Critical Review on Pull-In of Aluminium in Continuous Casting

INTERNATIONAL JOURNAL OF SCIENTIFIC & TECHNOLOGY RESEARCH VOLUME 8, ISSUE 11, NOVEMBER 2019 ISSN 2277-8616

Critical Review On Pull-In Of Aluminium In Continuous Casting

R. S. Fegade, Dr. R. G. Tated, Dr. R. S. Nehete,

Abstract: This study offers a comprehensive review of the research articles related to the continuous casting for a selected grade of Aluminium alloys. Data were obtained from various articles between the years of 1976 to 2018 in journals and conference proceedings. Five categories have been distinguished based upon the studies of casting surface defects, casting speed effects, mould parameters, thermal and heat flow and other continuous casting survey. The most important defect produced is Pull-in of the casting which results due to improper control over solidification parameters. Many researchers discussed the issues of steel casting and rolling ingot defects such as crack, cold shut, run out, filter puncture and drag marks. Rare research work was found on the Pull-in problem in the rolling ingot of aluminum casting. Researchers attempted to solve this problem by CFD approach or by Finite element analysis approach for steel casting, but there is ample scope for modeling to be developed for many casting grades of aluminum alloys. So there is need to develop model for selected aluminum alloys continuous casting.

Index Terms: Aluminium Rolling Ingot, Continuous Aluminium Casting, Pull In, Rolling Ingot defect, shell zone , solidification. ——————————  ——————————

1. INTRODUCTION base of ingot for steel, oxide film defect, meniscus defect, C ONTINUOUS casting is the primary method in the production porosity hydrogen, shrinkage porosity defect, non-invasive of Aluminium billets, blooms or slabs. In the continuous casting slag detection. process, the molten aluminium pours from ladle through tundish to the water cooled mould by a submerged entry 2.2 Studies on Casting speed effects nozzle. The molten metal gets solidified into ‗‗semis‘‘ and Casting speed effects on various factor in continuous casting subsequently pulled/rolled out into final product [1, 2]. The like solidification behaviour, mushy region thickness. tundish also used as a refining vessel to float out detrimental inclusion which may cause surface defects and internal stress 2.3 Studies on Mould parameters concentration during rolling operation. It is important to control In the mould design various parameter affected like a gap the casting speed to avoid the defects in final mould. Casting between shell and mould, mould slag frication, mould filling, speed needs to maintain same with incoming liquid metal, so mould thickness etc. the process ideally runs in steady state. The critical part of the continuous casting process is initial solidification process at 2.4 Studies on Thermal and Heat flow the meniscus, where the surface of the final mould produced. The included Thermal Stresses and Solidification Behaviour An oil or mould slag can be added in this part to avoid the Stress, Deformation Temperature Flow, Super Heat Flow, Heat surface defects. In recent years, there is need to advancement flow analysis, heat flux analysis etc. in engineering and technology is to provide high quality of casting product to all leading manufacturing industries paper. 2.5 Other continuous casting surveys There are several other models and study can be found in 2 A FRAMEWORK FOR CLASSIFICATION continuous casting process such as metal quality, viscosity This review paper summarises the studies on different mathematical model developed, composite interface, materials parameters and defects in the direct chill casting process for properties, DOE techniques. aluminium alloys. Five different categories have been distinguished to study the casting defects and effect of various 3 REVIEW OF LITERATURE parameters. In casting process, mechanical and metrological problems arise due the various heat treatments and handing 3.1 Studies on casting surface defects process. The current understandings of casting surface defects from the recent studies are longitudinal transverse crack, flat 2.1 Studies on casting surface defects surface analysis, bubble damage and fracture study, air gap This theme deals with casting defects like longitudinal formation due to shrinkage, shrinkage porosity defect, and transverse crack, flat surface analysis, bubble damage and non-invasive slag detection [3, 4]. Cracks are occurring on the fracture study, scheduling problem in aluminium casting surface and internal body are common in the continuous centre, air gap formation due to shrinkage, curvature as the casting process. Surface cracks are serious dispute because it oxidizes more in rolled product; also it causes the strand to be ———————————————— scrapped due to longitudinal cracks. Strand causes thermal  Prof. R. S. Fegade is currently pursuing PhD in Mechanical gradient and thermal stress. Longitudinal cracks may happen engineering in Dr. Babasaheb Ambedkar Marathwada University, due to improper mould design and uneven cooling. Air gap Aurangabad, India, PH-9975758469. E-mail: [email protected] formation continuous casting process between the solidified  Dr. R. G. Tated, Department of Mechanical Engineering Matoshri shell and wall has an adverse effect of process efficiency. College of Engineering & Research Center Eklahare, Nashik, India. Liquid metal changes the phase from liquid to solid state Email: [email protected] during solidification which causes the shrinkage in ingot, it  Dr. R. S. Nehete, Department of Mechanical Engineering, SIES causes the change in size of the final product. It reduces the Graduate School of Technology, Navi Mumbai, India. Email: quality of the continuous casting process. An extensive study [email protected]. on the surface defect during the continuous casting process 1950 IJSTR©2019 www.ijstr.org INTERNATIONAL JOURNAL OF SCIENTIFIC & TECHNOLOGY RESEARCH VOLUME 8, ISSUE 11, NOVEMBER 2019 ISSN 2277-8616

