Coupled thermal-stress model of the start-up phase of the aluminum direct chill casting process: Predictions relating to hot tearing

A three dimensional coupled thermal-stress model has been formulated to describe the thermal and stress/strain fields which evolve during the start-up phase of the direct chill (DC) casting process for AA5182 ingots. This model includes industry-scale ingot and bottom block geometries. The thermal analysis, as reported earlier, includes the various stages of heat transfer: primary (mold) cooling, secondary cooling (chill water impingement and …