Conference Technical Report

8th European Continuous Casting Conference

23-26 June 2014
Graz, Austria

Attendees:
GSB: Paulo C. Fernandes, Fabiano de Andrade
GSE: Juan José Laraudogoitia, Gonzalo Álvarez de Toledo, Javier Ciriza

1. INTRODUCTION
From June 23th to 26th, the eight edition of the European Continuous Casting Conference was
held at Graz (Austria) as a forum for the european continuous casting community to exchange
views on the status and future development of the continuous casting process.

Around 600 participants from 36 countries and 184 companies/institutes were attending the event.

Many presentations were given concerning simulations, quality issues and new equipments.

Main topics:
• Advanced technologies for the casting of slabs, blooms and billets
• Thin slab casting and direct rolling
• Modernization and new implementations
• Operational practice and maintenance
• Measurement, automation and process control
• Flow control, refractories and clogging
• Mold lubrication and heat transfer
• Product quality control: Surface quality and internal soundness
• Numerical simulation and modeling (solidification, metallurgy, fluid flow, benchmark
experiments)
• New developments in casting technologies

Gerdau made two presentations:

“Influence of composition and continuous casting parameters on the cracking of b-

microalloyed high Mn steel grades”.
G. Alvarez de Toledo (Gerdau Investigación y Desarrollo Europa S.A., Spain)
J. Komenda, K. Frisk (Swerea KIMAB AB, Sweden)
B. Stewart, A. Smith (Tata Steel Europe, United Kingdom)
T. Brune, RWTH (Aachen University, Germany)

“Continuous casting research at European RFCS program, emerging trends and

challenges”
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J. J. Laraudogoitia (Gerdau Investigación y Desarrollo Europa S.A., Spain)
R. Bachorczyk-Nagy, A. Haigh (European Commission, DG Research and Innovation, Belgium)

Three plant visits were offered:

• Voestalpine Stahl Linz
• Voestalpine Stahl Donawitz
• Acroni d.o.o.

2. CONFERENCE PRESENTATIONS
138 presentations were given divided in three parallel sessions.

Below it is a brief summary of the most interesting presentations grouped by main topics:

• Flows between tundish and mould

• Solidification and microstructure evolution
• Secondary cooling
• Surface quality
• Internal quality - cracking
• Internal quality - segregation
• Internal quality - cleanliness
• Mold fluxes
• Thin slab casting and direct rolling
• Advanced technologies for the casting of blooms, billets and slabs

FLOWS BETWEEN TUNDISH AND MOULD:

EXPERIMENTAL INVESTIGATION OF LIQUID METAL TWO-PHASE FLOWS IN A
CONTINUOUS CASTING MODEL. S. Eckert, Helmholtz-Zentrum Dresden-Rossendorf (HZDR),
Germany.

Interesting methodology that shows what happen in the stopper rod tip region and into the mould
tube using X-ray device at a lab test rig using liquid metal. As observed in some investigations at
GSE, nozzle doesn’t run full of steel, and steel within the nozzle is driven by the gas phase
pressure.

This paper described first experiments performed at the X-LIMMCAST facility, which was
especially designed for the visualization of the two-phase-flow by X-ray radiography.

The X-ray visualizations of the region around the stopper rod revealed a rather complex gas
injection process which is affected by the occurrence of void zones in the upper, low-pressure
region of the SEN. The process of bubble formation is dominated by a separation of relatively
large bubbles from the bottom domain of the void zones. The final size of the gas bubbles getting

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out from the nozzle are primary influenced by the shear flow at the bottom of the nozzle. The
bubbles in the mould exhibit a long residence time in the lower circulation roll of the mould flow.
Larger bubbles develop owing to coalescence and rise sporadically towards the free surface.

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LIQUID STEEL AT LOW PRESSURE: EXPERIMENTAL INVESTIGATION OF A WATER AIR
FLOW IN A CONVERGENT DIVERGENT NOZZLE. M. Thumfart, Johannes Kepler Universität
(JKU), Austria.

This paper deals with pressure working conditions between tundish and mould, and some
experiments to study what happens at the stopper rod when gas bubbles are nucleated due to air
entrance and steel-refractory reactions.

The model of a single phase flow of a completely filled SEN results in very low or even negative
pressure in the vicinity of the gap between stopper rod and SEN walls. While pure liquids are able
to stand certain negative pressures, in “real” liquids like water and liquid steel degassing starts at
gas bubbles and impurities (nuclei). Depending on the surface tension of the liquid, a certain
critical size of the nuclei has to be reached in order to enable gas bubbles to grow. Due to the high
surface tension of liquid steel, these nuclei need to be much larger than in water. While cavitation
in water can take place in the whole liquid due to the dense distribution of micro-particles (order of
magnitude 1 µm), cavitational effects in liquid steel can only arise at rough SEN and stopper rod
wall pores or at very dilute large non-metallic particles (all of them order of magnitude 100 µm).
Without the extra addition of inert gas, the formation of gas curtains at the SEN and stopper rod
walls filled with gasses dissolved from the liquid steel (Nitrogen, Oxygen and Hydrogen) and
possibly sucked gasses from the surrounding atmosphere is expected.

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MULTIPHASE FLOW AND LOW PRESSURE EFFECTS IN THE SEN. M. Javurek, Johannes
Kepler Universität, Austria

This paper makes a study on what happens in the stopper rod tip region when inert gas is injected
and why this practice reduces the clogging effect. In this respect the author defends that
degassing effects at low steel pressures could be responsible for the clogging of the SEN due to
the formation of oxide particles.