has been tabulated in table 1. Researches were done an thermal fluid flow and solidified process this is helpful for experimental and numerical study on the surface defects identifying the best process parameters. While Du et al. [9] cause and their remedy. The surface roughness of the casting worked on the finite element (FEA) model for continuous product can be predicted by the model developed by R. S. casting slab and their mould. Malhotra and Kumar [10] Taufik and S. Sulaiman [5]. They prepared a thermal discussed the casting defects that degrade the quality of the expansion model for casted aluminium silicon carbide the product. They studied different papers and find out main root squeeze casting method. Choudhari et al. [6] worked on cause of the casting. The above literature figures out that, designing of the feeder and optimized the location of the most of the researcher covers the FEA and CFD model on feeder for minimization of defects and compared the heat treatment, thermal analysis, various defects for steel but simulation result with the experimental trial. Batwara and limited research has been found on the pull in defect in Shrivastav [7] presented the relationship between factor and selected grade of aluminium alloy. Hence, there is an ample their responses using design of experiment techniques for the scope for researcher to work in selected grade of aluminium continuous casting product. For design of experiment analysis alloy. So there is need to develop model for aluminium alloys selected four factors in MINITAB software. In MINITAB in continuous casting process. Moulding temperature and software surface responded methodology use for finding the casting speed are two critical parameters which affect the relation between factor and responses study. quality especially the solidification and cross-section. Cross- Ravindra Pardeshi [8] focuses on the developing the model of section largely decides the yield in continuous casting. a steady-state computational fluid dynamics (CFD) and Use this computational fluid dynamics (CFD) model for studied the

TABLE 1 STUDIES ON CASTING SURFACE DEFECTS Reference Main purpose of the study Criteria considered Remarks

Choudhari et al. (2014) To minimize the casting defects like as sink, shrinkage Vector Gradient Method (VGM), Shrinkage [5] cavity and porosity by using appropriate feeding system. Auto Cast X Software Porosity Defect

To find out root causes of the formation of longitudinal Wu et al. (1988) [11] cracks and surface cracks of 7039 aluminium alloy by the Microscopic Analysis Cracks direct chill contiguous casting process.

To detect the transverse surface cracks were metallographic ally and the local segregation was found to Transverse Harada et al. (1990)[12] Metallographic Investigation be the origin of transverse surface cracks on continuously Cracks cast ingot and prevent the crack formation and segregation.

To find the effect and relationship of hot ductility of steels Transverse Mintz et al. (1991) [13] on the problem of transverse cracking during continuous Tensile Testing Cracks casting.

