A New Approach for Modelling Slag Infiltration and Solidification in a Continuous Casting Mould

TLDR

An extensive sensitivity study was performed using the model to assess how casting speed, mould flux properties, oscillation frequency and stroke, and superheat affect powder consumption, heat flux, and oscillation mark formation. The model, which couples metal, slag, and gas flow with heat flux and solidification, shows that powder consumption and heat flux vary consistently with casting conditions and agree well with experimental data. The study examined responses to casting conditions.

Abstract

A mathematical model of the continuous casting process has been developed which couples metal, slag and gas flow with heat flux and solidification. An extensive sensitivity study has been carried out with this model, studying the influence of changing casting conditions upon a number of quantifiable model predictions (i.e. responses). The casting conditions studied were: casting speed, mould flux properties (viscosity, break temperature), mould oscillation frequency and stroke, and superheat. The model was then applied to determine the influence of each of these parameters on the variations in: powder consumption (lubrication), heat flux (solidification) and oscillation mark formation (defects). It is shown that all three responses vary in a consistent manner through the cycle. Equations are derived for the powder consumption and heat flux, showing good agreement with prior experimental data.