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This paper proposes a novel intelligent scheduling method based on deep reinforcement learning (DRL) to solve the multi-objective steelmaking-continuous casting (SCC) scheduling problem, under time-of-use (TOU) tariffs for the first time. The intelligent scheduling system architecture is designed, and a mathematical model is established to minimise the total sojourn time and electricity cost. To effectively reduce production costs by avoiding peak periods of electricity consumption, the 'start time' of the system is generated based on the Markov Decision Process (MDP), and heuristic scheduling rules related to power cost are used as the action space, with corresponding reward functions designed according to the characteristics of these two objectives. To satisfy the continuous casting which is a particular SCC constraint, a backward strategy is developed. Additionally, a branching duelling double deep Q-network (BD3QN) is adapted to guide action selection and avoid blind search in the iteration process, and then applied to real-time scheduling. Numerical experiments demonstrate that the proposed method outperforms comparison algorithms in terms of solution quality and CPU times by a large margin. [ABSTRACT FROM AUTHOR]

The slag-metal reaction between traditional CaO-SiO 2 -CaF 2 -Na 2 O-based slag and high-titanium steel deteriorates the performance of the mold flux, negatively affecting the surface quality of the slab and causing issues in continuous casting. To maintain the stability of slag properties after the slag-metal interaction, BaO and Li 2 O were added to the mold flux as a potential new slag system of the BaO-CaO-SiO 2 -TiO 2 -CaF 2 -Li 2 O-Na 2 O seven-component slag for the continuous casting of high titanium steel. In this study, the effects of the BaO/CaO ratio on the structure and properties of the seven-component slag were examined using molecular dynamics simulation and Raman spectroscopy, and the effect of the BaO content on the amphoteric behavior of TiO 2 was also investigated. With the gradual substitution of CaO by BaO, the melt's basicity increases, and TiO 2 transforms from acidic TiⅤ to alkaline TiⅥ. Simultaneously, the addition of BaO promotes the conversion of O b into O f and O nb , resulting in a simplified melt structure. The continuous increase in content of structural units Q Si 0 and Q Si 1 , along with the continuous decrease in content of Q Si 3 and Q Si 4 , further elucidates this phenomenon. Hence, it can be inferred that BaO primarily functions as a depolymerizing agent within the network structure of the melt. [ABSTRACT FROM AUTHOR]

The deposition and accumulation of inclusions is the dominant mechanism in nozzle clogging of the submerged entry nozzle. Previous modeling attempts of inclusion deposition have assumed that any contact between the inclusion and nozzle wall results in adhesion. Herein, an Eulerian–Lagrangian simulation with a stochastic adhesion model is used to study the effects of different inclusion‐wall sticking probability (Swall) on inclusion deposition. The results indicate that inclusion deposition is affected by both melt height and Swall. Lower melt heights result in increased deposition deeper into the nozzle and greater maximum particle area number density. The effect of Swall on the global deposition ratio can be divided into two regimes. When Swall increases from 0–0.05, there is a rapid rise in the global deposition ratio. When Swall > 0.05, the global deposition ratio increases only modestly with Swall. Changes to Swall also affect the location of deposition. When Swall decreases, the high and mid cases show greater relative deposition in the cone and taper sections of the nozzle, while the low melt height case shows greater relative deposition in the straight section of the nozzle. [ABSTRACT FROM AUTHOR]

During high-speed continuous casting, the effect of secondary cooling on the quality of the billet is more obvious, and the possibility of quality problems is higher. This study takes the continuous casting machine producing 165 mm × 165 mm billet as the research object. The six different secondary cooling schemes are designed with the 4.5 m/min casting speed. By comparing the shell deformation, surface stress, surface temperature recovery, and metallurgical lengths at different secondary cooling schemes, the secondary cooling scheme applied in the high-speed continuous casting process is selected. The results show that the surface temperature recovery and stress of the billet in Scheme 1 are higher than those of other cooling schemes. The metallurgical length and shell deformation of the billet in Scheme 4 are higher than those of other cooling schemes. In Schemes 2, 3, 5, and 6, the shell deformation of Schemes 3 and 5 is higher than that of Schemes 2 and 6. In Schemes 2 and 6, the maximum surface central stress of the continuous casting billet in the secondary cooling zone is 36.3 MPa and 31 MPa, respectively. Scheme 6 is used as the secondary cooling scheme of high-speed continuous casting in this study. The water quantity in secondary cooling zone 1 ~ 5 segments of Scheme 6 is 28 m3/h, 31 m3/h, 16 m3/h, 10 m3/h, and 6 m3/h, respectively. Finally, the industrial trial is carried out, which proves that Scheme 6 can be applied to high-speed continuous casting. [ABSTRACT FROM AUTHOR]

To achieve the desired superheat of molten steel during the continuous casting process, optimization of process parameters such as molten steel temperature in ladle furnace, casting speed, and baking temperature is necessary. Therefore, obtaining the superheat corresponding to these process parameters in advance is particularly important. To address this issue, a model for predicting the temperature of molten steel in the tundish during continuous casting is designed. The model adopts a combined modeling approach of mechanistic model and data model. To address the issue of the mechanism model's inability to capture the variation of the lining's thermal parameters, this article improves the traditional physics-informed neural network (PINN) algorithm. It combines the constraints from both the forward and inverse problems, allowing for obtaining solutions to the equations while capturing the variation of equation parameters. Actual data from multiple casting sequences at a steel plant are collected to validate the accuracy and interpretability of the model. The results show that the error of the model is about 2.1k which has better accuracy compared to pure mechanistic model and pure data model. Additionally, it can capture the variation patterns of tundish lining thermal parameters under different operating conditions. Therefore, the model designed in this article can provide both profound physical interpretation ability and more practical predictions of molten steel temperature. [ABSTRACT FROM AUTHOR]

Flow efficiency in a two‐strand continuous casting tundish is studied by analyzing the residential time distribution (RTD) curves in a small‐scale tundish water model using a conductive NaCl solution tracer. The velocity fields in the tundish water model are measured by particle image velocimetry, which is used to validate the results of the mathematical model in the article. It is found that the tracer concentration has a significant impact on the predicted dead volume fraction in the RTD analysis. Validated mathematical modeling of the computational fluid dynamics (CFD) technology is performed to explore the root cause of the defective results in the RTD analysis. It is found that the flow inside the tundish is sensitive to density variations caused by the injected tracer. A denser tracer will stay lower in the tundish by gravity and flow out of the tundish more quickly. A proper tracer concentration in the water model experiments is discussed to visualize the dead volume and improve tundish furniture design efficiently for future work, a new method using CFD modeling is proposed in this article, which can directly demonstrate the dead volume's location. [ABSTRACT FROM AUTHOR]