Fernandez et al. (1995) To the analysis of flat surface and on line defects detection Flat Surface Automated Visual Inspection [14] in continuously casting of aluminium. Analysis

Bubble Damage Divandari and To study the mechanism of bubble damage and fracture in X-Ray Radiography And Fracture Campbell (1999) [15] continuous castings. Study

To develop a mathematical model for the prediction of cracks in the continuously cast steel beam blank using Lee et al. (2000) [16] Fluid Flow, Heat Transfer Cracks coupled analysis of fluid flow, deformation behaviour of a solidifying shell, and heat transfer. Scheduling To optimization of problems techniques for the solution of Continuous Horizontal Casting Problem In Gravel et al. [17] an industrial scheduling problem in aluminium continuous Process Aluminium casting. Casting Centre Air Gap Study of air gap formation due to shrinkage molten metal in Amin et al. (2003) [18] Enthalpy Method Formation Due a continuous casting mould. To Shrinkage Curvature As Williams et al. (2003) Development of a model for the start-up phase of direct Operational Optimization, The Base Of [19] chill casting. Computational Model Ingot For Steel

Developed mathematical Modelling for the entering oxide (OFET, 2-D), Volume Of Fluid Oxide Film Yang et al. (2004) [20] film defects in the filling of casting defects. (VOF) Defect To develop a computational model for continuous casting Meniscus Thomas (2005) [21] Computational Model defects related to mould flow. Defect, Cracks

Dispinara et al. (2010) Porosity Degassing, hydrogen and porosity phenomena in A356 Degassing [22] Hydrogen Analysis of longitudinal crack on slab surface at Longitudinal YU and LIU (2010) [23] straightening stage during continuous casting using the FEM, Solidification Analysis Cracks finite element method. The model was presented to study the macro-segregation Micro- Zaloznik et al. (2011) Volume-Averaged Two-Phase formation in the direct chill casting of aluminium alloy using segregation [24] Multistage Model transport mechanics. Formation Lalpoora et al. (2011) To find critical cracks size in several ingots at different Thermo-Mechanical Simulation Crack [25] casting conditions using thermo mechanical simulation. In this study, they have considered main mechanisms of Defects Katgerman and Eskin structure and defect formation during solidification of DC Experimental Techniques Formation In (2011) [26] cast ingot. Solidification

To find a cost-effective non-invasive slag detection system Takacs et al. (2017) Cumulative Sum (CUSUM) Non-Invasive which is based on the vibration signal measured during the [27] Control Chart Slag Detection casting.

3.2 Studies on Casting speed effects region, which shows an admirable result with related to the This section explains more about the effect of casting speed casting of aluminium ingot. Hasan and begum [30] by on the performance of the continuous casting process. The considering 3D turbulent melt flow and heat transmission in change in casting speed has a significant effect on for the liquid sump, vertical low head direct chill slab casting process formation of the defects in final cast such as bulging and was modelled for aluminum alloy AA-6061. Experimental cracks. These defects can be controlled by maintaining cooling results showed that only 10-15 % of heat from incoming melt and secondary cooling zone. Bulging, surface cracks may be was removed at the mould in vertical direct chill casting found due to the high casting speed, while a metallurgical process, while 85-90 % of heat was taken out through length of the strand can be increased with increase in casting secondary cooling by direct water injecting onto the emerging speed. With increase in casting speed increases sump depth ingot. Formation of air gap decreases heat transmission rate and eventually decreases the shell thickness. Also casting from ingot to mould which further cause reheating of shell will speed affect heat flux simultaneously, heat flux increases with promote to drag marks, segregation knot, surface cracks and increase in casting speed. The defect produced due to casting mixed microstructure (fine/course). Maurya and Jha [31] were speed are reported and briefly discussed by many authors in investigated effect of casting speed and superheat on steel table 2. Begum and Hasan [28] have presented the work for slab in continuous casting by developing three-dimensional the effect of casting speed and heat transfer coefficient on the mathematical models. The study is based on investigation of mould metal contact region on different parameters. The result solidification and heat transmission of steel within mould and presented and discussed in the form of velocity temperature, in secondary cooling zone. Porosity method was implemented solid shell thickness as well as mushy layer thickness. Begum for the mushy zone to treat as porous medium. They were and Hasan [29] were performed 3-D CFD simulation for observed mushy region to find out shell thickness of solidified aluminum AA-1050 alloy in vertical direct chill slab caster with shell. The study reported that casting speed has a major effect a submerged nozzle and a porous filter. Simulations were on temperature distribution, while superheat has less effect on conducted by changing three different significant factors of the metallurgical length of strand and on temperature distribution. problem, namely, the casting speed from 40 to 100 mm/min, Higher casting speed has tendency to breakout of solidified the effective heat transfer coefficient at the mould-metal shell and mould due to lack of slag film for lubrication between contact region from 0.75 to 3.0 kW/(m2 K), and the Darcy shell and mould. number of the porous filter. They observed that low porosity filter causes velocity depicts almost uniform flow in the mould

