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Effect of nozzle shape on solidification behaviour in high-speed twin-roll strip caster: a simulation approach

Abstract In twin-roll strip casting process, the solidification characteristics of the strip are directly influenced by the process parameters, i.e. casting speed, roll gap and nozzle shape, etc. To obtain a defect free strip, optimisation of the process parameters is inherently required. In the present investigation, a comprehensive three-dimensional model for top side pouring high-speed twin-roll strip casting of Al-4.5wt.% Cu alloy with different nozzle shape has been carried out. ANSYS 13.0 was used to model fluid flow, heat transfer and solidification behaviour during the top side pouring of liquid Al-4.5wt.% Cu alloy in twin-roll strip caster with different nozzle shape. The model takes into account the coupled fluid flow, heat transfer and solidification characteristics in the molten pool. The variations of nozzle shape on flow feature and solidification characteristics were studied. From the simulation results, it was found that with circular shape nozzle, uniform solidification takes place which results defect free strip as compared to the square shape, triangular shape and elliptical shape nozzles. It was observed that, the nozzle with circular shape was most favourable for high-speed twin-roll strip caster.