About this Abstract |
| Meeting |
2027 TMS Annual Meeting & Exhibition
|
| Symposium
|
Aluminum Cast Shop Technology Symposium and Supplier Forum
|
| Presentation Title |
Advanced Digital Twin Simulation for Predicting Dross Generation in Aluminum Melting Processes
|
| Author(s) |
Keisuke Kamiya, Akira Suzuki, Fumiya Nozaki, Yusei Shinomiya |
| On-Site Speaker (Planned) |
Keisuke Kamiya |
| Abstract Scope |
Increasing scrap usage for carbon neutrality in aluminum production leads to higher dross generation, which reduces melting yield. Predicting this dross generation is challenging due to complex physical factors like scrap shape and charging methods, meaning optimization via conventional empirical models has reached its limits. To overcome this, we developed a novel physical simulation model for the melting process that explicitly accounts for dross formation. By integrating heat transfer, multiphase fluid dynamics, phase changes, and alloy-specific oxidation reaction kinetics for aluminum and magnesium, this digital twin dynamically simulates dross generation during heating and melting. The model was validated against actual industrial furnace data for AA1050 and AA5083 alloys. It successfully reproduced both melting completion times and dross generation volumes, demonstrating strong alignment with actual plant data. This simulation provides a quantitative tool to optimize scrap arrangement and burner control, ultimately improving yield and advancing digital transformation in casting operations. |
| Proceedings Inclusion? |
Planned: Light Metals |
| Keywords |
Modeling and Simulation, Aluminum, |