Irregular initial solidification by mold thermal monitoring in the continuous casting of steels:A review

Occasional irregular initial solidification phenomena,including stickers,deep oscillation marks,depressions,and surface cracks of strand shells in continuous casting molds,are important limitations for developing the high-efficiency continuous casting of steels.The application of mold thermal monitoring(MTM) systems,which use thermocouples to detect and respond to temperature variations in molds,has become an effective method to address irregular initial solidification phenomena.Such systems are widely applied in numerous steel companies for sticker breakout prediction.However,monitoring the surface defects of strands remains immature.Hence,indepth research is necessary to utilize the potential advantages and comprehensive monitoring of MTM systems.This paper summarizes what is included in the irregular initial solidification phenomena and systematically reviews the current state of research on these phenomena by the MTM systems.Furthermore,the influences of mold slag behavior on monitoring these phenomena are analyzed.Finally,the remaining problems of the formation mechanisms and investigations of irregular initial solidification phenomena are discussed,and future research directions are proposed.

Secondary cooling technology for high-efficiency continuous billet-casting

The mathematical model of high-efficiency continuous billet casting was developed, incorporating the effective spraying water coefficient and the effective specific spraying water flowrate of secondary cooling. To realize uniform cooling in secondary cooling zones, the spraying cooling structure and the arrangement of nozzles were redesigned and optimized, and an additional spraying cooling zone was used. A new secondary cooling model of spraying water was built. It was found that the required spraying water flowrate of a cooling zone was related with the casting speed, the casting temperature, the compositions of liquid steel and the cooling water temperature of secondary cooling. The operation of the reformed caster proved that the spraying cooling structure and the new secondary cooling model were suitable, and the casting speed was greatly enhanced. The highest casting speed was （3.8 to 4.0） m/min for billet with a section of 150× 150 mm^2. The quality And the outout of the billet were imoroved, andthe economical benefit was heightened.

Formation and control of the surface defect in hypo-peritectic steel during continuous casting:A review

Hypo-peritectic steels are widely used in various industrial fields because of their high strength,high toughness,high processability,high weldability,and low material cost.However,surface defects are liable to occur during continuous casting,which includes depression,longitudinal cracks,deep oscillation marks,and severe level fluctuation with slag entrapment.The high-efficiency production of hypo-peritectic steels by continuous casting is still a great challenge due to the limited understanding of the mechanism of peritectic solidification.This work reviews the definition and classification of hypo-peritectic steels and introduces the formation tendency of common surface defects related to peritectic solidification.New achievements in the mechanism of peritectic reaction and transformation have been listed.Finally,countermeasures to avoiding surface defects of hypo-peritectic steels duiring continuous casting are summarized.Enlightening certain points in the continuous casting of hypo-peritectic steels and the development of new techniques to overcome the present problems will be a great aid to researchers.

Analysis of inhomogeneity of solidified microstructure of continuous casting copper tubular billet based on factor analysis

The horizontal continuous casting process,the initial step in TP2 copper tubular processing,directly determines the microstructure and properties of copper tubular.However,the process parameters of the continuous casting characterize time variation,multiple disturbances and strong coupling.As a consequence,their influence on a casting billet is difficult to be determined.Due to the above issues,the common factor and special factor analysis of the factor analysis model were used in this study,and the casting experiment and billet metallographic experiment were carried out to diagnose and analyze the reason of the microstructure inhomogeneity.The multiple process parameters were studied and classified using common factor analysis,2 the cast billets with abnormal microstructures were identified by GT^(2) statistics,and the most important factors affecting the microstructural homogeneity were found by special factor analysis.The calculated and experimental results show that the principal parameters influencing the inhomogeneity of solidified microstructure are the primary inlet water pressure and the primary outlet water temperature.According to the consequence of the above investigation,the inhomogeneity of the copper billet microstructure can be effectively improved when the process parameters are controlled and adjusted.

Analysis of Corrosion Behavior of ZrO_(2)-C Slag-line Materials in Continuous Casting

In view of the service failure and low continuous casting production efficiency due to the corrosion of refractories at the slag-line in submerged entry nozzles,a submerged entry nozzle for low-carbon aluminum killed steel continuous casting in one steel plant was sampled and taken as the research object to analyze the causes and the mechanism of refractory corrosion at the slag-line.The results show that the core issue of the corrosion and necking of the slag-line materials is that the slag-line material are eroded,dissolved,and reacted by the mold flux gradually.Therefore,it is important to suppress or avoid the contact and reaction between the mold flux and slag-line materials.

