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Accounting for Melt Flow Pattern and Solid Fraction Evolution in DC Casting of Al-Cu Alloy Using \( v^{2}{-}f \) Turbulence Model

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Abstract

Experimental techniques remain reliable approaches for investigating the effects of parameters of the direct chill (DC) casting process on macrosegregation, grain structure formation, and surface quality. However, experimental analysis methods of these effects are expensive and can often prove difficult to implement. Understanding of the complex physics of the solidification process remains limited, and this makes it indispensable to use accurate numerical modeling tools as a complement to experiments. Numerical modeling without consideration of turbulent flow is unsuitable for application to solidification occurring during DC casting, since significant turbulent flow exists in the upper section of the cast, where the liquid pool exists. The present work employed a low-Re \( v^{2}{-}f\) turbulence model and a dual-zone solidification flow model to predict the melt flow pattern, turbulence level, sump depth, transition zone thickness, and mushy zone thickness in the DC casting of Al-Cu alloy. The obtained results provided evidence of significant damping of the flow in the slurry zone. Furthermore, results of different simulation cases revealed a narrower transition zone and shallower sump.

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Acknowledgment

This work was conducted under the sponsorship of the Tertiary Education Trust Fund (TETFUND) (www.tetfund.gov.ng).

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Authors and Affiliations

  1. The Department of Mechatronics Engineering, Federal University of Technology Owerri, Owerri, Imo State, Nigeria

    G. C. Nzebuka

  2. The Department of Mechanical Engineering, Federal University of Agriculture Abeokuta, Abeokuta, Ogun State, Nigeria

    M. A. Waheed & S. I. Kuye

  3. The Department of Mathematics, Federal University of Agriculture Abeokuta, Abeokuta, Ogun State, Nigeria

    B. I. Olajuwon

Authors
  1. G. C. Nzebuka
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  2. M. A. Waheed
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  3. S. I. Kuye
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  4. B. I. Olajuwon
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Correspondence to G. C. Nzebuka.

Additional information

Manuscript submitted September 19, 2018.

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Nzebuka, G.C., Waheed, M.A., Kuye, S.I. et al. Accounting for Melt Flow Pattern and Solid Fraction Evolution in DC Casting of Al-Cu Alloy Using \( v^{2}{-}f \) Turbulence Model. Metall Mater Trans B 50, 866–880 (2019). https://doi.org/10.1007/s11663-018-01502-y

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