Horizontal Direct Chill (HDC) Billet Casting

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Direct Chill (DC) casting [SubsTech]

May 31, 2012· Dr. Dmitri Kopeliovich Direct Chill (DC) casting is a vertical semi-Continuous casting process used for fabrication cylindrical billets or rectangular ingots/blooms from non-ferrous metals such as Aluminum alloys, Copper alloys, Magnesium alloys. The Direct Chill (DC) cast ingots are further processed by either Extrusion, Rolling or Forging technologies.

US20050000679A1 - Horizontal direct chill casting ...

A casting apparatus ( 10 ) for direct chill casting metal includes a tundish ( 12 ) containing a supply of molten metal, a casting mold ( 14 ), and a starter block ( 44 ) associated with the casting mold ( 14 ). The casting mold ( 14 ) is in fluid communication with the tundish ( 12 ) through a passage ( 22 ) defined in the tundish wall.

Macrosegregation in horizontal direct chill casting of ...

A model for macrosegregation is applied to horizontal direct chill casting (HDC) of Al–4·5 wt-%Cu. The fluid flow in liquid is controlled by thermosolutal buoyancy, as well as shrinkage during solidification and the liquid metal inlet jet. Buoyancy acts perpendicularly to the casting direction and the top and bottom heat transfer rates are ...

Horizontal & Vertical Continuous Casting Production ...

Horizontal continuous casting is best suited for aluminum bronzes due to the material's metallurgy. As a result, our Birmingham plant has been dedicated almost exclusively to the production of aluminum bronze. During horizontal continuous casting, metal flows out the front of the crucible and into a water-cooled die where solidification takes ...

Xiang Jie Wang's research works | Northeastern University ...

The influence of different electromagnetic fields on the horizontal direct chill (HDC) casting of aluminum alloy is studied. 7075 aluminum alloy with 100-mm in diameter is produced by HDC casting ...

Simulation of vertical direct chill (DC) continuous ...

Jul 27, 2017· Continuous casting process is used in fabrication of billets and ingots from primarily aluminum, copper and magnesium non-ferrous alloys. Direct Chill (DC) process involves flow of metal alloy into a water cooled …

Direct-Chill Casting :: Total Materia Article

Direct-chill (DC) casting is currently the most common semi-continuous casting practice in non-ferrous metallurgy. The process is characterized by molten metal being fed through a bottomless water cooled mould where it is sufficiently solidified around the outer surface that it takes the shape of the mould and acquires sufficient mechanical strength to contain the molten core at the centre.

ARTICLE: Bharat Forge Aluminiumtechnik Expands with State ...

Apr 13, 2020· Small diameter horizontal direct chill (HDC) casting, with and without homogenization. ... Performing this with a large capacity VDC billet casting table or an HDC machine casting multiple strands with gang molds can be a challenge. Flextreme technology resolves this issue via a single strand control that makes the starting and ending periods ...

Continuous Casting | Wiley Online Books

Dr. Hilmar Müller is Senior Research Associate at Wieland Werke, Ulm (Germany). Wieland Werke are one of the world leading companies for the production of copper and copper alloy preforms. He is Chairman of the Organising Committee of the international "Continuous Casting 2005" conference.

Refractory Protective Coatings | Pyrotek

Aluminium / Casthouse / Metal Casting - Casthouse / Horizontal Direct Chill (HDC) Billet Casting / Refractory Protective Coatings. Refractory Protective Coatings. Overview. Coatings extend the service life of various refractory products by repelling surface metal adhesion and protecting the substrate material from attack by the molten metal ...

Horizontal Direct Chill (HDC) Billet Casting | Pyrotek

As an alternative to vertical direct chill billet casting, HDC billet casting is a continuous casting process wherein metal is fed to the casting moulds through a tundish, or headbox. Generally, the average HDC billet diametres are smaller than in VDC. Reducing downtime increases the length of each casting campaign and overall productivity.

Direct chill casting of magnesium extrusion billet and ...

Jan 01, 2012· Direct chill casting is a type of continuous casting developed in the 1930s in Germany (Roth, 1936, Zunkel, 1939) and in the 1940s in the USA as an improvement over casting extrusion and rolling ingots in permanent moulds.DC casting is characterised by a direct water spray impinging on the ingot as it continuously emerges from a water-cooled mould ().

(PDF) Macrosegregation in horizontal direct chill casting ...

The horizontal direct chill (HDC) casting process is a well-established production route for aluminum alloy ingots but the ingot may some times suffer from inhomogeneous microstructures due to ...

Influence of a low-frequency electromagnetic field on ...

Influence of a low-frequency electromagnetic field on aluminum alloy slabs during horizontal direct chill casting process L. Li1, Y. D. Zhang2,3, C. Esling2,3 and J. Cui1 1 Key Laboratory of Electromagnetic Processing of Materials, Ministry of Education, Northeastern University, Shenyang 110004, People’s Republic of China,

Continuous Casting - GBV

Horizontal Direct Chilled (HDC) Casting Technology for Aluminium F. Niedermair, Hertwich Engineering , Braunau (A) 293 Automatic "Bleed Out" Detection and Plug Off in VDC Billet Casting M. Luck, Wagstaff Inc., Spokane WA (USA) 300 The AIRSOL VEIL® Technology Package for Aluminium Billet Casting G. Bulian, M. Langen, VAW aluminium AG, Bonn ...

