Casting Technology

تاريخ التسجيل : 22/11/2009

Brian Cantor and Keyna O'Reilly
The editors would like to thank the following: the Oxford-Kobe Institute
Committee and St Catherine's College, Oxford University, for agreeing to
support the Oxford-Kobe Materials Seminar on Solidification and Casting;
Lord Plant, Sir Peter Williams, Professor Itsuo Ohnaka and Drs Lincon
Wallen, Helen Mardon and Kaizaburo Saito for help in organizing the
Seminar; and Ms Pippa Gordon and Ms Sophie Briant for help with preparing
the manuscripts.
Individual authors would like to make additional acknowledgements as
follows.
INDUSTRIAL PERSPECTIVE
Casting technology is developing rapidly, driven by a combination of
improvements in understanding of underlying solidification theory,
increased computer capacity for design simulation and on-line control, and
enhanced industrial competition in increasingly globalized world markets.
Wrought products are often dominated by the quality and yield of primary
solidification of ingot and billet feedstock. Moreover, many industrial sectors
are developing rapid prototyping and agile manufacturing processes to
reduce time to market and speed up responsiveness to customer demands.
Casting has much to offer as a near net shape technology, but important
issues of reproducibility and quality need to be improved. The overall industrial
perspective on casting technology is discussed in this section, concentrating
on recent innovations and challenges for the future.
Chapters 1 and 2 discuss respectively semi-continuous and continuous
methods of casting aluminium alloys, and chapter 3 discusses continuous
casting of steel. Chapters 4 and 5 discuss different aspects of the importance
of casting in the important automotive sector.
Chapter 1
Direct chill billet casting of
aluminium alloys
Martin Jarrett, Bill Neilson and
Estelle Manson- Whitton
Introduction
This chapter details the operational and technological developments of the
direct chill (DC) casting process for a high volume commercial extrusion
business. Other continuous casting processes are discussed in chapters 2
and 3. Modelling of DC casting is discussed in chapter 6. Improved extrusion
manufacturing efficiency is driving the need for better and more consistent
billet quality. This has necessitated significant technological and process
development of DC billet production, in order to produce extrusion ingots
of predictable performance. A thorough understanding is required of the
interaction of the equipment and process technologies that impact on the
metallurgical macro- and microstructure of the DC cast ingot, and its
subsequent performance in the extrusion process.
The first commercial semi-continuous casting machine for aluminium
alloys was opened in Germany in 1936, following development of vertical
continuous casting techniques for other metals, such as lead, since the
mid-nineteenth century [1]. Over the past 50 years, the DC casting process
has been developed to become the predominant process for extrusion
billet production [2, 3], with 6xxx alloy extrusion billet accounting for a
large percentage of the throughput of worldwide aluminium DC casting
production.
Together with market driven advancement, environmental considerations
are driving significant change in DC casting technology. The provision
of consistent high quality DC cast billets of predictable performance is
of fundamental importance in operating extrusion presses at maximum
efficiency, while meeting the stringent quality requirements of the
market place

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