In the continuous casting of steel a stopper rod is commonly used to control the flow rate from the
tundish into the mould. Agglomeration of solid material near the stopper rod and inside the
submerged entry nozzle (SEN) can lead to a reduced cross section and thus to a decreased
casting speed or even total blockage (“clogging”). It is known that the injection of argon gas at the
stopper rod tip reduces the clogging effect. Nevertheless the mechanisms involved in clogging are
still not fully understood. A key for a better understanding may be the consideration of the absolute
pressure: Single phase considerations of the flow in the region of the stopper rod result in a low or
even negative pressure at the smallest cross section due to the high flow velocities. This can
cause degassing of dissolved gases from the melt, evaporation of alloys and entrainment of air
through the refractory material. According to these considerations, a two phase liquid-gas flow is
expected even in the case when no gas is injected in the stopper-rod region. A mathematical
model for this two phase flow situation in the SEN is presented that links the throughput and the
pressure inside of the SEN with the geometrical parameters, the amount of gas in the SEN and the
pressure loss coefficient at the stopper rod. An explanation theory for the diminishing influence of
the gas injection on clogging is outlined.

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A COMPARATIVE STUDY OF MULTIPORT NOZZLES IN A SQUARE BILLET MOLD. K.
Morales-Higa, McGill University, Canada.

This paper presents the optimization of the nozzle design for a 165 mm sq. billet mould using
lateral ports and efficient rotational flows minimizing the impingement on mould faces (less risk of
breakouts and mould powder emulsification). This work was carried combining physical and
mathematical modeling.

A comparative study of a Submerged Entry Nozzle (SEN) with angled lateral ports capable of
delivering swirling flows through the mold cavity of a square billet mold has been conducted with
the aid of physical and mathematical modeling. The physical experiments of the full scale water
model included Particle Image Velocimetry (PIV) and video recordings of the dynamic water/oil
interface. The present swirl nozzle design is compared with a five ported nozzle, consisting of 4
straight lateral ports and a single port located at the bottom of the SEN. The five ported nozzle is
currently used at the plant at work. The jets emerging from the lateral ports of the five ported
nozzle impinge in regions near the mold corners at a high velocity, then split into upper and lower
flows. The upper flows emerge at the mold corners, with high momentum, thereby strongly
affecting the shape of the meniscus interface. The strong flows impingements compromise uniform
growth of the steel shell, while the fluctuations in the meniscus influence the generation of Mold
Powder Entrainment (MPE) and subsequent subsurface defects. The observed fluid flow patterns
when operating with the alternative SEN design, reduced the impingement of jets on the forming
shell and decreased mold level fluctuations in the meniscus region, as compared with the five
ported nozzle.

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COMBINING MODELS AND MEASUREMENTS TO BETTER UNDERSTAND STEEL
CONTINUOUS CASTING. B. G. Thomas, University of Illinois, USA.

Computational models can simulate the details of the phenomena and mechanisms which govern
complex commercial processes such as the continuous casting of steel. When combined together
with experimental measurements in the laboratory and plant, they become an accurate and
powerful tool to gain quantitative understanding, and to enable improvements in the commercial
process. This paper shows several examples to illustrate how to apply models and measurements
together to gain new insights into steel continuous casting. Firstly, models can augment laboratory
experiments to measure fundamental properties. For example, the crystallization properties of
mold slags can be extracted from videos of high temperature experiments of small liquid samples.
A recent computational model of the double-hotwire-thermocouple test (DHTT) shows how
temperature gradients and crystal motion driven by surface-tension (Marangoni) flow convection
influence the nucleation and growth of crystals during the experiment. Computational models can
also augment plant measurements. For example, velocity across the top surface of the mold can
be quantified using nailboard measurements, with the help of results from computational model
simulations of the free surface shape around the nails. This enhances the ability of nailboard
measurements to quantify flow conditions at the top surface, and thus to serve as a validation tool
for computational flow models. Finally, Large Eddy Simulation of transient turbulent flow in the
mold have been validated with plant measurements, matching the surface velocities, flow
directions, and surface level profiles. In addition to quantifying the flow pattern, the results reveal

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insights into flow instabilities in the mold under nominally steady casting conditions. The general
methodology presented here is readily applicable to other processes.

CONTINUOUS CASTING SIMULATOR FOR MEASUREMENT AND CONTROL OF LIQUID

METAL FLOWS DURING CASTING. P. E. Ramirez-Lopez, Swerea MEFOS AB, Sweden.

A new continuous casting simulation device is presented showing advantages compared to the
current simulators existing nowadays.

Despite the fact that extensive research has been carried out to study the flow of liquid steel within
the mould during continuous casting and its effects on quality; many of the complex details about
its behaviour are yet not clearly established. This is partly due to difficulties in observing the metal
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flow in a real caster due to the high temperatures at which the process occurs. Thus, water models
are frequently used to study the flow instead. However, velocities and pressure gradients in water
are of different magnitude compared to those seen in liquid steel (e.g. complete similarity cannot
be fulfilled due to large differences on scale, density, viscosity, surface tension, temperature, etc.).
A 1:1 scale physical model known as Continuous Casting Simulator 1 (CCS-1) has been
developed at Swerea MEFOS to address some of these shortcomings. The model uses a low-
melting point alloy (57%Bi-43%Sn) to study the metal flow through the submerged Entry Nozzle
(SEN) and mould since its fluid properties (e.g. viscosity and density) bear close resemblance to
liquid steel. The low melting point of the alloy (135°C) facilitates development and implementation
of sensors and probes, which provide a more complete picture of the flow inside a caster for
improved process control and stability. A showcase of possible measurements in the model is
presented together with a description on how the results can be used to address flow related
problems in the industrial practice.

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ADDING ARGON INJECTION TO AN ADVANCED MODEL FOR CONTINUOUS CASTING OF
STEEL. P. E. Ramirez-Lopez, Swerea MEFOS AB, Sweden.

