Modeling and Verification of Semi-Continuous Casting of Cylindrical Ingots from 1379c Alloy

Purpose. The purpose of this study is a detailed study of temperature fields during the preparation of alloy 1379c, transportation of the melt through a tray system, filtration of the melt through a foam ceramic filter and casting of cylindrical ingots by computer modeling in the ESI ProCAST software package with verification of models on a laboratory installation of semi-continuous casting of aluminum alloy ingots (UPNL).

Methods. The ProCAST software package was used for computer modeling. For physical modeling and verification of computer simulation results, a laboratory installation of semi-continuous casting of aluminum alloys (UPNL) was used. Ingots were obtained from alloy 1379c. The microstructure of the ingots obtained was evaluated by metallographic methods on an optical microscope using computer methods of quantitative metallography.

Results. The simulation of the process of semi-continuous casting of aluminum alloys at the site starting from the melt outlet from the melting furnace and ending with the crystallizer is carried out. As a result of metallographic study of the structure of the ingots obtained, it was determined that the average size of primary silicon crystals in ingots is 41 ±16 microns, while the size of small particles is 23 ±5 microns (30% fraction), the size of medium particles is 44 ±9 microns (56% fraction), the size of large particles is 69 ±9 microns (14%), the range of particle sizes in the ingot is 12-91 microns.

Conclusion. Dynamic models of melt overflow through a metallotract, melt filtration through a foam ceramic filter have been developed. Modeling of ingot casting with subsequent verification and correction of models based on the results of laboratory experiments allowed us to choose the optimal mode of ingot casting, to obtain in ingots the size of primary silicon crystals less than 25 microns and to achieve the accuracy of the simulation results of more than 93%.

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