The research described here deals with the design and fabrication of a laboratory-scale single-roll continuous caster and then the casting of aluminum sheet under various operating conditions. The results indicate that the sheet thickness decreases with increasing rotational speed and melt superheat but increases with increasing stand-off distance and metal head in the tundish. The tundish opening size and the cooling conditions at the inner surface have only a marginal effect on the thickness. After the initial stages of solidification, the sheet thickness varies more or less linearly with the square root of the solidification time.
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