Research Initiation: Fluid Flow and Heat Flow Modeling of Continuous Casting Processes

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This project will develop and apply three dimensional mathematical models of fluid flow and heat flow in the mold region of continuous casting processes. The models will be extended from previous work developing two dimensional finite- element models, which incorporate the turbulence equations, and separate meshes for the nozzle and mold cavity. The models will be validated through comparisons with experimental measurements conducted using water models of continuous slab casting molds at Inland Steel and ARMCO, Inc., which are being funded separately. By applying these models to investigate the influence of individual process variables, the mechanisms of defect formation can be better understood and improvements made to the steel slab casting process. Fundamental issues important to the numerical calculation of turbulent fluid flow and the accompanying heat transfer will also be investigated in this project. These include mesh refinement, convergence schemes, turbulence parameters, boundary conditions, and incorporation of two-phase flow and buoyancy. This work will help extend the current accuracy, range of application and state-of-the-art of mathematical fluid flow modeling. Once developed, the models will be extended to other casting processes, particularly the "near-net-shape" steel casting processes of continuous thin-slab, single-, and twin-roll casters. This project will help in the design of these new processes, and could have a tremendous impact on the future competitiveness of the American steel industry.