An advanced numerical model for Continuous Casting of steel able to account for argon injection
effects is presented. This includes the coupling of multiphase flow, heat transfer and solidification
predictions with the tracking of bubble trajectories in the nozzle, metal bulk and across the slag
bed. Hence, a description of a state-of-art method for adding gas injection (Discrete Phase Model,
DPM) in combination with a multiphase model for tracking metal/slag interfaces (Volume Of Fluid,
VOF) is provided. The present methodology allows studying the effect of argon injection on
process stability; particularly, the influence of argon on steel-slag flow dynamics, powder
consumption, solidification and shell growth. Different injection parameters such as bubble
diameter and gas flow rate were combined with specific casting practices to emulate the real
process. Application to the industrial practice is an ongoing task and preliminary results are
illustrated. For instance, identification of stable or unstable flows within the mould as a function of

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different argon flow rates under a variety of casting conditions (casting speed, nozzle
submergence depth, etc.). Moreover, the predicted flow behaviour and bubble trajectories
demonstrate good agreement with level fluctuations, standing waves and gas departure positions
on a Continuous Casting Simulator and industrial observations. Ultimately, the increased process
knowledge can be used to optimize the distribution of gas bubbles within the mould to increase
process stability (i.e. steady metal level). The robustness of the model combined with physical
model observations make possible the description of phenomena difficult to observe in the caster,
but crucial for its performance and the quality of final products.

Fig. 7: Argon bubble distribution and displacement through the slag-metal interface and through the slag with DPM+VOF
embedded into existing CC model.

(a) (b)

Fig. 9: Video snapshots of the metal slag interface during argon injection tests at CCS-1 (taken every 10 seconds for a
total time of 1 minute), a):4 lt/min and b)5 lt/min.

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SOLIDIFICATION AND MICROSTRUCTURE EVOLUTION:
PHASE TRANSFORMATIONS IN STEEL – FROM IN-SITU EXPERIMENTS TO
THERMODYNAMICALLY BASED MODELS. E. Gamsjäger, Montanuniversität Leoben, Austria.

Depending on pressure, temperature and composition various phase transformations may occur in
steels, e.g. solidification or melting, transformation from austenite-to-ferrite or vice versa and
bainitic or martensitic transformations. The properties of the final casting product are determined
by the kinetics of the occurring phase transformations. Microstructural changes can be
investigated in-situ by means of high temperature laser scanning confocal microscopy. These
investigations accompanied by measurements like high temperature X-ray diffraction, differential
calorimetry and dilatometry are expected to result in a comprehensive experimental data set.
Efforts are made to describe so far available experimental results by thermodynamically based
models. Predictions of simulated transformation kinetics are compared with the experimental
results.

Bainite with small amounts of retained austenite and martensite due to cooling programme A (recorded at 295°C). (b)
Perlitic bainitic microstructure due to cooling programme B (recorded at room temperature).

Schematic representation of the heat treatment for the dual phase steel.

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 Fig. 8: Experimentally obtained ferrite fraction compared with simulations based on an effective mobility model [2].

PHASE-FIELD INVESTIGATION OF THE INFLUENCE OF THE SOLID-LIQUID INTERFACE

ENERGY, CHEMICAL COMPOSITION AND FORCED CONVECTION ON THE DENDRITE
GROWTH MORPHOLOGY FOR HIGH MANGANESE STEELS. J. Rezende, RWTH Aachen
University, Germany.

High manganese steel alloys may deform by a combination of various mechanisms and are, for
this reason, quite promising materials for mechanical construction. The operative deformation
mechanism depends on the local chemical composition of the material. Phasefield simulations
may be utilized to simulate microsegregation during the solidification. Reliable values for certain
physical properties, e.g. for the liquid-solid interface energy must be used as an input of the
phase-field model. In the first part of this paper, the liquid-solid interface energy is experimentally
accessed and its influence on the simulation results is analyzed. In the second part, the effect of
convection on the dendrite morphology is also considered.

Fig. 1 Definition of the contact angle in the sessile-drop experiment.

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Fig. 3 Simulation results for the Fe-Mn-C alloy. Left-hand side: sl 0.204 J/m2, Right-hand side: sl0.461 J/m2.
Both areas are 360µm x 360µm large. Figures show only a cut-out of the original simulation domain. Only one fourth of
the domain was simulated.

Comparison between the dendrite morphology between the situation without flow (left) and with flow (right). Inflow
velocity 3µm/s.

The result of this calculation can be applied to explain the tilting of the dendritic growth during
solidification in the continuous casting under the effect of EMS. Convection disturbs the symmetry
of the equiaxed dendrite. In the case without convection, all main stems tend to grow with
approximately the same radius and velocity from them central nucleus. Side branches also
emanate symmetrically from each of the main stems. In the case with convection, the primary
dendrite growing upstream moves faster than the one growing downstream. This difference comes
from the asymmetry of the diffusion field around the growing dendrite. In the region of the
upstream growth, the flow steadily supplies fresh liquid (with the original alloy composition) to the
solidification front, what keeps the supersaturation high and stimulates the growth. In the wake
region, there is an excess of solute, which tends to inhibit the growth by reducing the local
supersaturation. A question that comes out from the simulations is whether fluid flow, by altering

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the concentration field around a growing dendrite, may also lead to changes in the
microsegregation behaviour.

3D NUMERICAL SIMULATION OF FLOW AND SOLIDIFICATION OF MOLTEN STEEL IN

BLOOM CONTINUOUS CASTING MOLD WITH ELECTROMAGNETIC STIRRING. Q. Liu,
University of Science and Technology Beijing, China.

In this article, a three-dimensional mathematical model was used to analyze the characteristics of
magnetic field, flow field and solidification of molten steel in the mold for 260mm×300mm bloom
with electromagnetic stirring. The results show that the simulated magnetic induction is consistent
with the measured data. The flow in the mold is characterized by a dominant swirling movement at
the transverse section. In addition, an upper recirculation zone and a lower recirculation zone with
the reverse melt flowing are found at the longitudinal section. The shell thickness increases slightly
with the effect of electromagnetic stirring, however, the liquid zone expands obviously in the
effective stirring region. Air gap in the mold has a great influence on the temperature of strand
corners and flow field of molten steel is obviously affected by solidification process.