TABLE 2 STUDIES ON CASTING SPEED Reference Main purpose of the study Criteria considered Remarks

To study the three-dimensional prediction of aluminium Casting Speed Begum and Hasan alloys Al 1050 solidification at the time of turbulent flow in a VFD and CFD And Heat (2016) [28] vertical direct chill casting. Transfer

To simulating the aluminium AA 1050 alloy vertical direct Casting Speed Begum and Hasan chill slab to developed a three-dimensional computational CFD And Heat (2014) [29] fluid dynamics model. Transfer Casting Speed Begum and Hasan Modelling of 3-D turbulent transport phenomena and Parametric Studies And Heat (2014) [30] solidification of a direct chill caster. Transfer

Casting Speed Maurya and Jha (2014) To developed three-dimensional mathematical models for 3- Model, Degree Of Superheat And Heat [31] the effect of the degree of superheat and casting speed. And Casting Speed Transfer

To develop the mathematical model describing the Casting Speed, Garcia and Prates displacement of solid and liquid isotherm and the Mathematical Model Of Solidification (1983) [32] temperature distribution during continuous casting of binary Continuous Casting Behaviour alloy.

Developing coupled finite-element m CON2D model, to Li and Thomas (2004) simulate temperature, shape development and stress Fem Model Casting Speed, [33] during continuous casting of steel.

Turbalioglu and Sun To improve manufacturing parameters of the vertical Casting Parameters Casting Speed (2011) [34] continuous casting method.

Sadat and Gheysari To find the effects of casting speed on steel continuous K-E Model,3-D Simulation Casting Speed (2011) [35] casting process. Casting Speed To analyze casting temperature and thermal deformation Twin-Roll Continuous Strip And Mushy Zhang (2014) [36] different casting processing parameters developed two- Casting Region dimensional finite element (FE) models. Thickness

To development of a steady-state computational fluid Casting Speed dynamics (CFD) model for treats fluid flow, solidification Metal Distribution System, Pardeshi (2017) [37] And Heat and heat transfer during more than one alloy direct chill Casting Speed, CFD Transfer casting.

3.3 Studies on Mould parameters the solid and liquid interfacial slag layers, and the effect of Table 3 explains the effect of mould parameters on the oscillation marks. They reported that model describes higher performance of the continuous casting process. Researchers casting speed increases heat flux through mould by two work numerically and experimentally to investigate the effect. combined effects a thinner interfacial gap near the top of the Keyser [38] were studied mould level regulation to improve mould and a thinner shell toward the bottom. Dai et al. [41] surface quality of cast in continuous steel casting machine. novel CRIMSON aluminum method was used to save potential Auto tuning and predictive control were introduced to improve energy. Casting industries uses an inconsistent amount of mould level regulation for improvement of steel quality. The energy which results in inefficient processes used compared advantage of the model-based predictive control approach is with its output. They reported that using a novel melting its simplicity when retuning the loop in order to balance method instead of usual method in traditional foundries could efficiently between robustness and performance. This method save energy in the order of 43 GJ tonne (11.9MWh tonne) can is useful where process characterized by large parameter for A354 alloy which can drastically reduce cost for casting variations during operations. Dai et al. [39] have developed a process. Abuluwefa et al. [42] were investigated factors two-dimensional program using two methods viz. finite affecting solidification of steel in the mould during continuous difference technique and the Marker and Cell (MAC) method casting of steel billets by using a mathematical model. Explicit to simulate the molten metal flow in a mould. Meng and finite element method was implemented to govern heat Thomas [40] was studied a mathematical model for heat transfer equations for the solidification process. The transfer and solidification process in continuous slab casting. magnitude of molten metal steel superheat entering to the The model consist treatment of the interfacial gap among the mould is most effective factor on solidified steel thickness in shell and mould, counting mass and momentum balances on the mould. The small thickness of mould wall affects thermal conductivity of mould material.

