Explicit Modelling of Slag Infiltration

In the competitive steel industry, enhancing productivity and quality is crucial for survival, which makes addressing defects a significant priority. This study aims to improve the prediction of defect formation during steel casting by developing advanced numerical models that simulate solidification processes within the mould, as existing models largely depend on fitting plant data. The research employs a combination of numerical simulations and laboratory experiments to analyze casting conditions such as powder consumption, casting speed, and mould oscillation, all of which contribute to defect formation including oscillation marks and cracks. The results demonstrate that conventional models fail under radical changes in casting conditions, such as increased speeds or the introduction of new steel grades with poor castability. Furthermore, the complexity of slag infiltration and its impact on thermal insulation and lubrication has been identified as a barrier to comprehensive defect analysis. This work highlights the necessity for innovative modelling techniques that account for intricate physical phenomena and improve our understanding of slag dynamics and initial solidification, ultimately aiming to reduce defect rates and enhance product quality.