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 (a) (b)

Fig. 6 Distribution of velocity vector on y-z plane at x=0 m. (a)without M-EMS; (b) with M-EMS

The Figure 6 shows that EMS produces a decrease of the penetration in the liquid pool of liquid
steel entering directly from the nozzle. A secondary liquid flow recirculation is produced
downwards the stirrer which dos not exist without EMS.

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 Fig. 10 Distribution of liquid phase on x-y plane at z=0.13 m. (a) without M-EMS; (b) with M-EMS.

The results of the figure 10 are not in agreement with GSE experience of the liquid shell
asymmetric growth at the corners with EMS, being the corner side against EMS induced liquid flow
thinner than the other corner side.

RESIDUAL STRESSES IN CONTINUOUSLY CAST STEEL SLABS. M. Schöbel, TU München,

Germany.

Very interesting paper where the stresses generated during gamma/alpha phase transition are
measured for samples in situ solidified. This work is of importance for studies which are carried out
nowadays by GSE as the cracking of microallooyed steels billets in the cooling bed.

Neutron diffraction technique is used or measurements, and he accumulated strain is based upon
the distortion in the neutron diffraction peaks produced when the distance between inter crystalline
plane varies. This paper was presented in two oral sessions and in a poster session. There is not
written paper in the conference proceedings and the graphs presented here correspond to photos
made of the poster.

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INITIAL SOLIDIFICATION BEHAVIORS OF MEDIUM CARBON STEELS DURING
CONTINUOUS CASTING. W. Wang, School of Metallurgy and Environment, Central South
University, China

The importance of initial solidification of molten steel in the mold has been widely acknowledged.
However, very few studies have been effectively developed due to the high transient nature of
thermodynamics and fluid flow in the upper mold. Based on the recent developed mold simulator
technology, a novel technique has been successfully developed to study the initial solidification
behavior of medium carbon steels, which gives rise to the clear understanding of the inter-
relationship between complex meniscus heat transfer, oscillation marks and mold hot surface
responding temperatures. The results suggested that the variations of the responding
temperatures and heat flux at meniscus may be associated with the movement of mold in/out of
the bath, the infiltration of mold flux and the latent heat release due to the meniscus solidification
during Negative Strip Time (NST). The presence of positive peaks in the derivative of the heat flux
are corresponding to each of the defects marks during NST, which suggests the significant heat
flux increase during the formation of Oscillation Marks. These could be explained as the meniscus
is deformed and getting close to the coldest mold at the beginning of NST, such that the liquid
meniscus would be solidified that gives rise the increase of heat flux. With the enhancement of flux
infiltration from the mid-NST to end NST, the thermal resistance between the solidified meniscus
and mold reduces; therefore, the shell continues to grow and the resulting heat transfer and mold
temperature also continuous to increase.

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DYNAPHASE: ONLINE CALCULATION OF THERMODYNAMIC PROPERTIES DURING
CONTINUOUS CASTING. S. Hahn, Siemens VAI Metals Technologies GmbH, Austria.

The Siemens VAI software model DynaPhase calculates thermodynamic properties depending on
the chemical analysis of steel. It can be used online together with Siemens VAI’s secondary
cooling model Dynacs 3D, which is a unique feature. Offline it can be used to investigate the
thermodynamic properties of steel grades and therefore supports the development of new grades.
The core of DynaPhase is a substitutional solution model for the Gibbs free energy for calculating
multi-component phase diagrams. The parameters of this model are determined by employing the
CALPHAD approach. This model is combined with a microsegregation model to account for the
interdendritic solidification process. New DSC (differential scanning calometry) measurements
conducted by the Department of Metallurgy at the Mining University of Leoben have been used to
improve and extend the DynaPhase database for high Al or Si concentrations. By comparing this
experimental data to calculations, it has been found that some of the widely used commercial
software tools do not describe the ternary system FeAlC for high aluminum concentrations
correctly. In this paper we will show how DynaPhase calculations for actual steel compositions
influence the thermal properties and the impact this has on the secondary cooling control system
in continuous casting.

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SECONDARY COOLING:
THE EFFECT OF SPRAY WATER TEMPERATURE ON SECONDARY COOLING SPRAY HEAT
TRANSFER COEFFICIENTS AND METHODS FOR IMPLEMENTING THE EFFECT IN A
DYNAMIC COOLING CONTROL MODEL. J. Horsky, University of Brno, Czech Republic.

Dynamic secondary cooling models developed at ArcelorMittal Global R&D use online calculated
surface temperatures at various slab positions to adjust secondary cooling water based on aim
surface temperatures. The latest development for this model is full implementation of
experimentally measured heat transfer coefficients determined as a function of spray water
volume, position under the spray nozzle and slab surface temperature. Water inlet temperature
can have a significant influence on the heat transfer coefficient and hence cooling efficiency of the
sprays. The Heat Transfer and Fluid Flow Laboratory of Brno Technical University (Brno)
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conducted experiments to determine the effect of the incoming spray water temperature on the
HTC. They tested two different nozzles, one hydraulic and the other air mist. The incoming spray
temperatures were 10, 20, 30, 50, and 70 °C.

The conclusions that can be reached from this study are the following. 1) As the incoming water
temperature increases above 20 ºC the HTC decreases by about 60% directly under the spray
nozzle for the air mist nozzle (17 l/min). The variation elsewhere is almost negligible. 2) As the flow
rate increases (22.7 l/min) the area directly below the air mist nozzle doesn’t experience a
decrease until the water temperature reaches 50 ºC and the affected area around the nozzle tip
increases and the area affected under the nozzles doubles. 3) As the incoming water temperature
increases above 50 ºC the HTC decreases by about 60% directly under the spray nozzle for the
hydraulic nozzle (3.79 l/min). The variation elsewhere is almost negligible. As the flow rate
increases (7.58 l/min) for this nozzle the effect remains the same.

