Multi-field coupling analysis of twin-roll casting process for achieving thin aluminum strip high-speed casting and fabricating laminated metal cladding materials
The twin-roll casting (TRC) process integrates solidification with deformation while emerging as a key research direction aligned with advancements in green and sustainable development. However, low casting velocity and non-uniform solidification significantly constrain both process efficiency and m...
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Elsevier
2025-08-01
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| Series: | Case Studies in Thermal Engineering |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2214157X25006835 |
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| author | Ce Ji Xin Di Xudong Liu Shibin Liu Jianmin Song Huagui Huang |
| author_facet | Ce Ji Xin Di Xudong Liu Shibin Liu Jianmin Song Huagui Huang |
| author_sort | Ce Ji |
| collection | DOAJ |
| description | The twin-roll casting (TRC) process integrates solidification with deformation while emerging as a key research direction aligned with advancements in green and sustainable development. However, low casting velocity and non-uniform solidification significantly constrain both process efficiency and material performance. To address these challenges, a multi-field coupling investigation was performed using a cellular automaton-finite element (CAFE) model to analyze transient heat transfer and steady-state solidification structures. The effect of casting velocity, nucleation rate, and casting roller materials on the heat transfer and solidification structure was analyzed, indicating that the main reason for improving casting velocity by using copper roller sleeves is to improve the nucleation rate and ensure the plastic strain simultaneously. In the twin-roll solid-liquid cast-rolling bonding (TRSLCRB) process for laminated metal cladding production, three substrate parameters, including feeding position, thickness, and material composition, were identified as critical determinants of heat transfer behavior and solidification morphology. For the multi-roll solid-liquid cast-rolling bonding (MRSLCRB) process targeting round-section cladding materials, the designed inverted conical cast-rolling area demonstrates the potential for optimizing grain refinement through synergistic interaction with ultrasonic vibration fields. The implemented CAFE-based multi-field coupling methodology provides systematic guidance for both process parameter optimization and microstructure-property control strategies. |
| format | Article |
| id | doaj-art-9d2510b86a2c4f9a8f3c4ded3cb8c30c |
| institution | Kabale University |
| issn | 2214-157X |
| language | English |
| publishDate | 2025-08-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Case Studies in Thermal Engineering |
| spelling | doaj-art-9d2510b86a2c4f9a8f3c4ded3cb8c30c2025-08-20T03:25:59ZengElsevierCase Studies in Thermal Engineering2214-157X2025-08-017210642310.1016/j.csite.2025.106423Multi-field coupling analysis of twin-roll casting process for achieving thin aluminum strip high-speed casting and fabricating laminated metal cladding materialsCe Ji0Xin Di1Xudong Liu2Shibin Liu3Jianmin Song4Huagui Huang5College of Mechanical Engineering, Yanshan University, Qinhuangdao, 066004, Hebei, China; National Engineering Research Center for Equipment and Technology of Cold Strip Rolling, Yanshan University, Qinhuangdao, 066004, Hebei, ChinaCollege of Mechanical Engineering, Yanshan University, Qinhuangdao, 066004, Hebei, China; National Engineering Research Center for Equipment and Technology of Cold Strip Rolling, Yanshan University, Qinhuangdao, 066004, Hebei, ChinaCollege of Mechanical Engineering, Yanshan University, Qinhuangdao, 066004, Hebei, China; National Engineering Research Center for Equipment and Technology of Cold Strip Rolling, Yanshan University, Qinhuangdao, 066004, Hebei, ChinaState Key Laboratory of Roll Composite Materials, Sinosteel Xingtai Machinery & Mill Roll Co., Ltd., Xingtai, 054000, Hebei, ChinaZhuoshen Non-ferrous Metals Plant & Equipment Co. Ltd., Baoding, 072750, Hebei, ChinaCollege of Mechanical Engineering, Yanshan University, Qinhuangdao, 066004, Hebei, China; National Engineering Research Center for Equipment and Technology of Cold Strip Rolling, Yanshan University, Qinhuangdao, 066004, Hebei, China; Corresponding author. College of Mechanical Engineering, Yanshan University, Qinhuangdao, 066004, Hebei, China.The twin-roll casting (TRC) process integrates solidification with deformation while emerging as a key research direction aligned with advancements in green and sustainable development. However, low casting velocity and non-uniform solidification significantly constrain both process efficiency and material performance. To address these challenges, a multi-field coupling investigation was performed using a cellular automaton-finite element (CAFE) model to analyze transient heat transfer and steady-state solidification structures. The effect of casting velocity, nucleation rate, and casting roller materials on the heat transfer and solidification structure was analyzed, indicating that the main reason for improving casting velocity by using copper roller sleeves is to improve the nucleation rate and ensure the plastic strain simultaneously. In the twin-roll solid-liquid cast-rolling bonding (TRSLCRB) process for laminated metal cladding production, three substrate parameters, including feeding position, thickness, and material composition, were identified as critical determinants of heat transfer behavior and solidification morphology. For the multi-roll solid-liquid cast-rolling bonding (MRSLCRB) process targeting round-section cladding materials, the designed inverted conical cast-rolling area demonstrates the potential for optimizing grain refinement through synergistic interaction with ultrasonic vibration fields. The implemented CAFE-based multi-field coupling methodology provides systematic guidance for both process parameter optimization and microstructure-property control strategies.http://www.sciencedirect.com/science/article/pii/S2214157X25006835Twin-roll castingCellular automationHeat transferSolidification microstructureKissing point |
| spellingShingle | Ce Ji Xin Di Xudong Liu Shibin Liu Jianmin Song Huagui Huang Multi-field coupling analysis of twin-roll casting process for achieving thin aluminum strip high-speed casting and fabricating laminated metal cladding materials Case Studies in Thermal Engineering Twin-roll casting Cellular automation Heat transfer Solidification microstructure Kissing point |
| title | Multi-field coupling analysis of twin-roll casting process for achieving thin aluminum strip high-speed casting and fabricating laminated metal cladding materials |
| title_full | Multi-field coupling analysis of twin-roll casting process for achieving thin aluminum strip high-speed casting and fabricating laminated metal cladding materials |
| title_fullStr | Multi-field coupling analysis of twin-roll casting process for achieving thin aluminum strip high-speed casting and fabricating laminated metal cladding materials |
| title_full_unstemmed | Multi-field coupling analysis of twin-roll casting process for achieving thin aluminum strip high-speed casting and fabricating laminated metal cladding materials |
| title_short | Multi-field coupling analysis of twin-roll casting process for achieving thin aluminum strip high-speed casting and fabricating laminated metal cladding materials |
| title_sort | multi field coupling analysis of twin roll casting process for achieving thin aluminum strip high speed casting and fabricating laminated metal cladding materials |
| topic | Twin-roll casting Cellular automation Heat transfer Solidification microstructure Kissing point |
| url | http://www.sciencedirect.com/science/article/pii/S2214157X25006835 |
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