Thermochemistry effects of ingot CAsting Powders – TheCAP

During casting of bottom-poured ingots, the metallic alloy is protected by a layer of mineral powder, called casting powder, which partially melts to form an airtight liquid slag film on top of the liquid metal. The layers of liquid slag and remaining powder play a paramount role in casting by its chemical and thermal insulation properties. Despite clear evidence of impact on both the skin quality and the internal metallurgical soundness of the ingots, the evolving thermochemical properties of the powder are not known and researches in this field remain mainly empirical.

TheCAP projects to understand the thermochemical mechanisms that drive the melting of casting powders and their consequences on the liquid metal and the final ingot quality. The ambitious are to get scientific expertise in an almost unexplored field, to improve numerical tools and to significantly optimize the metal yield of the casting route of bottom-poured ingots by eliminating grinding, its resulting scraps, as well as by accelerating the development of new grades of metallic alloys and casting powders.

For this purpose, experimental and numerical approaches will be concomitantly considered. Innovative experimental set-ups working at very high temperature and dedicated new instrumented trials will be developed, together with a comprehensive modelling of the powder thermochemistry including melting. The consortium is based on well established and proven effective collaborations among the partners who gather their forces in order to progress on the Thermochemistry of ingot CAsting Powders.