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Jiali Xiong

doi:10.1038/s41598-024-67434-7

Navigating the narrow processing window: Toward stable and high-quality direct chill casting of large-scale Al Alloys via integrated simulation, machine learning, and experiment

2026-04-24

0

PRE

AI

Y

Yuge Luo

X

Xiangyu An

T

Taili Chen

Z

Zihan Yang

J

Jin Zhang

Z

Zhilin Liu *

DOI：10.1016/j.jmatprotec.2026.119326

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Abstract

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• A novel optimization framework was developed for DC casting of difficult-to-cast Al alloys. • Mushy zone dynamics were rigorously unraveled across a range of casting conditions. • An empirical model of determining appropriate casting process was derived for industry. • Mechanisms linking sump profiles and casting parameters was revealed during solidification.

Keywords:

DC casting

Al alloys

mushy zone dynamics

sump profiles

process optimization

Navigating the narrow processing window: Toward stable and high-quality direct chill casting of large-scale Al Alloys via integrated simulation, machine learning, and experiment

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