Macroscopic and Microscopic Coupling Mathematical Model for Solidification Process of Twin-roll Thin Strip

A macroscopic and microscopic coupling mathematical model for solidification process of twin-roll thin strip is developed. In the model, the latent heat is treated by the enthalpy method, and the grid and node are divided by assumed streamline boundary. The heterogeneous nucleation and the columnar-equiaxed transform(CET)model are introduced, together with the revison of the dendrite growth dynamic model of KGT. With the help of solid fraction, the coupling of the macro/micro aspects is realized by using different grid-sizes and time-steps, macro and micro, together with the columnar dendrite front tracing. The columnar dendrite arm spacing and deflection angle calculated by proposed model are in agreement with the experimental ones. Therefore, the model is proved to be reliable, and it can be used to predict the effects of the processing parameters on the solidification structure of twin-roll thin strips.     

Advance in Mathematic Model of Solidification Heat Transfer Process in Continuous Casting

The mathematic model of solidification heat transfer process in continuous casting strand is useful for quantitatively analyzing heat transfer in continuous casting process, quality control and process control. The heat transfer in continuous cast strand in crystallizer and secondary cooling zone have been analyzed. The attention has been paid to basic logic and methodology in model building up. Typical methods determing solution condition and parameters for the model have been discussed. Some numerical methods at the present time for solving solidification heat transfer model, such as finite difference method, finite-element method and boundary element, have been investigated comparatively. In the future, working on solidification heat transfer model, which is more practical, and the integration of the control model will play an important role in the development of high efficiency continuous casting technology.     

An optimization method for the nozzle arrangement in secondary cooling zone of continuous casting

Based on the existing research on nozzle arrangement method in secondary cooling zone of continuous casting, the method of superposed water flow density is put forward to optimize the nozzle arrangement at casting direction and transverse section of slab according to the optimization principle. The two-dimension heat transfer model is established. The solidification morphology of cross-section at casting direction is simulated with consideration of the influence of water flow density inhomogeneity on solidification process at transversal section, and the temperature distribution of slab, solidification process, and quality of slab are compared between before and after optimization. The results indicate that the surface temperature of slab is dropped equably after optimization, and the casting blank is cooling uniformly in the water springing zone so as to ensure better quality of the casting blank.     

Modeling and realizing of integrated batch planning for steelmaking-continuous casting and hot strip rolling

An integrated batch planning mathematical model based on multi-object optimization is proposed to solve the orderly and efficient flow of material between different working stations in iron and steel enterprises, where production technology constraints, material variations and coupling between steelmaking-continuous casting and hot rolling are analyzed first. According to the requirements of the hot rolling steel strip contracts, the integrated batch planning is divided into sub-plans of rolling plan, casting plan and furnace plan which are independent and coupling to each other, forming rolling plan and furnace plan simultaneously to influence casting plan. Heuristic method based on modified co-evolutionary algorithm is advanced to resolve this problem. The results of simulation and analysis in an iron and steel plant for strip steel production shows that it is feasible to provide effective guidance for integrated batch plan making.     

The Numerical Simulation of Casting Process for Making Metal Matrix Composites

In this paper,a numerical simulation of the casting process for making the MMC.using the PEM, is studied.The convection of liquid metal and the release of latent heat of solidification are taken into account.The algorithm and program for axisymmetric casting model are developed to the problem of coupling between flow and heat transfer,as well as phase change.The variational curves of temperature,the position of flow front and the distrsbutions of volume fraction of solid metal in matrix and their variation with time are obtained.The influences of technological paarmeters to casting are discussed.     

Computational Simulation on Temperature Field of Slab Continuous Casting Mold

On the core concepts that the distributing of temperature and solidified slab shell in mold are a stable process, a new method to calculate the temperature field in mold has been promoted. Consequently, a coupling model on fluid filed and temperature field in stable state has also been established. The concept of effective heat capacity is introduced to deal with the latent heat source term from phase transformation. During the programming for computation, the dynamic updating method is also applied to simulate the influence of solidification on physical properties. The resolution results of this model are analyzed and compared with the tested thickness of solidified shell from casting broke out slab, which demonstrates the correctness and applicability of this model to the practical continuous casting process. Additionally, the thickness distribution of solidified shell in slab mold are also studied in detail.     

