Modeling and Monitoring of Single Roll Casting

9408623 Jim Chen本项目采用“材料智能加工”的概念，对改进型单辊连铸机进行建模和实验研究。这样的研究也将导致类似技术的进步，即熔融纺丝，这被称为快速凝固过程(RSP)。RSP生产的材料具有细小均匀的微观组织和显著改善的物理、磁性和力学性能。该项目在模拟热轧过程的基础上，与传统的铸轧、热处理等多道工序的炼钢工艺相比，具有降低能耗和制造成本50%以上的工艺潜力。这项研究将包括(1)用于预测熔体流动和凝固现象以及预测薄带几何形状的宏观模型的发展，(2)界面换热和凝固行为的实验研究，以及(3)模型的验证和工艺优化。初级金属加工技术正向着截面越来越薄的直接铸造方向发展。随着板坯直接一步连铸技术的发展，钢锭浇注与热轧之间的工艺环节逐渐被淘汰。下一步是消除板坯连铸，然后一步轧制，但薄带连铸仍然是一个技术挑战，特别是对于钢等熔点较高的金属。该项目的成功完成有可能彻底改变以较低的资本投资大幅降低成本生产金属薄带的方式。

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.