A hybrid approach towards evaluation of average heat transfer coefficient in twin-roll strip casting mold

Abstract

Continuous casting stands out as one of the most efficient and productive methods for producing billets, slabs, or thin sheets while conserving energy. Understanding the solidification dynamics and achieving defect-free sheets in continuous casting necessitates the accurate prediction of heat transfer coefficient (HTC) at the mold metal interface. Accurate prediction of HTC helps in selecting process parameters such as superheat temperature and casting velocity, which directly affect the production rate and quality of the cast component. Determining the HTC is a complex process, as it is influenced by various process parameters such as casting size, casting speed, superheat temperature, surface roughness, type of water used as a coolant, nozzle design and wettability. Therefore, the present study proposed a hybrid approach for finding HTC in a twin roll strip casting mold through a solidified shell shape, which is influenced by the factors affecting the heat transfer at the mold-metal interface. This approach integrates the experimental and simulation investigations. The numerical investigation used a three-dimensional coupled fluid flow and heat transfer equations with an assumed range of HTC (100–2000 W/(m2K)). The solidified shell shape for different HTCs was compared with the experimental solidified shape form at the outer wall of the mold using the solidification criteria. Results indicate that the initial HTC range of 100–1000 W/(m2K) does not lead to blockage of the graphite mold outlet. However, as HTC values approach 1000 W/(m2K) to 1400 W/(m2K), the melt obstructs the mold exit based on solidification criteria. The HTC values (1350 ± 150 W/(m2K)) obtained from the proposed methodology for mold, align well with the HTC values (1183 ± 593 W/(m2K)) calculated using lamellar spacing of the Al-Mg2Si composite microstructure. This hybrid approach presents a novel and straightforward method for determining HTC, offering accurate predictions that can enhance the precision of continuous casting models and provide a more nuanced understanding of solidification behavior.