A continuum mixture model of the direct chill casting process is compared to experimental results from industrial scale aluminum billets. The model, which includes the transport of free-floating solid particles, can simulate the effect of a grain refiner on macrosegregation and fluid flow. It is applied to an Al - 6 wt% Cu alloy and the effect of grain refiner on macrosegregation, sump profile, and temperature fields are presented. Two 45 cm diameter billets were cast under production conditions with and without grain refiner. Temperature and composition measurements and sump profiles are compared to the numerical results. The comparison shows excellent agreement for the grain refined case. It is believed that an incorrect assumption about the grain structure prevents good agreement in the non-grain refined billet.
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