Modelling and Analysis of a Horizontal Direct Chill Casting Process

The objective of this study is to analyze bleed-outs in Horizontal Direct Chill (HDC) casting process by using a finite element model (FEM). HDC casting machines for aluminium are made for continuous casting with typical duration from 3 to 20 days according to the equipment manufacturer. Reduced duration due to technical difficulties affects capacity, productivity and cost. In order to improve understanding of the operation and the effect of alternative casting parameters an FEM model was developed for a 36 bar HDC machine installed in the Alcoa Fjardaal casthouse. Simulations were done for alternative inlet metal temperatures, cooling water temperatures, cooling water flow rate and casting speed with the focus on extracting information about potential bleed out conditions of a cast bar. Physical measurements were done on the HDC under real casting conditions and compared with the results of the numerical simulation showing good agreement with the measured results.