Dealing with Thermal Exchange in Temperature Field Simulation in Low Pressure Die-casting Process

The main effort is to develop numerical simulation software of low pressure die casting on Windows platform in Personal Computer, based on the production of aluminum wheel in Die cast wheel manufacture Co. Ltd.. The heat conduction calculation is the basis of solidification simulation. A 3 dimentional model including the refrigeration medium block is set up based on the study of boundary heat exchange. Various calculation method is analyzed for different types of boundary element. A comprehensive calculation model is set up according to practically manipulable parameters in production.     

BOF-caster matching model in steelmaking plant of all plate and strip using precision design principle

Using precise design principle, a multi-objective programming mathematical model of the BOF-Caster matched is established for single production line in the steelmaking plant of all plate and strip, according to the segmentation of steel grade and product specification of product mix. Objectives of the model have less investment, less difference between production capacity of the converter and continuous caster, higher operating rate of converter and higher level of weighted average casting speed. The model is solved by the improved delaminating sequence method. Then, the overall configuration method of BOF-continuous casting in the steelmaking plant is proposed through integrating single production lines. According to the production outline of a new large steel plant, the result of the model shows that the configuration scheme of the steelmaking workshop of the steel plant is a better design scheme.     

NUMERICAL SIMULATIONS OF THE SOLIDIFICATION PROCESS IN HEAVY STEEL CASTINGS AND THE SHRINKAGE CAVITY PREDICTION

In this paper a numerical simulation software of the casting solidification process is designed with the implicit alternating direction method (i,e IAD) and the TRUE BASIC language. The solidification process of the cross-section A-A of the high pressure inner cylinder is simulated and the shrinkage cavity position is predicated by means of utility software. The simulation is agreeable to the measurement.     

Grain growth of continuous casting slab solidification based on cellular automata model

The cellular automaton (CA) method is coupled with finite difference method to establish a stochastic nucleation and growth model. According to the actual production conditions, the solidification structure of continuous casting slab is simulated and the evolution law of the inner structure is reconstructed. It is showed that grain transformation is from equiaxed crystal to columnar crystal and then to equiaxed crystal. Thickness of three crystal layers are different in various production technological systems, thickness of surface equiaxed crystal and inner equiaxed crystal are reduced, and the results of the columnar crystal thickness are contrary, while casting speed and superheat are increasing. The results show well agreement with the stochastic nucleation, preferred growth, competitive growth and random orientation of grain.     

Development of mold fluxes for welding rod steel at the Shuicheng Iron and Steel (Group) Co., Ltd.

The solidification characteristics of steel are analyzed with the aim of explaining the appearance of serious surface depressions and frequent breakouts when casting billet H08 steel at the Shuicheng Iron and Steel (Group) Co., Ltd., P.R. China     

Current Research Status of Micro-Scale Solidification Models of Binary Alloys

According to determine the non-equilibrium solidification path and local liquid solute concentration in the macro transport model during solidification process of binary alloys, the two kinds of micro-scale solidification models are discussed detailedly, viz. solidification kinetics model and miceosegregation model. The current research status of deterministic solidification kinetics model and semi-analytical microsegregation model are reviewed comprehensively, respectively. The main influencing factors of the two models have also been discussed, viz. undercooling and nucleation rate & back-diffusion and coarsening. Further more, the practical value in the coupled numerical simulation of alloy solidification and the future developmental directions of the micro-scale solidification models are elaborated.     

含铈耐热钢凝固过程中的夹杂物行为

建立了稀土耐热钢凝固过程中夹杂物析出与溶质元素微观偏析的耦合热力学模型,并通过工业试验与高温模拟实验验证了模型的准确性。利用该模型,依次考察了铈添加量,初始氧含量,初始硫含量对253MA耐热钢凝固过程中夹杂物析出行为的影响作用规律。在本模型条件下,随着铈添加量的增加,钢中的SiO2与MnS消失,且凝固过程中开始析出CeN;随着初始氧含量的增加,钢中开始析出Ce2O3,SiO2及MnS,其中SiO2与MnS在凝固过程中析出;随着初始硫含量的增加,钢中的Ce2O3消失,钢中开始析出Ce3S4与MnS,在凝固过程中析出的Ce3S4逐渐在液相线温度以上析出。研究工作对于稀土耐热钢连铸水口结瘤问题的解决具有理论指导意义。     

