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Modeling of casting technology of large-sized ingots from deformable aluminum alloys

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Abstract

An industrial technology for semi-continuous casting of large-sized ingots from wrought aluminum alloy 1580 has been developed through the use of complex modeling, including computer modeling and physical modeling. The ProCAST and ANSYS software packages equipped with the FLUENT module were used for computer modeling. The physical modeling was carried out on a laboratory semi-continuous casting unit (SCCU), which represents a tenfold reduced physical model of an industrial casting unit for the vertical semi-continuous casting of ingots from aluminum alloys. An aluminum-magnesium alloy with the addition of 0.05% (wt.) of scandium was used as the object of modeling. The results of computer modeling were tested at the SCCU, and then computer modeling was carried out for casting a large ingot. According to the modes obtained in the simulation, an ingot with a section of 1310 × 560 mm was cast under industrial conditions, which had a good surface quality with the absence of casting defects. In the microstructure of an industrial ingot and an ingot cast on the SCCU, there were no primary intermetallic compounds Al3(Sc, Zr), which makes it possible to strengthen the alloy upon annealing. To check the manufacturability during rolling, billets with a size of 40 × 120 × 170 mm were cut from these ingots, which were hot-rolled to a thickness of 5 mm, and then cold rolled to a thickness of 1 mm. The rolling results revealed good workability of the alloy, which was reflected in the high quality of the surface and the absence of cracks at the edges of the rolled stock. The mechanical properties of sheets obtained from both ingots were at the same level, which proves the reliability of casting modes for ingots obtained by complex modeling and the validity of their use for industrial conditions of the semi-continuous casting of large ingots from aluminum alloys.

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Availability of data and materials

The model was developed using the commercial software package ProCAST (a trademark of the ESI Group). The authors completed the calculation work of ProCAST at Siberian Federal University.

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Acknowledgements

Use of equipment of Krasnoyarsk Regional Center of Research Equipment of Federal Research Center “Krasnoyarsk Science Center SB RAS” is acknowledged.

Funding

The research was carried out within the framework of the state assignment of the Ministry of Science and Higher Education of the Russian Federation (scientific theme code FSRZ-2020–0011).

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Authors and Affiliations

  1. Siberian Federal University, Krasnoyarsk, Krasnoyarsk Region, 660025, Russian Federation

    Aleksandr Innokentyevich Bezrukikh, Vladimir Nikolaevich Baranov, Igor Lazarevich Konstantinov, Sergey Borisovich Sidelnikov, Anton Viktorovich Zavizin, Boris Petrovich Kulikov, Pavel Olegovich Yuryev, Denis Sergeevich Voroshilov, Yuriy Viktorovich Baykovskiy & Evgeniy Gennadyevich Partyko

  2. LLC “RUSAL ETC”, Krasnoyarsk, Krasnoyarsk Region, 660111, Russian Federation

    Aleksey Aleksandrovich Iliin

  3. JSC “Scientific and Industrial Consultants”, Moscow, 121351, Russian Federation

    Dmitriy Nikolaevich Bondarenko

  4. Tashkent State Transport University, Tashkent, 100000, Uzbekistan

    Yulbarskhon Nabievich Mansurov

  5. Huanggang Normal University, Huangzhou District, Huanggang, Hubei, 438000, China

    Yulbarskhon Nabievich Mansurov

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  1. Aleksandr Innokentyevich Bezrukikh
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  2. Vladimir Nikolaevich Baranov
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The authors declare that they are all participants in the work and none of them performed only administrative functions.

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Correspondence to Denis Sergeevich Voroshilov.

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Bezrukikh, A.I., Baranov, V.N., Konstantinov, I.L. et al. Modeling of casting technology of large-sized ingots from deformable aluminum alloys. Int J Adv Manuf Technol 120, 761–780 (2022). https://doi.org/10.1007/s00170-022-08817-w

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