Determination of Secondary Cooling Zone Heat Transfer Coefficient with Different Alloy Types and Roughness in DC Casting by Inverse Heat Conduction Method

The cooling characteristic curves in a heated ingot with a diameter of 100 mm quenched by a water jet were measured under different conditions. A two-dimensional calculation model was established to calculate the HTC of magnesium alloy ingot with water spray cooling. Data from cast-in thermocouples trail were input into the model and the HTCs were back-calculated for the water quench region. The HTCs were calculated under different alloy types and roughness conditions, and the relationship between the ingot surface temperature, roughness, and the HTC was established accordingly. The results show that the greater the thermal conductivity of the alloy, the greater the heat transfer coefficient (HTC). The HTCs of AZ80, AZ31, and ZK60 alloys increase successively. With the decrease in the surface temperature, the HTC in both the impingement zone and the free−falling zone shows a trend of a rapid increase at first, then slowly increasing to the maximum value, and finally, a rapid decrease, with the peak value appearing at about 400 K. Considering the influence of the ingot surface temperature and the surface roughness on the HTC, the mathematical relationships between them are established.