Sebastian Michelic

A modified cellular automaton method for polydimensional modelling of dendritic growth and microsegregation in multicomponent alloys

Numerous numerical models for simulating solidification of metals on a microscopic scale have been proposed in the past, among them are most importantly the phase-field method and models based on cellular automata. Especially the models based on cellular automata (adopting the virtual front tracking (VFT) concept) published so far are often only suitable for the consideration of one alloying element. Since industrial alloys are usually constituted of multicomponent alloys, the possibility of applying cellular automata is rather limited. With the aim of enhancing this modelling technique, a new, modified VFT model, which allows for the treatment of several alloying elements, in the low Peclet number regime is presented. The model uses the physical fundamentals of solute and heat diffusion in two dimensions as a basis for determining the solidification progress. By a new and effective approach, based on a functional extrapolation of the concentration gradient, dendritic growth in multicomponent Fe-C-Si-Mn-P-S alloys could be studied. The model shows the typical behaviour of dendritic solidification, such as parabolic tip and secondary dendrite arm formation as well as selection of preferably aligned columnar dendrites. A validation of the model is performed by the evaluation of morphological parameters and comparing them to experimentally determined values. The results for free and constrained dendritic growth effectively demonstrate the capabilities of this new model. The model is especially attractive for bridging the gap between one-dimensional microsegregation models and multidimensional morphology models with regard to modelling the complex interrelations between segregation on a multidimensional level and morphology formation.

Formation of shrinkage porosity during solidification of steel: Numerical simulation and experimental validation

The phase transformations in solidification of steel are accompanied by shrinkage and sudden changes in the solubility of alloying elements, resulting in negative side effects as micro- and macrosegregation and the formation of gas and shrinkage porosities. This paper deals with the numerical and experimental simulation of the formation of shrinkage porosity during the solidification of steel. First the physical basics for the mechanism of shrinkage pore formation will be discussed. The main reason for this type of porosity is the restraint of fluid flow in the mushy zone which leads to a pressure drop. The pressure decreases from the dendrite tip to the root. When the pressure falls below a critical value, a pore can form. The second part of the paper deals with different approaches for the prediction of the formation of shrinkage porosity. The most common one according to these models is the usage of a simple criterion function, like the Niyama criterion. For the computation of the porosity criterion the thermal gradient, cooling rate and solidification rate must be known, easily to determine from numerical simulation. More complex simulation tools like ProCAST include higher sophisticated models, which allow further calculations of the shrinkage cavity. Finally, the different approaches will be applied to a benchmark laboratory experiment. The presented results deal with an ingot casting experiment under variation of taper. The dominant influence of mould taper on the formation of shrinkage porosities can both be demonstrated by the lab experiment as well as numerical simulations. These results serve for the optimization of all ingot layouts for lab castings at the Chair of Ferrous Metallurgy.

CHALLENGES TO STATE-OF-THE-ART MOULD LEVEL CONTROL SYSTEMS AND INNOVATIVE SOLUTIONS

State-of-the Art Mould Level Control Solutions for continuous casting applications face different challenges. On the one hand, technological phenomena such as clogging and unclogging, unsteady bulging or waving can create unpredicted meniscus disturbances by completely changing the casting channel geometry and the flow behaviour of liquid steel to the mould. On the other hand, from the viewpoint of caster operations, long lifetime, quick interchange-ability and integration capability into existing systems must be achieved. In the present contribution, the overall development of INTECO TBR’s mould level master – a comprehensive mould level control solution for all continuous casting applications – will be introduced. The basis for the presented system is a development over several years which includes investigations of all critical components such as shroud, stopper, stopper mechanism, servo actuator and mould level control program. These investigations finally resulted in a new-ly developed control algorithm for a highly dynamic servo actuator. The control algorithm with its basic functionality such as the prevention, identification and removal of clogging impacts with the associated automation functions to reduce their influence onto the overall mould level control performance will be presented. The scientific basis, the resulting control functions and their related automation implementation will also be illustrated. Finally, a patented control algorithm and control functionality for unsteady bulging and waving effects with the associated automation functions to reduce their influence onto the overall mould level control performance.

Experimental und numerical investigations on cooling efficiency of Air-Mist nozzles on steel during continuous casting

Cooling strategies in continuous casting of steel can vary from rapid cooling to slow cooling, mainly controlled by adjusting the amount of water sprayed onto the surface of the product. Inadequate adjustment however can lead to local surface undercooling or reheating, leading to surface and inner defects. This paper focuses on cooling efficiency of Air-Mist nozzles on casted steel and the experimental and numerical prediction of surface temperature distributions over the product width. The first part explains the determination of heat transfer coefficients (HTC) on laboratory scale, using a so called nozzle measuring stand (NMS). Based on measured water distributions and determined HTCs for air-mist nozzles using the NMS, surface temperatures are calculated by a transient 2D-model on a simple steel plate, explained in the second part of this paper. Simulations are carried out varying water impact density and spray water distribution, consequently influencing the local HTC distribution over the plate width. Furthermore, these results will be interpreted with regard to their consequence for surface and internal quality of the cast product. The results reveal the difficulty of correct adjustment of the amount of sprayed water, concurrent influencing water distribution and thus changing HTC distribution and surface temperature.