TABLE 3 STUDIES ON MOULD PARAMETERS Reference Main purpose of the study Criteria considered Remarks

Meng and Thomas To modelling transient slag-layer phenomena in the mould Mould Slag Heat Transfer, Mod-Slag Friction (2003) [1] gap in continuous casting of steel Frication To improve mould level regulation by two new approaches Mould Control Keyser (1997) [38] first one is auto tuning and the second one is predictive PID-Control Strategies For Steel control.

To simulate the molten metal flow during filling a mould by Dai et al. [39] (2012) developing two dimensional programs using a finite FDM And MAC Methods Mould Filling difference technique and the Marker and cell (MAC) method.

To developed model for the heat transfer and solidification of Meng and. Thomas Gap Between the steel molten metal in the mould by continuous casting 1-D And 2-D Models (2003) [40] Shell And Mould process.

To the improvement of aluminium casting process control X. Dai et al. (2012) [41] CRIMSON Process Mould Filling using of the new crimson process To develop a mathematical model for factor affecting on Abuluwefa et al. [42] solidification of steel in the mould during continuous casting Mathematically Modelled Mould Thickness (2012) of steel billets.

3.4 Studies on Thermal and Heat flow Senthil and Amirthagadeswaran [44] have worked on to Study of process parameters and their effect to improve prepare AC2A aluminium alloy castings of an unsymmetrical productivity is important but also it needs to concentrate on the component using squeeze casting process. The optimum elimination of the mechanical and metallurgical defects such squeeze casting conditions were also developed with as macro segregation, cracks in final cast. Heat transfers in mathematical models for the same process. Mazumdar and continuous casting process have been hugely investigated in Ray [45] were carried out a study to control solidification frequent studies. There is a large deformation of the slab and process in continuous casting method by different parameters the related thermal stresses are the main attraction. Many mainly heat transmission during solidification, friction and researchers did a study on temperature profile during lubrication at the solid and liquid surface of solidifying shell. solidification process and evaluation of the solid shell during Mould oscillation aided by lubrication can minimize the friction the liquid core reduction process. A CFD analysis was and continuous release of shell from the mould. Friction performed by authors to investigate the thermal stresses and among strand surface and mould wall below critical shell deformations in it. Table 4 explains briefly the different effects strength can minimize shell sticking and tearing. Seetharamu of heat treatment in the performance of the continuous casting et al. [46] were studied solidification phenomena by modelling process. Du et al. [9] did analysis on non-uniform thermo- analytical model. Simulations were made by using Finite mechanical behaviours of slab during continuous casting. Heat element method to evaluate heat transfer in Solidification flux was calculated by using inverse algorithm while process. They reported that Non-uniform shrinkage causes temperatures by thermocouples. They reported that thermal distortion in casting. Higher casting speed causes breaking and mechanical conditions of slab were not symmetric, and tears out of casting. Li et al. [47] were simulated fast roll reflected non-uniform nature of thermo-mechanical behaviors. casting process. Comprehensive Modelling of fast roll casting Hasan and begum [30] by considering 3D turbulent melt flow needed for understanding behaviour of parameters mainly and heat transmission in liquid sump, vertical low head direct flowing and temperature region of molten metal into casting chill slab casting process was modelled for aluminum alloy AA- tip, stress field used for simulation of casting process. A model 6061. Computed results were obtained by controlling for the temperature region of molten metal in casting tip and parameters like casting speed, superheats, cooling molten pool was established. Analyzed computer results temperature of mould and effective heat transfer. Experimental showed that temperature distribution is comparatively smaller results showed that only 10-15 % of heat from incoming melt in the crystallized zone than rolling zone. Higher rolling was removed at the mould in vertical direct chill casting velocity causes higher exit temperature which influences the process, while 85-90 % of heat was taken out through length of the molten pool. Nowak et al. [48] were investigated secondary cooling by direct water injecting onto the emerging a three-dimensional numerical analysis of the inverse ingot. Formation of air gap decreases heat transmission rate boundary problem for CC (continuous casting) process of an from ingot to mould which further cause reheating of shell will aluminum alloy. Focus was on identifying heat fluxes along the promote to drag marks, segregation knot, surface cracks and external surface of ingot. A sensitivity analysis was mixed microstructure (fine/course). Choudhari et al. [43] implemented to evaluate the boundary condition retrieval in developed a steady-state three-dimensional heat flow the inverse process. This technique was independent of mesh mathematical model to evaluate heat transmission in size, starting value of the assumed boundary condition and the continuous casting. Compared to bulk motion of descending maximum error of measurements used for calculations. They strand, axial conduction of heat was negligible. Computed reported that the average percentage error in the sensors was results were relatively insensitive to the Effective thermal noticeably fewer than the maximum percentage error of the conductivity value within range of 1k to 7k. numerically simulated measurements.

