Modeling and Monitoring of Single Roll Casting

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9408623 Jim Chen This project addresses both modelling and experimentation to investigate a modified single roll caster using the concept of "Intelligent Processing of Materials". Such a study will also lead to the advancement of similar technology, melt spinning, which is known as a rapid solidification process (RSP). The materials produced by RSP possess refined and homogeneous microstructures and much improved physical, magnetic, and mechanical properties. Building on prior work of simulating hot rolling process, this project on single roll casting of thin strips has the process potential to reduce the energy consumption and manufacturing cost by more than 50% as compared with the conventional steel making where several process steps are involved including casting, rolling and heat treating. The study will include the development of (1) macro-scale modeling for predicting the melt flow and solidification phenomena as well as predicting the ribbon geometry, (2) experimental investigation of interface heat transfer and solidification behavior, and (3) model validation and process optimization. Primary metals processing technology has been moving towards direct casting of thinner and thinner cross sections. Initially, the process step between ingot casting and hot rolling was eliminated by the development of direct, one step, continuous slab casting. The next step of eliminating slab casting followed by rolling by a single step, continuous strip casting remains a technical challenge, particularly for higher melting metals such as steel. Successful completion of this project has the potential to revolutionize the way thin strips of metals are manufactured at substantially reduced cost with a low capital investment.