Computational models are powerful tools to quantify physical phenomena to gain valuable insights into a manufacturing process. Their accuracy is hindered, however, by uncertainty in the input data. Furthermore, when calibrating models with plant measurements, it helps to understand which variables have greatest effect on the critical model outputs. This work applies uncertainty quantification and sensitivity analysis to determine the most influential input parameters in the CON1D model of heat transfer and solidification in steel continuous casting with slag. Results show that the slag rim greatly affects heat flux near the meniscus, so control of its size is important. Heat flux and temperature down the mold depend greatly on velocity of the solid slag layer, and slag solidification temperature, which control the slag layer thickness, which in turn affects the interfacial resistance that controls heat transfer in the process. Scale formation on the mold coldface greatly increases mold temperatures. Based on the results presented here, models of heat transfer in continuous casting such as CON1D would benefit from plant measurements such as slag rim size and solid slag velocity, and lab measurements such as slag viscosity at lower temperatures, to better characterize this important slag property. [ABSTRACT FROM AUTHOR]

This review article reports the critical issue of reoxidation in clean steel production during secondary refining and continuous casting processes. Reoxidation presents substantial challenges to process stability and final product quality. Various sources of reoxidation, including exposure to oxidizing gases, reducible oxides in slag and refractories, and the presence of ferroalloys are explored. Fundamental reactions and their consequences, such as changes in steel composition, inclusion composition/morphology, and the formation of reaction products at the interface between liquid steel and refractory materials, are reviewed. High oxygen partial pressure on the refractory side is identified as a significant factor, particularly in tundish and continuous casting processes. To address reoxidation effectively, the review discusses modeling approaches like computational fluid dynamics and thermodynamic/kinetic modeling. In the industrial context, reoxidation in the tundish is mainly attributed to open‐eye formation in the tundish flux and reducible oxides like SiO2 in an insulating cover powder, for example, rice hust ash. Maintaining precise tundish flux control is crucial for steel cleanliness. In conclusion, this review highlights the multifaceted nature of reoxidation challenges in clean steel production. A comprehensive understanding of reoxidation mechanisms and the implementation of effective strategies are essential for achieving cleaner steel production. [ABSTRACT FROM AUTHOR]

It is herein considered a new product composed of solid–liquid dispersion of a conveniently formulated continuous casting powder in synthetic oil‐based esters, where hypothetical limit to consider this liquid slurry as a liquid powder is a mix with at least 50% in weight powder load preserving suitable fluidity for effective and stable pumping. After a relatively long and intense industrial application period, one of most critical points when using liquid powder for steel continuous casting proves to be mold feeding. This is mainly because of weird properties of such material which behaves as a non‐Newtonian fluid. A thorough rheological study on samples of liquid powder for continuous casting is carried out. Based on meticulous characterization of a set of laboratory samples, the dispersion flow curve is determined. Most commonly used rheological models are then tested for fitting with the experimental data. Sisko model is identified as the best fitting one. This model is then implemented to derive the system curve describing its behavior under its industrial application conditions. The mathematical process to apply Sisko model and its numerical solutions is explained. The results found are consistent with the field experience of the industrial application of the material under study. [ABSTRACT FROM AUTHOR]

Transverse corner cracks are among the most common defects in high carbon and high carbon micro-alloyed grade slab casting. Calculation and analysis were done to minimize the negative strip time of mold oscillation, which is responsible for reducing the depth of the oscillation mark formed on the slab surface. The value of negative strip time decreases with an increase in the frequency of mold oscillation. Based on the trial results, it was suggested that the oscillation proportionality be adjusted from 1.2 to either 1.25 or 1.3. This adjustment will reduce the depth of oscillation marks and the tendency to form transverse cracks. The transverse crack on the narrow face of the slab was examined for crack analysis and compositional analysis. Microstructural analysis revealed that the crack has no branching and consists of an iron scale inside it. Furthermore, it is observed that the crack propagates across the allotriomorphic ferrite grains. [ABSTRACT FROM AUTHOR]

Due to the growing interest in lightweight constructions, the continuous casting of nonferrous metals is continuously developing as a result of the cost-effectiveness of this process, which combines several stages of sheet production. Unfortunately, because of the characteristics of the process, the parameters in the roll gap, such as, for example, pressure and temperature, are unknown, significantly affects the understanding of the phenomena occurring in the material during rolling. Therefore, at IMF Freiberg, a sensor consisting of a piezo sensor and two thermocouples measuring the temperature at two different heights was mounted on the surface of the roll, making it possible to control the process parameters live during the TRC trial. The measurements were further supported by a digital twin in the form of a layer model, combining a viscous and solid region for each layer in a single tool. The computations in this tool are performed offline and the computation time is in the order of seconds, thus much less than that of the finite element method. Because the layer model measures the temperature of the magnesium strip, FEM simulations were used to validate measurements from thermocouples. Experimental results have been obtained that allow for a direct correlation between the development of the pressure and temperature and the length of the fully solidified LD part in the roll gap zone, which correlates directly with the effective total equivalent strain. Using the sensor and layer model, it is possible to train a digital twin that can be used for online estimation of the final strip properties obtained in the TRC process. [ABSTRACT FROM AUTHOR]

Low‐basicity fluorine‐containing mold flux, which forms a porous slag film with NaF pores, is expected to solve the contradiction between heat transfer and lubrication in the continuous casting of peritectic steel. Herein, the kinetic mechanism and the influence of NaF gas formation based on the different fluorine raw materials (NaF, CaF2, and Na3AlF6) at 0.9 basicity and 6 wt% fluorine are investigated by the combination of experiments and calculations. The results show that CaF2 is the first to generate NaF gas at 1189 K, followed by Na3AlF6 (1238 K) and NaF (1328 K). NaF raw material produces the most NaF gas with the lowest activation energy in the three raw materials, due to high Na ion kinetic energy, the simple degree of polymerization, and Na‐F1 bonds. Correspondingly, NaF bubbles in the molten slag are the largest based on their aggregation. Na3AlF6 and CaF2 raw materials rank second and third, with F atoms primarily bonded as Al‐Fx and Ca‐Fx and the higher proportion of QSi−O−Al2$Q_{\text{Si} - \text{O} - \text{Al}}^{2}$ and QSi−O−Si4$Q_{\text{Si} - \text{O} - \text{Si}}^{4}$ structure. Notably, at 0.9 basicity and 6 wt% fluorine, Na3AlF6 as raw material generates a suitable amount of gas, making diffuse and fine NaF bubbles in the molten slag. [ABSTRACT FROM AUTHOR]

