Mold powders are used as raw materials in continuous casting of steel industry; Also they are mostly composed of aluminum, calcium, silica oxides, alkaline and earth-alkaline oxides along with carbon and fluor. Two of the most important duties of mold powders are the lubrication of the space between mold walls and steel shell, and heat transfer control between steel shell and the copper mold. F...

Water-cooling plays a major role in extracting heat from both the mold and solidifying metal during the continuous casting of steel and aluminum alloys and is characterized by complex boiling phenomena. Heat extraction rates during water-cooling, which have strong dependence on the metal surface temperature, can rapidly change with time as the strand cools down. Consequently, uncontrolled cooli...

A finite-element model, CON2D, has been developed to simulate temperature, stress, and shape development during the continuous casting of steel, both in and below the mold. The stress model features an elastic-viscoplastic creep constitutive equation that accounts for the different responses of the liquid, semi-solid, delta-ferrite, and austenite phases. Temperature and composition-dependent fu...

Oscillation marks accompanied by sub-surface hooks routinely appear on the surface of continuously cast steel slabs, and are especially severe in ultralow carbon steel. This paper presents a new detailed mechanism for their formation, which has been developed by combining existing theoretical modeling results, experimental observations, and analyses based on optical and scanning electron micros...

A linear perturbation method is used to solve two-dimensional heat conduction problem in which a liquid becomes solidified by heat transfer to a plane mold of finite thickness. Heat flux drawn from the lower surface of the mold is approximately uniform, but contains a small sinusoidal perturbation in one space dimension. Numerical results are obtained for the consequent sinusoidal perturbation ...

Determining alloy shrinkage factors is very important for the investment casting process. Casting dimensions can be obtained from numerical simulations of heat transfer and deformation phenomena. The accuracy of the dimensional results depends on heat transfer results. In order to validate heat transfer models, temperature data were obtained during casting of aluminum alloy A356 in shell molds ...

A finite-element model, CON2D, has been developed to simulate temperature, shape, stress, and hot-tear crack development during the continuous casting of steel, both in and below the mold. The stress model features an elastic-viscoplastic creep constitutive equation that accounts for the different responses of the liquid, semi-solid, delta-ferrite, and austenite phases. Temperature and composit...

This study deals with the experimental measurements and numerical predictions of alloy shrinkage factors (SFs) related to the investment casting process. The dimensions of the A356 aluminum alloy casting were determined from the numerical simulation results of solidification, heat transfer, fluid dynamics, and deformation phenomena. The investment casting process was carried out using wax patte...

In continuous casting of steel, the interfacial gap between the mold and the solidifying shell controls heat transfer in the process and is responsible for lubrication and the prevention of cracks and other defects. Mold slag forms when mold powder added to the top surface of the steel melts, and is the best current practice to perform these important functions. The properties and behavior of t...