Advanced multi-scale analysis of segregation mechanisms in twin-roll casting of Al-Cu-Li alloys

In this paper, a detailed analysis of the rheological behaviour and segregation mechanisms within twin-roll casting (TRC) processes for 2060 Al-Cu-Li alloys is presented. Building on previous research where fixed roll gaps limited the adjustability of cast-rolling speed, this study expands the scope by adjusting roll gaps from 3 mm (TRC-3), to 6 mm (TRC-6), to 10 mm (TRC-10). This approach yields three typical process ranges with gradually increasing roll gaps and a wide range of decreasing cast-rolling speeds, allowing us to investigate the inherent nature of segregation and identify conditions conducive to segregation-free processing. A significant contribution of this study is the development of a novel multi-scale simulation model that integrates the thermal, flow, mechanical, solute and phase fields. This advanced simulation framework enhances our understanding of TRC processes and aids in exploring the interplay between the various factors affecting alloy fabrication. This study identified two primary stress-induced inverse segregation mechanisms: the reflux of the semi-solid phase due to rolling stress and expansion of the solidifying shell under shearing stress. Using these insights, a low-stress, low-segregation process, termed TRC-6, was established, which showed notable improvements in the mechanical properties. Specifically, TRC-6 demonstrated a remarkable strength of 562.9 MPa post-T8-treatment, surpassing those of TRC-3 and TRC-10 by 9.0 % and 5.2 %, respectively. These findings offer valuable insights for future TRC process designs with the aim of eliminating segregation defects and enhancing the sustainable and efficient production of Al-Cu-Li alloys. [Display omitted] •First-ever integrate model of heat-flow-mechanical-solute, providing enhanced insights into TRC processes.•Unveiled two unique stress-induced segregation mechanisms, offering clearer views on TRC challenges.•Introduced a revamped TRC process design strategy, indicating a potential pathway for advancing TRC production.