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TMS 2018: Light Metals 2018 pp 895–900Cite as

Experimental Study and Numerical Analysis of Cracking During DC Casting of Large Dimension 7075 Aluminium Billets

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Part of the book series: The Minerals, Metals & Materials Series ((MMMS))

Abstract

AA7xxx alloys are hard to cast as the chemistry of the alloys make them prone to both hot and cold cracking. The difficulty to cast sound billets increases with billet diameter due to increasing thermal gradients and associated stress build-up in the center. In this paper, 7075 Ø405 mm billets with varying chemical composition cast by the Low Pressure Casting technology™ have been studied using numerical modelling and industrial casting trials. The microscopic structure evolution including solidification paths and secondary phase formation has been simulated using a microstructural software and combined with semi-quantitative predictions of both hot tearing and cold cracking tendencies using process modelling software. Combined with results from industrial casting trials, the correlation between alloy chemistry and critical casting speed has been analyzed.

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Acknowledgements

Funding of this work by the ABC Design-project (Alloy Based Casting Design) is gratefully acknowledged. Project partners are Hycast. Hydro Aluminium ASA. Stiftelsen SINTEF and Institute for Energy Technology (IFE). The project is supported by the Norwegian research council through the BIA programme.

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Authors and Affiliations

  1. SINTEF Materials and Chemistry, Oslo, Norway

    K. Ellingsen, Q. Du & M. M’Hamdi

  2. Hycast, Sunndalsøra, Norway

    B. E. Gihleengen, R. Ledal & A. Håkonsen

  3. Hydro Research and Development Center, Sunndalsøra, Norway

    K. O. Tveito

Authors
  1. K. Ellingsen
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  2. Q. Du
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  3. M. M’Hamdi
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  4. B. E. Gihleengen
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  5. R. Ledal
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  6. K. O. Tveito
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  7. A. Håkonsen
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Corresponding author

Correspondence to K. Ellingsen .

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Editors and Affiliations

  1. Rio Tinto Alcan, Saint Jean, France

    Olivier Martin

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© 2018 The Minerals, Metals & Materials Society

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Ellingsen, K. et al. (2018). Experimental Study and Numerical Analysis of Cracking During DC Casting of Large Dimension 7075 Aluminium Billets. In: Martin, O. (eds) Light Metals 2018. TMS 2018. The Minerals, Metals & Materials Series. Springer, Cham. https://doi.org/10.1007/978-3-319-72284-9_116

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