The Southwire Continuous Rod (SCR) process is widely used for producing low-oxygen copper rods, yet pore defects remain a significant challenge, affecting the performance and drawability of copper wire. In this study, the influence of casting speed o...
With the increasing demand for high-efficient continuous casting, parameter optimization during high-speed continuous casting is critical. To clarify the changes in flow characteristics in a multistrand tundish and the optimization principles for the...
Endless rolling urgently requires an increase in the casting speed of continuous casting. For the continuous casting process of a high-casting-speed billet, the heat flux of the mold would be much higher, requiring a stronger cooling performance and...
Ultrahigh-speed continuous casting is a critical element in achieving high-efficiency continuous casting. In the present work, a three-dimensional model of a 160 mm × 160 mm billet ultrahigh-speed continuous casting mold was developed for use i...
The role of the roll separating force in the high-speed twin-roll casting of aluminum alloys was examined. In horizontal-type twin-roll casting, as the casting speed increased upon decreasing the roll separating force, the strip texture changed from...
The industrial production of high-speed steel via continuous casting has been impeded by considerable technical obstacles, due to its high carbon content and fast cooling speed, which predispose it to severe segregation and poor high-temperature plas...
Mold structure and cooling parameters are significant factors that affect the heat transfer capacity of high-speed continuous casting molds of billets. Therefore, a three-dimensional fluid flow and heat transfer model of a 160 mm × 160 mm bille...
High casting speed coincides with the development trend of billet continuous casting, which significantly changes the casting characteristics. A mathematical model of the billet mold, which includes multiphase fluid flow, transient heat transfer, and...
A reasonable flow field in the continuous casting mold is beneficial to produce high quality billets, and the design of the nozzle parameters of the mold is key to regulating the flow behavior of molten steel. Through combining the numerical simulati...
When the casting speed of the thin slab continuous caster is increased, the ratios of the solid and liquid phases in the solidification front of the molten steel in the mold change, which affects the thickness of the solidified shell. In order to acc...
To improve the mechanical properties of the casting alloys, various attempts have been made to use alternative casting technologies. The Ohno continuous casting (OCC) process is a unidirectional solidification method, which leads to high-quality cast...
Longitudinal crack defects are a frequent occurrence on the surface of thin slabs during the high-speed continuous casting process. Therefore, this study undertakes a detailed analysis of the solidification characteristics of hyper-peritectic steel t...
Limiting casting expression speed was obtained and the flow redistribution and thermal history in a horizontal direct-chill (HDC) casting was predicted using the numerical modeling approach. The governing solidification equations were non-dimensional...
A conventional twin-roll caster usually casts strips at a speed slower than 2 m/min and a roll load greater than 2 kN/mm. A vertical-type high-speed twin-roll caster can cast aluminum alloy strips at a speed higher than 10 m/min and a roll load small...
In the present study, a new electroslag cladding method by using of the advanced current supplying mold technology was used for manufacturing the high speed steel (HSS)/ductile cast iron (DCI) composite roll. The graphite morphology, matrix microstru...
The solidification process in strip casting using a vertical-type high-speed twin-roll caster was clarified by inserting a 0.1 mm diameter K-type thermocouple into a strip during casting. The roll speeds of the copper rolls were 10 m/min and 30 m/min...
This work focuses on the production of gradient composite materials with an alumina matrix containing copper and chromium and examines the effect of the reinforcement and casting speed on the obtained microstructure. Al2O3-Cu-Cr composites with a mic...
A vertical-type high-speed twin-roll caster can cast strips at a speed of 60 m/min. However, ripple marks, which are typical surface defects on strips cast using a twin-roll caster, also appear on strips cast using this caster. In the present study,...
A solid/liquid continuous composite casting technology was developed to produce brass-clad copper stranded wire billets efficiently with continuous casting speeds ranging from 200 mm/min to 1000 mm/min. As the casting speed increased, the microstruct...
The flow behavior in the mold has a considerable influence on the final product quality of the strand. In this paper, the variation of flow field, level fluctuation, and liquid slag distribution was analyzed by a hydraulic modeling experiment of a hi...
A vertical-type high-speed twin roll caster can cast aluminum alloy strip at speeds from 20 to 90 m/min; however, surface cracks occur on the cast strip. In Al-Si alloys, surface cracks are known to occur when the Si content is less than 5 mass%. The...
The effects of a reduction in area (RA) and the speed ratio between the top and bottom rolls on a shear strain and the crystallographic texture evolution of Al-Si-Mg (1.0%Si-0.6%Mg) aluminum alloys fabricated by twin roll casting (TRC) were comprehen...
The surfaces of cold-rolled titanium-containing ferrite stainless steel (TCFSS) strips produced from scrap are prone to severe peeling owing to cracking near slab inclusions during hot rolling. In this study, the Taguchi method was used to prevent pe...
Ultra-wide slabs have a good application market and prospect, but there is still a lack of research on the flow field. To explore the characteristics of its flow field, this study built a 0.5-scale physical model of mold using Perspex. The effect of...
In this work, the friction stir weldability of two structural high-pressure die casting aluminum alloys designed to manufacture thin-walled automotive components is investigated and compared. AlSi10MnMg and AlMg4Fe2 alloys were friction stir welded a...
