Study On 4045/3003 Composite Ingot Of Cladding Casting

The properties and characteristics of composite material are better than singular material. The applications become more extensive, so they have been successfully applied in many fields such as aviation, spaceflight, nuclear energy, communication, telecom, as well as machine manufacturing and traffic. In this paper, we manufactured 4045/3003aluminium alloys composite ingot by direct cooling continuous casting. This is an effective way to save energy, improve the production efficiency and so help to keep costs under control. For cladding ingot, the most important part is the composite interface. Study on the interface characteristics and casting parameters are very important. Then simulate casting process parameters and design a reasonable experimental device.Firstly, establish a mathematical model by the finite element software Fluent. The mathematical model can accurately describe the flow filed and the temperature field of the process of the coated casting of the composite ingot and the process of solidification of the composite ingot. The size of the composite ingot is Φ140mm/Φ110mm,4045 aluminum alloy as outer material and 3003 aluminum alloy as core material. In this paper, Fluent was used to simulate the flow field, temperature field and composite interface during the process of casting in different casting speed, casting temperature and contact height.We get the following facts:The cladding ingot composite incompletely when the casting velocity is 90mm/min, the cooling time is so long that the temperature of core material supporting layer is too low; The cladding ingot composite completely when the casting velocities are from 110mm/min to 150mm/min; When the casting velocity increase to 170mm/min, the outer material of temperature is too high, it will remelt the solidified core material. So the best casting velocity are from 110mm/min to 150mm/min.Increase the temperature of outer material and core material have little influence on the process of solidification, but an appropriate increase can increase the smoothness of the outer surface of the supporting layer and be conducive to the composite of the alloys.The contact height of the outer material should be a higher value, which is close to the liquid level of the core material, in order to decrease the difference in pressure between the inner and the outer of the supporting layer. It can be set from 40 mm to 50 mm.According to the process parameters of numerical simulation, we do casting experiment to verify the results in different casting velocity. The composite ingot solidifies on the thermal insulation material when the casting velocity is 90mm/min; when the casting velocities are from 110mm/min to 150mm/min, the macrostructure of composite interface is fine. But the microstructure of interface composite incompletely when the casting velocity is 110mm/min; there was a transition layer near the interface of cladding ingot when the casting velocity is 130mm/min, the Si content reduced quickly from 4045 aluminum alloy to 3003 aluminum alloy and the Mn content reduced quickly from 3003 aluminum alloy to 4045 aluminum alloy, Then the composite zone was formed a wide diffusion layer. The interface mixed flow when the casting velocity is 150mm/min. In tension test, the tension strength of 2#、3#、4#、5# specimens are stronger than 3003 aluminum alloy. From the above, 130mm/min is the best casting velocity.