The direct chill (DC) semi-continuous casting process has been the backbone of the aluminium industry for the production of ingots. Though the basic engineering of DC casting is relatively simple, the interaction of process parameters with occurrence of defects and micro-structural evolution is quite complex.
Through understanding of the physical phenomena involved during casting, computational models give the opportunity to establish quantitative relationships between materials, processes, and performance. However, when it comes to accurately predicting casting performance and in particular, the occurrence of defects like cracks, segregation and porosity, there is certainly some way to go. In this paper, the current developments in DC casting technology will be reviewed.