Continuous Casting

Edited by K. Ehrke and W. Schneider

L03 ©WILEY-VCH Deutsche Gesellschaft Weinheim • New York • Chichester flir Materialkunde e.V. Brisbane • Singapore • Toronto Contents

25 Years of DGM Continuous Casting Research W. Schneider, VAWaluminium AG, Research and Development, Bonn (D)..

Melt Treatment

Hydrogen in Aluminum Containing Copper Alloy Melts - Solubility Measurement and Removal K. Neumann, B. Friedrich, K. Krone, IME Process Metallurgy and Metal Recycling, RWTH Aachen (D) J. Jestrabek, E. Nosch, Schwermetall Halbzeugwerk GmbH, Stolberg (D) 15

Fundamental Research About Liquid Metal Filtration B. Hubschen, J. Kruger, RWTH Aachen (D) N. Keegan, Pyrotek Engineering Materials Limited, Dudley (GB) W. Schneider, VAW Aluminium AG, Bonn (D) 20

Impact of Grain Refiner Addition on Ceramic Foam Filter Performance N. Towsey, W. Schneider, H.-P. Krug, VAW aluminium AG, Research and Development, Bonn (D) A. Hardman , London & Scandinavian Metallurgical Co. Limited, Rotherham, South Yorkshire (GB) N. Keegan, Pyrotek Engineering Materials Ltd., Netherton, West Midlands (GB) 26

Review of Dissolution Testing and Alloying Methods in the Casthouse G. Borge, Bostlan, S.A., Larragane, Mungia (E) P. Cooper, S. Thistlethwaite, LSM Co.Ltd., Rotherham (GB) 33

The Effect of Casting Parameters on the Metallurgical Quality of Twin Roll Cast Strip Y. Birol, Marmara Research Center, Gebze-Kocaeli (TR) G. Kara, A. Soner Akkurt, ASSAN Aluminum Works, Istanbul (TR) C. Romanowski, FATA Hunter Inc., Riverside (USA) 40

Casting Technology and Processes - Aluminium

Influence of Different Lubricants on the Friction between the Solidifying Shell and the Mould during the DC Casting of AlMgSi0.5 F. Domenburg, VAW aluminium AG, Research and Development, Bonn (D) S. Engler, Foundry Institute, Aachen University of Technology, Aachen (D) 47

Prediction of Boundary Conditions and Hot Spots during the Start-up Phase of an Extrusion Ingot Casting S. Benum, Hydro Aluminium R&D Materials Technology, Sunndals0ra (N) D. Mortensen, H. Fjcer, Institute for Energy Technology, Kjeller(N) 54 VIII

Improved Metal Distribution during DC-casting of Aluminum Alloy Sheet Ingots P. T0ndel, J. Hayes, I. Thorvaldsen, Elkem Aluminium, Mosj0en (N) G. Grealy, G. Tahitu, Corus Research Development & Technology, Ijmuiden (NL) E. Jensen, Elkem Research, Kristiansand (N) D. Brandner, Corus Aluminium Walzprodukte GmbH, Koblenz (D) 61

Determination of Material Properties and Thermal Boundary Condition from Casting Trial on Alloy AA7075 J. Rabenberg, J. Storm, Corus Research Development & Technology, Ijmuiden (NL) I. Opstelten, Corus Research Development & Technology, now with TNO Bouw, Delft (NL) J.-M. Drezet, Ecole Polytechnique Federate de Lausanne, Lausanne (CH) 71

Single-roll Strip Casting of Aluminium Alloys E. Straatsma, W. Kool, L. Katgerman, Delft University of Technology, Laboratory for Materials, Delft (NL) 77

Continuous Casting of Semisolid Al-Si-Mg Alloy T. Motegi, F. Tanabe, Chiba Institute of Technology 82

Casting Technology and Processes

Yield and Quality Improvements for Semi-Continuously Cast Copper Alloys C.-M. Raihle, Outokumpu Process Automation, Vdsterds (S) 89

Continuous Casting Technology for Magnesium U. Holzkamp, H. Haferkamp, M. Niemeyer, University of Hanover, Institute of Materials Science, Hanover (D) 94