Influence of Melt Feeding Scheme and Casting Parameters ...

Aug 21, 2012· Direct-chill (DC) casting billets of an AA7050 alloy produced with different melt feeding schemes and casting speeds were examined in order to reveal the effect of these factors on the evolution of microstructure. Experimental results show that grain size is strongly influenced by the casting speed. In addition, the distribution of grain sizes across the billet diameter is …

NUMERICAL MODELING OF MACROSEGREGATION DURING …

model to a horizontal direct chill casting (HDC) of an Aluminum-Copper alloy, where buoyancy acted perpendicularly to the casting direction and significant asymmetry was seen in the flow patterns and macrosegregation profiles. Focusing on numerical complexities of the …

Macrosegregation in horizontal direct chill casting of ...

Macrosegregation in direct chill casting processes is controlled by fluid flow due to the thermosolutal natural and forced convection, shrinkage, and transport of unattached solid grains. Because grain refinement is usually used in aluminum direct chill casting, some effort must be made to model free-floating solid grains, and their attachment to a rigid mushy zone.

Horizontal Continuous Casting | Scientific.Net

When the final products do not require high strength, this process appears to be low efficiency and high cost. We try to design a new technology to cast aluminum bar by horizontal direct chill (HDC) casting process directly. An electromagnetic field is applied during the horizontal continuous casting of 6061 aluminium bar with a diameter of 30mm.

Horizontal Direct Chill Casting | Scientific.Net

Abstract: The horizontal direct chill (HDC) casting process is a well-established production route for an aluminum alloy ingot; however, the ingot may suffer from inhomogeneous microstructures and serious macrosegregation due to the unbalanced cooling condition and gravitational effect.

The Effect of High Speed Direct Chill Casting on ...

In this paper, high-speed direct chill casting was investigated to improve the microstructure and mechanical properties of Al-Mg-Si-Fe alloy billet. With the increase of casting speed, the size of grain decreased from 82 to 23 μm; Fe-containing intermetallic phase significantly refined and transformed from bone to short rod-like shape.

MERC 2009 - University of British Columbia

The horizontal direct chill (HDC) casting is a continuous process used to produce extrusion billet and re‐melt ingot. As in vertical DC casting, secondary cooling, where water directly impinges on the cast surface, is an important stage that …

Horizontal Direct Chilled (HDC) Casting Technology for ...

Horizontal Direct Chilled (HDC) Casting Technology for Aluminium and Requirements to Metal Cleanliness. Franz Niedermair M D. ... Extrusion Billet and SSM‐Feedstock. Casting of Forging Stock (Spaghetti Production) Plant Description and Capacities of …

A Simplified Empirical Model of Precipitation ...

casting (vertical direct chill, VDC, or horizontal direct chill, HDC). The billet is homogenised to eliminate segregation, to transform, break-up and spheroidise Fe-containing intermetallic phases and to generate evenly distributed precipitates that are readily dissolved during extrusion. Homogenised billet is preheated and extruded to final ...

Horizontal Direct Chilled (HDC) Casting Technology for ...

Horizontal Direct Chilled (HDC) Casting Technology for Aluminium and Requirements to Metal Cleanliness. ... small diameter extrusion billets and forging feedstock, due to its high productivity and ...

(PDF) Floating Grains in the HDC Casting 7075 Aluminum ...

Direct-chill (DC) cast billets 192 mm in diameter of an Al-Cu-Mg alloy were examined in detail with the aim to reveal the effects of grain refining (GR) and casting speed on structure, “floating ...

Products | Century Aluminum

T-Ingot, Extrusion Billet and Horizontal Direct Chill (HDC) Ingot. Billet Capabilities –Airslip or conventional casting capability –Lengths – Up to 298 inches (7.533 meters) cropped and 310 inches (7.836 meters) uncropped

Floating Grains in the HDC Casting 7075 Aluminum Alloy ...

7075 aluminum alloy ingot with the diameters of 100 mm was produced by Horizontal Direct-Chill (HDC). The temperature in the melt was measured and the ingots were examined in detail with the aim to reveal the floating grains in the HDC ingot. Experimental results show that very large floating grains with coarse dendrite arm spacing (DAS) mainly concentrate in the half …

Casting Speed - an overview | ScienceDirect Topics

Ruiyu Yin, in Theory and Methods of Metallurgical Process Integration, 2016. 6.4.3 Practical Performance of Billet Direct Hot Charging Between No.5 Caster and No.2 Bar Mill. The strand number, section dimension, and metallurgical length of No.5 casting machine were similar to those of No.6 caster, and it matched the production of No.4 converter.

IV B 4-ICASP3 Vusanovic Krane FINAL-bild4

casting, which is a batch process for casting round billets and rectangular ingots over a wide range of sizes. Because of the short sump depths in these processes, it is not practical to bend the metal so that it moves horizontally, enabling a continuous casting process. Horizontal direct chill (HDC) casting is