A 3D conjugate heat transfer model for continuous wire casting

A three-dimensional (3D) model of heat transfer and equilibrium-solidification for a continuous wire casting process has been established using a commercial fluid dynamics programme, Fluent®. The melt/solid interface was not tracked explicitly. Instead a liquid fraction value was used for each control volume in the domain. Thermal profiles in the melt and throughout the casting assembly were calculated along with solid fraction profiles and fluid flow velocity vectors. 3D visualisation of the melt behaviour inside the casting channel was possible, thus enabling optimum processing windows to be predicted. Fluid flow visualisation also assists the improvement of casting channel design.