Prediction of Periodic Centerline Porosi

This research examines the formation of pulse mark defects and periodic macroporosity in continuously cast copper rods, specifically an 8 mm oxygen-free copper (OFCu) rod. The objective is to investigate the effects of casting motions—withdrawal, dwell, and pushback—on these defects, aiming to identify preventive measures. Methodology includes characterization through tensile testing and advanced imaging techniques like optical and computed tomography, showcasing correlations between the casting motions and the defects. Additionally, computational fluid dynamics (CFD) modeling via Ansys Fluent was utilized to predict the internal behavior of the casting process, particularly focusing on the formation and dissipation of localized hotspots within the die. Results indicate that a clear mechanism for periodic porosity was identified, demonstrating a consistent relationship regardless of varying withdrawal rates. This allows for accurate predictions regarding the location, frequency, and severity of macroporosity defects in the casting process, ultimately contributing to enhanced production efficiency and output quality in copper alloy manufacturing.