Modeling and experimental study for horizontal twin-roll casting of copper/aluminum clad sheet

A mathematical model has been developed and validated for the horizontal twin-roll casting of copper/aluminum clad sheet. The influences of the heat transfer coefficient for copper/roll interface, casting speed and clad sheet thickness on the sump depth and temperature distribution of the copper/aluminum interface were studied. The interface morphologies and chemical compositions of the intermetallic compound layers were analyzed. The results showed the sump depth decreased with the increase of heat transfer coefficient for copper/roll interface and moved to the outlet with the increase of the casting speed. Casting speed was linear with the sump depth ratio to set-back distance on the centerline for different clad sheet thicknesses. The thickness of the intermetallic compound layer increased with the increase of the clad sheet thickness. Only Al2Cu layer formed on the copper/aluminum interface with clad sheet thickness of 6mm, and the second layer of Al4Cu9 formed near the copper side with the increase of the thickness.