Numerical Simulation of Vertical Direct Chill Casting Using CFD Method

A computational fluid dynamics (CFD) model with estimated heat transfer coefficient was used to simulate the vertical direct chill casting process. The model helps to understand how changes in parameters (such as casting temperature, casting speed, and cooling conditions) during casting affect the final temperature distribution in the casting ingot. Furthermore, it establishes correlations between these parameters and helps to optimize the temperature gradient between the high and low melting temperature regions. Temperature distribution and sump profile were validated experimentally in a DC casting pit for AA6082 Aluminum alloy.