The instantaneous abnormal mold level fluctuation (IAMLF) has significant harmful effects on slab quality. This article proposes a prediction and control method for IAMLF. First, the data processed by difference method is used for the IAMLF prediction and stopper‐rod position prediction. Then, the bidirectional long short‐term memory (BI‐LSTM) is introduced to predict the IAMLF; the corresponding stopper‐rod position is predicted according to the mold level prediction result. BI‐LSTM can predict the IAMLF with the mean absolute error of 1.52 mm and the false alarm rate of 1.8%, and also performs well in predicting the stopper‐rod position with a mean absolute error of only 1.92 mm. Furthermore, the two prediction models are combined to form a closed loop, where the mold level fluctuation is predicted according to the industrial data processed by data difference method, and the stopper‐rod position is adjusted in advance to eliminate IAMLF. Finally, the fuzzy proportional‐integral‐derivative (PID) controller is used to control mold level based on the mold level and stopper‐rod position prediction results. The prediction accuracy of IAMLF reaches 98.4%, and the present proposed fuzzy PID controller can effectively prevent the occurrence of IAMLF with a success rate of 95.6%. [ABSTRACT FROM AUTHOR]

Lotus-type porous copper was fabricated using a continuous casting method in pressurized hydrogen and nitrogen gas atmospheres. This study evaluates the effects of process parameters, such as the hydrogen ratio, total pressure, and transference velocity, on the resulting pore structure. A continuous casting process was developed to facilitate the mass production of lotus-type porous copper. To achieve the desired porosity and pore diameter for large-scale manufacturing, a systematic evaluation of the influence of each process parameter was conducted. Lotus-type porous copper was produced within a hydrogen ratio range of 25–50%, a transference velocity range of 30–90 mm∙min−1, and a total pressure range of 0.2–0.4 MPa. As a result, the porosity ranged from 36% to 55% and the pore size varied from 300 to 1500 µm, demonstrating a wide range of porosities and pore sizes. Through process optimization, it is possible to control the porosity and pore size. The hydrogen ratio and total pressure were found to primarily affect porosity, whereas the hydrogen ratio, transference velocity, and total pressure significantly influenced pore diameter. When considering these parameters together, porosity was most influenced by the hydrogen ratio, whereas the total pressure and transference velocity had a greater influence on pore diameter. Reducing the hydrogen ratio and increasing the transference velocity and total pressure reduced the pore diameter and porosity. This optimization of the continuous casting process enables the control of porosity and pore diameter, facilitating the production of lotus-type porous copper with the desired pore structures. [ABSTRACT FROM AUTHOR]

The clogging of the submerged entry nozzle (SEN), as an important device to connect the tundish and the mold, has been widely concerned. However, until now, the clogging of the SEN cannot be eliminated during the casting. Herein, the clogging behavior of the SEN during the casting of ultralow‐carbon steel is studied using an external DC electric field. The findings demonstrate that the DC electric field inhibits the growth of the clogging on the outlet and the thickness of the clogging layer is small, which ensures the integrity of the profile of the outlet. After DC treatment, the interface of the clogging is clear and the density is increased, which reduces the pollution to molten steel. At the same time, the fluctuation of the mold level is significantly improved, and the defect rate of cold rolling is effectively reduced to 30% of the original level, which is beneficial to the overall performance of the slab. [ABSTRACT FROM AUTHOR]

In this article, a brief review of the development of the Knudsen effusion mass spectrometric (KEMS) approach in the Theoretical Metallurgy Department of the KTH Royal Institute of Technology and in the in the Laboratory of Metallurgy of the Helsinki University of Technology and modifications of quadrupole model QMG420 mass spectrometers, is presented. The thermodynamic data obtained from vaporization of standards, such as NaCl, CsCl, B2O3, and Ag, and of the B2O3–Al2O3 and ZnO–P2O5 systems is compared with the data obtained using a magnetic MS1301 mass spectrometer. For the first time, composition of the vapor phase over the Dy2O3–DyF3, CaO–CaCl2, and Cu–Mg systems and the partial pressures of components at high temperatures are investigated. The experimental data obtained for the investigated systems are used for prediction of the vaporization processes and modeling of thermodynamic properties and high‐temperature phase equilibria in the multicomponent systems used in metallurgy. An account is given of the detailed studies of the vaporization processes and thermodynamic properties of some multicomponent systems composed of oxides, fluorides, and carbonates forming mold powders for continuous casting of steel. Some new directions of the ongoing studies by the KEMS method are summarized. [ABSTRACT FROM AUTHOR]

The effect of strand (S‐) and final (F‐) electromagnetic stirring (EMS) on solidification structure characteristic of a φ690 mm continuously cast round bloom has been investigated industrially and theoretically. The newly designed S1‐EMS equipped just below the foot zone takes great effect on both equiaxed ratio and distribution alignment, as well as central porosity. Larger current S1‐EMS leads to higher equiaxed ratio, more symmetrical equiaxed zone, and smaller diameter of central porosity, and the effect is much more obvious than conventional S2‐EMS and F‐EMS. It is also noticed that there should be a saturation effect of S1‐EMS on the promotion of equiaxed dendrite nucleation. The S2‐EMS is beneficial for the expanding of equiaxed zone and improving of central porosity. When S1‐EMS is weak, strong S2‐EMS results in more asymmetrical equiaxed zone. However, when S‐EMS is strong, strong S2‐EMS results in more symmetrical distribution of equiaxed zone. The F‐EMS takes a little impact on the expanding of equiaxed zone in the large‐sized round bloom, and almost no effect on the alignment. The central porosity, however, is improved by F‐EMS with the help of decrease in temperature gradient and compensation of solidification contraction. [ABSTRACT FROM AUTHOR]

This paper demonstrates the feasibility of producing thin-thin slabs from a wide range of aluminum alloys using the twin-roll casting method. In the course of the research, the design and technological solutions of the currently known methods of continuous casting and rolling of sheet metal products were analyzed. In a laboratory setup for strip metal casting, the physical and technological parameters (such as temperature, casting speed, and heat removal rate) were tested to ensure a stable process for the production of thin-thin slabs (1–5 mm) from the aluminum alloys under study. For the first time in the field of metallurgy, the improvement of twin-roll casting technology allowed the cast thin slabs from wide-range aluminum alloys, specifically EN2024 (D16) (≥ 130 °C) and EN7075 (B95) (≥ 160 °C), to be produced. In the initial phase of the research, the impact of the heat removal rate from the solidifying metal on the primary structure of the cast blank was investigated. It is demonstrated that, irrespective of the cooling rate, the α‑phase serves as the basic structure that determines the mechanical characteristics of the metal in cast workpieces for all the studied aluminum alloys. It was demonstrated that as the cooling rate increases to a level characteristic of twin-roll casting, the α‑phase in cast slabs exhibits a more uniform fine-grained structure. In this case, the small inclusions of dispersed intermetallic and eutectic phases present in the structure of cast slabs are evenly distributed across their cross-sections. As is known, there is a hereditary phenomenon between the primary structure of cast slabs and the quality of the final metal product. This relationship was confirmed by the improved strength characteristics of strips obtained by rolling experimental slabs. [ABSTRACT FROM AUTHOR]

