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Structure and Defect Formation during DC Casting of Aluminium Alloys

Research activities on aluminium production technology focus on the successive steps in the production chain of aluminium wrought products. Direct-chill casting of aluminium alloys is a well-developed technology with a long history. But only in the last 20 years, the development of computer modelling offered a means of better understanding of the physical phenomena involved in solidification. The main scientific challenge is to obtain a fundamental insight into the processing of aluminium alloys and to establish quantitative relationships between materials, processes, and performance. A systems approach is employed, covering theoretical and experimental studies on processing into semi-finished products. Special emphasis is placed on experimental verification and industrial applicability with the availability of pilot scale experimental facilities at M2i-TUD. This facilitates the design of process conditions as desired for experimental validation studies. In this paper we will consider main mechanisms of structure and defect formation during solidification of DC cast billets, mostly based in the results obtained in cooperation between Delft University of Technology and Materials Innovation Institute (M2i).