Aluminum DC Casting Process With MAGMA CC

The direct chill (DC) casting process is integral to the manufacturing of semi-finished products. In this process, liquid metal is introduced into a short, intensely cooled mold from a launder. Simultaneously, metal is withdrawn from the mold, requiring the establishment of a stable solidified shell at the mold's exit. MAGMA CC, a fully integrated turn-key solution, plays a crucial role in simulating and optimizing both vertical and horizontal DC casting processes.

Key features:

  • Robust solutions for aluminum production with DC and CC casting processes
  • Design process conditions for optimized flow and solidification, enhancing product quality
  • Integrated simulation of casting stresses, including cracks and hot tears, for comprehensive process evaluation
  • Integrated process chain for casting with subsequent forging and rolling processes

Process Simulation Capabilities Include:

  • Realistic representation of the entire DC casting process, assessing flow conditions during start-up and strand withdrawal
  • Consideration of forced and natural convection in the liquid metal and in the mushy zone
  • Determination of the stationary temperature distribution in strand and mold, allowing the evaluation of influencing parameters
  • Accurate prediction of the sump profile and assessment of optimal process parameters for improved energy efficiency
  • Calculation of the solidification front to prevent bleedout and evaluation of thermal gradient and cooling rate
  • Assistance in achieving high productivity as well as cost and energy efficiency
  • Reduced porosity, shrinkage, and optimization of launder and distribution design
  • Virtual design and optimization of the direct chill casting process
Publicación en el área de fundición continua

Autonomous Mathematical Optimization of Continuous Casting Processes


Wilfried Schäfer, Götz Hartmann, Erik Hepp, MAGMA GmbH, Aachen, Germany
Dieter G. Senk, Sonja Stratemeier, IEHK RWTH Aachen University, Germany

The publication introduces a numerical simulation based optimization strategy, following rigorous thermodynamic and thermo mechanical models as well as a strictly methodic approach.

Leer Publicación