Modeling and Monitoring of Single Roll Casting

9408623 Jim Chen该项目采用“材料智能加工”的概念，通过建模和实验来研究一种改进的单辊连铸机。这样的研究也将导致类似技术的进步，熔体纺丝，被称为快速凝固过程（RSP）。RSP生产的材料具有精致和均匀的微观结构，并大大改善了物理，磁性和机械性能。在先前模拟热轧工艺的基础上，与传统的包括铸造、轧制和热处理在内的几个工艺步骤的炼钢工艺相比，这个单辊铸造薄带钢的项目具有降低能耗和制造成本50%以上的工艺潜力。该研究将包括(1)宏观模型的发展，用于预测熔体流动和凝固现象以及预测带状几何形状；(2)界面传热和凝固行为的实验研究；(3)模型验证和工艺优化。原金属加工技术正朝着截面越来越薄的直铸方向发展。最初，铸锭和热轧之间的工序被直接、一步、连续板坯连铸的发展所消除。下一步是消除板坯铸造，然后是一步轧制，连续带钢铸造仍然是一个技术挑战，特别是对于高熔点的金属，如钢。该项目的成功完成有可能彻底改变薄金属条的生产方式，大大降低了成本，降低了资本投资。

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.