Domination and effect of multi-parameters in direct chill casting based on establishment of thermo model by numerical simulation and experiment

In this paper, a mathematical model validated by in-situ temperature measurement data of the direct chill (DC) casting process has been established in order to study the domination and effect of multi-parameters including secondary cooling water flow rate (Q), casting speed (V), condition of primary cooling, and spraying water temperature (Tw) on DC casting index of sump depth (dsump), maximum and minimum temperature gradient (Tg,max and Tg,min) at mushy zone and shape of solidus line. Further, the height of impingement zone (Hip) is systematic quantitative analysis by a novel designed test (Hip=1.08865Q`+0.06272V−4.75597). The calculated temperature using the numerical simulation exhibits a good match with the actual temperature measurement data. The results of multi-factors on index by the designed orthogonal test indicate that V dominates the dsump (dsump=0.033+27.74V) and Tg,min (Tg,min=2569.15−766342.20V) at mushy zone, Q dominates the Tg,max (Tg,max=9195.12+2344770Q−27.83Tw) by analysing the range (R), variance (S) and significance (F). Likewise, by discussing the combination of R, S, F and microstructure observation, the priority influencing the shape of solidus line at center part was V. The Q dominates the shape of solidus line at the position between the center and edge part.