Key Lubrication Concepts to Understand the Role of Flow, Heat Transfer and Solidification for Modelling Defect Formation during Continuous Casting

Continuous casting (CC) is the predominant method for shaping liquid steel into solid forms, yet it is plagued by surface defects that adversely affect yield and productivity in steel production. This study aims to elucidate the role of flow, heat transfer, and solidification in the defect formation process during CC, thereby improving understanding and mitigation strategies for these challenges. Employing numerical modelling techniques, we analyze the mechanisms of defect formation in relation to various process variables, revealing that certain contemporary demands like the introduction of new steel grades and increased casting speeds challenge traditional operational limits. Our findings indicate that significant oversimplifications in industrial simulations often omit critical material property variations and other process details. The insights gleaned from this research are anticipated to facilitate the optimization of CC operations and enhance the overall quality of steel products by addressing defect formation more comprehensively.