Numerical Mass and Heat Flow Predictions in Aluminum DC Casting: A Comparison of Simulations with Melt Pool Measurements

  1. Dipl.-Ing. K. Ehrke Chairman5 and
  2. Prof. Dr. W. Schneider6
  1. Andreas Buchholz1,
  2. Benoît Commet2,
  3. Gerd-Ulrich Grün3 and
  4. Dag Mortensen4

Published Online: 21 APR 2006

DOI: 10.1002/3527607331.ch18

Continuous Casting

Continuous Casting

How to Cite

Buchholz, A., Commet, B., Grün, G.-U. and Mortensen, D. (2000) Numerical Mass and Heat Flow Predictions in Aluminum DC Casting: A Comparison of Simulations with Melt Pool Measurements, in Continuous Casting (eds K. Ehrke and W. Schneider), Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim, FRG. doi: 10.1002/3527607331.ch18

Editor Information

  1. 5

    ALUMINIUM Essen GmbH, Sulterkamp 71, D-45356 Essen, Germany

  2. 6

    VAW Aluminium AG, Forschung und Entwicklung, Georg-von-Boeselager-Str. 25, D-53117 Bonn, Germany

Author Information

  1. 1

    Corus Research, Development & Technology, P.O. Box 10000, NL-1970 CA Ijmuiden, The Netherlands

  2. 2

    Pechiney Centre de Recherche Voreppe, BP 27, F-38340 Voreppe, France

  3. 3

    VAW aluminium AG, Research and Development, P.O. Box 2468, D-53014 Bonn, Germany

  4. 4

    Institute for Energy Technology, P.O. Box 40, N-2027 Kjeller, Norway

Publication History

  1. Published Online: 21 APR 2006
  2. Published Print: 29 NOV 2000

ISBN Information

Print ISBN: 9783527302833

Online ISBN: 9783527607334



  • continuous casting;
  • modelling;
  • aluminum DC casting;
  • numerical mass;
  • heat flow prediction


This paper presents a comparison of three-dimensional steady state calculations of mass and heat transport with temperature and sump profile measurements during the DC casting of rolling ingots of an AA3004 and AA5182 alloy. The calculations are made with different CFD codes, which have been cross-checked in a previous benchmark. The temperatures are measured in specific planes of the melt pool using an array of thermocouples. In addition, the shape of the solidification front is scanned with a mechanical device. Simulated thermal fields and measured temperatures are compared for two completely different flow situations: In the first case the usual casting technique using a spout and distributor bag is applied, while in the second case the distributor bag is removed. Since certain features of the temperature field pattern are closely related to specific flow phenomena the comparison provides a means to assess the validity of the flow calculations. In both cases the results agree well with the related measurements.