We discuss the problem of cracks that appear in the industrial casting of Copper billets. In order to address this problem, we performed ANSYS/Fluent CFD simulations of the solidification process. As a result of these simulations, a new casting setup was implemented that allowed a significant increase in productivity.
Ioannis Contopoulos is heading the Numerical Modeling Department of the Hellenic Center for Metals Research (ELKEME S.A.). He is also an Astrophysicist with the Research Center for Astronomy and Applied Mathematics of the Academy of Athens, and has extensive experience in the modeling of hydrodynamic and magnetohydrodynamic flows in astrophysics and in industry. He has worked as Production Engineer in the Hellenic Aluminum Industry (ELVAL S.A. 1999-2004), as Visiting Professor at the University of Crete (1997-1998), and as Research Associate at the University of Chicago (1995-1997) and NASA (1993-1995). He holds a PhD (1992) and a Master’s (1990) degree in Astrophysics from Cornell University, and a Bachelor’s degree in Electrical Engineering from the National Technical University of Athens (1987).