The high-pressure die-casting process can effectively manufacture aluminium alloy castings with complex shapes and thin wall thicknesses. However, due to the complex flow characteristics of the liquid metal during the mould-filling process, there are...
In the current work, a rod deflection method (RDM) is conducted to measure the velocity of molten steel near the surface in continuous casting (CC) mold. With the experimental measurement, the flow velocity and direction of molten steel can be obtain...
During continuous casting of aluminum-killed steel, clogging of tundish nozzle frequently occurs, which seriously disrupts the normal casting sequences and deteriorates strand quality. Generally, argon blowing technology in the form of a stable and c...
Precise control of casting velocity and effective throwing kinetic energy conversion efficiency in blasting engineering are challenges. To provide a theoretical basis and reference for the implementation plan and fine construction of the cast blastin...
The technological process of the centrifugal casting of short and long castings is examined during development. The values of the technological parameters at applying heat-resistant coating on the working surface of metal molds were established. With...
The mechanical properties of high-pressure die-casted parts are directly influenced by their microstructure. This article aims to evaluate the effect of the fast-shot speed on the structural component and overall microstructure for two geometrically...
In the gel-casting process, the proper selection of technological parameters is crucial for the final quality of a green body. In this work, the finite element method is used to investigate the mold characteristics in the gel-casting process, and the...
The slow-shot speed phase in high-pressure die casting critically governs molten metal flow within the shot sleeve, directly influencing air entrapment and casting defect formation. Conventional water modeling has been widely used to analyze this sta...
Fluidity tests of 99.9%Al and 99.7%Al were conducted using a die casting machine equipped with a spiral die with a channel gap of 0.5 mm. The effects of die temperature and plunger speed on the fluidity were investigated. To clarify the flow length f...
The flow field, tracer dispersion and uniformity of strands in two designs of four-strand tun-dishes under normal conditions and single-strand blockage conditions are studied by numerical simulation. The casting speed (flow rate) of strands are incre...
Porous carbon fiber-reinforced Al-Si alloy matrix composites and carbon fiber felt-reinforced Al-Si alloy matrix composites with carbon content of 10 wt.% were prepared by die casting. The dry tribological properties of these two composites and Al-Si...
In the current investigation, additive friction stir-deposition (AFS-D) of as-cast hypoeutectic A356 Al alloy was conducted. The effect of feeding speeds of 3, 4, and 5 mm/min at a constant rotational speed of 1200 rpm on the macrostructure, microstr...
This study’s novelty lies in providing first-time insights into the isolated role of Friction Stir Processing (FSP) travel speed on microstructure evolution and mechanical performance (micro-hardness, tensile properties, impact energy, and wear...
A novel dual-speed tool for which the shoulder and pin rotation speeds are separately established was utilized to friction stir weld cast magnesium AZ91 with wrought aluminum 6082-T6. To assess the performance and efficacy of the dual-speed tool, bas...
Metal casting is an industrially important manufacturing process offering a superior combination of design flexibility, productivity and cost-effectiveness, but has limitations due to filling related defects. Several semisolid casting processes are a...
A series of dynamic large-scale model tests and three-dimensional finite element analyses were conducted to investigate the dynamic response of track embankment and XCC pile-raft composite foundation in soft soil for a ballastless high-speed railway...
AISI M2 steel was smelted in a 150 kg medium-frequency induction furnace and cast to form round billets with a cross-section diameter of 100 mm via a vertical continuous caster and sand mold. The secondary dendrite arm spacing (λ2), cooling ra...
The AZ series of Mg alloys have become promising in several industrial fields thanks to its potential microstructure refinement and the β-Mg17Al12 eutectic that controls the mechanical behaviour. Simultaneously, the rapid degradation characteriz...
Two types of high-speed twin-roll casters and a single-roll caster equipped with a scraper were proposed. One of the twin-roll casters is a vertical-type high-speed twin-roll caster, and the other twin-roll caster is an unequal-diameter twin-roll cas...
A heat transfer model and a cellular Automation-Finite Element (CAFE) coupling model were established to analyze the solid/liquid (S/L) interface and solidification structure evolution of high purity copper Direct-chill (DC) casting billet under diff...
This study introduces a novel vertical bending continuous casting technology for producing thin slabs of pure aluminum and aluminum alloys, offering significant advancements over traditional vertical casting methods. The newly designed equipment and...
Tool steel for hot working is usually used for the rolls of conventional twin-roll casters for aluminum alloys. In a vertical high-speed twin-roll caster, copper rolls are used to rapidly solidify the aluminum alloys and to increase the casting speed...
In this study, the relationship between macro segregation and the equiaxed zone in high-carbon grades with continuous casting parameters was investigated and optimized at the İsdemir iron and steel plant. The work was conducted for the 1080 qual...
In the current study, the transient flow characteristics on the top surface of a steel slab continuous casting strand were numerically investigated using a large eddy simulation combined with volume of fluid (LES + VOF) model. The validation of numer...
The high-speed, low-load twin-roll casting of Al-Si alloys with a Si content of approximately 1 at% is needed to prevent the occurrence of cracks. In twin-roll casting, however, the roll load reaches the lower limit required for the sufficient solidi...
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