The direct chill (DC) casting process is integral to the manufacturing of semi-finished products. In this process, liquid metal is introduced into a short, intensely cooled mold from a launder. Simultaneously, metal is withdrawn from the mold, requiring the establishment of a stable solidified shell at the mold's exit. MAGMA CC, a fully integrated turn-key solution, plays a crucial role in simulating and optimizing both vertical and horizontal DC casting processes.

Key features:

• Robust solutions for aluminum production with DC and CC casting processes
• Design process conditions for optimized flow and solidification, enhancing product quality
• Integrated simulation of casting stresses, including cracks and hot tears, for comprehensive process evaluation
• Integrated process chain for casting with subsequent forging and rolling processes

• Realistic representation of the entire DC casting process, assessing flow conditions during start-up and strand withdrawal
• Consideration of forced and natural convection in the liquid metal and in the mushy zone
• Determination of the stationary temperature distribution in strand and mold, allowing the evaluation of influencing parameters
• Accurate prediction of the sump profile and assessment of optimal process parameters for improved energy efficiency
• Calculation of the solidification front to prevent bleedout and evaluation of thermal gradient and cooling rate
• Assistance in achieving high productivity as well as cost and energy efficiency
• Reduced porosity, shrinkage, and optimization of launder and distribution design
• Virtual design and optimization of the direct chill casting process