A Thermal Simulation Method for Solidification Process of Steel Slab in Continuous Casting
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RECENT breakthroughs in casting, deformation, and heat-treatment technologies have made possible the production of high purity steel with refined microstructures. Properties of continuously casted steels are a reflection of the solidification structure and defects inside these steels. Solidification defects, however, such as macrosegregation and shrinkage cavities in steel slabs, cannot be eliminated by purification, deformation, or thermal treatment.[1] Progress in this area depends on physical simulation,[2] numerical simulation,[3,4] and industrial experiments.[5] However, because of the high melting points and non-transparency of steel slabs, few in situ methods can be applied to the study of the solidification process within a continuously cast slab. Industrial experiment,[5,6] of course, reveals in a full scale the relationship between the processing parameters and actual solidified structure of slabs, but this method is often prohibitively expensive or physically impossible. Physical simulation has sometimes been adopted using transparent materials[7] or metals with low melting points to study flow fields,[8,9] and solidification behaviors.[10–12] This is the method that has most commonly
HONGGANG ZHONG and XIANGRU CHEN, Lecturers, and QIJIE ZHAI, Professor, are with the State Key Laboratory of Advanced Special Steel, Shanghai Key Laboratory of Advanced Ferrometallurgy, School of Materials Science and Engineering, Shanghai University, P.O. Box 275, 149 Yanchang Road, Shanghai 200072, P.R. China. Contact e-mail: [email protected] QINGYOU HAN, Professor, is with the Department of Mechanical Engineering Technology, Purdue University, 401 North Grant Street, West Lafayette, IN. KE HAN, Professor, is with the National High Magnetic Field Laboratory, 1800 E. Paul Dirac Drive, Tallahassee, FL. Manuscript submitted September 20, 2015. METALLURGICAL AND MATERIALS TRANSACTIONS B
been used to develop current solidification theories,[2] and it has contributed considerably to the study of flow fields in mold during continuous casting (CC).[13,14] Based on previous work, it is desirable to undertake physical simulation on CC of steel itself. Machingawuta et al.,[15] developed a dip-type simulator and this method helped us to directly investigate the heat flux, slag film, shell thickness, and surface quality of cast shells.[16,17] Unfortunately, this method can only simulate the initial solidification behavior of steel in a CC mold. Progress in computer science has enabled researchers to apply numerical simulation to studies of heat conduction,[18] liquid flow,[19] and solidified structure[20] of CC. Solidification, however, is a complicated non-equilibrium process that presents a big challenge to numerical simulation. Because of a scarcity of established thermal–physical parameters, prediction of solidified structure of steel still has a long way to go.[3,21] Currently, numerical simulation and physical simulation are often used together to study large-scale industrial production. Numerically simulated thermal field data can be use
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