ANALYSIS AND CALCULATION OF CONDENSATION HEAT TRANSFER ON HORIZONTAL LOW-FINNED TUBE ATTACHED BY A POROUS DRAINAGE STRIP

An analytical model was proposed for the condensation heat transfer on the horizontal low-finned tube attached by a porous drainage strip, and compared with the experimental data with a good agreement. The permeability of the porous drainage strip was also experimentally determined.     

板坯连铸结晶器内凝固坯壳的三维数值模拟

基于流场和温度场的计算,对断面为1 780 mm×225 mm的板坯结晶器进行数值模拟,考虑3种不同水口条件下,钢液流动对凝固壳的冲刷,计算出凝固壳厚度的三维分布特征,并与二维切片法的计算结果进行了对比。结果表明：有水口时结晶器角部位置凝固壳最大值为约45 mm,宽面和窄面中心凝固厚度壳最大值为24 mm,分别比无水口条件下凝固壳薄1~2 mm;钢液的扩散会使凝固壳在距离结晶器角部300 mm和顶部400 mm的位置形成约深度2.5 mm的凹陷;同时钢液会冲刷整个结晶器窄面的凝固壳,在窄面中心最严重;对比不同的水口,凸底水口冲刷最大,凹底最小。     

Control model for secondary cooling of continuous casting based on compensation temperature of the difference between liquidus and solidus

During continuous casting process, the composition of molten steel often varies with different heats, which leads to the big fluctuation of billet surface temperature when the traditional parameter water control model is applied to control the process. Additionally, it is difficult to keep the temperature at the straightening point of the billet within a reasonable range. Given above consideration, a new control model for secondary cooling of continuous casting based on compensation temperature of the difference between liquidus and solidus has been presented. Meanwhile, the temperature field of the billet is simulated with both the parameter water control model and the new secondary cooling control model, and the results indicate that the new control model for secondary cooling of continuous casting could perform better when it is used to control the surface temperature at straightening points of billet, thereby ensuring the quality of the billet.     

Dynamical Solidification Characteristic of Metal Surface Alloying by Action of Continuous Laser

The solidification microstructures and their nucleation models are discussed,and the effect of the shape effect of moving melton pool on the solidification features is anslyzed on the basis of experiments. The experimental results show that its solidification behavior is complex,because the continuous laser alloying is a dynamical process. The reason for this complexity is that the dynamical solidification characteristic is significantly controlled by the laser alloying parameters and the molten pool shape. On the other hand,the solidification structures of laser alloying have a series of specialities,and their nucleation mechanisms are mainly heteroepitaxial growth and heterogeneous nucleation growth.     

Calculation model for the turnover number of steel ladle based on casting schedule

In order to realize optimization of production organization and put forward a reasonable calculation model for the turnover number of steel ladle, the turnover process and time of steel ladle are analyzed with steel ladle of Q steelmaking plant. Gantt charts of steel ladle turnover for single casting schedule and double casting schedule are drawn. Calculation model for turnover number of steel ladle is put forward by analyzing the relationship between casting schedule and the turnover time of steel ladle, and the accuracy of the model is verified by simulation method. Researches show that the turnover number of steel ladle can be reduced 1-2 by adjusting cast starting time, and have significance for the optimization of steel ladle production organization.     

Prediction Model of Intermixing Slab Length During Continuous Casting Grade Transition Process

In order to increase decision accuracy of the intermixing slab length and position, and decrease the slabs which are offgraded or scrapped. Water model experiments were conducted to simulate the continuous casting grade transition process of No. 2 continuous caster at Bao Steel. The dimensionless concentration profiles along slab length with different continuous casting conditions were measured. Based on the profiles a mathematical model was developed to predict the final composition distributions and length of intermixing slab. Comparison of predicted dimensionless concentration profile with plant data shows that the precision of the model is considerably satisfied to meet the need of steel grade transition evaluation.