5th International Conference on Advances in Solidification Processes (ICASP-5) 5th International Symposium on Cutting Edge of Computer Simulation of Solidification, Casting and Refining (CSSCR-5)

The ongoing RFCS project SUPPORT-CAST is aimed at finding optimal casting parameters and cooling rates to improve product quality based on high-resolution visualization topography scanning in combination with advanced numerical modelling. Surface scanning is performed by a blue laser sensor adapted to withstand temperatures up to 1200°C and capable of resolutions up to 30 microns. This enables detection of defects such as depressions and oscillation marks as well as small corner cracks. Furthermore, the full slabs sections can be reconstructed from the scans to create a virtual representation of the products. At the same time, advanced numerical models have been developed to account for the flow generated by the nozzle/SEN as well as including extensive details of the mould geometry; steel grade, slag and casting conditions (e.g. mould oscillation, superheat, cooling water, etc.). The model developed comprises a ¼ section of an industrially produced slab with 2000 x 150 mm dimensions. A reference case including flow, heat transfer and solidification is undergoing validation in order to identify casting combinations that lead to formation of defects during shell growth in the mould. The final aim is to develop online-monitoring systems and numerical models able to identify defects as well as support decision making to formulate guidelines that improve the surface quality of cast products.