8 inch AA6063 billet for dc casting process with simulation program casting billet mold design and production

This study is to aim to develop of the casting quality of the 6XXX aluminium billet, which is one of the most important parameters for the extrusion of the studied aluminium alloy series as well as increasing the profile quality reducing the quality errors. In billet casting, many different parameters affect the billet quality at both macro and micro levels. Physical parameters such as the physical condition of the billets, the surface quality, the smoothness of the surface, the micro-structure features, the shell thickness, the grain size, the start-up of solidification at the right place and time play crucial role as well as the cooling and the design of the casting molds The production of 8 inch diameter billets have some severe problems so this thesis focused to design suitable mold geometry with the support of the simulation in order to improve the billet quality.