Based on a physical water model with a scaling factor of 0.5 and a coupled flow–heat transfer–solidification numerical model, this study investigates the influence of the submerged entry nozzle (SEN) depth on the mold surface behavior, slag entrapment, internal flow field, temperature distribution, and initial solidification behavior in slab casting. The results indicate that when the SEN depth is too shallow (80 mm), the slag layer on the narrow face is thin, leading to slag entrapment. Within a certain range of SEN depths (less than 170 mm), increasing the SEN depth reduces the impact on the mold walls, shortening the "plateau period" of stagnated growth on the narrow face shell. This allows the upper recirculation flow to develop more fully, resulting in an increase in the surface flow velocity and an expansion in the high-temperature region near the meniscus, which promotes uniform slag melting but also heightens the risk of slag entrainment due to shear stress at the liquid surface (with 110 mm being the most stable condition). As the SEN depth continues to increase, the surface flow velocity gradually decreases, and the maximum fluctuation in the liquid surface diminishes, while the full development of the upper recirculation zone leads to a higher and more uniform meniscus temperature. This suggests that in practical production, it is advisable to avoid this critical SEN depth. Instead, the immersion depth should be controlled at a slightly shallower position (around 110 mm) or a deeper position (around 190 mm). [ABSTRACT FROM AUTHOR]

In the continuous casting process, the heat transfer effect of secondary cooling plays an important role in the quality of the slab. The cooling intensity and cooling uniformity of the secondary cooling nozzle need more efficient spray cooling to achieve. Herein, the cold characteristics of different types of nozzles were compared. It is found that the second type of air mist nozzles have more uniform water density and striking force. On this basis, high‐temperature heat transfer experiments for casting billets were carried out to study the heat transfer coefficients of different air mist nozzles in the secondary cooling zone of continuous casting. It is found that the heat transfer coefficient increases as the distance of the temperature measurement point from the nozzle directly below increases. The heat transfer coefficients of the casting billet in both the jet and non‐jet zones are decreasing to varying degrees. When the temperature drops to 600 °C, the second type of air mist nozzle shows a faster temperature drop at the point of measurement, a smaller difference in time taken for temperature drop between jet and non‐jet zones, and faster and more uniform spraying, leading to a more significant trend of increasing heat transfer coefficient. [ABSTRACT FROM AUTHOR]

With the thinner of the automobile panel, the press crack defects caused by the large‐size calcium aluminate inclusions at the automakers become obvious. Herein, in order to stabilize the control of calcium aluminate inclusions in the molten steel, the vortex slag entrainment (VSE) of a 300 ton ladle is investigated by the numerical simulation. The effects of the steel throughput, cofferdam height close to the nozzle, and ladle bottom structure on the VSE are analyzed. Results demonstrate that the residual molten steel (RMS) in the ladle and the critical height of the vortex increase with the increasing of the steel throughput. The RMS increases with the increasing of the cofferdam height when the VSE occurs. When the cofferdam height is 50, 100, and 150 mm, the RMS are 4.71, 7.19, and 9.62 t at the initial time of the VSE with a 7.5 ton min−1 steel throughput. In addition, the industrial trial of transforming the flat bottom ladle into the slope bottom ladle is carried out to control the VSE and reduce the RMS. The average weight of the RMS after pouring 25 heats of the slope ladle bottom ladle is 1.85 t less than that of the flat bottom ladle. [ABSTRACT FROM AUTHOR]

Controlling the flow activity at the meniscus in the mold during the continuous casting of ultrathick slab is challenging due to the complex flow behavior, which is not extensively documented. Herein, a multiphase transient model of the ultrathick slab mold has been developed to describe the flow of molten steel, velocity distribution, and stream pattern at different submerged entry nozzle (SEN) outlets. The position of impact points and the fluctuation of liquid level are discussed as well. After ejecting from the port, the stream of the S‐shaped SEN splits into upper and lower streams. The upper stream moves to the liquid level, which improves the liquid level activity near the SEN. However, the reduced mainstream momentum alleviates the occurrence of slag layer exposure. Industrial application of the S‐shaped SEN results in uniform slag distribution and smooth casting operations. [ABSTRACT FROM AUTHOR]

Strand surface defects originate from the initial solidification of molten steel in continuous casting mold. This article investigates the initial solidification behavior during the continuous casting of 55SiCr spring steel billet using a novel mold simulator. First, the high‐frequency responding temperatures and high‐frequency heat fluxes across the mold corner and hot face are calculated by the 2D‐inverse heat conduction program mathematical model and the fast Fourier transformation, and the results indicate that the temperature variations and heat flux fluctuations around mold corner are stronger than those at mold hot face. Then, the characteristic heat fluxes around the meniscus at mold corner and hot face are analyzed, and their four corresponding signals are discussed with the help of power spectral density analysis. The average solidification factor K for shell corner is greater than shell face, which indicates that the cooling intensity of shell at corner is stronger due to the two‐dimensional heat transfer near mold corner, as demonstrated by heat transfer and dendrite structure analysis. Finally, the interrelations between the shell profile, mold oscillation, heat flux change rate, high‐frequency heat flux, temperature change rate, and high‐frequency temperature for the two cases are discussed. [ABSTRACT FROM AUTHOR]

The aim of the work was to obtain advanced oxide materials, obtained through technologies compatible with sustainable development materials. These materials are used in special operating conditions, such as in the case of continuous steel casting, where there is a temperature difference of over 10000C between the mold wall and the steel crust. These are the lubricating powders for the crystallizer. [ABSTRACT FROM AUTHOR]

As the metal additive manufacturing (AM) field evolves with an increasing demand for highly complex and customizable products, there is a critical need to close the gap in productivity between metal AM and traditional manufacturing (TM) processes such as continuous casting, machining, etc., designed for mass production. This paper presents the development of the scalable and expeditious additive manufacturing (SEAM) process, which hybridizes binder jet printing and stereolithography principles, and capitalizes on their advantages to improve productivity. The proposed SEAM process was applied to stainless steel 420 (SS420) and the processing conditions (green part printing, debinding, and sintering) were optimized. Finally, an SS420 turbine fabricated using these conditions successfully reached a relative density of 99.7%. The SEAM process is not only suitable for a high-volume production environment but is also capable of fabricating components with excellent accuracy and resolution. Once fully developed, the process is well-suited to bridge the productivity gap between metal AM and TM processes, making it an attractive candidate for further development and future commercialization as a feasible solution to high-volume production AM. [ABSTRACT FROM AUTHOR]

