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Research Papers

Industrial Direct Chill Slab Caster of Tin Bronze (C903) Using a Porous Filter in the Hot-Top

[+] Author and Article Information
Mainul Hasan

Mem. ASME
Department of Mining and
Materials Engineering,
McGill University,
M. H. Wong Building,
3610 University Street,
Montreal, QC H3A 0C5, Canada
e-mail: Mainul.hasan@mcgill.ca

Latifa Begum

NSERC-PDF,
Department of Mechanical and
Industrial Engineering (MIE),
Concordia University,
1455 De Maisonneuve Boulevard West,
Montreal, QC H3G 1M8, Canada
e-mail: Latifa.begum@mail.mcgill.ca

1Corresponding author.

Contributed by the Heat Transfer Division of ASME for publication in the JOURNAL OF THERMAL SCIENCE AND ENGINEERING APPLICATIONS. Manuscript received May 5, 2016; final manuscript received May 19, 2017; published online August 29, 2017. Assoc. Editor: Ranganathan Kumar.

J. Thermal Sci. Eng. Appl 10(2), 021001 (Aug 29, 2017) (14 pages) Paper No: TSEA-16-1115; doi: 10.1115/1.4037196 History: Received May 05, 2016; Revised May 19, 2017

A 3D computational fluid dynamics (CFD) modeling study has been carried out for the tin bronze (C903) slab of industrial size in a vertical direct chill caster. The melt is delivered from the top across the entire cross section of the caster. An insulated hot-top is considered above the 80-mm mold to control the melt level in the mold. A porous filter is considered in the hot-top region of the mold to arrest the incoming inclusions and homogenize the flow into the mold. The melt flow through the porous filter is modeled on the basis of the Brinkmann–Forchheimer-extended non-Darcy model. Results are obtained for four casting speeds varying from 40 to 100 mm/min. The metal–mold contact region, as well as the convective heat transfer coefficient at the mold wall, is also varied. In addition to the above, the Darcy number for the porous media is also changed. All parametric studies are performed for a fixed inlet melt superheat of 62 °C. The results are presented pictorially in the form of temperature and velocity fields. The sump depth, mushy region thickness, solid shell thickness (ST) at the exit of the mold, and axial temperature profiles are also presented and correlated with the casting speed through regression analysis.

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References

Grandfield, J. F. , Eskin, D. G. , and Bainbridge, I. , 2013, Direct-Chill Casting of Light Alloys: Science and Technology, Wiley, Hoboken, NJ, p. 242; 334.
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Begum, L. , and Hasan, M. , 2014, “ 3-D CFD Simulation of a Vertical Direct Chill Slab Caster With a Submerged Nozzle and a Porous Filter Delivery System,” Int. J. Heat Mass Transfer, 73, pp. 42–58. [CrossRef]
Begum, L. , and Hasan, M. , 2015, “ A Numerical Study of 3D Turbulent Melt Flow and Solidification in a Direct Chill Slab Caster With a Porous Combo Bag Melt Distributor,” Numer. Heat Transfer, Part A, 67(7), pp. 746–770. [CrossRef]
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Morgan Bronze Products Inc., 2017, “ Morgan Bronze Products,” Morgan Bronze Products, Inc., Lake Zurich, IL, accessed July 7, 2017, www.morganbronze.com/pdf/c903_tin_bronze.pdf
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Voller, V. R. , and Prakash, C. A. , 1987, “ Fixed Grid Numerical Modeling Methodology for Convection-Diffusion Mushy Region Phase-Change Problems,” Int. J. Heat Mass Transfer, 30(8), pp. 1709–1719. [CrossRef]
Seyedein, S. H. , and Hasan, M. A. , 1997, “ Three-Dimensional Simulation of Coupled Turbulent Flow and Macroscopic Solidification Heat Transfer for Continuous Slab Casters,” Int. J. Heat Mass Transfer, 40(18), pp. 4405–4423. [CrossRef]
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Vreeman, C. J. , and Incropera, F. P. , 2000, “ The Effect of Free-Floating Dendrites and Convection on Macrosegregation in Direct Chill Cast Aluminum Alloys—Part II: Predictions for Al-Cu and Al-Mg Alloys,” Int. J. Heat Mass Transfer, 43(5), pp. 687–704. [CrossRef]
Pedras, M. H. J. , and de Lemos, M. J. S. , 2001, “ Macroscopic Turbulence Modeling for Incompressible Flow Through Undeformable Porous Media,” Int. J. Heat Mass Transfer, 44(6), pp. 1081–1093. [CrossRef]
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Begum, L. , 2013, “ 3-D Transport Phenomena in Vertical Direct Chill Casting Processes,” Ph.D. thesis, McGill University, Montreal, QC, Canada. http://digitool.library.mcgill.ca/R/?func=dbin-jump-full&object_id=121239&local_base=GEN01-MCG02
Begum, L. , and Hasan, M. , 2015, “ A Numerical Study of 3D Turbulent Melt Flow and Solidification in a Direct Chill Slab Caster With an Open-Top Melt Feeding System,” Numer. Heat Transfer, Part A, 67(7), pp. 719–745. [CrossRef]
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Figures

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Fig. 1

The physical domain of a vertical DC caster is shown schematically. The vertical light gray color region shows the actual computational domain.

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Fig. 2

Three-dimensional surface plots of temperature and velocity fields for three cases (1–3). (a) Temperature contours, (b) velocity field, (c) temperature contours, (d) velocity field, and (e) temperature contours: (i) us = 40 mm/min, (ii) us = 60 mm/min, and (iii) us = 80 mm/min.

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Fig. 3

Longitudinal 2D views of temperature contours and velocity vectors for case 1: (a) z = 0 mm, (b) z = 62.5 mm, and (c)z = 312.5 mm

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Fig. 4

Longitudinal 2D views of temperature contours and velocity vectors for case 2: (a) z = 0 mm, (b) z = 62.5 mm, and (c)z = 312.5 mm

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Fig. 5

Longitudinal 2D views of temperature contours and velocity vectors for case 3: (a) z = 0 mm, (b) z = 62.5 mm, and (c)z = 312.5 mm

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Fig. 6

Contours of solidus and liquidus temperatures at various transverse cross-sectional planes for four cases (1–4): (a) casting speed = 40 mm/min, (b) casting speed = 60 mm/min, (c)casting speed = 80 mm/min, and (d) casting speed = 100 mm/min

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Fig. 7

Shell thickness in middle of the narrow slab face and in the middle of the wide slab face of mold exit versus casting speed for cases (1–4)

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Fig. 8

Variations of surface temperature along the axial direction of the strand at four locations of the caster for (a) us = 60 mmmin−1 (case-2) and (b) us = 80 mmmin−1 (case-3)

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Fig. 9

Shell thickness at the middle of the narrow face at mold exit versus effective HTC (W/(m2 K)) for six cases (2, 3, and 5–8)

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Fig. 10

Shell thickness at the middle of the narrow face at mold exit versus metal–mold contact length (mm) for eight cases (2, 3, 9–12, 15, and 16)

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Fig. 11

Shell thickness at the middle of the narrow face at mold exit versus Darcy number for four cases (2, 3, 13, and 14)

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