During the continuous casting of steels, a carbon-enriched layer forms on top of the liquid slag. Owing to fluctuations in the mold, liquid steel may come into contact with this layer, leading to re-carburization. Previous attempts to mitigate this phenomenon seemed insufficient for the intended applications; therefore, mold powders with reduced or zero carbon content are desired. For mold...
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In continuous steel casting, the turbulent liquid steel flow in the mold has a significant influence on the produced steel quality. The varying process parameters casting speed and inert gas injection at the stopper rod tip influence the mold flow pattern. Most investigations consider the original geometry of the submerged entry nozzle. During the casting process, material deposition and...
Simulation-based analysis of flow phenomena in continuous casting moulds is a mature and well-established practice. Commonly applied approaches include Computational Fluid Dynamics (CFD) and physical modelling techniques, such as water modelling and, more recently, liquid metal experiments. These methods enable detailed evaluation of submerged entry nozzles (SEN) performance and support their...
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In the continuous casting of steel billets, the initial solidification at the meniscus is the critical determinant of surface quality. The shell characteristics and geometry are intrinsic features of the process, resulting from the interaction between mold process parameters and the solidifying meniscus. However, defects and irregularities significantly alter the local heat transfer...
Surface quality is a well-known critical factor affecting the fatigue life of components. Therefore, the quality of the initial feedstock is mandatory for producing wire rod suitable for high stress applications, such as automotive suspension springs. This paper describes the successful experience of ABS (Acciaierie Bertoli Safau, Italy) during the development of a dedicated casting process of...
The required properties and the higher strength demands for steel products have been increasing in recent years, leading to the various production routes and the increase in the content of alloying elements. Furthermore, steel industries are facing pressure to transform their production processes to achieve a carbon-neutral society. In these environmental changes, maintaining and further...
One of the typical quality problems of near-net-shape products such as the beam blank is the appearance of surface and sub-surface cracks. The complex shape of the mould makes the casting of crack sensitive grades particularly challenging. This paper describes the process of modifying an existing beam blank section to improve its quality performance. It starts with the analysis carried out to...
Continuous casting of slabs demands stringent control of thermal and mechanical conditions to ensure crack-free surfaces and dimensional accuracy. The rising concentration of tramp elements in steel, resulting from modern steelmaking practices, significantly increases susceptibility to hot cracking, particularly within the straightening zone. Maintaining temperatures above the second...
Rising demands on the surface quality and the necessity for 100% inspected billets are requested by the customers. Surface defects on billets, like longitudinal or transversal cracks, can – if not removed e.g. by grinding - lead to increased reject rates, or in the worst case to a complete production stop, in the further rolling process route.
The surface inspection at voestalpine Stahl...
Designing the continuous casting process of advanced high strength steels(AHSS) requires precise simulation of fracture formation based on high-temperature properties of steel grades and casting conditions in order to minimize surface defects of the slab. Reduction of area(RA) as an indicator of ductility was utilized to correlate with the cracking performance of the continuous caster of...
The surface quality of continuously-cast products remains an important research topic due to its economic and practical implications for steelmakers. Surface quality problems are generally attributed to the presence of various kinds of defects originating from continuous casting. While the root causes of defects can be considered well-defined in scientific literature today, a frequent...
The quality of continuously cast slabs is strongly influenced by steel grade and casting parameters. The Strand Quality Index (SQI) enables probabilistic prediction of crack formation based on these factors. By integrating the Mold Expert, which calculates depressions in the mold using temperature profiles, the SQI now receives additional event information, significantly improving the accuracy...
The transition toward low-carbon steelmaking increases the reliance on scrap-based electric arc furnace routes, inevitably introducing higher levels of tramp elements such as Cu and Sn. Because these elements cannot be removed through conventional metallurgical refining, they may influence subsequent process steps. Their distinct oxidation behavior promotes the formation of low-melting,...