Numerical Simulation of the Effect of Process Parameters on Cooling Rate and Secondary Dendrite Arm Spacing in High-Speed Twin Roll Strip Casting of Al–15 wt % Cu Alloy

Twin roll casting is a process used to produce thin strips of metals by continuously pouring melt on to rotating rolls. In order to make the process more productive and economical, high roll speed is recommended. The numerical simulation of high-speed twin roll casting is performed by analyzing fluid flow, heat transfer, and solidification behavior of Al–Cu hypo-eutectic alloy. The flow field, temperature, liquid fraction distribution, and cooling rate are analyzed by solving governing transport equations of continuity, momentum, energy, and turbulence. The low-Re Turbulence model is used to capture turbulence effects in the process and enthalpy-porosity technique used to account for the rise in viscosity due to phase change. The effect of melt pool height and roll velocity on average cooling rate along the strip surface is investigated. It is found that the increase in melt pool height and roll speed increases the average cooling rate along strip surface due to rise in heat transfer up to certain roll velocity but beyond that process fails due to breakout. The average cooling rate of process affects the microstructure and properties of strips. It is found that higher cooling rates result in a decrement of secondary dendrite arm spacing (SDAS) of 1 mm thin strip along strip surface results in the fine and homogeneous microstructure.