In situ steel solidification imaging in continuous casting using magnetic induction tomography

Abstract

The solidification process in continuous casting is a critical part of steel production. The speed and quality of the solidification process determines the quality of the final product. Computational fluid dynamics (CFD) simulations are often used to describe the process and to design its control system but, so far, there has been no tool that provides an online measurement of the solidification front of hot steel during the continuous casting process. This paper presents a novel magnetic induction tomography (MIT) solution, developed in the EU-funded SHELL-THICK project, to work in a real casting setting and to provide a real-time and reliable measurement of the shell thickness in a cross section of the strand. The new MIT system was installed at the end of the secondary cooling chamber of a casting unit and tested over several days in a real production process. MIT is able to create an internal map of the electrical conductivity of hot steel deep inside the billet. The image of electrical conductivity is then converted to a temperature profile that allows the measurement of the solid, mushy and liquid layers. In this study, such a conversion is done by synchronizing in one time step the MIT measurement and the thermal map generated with the actual process parameters available at that time. The MIT results were then compared with the results obtained with the CFD and thermal modelling of the industrial process. This is the first time in situ monitoring of the interior structure has been carried out during a real continuous casting.