Direct measurement of the wetting angles of the mold fluxes is a strenuous work and time-consuming, and a mathematical model relating the wetting angle of mold flux to its chemical composition is rarely found up to now. In this work, multiple linear regression (MLR), backpropagation neural network (BPNN), and GA-BP neural network (GA-BPNN) are used to model and predict the wetting angle of mold flux. Results show that the accuracy of MLR, BPNN, and GA-BPNN model is 76, 62, and 83 pct; the GA-BPNN model has the highest prediction accuracy. In addition, according to the standardized coefficients in the MLR model, the influence degree of different chemical components on the wetting angle of mold fluxes is analyzed. The importance of the influence of various components on the wetting angle is Fe2O3, F−, Li2O, Na2O, R, MnO, Al2O3, B2O3, and MgO from high to low. Among them, Fe2O3, Li2O, Na2O, R, and MnO have a negative effect on the wetting angle of mold flux, while F−, Al2O3, B2O3, and MgO have a positive effect. The established GA-BPNN model could facilitate the design and optimization of mold slag in the steel continuous casting process. [ABSTRACT FROM AUTHOR]

In the current study, a three-dimensional mathematical model that integrated the large eddy simulation (LES) turbulent model, volume of fluid (VOF) multiphase model, and the dynamic mesh model, was developed to investigate the influence of the mold oscillation on the steel, slag, and air multiphase flow and the slag entrainment in a slab continuous casting mold. The results indicated that the mold oscillation led to an increase of about 0.35 m/s in the speed of molten steel at the impact point of the upper and lower circulation on the narrow surface. However, it reduced about 0.047 m/s in the maximum speed of the meniscus at 1/4 width of the mold. The Fast Fourier Transform (FFT) analysis revealed that the characteristic frequency of the speed fluctuation in the gravity direction of the meniscus near the narrow surface was 1.27 Hz without the consideration of the mold oscillation. Upon the application of the mold oscillation, a new characteristic frequency of 3 Hz, matching the mold oscillation frequency, emerged with twice the intensity of the original 1.27 Hz frequency. Moreover, the mold oscillation had little effect on the characteristic frequency of the speed fluctuation on the meniscus far away from the narrow surface. A user-defined function (UDF) was employed to quantify the number, size, and spatial distribution of entrained slag droplets. The net slag entrainment rate was reduced from 0.0152 to 0.0113 kg/s after the consideration of the mold oscillation, and the number of entrained slag droplets was also decreased. The effect of mold oscillation on the size distribution of entrained slag droplets and the occurrence location of the slag entrainment on the meniscus were not significant. [ABSTRACT FROM AUTHOR]

As a typical metallurgical defect, macrosegregation seriously affects the internal quality of the continuous casting billet, and it cannot be solved by processes such as high-temperature diffusion and rolling. For continuous casting billet, the solidification shrinkage and thermal shrinkage of the microstructure directly affect the macrosegregation defect. In order to reveal the effects of solidification shrinkage and thermal shrinkage on the melt flow, microstructure distribution, and solute segregation, a multiphase solidification model based on the Eulerian–Eulerian approach was established in this work. The growth behaviors of the columnar dendrite trunk and the columnar dendrite tip were fully considered, as well as the nucleation, growth, free migration of equiaxed grains, and the columnar-to-equiaxed transition (CET). Besides, the corresponding relationship between the secondary dendrite arm spacing (SDAS) and the cooling rate has also been taken into account in the model, which makes the net mass transport source term of the mass conservation equations more accurate. The calculation results show that when no any shrinkage behavior is considered in the model, the melt flow velocity in front of the solidification end will gradually decrease until it is the same as the casting speed, and the segregation index at the billet center will gradually increase until it reaches the maximum value at the solidification end. Both thermal shrinkage and solidification shrinkage can generate a negative pressure zone in the billet center, sucking the poor-solute melt located the upstream of continuous casting strand flows towards the solidification end, and mixing with the enriched-solute melt before the solidification end, thereby inhibiting macrosegregation. However, compared with the solidification shrinkage, the effect of thermal shrinkage on reducing the positive segregation index in the billet center is limited. [ABSTRACT FROM AUTHOR]

Understanding the formation of a slag rim on the mold meniscus is crucial for controlling surface defects in the initial shell. However, there is a scarcity of quantitative studies on this matter. This study has developed a comprehensive three-dimensional (3D) numerical model for analyzing the meniscus multi-phase flow, heat transfer, and solidification, considering mold oscillation. The 3D morphology of the solidifying shell and the slag rim in the meniscus region were accurately reproduced. The solidification depth (DIS), solidification length (LIS) and oscillation mark depth (DOM) of the initial shell were used to quantify the morphological characteristics of the initial shell. The results confirmed that the formation position difference of the slag rim along the circumferential direction of the mold significantly affects the initial solidification and uniform growth of the shell. In the corner of the mold, the deeper overflow makes the oscillation mark extend 2.8 to 3.2 mm in the direction of casting. In addition, in order to quantitatively investigate the influence of the slag rim, a two-dimensional (2D) model is established with phenomena and parameters considered the same as those of the 3D model. According to the slag rim morphology obtained by the 3D model, in the 2D model, it is proposed to construct three slag rims with the same maximum thickness of 6 mm at 10, 20 and 35 mm above the meniscus (HRim). The simulation of initial shell morphology revealed that a lower formation position of the slag rim led to more severe overflow of molten steel from the meniscus, resulting in non-uniform continuous growth of the initial shell. This increases the likelihood of potential blockage in the liquid slag flow towards the slag channel between solidified shell and mold. [ABSTRACT FROM AUTHOR]

