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Hot Tearing and Deformation in Direct-Chill Casting of Aluminum Alloys

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Hot Tearing and Deformation in Direct-Chill Casting of Aluminum Alloys Hot tearing and deformation in direct-chill casting of aluminum alloys Suyitno Hot tearing and deformation in direct-chill casting of aluminum alloys Proefschrift ter verkrijging van de graad van doctor aan de Technische Universiteit Delft, op gezag van de Rector Magnificus Prof. dr. ir. J.T. Fokkema, voorzitter van het College voor Promoties, in het openbaar te verdedigen op maandag 30 mei 2005 te 10.30 uur door Suyitno bachelor of engineering in werktuigbouwkunde master of science in materialkunde geboren te Semarang, Indonesia Dit proefschrift is goedgekeurd door de promotor: Prof. ir. L. Katgerman Toegevoed promotor: Dr. W.H. Kool Samenstelling promotiecommissie: Rector Magnificus, voorzitter Prof. ir. L. Katgerman, Technische Universiteit Delft, promotor Dr. W.H. Kool, Technische Universiteit Delft, toegevoed promotor Prof. dr. R. Boom, Technische Universiteit Delft & CORUS Prof. dr. I.M. Richardson, Technische Universiteit Delft Prof. dr. ir. S. van der Zwaag, Technische Universiteit Delft Prof. dr. A. Mo, SINTEF Materials Technology, Oslo, Norway Dr. ir. R.N. Kieft, CORUS RD&T, Ijmuiden This research was carried out as part of the strategic research program of the Netherlands Institute for Metals Research (NIMR) on the “Experimental description and process simulation of direct-chill (DC) casting of aluminum alloys” project number MP 97014. ISBN 90-9019393-6 Copy right © 2005 by Suyitno All right reserved. No part of the material protected by this copy right notice may be reproduced or utilized in any form or by any means, electronical or mechanical, including photocopying, recording or by any information storage and retrieval system, without written permission from the author. Table of Contents Chapter 1....................................................................................................................1 Introduction................................................................................................................1 1.1 Direct-chill casting of aluminum alloys ....................................................1 1.2 Hot tearing.................................................................................................4 1.3 Outline of this thesis................................................................................10 Chapter 2..................................................................................................................15 FEM simulation of mushy zone behavior during direct-chill casting of an Al−4.5%Cu alloy .....................................................................................................15 2.1 Introduction.............................................................................................16 2.2 Modeling .................................................................................................17 2.3 Experiment ..............................................................................................26 2.4 Results.....................................................................................................27 2.5 Discussion ...............................................................................................34 2.6 Conclusions.............................................................................................37 Chapter 3..................................................................................................................41 Hot tearing criteria evaluation for direct-chill casting of an Al−4.5%Cu alloy .......41 3.1 Introduction.............................................................................................42 3.2 Modeling .................................................................................................43 3.3 Hot Tearing Criteria ................................................................................45 3.4 Results.....................................................................................................52 3.5 Discussion ...............................................................................................60 3.6 Conclusions.............................................................................................67 Chapter 4..................................................................................................................69 Effects of casting speed and alloy composition on structure formation and hot tearing during direct-chill casting of Al–Cu alloys..................................................69 4.1 Introduction.............................................................................................70 4.2 Experimental procedure ..........................................................................72 4.3 Computer simulation...............................................................................74 4.4 Results.....................................................................................................78 4.5 Discussion ...............................................................................................90 4.6 Conclusions.............................................................................................94 Chapter 5..................................................................................................................99 Hot tearing study of Al–Cu billets produced by direct-chill casting........................99 5.1 Introduction...........................................................................................100 5.2 Experimental procedure ........................................................................100 5.3 Results...................................................................................................101 5.4 Discussion .............................................................................................110 5.5 Conclusions...........................................................................................112 Chapter 6................................................................................................................117 Model and simulation for prediction of hot tearing in aluminum alloys................117 6.1 Introduction...........................................................................................118 6.2 Physical model ......................................................................................119 6.3 Mathematical model..............................................................................121 6.4 Simulation .............................................................................................125 6.5 Results...................................................................................................128 6.6 Discussion .............................................................................................141 6.7 Conclusion.............................................................................................147 Chapter 7................................................................................................................151 Thermal contraction experiment for prediction of ingot distortions......................151 7.1 Introduction...........................................................................................152 7.2 Experimental Procedure ........................................................................153 7.3 FEM Simulation....................................................................................154 7.4 Results and Discussion..........................................................................155 7.5 Conclusions...........................................................................................161 Summary................................................................................................................163 Samenvatting .........................................................................................................167 Appendix A............................................................................................................171 List of Publications ................................................................................................175 Acknowledgment ...................................................................................................179 Curriculum Vitae ...................................................................................................181 Chapter 1 Introductionα 1.1 Direct-chill casting of aluminum alloys Direct-chill (DC) casting, which was invented independently in the early 1930s [1] and 1940s [2], is a semi-continuous process for producing extrusion billets and rolling slabs. Although the process has been known for a relatively long time, the continuous technological development is still going on. This is due to the demand for more effectiveness and efficiency in this process with improving quality and productivity. Also more critical alloys are cast. Some comprehensive papers reviewing recent developments can be found in refs. [3-5]. The DC casting processes can be classified based on the applied casting orientation and are distinguished between vertical or horizontal direct-chill casting where the slab or billet moves in downward or horizontal direction, respectively. α Adapted from the paper in: Progress in Materials Science, vol. 49, no. 5, 2004, pp. 629-711 Chapter 1 For casting aluminum billets and slabs, which will be used in wrought alloy applications, DC casting is the standard industrial casting technique. The vertical DC casting process is schematically shown in Fig. 1.1. Casting is performed by pouring the liquid
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