Control of surface inverse segregation in Al–4.5Mg strips produced by industrial twin-roll casting process

Abstract

This study investigates the control of surface inverse segregation in Al−4.5Mg alloy strips produced using the industrial twin-roll casting (TRC) process. The effects of the casting speed, melt temperature, interfacial heat transfer coefficient, and melt pool height on the solidification behavior were evaluated using simulations. The findings revealed that minimizing the shrinkage deformation of the solidifying shell near the kiss point (KP) is critical for controlling inverse segregation. The total thickness of the solidifying shell was reduced by shifting the KP toward the roll nip direction, enhancing the strip quality. By applying the strategy of KP adjustments to TRC conditions, we successfully reduced the strip thickness and produced high-quality strips without an inverse segregation layer on the strip surface.