Solidification of horizontally continuous casting of super-thin slab in stable magnetic field and alternating current

The solidified structures of horizontally continuous casting（HCC） of super-thin slab and its relations with the current were studied under the electromagnetic vibration（EMV）.The results show that,under the action of the periodical forces from EMV,the solidified structures of the super-thin slab of pure tin is greatly refined,and the extent of grain refinement is increased with the magnitude of alternating current.For the Sn-10%Pb alloy,it is shown that the EMV promotes the growth of equiaxed grains in the center of super-thin slab,and the grains are refined with the alternating current increasing.This is useful to prevent some solidification defects in the horizontally continuous casting of super-thin slab,such as columnar grains butting,porosity,inclusions and gases gathering,and composition segregation in the centre of slab.

Surface quality, microstructure and mechanical properties of Cu-Sn alloy plate prepared by two-phase zone continuous casting

Cu-4.7%Sn （mass fraction） alloy plate was prepared by the self-developed two-phase zone continuous casting （TZCC） process. The relationship between process parameters of TZCC and surface quality of the alloy plate was investigated. The microstructure and mechanical properties of the TZCC alloy plate were analyzed. The results show that Cu-4.7%Sn alloy plate with smooth surface can be obtained by means of reasonable matching the entrance temperature of two-phase zone mold and the continuous casting speed. The microstructure of the TZCC alloy is composed of grains-covered grains, small grains with self-closed grain boundaries, columnar grains and equiaxed grains. Compared with cold mold continuous casting Cu-4.7%Sn alloy plate, the room temperature tensile strength and ductility of the TZCC alloy plate are greatly improved.

Horizontal continuous casting process under electromagnetic field for preparing AA3003/AA4045 clad composite hollow billets

A modified horizontal continuous casting process under the electromagnetic field was proposed for preparing AA3003/ AA4045 clad composite hollow billets. To investigate the effect of electromagnetic field on this process, a comprehensive three-dimensional model was developed. Two cases with and without electromagnetic field were compared using the simulations. When rotating electromagnetic stirring is applied, the flow pattern of fluid melt is greatly modified; the mushy zone becomes much wider, the temperature profile becomes more uniform, and the solid fraction decreases for both the external and internal alloy melt layers. These modifications are beneficial for the formation of a bimetal interface and fine and uniform grain structure of the clad composite hollow billet. Experiments conducted using the same electrical and casting parameters as the simulations verify that under the electromagnetic field the microstructure of the clad composite hollow billet becomes fine and the diffusion of the elements at the interface is promoted.

Microstructure and properties of Al-0.70Fe-0.24Cu alloy conductor prepared by horizontal continuous casting and subsequent continuous extrusion forming

A novel process for manufacturing A1-0.70Fe-0.24Cu alloy conductor was proposed, which includes horizontal continuous casting and subsequent continuous extrusion forming （Conform）. The mechanical properties, electrical conductivity and the compressed creep behaviour of the alloy were studied. The results indicate that the Conform process induces obvious grain refinement, strain-induced precipitation of AI7CuzFe phase and the transformation of crystal orientation distribution. The processed alloy has good comprehensive mechanical properties and electrical conductivity. Moreover, a better creep resistance under the conditions of 90 ~C and 76 MPa is shown compared with pure A1 and annealed copper, and the relationship between primary creep strain and time may comply with the logarithmic law. The enhanced properties are attributed to the grain refinement as well as the fine and homogeneously distributed thermally stable A1Fe and A17Cu2Fe precipitation phases.

Effect of Electromagnetic Frequency on Microstructures of Continuous Casting Aluminum Alloys

The relationship between electromagnetic frequency and microstructures of continuous casting aluminum alloys was studied. 7075 aluminum alloy ingot of 100 mm in diameter was produced by electromagnetic continuous casting process, the microstructures of as-cast ingot was examined by scanning electron microscopy (SEM) equipped with energy dispersive spectrometer (EDS). The results showed that electromagnetic frequency greatly influenced segregation and microstructures of as-cast ingot, and product quality can be guaranteed by the application of a proper frequency. Electromagnetic frequency plays a significant role in solute redistribution; low frequency is more efficient for promoting solution of alloying elements.