Feeding strip significantly enhances continuous cast slab quality. To clarify its impact on inclusion distribution, a mathematical model coupling flow, solidification and inclusion motion have been developed. The upper recirculation, lower recirculation, and unformed recirculation flow occur during continuous casting. Under the resultant forces of drag, virtual mass, pressure gradient, Saffman, gravity, buoyancy, etc., the inclusion motion can be divided into two stages: Injection and Split flow. Feeding strip mainly affects inclusion motion by altering the drag, virtual mass, pressure gradient, and Saffman forces, which are closely related to the molten steel flow. After feeding strip, the lower recirculation on the strip feeding side is compressed, while it on the no-feeding side is expanded. The unformed recirculation flow on strip feeding side squeezes the flow below lower recirculation on no-feeding side. A higher strip feeding speed promotes downward inclusion motion, increasing the chance of being captured between the slab edge and strip. Unformed recirculation flow guides inclusions on the no-feeding side toward the slab edge, while expanded flow directs them toward the center. Consequently, inclusions on strip feeding side gradually gather between slab edge and quarter, while inclusions on no-feeding side first gather toward center and then toward edge of slab with increased strip feeding speed. [ABSTRACT FROM AUTHOR]

Thin slab casting and rolling (TSCR) is a near-net-shape manufacturing process and a key development technology in China's iron and steel industry. This study uses cross-scale calculations to analyze the complete process of thin slab casting. The focus is on simulating and predicting the final solidification structure by adjusting process parameters. The aim is to enable further investigation into material performance and establish a foundation for researching deformation and phase transformation. To achieve this, a coupled model has been developed to simulate the entire thin slab casting process, using hot stamping steel as the research subject. The model encompasses fluid flow, heat transfer, and solidification. The study identifies the optimal combination for flow field, temperature distribution, and equiaxed grain ratio within the specified parameter range at a casting speed of 4.0 m/min and a superheat of 40 °C. The aim of the study is to establish an integrated computational materials engineering (ICME) research system for near-net-shape automotive steel casting processes. [ABSTRACT FROM AUTHOR]

In the current study, the quantity, size, and spatial distribution of non-metallic inclusions along the thickness direction of an ultralow carbon IF steel were detected employing an automatic SEM-EDS scanning system. And the distribution of the slab subsurface inclusions was mainly analyzed. In addition, the total oxygen content in the steel and the solidification structure of the slab were analyzed. Upon the application of M-EMS, the solidification front was flushed due to the stirring effect generated by the electromagnetic force, promoting the floating removal of inclusions, thereby improving the overall cleanliness of the slab. However, the probability of the collision and agglomeration of inclusions was increased by applying M-EMS, resulting in an increase in the size of inclusions. The influence of M-EMS on inclusions was primarily on the slab subsurface. Following the application of M-EMS, the inclusions in the slab subsurface were experienced a reduction in number density from 9.99 to 6.11 #/mm2, and the area fraction was decreased from 69.51 × 10−6 to 57.31 × 10−6. However, the average size of inclusions was increased from 2.45 to 2.87 μm. With the application of M-EMS, the total oxygen content in the subsurface of the slab was reduced by 1–3 ppm, and the total oxygen content in the center of the slab was reduced by 0–1 ppm. These results indicated that the adoption of M-EMS contributed positively to the reduction of inclusions from the slab subsurface, thereby enhancing the surface quality of the slabs. Furthermore, the analysis revealed that the equiaxed crystal area comprised 12.06 pct of the total area without the consideration of M-EMS, while with the application of M-EMS, this proportion increased to 20.99 pct. [ABSTRACT FROM AUTHOR]

Non-uniform solidification of shell in continuous casting mold is the main cause of the high incidence of surface cracks of ultra-large beam blank (ULBB). To investigate the behaviors of the shell non-uniform heat transfer and its micro-structure growth, a thermomechanical model (TMM) of shell solidification in mold with the consideration of the mold flux and air gap dynamically filling in the shell-mold interface and a cellular automata-finite element (CAFE) model to describe the micro-structure growth of the shell were developed. In the models, the interfacial heat flux between the ULBB surface and mold calculated from the TMM was loaded on the CAFE model, and therefore, the cross-scale simulation of the shell solidification and the micro-structure growth were coupled. The results show that the air gap would not form at the positions of the web, fillet, and the center area of narrow face of the ULBB during the whole solidification in the mold. The thick air gap forms and concentrates in the flange tip, inner and outer corners of the flange as well as theirs surrounding areas. The thick mold flux mainly distributes in the areas of the flange outer corner, and the flange tip and the narrow face that are 0 to 45 mm and 0 to 31 mm away from the two edges of the flange outer corner. The maximum thicknesses of the air gap and mold flux appear at the positions of the inner and outer corners of the flange to the joints of the flange tip at the mold exit, which are about 0.75 mm and 0.99 mm, respectively. The maximum differences of the thickness of air gap and mold flux along the circumference of the mold are about 0.75 mm and 0.67 mm at the mold exit. The highest and lowest temperatures of the shell with a difference of 215 K appear at the flange tip and the flange inner corner. The maximum and minimum thickness of the shell appear at the center of the flange inner corner and the fillet of 617 mm from the center of the web, which are about 27.0 mm and 16.3 mm, with a difference of 10.7 mm. The maximum and minimum average grain sizes of the shell appear at the fillet and the flange inner corner, which are about 507.1 μm and 474.5 μm, with a difference of 32.6 μm. [ABSTRACT FROM AUTHOR]

Fe-Mn-C-Al high manganese steel has a large tendency to hot tearing, making it difficult to continuously cast and even leading to steel leakage accidents. In this paper, the effects of cooling rate and strain rate on the hot tearing behavior of Fe-18Mn-0.6C-2.6Al (18Mn) steel are investigated. The results show that 18Mn steel is prone to forming multiple cracks. When cracks propagate at higher temperatures, the stress rapidly decreases and exhibits brittle fracture characteristics. However, when the crack propagation temperature is lower, the rate of stress reduction significantly decreases, exhibiting ductile fracture characteristics. The temperature range of hot tearing of 18Mn steel is 1364 °C to 1344 °C, corresponding to the solid fraction of 0.88 to 0.99, and the initial crack propagation stress was 10.73 to 20.03 MPa. It indicates that, with the increase of the strain rate or the decrease of the cooling rate, the cracking temperature increases, and the peak stress decreases. In addition, when the propagation temperature is lower than the solidus, the cracks are no longer called hot tearing, but it will still cause damage in production. This study is valuable for the prediction of hot tearing and process design of continuous casting of Fe-Mn-C-Al high manganese steel. [ABSTRACT FROM AUTHOR]

Copyright of Metal Working (1674-165X) is the property of Metal Working Editorial Office and its content may not be copied or emailed to multiple sites or posted to a listserv without the copyright holder's express written permission. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)