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Important results which need to be validated. During summer time incoming water temperature
could reach high values affecting significantly the HTC values.

OPERATIONAL EXPERIENCES WITH THE OPTIMIZATION OF SECONDARY COOLING. J.

Stetina, Brno University of Technology,Faculty of Mechanical Engineering, Czech Republic.

Surface temperatures of cast slabs at small radius segments in front of as well as at the unbending
point belong to parameters that affect the surface quality of continuously cast slabs. Older
machines for continuous casting were designed with regard to the performance (to amount of cast
slabs) rather than to the quality. Therefore, the adaptation of secondary cooling is required in order
to accomplish the desired surface temperatures. The modification consists in the dynamic control
of secondary cooling, surface temperatures monitoring by means of the numerical model of
temperature field as well as in a prospective replacement of cooling nozzles. The paper deals with
relationships of described influences and their impacts to the temperature field of cast slabs. The
results are presented for the 1530x250 mm slabs that are cast in Evraz Vítkovice Steel where the
main author’s dynamic 3D solidification model is used to control the production. The results and
experiences obtained after the replacement of cooling nozzles are compared to long-time
operational data for the preceding setup of cooling nozzles. The comparison is performed with the
use of data acquired from the dynamic solidification model and with the use of the statistical
operational data.

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ADVANCED CONTROL OF SPRAY COOLING HEAT TRANSFER IN LONG PRODUCT
CASTING. R. Wolff, LECHLER GmbH, Germany.

Conventional airmist full cone nozzles either show an unstable spray angle with varying water
pressure or a limited water turndown range. A new generation of air-mist full cone nozzles, the
Billetcooler Flex, has been developed providing additional options to control the local heat
extraction still maintaining a stable spray angle and a high water turndown ratio. The heat
extraction can be controlled by the liquid distribution profile which can be either high centre (centre
pronounced), flat centre (even) or low centre (edge pronounced). HTC testing has been conducted
to verify the correlation between dynamic liquid distribution and heat extraction. These tests
confirmed the flexibility in terms of local heat extraction of the new nozzle type and show the
potential for long product casting process improvements.

This is the Air-Mist nozzle design proposed by Lechler for Zone 3 and Zone 4 at the billet caster of
GSE Basauri Plant.

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SURFACE QUALITY:
INVESTIGATION OF STEEL COMPOSITION ON THE CRACK FORMATION ON CASTING
SLABS BY MEANS OF LITERATURE, MODELING, LABORATORY EXPERIMENT AND
PRACTICAL OBSERVATION. G. Xia, Voestalpine Stahl GmbH, Austria.

Cracks formation on the slab surface or in the slab is one problem of production of continuous slab
casting. These cracks occur in the mould and/or in the secondary cooling zone. It is, however, well
known that cracking is strongly dependent on the steel composition. For certain steel grades
cracking cannot completely be avoided even for modern continuous casting machines. Hence the
production of cracking sensitive steel is the most challenging for casting operators. In many cases
a lot of cracking sensitive steel has excellent mechanical properties. The influence of chemical
elements is complex both for cracking to occur on the slab and for their mechanical properties.
Thus it is important for the steel industry to have an applicable model to predict the influence of
steel composition on the cracking in the slab during casting. The model to be described favours a
close cooperation between caster, material developer and steel user and enables an optimisation
of steel composition with regard to the high quality of the slabs and steel mechanical properties.
Furthermore these models allow a prediction of cracking sensitivity for new steel grades. By
application of the knowledge from literature, mathematical solidification models, laboratory
investigation and practical experience, models have been developed to predict the internal and
surface crack formation in the mould and in the secondary cooling zone. In this work the principles
of the modelling and the application in the casting process will be presented.

A model for the prediction of the influence of the composition of steel on cracking sensitivity in the
secondary cooling (CRSsec ) was developed with the data from literature, production data and
laboratory experiments. The model consists of three parts:

• Steel composition: Si, Cu, Ni, S, N which can be fully or partly in soluble form
• Austenite grain size: mainly influenced by C, Si, Mn, P, Mo, Ni, Cr
• Precipitation: Nb(C,N), AlN, VN

Paper useful for knowing the influence of different chemical elements on CC cracking. However, it
seems that when trying to develop a universal mathematical expression explaining all cracks, it
does not take into account that one of the chemical elements having a anomalous value can be
itself the cause of cracking.

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IDENTIFICATION OF PERITECTIC STEEL GRADES BY THERMAL MOLD MONITORING AND
DSC MEASUREMENTS. P. Presoly, Montanuniversität Leoben, Austria.

The characteristics of the initial solidification in continuous casting, especially the peritectic phase
transition, have a considerable effect on the surface quality, casting productivity and operational
safety. To supervise the thermal behaviour in the continuous casting mould an online thermal
monitoring system has been installed by voestalpine Stahl GmbH. The higher the temperature
fluctuation in the mould is, the more less uniform the strand surface. This significant operational
behaviour corresponds with the chemical composition, especially for steel grades in the peritectic
region. As commercial steels are always multi-component alloys, also the influence of alloying
elements besides carbon on the peritectic phase transition need to be taken into account. Since
mathematical methods (Cp-Formulas) and ∆G-Minimizers (e.g. ThermoCalc or FactSage) are
sometimes insufficient to safely describe the peritectic range in new alloys, reliable experimental
methods are necessary. Differential Scanning Calorimeter (DSC) is a proved method which allows
a clear prediction of whether an alloy is peritectic (i.e. critical to cast) or not. In the following study
a combined investigation of selected steel grades by mould thermal monitoring (= casting
behaviour) and DSC experiments (= phase transformations) will be carried out and discussed.