Study on Multiple Electromagnetic Continuous Casting of Aluminum Alloy

To obtain semi-solid Al alloy billet with high quality, an investigation was carried out by imposing a multiple magnetic field from the outside of a copper mold in the continuous casting. AISi6Mg2 alloy designed for semi-solid metal （SSM） processing was continuously cast through a submerged entry nozzle under various conditions. Effects of multiple magnetic field on meniscus motion, temperature distribution and billet quality were examined. The experimental results showed that meniscus disturbance caused by electromagnetic stirring could be controlled effectively and the surface quality of semi-solid AI alloy billet was improved greatly, and an uniformly fine, globular microstructure across the transverse section of the billet was achieved by optimizing the distribution of multiple magnetic field.

Meniscus Behavior in Electromagnetic Soft-Contact Continuous Casting Round Billet Mold

Using molten Pb-Sn-Bi alloy, the meniscus shape under high frequency magnetic field of φ100 mm round billet caster was investigated. The effect of some parameters on meniscus shape was studied. The results show that for a mold with 12 segments, the meniscus shape is relatively stable. With increasing power input, the menis- cus height increases with intensification of fluctuation. For the given caster, the reasonable power input is about 70 kW. The coil should be near to the top of mold and/or the initial meniscus should be near to the center of the coil. The lower the frequency, the higher is the meniscus height. With increasing frequency, the free surface is more flattened and meniscus becomes more stable. In practice, the power input should be increased simultaneously with frequency. The optimal frequency is about 20 kHz.

Microstructure and mechanical properties of BFe10 cupronickel alloy tubes fabricated by a horizontal continuous casting with heating-cooling combined mold technology

A new horizontal continuous casting method with heating-cooling combined mold （HCCM） technology was explored for fabri- cating high-quality thin-wall cupronickel alloy tubes used for heat exchange pipes. The microstructure and mechanical properties of BFe 10 cupronickel alloy tubes fabricated by HCCM and traditional continuous casting （cooling mold casting） were comparatively investigated. The results show that the tube fabricated by HCCM has smooth internal and external surfaces without any defects, and its internal and external surface roughnesses are 0.64 μm and 0.85 μm, respectively. The tube could be used for subsequent cold processing without other treatments such as surface planning, milling and acid-washing. This indicates that HCCM can effectively reduce the process flow and improve the pro- duction efficiency of a BFel0 cupronickel alloy tube. The tube has columnar grains along its axial direction with a major casting texture of {012}〈 621 〉. Compared with cooling mold casting （6 = 36.5%）, HCCM can improve elongation （3 = 46.3%） by 10% with a slight loss of strength, which indicates that HCCM remarkably improves the cold extension performance of a BFe 10 cupronickel alloy tube.

Fluid Flow and Solidification Simulation in Beam Blank Continuous Casting Process With 3D Coupled Model

Based on turbulent theory, a 3D coupled model of fluid flow and solidification was built using finite difference method and used to study the influence of superheating degree and casting speed on fluid flow and solidification, analyze the interaction between shell and molten steel, and compare the temperature distribution under different technological conditions. The results indicate that high superheating degree can lengthen the liquid-core depth and make the crack and breakout possible, so suitable superheating should be controlled within 35℃ according to the simulation results. Casting speed which is one of the most important technological parameters of improving production rate, should be controlled between 0. 85 m/min and 1.05 m/min and the caster has great potential in the improvement of blank quality.

Liquid-solid interface control of BFe10-1-1 cupronickel alloy tubes during HCCM horizontal continuous casting and its effect on the microstructure and properties

Based on horizontal continuous casting with a heating-cooling combined mold （HCCM） technology, this article investigated the effects of processing parameters on the liquid-solid interface （LSI） position and the influence of LSI position on the surface quality, microstructure, texture, and mechanical properties of a BFe10-1-1 tube （φ50 mm × 5 mm）. HCCM efficiently improves the temperature gradient in front of the LSI. Through controlling the LSI position, the radial columnar-grained microstructure that is commonly generated by cooling mold casting can be eliminated, and the axial columnar-grained microstructure can be obtained. Under the condition of 1250℃ melting and holding temperature, 1200-1250℃ mold heating temperature, 50-80 mm/min mean drawing speed, and 500-700 L/h cooling water flow rate, the LSI position is located at the middle of the transition zone or near the entrance of the cooling section, and the as-cast tube not only has a strong axial columnar-grained microstructure （{hkl}〈621〉, {hkl}〈221〉） due to strong axial heating conduction during solidification but also has smooth internal and external surfaces without cracks, scratches, and other macroscopic defects due to short solidified shell length and short contact length between the tube and the mold at high temperature. The elongation and tensile strength of the tube are 46.0%-47.2% and 210-221 MPa, respectively, which can be directly used for the subsequent cold-large-strain processing.