In order to develop the aluminum sheets suitable for the twin-belt continuous casting and direct rolling, the composition optimization of Al-Mg-Mn alloys evolved from AA5052 (Al-2.5 Mg) alloy was firstly carried out via the synergy between the PANDAT software and the micro–hardness test. Subsequently, the influence of Er and Zr on the microstructure and mechanical properties of the optimized Al-Mg-Mn sheet (Al-1.5 Mg-0.8Mn) was investigated in this work. The results showed that the tensile properties of Al-1.5 Mg-0.8Mn sheets processed by the rolling and the subsequent annealing were improved by the co-addition of the Zr and Er. The optimized tensile properties (UTS: 320.5 MPa; YS: 231.6 MPa; E.L.: 6.75%) were achieved in Al-1.5 Mg-0.8Mn sheets modified by 0.2 wt.% Zr and 0.3 wt.% Er, which is attributed to the finest fibrous grains, the fine, homogeneously distributed residual Al6Mn, Al3Zr and Al3(Zr, Er) second phases and more nano-sized Al3(Zr, Er) precipitations. [ABSTRACT FROM AUTHOR]

Wettability of mold flux on stainless steel is a very important index to reflect the possibility of slag entrapment during the continuous casting process. In this study, the wetting behavior of mold flux droplet with different size on stainless steel is investigated using sessile drop method. Results show that the contact angle at 1573 K increases from 64.62 ± 0.25°, 62.56 ± 0.2° to 61.46 ± 0.2° and 60.56 ± 0.2°, with the size of the original flux sample increasing from 3, 4 to 5 and 6 mm. No chemical reaction occurs at the interface between mold flux and steel substrate via the thermodynamic calculation and microstructure analyses. Furthermore, the line tension of flux droplet/stainless steel/Ar‐5%H2 system ranges from 160.55 to 125.19 mN m−1 at the temperature range of 1473–1573 K. It is due to the positive line tension (line energy) which decreases the wettability of flux droplet on steel substrate and results in an increase of contact angle when the droplet size reduces. [ABSTRACT FROM AUTHOR]

The numerical simulation is combined with high‐temperature measurement to study the effects of electromagnetic braking (EMBr) and casting speed on the flow field, the fluctuation of the interface of the steel and slag, the distribution of argon gas bubbles, and the removal ratios of inclusions in the mold with a size of 1050 × 230 mm. The numerical simulation results and the high‐temperature measurement results of the velocities of molten steel at the 1/4 width and center of the thickness near the mold surface are in good agreement. The EMBr can reduce the velocity near the mold surface, the fluctuation of the interface between steel and slag, and the number of argon gas bubbles near narrow walls and decrease the total removal ratio of inclusions from 27.29 to 23.24%. When the casting speed is increased from 1.6 to 2.0 m min−1 with EMBr, the velocity of molten steel near the mold surface is increased. Even under the condition of a high casting speed of 2.0 m s−1, the velocity of molten steel near the surface is still in a reasonable range with EMBr. The total removal ratio of inclusions increases from 20.76 to 23.90%. [ABSTRACT FROM AUTHOR]

Continuous casting is the most common method for producing steel into semi-finished shapes like billets or slabs. Throughout this process, steel experiences mechanical and thermal stresses, which influence its mechanical properties. During continuous casting, decreased formability in steel components leads to crack formation and failure. One reason for this phenomenon is the appearance of the soft ferrite phase during cooling. However, it is unclear under which conditions this ferrite is detrimental to the formability. In the present research, we investigated what microstructural changes decrease the formability of microalloyed steels during continuous casting. We studied the hot compression behaviour of microalloyed steel over temperatures ranging from 650 °C to 1100 °C and strain rates of 0.1 s − 1 to 0.001 s − 1 using a Gleeble 3800® (Dynamic Systems Inc, Poestenkill, NY, USA) device. We examined microstructural changes at various deformation conditions using microscopy. Furthermore, we implemented a physically-based model to describe the deformation of austenite and ferrite. The model describes the work hardening and dynamic restoration mechanisms, i.e., discontinuous dynamic recrystallisation in austenite and dynamic recovery in ferrite and austenite. The model considers the stress, strain, and strain rate distribution between phases by describing the dynamic phase transformation during the deformation in iso-work conditions. Increasing the strain rate below the transformation temperature improves hot ductility by reducing dynamic recovery and strain concentration in ferrite. Due to limited grain boundary sliding, the hot ductility improves at lower temperatures (<750 °C). In the single-phase domain, dynamic recrystallisation improves the hot ductility provided that fracture occurs at strains in which dynamic recrystallisation advances. However, at very low strain rates, the ductility decreases due to prolonged time for grain boundary sliding and crack propagation. [ABSTRACT FROM AUTHOR]

In the course of the decarbonization of steel production, electric steel production will continue to gain importance. The processing of low‐quality scrap will also play an important role, which may lead to an increase in the content of so‐called tramp elements in steel production and further processing. This article examines the effect of the elements Cu, Sn, and Ni on the formation of surface cracks under the conditions of the continuous casting process. Results of an in situ bending test are compared with the results of the experimental simulation of high‐temperature oxidation and thermodynamic analysis based on the CALculation of PHase Diagrams (CALPHAD) approach. For a temperature of 900 °C, an equivalent Cu content of 0.20 wt% must be considered as the critical upper limit. The presumable reason is the existence of Cu‐ and Sn‐rich liquid phases at the austenite grain boundaries. The results clearly show the effect of the investigated elements but also point to the importance of the gas atmosphere and cooling conditions on the results. This can be a groundbreaking result for extending the process window for casting steels with increased tramp element contents. [ABSTRACT FROM AUTHOR]

The effects of rare‐earth treatment on cleanliness, corrosion resistance, microstructure, and mechanical properties of 75Cr1 steel are investigated by industrial trial. In the results, it is shown that the appropriate La–Ce addition can effectively remove oxygen and sulfur elements in steel, and total oxygen (T.O) and S contents decrease by 45% and 33%, respectively. After La–Ce treatment, the typical inclusions in steel are transformed from (Mg–Al–O)–CaS composite inclusions to RExSy–CaS inclusion with a small amount of Al2O3. The number and average size of inclusions in steel are significantly reduced, and the morphology of inclusions changes from irregular shape to spherical shape, which contributes to the improvement of the corrosion resistance of 75Cr1 steel. Furthermore, the pearlite spacing and the grain size are refined, the tensile and yield strengths are significantly enhanced in the test of La–Ce‐treated steel. The 75Cr1 steels are fabricated in small batches, which avoids the nozzle clogging resulted by rare‐earth treatment during continuous casting. It implies that rare‐earth treatment to improve the quality of 75Cr1 steel shows the strong industrial applicability. [ABSTRACT FROM AUTHOR]

