A Numerical Study of the Direct-Chill Co-Casting of Aluminum Ingots via Fusion™ Technology

For the last 70 years, direct-chill (DC) casting has been the mainstay of the aluminum industry for the production of monolithic sheet and extruded products. Traditionally, clad aluminum sheet products have been made from separate core and clad DC cast ingots by an expensive roll-bonding process; however, in 2005, Novelis unveiled an innovative variant of the DC casting process called the Fusion™ Technology process that allows the production of multialloy ingots that can be rolled directly into laminated or clad sheet products. Of paramount importance for the successful commercialization of this new technology is a scientific and quantitative understanding of the Fusion™ casting process that will facilitate process optimization and aid in the future development of casting methodology for different alloy combinations and ingot and clad dimensions. In the current study, a numerical steady-state thermofluids model of the Fusion™ Technology casting process was developed and used to simulate the casting of rectangular bimetallic ingots made from the typical brazing sheet combination of AA3003 core clad with an AA4045 aluminum alloy. The analysis is followed by a parametric study of the process. The influence of casting speed and chill-bar height on the steady-state thermal field within the ingot is investigated. According to the criteria developed with the thermofluids model, the AA3003/AA4045 combination of aluminum alloys can be cast successfully with casting speeds up to 2.4 mm s⁻¹. The quality of the metallurgical bond between the core and the clad is decreased for low casting speeds and chill-bar heights >35 mm. These results can be used as a guideline for improving the productivity of the Fusion™ Technology process.