Modeling and Experimental Validation of Rapid Cooling and Solidification during High-Speed Twin-Roll Strip Casting of Al-33 wt pct Cu

The numerical modeling of heat transfer and solidification during twin-roll strip casting involves incorporating fluid flow, heat transfer, and phase change in the liquid metals and knowledge of heat flux distribution at the liquid metal–roll interface. Although efforts have been put in the development of comprehensive modeling of the process simulation of the heat transfer, solidification during high-speed twin-roll casting and its experimental validation has not been attempted. In the current paper, the results of simulation of twin-roll strip casting up to high speeds has been reported for Al-33 wt pct Cu using FLUENT 6.3.16 (ANSYS, Inc., Canonsburg, PA). Further Jackson-Hunt plot for Al-33 wt pct Cu has been used to validate the simulation. It has been shown by simulation as well as experiment that high speed twin-roll casting can be a method for direct production of layered materials.