Effect of water cooling conditions on splash break occurance during aluminum DC casting

Makoto Morishita, Mitsuhiro Abe, Makoto Yoshida

    Research output: Contribution to journalArticle

    Abstract

    The cooling water used in vertical aluminum DC casting is generally induced to just under the mold to prevent molten aluminum break out. However, the cooling water leaks into the air gap between the mold and the surface of ingot, so water splashes over the top of the molten aluminum, resulting in uneven cooling. But the quantitative survey on the splash break behavior and the change in the cooling condition has not been conducted. Hence, to quantify the splash break condition and the cooling capability, we have made the "Cooling water simulator" capable of freely controlling the potential splash causing factors such as temperature of cooling water, water flow rate, air gap amount, and angle of the water flow, reproducing the splash, and measuring the heat transfer value. The experimental result reveals that the temperature of cooling water is not a factor highly influencing on heat flux and splash, but the splash behavior highly depends on three factors which are the water flow rate, the angle of water flow, and the distance between the cooling water hit point level and the cooling water exit level. And that the heat flux also increases when splash occurs. In addition, the splash break parameter was drawn based on the above three factors, and the correlation between splash break parameter and heat flux was clarified. Use of splash break parameter enables setting of the casting condition where the maximum heat flux is obtained while preventing splash.

    Original languageEnglish
    Pages (from-to)379-385
    Number of pages7
    JournalKeikinzoku/Journal of Japan Institute of Light Metals
    Volume60
    Issue number8
    DOIs
    Publication statusPublished - 2010

    Fingerprint

    Cooling water
    Aluminum
    Casting
    Heat flux
    Water
    Cooling
    Molten materials
    Flow rate
    Flow of water
    Ingots
    Air
    Simulators
    Heat transfer
    Temperature

    Keywords

    • Air gap
    • DC casting
    • Heat flux
    • Mold
    • Water splash

    ASJC Scopus subject areas

    • Materials Chemistry
    • Metals and Alloys
    • Mechanical Engineering
    • Mechanics of Materials

    Cite this

    Effect of water cooling conditions on splash break occurance during aluminum DC casting. / Morishita, Makoto; Abe, Mitsuhiro; Yoshida, Makoto.

    In: Keikinzoku/Journal of Japan Institute of Light Metals, Vol. 60, No. 8, 2010, p. 379-385.

    Research output: Contribution to journalArticle

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