Numerical Simulation of Wire Rod Casting of AA1370 and AA6101 Alloys

Wire rod casting, where molten aluminum is continuously fed into a trapezoidal cross-section of a rotating copper wheel, are facing challenging issues with respect to the quality of the wire rod. Valuable insight into the solidification of the bar emerging from the casting wheel can be provided by numerical simulations. These must account for complex thermal and mechanical processes, especially bar shrinkage inside the mould cavity leading to air gap formation and reduced heat transfer. Numerical simulation of this process is challenging, and limited studies have been published. A three-dimensional thermo-mechanical model has been applied for casting of EC grade 1370 alloy. Comparison to existing measurements has been done to obtain confidence in the model results and the applied boundary conditions. The model has then been used for an Al–Mg–Si alloy (AA6101) to propose a new speed for the casting wheel.