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A NOVEL APPROACH FOR THE SIMULATION OF SURFACE CRACK FORMATION IN
CONTINUOUS CASTING. P. Krajewski, Montanuniversität Leoben, Austria

This study describes the possibilities of new experimental and numerical methods to predict the
crack susceptibility under continuous casting (CC) conditions. The first method – the In-Situ
Material Characterization by Bending (IMC-B) Experiment allows measuring of the critical strain
values for surface defects upon all the most important process and material parameters. The IMC-
B experiment uses solidified samples obtained directly from the melt and it is based on the 3-point
bending test. Hence the material and process parameters are similar to CC. Strains are calculated
directly after the experiment uses a simulation in Abaqus. The risk of surface cracks is provided
using the new numerical tool, so-called defect indices implemented in IDS. In the framework of
practical series a crack susceptibility of the commercial Nb-microalloyed steel is investigated after
the subsequent cooling to the test temperature. The test temperature corresponds to the
temperature at the beginning of straightening zone in cc. Samples cast at two different cooling
conditions show another distribution of surface defects and critical strain value.

Fig. 1 Performing of the In-Situ Material Characterization by Bending (IMC-B) experiment [7].

34
INTERNAL QUALITY - CRACKING:
INFLUENCE OF COMPOSITION AND CONTINUOUS CASTING PARAMETERS ON THE
CRACKING OF B-MICROALLOYED HIGH MN STEEL GRADES. G. Alvarez de Toledo, Gerdau
Investigación y Desarrollo Europa S.A., Spain.

This paper deals with the high internal cracking sensitivity observed in the as-cast structures of the
Boron grades. This work is being conducted within the frame of an RFCS European Research
Programme in a project called PMAP (Influence of composition and continuous casting parameters
on the precipitation of microalloyed particles of B microalloyed and Mn alloyed steel grades).

Samples of slabs, billets and laboratory ingots of B and high Mn steel grades, presenting some
characteristic defects in the as-cast semis, have been analysed in order to clarify the role played
by casting parameters and microalloyed elements in the cracking mechanism. In this respect, a

35
discussion is presented based upon interdendritic segregation during solidification and new
ThermoCalc calculations of the Fe-C-B pseudo-binary diagrams. A comparative study of the B
enhancing cracking with the one produced by the S is also included. This cracking phenomenon is
clearly related to the B content since similar steel grades without B do not present such internal
cracking problem. Pseudo-binary equilibrium phase diagrams calculations of the Fe-0.30%C-B
shows that for B content higher than 40 ppm end solidification temperature is produced at 1140
ºC, with the precipitation of M2B. Furthermore, it has been observed that the interdendritic liquid
segregation of B is quite similar to the one corresponding to S when having a low Mn/S ratio.

36
37
OPTIMIZATION OF MOLD TAPER DESIGN FOR PREVENTING FLANGE TIP INTERNAL
CRACKS IN BEAM BLANK. T. Nishimura, JFE steel Corporation, Japan.

It is necessary to prevent breakout because it has quite a negative effect on stable continuous
casting operation. We investigated a cause of beam blank breakouts and internal crack at the
flange tip, and modified mold taper design. As a result of various investigation, we estimated that
the air gaps whose heat thermal resistance could delay solidifying shell growth between mould
inner surface and beam blank existed, and the cracks were formed by the stress concentration
caused by partial delay of solidification. Not to generate air gaps in the mould, we developed
thermal conduction and solidification model, which took into account mould taper and shell heat
shrink, and we acquired the mould taper condition from the model. After introducing modified
mould, internal cracks at the flange tip disappeared completely and it contributed to the stable
operation.

38
39
HOT TEARING PREDICTION DURING SLAB CONTINUOUS CASTING OF STEEL THROUGH
THERMOMECHANICAL SIMULATION. B. Rivaux, ArcelorMittal Global Research & Development,
France.

Hot tears (cracks formed during steel solidification) are defects that affect slab internal soundness.
This can cause break when slabs are transformed into sheets. New steel grades containing high
levels of alloying elements are sensitive to hot tears. Predicting hot tears is thus of primary interest
in order to identify key process parameters which lead to hot tears and to give process
recommendations in order to limit these defects. The aim of this study was to evaluate the risks of
hot tears during the continuous casting process through thermomechanical simulations coupled
with computation of an internal crack criterion. First the thermomechanical model as well as the
internal crack criteria used for the simulations are detailed. Simulations of two industrial
configurations are then presented. The first case corresponds to a local slab surface temperature
40
reheating at the bending zone which simulates clogging of water sprays during the secondary
cooling. The second case focuses on a mechanical aspect of the continuous caster, in this case a
2mm roll misalignment in the horizontal part of the caster. Results show an increase of the internal
crack criterion when the local slab surface temperature reheating gradient is above 100°C/m and
when rolls are misaligned by 2mm. These results are in agreement with industrial observations.

41
42
INTERNAL QUALITY – SEGREGATION:
CHARACTERIZATION AND DESCRIPTION OF FINAL SOLIDIFICATION AND CENTERLINE
SEGREGATION IN THICK CC SLABS. T. Brune, Institute of Ferrous Metallurgy RWTH Aachen
University, Germany.

During the solidification of CC (Continuous Casting) slabs, a controlled and homogenous

solidification is significantly to achieve. Plant operators have to continually improve their steel
products. To reduce the extent of macrosegregations over large distances within the slab, it is
decisive to investigate the formations of shrinkage holes and segregations.

For this purpose, the formation of centerline segregation and porosities during the solidification is
described. Samples with dimensions of 350 x 2600 mm, of the continuous caster No.4 of the
company Salzgitter Flachstahl GmbH in Germany are taken. Investigations were conducted in
longitudinal and width direction to analyze the flow rating of the melt in the mushy zone. It was
found that there are V- shaped segregations in longitudinal direction.

