Influence of direct chill casting process variables on surface quality of aluminum alloy sheet ingots

• Surface defects formation and their effects on the surface quality of aluminum direct-chill cast sheet ingots have been investigated by metallographic examinations and mathematical modeling. The influence of process variables such as alloy composition, casting speed and lubricant on the surface defects especially extruded surface segregation layer has been determined. The metallographic study for collected samples of plant trials involved visual, micro-examinations and macrosegregation analysis. A 2-D mathematical model has been developed to characterize the thermal, solidification, interdendritic strain and macrosegregation distributions. Also, the model contained a new approach to evaluate qualitatively the macrosegregation formed during dendritic solidification. The model predications were compared to measurements from collected samples to verify the model, where a good agreement was obtained. The model predications illustrate that all the process variables tested have an observed effect on the surface quality by different levels. The mathematical analysis of strain fields as well as metallographic study has been used to explain and discuss the effects of different process variables on the surface quality.

Ämnesord

TEKNIK OCH TEKNOLOGIER  -- Materialteknik -- Metallurgi och metalliska material (hsv//swe)

ENGINEERING AND TECHNOLOGY  -- Materials Engineering -- Metallurgy and Metallic Materials (hsv//eng)

Nyckelord

Aluminum

Exhibitions

Ingots

Mathematical models

Metallography

Solidification

Surface segregation

Alloy compositions

Aluminum alloy sheet

Casting speed

Defects formation

Dendritic solidification

Direct chill casting

Extruded surface segregation layer

Macrosegregations

Mathematical analysis

Mathematical modeling

Metallographic examination

Plant trials

Process Variables

Sheet ingots

Strain fields

Surface properties

Surface quality

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