TABLE 4 STUDIES ON THERMAL AND HEAT FLOW Reference Main purpose of the study Criteria considered Remarks Taufik and Sulaiman To develop of thermal expansion model for casted Thermal Expansion Model Thermal Stresses (2013) [3] aluminium silicon carbide. To develop mould and full scale finite element model for Thermo mechanical Du et al. (2018) [9] FEM Model, Inverse Algorithm continuous casting. Behaviours of Slab To simulate a Low-Head (LH) vertical Direct Chill (DC) Hasan and Begum rolling ingot for the magnesium alloys AZ31 using three Temperature and Numerical Model (2014) [30] dimensional turbulent computational fluid dynamics Velocity Field (CFD). Choudhari et al. To develop effective thermal conductivity by using Mathematical Model For Heat Flow (1993) [43] steady-state three-dimensional heat flow model. Continuous Casting Senthil and Squeeze Pressure, To optimization of squeeze casting parameters using Squeeze Casting Process, Amirthagades-waran Die Preheating Taguchi method for AC2A aluminium alloy castings. Taguchi Method (2012) [44] Temperature 1954 IJSTR©2019 www.ijstr.org INTERNATIONAL JOURNAL OF SCIENTIFIC & TECHNOLOGY RESEARCH VOLUME 8, ISSUE 11, NOVEMBER 2019 ISSN 2277-8616

Compression

Mazumdar and Ray To control the solidification parameters depend on the Mode of Solid–Liquid Interface (2001) [45] solidification in continuous casting of steel. Solidification To carried out the simulation of the shrinkage and Seetharamu et al. Solidification of thermal stresses of the continuous casting using finite Fem Model (2001) [46] Distortion Casting element methods.

Comprehensive Modelling Of Temperature Flow Li et al. (2003) [47] To model and simulate the fast roll casting process. Multi-Subjects And Heat Transfer

Nowak et al. (2009) To do analysis for the identifying of the heat fluxes along FEM Model Heat Flux [48] the external surface of the ingot.

F'redman et al. (1997) To improve the temperature control in steel plant using a Mathematical Model Heat Flow [49] suitable mathematical model.

Thermal Stresses Lewis and Ravindran To develop finite element algorithms for the entire FEM, Solidification Analysis And Solidification (2000) [50] casting process. Behaviour To study and observe rheological behaviour of Gleeble-1500 Thermal- Zhan et al. (2005) [51] aluminium alloy and its influencing factors in physical Stress Deformation Mechanical Simulation Tester simulation of continuous roll casting process. To develop a finite difference model for finding Wang et al. (2007) Temperature Flow, temperature distribution and solid shell thickness profile FDM Model [52] Super Heat Flow of continuous casting. To do computer aided analysis and experimental Solidification Behera and Kayal.S validation of solidification behaviour and detection of FEM And VEM Behaviour And Hot (2011)[53] hotspots in aluminium alloy castings. Spot Optical Microscopy, Scanning To determine the effect of cooling rate on morphological Electron Microscopy, Energy Fabrizi et al. (2014) structure and chemical composition using several Dispersive Spectroscopy And Cooling Rate [54] analysis techniques. Backscattered Electron Diffraction. To numerical study of the effect of process parameters Pouring Sahoo (2015) [55] on solidification of Al-33Cu strip in high speed using Fluent Software Temperature fluent software. And Roll Study To study and observe the cooling rate of micro-alloyed Yang et al. (2017) [56] Andersen-Grong Equation Cooling Rates steel during continuous casting. To develop two-dimensional numerical models by fluent Zhang et al. (2017) software for simulation of fluid flow, solidification Fluent Software, VOF Model Heat Transfer And [57] behaviour and heat transfer molten metal of steel in the And K-Ε Model Solidification mould.

