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

El-Bealy, Mostafa Omar (author)
KTH,Department of Metals Processing and Technology, ASU, Egypt; CTU, Germany; Massachusetts Institute of Technology MIT, Materials Processing Center MPC, University Materials Council, Cambridge, MA, United States,Materialens processteknologi
 (creator_code:org_t)
Cham : John Wiley & Sons, 2012
2012
English.
In: Proceedings TMS Light Metals. - Cham : John Wiley & Sons. ; , s. 1107-1112, s. 1107-1112
  • Conference paper (peer-reviewed)
Abstract Subject headings
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  • 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.

Subject headings

TEKNIK OCH TEKNOLOGIER  -- Materialteknik -- Metallurgi och metalliska material (hsv//swe)
ENGINEERING AND TECHNOLOGY  -- Materials Engineering -- Metallurgy and Metallic Materials (hsv//eng)

Keyword

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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