The main purpose of this study was to optimize the performance parameters of the casting process using a neural network approach. The casting process is molten or liquefied metal is poured into the mould cavity, after solidification it takes the near net shape of the cavity. The entire manufacturing process goes through six stations viz Pouring turret "ladle", "Tundish", "Mould", "Water spray chamber", "Support roller" and "Torch cutter". The Artificial Neural Network (ANN) technique is used in this paper to analyze the casting system's availability, profitability, and state probability variation. An effort has been made to identify the most critical component of the system. The outcomes of the analysis will help the practitioners in deciding effective maintenance strategies. [ABSTRACT FROM AUTHOR]

Summary: The accurate characterisation of centreline segregation requires precise measurements of composition variations over large length scales (10−1$^{-1}$m${\rm {m}}$) across the centreline of the cast product, while having high resolution, sufficient to quantify the significant composition variations between dendrites due to microsegregation at very small length scales (10−5m$^{-5}{\rm {m}}$). This study investigates the potential of a novel microscopy technique, named Synchrotron Micro X‐ray Flurorescence (SMXRF), to generate large‐scale high‐resolution segregation maps from a steel sample taken from a thin slab caster. Two methods, Point Analysis and Regression Analysis, are proposed for SMXRF data calibration. By comparing with the traditional Laser‐Induced Breakdown Spectroscopy (LIBS), and Electron Probe Micro Analyser (EPMA) techniques, we show that SMXRF is successful in quantitative characterisation of centreline segregation. Over large areas (e.g. 12 ×$\times$ 16 mm2${\rm {mm}}^2$) and at high resolution (10–50 μm$\mu\text{m}$ pixel size) various techniques yield comparable outcomes in terms of composition maps and solute profiles. The findings also highlight the importance of both high spatial resolution and large field of view to have a quantitative, accurate, and efficient measurement tool to investigate segregation phenomena. [ABSTRACT FROM AUTHOR]

An experimental study is conducted to reveal the formation mechanism of transverse corner cracks by analyzing the metallurgical structure, crack morphology, and hot ductility. The results reveal that the corner temperature of the billet tends to be lower during mold solidification, leading to the formation of grain boundary low‐plasticity ferrite. Additionally, during the straightening process, the corner temperature of the billet falls into the serious low‐temperature brittle zone with temperature lower than 850 °C. These two factors contribute to the formation and propagation of cracks along the grain boundary ferrite under straightening forces. Therefore, after the verification of mold simulation test and industrial trial, the temperature at billet (section size 150 × 150 mm2) corner is improved by increasing the mold chamfer radius from 6 to 12 mm. This adjustment ensures that the straightening temperature at billet corner elevated from 830 to 880 °C, remaining outside the serious low‐temperature brittle zone, and the maximum depth of corner cracks decreases from 741.49 to 344.89 μm. [ABSTRACT FROM AUTHOR]

This study identifies optimal cooling rates and critical strain thresholds to prevent cracking in Cr12MoV billets during continuous casting through thermoplastic experiments, high‐temperature tensile tests, and a thermal–mechanical coupled simulation model. The result shows that the critical strain (dimensionless) for corner crack propagation at temperatures of 750, 800, and 850 °C are determined to be 0.125, 0.132, and 0.147, respectively. The critical strain for internal crack formation is found to be 0.03. The simulation results indicate that as the billet enters the first straightening roll, the corner strain is 0.035 and the central strain is 0.025. Upon exiting the fourth straightening roll, the corner strain increases to 0.038, while the central strain decreases to 0.021. Through simulation and high‐temperature confocal in situ observation, it can be concluded that a surface cooling rate of ≥5 °C s−1 effectively prevents cracks during the bending and straightening stage of continuous casting. [ABSTRACT FROM AUTHOR]

Copyright of Refractories / Naihuo Cailiao is the property of Naihuo Cailia (Refractories) Editorial Office and its content may not be copied or emailed to multiple sites or posted to a listserv without the copyright holder's express written permission. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)

Copyright of Iron Steel Vanadium Titanium is the property of Iron Steel Vanadium Titanium Editorial Office and its content may not be copied or emailed to multiple sites or posted to a listserv without the copyright holder's express written permission. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)

This article presents a computational study of the influencing parameters on the solidification of the thermoplastic beryllium oxide slurry in an annular forming cavity. The main purpose of this paper is to study the effect of cooling and casting conditions on the solidification of the BeO suspension by considering the temperature-dependent rheological and physical properties. The results of calculations of the Bingham–Papanastasiou rheological model with experimental data in the intervals of phase transitions with different casting rates of beryllium ceramics have been validated. The use of the regularization parameter made it possible to approximate the flow of the slurry at all levels of its shear rates as highly viscous, followed by a continuous transition to a solid state. The speed of heat removal from the molding during the solidification period is determined by the speed of movement of the slurry and the temperature field on which the width of the transition region depends. The process of solidification of the slurry mass has been evaluated by changing its heat flow distribution and density along the length of the concentric channel. The obtained model calculation results make it possible to control the casting process and eventually realize a uniform structure of castings. [ABSTRACT FROM AUTHOR]

An innovative method has been developed for estimating the heat flux in a funnel type mold. Conjugate Gradient Method (CGM) was used to solve the Three-Dimensional Inverse transient Heat Conduction Problem (3D-IHCP). The model was validated by comparing the results with derived from a well-established 2D-IHCP. Besides, the effect of measurement noise on the reconstruction results were discussed. Subsequently, the method was implemented to determine the heat flux in a mold simulator experiment. The analysis revealed that the heat fluxes and temperatures calculated by 3D-IHCP exhibited a similar variation trend as those obtained from the 2D-IHCP. However, for locations in the transition region beneath the meniscus, the maximum heat flux calculated by 3D-IHCP (3.14 MW/m2) was approximately 1.2 times greater than that calculated by 2D-IHCP (2.62 MW/m2), attributable to the inclined wall and convex curvature characteristics of the funnel mold. [ABSTRACT FROM AUTHOR]

The effect of reduction process, especially the reduction zone on the internal quality of continuous casting high carbon steel billets was studied by shifting active reduction rolls while at same casting condition, as well as identical reduction amount and gradient. In the present study, the heredity of the main internal defects emerged in billets with different reduction zones was also investigated after subsequent rolling process in terms of severity, regional distribution, and microstructure formation as well. For the investigated high carbon steel grade, the evolution of the internal quality in relation to the macrosegregation, internal crack and porosity illustrates the effectiveness and importance of applying mechanical reduction for the homogeneity improvement from the cast billet to the as-rolled wire rod product. Meanwhile, it is also suggested by the investigation the necessity of fine control for the implement of mechanical reduction process, or it may not have sufficient positive impact on homogeneity and compactness of billet and as-rolled product, but some other undesirable defects may even be induced by mechanical reduction. [ABSTRACT FROM AUTHOR]