Three-Dimensional Modeling of Direct Chill Caster with Partial Porous Plate
Bibliographic record
Abstract
A three-dimensional control-volume-based finite difference code is developed to simulate a vertical direct chill casting process for aluminum alloy AA-1050. The rectangular slab caster is fitted with a porous plate occupying 50% of the width of the ingot and is placed near the top in the central region. The turbulence in the liquid sump is modeled employing a popular version of the low Reynolds number model. The enthalpy–porosity technique is used to solve the coupled melt flow and solidification heat transfer problem. To model the porous plate, the Brinkman–Forchheimer extended Darcy equation is considered. The code is first verified with the available experimental solidification profile data for a direct chill caster of a rolling ingot AA-3104. The effects of casting speed and heat transfer coefficient at the metal-mold contact region on solidification characteristics are investigated. By varying the latent heat of solidification of the said alloy, sensitivity analysis is also carried out. The temperature and velocity profiles, along with the solid shell thickness, sump depth, mushy thickness, and local surface heat flux, are presented and discussed. All results reported here are new and have direct industrial significance.
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How this classification was reachedexpand
Full frame machine prediction
Teacher imitationNot calibrated prevalence, not ground truth. Human validation pending. The Gemma side is a direct model label for every work in the frame, read from the title-only record. The Codex side is a classifier learned from the 10,348 direct Codex labels and calibrated to design-weighted sample rates; fields without enough sample support carry no Codex call. Candidate is the union of the two sides; consensus is their intersection. These outputs are machine_predicted_unvalidated and are not human labels.
Distilled classifier scores by category (both heads)
| Category | Codex | Gemma |
|---|---|---|
| Metaresearch | 0.000 | 0.000 |
| Meta-epidemiology (narrow) | 0.001 | 0.000 |
| Meta-epidemiology (broad) | 0.001 | 0.001 |
| Bibliometrics | 0.000 | 0.000 |
| Science and technology studies | 0.001 | 0.001 |
| Scholarly communication | 0.001 | 0.000 |
| Open science | 0.002 | 0.001 |
| Research integrity | 0.001 | 0.001 |
| Insufficient payload (model declined to judge) | 0.003 | 0.000 |
Machine scores (provisional)
The two teacher heads of the student model, read on this work. A score orders the frame for review; it never asserts a category, and the validation status ships verbatim with every row.
Baseline scores from an immature model (maturity gate not passed, 7 training rounds). Scores rank; they never assert a category.
score_only:v0-immature-baseline · verbatim from the scoring run: score_only means the number may rank works, and no category label ships from itClassification
machine, unvalidatedMachine predicted; a candidate call from one source (direct Gemma or distilled Codex), not a consensus.
How this classification was reached, model by model and score by score, is at the end of the page under "How this classification was reached".