Presidential Young Investigator Award: Mathematical Modeling of Continuous Casting Processing

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The project work will develop applied mathematical models to simulate two-dimensional heat flow and stress development in a static-cast ingot using finite-element modeling of transient thermal-stress development in solidification. The intent is to continue the application of mathematical models, industrial experimentation, and metallurgical studies to increase understanding and solve problems in other metal casting processes. While still incomplete, these models have already helped to improve understanding of fluid flow from submerged nozzles, the distorted shape of a continuous slab casting mold, the mechanical behavior of steel at elevated temperatures, the problems in casting of high-quality steel, such as inclusion entrainment and shell thinning due to shell jet impingement on the solidifying steel shell, formation of surface shape defects in stainless steel slabs due to inadequate mold taper, and crack formation due to thermal stresses.