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Meeting 2023 TMS Annual Meeting & Exhibition
Symposium 2023 Light Metals Keynote Session
Presentation Title Issues in Macroscopic Modeling of Aluminum Direct Chill Casting
Author(s) Matthew John Krane
On-Site Speaker (Planned) Matthew John Krane
Abstract Scope Most wrought aluminum is produced by Direct Chill (DC) casting, a semi-continuous solidification process providing feedstock for downstream deformation processing. Transport phenomena and solidification behavior in DC casting has been the subject of modeling over the past 30 years and, while this work has led to distinct improvements in understanding process behavior, there are still many outstanding issues. In this talk, we begin with available experimental observations of industrial scale DC casting. We then examine different approaches to modeling the slurry of free-floating solid which forms from the grain-refined liquid pool, as well as ways to estimate the coalescence of that slurry into a rigid, solid matrix. Finally, we consider the purpose of these models, the reliability of the model outputs as a function of uncertainty in model input parameters, and the effect of choices for inclusion and form of representation of various physical mechanisms.
Proceedings Inclusion? Planned: None Selected


Data Analytics for Advanced Process Monitoring and Control in Primary Aluminum Smelting
Data Driven Methods to Increase Aluminum Recycling
Hydro Aluminium - Smelter Improvements Through Modelling and Digitalization
Importance of Transparent Data and Standardised Data Analysis for Decarbonisation of the Aluminium Sector
Improving Safety and Performance of DC Casting Lines by Applying Digital Twins, Process Models and Vision Systems
Issues in Macroscopic Modeling of Aluminum Direct Chill Casting
Microstructure Simulation as a Basis for Material Property and Casting Defect Predictions
Numerical Modeling Tools for the Assessment of High-Amperage DC Busbars

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