Local Distribution of the Heat Transfer in Water Spray Quenching F. Puschmann, E. Specht, J. Schmidt, University of Magdeburg, Institute of Fluid Dynamics and Thermodynamics, Magdeburg (D) 101

Grain Structure, Microstructure and Texture of Copper Ingots Produced during the Continuous Casting Process V. Plochikhine, V. Karkhin, H. Bergmann, Department of Metallic Materials, University of Bayreuth (D) 109

Technologies and Installation for Electrochemical Hardening of Wear Surfaces R. Boiciuc, V. Munteanu, G. Petrache, Uzinsider Engineering S.A., Galati (ROM) 115 IX

Modelling - Heat and Fluid Flow; Nucleation

Numerical Mass and Heat Flow Predictions in Aluminum DC Casting: A Comparison of Simulations with Melt Pool Measurements A. Buchholz, Corus Research Development &Technology, Ijmuiden (NL) B. Commet, Pechiney Centre de Recherches de Voreppe (F) G.-U. Griin, VAW aluminium AG, Research and Development, Bonn (D) D. Mortensen, Institute for Energy Technology, Kjeller(N) 123

Investigations of the Primary Cooling in Sheet Ingot Casting H. Fjcer, D. Mortensen, Institute for Energy Technology, Kjeller (N) A. Buchholz, Corus Research Development & Technology, Ijmuiden (NL) B. Commet, Pechiney Centre de Recherches de Voreppe (F) J.-M. Drezet, Laboratoire de Metallurgie Physique, EPFL, Lausanne (CH) 131

Boiling Curve Approach for Thermal Boundary Conditions in DC Casting J. Zuidemajr., L. Katgerman, Netherlands Institute for Metals Research, Laboratory for Materials, Advanced Materials and Solidification Technology, Delft (NL) I. Opstelten, Corus Research Development & Technology, Ijmuiden (NL) 138

Theoretical and Experimental Study of Vertical Continuous Casting of Copper M. Uoti, Helsinki University of Technology, Laboratory of Metallurgy, Helsinki (SF) M. Immonen, K. Hdrkki, Outokumpu Poricopper OY, Kuparitie, Pori (SF) 143

Modeling of Grain Refinement in Aluminum Alloys A. Greer, A. Tronche, University of Cambridge (GB) 149

Modeling of the Grain Refinement in Directionally Solidified Al -4.15 wt.% Mg Alloys using Cellular Automaton - Finite Element Approach M. Vandyoussefi , A. Greer, University of Cambridge (GB) 154

Modelling - Stress and Structure

ContiSim™: Process and Material Modelling of Continuous Casting in Macro and Micro Scale J. Boehmer, Process Modelling and Informatics, Betzdorf/Sieg (D) 163

Crystal Growth Morphology during Continuous Casting C. Caesar, Munich (D) 169

3D-Modeling of Ingot Geometry Development of DC-Cast Aluminum Ingots during the Start-Up Phase W. Droste, G.-U. Griin, W. Schneider, VAW aluminium AG, Research and Development, Bonn (D) J.-M. Drezet, CALCOMSA, Pare Scientifique, Lausanne (CH) 175 X

The Influence of Casting Practice on Stresses and Strains in 6xxx Billets - A Statistical and Modelling Study B. Henriksen, S. Braathen, E. Jensen, Elkem ASA Reasearch, Kristiansand(N) 184

Modelling of Macrosegregation in Continuous Casting of Aluminium T. Jalanti, M. Rappaz, Ecole Polytechnique Federate de Lausanne, Laboratoire de Metallurgie Physique, Lausanne (CH) M. Swierkosz, M. Gremaud, Calcom SA, Lausanne (CH) 191

The Effect of the Differencing Scheme on the Numerical Diffusion in the Simulation of Macrosegregation B. Venneker, Netherlands Institute for Metals Research, Delft (NL) L. Katgerman, Delft University of Technology, Laboratory for Materials, Advanced Materials and Solidification Technology, Delft (NL) 199

Application of a New Hot Tearing Analysis to Horizontal Direct Chill Cast Magnesium Alloy AZ91 J. Grandfield, Cooperative Reasearch Centre for Cast Metals Manufacturing, CSIRO Manufacturing Science & Technology, The University of Queensland (AUS) C. Davidson-, J. Taylor, Department of Mining, Minerals and Materials Engineering, The University of Queensland (AUS) 205

