Modeling of the as-cast structure and macrosegregation in the continuous casting of a steel billet: Effect of M-EMS

The multiphase flow, heat transfer, and initial solidification behaviors in a 230 × 1300 mm2 continuous casting slab mold under different argon blowing rates were investigated by a multi-physical model. Water model experiments were conducted to validate the numerical models. The results showed that the simulated steel/slag level fluctuation and argon bubble trajectories were basically consistent with the experimental results. Only the bubbles less than 1 mm were dragged to the narrow face, while larger bubbles were more likely to escape from the free surface. When the argon blowing rate increased from 0 to 15 L/min, the impact depth of the molten steel decreased. The velocity and level fluctuation range near the submerged entry nozzle (SEN) first decreased and then increased. Moreover, the largest level fluctuation decreased to 4 mm when the argon blowing rate was 5 L/min. Meanwhile, the solidified shell thickness at narrow face of mold outlet decreased from 12.5 to 6.7 mm and became too thin to easily break out when argon blowing rate reached over 10 L/min. By comprehensively considering the multiphase flow, heat transfer, and solidification behavior in the mold, the proper argon blowing rate range should be 5 L/min, by which the disqualification rate of inclusion at strip edge can be decreased from 4.28 to 1.75 pct.

Effect of Argon Blowing Rate on Multiphase Flow and Initial Solidification in a Slab Mold

Effect of the Gap Between Copper Mold and Solidified Shell on the Fluid Flow in the Continuous Casting Strand with Mold Electromagnetic Stirring

A 3D/2D hybrid multi-physical-field mathematical model, which takes into consideration the thermosolutal buoyance, was developed to predict the macrosegregation of gear steel 20CrMnTi continuously cast by a curved billet caster with size of 160 mm × 160 mm, and investigated the effect of final electromagnetic stirring (F-EMS) on the fluid flow, heat transfer and solute distribution in the liquid core of continuously cast steel. The results show that the application of F-EMS eliminates the effect of thermosolutal buoyancy on the asymmetric distribution of carbon concentration in the cross section of billet and accelerates the final solidification of resident molten steel in the liquid core of strand, but promotes the negative carbon segregation near the billet center. When the gear steel 20CrMnTi is cast at the temperature of 1803 K and speed of 1.7 m/min, the solidification end advances forward from 9.84 to 9.72 m, and center carbon segregation ratio of billet decreases from 1.24 to 1.17 with the increase in current density of F-EMS from 0 to 350 A.

Numerical simulation of macrosegregation in continuously cast gear steel 20CrMnTi with final electromagnetic stirring

Ultrahigh‐speed casting is the most remarkable feature of billet high‐efficiency continuous casting. The transient fluid flow, heat transfer, and solidification behavior under different casting speeds, submerged entry nozzle (SEN) parameters, and mold electromagnetic stirring (M‐EMS) are investigated using a 3D transient mathematical model. The results show that a typical roll flow pattern is generated for all casting speeds, while a third small recirculation zone developed near the solidified shell at the casting speed of 6.0 m min−1. When the casting speed increases, the impact depth of the molten steel increases from 0.748 to 0.844 m, the velocity and level fluctuation at the steel/slag interface increases, the high‐temperature zone moves downward, and the shell thickness is reduced from 16.2 to 11.1 mm. As the SEN inner diameter and immersion depth increases, the impact depth increases, the velocity and level fluctuation at the steel/slag interface decreases, and the shell thickness at the mold exit is ≈11.0 mm. When the SEN immersion depth and inner diameter are 120 and 40 mm, respectively, the flow and temperature fields in the mold are the most appropriate. In addition, the M‐EMS have a great effect on the fluid flow and heat transfer behavior.

Numerical Simulation of the Fluid Flow, Heat Transfer, and Solidification in Ultrahigh Speed Continuous Casting Billet Mold

Electromagnetic stirring in mold (M-EMS) has been widely used in continuous casting process to improve the solidification quality of the steel strand. In the present study, a 3D multi-physical-field mathematical model was developed to predict the macro transport phenomena in continuous casting mold with M-EMS using ANSYS commercial software, and was adopted to investigate the effect of current intensity (0, 150, 200, and 240 A) on the heat, momentum, and species transports in the billet continuous casting mold with a size of 160 mm × 160 mm. The results show that when the M-EMS is on, the horizontal swirling flow appears and shifts the high-temperature zone upward. With the increase of current intensity, two swirling flows form on the longitudinal section of continuous casting mold and become more intensive, and the flow velocity of the molten steel at the solidification front increases. Thus, the wash effects of the fluid flow on the initial solidified shell become intensive, resulting in a thinner shell thickness at the mold exit and a significant negative segregation of carbon at the billet subsurface.

Numerical Simulation of Fluid Flow, Heat Transfer, Species Transfer, and Solidification in Billet Continuous Casting Mold with M-EMS

The invention provides a method for predicting fluctuation of a steel slag interface of a crystallizer in the continuous casting production, and relates to the technical field of metal casting. The method includes the steps of establishing a crystallizer three-dimensional geometrical model through modeling software according to the process size of a continuous casting device in a steel plant, meshing the model, formulating model boundary conditions, exporting an .msh file, importing the .msh file into fluid calculating software for simulating calculation, extracting data of the position, shapeand nearby flow field of the steel slag interface of the crystallizer, establishing a rectangular coordinate system scatter gram of a central surface radial distance and a liquid surface fluctuationheight corresponding to the central surface radial distance of a casting blank in postprocessing software, judging the fluctuation conditions of the steel slag interface according to the scatter gram,adjusting the insertion depth and shape of a water gap of the casting blank, and repredicting the fluctuation conditions of the steel slag interface. By means of the method, the flow field distribution of the casting blank in the continuous casting process and the steel slag interface fluctuation behaviors can be judged, and therefore the quality of the casting blank is improved.

Method for predicting fluctuation of steel slag interface of crystallizer in continuous casting production

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Numerical Simulation of Fluid Flow, Heat Transfer, Species Transfer, and Solidification in Billet Continuous Casting Mold with M-EMS

Method for predicting fluctuation of steel slag interface of crystallizer in continuous casting production