LIQUID METAL JET OPTIMIZATION IN DIRECT CHILL CASTING
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Mar 24, 2017
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Mar 25, 2016
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A liquid metal jet supplying molten metal during a direct chill casting operation can be optimized to erode the slurry region of the molten sump, but not the solidified metal, at a rate equal to the casting speed. A model of the erosion of solidifying grains in the slurry region of the molten sump can be non-dimensionalized to be used to generate casting parameters (e.g., optimally sized nozzle openings and optimal molten metal flow rates) that would provide the optimized liquid metal jet during the casting process. An ingot cast using such an optimized liquid metal jet would have improved macrosegregation properties (e.g., reduced macrosegregation or more evenly distributed macrosegregation), such as having ingot solute concentrations varying from the molten metal supply concentration approximately 10% or less or 5% or less across the width or height of the ingot.
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