A new belt casting process has been developed to cast aluminum-aluminum alloy compound strips. The first strip is cast by a conventional glass fiber belt caster. At a defined distance from the location of the primary solidification, a second casting unit is placed. The local upper surface temperature of the substrate is essential for the forming of a sound metallurgical compound. Numerical simulation models of an existing single strip belt casting process were set up and extended to describe the new double strip casting process. The influence of process parameters (cooling conditions, casting speed) and constructive modifications on the crucial surface temperature of the substrate were investigated. Temperatures measured in the casting strip and in the cooling plates were used to calibrate the simulations. Casting parameters for the new compound casting process as well as the appropriate position of the second casting unit were derived from the simulation results.
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