An explanation for these V-shaped segregation will be presented, which is manifested by various
calculations and electron microprobe mappings.

43
SOFT REDUCTION AT A ROUND BLOOM CASTER: IMPLEMENTATION AND RESULTS. W.
Rauter, Voestalpine Stahl Donawitz GmbH, Austria

The steadily increasing demand of high quality steel products motivated voestalpine Stahl
Donawitz GmbH to start investigations on SR technique on the round bloom caster CC3 (diameter
230 mm). At the beginning the experiments were carried out on a pilot strand, and after positive
results concerning the minimization of the center segregation in combination with promising results
from the wire rod mill, SR was implemented at the remaining four strands during summer 2010.

The great effect can be seen in the homogenization of both the structure and the segregation
values along the whole process route from bloom to wire. Another aspect is the superheat in the
44
tundish. In general, it is known that changing superheat influences the point of solidification, which
is a major issue in the field of SR. Thus it should have an influence on the segregation for a static
SR application like the discussed one. However, in all the numerous trails this influence could not
be revealed.

Since the implementation on all five strands many different steel grades are soft reduced by
default. A further step is the broadening of SR to other steel grades..

Examples are given showing excellent results as the one below concerning a bearing steel grade
(100Cr6). A significant difference between the longitudinal macro-etches with and without SR can
be observed. The soft reduced sample shows only little remaining center porosity. Furthermore the
V-segregations are almost vanished.

Longitudinal macro-etches of a round bloom of steel grade B (superheat 38 °C): a) SR active b) standard without SR.

Throughout the whole research work it was clear that wrong SR parameters can lead to massive
hot tears in the vicinity of the core zone. Heavy pinch roll loads as well as too high casting speed
can lead to hot tears. In addition, the existing macroscopic structure plays a decisive role, because
the equiaxed structure is more resistant to crack propagation as a columnar one. Due to that
reason SR around 0.5 %C is a challenging task because the equiaxed amount is a minimum and
therefore the columnar, strain critical, structure reaches a maximum. The next figure shows a clear
example for a 0.55%C grade showing severe hot tears with applied SR.

45
Longitudinal macro-etches 0,55%C grade casted with a superheat of 27 °C: a) with SR: cracks in the marked region and
eccentric equiaxed region b) without SR

INTERNAL QUALITY - CLEANLINESS:

CFD SIMULATION OF TUNDISH AT GEORGSMARIENHÜTTE GMBH. Z. Carncarevic,
Georgsmarienhütte GmbH, Germany

The liquid steel flow, the slag and the non-metallic inclusions behavior inside of the 6-strand
tundish at Georgsmarienhütte GmbH are investigated. Three-phase free surface flow with extreme
density ratio (liquid steel, liquid slag, air) was simulated. At this stage all calculations were
performed under isothermal condition (1530°C). The steady state data are used as the starting
point and, after approximately ten minutes non-metallic inclusions are injected and a transient
calculation performed. The process simulation time was 40min. A total amount of about 2600
particles within time span of 0.2s was randomly injected in the subentry shroud. The particles size
was chosen according to Gaussian distribution (10um-10%; 20um-40%; 40um-40%; 65um -10%).
The turbulent flow of the liquid steel and its influence on inclusions behavior were analyzed. The
simulated distribution of the non-metallic inclusions in blooms was compared with experimental
results (ultrasonic inspection). The simulation results show a high degree of correlation to those
obtained by experiments.

The goal of the work was to reduce absolute amount of non-metallic inclusion and decrease
variation difference of them between strands, and it was reached through the validation of a
modified tundish furniture (Tipe II), and that modifications have been successfully implemented at
Georgsmarienhütte GmbH.

In this study the potential of tundish slag to absorb inclusions from steel was not evaluated.
Further investigation should include systematic exploration of the non-isothermal condition and
slag non-metallic inclusion reaction.

46
Standard configuration (Type I):

• Tundish nominal capacity: 26t of liquid steel

• 6 strands
• T type with some Flow Control Devices (FCDs). It has not Impact Pads (IPs) or a Turbo
guard (Type I)
• Refractory lining is made up mostly of MgO.

Optimised design(Type II):

• Equipped with dams and weirs (same T-form although the optimized workspace has two
chambers which separate the inlet influence zone from the nozzle zone to promote
ascending streams. These streams are essential for growing and separating inclusions due
to flotation.
• No a clear view of the dams and weirs was given, but it seems to be quite similar to the
RHI proposal to the billet caster of GSE Basauri plant (four walls in parallel promoting a
clear upwards flow, and avoiding short-circuit towards strands 3 and 4).

47
Results:

Standard configuration (Type I)

New configuration (Type II)

48
MOLD FLUXES:
ANALYSING THE PERFORMANCE OF MOULD POWDERS FOR NICHE STEELS THROUGH
ADVANCED NUMERICAL MODELLING. P. Nazem Jalali, Swerea MEFOS AB, Sweden.

A 2D numerical model for continuous casting based on the commercial CFD code ANSYS-
FLUENT was applied to different mould powders used during casting of peritectic steel grades.
The model explicitly includes the interactions between mould powder, liquid/solidified steel and
heat transfer under transient conditions. The model solves the Navier-Stokes equations coupled
with an interface tracking technique known as Volume of Fluid for a multiple phase system
consisting of steel, slag and air. Mould powder performance and evaluation of shell growth is
possible due to a particularly small size mesh (25 µm) for the meniscus curvature and along the
mould length. A new User Defined Function related to heat transfer through the multi-phase
system and non-sinusoidal mould oscillation has been developed. These new developments allow
exploring the influence of mould powders and oscillation settings on casting stability and shell
formation during a casting sequence.

