Continuous compound casting of rotationally symmetrical Cu-Al-semi-finished products

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The increasing demands on mechanical and physical properties of metallic components are challenging. Metallic composites allow to combine specific positive properties of various metals into one component.Due to the combination of the excellent electrical, thermic and antimicrobial properties of copper (Cu) with the also good electrical and thermic properties and the low density of aluminium (Al), copper-aluminium-composites are subject to recent investigations. One focus of recent academic and industrial studies is on the composite casting technology with a particular interest in continuous composite casting of semi-finished products.In a preceding project the basic correlations between processing conditions, metallurgic processes and resultant properties of the composites have been experimentally investigated and numerical models have been developed to predict the phase formation in the boundary-layers. With this knowledge a new innovative vertical continuous composite casting process is developed to produce Cu alloyed rods recast by Al alloys. A robust process is as essential as the comprehension of the metallurgical mechanisms during the formation of the boundary layer. Therefore cause-and-effect-analysis of the process parameters and the resulting mechanical properties is in the focus of these investigations. Furthermore an enhanced simulation model to predict the resulting microstructure in dependence on the process conditions during continuous composite casting is developed and validated.The main objective of this study is to generate a prognosis model for the properties of the composites in dependence on the chemical composition and the process parameters.