Universität München, Institute of Metal Forming and
Casting (utg), Garching, Germany; Honsel, C., RWP GmbH, Roetgen, Germany
Modeling Continuous Casting of Metal Wire Rods 213
Chang Hung-Ju, Hwang Weng-seng, Department of Material Science and
Engineering, National Cheng Kung University, Tainan, Taiwan; Chao Long-sun,
Pan Wensen, Department of Engineering Science, National Cheng Kung
University, Tainan, Taiwan; Lai Yi Lin, Metal Industries Research &
Development Center
Modeling of Macrosegregations in Continuous Casting of Sn-Bronze 219
Gruber-Pretzler, M., Mayer, F., Wu, M., Ludwig, A., Christian-Doppler
Laboratory for Multiphase Modeling of Metallurgical Processes, Department
of Metallurgy, University of Leoben, Leoben, Austria
Continuous Casting Simulation: From Solidification and Fluid Flow to the
Calculation of Grain Structures 226
Eberle, R., Wieland-Werke-AG, Ulm, Germany
Mould Temperature Fields during Continuous Casting of DHP-Copper 234
Mäkinen, M., Helsinki University of Technology, Espoo, Finland; Uoti, M.,
Outokumpu Copper R&D, Pori Finland
Simulation of Heat Transfer and Solidification in Continuous Casting of Copper
Alloys and the Effect of Fluid Flow 240
Vapalahti, S., Louhenkilpi, S., Mäkinen, M., Väyrynen, P., Helsinki University
of Technology, Laboratory of Metallurgy, Espoo, Finland
Micro / Macro Structure 247
Spray Forming and Post Processing of Superalloy Rings 249
Uhlenwinkel, V., Ellendt, N., University Bremen, Bremen, Germany; Walter, M.,
Böhler Edelstahl, Kapfenberg, Austria; Tockner, J., Böhler Schmiedetechnik,
Kapfenberg, Austria
Macro- and Microstructure of Spray-Formed Tin-Bronze 256
V. Kudashov, D., Müller, H.R., Zauter, R., Wieland-Werke AG, Ulm, Germany
XI
Influence of the Crystallization Conditions on the Microstructure and Mechanical
Properties of TiAl- and Ti Al-Based Alloys 265
3
Greenberg, B.A., Kazantseva, N.V., Volkov, A.E., Akshentsev, Yu.N., Institute
of Metal Physics, Ural Division, Russian Academy of Sciences, Ekaterinburg,
Russia
Effects of Process Parameters on the Characteristics of the Billet Sump and
Related Defect Formation during DC Casting of Aluminum Alloys 271
Eskin, D.G., Netherlands Institute for Metals Research, Delft, The Netherlands;
Katgerman, L., Delft University of Technology, Dept. Materials Science and
Engineering, Delft, The Netherlands
Effect of Casting Speed and Grain Refining on Macrosegregation of a
DC Cast 6061 Aluminum Alloy 277
Kumar Nadella, R., Eskin, D., Netherlands Institute for Metals Research, Delft,
The Netherlands; Katgerman, L., Delft University of Technology, Department
of Materials Science and Technology, Delft, The Netherlands
Effect of Melt Flow on Macrostructure and Macrosegregation of an
Al–4.5% Cu Alloy 283
Turchin, A.N., Eskin, D.G., Netherlands Institute for Metals Research, Delft,
The Netherlands; Katgerman, L., Delft University of Technology, Department
of Material Science and Engineering, Delft, The Netherlands
Quenching Study on the Solidification of Aluminum Alloys 290
Ruvalcaba, D., Eskin, D., Netherlands Institute of Metals Research, Delft,
The Netherlands; Katgerman, L., Kiersch, J., Delft University of Technology,
Delft, The Netherlands
Numerical Study of the Influence of an Applied Electrical Potential on the
Solidification of a Binary Metal Alloy 296
Nikrityuk, P.A., Eckert, K., Grundmann , R., Institute for Aerospace
Engineering Dresden University of Technology, Dresden, Germany
Microstructure and Strain Distribution Influence on Failure Properties in
Eutectic AlNi, AlFe Alloys 309
Olaru, P., INAV-S.A., Bucharest, Romania; Gottstein, G., IMM, RWTH-Aachen,
Germany; Pineau, A., ENSM, Paris, France
Dendrite Coarsening and Embrittlement in Continuously Cast Tin Bronzes 314
Virtanen, T., Tampere University of Technology, Tampere, Finland
Continuous Casting of Tin Containing Alloys and their Transformation 320
Lebreton, V., Sadi, F., Bienvenu, Y., Centre des matériaux P.M.Fourt, Ecole
Nationale Supérieure des Mines de Paris, Evry, France