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INTERFACIAL PHENOMENA BETWEEN FLUXES AND LIQUID METAL IN CC PROCESS. P.
R. Scheller, TU Bergakademie Freiberg, Germany.

The conditions and parameters in the CC process have a strong effect on the generation of
surface and sub-surface defects in the strand. Phenomena like separation of non-metallic
inclusions, instabilities of the interface, dispersion of flux micro-droplets into steel, chemical
reactions between steel and flux at the meniscus causing new inclusions and change of flux
properties occur in the casting process. The present study reports about the experimental
investigation of the above mentioned phenomena as well in laboratory experiments as in the
industrial CC process. The separation of non-metallic particles into slag was investigated in the
laboratory scale and show that the separation kinetics is strongly dependent on the nature of
particles and slag. In cold physical models the interfacial instabilities and transport of tracer in the
vicinity of the interface were investigated. Using samples taken directly in the mould in the CC
process the dispersion of flux in liquid steel was detected and the effect of interfacial convection on
mass transport between steel and flux was quantified.

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MOLD SLAG FILM INVESTIGATION FOR HIGH AL AHSS CASTING. H. Yin, ArcelorMittal
Global R&D East Chicago Center, USA.

Advanced High Strength Steels with high Al content are becoming a significant portion of material
used in state of the art ultra light auto body designs for improved fuel economy and environment
impact. During casting of this new generation of steels, slag chemistry shifts significantly from the
original design due to the reaction between Al in steel and reducible oxides in mold slag. When the

51
reacted slag moves into the gap between mold and shell, the slag film and its lubrication and heat
transfer properties are altered due to the reaction and become unknown. In this study, a slag film
sample and a slag rim sample were taken after two heats cast of a high Mn, high Al and high Si
AHSS steel grade. A detailed investigation was made of the crystal structures that formed in the
slag film with SEM and CLM and their compositions with EDAX. In addition, the slag film sample
was remelted in a platinum crucible under a Confocal Laser Scanning Microscope and the
crystallization process was observed at various cooling rates, in an attempt to match the crystals
observed in the slag film in order to find out the actual cooling the film experienced during casting.
This paper summarizes the current understanding of the working slag film based on the present
study

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54
REVEALING THE UNKNOWN: MONITORING THE IN-MOLD PERFORMANCE DURING
CONTINUOUS CASTING OF STEEL. J. Kromhout, Tata Steel Research, Netherlands.

During the last fifty years, continuous casting of steel as an industrialised method of solidification
processing has made enormous advances. However, the continuous casting process still faces
increasing demands related to production and product quality. The challenge to increase the
output of the existing casters is evident as well as the need to improve the quality of the cast
product. Furthermore, the product mix is continuously expanding to include more high-strength
steels for critical applications. For these reasons, an in-depth knowledge of continuous casting, in
particular related to in-mould processes, is crucial. Two of the main aspects of the continuous
casting process of steel are mould fluid flow and mould heat transfer. This paper gives an
overview of some techniques to monitor the casting process and casting process stability at the
casters of Tata Steel in IJmuiden. Attention is given to both mould fluid flow and mould heat
transfer; the role of mould thermocouples to monitor in-mould behaviour and meniscus
phenomena is highlighted. Results are used for a further understanding of the casting process and
to guide future developments.

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THIN SLAB CASTING AND DIRECT ROLLING:
RELEVANCE OF THE AS-CAST MICROSTRUCTURE ON FINAL CHARACTERISTICS IN
TSDR TECHNOLOGIES. J.M. Rodriguez-Ibabe, CEIT, Spain.

Thin slab direct rolling (TSDR) technologies have some key metallurgical differences when
compared to conventional routes. These differences include the as-cast austenite microstructure
at the entry of the first rolling stand, changes in the recrystallisation kinetics during rolling, the
possible different behaviour of some microalloying elements (Ti and Nb) and the key role of strain
induced precipitation and the final amount of accumulated strain before austenite transformation
during cooling down. Some of these singularities have been well identified and considered from
the beginning of TSDR application in industry. Nevertheless, as customers are demanding thicker
final gauges and higher mechanical properties, including better toughness, new plant
configurations are being proposed by industrial suppliers to cope with these requirements. In this
context, this manuscript will focus on the aforementioned TSDR metallurgical singularities that
should be taken into account when high microstructural homogeneities are required. It is worth
emphasising that the as-cast microstructure at the exit of continuous casting appears as a key
factor.

Fig. 1. Comparison between cold, direct and hot charging procedures prior to hot rolling.

57
ADVANCED TECHNOLOGIES FOR THE CASTING OF BLOOMS,
BILLETS AND SLABS:
A NEW BENCHMARK IN SPECIAL STEEL CASTING: NEW TWIN STRAND VERTICAL
CASTER AT POSCO SPECIALTY STEEL, KOREA. A. Sgro, Danieli CentroMet, Danieli Officine
Meccaniche SpA, Italy.

The new Danieli 2-strand Vertical Caster (VCCM) producing 420x530 mm sections is in operation
at Posco Specialty Steel, Korea, casting a very wide range of carbon, stainless, and tool steel
grades. Due to the peculiar grades produced, which are extremely difficult to cast, special
solutions have been used, like: vertical casting, CFD simulations for tundish design, optimized
mold taper and cooling design, Danieli patented INMO oscillating bench. Also mechanical soft
reduction (MSR) and movable final stirrers (F-EMS) are optimized through dynamic set up based
on real-time solidification model (LPC). As a consequence, good results were achieved for surface
quality -with no need of scarfing-, internal quality -not only on high carbon grades but also on ULC
austenitic stainless steels-, excellent equiaxial zone, centre porosity, and segregation indexes in
all casting conditions. This paper describes the technological solutions used in the design and the
implementation of the vertical caster, and the results achieved during the first year of operation.

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 3th of August, 2014

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