Motegi and Tanabe Horizontally Continuous To invent a casting machine for semisolid alloy. Cooling Rate (2018) [58] Casting

3.5 Other continuous casting surveys turbulence on the surface of the melt that introduced film. Shrivastav 2015 [7] were studied the effect of process When no diffusers were used in the holding furnace there was parameters on the casting solidification by using CFD software deterioration in the quality of melt from the beginning to the ANSYS FLUENT. To find out relation between factors and their end of the casting. One diffuser increases metal quality responses they have used surface methodology by using significantly rather than using two. Okayasu et al. 2015_[60] MINITAB software. For simulation turbulence model is very were carried out work to develop high quality cast aluminum important for the analysis of solidification and melting process. alloys by adapting a new casting technology. Ultrasonic Box-Behnken Design methodology was used for experiment vibration along with heated mould continuous casting was generation by using Minitab software. They studied signal to used to create commercial aluminum alloys. Crystal orientation noise ratio analysis and reported that solidus and liquids and grain size of the aluminum alloys were controlled by using temperature has great impact while in solidification of cast in heated mould continuous casting. Electron backscattered proper time. Dispinar and Campbell [59] were investigated diffraction was used to detect disordered more fine and study to know the effect of diffusers and casting techniques spherical grains. They reported that mechanical properties of consisting of different degrees of turbulence. Metal quality ultrasonic vibration heated mould continue casting Al alloys changes in the holding furnace as a function of time during a were marginally higher than cast aluminum alloys without pour. Metal quality improves by parameters like Casting ultrasonic vibration. Heated mould continuous casting (HMC) – density and bifilm index. By using diffusers and reducing pure aluminum has 10 % higher electrical conductivity than turbulence to minimum metal quality were increased that of wrought pure Al. lattice structure rising from the significantly and maintained throughout the casting operation. vibration in solidification process decreases electrical Change in high gas flow rates causes violent surface conductivity about 25% for the heated mould continuous

casting with ultrasonic vibration process. High hardness can process. Kaisarlis et al. [61] were presented a study on the DE be obtained if cast aluminum alloys vibrated at high amplitude agglomeration and dispersion of fine coal fly ash (CFA) (240V). By increasing ultrasonic vibration (400 Hz) Vickers reinforcing particles in an A380 aluminum matrix by means of hardness of the heated mould continuous casting-ADC6 a piston-actuated oscillating micro-grid mixing technique with increases. Using ultrasonic vibration process increases tensile particularly designed grid geometry by using an analytical, strength of HMC-aluminum alloys, hence they reported that numerical model. Oscillating micro-grid produces a more even mechanical properties changes by using ultrasonic vibration distribution of the micro-hardness in cast specimen.

TABLE 5 OTHER CONTINUOUS CASTING SURVEYS Reference Main purpose of the study Criteria considered Remarks

CFD Software ANSYS The aim of this study is to numerically simulate the Batwara and FLUENT,DOE Technique, DOE continuous casting products using commercial CFD Shrivastav (2015) [7] Box-Behnken Design Techniques software ANSYS FLUENT. Methodology Dispinar and Campbell To observe the effect of casting conditions on aluminium Metal Quality (2007) [59] metal quality. Heated Mould Continuous Okayasu et al. (2015) To develop high-quality aluminium casting alloys using a Materials Casting (HMC) With [60] new casting technology. Properties Ultrasonic Vibration (UV) To study analytical, numerical and experimental on the process of breaking up agglomerates and dispersion of Piston-Actuated Kaisarlis et al. (2017) fine coal capacity ash reinforcing particles in an Al380 Oscillating Micro-Grid Mixing Oscillating [61] aluminium matrix using a piston actuated oscillating micro Method, Analytical, Numerical Micro-Grid Mixing grid mixing method with a specially designed grid And Experimental Techniques geometry.

Casting Study Emley (1976) [62] To study the vertical and horizontal direct chill casting. DC Continuous Casting Reviews

To observe the changes of viscosities of a series of mould Viscosity Yu et al. (2009) [63] fluxes with different additives and addition amounts were Mould Fluxes Mathematical examined by a rotating viscometer. Model Developed

To prepare three-layer composite aluminium alloy ingot of DC Semi Continuous Composite Jiang et al. (2011) [64] 4045/3004/4045 by direct-chill semi-continuous casting Casting Interface process.

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