Micro- and Macrostructures

Nucleation Studies of Grain Refiner Particles in Al-Alloys P. Schumacher, University of Oxford (GB) 213

Effect of Solute Elements on the Grain Structures of Al-Ti-B and Al-Ti-C Grain-Refined Al Alloys A. Tronche, University of Cambridge (GB) A. Greer, University of Cambridge (GB) and Pechiney Centre de Recherches de Voreppe (F) 218

Grain Refinement Process in Aluminium Alloys Type AlZnMgZr T. Stuczynski, M. Lech-Grega, Institute of Non-Ferrous Metals, Light-Metals Division, Skawina (PL) 224

Coupled Influence of Convection and Grain-refining on Macrosegregation of ID Upwardly Solidified Al 4.5% Cu P. Jarry, Pechiney Centre de Recherches de Voreppe (F) H. Combeau, G. Lesoult, LSG2M, Ecole des Mines de Nancy (F) 233

Tensile Behaviour of DC-cast AA5182 in Solid and Semi-solid State W. van Haaften, W. Kool, L. Katgerman, Laboratory of Materials, Delft University of Technology, Delft (NL) 239 XI

The Columnar to Equiaxed Transition in Horizontal Direct Chill Cast Magnesium Alloy AZ91 J. Grandfield, Cooperative Reasearch Centre for Cast Metals Manufacturing, CSIRO Manufacturing Science & Technologiy, The University of Queensland (AUS) C. Davidson, J. Taylor, Department of Mining, Minerals and Materials Engineering, The University of Queensland (AUS) 245

Study of Heterogeneous Nucleation of oc-Al on Grain Refiner Particles during Rapid Solidification P. Cizek, B. McKay, P. Schumacher, University of Oxford (GB) 251

Effect of Instability of TiC Particles on the Grain-Refining Behavior of Al-Ti-C Inoculants in Aluminum Alloys M. Vandyoussefi, A. Greer, University of Cambridge (GB) 257

Grain Refiners for Thin Strip Twin Roll Casting R. Cook, London & Scandinavian Metallurgical Co. Limited, Rotherham (GB) 263

Characterisation and Optimisation of Thixoforming Feedstock Material S. Engler, Giefiereiinstitut, RWTH Aachen (D) D. Hartmann, EFU Gesellschaft fur Ur-/Umformtechnik mbH, Simmerath (D) I. Niedick, Volkswagen AG, Braunschweig (D), (former EFU GmbH) 269

Experimental Study of Linear Shrinkage during Solidification of Binary and Commercial Aluminum Alloys D. Eskine , L. Katgerman, Netherlands Institute for Metals Research, Delft (NL) 276

The Influence of the Cooling Rate on the Type of the Intermetallic Phases in the Aluminium Alloys of the 3XXX (AlMnMgSi) Group T. Stuczyriski, M. Lech-Grega, Institute ofNon-Ferrous Metals, Light Metals Division, Skawina(PL) 282

Suppliers Session - Aluminium

Horizontal Direct Chilled (HDC) Casting Technology for Aluminium F. Niedermair, Hertwich Engineering GmbH, Braunau (A) 293

Automatic "Bleed Out" Detection and Plug Off in VDC Billet Casting M. Luck, Wagstaff Inc., Spokane WA (USA) 300

The AIRSOL VEIL® Technology Package for Aluminium Billet Casting G. Bulian, M. Langen, VAW aluminium AG, Bonn (D) 302

The Manufacturing, Design and Use of Combo Bag Distributors in Sheet Ingot Casting S. Tremblay, Pyrotek High-temperature Industrial Products Inc., Chicoutimi (CAN) R. Green, Pyrotek Engineering Materials Ltd., Netherton (GB) 310 XII

Recent Quality and Efficiency Improvements Through Advances in In-Line Refining Technology V. Dopp, S. Simmons, Pyrotek, Inc., Tarrytown, New York (USA) 316

Suppliers Session - Copper

Horizontal Continuous Casting of Copper Alloy Billets M. Brey, SMS Meer GmbH, Demag Technica, Veitshochheim (D) 325

The Outokumpu UPCAST® System L. Eklin, Outokumpu Castform Oy, Pori (SF) 333

Author Index 341

Subject Index 343