Huixue Jiang

Direct-chill semi-continuous casting process of three-layer composite ingot of 4045/3004/4045 aluminum alloys

Abstract Three-layer composite ingot of 4045/3004/4045 aluminum alloys was prepared by direct-chill semi-continuous casting process, the temperature field distribution near the composite interface, macro-morphology, microstructure and composition distribution of the composite interface were investigated. The results show that semi-solid layer with a certain thickness forms near the interface due to the effect of cooling plate, which ensures successful implementation of casting the composite ingot. Two different aluminum alloys are well bonded metallurgically. The mechanical properties of composite interface were measured, the tensile and shearing strengths of composite interface are 105 and 88 MPa, respectively, which proves that the composite interface is a kind of metallurgical bonding.

Crystallographic features of the primary Al3Fe phase in as‐cast Al–3.31wt% Fe alloy

The preferred crystallographic extension directions of the primary Al3Fe phase formed during the solidification of the Al–3.31wt% Fe alloy have been confirmed as 〈010〉 or 〈011〉. Two sorts of twins related to the extension directions were found and their complete twinning elements determined. The morphologies of the primary Al3Fe phase related to the crystallographic extension directions and twinning modes are analysed. The crystallographic surface planes binding the primary phase in the extension directions are identified. The formation of the twins is attributed to these surface planes.

Study on DC Casting Process of Three‐Layer Composite Ingots of 4045/3004/4045 Aluminum Alloys

In this study, experiments are combined with numerical simulation to study the temperature field and flow field during the casting process of 4045/3004/4045 three-layer composite ingots with section of 500mm×420mm. The effects of casting temperature, casting speed, contacting height and cooling intensity of cooling plate on the casting process were discussed. The macromorphologies and microstructures of the composite ingots, the temperature distribution and the element distribution in the interface zone were investigated, also the interface bonding strength was measured. The optimal parameters for casting composite ingots were obtained. Results show that the solid supporting layer formed on the cooling plates plays a key role in the casting process of composite ingots. The solid supporting layer can prevent the blending of two melts by resisting the impact of alloy melt, which ensures the stable casting process and casting high quality composite ingots.

Rapid air film continuous casting of aluminum alloy using static magnetic field

The influences of the cooling style and static magnetic field on the air film casting process were investigated. Ingots of 6063 aluminum alloy were produced by AIRSOL VEIL casting with double-layer cooling water and static magnetic field. Surface segregation, hot crack and variation of solute content along the radius direction of ingot were examined. The results showed that double-layer cooling water can improve the surface quality and avoid of hot crack, which created conditions to increase the casting speed. The electromagnetic casting process can effectively improve the surface quality in high speed casting process, and static magnetic field has a great influence on solute distribution along the radius direction of ingot.