Simulation of heat transfer in steel billets during continuous casting

This work is focused on the development of computational algorithms to create a simulator for solving the heat transfer during the continuous casting process of steel. The temperatures and the solid shell thickness profiles were calculated and displayed on the screen for a billet through a defined continuous casting plant （CCP）. The algorithms developed to calculate billet temperatures, involve the solutions of the corresponding equations for the heat removal conditions such as radiation, forced convection, and conduction according to the billet posi- tion through the CCP. This is done by a simultaneous comparison with the kinematics model previously developed. A finite difference method known as Cmnk-Nicholson is applied to solve the two-dimensional computational array （2D model）. Enthalpy （HIJ） and temperature （TIL） in every node are updated at each step time. The routines to display the results have been developed using a graphical user interface （GUI） in the programming language C＋＋. Finally, the results obtained are compared with those of industrial trials for the surface temperature of three steel casters with different plant configurations in different casting conditions.

Morphology and Precipitation Kinetics of MnS in Low-Carbon Steel During Thin Slab Continuous Casting Process

The morphology of manganese sulfide formed during thin slab continuous casting process in low-carbon steel produced by compact strip production （CSP） technique was investigated. Using transmission electron microscopy analysis, it was seen that a majority of manganese sulfides precipitated at austenite grain boundaries, the morphologies of which were spherical or close to the spherical shape and the size of MnS precipitates ranged from 30 nm to 100 nm. A mathematical model of the manganese sulfide precipitation in this process was developed based on classical nucleation theory. Under the given conditions, the starting and finishing precipitation temperatures of MnS in the continuous casting thin slab of the studied low-carbon steel are 1 189 ℃ and 1 171 ℃, respectively, and the average diameter of MnS precipitates is about 48 nm within this precipitation temperature range. The influences of chemical components and thermo-mechanical processing conditions on the precipitation behavior of MnS in the same process were also discussed.

Effect of low-frequency electromagnetic field on the as-cast microstructure of a new super high strength aluminum alloy by horizontal continuous casting

The super high strength aluminum alloy ingots with 100 mm in diameter were cast by the process of low-frequency electromagnetic horizontal continuous casting (LFEHC) and the effect of electromagnetic field on the as-cast microstructure was studied. Results show that microstructure of the sample prepared by the LFEHC process was greatly refined. Microstructures at the border and the center of the ingots were fine, uniform and rosette-shaped. Electromagnetic frequency plays a key role in microstructure refining. Fine and uniform microstructures can be obtained with optimal electromagnetic frequency. In this experiment, under a frequency of 30 Hz the microstructure was the finest and the most uniform.

Temperature distribution and dynamic control of secondary cooling in slab continuous casting

To predict and optimize the temperature distribution of slab continuous casting in steady operational state, a three-dimensional model （named ＂offline model＂） based on the heat transfer and solidification theories was developed. Both heat transfer and flux distribution characteristics of the nozzle sprays on the slab were considered, and the complicated boundary conditions, such as spray cooling, natural convection, thermal radiation as well as contact cooling of individual rolls were involved in the model. By using the calibrated caster dependent model factors, the calculated temperature and shell thickness accorded well with the measured. Furthermore, a dynamic secondary water cooling control system was also developed on the basis of a two-dimensional transient heat transfer model （named ＂online model＂） and incremental PID control algorithm to reduce slab surface temperature fluctuation in unsteady state. Compared with the traditional spray table control method, the present online model and dynamic PID control demonstrate a higher capability and flexibility to adjust cooling water flowrate and reduce slab surface temperature fluctuation when the casting speed is changed.

Numerical simulation of temperature field in horizontal core-filling continuous casting for copper cladding aluminum rods

The steady-state temperature field of horizontal core-filling continuous casting （HCFC） for producing copper cladding aluminum rods was simulated by finite element method to investigate the effects of key processing parameters on the positions of solid-liquid interfaces （SLIs） of copper and aluminum. It is found that mandrel tube length and mean withdrawing speed have significant effects on the SLI positions of both copper and aluminum. Aluminum casting temperature （TAI） （1003-1123 K） and secondary cooling water flux （600-900 L.h-1） have little effect on the SLI of copper but cause the SLI of aluminum to move 2-4 mm. When TA1 is in a range of 1043-1123 K, the liquid aluminum can fill continuously into the pre-solidified copper tube. Based on the numerical simulation, reasonable processing parameters were determined.