The DC casting process used for the production of cast aluminium alloy products intended for processing by rolling, extrusion or forging is an economically important process with approximately 10 million tonnes of DC cast product being produced annually world wide [1]. Process productivity, particularly with respect to elimination of casting defects and hence process scrap is an important factor to DC cast product producers. The literature reporting the DC casting process, particularly with respect to the formation of defects on the cast surface, is reviewed and the mechanisms for the formation of such defects examined. A universally understood and accepted explanation was found for only one of the normal surface defects encountered in practice. A number of samples of commercially cast DC products were subject to detailed cast surface examination, particularly surface microstructures. The results of this examination and the literature survey identified molten metal surface tension as a possible contributing factor affecting the molten metal meniscus stability within the DC casting mould. Meniscus instability is linked with the formation of surface defects. The literature on surface tension of aluminium alloys provided only limited information hence the surface tension of a range of binary and ternary alloys, including commercial alloys was determined, producing data hitherto not available. Of the common alloying elements used in commercial aluminium alloys, iron and magnesium were found to significantly reduce the surface tension. Surface fracture also resulted in a reduction in surface tension for the majority of alloys tested. The surface tension data is combined with mould thermal and physical model calculations to propose a mechanism for the formation of the cast surface defects. The model proposes a maximum stable size for the meniscus according to the alloy and mould conditions. Conditions outside these limits result in meniscus instability and the formation of cast surface defects. The model suggests possible operating changes that may reduce the incidence of surface defect formation. The work also identifies a number of areas requiring further investigation before major practical process changes aimed at cast surface defect elimination, may be formulated.
| Identifer | oai:union.ndltd.org:ADTP/289631 |
| Creators | Bainbridge, Ian Frank |
| Source Sets | Australiasian Digital Theses Program |
| Detected Language | English |
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