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Meeting 2025 TMS Annual Meeting & Exhibition
Symposium Melt Processing, Casting and Recycling
Presentation Title Modeling, Simulation and Validation of Cold Hearth Continuous Casting of Titanium Alloys
Author(s) Arul Mozhi Varman Jayaraman Palanivel, Tharmalingam Sivarupan, Georgarakis Konstantinos , Salonitis Konstantinos , Mark Jolly
On-Site Speaker (Planned) Arul Mozhi Varman Jayaraman Palanivel
Abstract Scope In the present study, an alternative sustainable method of manufacturing of Ti6Al4V alloys from industrial swarfs is discussed. CFD modeling and simulation of cold hearth continuous casting process is done using Flow-3D TruVOF and FAVOUR techniques. A High-Performance Supercomputing is utilised to optimise the computing resources to precisely quantify the flow properties and thermal distribution. Experimental validation on the molten pool of Ti6Al4V is compared with the simulated molten pool for different quantities. These findings provide valuable insights into understanding of flow properties and thermal distribution for reliable molten metal delivery contributing to efficient recycling and sustainable manufacturing processes.
Proceedings Inclusion? Planned: Light Metals
Keywords Titanium, Modeling and Simulation, Sustainability

OTHER PAPERS PLANNED FOR THIS SYMPOSIUM

4D synchrotron X-ray tomographic operando study and multiphysics modelling of the multiphase coupled growth in a recycled Al alloy during solidification under pulse magnetic fields
Achieving Grain Refinement by Recycling Magnesium Alloy Chips via Stir Casting
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BATSCAN – A Breakthrough for Industrial Inclusion Measurement in Aluminium Casthouses
Development of Numerical Model of Plasma Burner for Primary Aluminium Casthouses
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High Emissivity Refractory for Aluminum Melting Furnace
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Investigation of Al6(Fe, Mn) Intermetallics Formation on AA8006 Aluminum Alloy produced by Twin-Roll Casting at Different Solidification Conditions
Investigation of the Effect of Lacquered and Delacquered Scrap on Casting Impurities for Recycling Efficiency
Kinetics of dissolved hydrogen from water vapour into and out of molten aluminium
Liquid composition analysis of wrought aluminium alloys using Laser Induced Breakdown Spectroscopy (LIBS) for industrial melting/holding furnace applications
Loading solid and liquid charges into melting furnaces is a critical step in the melting process, impacting melt efficiency in terms of cycle time and energy consumption. It also affects refractory integrity, burner efficiency, and liquid metal security. Determining the optimal timing for loading stages is contentious and often relies on standard practices within the cast-shop or other deterministic rules. Novamet's SmartMelt technology was developed to enhance the efficiency of aluminum melters by integrating a rapid and precise digital twin of the furnace. Utilizing real-time data acquisition, SmartMelt predicts the ideal loading times for both liquid and solid charges based on the specific scrap type. This optimization has demonstrated a potential efficiency improvement of up to 10%. Furthermore, it provides warnings for potential overheating incidents when thermocouples are not correctly inserted. Any delays or deviations from these recommendations are monitored and logged in a dedicated database, ensuring comprehensive process control and optimization.
Modeling, Simulation and Validation of Cold Hearth Continuous Casting of Titanium Alloys
Nano-treating Enhanced Ductility and Fluidity of Zamak 3
New Innovations in Fiber Optic Sensing for Metalmaking Process Control
Nucleation and growth of Al-Fe-Si intermetallics in model aluminium alloys: a dynamic in situ observation
On the influence of oxide layer formation and alloying in the Mg vapor pressure for ternary dilute Al-Mg alloys
Oxidation of aluminium melts in dry and moist atmospheres
Recycling if Ti and Ti6Al4V chips by consolidation with severe plastic deformation
Removal efficiencies of Hydrogen and inclusions in a combined filter with de-gassing and CFF
Removal of metallic impurities from aluminum alloy using gravity sedimentation technique
Removal of Zn and other tramp elements from molten Al by vacuum refining
Review of Recent Force 3 Molten Metal Explosions and Their Causes
Sedimentation Of Inclusions In Melts Of Aerospace Structural Aluminum Alloy Castings: A Sustainable Approach
Smart sensors for additive manufacturing and aluminum foundry 4.0 initiatives
SmartBurner: Advanced Monitoring System to Enhance Gas Burner Performance
The Effect of Nucleating Particle Agglomerates on Grain Refiner Efficiency of 7xxx Aluminium Alloys
The Relationship Between Casting Thickness and Surface Quality of 8079 Alloy Foils in Twin-Roll Casting
ThermaSiC coating for applications in contact with molten aluminum
Tracking Primary Al3Ti and Al3Zr Phase Formation in Liquid Aluminum Alloys Using LIBS
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